Still RX50-10, RX50-13, RX50-15, RX50-16 Operator Manual

Original instructions

Electric forklift truck

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

5060 5061 5063 5065 5066

55048011501 EN - 12/2015

Preface

Address of manufacturer and contact details

STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.still.de

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048011501 EN - 12/2015 I

55

Table of contents

1 Foreword

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

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

CElabelling ......................................................... 2

EC declaration of conformity in accordance with Machinery Directive ............... 3

Accessories ......................................................... 3

Information about documentation ......................................... 4

Documentationscope ................................................. 4

Issue date and topicality o

Copyrightandtrademarkrights ........................................... 5

Explanation of information symbols used . . ................................. 5

Listofabbreviations ................................................... 6

Definitionofdirections ................................................. 9

Schematicviews ..................................................... 9

Environmental consider

Packaging ......................................................... 11

Disposal of components and batteries ..................................... 11

ftheoperatinginstructions ........................... 5

ations .......................................... 11

2 Introduction

Use oftruck ........................................................ 14

Proper usage ....................................................... 14

Proper use during towing .............................................. 14

Impermissibleuse ................................................... 14

Placeofuse ........................................................ 15

Parkingintemperaturesbelow-10°C ..................................... 16

Using working platf

Residual risk ....................................................... 17

Residual dangers, residual risks ......................................... 17

Special risks assoc

Overviewofhazardsandcountermeasures ................................. 20

Danger to employees . . ............................................... 23

orms ............................................... 16

iatedwithusingthetruckandattachments ................... 18

g

3Safety

Definition of resp

Operatingcompany .................................................. 26

Specialist .......................................................... 26

Drivers ........................................................... 27

Essentials for safe operation ........................................... 29

Insurance cover on company premises .................................... 29

onsible persons ........................................ 26

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Table of contents

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Changes and retrofitting ............................................... 29

Changes to the overhead guard and roof loads . . . ........................... 32

Warning regarding non-origin

Damage, defects and misuse of safety systems . . . ........................... 33

Tyres ............................................................. 33

Medicalequipment ................................................... 34

Exercise caution when handling gas springs and accumulators .................. 35

Lengthoftheforkarms ................................................ 35

Safety tests ........................................................ 37

Regularsafetyinspectionofthetruck ..................................... 37

Insulationtesting .................................................... 37

Safety regulations for han

Permissibleconsumables ............................................. 39

Oils .............................................................. 39

Hydraulicfluid ...................................................... 40

Batteryacid ........................................................ 41

Brakefluid ......................................................... 42

Disposal of consumables

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

alparts ..................................... 32

dling consumables ............................... 39

.............................................. 44

4Overviews

General view of truck ................................................. 50

General view of drive

Operating devices and display elements ................................... 53

Display and operating unit . . . .......................................... 53

Operating devices f

Multi-lever ......................................................... 56

Doublemini-lever .................................................... 57

Three-way mini-lev

Four-waymini-lever .................................................. 59

Joystick4Plus ...................................................... 60

Fingertip .......................................................... 61

Miniconsole ....................................................... 62

Identification points .................................................. 64

Overview .......................................................... 64

Nameplate ......................................................... 65

Productionnumber .................................................. 66

StVZO (Road Traf

r’s compartment ..................................... 52

orhydraulicandtractionfunctions ......................... 55

er ................................................. 58

fic Licensing Regulations) information ....................... 66

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Table of contents

5 Operation

Checks and operations prior to commissioning .............................. 68

Visualinspections ................................................... 68

Fillingthewashersystem .............................................. 70

Checking the condition of the wheels and tyres .............................. 71

Adjusting the GS15 driver’s

AdjustingtheMSG65/MSG75driver’sseat ................................ 74

Adjustingthearmrest ................................................. 77

Commissioning ..................................................... 79

Climbingon/off ...................................................... 79

Connecting the battery male connector .................................... 81

Shelfandcupholder ................................................. 81

Unlockingtheemergencyoffswitch ...................................... 82

Switchingonthekeyswitch ............................................ 83

Access authorisation wit

Operating the signal horn .............................................. 96

Seatbelt .......................................................... 97

Checking the brake syste

Checkingthesteeringsystemforcorrectfunction ............................100

Checking the emergency stop function ....................................101

Zero adjustment of the l

Checking the vertical lift mast position (variant) for correct function . ...............103

Driving ............................................................104

Safety regulations wh

Driveways ....................................................... . . 106

Settingthedriveprograms .............................................108

Reducing speed with a

Special overhead guard for drive-in racks (variant) ...........................109

Selectingthedrivedirection ............................................111

Actuating the drive d

Actuatingthedrivedirectionswitch,mini-leverversion .........................112

Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 113

Actuate the drive di

Actuatingthedrivedirectionswitch,mini-consoleversion ......................114

Startingdrivemode ..................................................114

Starting drive mode

Operatingtheservicebrake ............................................119

Actuating the mechanical parking brake . . . ................................120

Steering ...........................................................121

Reducing speed when turning (Curve Speed Control) .........................122

rectionswitch,fingertipversion ...........................113

seat ......................................... 72

hPINcode(variant) ................................ 86

mforcorrectfunction .............................. 99

oadmeasurement(variant) ...........................101

endriving .........................................104

raisedload(variant) ................................109

irectionswitch,multiple-leverversion ......................112

, dual-pedal version (variant) .............................116

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Table of contents

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Lifting ............................................................123

Liftingsystemvariants ................................................123

Automatic lift cut out (varian

Liftmastverticalposition(variant) ........................................124

Typesofliftmast ....................................................128

Malfunctions during lifting m

Liftingsystemoperatingdevices .........................................131

Hydraulicblockingfunction .............................................132

Multi-lever lifting system

Controlling the lifting system using a double mini-lever .........................135

Controllingtheliftingsystemusingatriplemini-lever ..........................136

Controlling the lifting sy

Controllingtheliftingsystemusingthejoystick4Plus ..........................138

Controllingtheliftingsystemwiththefingertipconsole .........................140

Changing the fork arms ...............................................141

Forkextension(variant) ...............................................143

Operationwithreversibleforkarms(variant) ................................145

Workingwithloads ...................................................147

Safety regulations when handing loads ....................................147

Beforetakingupload .................................................148

Load measurement (vari

Picking up loads .....................................................152

Danger area .......................................................153

Transportingpallets ..................................................1

Transportofswingingloads ............................................154

Pickingupaload ....................................................155

Transporting loads ...................................................1

Setting down loads ...................................................160

Driving on ascending and descending slopes ...............................162

Drivingonlifts ......................................................162

Drivingonloadingbridges .............................................164

Workingwithattachments .............................................165

Fitting attachment

Releasingthepressurefromthehydraulicsystem ............................167

General instructions for controlling attachments . . ...........................169

Controlling attach

Controlling attachments using multi-lever operation and the 5th function ...........172

Controlling attachments using a double mini-lever . ...........................174

Controlling attac

Controllingattachmentsusingatriplemini-lever .............................178

Controlling attachments using the three-way mini-lever and the 5th function .........180

s ..................................................165

ments using multi-lever operation ...........................171

hmentsusingthedoublemini-leverandthe5thfunction ...........176

t) ...........................................123

ode .........................................130

...............................................134

stem using a quadruple mini-lever ......................137

ant) ...........................................149

54

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Table of contents

Controlling attachments using a quadruple mini-lever .........................182

Controlling attachments using the four-way mini-lever and the 5th function ..........184

Controlling attachments via t

Controlling attachments using the joystick 4Plus and the 5th function . . . ...........187

Controlling the attachments with fingertip . . ................................188

Controlling attachments with

Clamp locking mechanism (variant) ......................................191

Takingupaloadusingattachments ......................................195

Operation of additional equ

Switchinglightingonandoff ............................................197

Switching the rotating beacon on and off . . . ................................197

Switching the hazard warni

Switchingdirectionindicatorsonandoff ...................................198

Switching the double working spotlights on and off. ...........................201

Operating the windscreen

FleetManager (variant) . ...............................................203

Accidentrecorder(variant) .............................................204

Driver restraint system

Clipboard (variant) ...................................................204

Trailer operation ....................................................205

Towedload ....................................................... . 205

Tow coupling RO*230 . ...............................................206

Tow coupling RO*244 . ...............................................208

Towingtrailers ......................................................210

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

Operating the display and operating unit ...................................214

Indicators .........................................................214

Adjustingthedisplays ................................................217

Symbolsinthedisplay ................................................217

Setting the date or ti

Resetting the daily kilometres and daily operating hours .......................222

Setting the language . . ...............................................223

Soft key button for o

ConfiguringBlue-Qefficiencymode ......................................224

Blue-Q efficiency mode ...............................................226

Functional descri

Effects on additional consumers .........................................226

SwitchingefficiencymodeBlue-Qonandoff ................................227

Malfunctions .......................................................229

Screencontent ................................................... . . 229

ption ................................................226

hejoystick4Plus ...............................186

fingertip and the 5th function ......................189

ipment .......................................196

ngsystemonandoff .............................198

wiper/washer ...................................203

s(variants) .......................................204

me ................................................222

perating various equipment variants .......................223

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Table of contents

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EMERGENCYSWITCHmessage .......................................230

SEATSWITCHmessage ..............................................230

SAFETYBELTmessage ..............................................233

APPLYHANDBRAKEmessage .........................................234

LOWERFORKSmessage .............................................235

REFERENCECYCLEmessage .........................................235

SERVICEBRAKEmessage ............................................236

Operation in special operating situations ...................................237

Transporting .......................................................237

Towing .......................................................... . 240

Craneloading ......................................................243

Behaviour in emergencies .............................................2

Emergency shutdown ................................................247

Procedureiftrucktipsover .............................................248

Emergency lowering .................................................248

Handling the battery ..................................................251

Safety regulations when handling the battery ...............................251

Opening and closingthe b

Opening/closing the battery door ........................................259

Disconnecting the battery male connector ..................................261

Battery replacement us

Batterytransportwithcrane ............................................269

Changing the battery using the internal roller channel .........................270

Battery replacement u

Battery installation or battery replacement without onboard devices . . . ............277

Maintainingthebattery ................................................278

Decommissioning ...................................................282

Parkingthetrucksecurelyandswitchingitoff ...............................282

Wheel chock (variant) ................................................284

Shutting down and sto

Recommissioningafterstorage .........................................286

Cleaning ..........................................................288

Cleaning the truck ...................................................2

Cleaning the electrical system ..........................................290

Cleaning load chains .................................................291

Afterwashing .......................................................292

attery hood .....................................254

ingabridge .......................................262

sing an external roller channel ..........................273

ringthetruck ......................................284

47

88

6 Maintenance

General maintenance information ........................................294

Personnelqualifications ...............................................294

II 55048011501 EN - 12/2015

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Table of contents

Informationforcarryingoutmaintenance ..................................294

Maintenance — 1000 hours/annually .....................................297

Maintenance - 3000 hours/ever

Orderingsparepartsandwearingparts ....................................301

Quality and quantity of the required operating materials ........................301

Maintenance data table ...............................................303

Safety regulations for maintenance .......................................306

Generalinformation ..................................................306

Working on the hydraulic equ

Working on the electrical equipment ......................................306

Safetydevices ......................................................307

Setvalues ....................................................... . . 307

Liftingandjackingup .................................................307

Workingatthefrontofthetruck ..........................................308

Providing access to maint

Removing/installingthevalvecover ......................................310

Removing/installingthebottomplate .....................................311

Removing/installing th

Maintenance .......................................................315

Lubricatingthejointsandcontrols ........................................315

Checking the battery ho

Maintainingtheseatbelt ...............................................316

Checkingthedriver’sseat .............................................318

Servicing wheels and t

Checking the drive axle for oil level, leaks and general condition . .................320

Checkingthebrakefluidlevel ...........................................321

Checking the brake flu

Checking the battery condition, acid level and acid density ......................324

Checkingthefuses ...................................................325

Changing fuses .....................................................327

Checkingthehydraulicoillevel ..........................................329

Checkingthehydraulicsystemforleaks ...................................330

Lubricating the lif

Maintenance for trucks used in cold stores . ................................331

Maintaining the tow coupling ............................................331

1000-hour maintena

Othertasks ...................................................... . . 333

Checking the cable connections .........................................333

Checking accelera

Checkingthebrakesystemforcorrectoperationandleaks .....................333

Checking the dual pedal ...............................................334

e bottom plate for dual pedal operation (variant) .............313

yres .............................................318

idlevelsensor .....................................322

tmastandrollertrack ....................................331

nce / Annual maintenance ..............................333

tor pedal and brake pedal ................................333

ytwoyears .................................301

ipment ......................................306

enance points ...................................310

odlock ..........................................315

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Table of contents

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Checking the lift cylinders and connections for leaks ..........................334

Checkingforkarms ..................................................335

Checking the reversible fork a

rms ........................................335

7 Technical data

Dimensions ........................................................338

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

VDI datasheet: RX50-15 an

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

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

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

dRX50-16 ....................................343

X5

5048011501 EN - 12/2015

1

Foreword

1 Foreword

Your truck

Your truck

General

The truckdescribed inthese operating instruc­tions corresponds to the applicable standards
and safety regulations.

If the truck is to be operated on public roads, it
must conform to the existing national regula­tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.

Thetruckshavebeenfittedw
art technology. All that re
the truck safely and maint

These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.

CE labelling

The manufacturer uses CE labelling to indi­cate that the truck complies with the standards
and regulations valid at the time of marketing.
This isconfirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.

An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.

The EC declaration o
carefully stored an
responsible author

dmadeavailabletothe
ities.

ith state-of-the-

mains is to handle

ain its functionality.

f conformity must be

25

5048011501 EN - 12/2015

CE-Symbol

Foreword 1

Your truck

EC declaration of conformity in accordance with Machinery Directive

Declaration

STILL GmbH

Berzeliusstraße 10

D-22113 Hamburg Germany

We declare that the

Industrial truck

Model

according to these operating instructions

according to these operating instructions

conforms to the latest version of the Machinery Directive 2006/42/EC.

Personnel authorised to compile the technical documents:

See EC compliance declaration

STILL Gmb

.

H

Accessories

• Key for key switch (two pieces)

• Hexagon socket wrench for emergency
lowering (not in multi-lever operation)

048011501 EN - 12/2015 3

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1 Foreword

Information about documentation

Information about documentation

Documentation scope

• Original operating instructions

• Original operating instructions for attach­ments (variant)

• Spare parts list

• VDMA rules for the proper use of industrial
trucks

These operating instructions describeall mea­sures necessary for the safe operation and
proper maintenance of your truck in all pos­sible variants available at the time of printing.
Special versions to meet customer require­ments are documented in separate operating
instructions. If you have any questions,please
contact your authorised service centre.

Enter the production num
manufacturer from the na
provided:

Production number

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

Year of manufacture

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

Please quote the produ
technical enquiries.

Each truck comes with a set of operating
instructions. These instructions must be
stored carefully and must be available to the
driver and operating company atany time. The
storage location is specified in the "Overviews"
chapter.

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

The operating instr
spare parts list and
a spare part.

The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.

The operating company must ensure that all
users have received, read and understood
these operating instructions.

ber and year of

meplate in the space

ction number during all

uctions are included in the

can be reordered there as

45

5048011501 EN - 12/2015

Foreword 1

Information about documentation

NOTE

Please observe the definition o
responsible persons: "operat

f the following

ing company"

and "driver".

Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any errors, please contact
the authorised service centre.

Issue date and topicality of the operating instructions

The issue date of these operating instructions
can be found on the title page.

STILL is constantly engaged in the further
development of trucks. These operating
instructions are subject to change, and any
claims based on the information and/or
illustrations contained in them cannot be
asserted.

Please contact your au
for technical support

thorised service centre

relating to your truck.

Copyright and tradem

These instruction
translated or made
ties—including as
express written ap

s must not be reproduced,

excerpts—except with the
proval of the manufacturer.

Explanation of in

ark rights

accessible to third par-

formation symbols

used

DANGER

Indicates proceduresthat must be strictly adhered
to in order to prevent the risk of fatalities.

WARNING

Indicates procedures that must be strictly adhered
to in order to prevent the risk of injuries.

048011501 EN - 12/2015 5

55

1 Foreword

Information about documentation

CAUTION

Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.

NOTE

For technical requirements that require
special attention.

ENVIRONMENT NOTE

To prevent environmental damage.

List of abbreviations

NOTE

This list of abbreviations applies to all types
of operating instructions. Not all of the abbre­viations that are listed here will necessarily
appear in these operating instructions.

Abbreviation

°C

°F

A

ABE

ArbSchG

BetrSichV

BG

BGG

BGR
German Social

Accident
Insurance

Approx.

CE

CEE

cm

65

Meaning

Degrees Celsius

Degrees Fahrenheit

Amperes

Display operating unit

German labour protection law

German Ordinance on Industrial Safety and Health

Employers’ liability insurance association

Employers’ liability insurance association act

Employers’ liability insurance association rule

Employers’ liability insurance association regulation

Approximately
Symbol that confirms conformity with the valid product-specific European

directives
International Commission on the Rules for the Approval of Electrical Equip­ment

Centimetres

5048011501 EN - 12/2015

Foreword 1

Information about documentation

Abbreviation

3

cm

Meaning

Cubic centimetres

dB Decibels

DFÜ

Remote data transmission

DIN German standard

EG

EN
FEM
F

max

g

GAA

European Community

European standard

Fédération Européene de
Maximum power

Grams
Industrial inspectorate

la Manutention

If applicable If applicable

GPRS General Packet Radio Service

h/d

Hours per day (time driven each day in hours)

ID no. ID number

ISO International standard

kg Kilograms

3

kg/m
km/h
km/d

Kilograms per cubic metre
Kilometres per hour
Kilometres per day (kilometres driven each day)

kN Kilonewtons

kW Kilowatts

kWh/h

Energy consumption

lLitres

l/h

l/min

Litres per hour

Litres per minute

LAN Local area network

LED
L

p

L

pAZ

LSP

o.s.

m

Light emitting diode

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

Load centre of gravity

milar

Or si

Metres

048011501 EN - 12/2015 7

55

1 Foreword

Information about documentation

Abbreviation

m/s

2

m/s

MAK

Meaning

Metres per second

Metres per second squared

Maximum workplace concentration

Max. Maximum

Min. Minimum

min Minutes
rpm

mm

Revolution(s) per minute

Millimetres
N Newtons
Nm Newton metres
PIN

SE

SIT

StVZO

t

TRGS

a.s.

Personal identifica

Superelastic

Snap-in tyre for simplified assembly

German Road Traffic Licensing Regulations

Tonnes

Technical Regulations for Hazardous Substances

And similar

tion number

VVolts

VDE

VDI

VDMA

Association for Electrical, Electronic & Information Technologies

Association of German Engineers

German Engineering Federation

W Watts

WLAN Wireless
e.g.

.

For example

local area network

85

5048011501 EN - 12/2015

Foreword 1

Information about documentation

Definition of directions

The directions"forwards" (1), "backwards" (3),
"right" (2) and "left" (4) refer to the installation
position of the parts as seen from the driver’s
compartment; the load is to the front.

Schematic views

View of functions and operations

This documentati
sequential) cha
ations. Schemat
ance truck are us
dures.

NOTE

These schemati
tative of the s
truck. The dia
purpose of cla

on explains the (usually

in of certain functions or oper-

ic diagrams of a counterbal-

ed to illustrate these proce-

c diagrams are not represen-

tructural state ofthe documented

grams are used solely for the
rifying procedures.

1

4

2

3

6210_001-031

6210_003-062

048011501 EN - 12/2015 9

55

1 Foreword

Information about documentation

View of the display operating unit

NOTE

Views of operating statuses and values in
the display of the display operating unit are
examples and partly dependent on the truck
equipment. As a result, the displays shown
of the actual operating statuses and values
can vary. Information that is not relevant for
descriptions is not shown.

10

55048011501 EN - 12/2015

Foreword 1

Environmental considerations

Environmental considerations

Packaging

During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.

ENVIRONMENT NOTE

The packaging material mu
properly after delivery o

st be disposed of

f the truck.

Disposal of component

s and

batteries

The truckis composed
components or batter
and disposed of, they

• disposed of,

• treated or

• recycled in accorda
national regulatio

NOTE

The documentation provided by the battery
manufacturer must be observed when dispo­sing of batteries.

ENVIRONMENT NOTE

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

of different materials. If

ies need to be replaced

must be:

nce with regional and

ns.

048011501 EN - 12/2015 11

55

1 Foreword

Environmental considerations

12

55048011501 EN - 12/2015

2

Introduction

2 Introduction

Use of truck

Use of truck

Proper usage

The truck described in these operating in­structions is suitable for lifting, transporting
and stacking loads.

The truck may only be used for its proper
purpose as set out and described in these
operating instructions.

If the truck is to be used for
than those specified in the o
tions, the approval of the m
applicable, the relevant r
must be obtained beforeha
ards.

The maximum load to be lifted is specified on
the capacity rating plate (load diagram) and
must not be exceeded; see also the chapter
entitled "Before picking up a load".

Proper use during towing

This truck is suitable for the occasional towing
of trailersand is equipped with a towing device
for this purpose. This occasional towing may
not exceed 2% of the daily operating time. If
the truck is to be used for towing on a more
regular basis, the manufacturer should be
consulted.

The regulations regarding trailer operation
must be observed; see chapter "Trailer
operation".

purposes other

perating instruc-

anufacturer and, if

egulatory authorities

nd to prevent haz-

Impermissible use

The operating company or driver, and not the
manufacturer, is liable for any hazards caused
by improper use.

NOTE

Please observe the definition of the following
responsible persons: "operating company"
and "driver".

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

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55048011501 EN - 12/2015

Introduction 2

Use of truck

DANGER

There is a risk of fatal injury from
falling off the truck while it is moving!

– It is prohibited to carry passengers

on the truck.

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

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

Place of use

The truck can be used both outside and in
buildings. Operation on public roads is only
permitted if the "StVZO" (German Road Traffic
Licensing Regulations) equipment variant is
installed.

If the truck is to be operated on public roads, it
must conform to the existing national regula­tions for the country in which it is being used.

The ground must have an adequate load
capacity (concrete, asphalt) and a rough
surface. Routes, work areas and aisle widths
must conform to the specifications in these
operating instructions, see the "Routes"
chapter.

Driving on upward and downward gradients
is permitted provided the specified data and
specifications are observed, see the "Routes
"chapter.

The forklift truck is suitable for indoor and
outdoor use in countries ranging from the
Tropics to Nordic regions (temperature range:

-20°C to +40°C).

If the truck is to be used in a cold store, it must
be configured accordingly and, if necessary,
approved for such an environment; see the
chapter entitled "Cold store application".

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55

2 Introduction

Use of truck

CAUTION

Batteries can freeze!
If the truck is parked in an ambient temperature of

below –10 °C for an extended period, the batteries
cool down. The electrolyte may freeze and damage
the batteries. The truck is thennot ready for opera­tion.

– In an ambient temperature of below –10 °C, only

park the truck for shortperiods.

The operating company must ensure suitable
fire protection for the relevant application in
the truck’s surroundings. Depending on the
application, additional fire protection must be
provided on the truck. If in doubt, contact the
relevant authorities.

NOTE

Please observe the definition of the following
responsible person: "operating company".

Parking in temperatures below -10°C

CAUTION

Batteries can freeze!
Ifthetruckisparkedinanambienttemperature

below -10°C for an extended period, the batteries
will cool down. The electrolyte may freeze and
damage the batteries. The truck is then not ready
for operation.

– When the ambienttemperature is below -10°C,

only park the truck for short periods of time.

Using working platforms

WARNING

The use of working platforms is regulated by na­tional law. The use of working platforms is only
permitted by virtue of the jurisdiction in the country
of use.

– Observe national legislation.
– Before using working platforms, consult the

national regulatory authorities.

16

55048011501 EN - 12/2015

Introduction 2

Residual risk

Residual risk

Residual dangers, residual risks

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

The truck and all other system components
comply with current safety requirements.
Nevertheless, even when the truck is used
for its proper purpose and all instructions
are followed, some residual risk cannot be
excluded.

Even beyond the narrow dan
truck itself, a residual r
Persons in this area aroun
exercise a heightened deg
so that they can react imme
of any malfunction, incid

WARNING

All persons that are in the vicinity of the truck
must be instructed regarding these risks that arise
through use of the truck.

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

ger areas of the

isk cannot be excluded.

d the truck must
ree of awareness,

diately in the event

ent or breakdown etc.

The risks can include:

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

• Risk of accident when driving over difficult
ground such as gradients, smooth or
irregular surfaces, or with poor visibility
etc.

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

• Fire and explosion risks dueto batteries and
electrical voltages

• Human error resulting from failure to
observe the safety regulations,

• Unrepaired damage or defective and worn
components,

• Insufficient maintenance and testing

• Use of incorrect consumables

• Exceeding test intervals

048011501 EN - 12/2015 17

55

2 Introduction

Residual risk

The manufacturer is not held responsible for
accidents involving the truck caused by the
failure of the operating company to comply
with these regulations either intentionally or
carelessly.

Stability

The stability of the truck has been tested to the
latest technological standards and is guaran­teed provided that the truck is used properly
and according to its intended purpose. These
standards only take into account the dynamic
and static tipping forces that can arise during
specified use in accordance with the operat­ing rules and intended purpose. However, the
danger of exceeding the moment of tilt due to
improper use or incorrect operation and losing
stability can never be excluded.

The loss of stability can b
imised by the following ac

– Always secure the load against slipping,

e.g. by lashing.

– Always transport unstable loads in suitable

containers.

– Always drive slowly whe

– Drive with the load lowered.

– Even with sideshifts, align the load as

centrally as possible with the truck and
transport in this position.

– Avoid turning and dia

slopes or gradients.

– Never have the load facing downhill when

travelling on slopes or gradients.

– Pick up only loads of the approved width.

– Always take great ca

swinging loads.

– Do not drive over ramp edges or steps.

e avoided or min-

tions:

n cornering.

gonally driving across

re when transporting

Special risks associated with using the truck and attachments

Approval from the manufacturer and attach­ment manufacturer must be obtained each

18

55048011501 EN - 12/2015

Introduction 2

Residual risk

time the truck is used in a manner that falls
outside the scope of normal use, and in cases
where the driver is not certain that he can use
the truck correctly and without the risk of acci­dents.

048011501 EN - 12/2015 19

55

2 Introduction

Residual risk

Overview of hazards and counter­measures

NOTE

This table is intended to help evaluate the
hazards in your facility and applies to all drive
types. It does not claim to be complete.

– Observe the national regulations for the

country in which the truck is being used.

Hazard Measure

Truck equipment does
not comply with local
regulations

Lack of skills and
qualification of driver

Usage by unautho­rised persons

Truck not in a safe
condition

Risk of falling when
using working
platforms

Impaired visibility due
to load

Contamination of
respiratory air

Test

Driver training (sit-on
and stand-on)

Access with key only
for authorised persons

Recurrent testing and
rectification of defects

Compliance with
national regulations
(different national
laws)

Resource planning

Assessment of diesel
exhaust gases

Assessment of LPG
exhaust gases

Check note
√ Complete

- Not applicable
O If in doubt, consult

O BGG 925

O

O German Ordinance on

O German Ordinance on

O German Ordinance on

O

O German threshold

Notes

competent factory
inspectorate or
employers’ liability
insurance association

VDI 3313 driver permit

Industrial Safety and
Health (BetrSichV)

Industrial Safety and
Health (BetrSichV)
and employer’s
liability insurance
associations

Industrial Safety and
Health (BetrSichV)

Technical Regulations
for Hazardous
Substances (TRGS)
554 and the German
Ordinance on
Industrial Safety and
Health (BetrSichV)

limit values list
(MAK-Liste) and the
German Ordinance on
Industrial Safety and
Health (BetrSichV)

20

55048011501 EN - 12/2015

Introduction 2

Residual risk

Hazard Measure

Impermissible usage
(improper usage)

When fuelling

a) Diesel Note the German

b) LPG Note German Social

Issuing of operating
instructions

Written notice of
instruction to driver

Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules

Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules

Accident Insurance
(DGUV) regulation
D34, the operating
instructions and the
German Engineering
Federation (VDMA)
rules

Check note
√ Complete

- Not applicable
O German Ordinance on

O German Ordinance on

O

O

O

Notes

Industrial Safety and
Health (BetrSichV)
and German Health
and labour protection
law (ArbSchG)

Industrial Safety and
Health (BetrSichV)
and German Health
and labour protection
law (ArbSchG)

048011501 EN - 12/2015 21

55

2 Introduction

Residual risk

Hazard Measure

When charging the
traction battery

When using battery
chargers

When parking LPG
trucks

With driverless transport systems

Roadway quality
inadequate

Load carrier
incorrect/slipped

Drive behaviour
unpredictable

Driveways blocked Mark driveways

Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules

Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers’ liability
insurance association
regulation 104 and the
operating instructions

Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers’ liability
insurance association
regulation 104 and the
operating instructions

Clean/clear driveways O German Ordinance on

Reattach load to pallet

Employee training

Keep driveways clear

Check note
√ Complete

- Not applicable
O Association for

O German Ordinance on

O German Ordinance on

O German Ordinance on

O German Ordinance on

O German Ordinance on

Notes

Electrical, Electronic
and Information
Technologies (VDE)
regulation 0510: In
particular

- Ensure adequate
ventilation

- Insulation value
within the permissible
range

Industrial Safety and
Health (BetrSichV)
and employers’
liability insurance
association regulation
104

Industrial Safety and
Health (BetrSichV)
and employers’
liability insurance
association regulation
104

Industrial Safety and
Health (BetrSichV)

Industrial Safety and
Health (BetrSichV)

Industrial Safety and
Health (BetrSichV)

Industrial Safety and
Health (BetrSichV)

22

55048011501 EN - 12/2015

Introduction 2

Residual risk

Hazard Measure

Driveways intersect

Announce right-of­way rule

No person detection

Employee training
during depositing and
retrieval

.

Danger to employees

According to the German Ordinance on Indus­trial Safety and Health (BetrSichV) and labour
protection law (ArbSchG), the operating com­pany must determine and assess hazards
during operation, and establish the labour
protection measures required for employ­ees (BetrSichVO). The operating company
must therefore draw up appropriate operating
instructions (§ 6 ArbSchG) and make them
available to the driver. A responsible person
must be appointed.

NOTE

Please observe t
responsible per
and "driver".

The construction and equipment of the
truck correspond to the Machinery Directive
2006/42/EC and are therefore marked with
CE labelling. These elements are therefore
not included in the hazard assessment. At­tachments possess their own CE labelling and
likewise are not included for that reason. The
operating company must, however, select the
type and equipment of thetrucks so as to com­ply with the local provisions for deployment.

The result must be documented (§ 6 Arb­SchG). In the case of truck applications involv­ing similar hazard situations, the results may
be summarised. This overview (see chapter
"Overview of hazards and countermeasures")
provides help on complying with this regula­tion. The overview specifies the main hazards
that are the most frequent cause of accidents
in the event of non-compliance. If other major

he definition of the following

sons: "operating company"

Check note
√ Complete

- Not applicable
O German Ordinance on

O German Ordinance on

Notes

Industrial Safety and
Health (BetrSichV)

Industrial Safety and
Health (BetrSichV)

048011501 EN - 12/2015 23

55

2 Introduction

Residual risk

operational hazards are involved, they must
also be taken into consideration.

The conditions of use for trucks are broadly
similar in many plants, so the hazards can
be summarised in one overview. Observe
the information provided by the relevant
employers’ liability insurance association on
this subject.

24

55048011501 EN - 12/2015

3

Safety

3 Safety

Definition of responsible persons

Definition of responsible persons

Operating company

The operating company is the natural or legal
person or group who operates the truck or on
whose authority the truck is used.

The operating company must ensure that the
truck is only used for its proper purpose and in
compliance with the safety regulations set out
in these operating instructions.

The operating company must
all users read and understa
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 qualified person is defined as a service
engineer or a person who fulfils the following
requirements:

• A completed vocation
demonstrably proves
expertise. This proo
a vocational qualifi
document.

• Professional experience indicating that
the qualified person has gained practical
experience of industrial trucks over a
proven period during their career During
this time, this person has become familiar
with a wide range of symptoms that require
checks to be carried out, such as based
on the results of a hazard assessment or a
daily inspection

• Recent professional involvement in the
field of the industrial truck test in question
and an appropriate further qualification
are essential. The qualified person must
have experience of carrying out the test
in question or of carrying out similar tests.
Moreover, this person must be aware of
the latest technological developments

cation or a similar

ensure that

nd the safety

al qualification that
their professional

f should consist of

26

55048011501 EN - 12/2015

Safety 3

Definition of responsible persons

regarding the industrial truck to be tested
and the risk being assessed

Drivers

This truck may only be driven by suitable per­sons who are at least 18 years of age, have
been trained in driving, have demonstrated
their skills in driving and handling loads to
the operating company or an authorised rep­resentative, and have been specifically in­structed to drive the truck. Specific knowledge
of the truck to be operated is also required.

The training requirements under §3 of the
Health and Safety at Work Act and §9 of the
plant safety regulations are deemed to have
been satisfied if the driver has been trained in
accordance with BGG (General Employers’
Liability Insurance Association Act) 925.
Observe the national regulations for your
country.

Driver rights, duties and rules of be­haviour

The driver must be trai
duties.

The drivermust be grantedthe required rights.

The driver must wear protective equipment
(protection suit, safety footwear, safety
helmet, industrial goggles and gloves) that
is appropriate for the conditions, the job and
the load to be lifted. Solid footwear should be
worn to ensure safe driving and braking.

Thedrivermustbefa
instructions and ha
times.

The driver must:

• have read and understood the operating
manual

• have familiarised himself with safe opera­tion of the truck

• be physically and m
truck safely

ned in his rights and

miliar with the operating

ve access to them at all

entally able to drive the

048011501 EN - 12/2015 27

55

3 Safety

Definition of responsible persons

DANGER

The use of drugs, alcohol or medicationsthat affect
reactions impair the ability to drive the truck!

Individuals under the influence of the aforementio­ned substancesare not permitted to perform work
of any kind on or with the truck.

Prohibition of use by unauthorised
persons

The driver is responsible for the truck during
working hours. He must not allow unautho­rised persons to operate the truck.

When leavingthe truck, thedriver must secure
it against unauthorised use, e.g. by pulling out
the key.

28

55048011501 EN - 12/2015

Safety 3

Essentials for safe operation

Essentials for safe operation

Insurance cover on company premises

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

NOTE

The business liability insurance should be
reviewed to ensure that, in the event of any
damage caused in restricted public traffic
areas, there is insurance cover for the truck in
respect of third parties.

Changes and retrofitting

If the truck is used for work that is not listed
in the guidelines or in these instructions and
has to be converted or retrofitted accordingly,
you must note that any change to its structural
state can affect the handling and stability of
the truck, which in turn can lead to accidents.

You should therefor
centre beforehand.

Changes that will adversely affect stability,
load capacity and safety systems, among
other things, must not be made without the
manufacturer’s approval.

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

Changes to the bra
elements, circum
variants (e.g. at
made without the p
manufacturer.

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

e contact your service

kes, steering, control

ferential view, equipment

tachments) must also not be

rior written approval of the

048011501 EN - 12/2015 29

55

3 Safety

Essentials for safe operation

DANGER

Risk ofinjury if truck tips over!
Even when using an approved

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 seat belt protects against the
consequences of rear-end collisions
and fallingoff a ramp.

– Use the seat belt too.

When carrying out welding work on the
truck, it is essential that the battery and all
connections to the electronic control cards are
disconnected. Contact the authorised service
centre on this matter.

DANGER

Risk of explosion from additional
holes in the battery hood!

Explosive gases can escape and
lead to potentially fatal injuries if they
explode. Sealing holes with plugs
is not sufficient to prevent gas from
escaping.

– Do not drill any holesin the battery

hood.

DANGER

Risk of accident from additional holes in the battery
hood!

The rigidity of the battery hood is impaired and
the battery hood may fracture. The driver’s seat
may collapse, leading to a risk of accident due to
uncontrolled steering movements whilstdriving.

– Do not drill any holes in the battery hood.

30

55048011501 EN - 12/2015

Safety 3

Essentials for safe operation

DANGER

Risk to life from falling load!
If the truck is not equipped with an overhead guard,

there is a risk to the driver’s life, as he may be struck
by a load falling from a lift height of 1800 mm or
greater.

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

– For lift heights of 1800 mm and above, only use

trucks withan overhead guard.

In the event of the manufacturer going into
liquidation and the company not being taken
over by another legal person, the operating
company can make changes to the truck.

To do so, the operating company must fulfil
the following prerequisites:

Construction documents, test documents
and assembly instructions associated with
the change must be archived and remain
accessible at all times.

Check that the capacity rating plate, decal in­formation, hazard warnings and the operating
instructions are consistent with regard to the
changes and modify if necessary.

The change must be designed, checked
and implemented by a design office that
specialises in industrial trucks in accordance
with the standards and directives valid at the
time the changes are made.

Decal information with the following data must
be permanently affixed to the truck so it is
clearly visible:

– Type of change

– Date of change

– Name and address of the company imple-

menting the change.

048011501 EN - 12/2015 31

55

3 Safety

Essentials for safe operation

Changes to the overhead guard and roof loads

DANGER

In the event of the overhead guard failing due to
a falling load or the truck tipping over, there are
potentially fatal consequences for the driver. There
is a risk to life!

Welding and drilling on the overhead guard chan­ges the material characteristics and the structural
design of the overhead guard. Excessive forces
caused by falling loads orthe trucktipping over may
result in buckling of the modified overhead guard
andnoprotectionforthedriver.

– Do not perform welding on the overhead guard.
– Do not perform drilling on the overhead guard.

CAUTION

Heavy roof loads damage the overhead guard!
To ensure the stability of the overhead guard at

all times, a roof load may only be mounted on the
overhead guard if the structural design has been
tested and the manufacturerhas given approval.

– Seek advice from the authorised service centre

for the mounting of roof loads.

Warning regardingnon-original parts

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

CAUTION

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

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

32

55048011501 EN - 12/2015

Safety 3

Essentials for safe operation

Damage, defects and misuse of safety systems

Damage or other defects on the truck or
attachment must be reported to the supervisor
or responsible fleet manager immediately so
that they can have the defect rectified.

Trucks andattachments that are not functional
or safe to drivemay not be used until they have
been properly repaired.

Do not remove or deactivate
and switches.

Fixed set valuesmay only be changed withthe
approval of the manufacturer.

Work onthe 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 removabl
not be removed, as they a
protect against small f

safety systems

e, roof panels may

re designed to

alling objects.

Tyres

DANGER

Risk to stability!
Failure to observe the following information and

instructions can lead to a loss of stability. The truck
may tip over, risk of accident!

Thefollowingfactorscanleadtoalossof
stability and are therefore prohibited:

• Different tyres on the same axle, e.g.
pneumatic tyres and superelastic tyres

• Tyres not approved by the manufacturer

• Excessive tyre wear

• Tyres of inferior quality

• Changing rim wheel parts

• Combining rim wheel parts from different
manufacturers

048011501 EN - 12/2015 33

55

3 Safety

Essentials for safe operation

The following rules must be observed to
ensure stability:

• Only use tyres with equal and permitted
levels of wear on the same axle

• Only use wheels and tyres of the
on the same axle, e.g. only supe
tyres

• Only use wheels and tyres approved by the
manufacturer

• Only use high-quality products

Wheels and tyres approved by
facturer can be found on the s
If other wheels or tyres are t
thorisation from the manu
obtained beforehand.

– Contact the authorised service centre on

this matter.

When changing wheels or tyres, always
ensure that this does not cause the truck to
tilt to one side (e.g. always replace right­hand and left-hand wheels at the same
time). Changes must only be made following
consultation with the manufacturer.

Ifthetypeoftyreusedon
for example from superel
matic tyres, the load dia
accordingly.

– Contact the authorised service centre on

this matter.

facturer must be

an axle is changed,

astic tyres to pneu-

gram must be changed

same type
relastic

the manu-

pare parts list.

o be used, au-

Medical equipment

WARNING

Electromagneticinterference may occuron medical
devices!

Only use equipment that is sufficiently protected
against electromagnetic interference.

Medical equipment, such as pacemakers or
hearing aids, may not work properly when the
truck is in operation.

– Ask your doctor or the manufacturer of

the medical equipment to confirm that the
medical equipment is sufficiently protected
against electromagnetic interference.

34

55048011501 EN - 12/2015

Safety 3

Essentials for safe operation

Exercise caution when handling gas springs and accumulators

WARNING

Gas springs are under high pressure. Improper
removal resultsin an elevated risk of injury.

For ease of operation, various functions on the
truck can be supported by gas springs. Gas springs
are complex components that are subject to high
internal pressures (up to 300 bar). They may under
no circumstances be opened unless instructed to
do so, and may be installed only when not under
pressure. If required, the authorised service centre
will depressurise the gas spring in accordancewith
the regulations before removal. Gas springs must
be depressurisedbefore recycling.

– Avoid damage, lateral forces, buckling, tempe-

ratures over80°C and heavy contamination.

– Damaged or defective gas springs must be

changed immediately.

– Contact the authorised service centre.

WARNING

Accumulators are under high pressure. Improper
installation of an accumulator results in an elevated
risk of injury.

Before starting work on the accumulator it must be
depressurised.

– Contact the authorised service centre.

Length of the fork arms

DANGER

Risk of accident due to the incorrect selection of
fork arms!

– The fork arms must match the depth of the load.

If the fork arms are too short, the load may
fall off the arms after it has been picked up.
In addition, be aware that the load centre of
gravity may shiftas a result of dynamic forces,
such as braking. A load that is otherwise
resting safely on the fork arms may move
forwards and fall.

If the fork arms are too long, they can catch
on loading units behind the load that is to be

048011501 EN - 12/2015 35

55

3 Safety

Essentials for safe operation

picked up. These other loading units then fall
over when the load is raised.

– For help with selecting the correct fork arms,

contact the authorised service centre.

36

55048011501 EN - 12/2015

Safety 3

Safety tests

Safety tests

Regular safety inspection of the truck

Safetyinspectionbasedontimeand
extraordinary incidents

The operating company must ensure that the
truck is checked by a specialist at least once a
year or after particular incidents.

As part of this inspection
of the technical conditio
performed with regard to a
In addition, the truck mus
checked for damage that co
have been caused by impro
log must be created. The r
inspection must be retai
inspections have been ca

The inspection date is indicated by an adhe­sive label on the truck.

– Arrange for the service centre to perform

periodic safety inspections on the truck.

– Observe guidelines fo

on the truck in accorda

The operator is responsible for ensuring any
defects are remedied without delay.

– Contact your service centre.

, a complete check

n of the truck must be

ccident safety.

t be thoroughly

uld potentially

per use. A test

esults from the

ned until a further two

rried out.

r checks carried out

nce with FEM 4.004.

NOTE

Observe the national regulations for your
country!

Insulation testing

The truck insulation must have sufficient insu­lation resistance. For this reason, insulation
testing in accordance with DIN EN 1175 and
DIN 43539, VDE 0117 and VDE 0510 must be
conducted at least once a year.

NOTE

The truck’s el
ries must be ch

ectrical system and drive batte-

ecked separately.

048011501 EN - 12/2015 37

55

3 Safety

Safety tests

Measuring the battery’s insulation
resistance

NOTE

Nominal battery voltage < test voltage < 500
V.

– Measure the insulation resistance with a

suitable measuring device.

The insulation resistance can be considered
sufficient if it measures at least 500
nominal battery voltage against ground.

– Contact the authorised service centre.

Measuring the insulation resistance of
the electrical system

NOTE

Nominal battery voltage < test voltage < 500
V.

– Ensure that all volt

disconnected from t

– Measure the insulation resistance with a

suitable measuring device.

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

– Contact the author

age sources have been

he circuit to be tested.

ised service centre.

/V for the

/V for

38

55048011501 EN - 12/2015

Safety 3

Safety regulations for handling co

nsumables

Safety regulations for handling consumables

Permissible consumables

DANGER

Failure to observe the safety regulations relatingto
consumables mayresult in a risk of injury, death or
damage to the environment.

– Observe the safety regulations when handling

such materials.

Refer to the maintenance data table for the
permissible substances that are necessary for
operation (see ⇒ Chapter "Maintenance data
table", P. 6-303).

Oils

DANGER

Oils are flammable!
– Follow the statutory regulations.
– Donotallowoilstocomeinto

contact with hot engine parts.

– No smoking,fires ornaked flames!

DANGER

Oils are toxic!
– Avoid contact and consumption.
– If vapour or fumes are inhaled,

move to fresh air immediately.

– In the event of contact with the

eyes, rinsethoroughly (for at least
10 minutes) with water and then
consult an eye specialist.

– If swallowed, do not induce

vomiting. Seek immediate medical
attention.

048011501 EN - 12/2015 39

55

3 Safety

Safety regulations for handling co

WARNING

Prolonged intensive contact with the
skin can result in dryness and irritate
the skin!

– Avoid contact and consumption.
– Wear protective gloves.
– After any contact, wash the skin

with soap and water, and then
apply a skin care product.

– Immediately change soaked

clothing and shoes.

WARNING

There is a risk of slipping on spilled oil, particularly
when combined with water!

– Spilt oil should be removed immediately with

oil-binding agents and disposed of according to
the regulations.

ENVIRONMENT NOTE

Oil is a water-polluting substance!

•

Always store oil in containers that comply
with the applicable regulations.

•

Avoid spilling oils.

•

Spilt oil should be removed immediately
with oil-binding agents and disposed of
according to the regulations.

•

Dispose of old oils according to the regula­tions.

nsumables

Hydraulic fluid

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

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

contact withhot engine parts.

40

WARNING

55048011501 EN - 12/2015

Safety 3

nsumables

WARNING

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

– Do not allow the fluids to come into

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

fluids into the skin is particularly

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

Safety regulations for handling co

Hydraulic fluid is a water-polluting substance.

•

Always store hydraulic fluid in containers
that comply with regulations

•

Avoid spills

•

Spilt hydraulic fluid should be removed
immediately with oil-binding agents and
disposed of according to the regulations

•

Dispose of old hydraulic fluid according to
the regulations

Battery acid

Battery acid contains dissolved
sulphuric acid. This is toxic.

– Avoid touching or swallowing the

– In case of injury, seek medical

WARNING

battery acid at all costs.

advice immediately.

048011501 EN - 12/2015 41

55

3 Safety

Safety regulations for handling co

WARNING

Battery acid contains dissolved
sulphuric acid. This is corrosive.

– When working with battery acid,

always wear a protection suit and
eye protection.

– When working with battery

acid, never wear a watch or any
jewellery.

– Do not allow any acid to get

onto clothing or skin or into the
eyes; if this does happen, rinse
immediately with plenty of clean
water.

– In case of injury, seek medical

advice immediately.

– Immediately rinse away spilt

battery acid with plenty of water.

– Follow the statutory regulations.

ENVIRONMENT NOTE

– Dispose of used battery acid in line with the

applicable regulations.

Brake fluid

nsumables

WARNING

Brake fluid is poisonous!
– Avoid swallowing. In the event

of swallowing, do not induce
vomiting. Rinse out your mouth
thoroughly with water and ask a
doctor for advice.

– Avoid aerosolisation and inha-

lation. In the event of inhalation,
seek freshair. Ask a doctor for ad­vice if necessary.

42

55048011501 EN - 12/2015

Safety 3

nsumables

WARNING

Brake fluid is hazardous to your
health!

Brake fluid irritates the eyes and
can dry out the skin upon prolonged
contact.

– Coat your hands with a protective

skincreampriortostartingwork.
– Avoid prolonged or intensive

skin contact. In the event of skin

contact, cleanthe wetted skin with

water and soap, and subsequently

apply a skin care product.
– Prevent contact with the eyes. In

the event of contact with the eyes,

wash out the affected eye(s) with

clean water for ten minutes and

then aska doctor for advice.
– Change clothing soiled with brake

fluid as soon as possible.

CAUTION

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

hot motor parts.

– Smoking, fires and naked flamesare prohibited.

Safety regulations for handling co

CAUTION

Brake fluid has strong dissolvingand colour-chan­ging properties.

– Immediately rinse off any brake fluid that has

splashed on paint, clothing, and shoes with
plenty of water

ENVIRONMENT NOTE

Brake fluid is a water pollutant!

•

Always store brake fluid in containers
complying with the regulations..

•

Do not spill brake fluid.

•

Spilt brake fluid must be removed immedia­tely using an oil binding agent and disposed
of in accordance with regulations

•

Dispose of old brake fluid according to the
regulations.

•

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

048011501 EN - 12/2015 43

55

3 Safety

Safety regulations for handling co

Disposal of consumables

ENVIRONMENT NOTE

Materials that accumulate during repair,
maintenance and cleaning must be collected
properly and disposed of in accordance with
the national regulations for the country in
which the truck is being used. Work must
only be carried out in areas designated for the
purpose. Care must be taken to minimise any
environmental pollution.

– Soak up any spilt fluids such as hydraulic

oil, brake fluid or gearbox oil using an
oil-binding agent.

– Neutralise any spilt bat

ately.

– Always observe national regulations con-

cerning the disposal of used oil.

tery acid immedi-

nsumables

44

55048011501 EN - 12/2015

Safety 3

Emissions

Emissions

The values specified apply to a standard truck
(compare the specifications in the "Technical
data" chapter). Different tyres, lift masts,
additional units etc. may produce different
values.

Noise emissions

The values were determined based on
measuring procedures from the standard
EN 12053 "Safety of industrial trucks. Test
methods for measuring noise emissions",
based on EN 12001 and EN ISO 3744 and the
requirements of EN ISO 4871.

L

pAZ

lowing sound

This machine emits the fol
pressure levels:

Continuous sound pressure level in the

driver’s compartment

< 70 dB(A)

The values were determ
on an identical machin
values for operating s

Time proportions:

• 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 tothe most
recent version of Directive 2003/10/EC (daily
personal noise pollution). If required, these
noise emissions must be determined directly
at the workplaces under the actual conditions
present (further sources of noise, particular
application conditions, sound reflections) by
the operating company.

NOTE

Please observe th
responsible per

son: "operating company".

ined in the test cycle

e from the weighted

tatuses and idling.

e definition of the following

048011501 EN - 12/2015 45

55

3 Safety

Emissions

Vibrations

The vibrations of the machine have been
determined on an identical machine in ac­cordance with the standards DIN EN 13059
"Safety of industrial trucks - Test methods
for measuring vibration" and DIN EN 12096
"Mechanical vibration - Declaration and verifi­cation of vibration emission values".

Frequency-weighted effective value of accel­eration on the seat

MSG 65 driver’s seat

0.68 m/s

Tests have indicated that the amplitude of the
hand and arm vibrations on the steering wheel
or the operating devices in trucks is less than

2.5 m/s
ment guidelines for these measurements.

The individual vibrati
over the course of a work
determined by the oper
accordance with Direc
the actual place of use
additional influences
intensity of use etc.

2

2

. There are therefore no measure-

Measurement

uncertainty

0.204 m/s

on load on the driver

ing day must be

ating company in

tive 2002/44/EC at

in order to consider all

, such as driving route,

2

NOTE

Please observe the definition of the following
responsible person: "operating company".

46

55048011501 EN - 12/2015

Safety 3

Emissions

Battery

DANGER

Risk of explosion due to flammable
gases!

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

– Make sure that there is always

sufficient ventilation in working

areas that are entirely or partially

enclosed.
– Keep away from open flames and

flying sparks
– Do not smoke.
– Observe the safety regulations for

handling the battery.

048011501 EN - 12/2015 47

55

3 Safety

Emissions

48

55048011501 EN - 12/2015

4

Overviews

4 Overviews

General view of truck

General view of truck

1

2

12

3

11

10

9

1Liftmast
2 Overhead guard
3 Driver’s compartment
4 Battery door
5 Battery hood
6 Connection for towing bracket / towcoupling

(optional)

8

7 Drive wheel
8 Right-hand bottomplate
9 Left-hand bottomplate
10 Running axle
11 Fork arms
12 Lift cylinder

4

5

5060_003-094_V2

6

7

50

55048011501 EN - 12/2015

Overviews 4

General view of truck

048011501 EN - 12/2015 51

55

4 Overviews

4

General view of driver’s compartme

nt

General view of driver’s compartment

15

14

13

1

34

2

5

6

7

8

9

5060_003-093_V2

12

1 Parking brake lever
2 Steering wheel
3Switchkey
4 Display operating unit
5 Document holder and storage location for

operating instructions

6 Operating devices for hydraulic and traction

functions

7 Emergency stop switch (only in multiple-

lever version)

52

11

55048011501 EN - 12/2015

10

8 Storage box
9 Cup holder for bottles max. 1 l
10 Battery hood handle
11 Battery hood release
12 Driver’s seat
13 Accelerator pedal
14 Brake pedal
15 Signal horn foot switch

Overviews 4

Operating devices and display elem

ents

Operating devices and display elements

Display and operating unit

2

1

26

25

5060_003-087

1 Hazard warni
2 Front winds
3 Front worki
4 Drive prog
5 Rear work
6 Rear wor
7 Not ass
8 Batte
9Drive
10 Left
11 For
12 Rig
13 Ma

24

ram selectorbutton
ing spotlightbutton

king spotlight symbol

igned

ry charge display (percent)

programme display (numerical)

direction indicator light
ward travel display
ht direction indicator light

lfunction display

4

3

3

1

2

5

22

23

ng system button

creen wiper button

ng spotlight button

56

8

6

9

7

0

20

21

19

7

75

%

2

90°

12:15

17

18

14 Reverse trav
15 Steering po
16 Time displa
17 Not assign
18 Rotating
19 Not assi
20 Not ass
21 Not as
22 Not as
23 Menu
24 Lig
25 Blu
26 Re

gned

igned
signed
signed
change button

hting button

e-Q button

ar window wiper button

8

9

15

16

el display
sition display (degrees)
y (digital)

ed

beacon display

10

11

12

13
14

NOTE

The buttons (5, 21, 22) and the corresponding
indicators (6, 7, 18, 19, 20) are assigned
according to the auxiliary equipment installed.

The assignment shown here is an example
and may differ from the assignment actually
programmed on the truck. Buttons may be
assigned multiple functions that are called up
according to the menu navigation. For further
information, see the "Operating the display
and operating unit" chapter.

048011501 EN - 12/2015 53

55

4 Overviews

Operating devices and display elem

– If you have any questions, please contact

your authorised service centre.

ents

54

55048011501 EN - 12/2015

Overviews 4

Operating devices and display elem

ents

Operating devices for hydraulic and traction functions

Different versions of the operating devices are
available for operating the truck’s hydraulic
and traction functions.

The truck can be equipped with the following
operating devices:

• Multiple-lever

• Double mini-lever

• Triple mini-lever

• Quadruple mini-lever

• Joystick 4Plus

• Fingertip

• Mini-console

048011501 EN - 12/2015 55

55

4 Overviews

Operating devices and display elem

Multi-lever

ents

123

6

1 "Lift/lower" operating lever
2 "Tilt" operating lever
3 Operating lever for attachment(variant)

4

5

5060_003-168

4 Operating lever for attachment (variant)
5 "5th function"function switch (variant)
6 Drive direction switch

NOTE

In the dual-pedal version (variant), the truck is
equipped with a signal horn button instead of
the drive direction switch.

56

55048011501 EN - 12/2015

Overviews 4

Operating devices and display elem

ents

Double mini-lever

3

2

1

8

1 "Lift mast" 360° lever
2 Function key F1
3 Function key F2
4 "Drive direction / turnindicator" crosslever

4

F1

F2

7312_003-002

5 Function key "5th function"
6 "Attachments" cross lever
7 Emergency stop switch
8 Signal horn button

5

6

7

NOTE

Depending on the specification, various
electric attachment parts can be controlled
via function keys (2) and (3). Changes must
only be made by the authorised servicecentre.

048011501 EN - 12/2015 57

55

4 Overviews

Operating devices and display elem

Three-way mini-lever

ents

3

2

1

9

1 "Lift mast" 360° lever
2 Function key F1
3 Function key F2
4 "Drive direction/ turn indicator" cross lever
5 Function key "5th function"

NOTE

Depending on the specification, various
electric attachment parts can be controlled
via function keys (2) and (3). Changes must
only be made bythe authorised service centre.

4

5

6

7

5060_003-089

6 "Auxiliary hydraulics 1" operating lever
7 "Auxiliary hydraulics 2" operating lever
8 Emergency stop switch
9 Signal horn button

8

58

55048011501 EN - 12/2015

Overviews 4

Operating devices and display elem

ents

Four-way mini-lever

4

3

2

1

10

1 "Lift/lower"
2 "Tilt" opera
3 Function ke
4 Function k
5 "Drive dir

NOTE

Depending on the specification, various
electric attachment parts can be controlled
via function keys (3) and (4). Changes must
only be made by the authorised servicecentre.

operating lever
ting lever

yF1

ey F2

ection / turn indicator"cross lever

5

6

5060_003-088

6 Function key "
7 "Auxiliary h
8 "Auxiliary
9 Emergency
10 Signal hor

ydraulics 1" operating lever

hydraulics 2" operating lever

n button

7

8

9

5th function"

stop switch

048011501 EN - 12/2015 59

55

4 Overviews

Operating devices and display elem

Joystick 4Plus

ents

9

1

8

7

6

5

1 Horizontal rocker button for "3rd hydraulic

function", tilt the lift mast
2 Pictograms for the basic hydraulic functions
3 Pictograms for the5th hydraulic functionand

the clamp locking mechanism (variant)
4 Pictograms for the 3rd & 4th hydraulic

functions

2

3

6210_003-087

4

5 LED forclamp locking mechanism (variant)
6 Slider for the "4th hydraulic function", e.g.

reach frame forwards/backwards
7 Vertical rocker buttonfor the "drivedirection"
8Shiftkey"F"
9 Signal horn button

60

55048011501 EN - 12/2015

Overviews 4

F1

F2

Operating devices and display elem

ents

Fingertip

1

12

23456

F2

F1

11

10

7

89

1 Function key F1
2 Function key F2
3 Left-hand turn indicator button
4 Signal horn button
5 Right-hand turn indicator button
6 Button for 5th function

NOTE

Depending on the specification, various
electric attachment parts can be controlled
via function keys (1) and (2). Changes must
only be made by the authorised servicecentre.

048011501 EN - 12/2015 61

55

6321_003-004

7 Emergency stop switch
8 "Attachments" operating lever
9 "Attachments" operating lever
10 "Tilt" operating lever
11 "Lift/lower" operating lever
12 Travel direction switch

4 Overviews

Operating devices and display elem

Mini console

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

ents

2

1

1 Travel direction s
2 Direction indica

7311_003-056

witch

tor switch

62

55048011501 EN - 12/2015

Overviews 4

Operating devices and display elem

ents

048011501 EN - 12/2015 63

55

4 Overviews

Zum Önen der Haube den Fahrersitz
und die Armlehne ganz nach hinten
schieben und letztere zusätzlich in
unterste Position bringen

To open the batteryhood the driver seat
and the armrest must be moved
completely back and the last one
has to be placed in the lowest position

ACHTUNG - ATTENTION !

ATC

Assistance Truck Control

Identification points

Identification points

Overview

8

16

DANGER

12

15

13

DANGER

9

4

3

DANGER

5

2

6

ACHTUNG - ATTENTION !

Zum Önen der Haube den Fahrersitz
und die Armlehne ganz nach hinten
schieben und letztere zusätzlich in
unterste Position bringen

To open the batteryhood the driver seat
and the armrest must be moved
completely back and the last one
has to be placed in the lowest position

Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr

Rated capacity
Capacité nominale
Nenn-Tragfähigkeit

Battery voltage
Tension batterie
Batteriespannung

Rated drive power
Puissance motr.nom.
Nenn-Antriebsleist.

8

17
16

15

13

14

kg

V

kW

* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung

Unladen mass
Masse à vide
Leergewicht

5060_003-175_V2

18

17

2

1

3

4

5

4

6

7

8

9

2

4

10

11

12

10

13

2

6

1

3

5

4

9

9

1

7

7

6

7

5

1

10

2

IDENT-NR. 0009381511

1

5

5

6

2

5

11 4

11

15

14

18

7

STILL GmbH Hamburg

Regelmäßige Prüfung

(FEM 4.004)
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:

20xx

kg

max

kg

min.*

kg

*

kg

2009/104/EG, 99/92/EG

Nächste Prüfung

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Mitglied der:
Fédération
Européene
de la Manutention

56344391019

BATTERIESERVICE

Nächste Prüfung

Ihr STILL Service

STILL Hamburg
Berzeliusstr. 10
22113 Hamburg
Tel.: 01804 / 784 55 24

733906

64

55048011501 EN - 12/2015

Overviews 4

Identification points

1 Decal information: Actions to be performed

when replacing battery using a bridge

(variant)
2 Decal information: Assistance TruckControl
3 Warning sign: Risk of short circuit due to

shearing
4 Warning sign: Risk of crushing
5 Warning sign: Cleaning electrical system

parts with water is forbidden
6 Decal information: Actions to be performed

before openingthe battery hood
7 Decal information: Cold store application
8 Decal information: Lifting gear attachment

point
9 Decal information: Capacity rating plate
10 Decal information: FEM test
11 Decal information: Battery test

Nameplate

The truck can be identified from the informa­tion on the nameplate.

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

fork/Do notstand on the fork
14 Decal information: Nameplate
15 Warning sign: Do not stand underneath the

fork/Do not stand on the fork/Danger due to

shearing/Danger due to high fluid pressure
16 Decal information: Caution/Read the op-

erating instructions/Fastenseat belt/Apply

parking brake when leaving the truck/Pas-

sengers are not allowed/Do not jump off if

the truck is tipping over/Lean in the opposite

direction to which the truck is tipping
17 Manufacturer’s label text
18 Decal information: Caution/read operating

instructions/drive slowly with raised load

1

Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr

12

Rated capacity
Capacité nominale
Nenn-Tragfähigkeit

11

Battery voltage
Tension batterie
Batteriespannung

10

Rated drive power
Puissance motr.nom.
Nenn-Antriebsleist.

2

Unladen mass

kg

Masse à vide
Leergewicht

V

kW

* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung

kg

max
min.*

*

kg
kg

kg

3

4

5
6

7

9

8

6210_921-003_V2

1 Type
2 Production number
3 Year of manufacture
4 Tare weight in kg
5 Max. permissible battery weight in kg (for

electric forklift trucks only)
6 Min. permissible battery weight in kg (for

electric forklift trucks only)
7 Ballast weightin kg (for electric forklift trucks

only)
8 Refer to the technical data listed in these

operating instructions for more detailed

information
9 CE labelling
10 Nominal drive power in kW
11 Battery voltage in V
12 Rated capacity in kg

048011501 EN - 12/2015 65

55

4 Overviews

Identification points

Production number

NOTE

The production number is used to identify the
truck. It can be found on the nameplate and
must be referred to in all technical questions.

The production number con
coded information:

(1) Production location

(2) Model

(3) Year of manufacture

(4) Sequential number

tains the following

StVZO (Road Traffic Licensing
Regulations) information

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

xx xxxx x xxxxx

1

2

3

4

7090_921-004

12

5

1 Tare weight (in kg)
2 Permitted total weight (in kg)
3 Permitted front axle weight (in kg)
4 Permitted rear axle weight (in kg)
5 Payload (in kg)

66

55048011501 EN - 12/2015

34

7094_003-098

5

Operation

5 Operation

Checks and operations prior to comm

issioning

Checks and operations prior to commissioning

Visual inspections

WARNING

Risk of accident due to damage orother defects on
the truck or on the attachment (variant)!

Damage to the truck or the attachment(variant) can
lead to unpredictable and dangerous situations.
If damage or other defects are identified on the
truck or attachment (variant) during the following
inspections, the truck must not be used until it has
been properly repaired.

– Do not remove or deactivate safety devices and

switches.
– Do not change predefined set values.
– Do not use the truck until it has been properly

repaired

WARNING

There is a risk of falling when working on high parts
of the truck.

– Use only the steps provided on the truck.
– Do not stand on truck componentsor use them

to help you climb onto the truck.
– Use suitable equipment.

Prior to start-up, ensure that the truck is safe
to be operated:

• The fork arms must be secured against

lifting and shifting.

• The locking devices (1) of the fork arms

must not be damaged or deformed.

• Fork arms and other lifting accessories

must not show any noticeable damage (e.g.

bends, cracks, significant wear).

• The roller tracks (2) must be lubricated with

a visible grease film.

• The chains must not be damaged and must

be evenly and adequately tensioned.

• Check the area under the truck for leaking

consumables.

• The guard grille (variant) and overhead

guard must be undamaged and securely

mounted.

68

55048011501 EN - 12/2015

2

1

6210_000-002

Operation 5

issioning

• Attachments (variant) must be properly
mounted and function according to the
operating instructions.

• All decal information signs must be in
place and legible. Replace damaged or
missing adhesive labels in accordance with
the overview in the "Identification points"
chapter.

• Any warning units(e.g. sign
in perfect condition and fun

• Check the visible areas of the hydraulic
system and hydraulic oil tank for damage
and leaks. Damaged hoses must be
replaced by the authorised service centre.

• The battery must be securely locked.

• Check the battery male conn
age (e.g. cracks, breaks or
the housing, bent or damage
necessary, havethe batter
replaced by the authorised

• The battery door must be closed correctly
and the door lock mustbe properly secured.

• The battery lock latches, the battery door
and the battery hood must not be damaged
or deformed.

• The battery hood must be c
and the hood lock mustbe p

• The battery hood and battery door must
show no noticeable damage (e.g. cracks or
breaks).

• Steps must be clean and free of ice.

• Any panes of glass (vari
screen) must be clean an

• Depending on the tyres, the truck may be
fitted with an antistatic belt. The antistatic
belt must not be damaged. It must also be
clean and long enough to touch the ground

• A tow coupling (variant) must show no
noticeable damage (e.g. coupling pin
bent, cracks or breaks). Every removable
coupling pin must be secured against loss
with a securing device (e.g. a chain, a split
pin or a rope).

• Damage or other defec
attachment (variant
the supervisor or res
immediately sothat t
defect to be rectified

al horn) must be

ction correctly.

ector for dam-

deformation of

d contacts). If

y male connector

service centre.

losed correctly
roperly secured.

ant, e.g. wind-

dfreeofice.

ts on the truck or

) must be reported to

ponsible fleet manager
hey can arrange for the
.

Checks and operations prior to comm

048011501 EN - 12/2015 69

55

5 Operation

Checks and operations prior to comm

WARNING

Risk of component damage!
A deformed or damaged battery male connector

can cause overheating and related consequential
damage.

– Check the battery male connector for damage.
– If necessary, have the battery male connector

replaced by the authorised service centre.

DANGER

Risk of explosion if hydrogen builds
up in the cab!

If the truck is equipped with a
cab, hydrogen from the battery
compartment can penetrate the cab
through unsealed boresin thebattery
hood. A build-up of hydrogen can
lead to explosions.

There must be no unsealed bores in
the batteryhood. Sealing bores with
plugs is not sufficient to prevent gas
from escaping.

– Have unused bores in the battery

hood sealed by the authorised
service centre.

issioning

Filling the washer system

CAUTION

If there is no anti-freeze in the system, the washer
system can be damaged.

Always use washer fluid containing anti-freeze.

NOTE

The washer system container is at the front
right, beneath the valve cover. The filling
opening is accessible from above

70

55048011501 EN - 12/2015

Operation 5

1

Checks and operations prior to comm

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

(variant).

– Fill the windscreen washer container with

washer fluid containing anti-freeze ac­cording to the maintenance data table
(see ⇒ Chapter "Maintenance data ta­ble", P. 6-303).

NOTE

issioning

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

– Close the filler cap.

– Operate washer system un

discharged from the spra

til washer fluid is

y nozzles.

5060_003-150_V2

Checking the cond

ition of the wheels

and tyres

WARNING

Risk of accident!
Uneven wear reduces the stability of the truck and

increases the braking distance.
– Renew left and right worn or damaged tyres

without delay.

WARNING

Risk of tipping!
Tyre qualityaffects the stability of the truck.
If you wish to use a different type of tyre on the truck

from the tyres approved by the truck manufacturer,
or tyres from a differentmanufacturer, you must first
obtain approval from the truck manufacturer.

WARNING

Risk to stability!
When using pneumatic tyres or solid rubber tyres,

rim wheel parts must never be changed and rim
wheel parts from different manufacturers must not
be mixed.

NOTE

Only approved types of tyre may be used; see
chapter entitled "Tyres".

048011501 EN - 12/2015 71

55

5 Operation

Checks and operations prior to comm

issioning

– Check tyres (1) for wear or damage.

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

NOTE

Observe the safety regulations in the chapter
entitled "Tyres".

Adjusting the GS15 driver’s seat

DANGER

There is arisk of accidentif the seator seat backrest
shifts suddenly, which could cause the driver to
move in an uncontrolled manner. This may result in
unintentional actuation of the steering or operating
devices and thus cause the truck or load to move in
an uncontrolled fashion.

– Do not adjust the seat or seat backrest while

driving.

– Adjust the seat and the seat backrest so that all

operating devices can be actuated safely

– Ensure that the seat and seat backrest are

securely engaged.

1

5051_460-004

WARNING

On some equipment variants, the
amount of head clearance on the
truck may be restricted.

On these specific equipment va­riants, the distancebetween the head
and the lower edge of the roofing
sheet mustbe at least 40 mm.

NOTE

If there are separate operating instructions for
the seat, they must be followed.

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WARNING

To obtain optimum seat cushioning, you must ad­just the seat suspension to your own body weight.
This is betterfor yourback and protects your health.

– To prevent injury, make sure that there are no

objects within the swivel area of theseat.

Checks and operations prior to comm

Moving the driver’s seat

– Lift the lever (1) and hold.

– Shift the driver’s seat into the desired

position.

– Release the lever and make sure that the

driver’s seat engages.

3

Adjusting the seat backrest

– Turn the knob (2) to the right or left until the

seat backrest is in the desired position.

Adjusting the seat suspension

NOTE

The driver’s seat is designed for people weig­hing between 50 kg and 120 kg. Depending
on the driver’s weight, three different weight
classes can be set for the seat (light, medium
and heavy).

NOTE

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

– Push the lever (3) and hold.

– Move the lever to the desired weight class.

– Release the lever and make sure that it

engages.

2

1

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5 Operation

Checks and operations prior to comm

Adjusting the MSG 65/MSG 75
driver’s seat

DANGER

There is arisk of accidentif the seator seat backrest
shifts suddenly, which could cause the driver to
move in an uncontrolled manner. This can result
in unintentional actuation of the steering or the
operating devices and thus cause uncontrolled
movements of the truck or load.

– Do not adjust the seat or seat backrest while

driving.

– Adjust the seat and seat backrest so that all

operating devices can be actuated safely.

– Ensure that the seat and seat backrest are

securely engaged.

WARNING

On some equipment variants, the
amount of head clearance on the
truck may be restricted.

On these specific equipment va­riants, the distancebetween the head
and the lower edge of the roofing
sheet mustbe at least 40 mm.

issioning

NOTE

If there are separate operating instructions for
the seat, they must be followed.

WARNING

To obtain optimum seat cushioning, you must ad­just the seat suspension to your own body weight.
This is betterfor yourback and protectsyour health.

– To prevent injury, make sure that there are no

objects withinthe seat’s swivel area.

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Checks and operations prior to comm

issioning

Moving the driver’s seat

– Lift the lever (1) and hold.

– Push the driver’s seat into the

position.

– Release the lever.

– Ensure that the driver’s seat is securely

engaged.

desired

Adjusting the seat backrest

Do not put pressure on the seat backrest while
engaging it.

– Lift the lever (2)

and hold.

– Push the seat backrest into the desired

position.

– Release the lever.

– Ensure that the s

eat backrest is securely

engaged.

NOTE

The backwards tilt angle of the seat backrest
can be restricted by the structural condition of
the truck.

1

7094_003-006

2

7094_003-008

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5 Operation

Checks and operations prior to comm

Adjusting the seat suspension

NOTE

The driver’s seat can be adjusted to suit the
weight of the individual driver. In order to
achieve the best seat suspension setting, the
driver should perform the adjustment whilst
sitting in the seat.

NOTE

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

– Fully extend weight adjusting lever (3).

– Pump it upor downto setthe driver’sweight.

– Return the weight adjusting lever to the

central initial position before each new lift
(audible click).

– Fully fold in the weight adjusting lever once

adjustment is complete.

NOTE

The correct driver’s weight has been selected
when the arrow (4) is in the centre of the
inspection window. A noticeable empty lift on
the weightadjusting lever shows that you have
reached the minimum or maximum weight
setting.

issioning

4

3

6321_003-038

Adjusting the lumbar support (variant)

NOTE

The lumbar support can be adjusted to suit
the contours of the individual driver’s spine.
Adjusting the lumbar support moves a convex
support cushion into the upper or lower part of
the backrest.

– Turn the turning knob (5) up or down until

the lumbarsupport isin the desired position.

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5

6321_003-039

Operation 5

Checks and operations prior to comm

issioning

Adjusting the backrest extension
(variant)

– Adjust the backrest extension (6) by pulling

it out or pushing it into the desired position.

To remove the backrest extens
past the end stop by jolting i

ion, move it

t upwards.

Switching the seat heater (variant) on
and off

NOTE

The seat heater only functions if the seat
contact switch is active, i.e. when the driver is
sitting on the driver’s seat.

– Switch theseat heater (7) on or off using the

switch.

6

6321_003-040

7

Adjusting the armrest

DANGER

There isa risk of accident ifthe armrest lowers sud­denly, causing the driver to move in an uncontrolled
manner. This can result in unintentional actuation
of the steering or the operating devices and thus
cause uncontrolledmovements ofthe truck or load.

– Do not adjust the armrest while driving.
– Adjust the armrest so that all operating devices

canbeactuatedsafely.

– Ensure that the armrest issecurely tightened.

048011501 EN - 12/2015 77

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6321_003-041

5 Operation

Checks and operations prior to comm

Adjusting the length of the armrest

– Release the star-grip handle (1) by turning

it anti-clockwise.

– Shift the armrest (2) into the d

tion.

– Tighten the star-grip handle by turning it

clockwise.

– Check that the armrest is firmly attached.

esired posi-

Adjusting the height of the armrest

– Release hand wheel (3) by tu

clockwise.

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

tion.

– Tighten the hand wheel by turning it clock-

wise.

– Check that the armrest is

rning it anti-

firmly attached.

issioning

3

2

1

7331_342-001

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Operation 5

Commissioning

Commissioning

Climbing on/off

WARNING

Risk of injury when climbingon andoff the truck due
to slipping, hitting parts of the truck or becoming
stuck!

If thefootwell cover is very dirty or smearedwith oil,
there is a risk of slipping. There is a risk of hitting
your head on the post of the overhead guard or of
your clothesbecoming stuck when climbing off the
truck.

– Ensure that the footwell cover is non-slip.
– Do not jump into or out of the truck.
– Ensure that you have a secure grip on the truck.

WARNING

Risk of injury when jumping off the truck!
If your clothing or jewellery (e.g. watch, ring etc.)

becomes stuck on a component while you are
jumping out of the truck, this can lead to serious
injuries (e.g. from falling, loss of fingers etc.). It is
forbiddentojumpoffthetruck.

– Do not jump off the truck.
– Do not wear jewellery at work.
– Do not wear loose-fitting workwear.

2

1

4

3

5060_003-164

CAUTION

Component damage through incorrectuse!
Truck components, such as the driver’s seat,

steering wheel, parking brake lever etc., are not
designed to be used for climbing on and off the
truck and can be damaged due to misuse.

– Only use the devices specifically designed for

the purposeof climbing on and off.

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

Always climb onto the truck in a forwards
motion:

– Grip the handle (1) with your left hand and

hold on.

– Put your left foot on the step (4).

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5 Operation

Commissioning

– Use your right foot to enter the truck, and sit

down on the driver’s seat (3).

Always climb off the truck backwards:

– Grip the handle (1) with your le

hold on.

– Stand up from the driver’s seat and climb

out of the truck with your right foot first.

ft hand and

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Operation 5

4

Commissioning

Connecting the batterymale connec­tor

– Open the battery door.

CAUTION

Risk of component damage!
If you connect the battery male connector with the

key switch switched on (under load), an arc will
be produced. This can lead to corrosion at the
contacts, which considerably shortenstheir service
life.

– Do not connect the battery male connector with

the key switch switched on.

– Make sure that the key switch is switched off

before connecting the batterymale connector.

– Insert the battery male connector (1) fully

into the plug connection on the truck.

CAUTION

There is a risk of short circuit if the
cables are damaged.

Do not crush the batterycable when
closing the battery cover.

– Ensure that the battery cable does

not come into contact with the
battery cover.

6327_600-001

1

– Close the battery door.

Shelf and cup holder

WARNING

Objects may fall into the footwell and obstruct the
pedals — there is risk of accident!

Objects to be stored must be of the correct size so
they do not fall from the shelves (1, 2) or out of the
cup holder (3). Objects that fall into the footwell
during travel as a result of steering or braking can
slip between the pedals (4) and stop them working
correctly. The truck may subsequently not be able
to be braked when necessary.

– Bottles of 1 l or smaller may be stored in the cup

holder.

– Make sure that stored objects cannot fall from

the shelveswhen the truck is started up, steered
and braked.

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1

4

2

3

5 Operation

F

1

F2

Commissioning

Unlocking the emergency off switch

– Pull out/turn the emergency off switch (1)

until it unlocks.

I

F1

F

2

II

1

1

III

1

IV

1

F2

1

F

6321_003-145

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Switching on the key switch

WARNING

Before switching on the key switch, all tests prior to
start-up must be performed without detecting any
defects.

– Perform the tests prior to commissioning.
– Do not operate the truck if defects have been

detected.

– Notify the authorised service centre.

NOTE

If the truck is switched on with the steering
wheel turned, the maximum driving speed
is limited. The driving speed limitation is
disabled as soon as the truck is steered out of
cornering to drive in a straight line. A change
in steering angle of around half a revolution is
sufficient for this to be the case.

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

turn to position "I".

0

I

5060_003-029_V2

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1

5 Operation

Commissioning

This initiates a self-test. All lamps in the drive
direction and turn indicator displays light up
briefly.

7312_003-085

When the key switch is switched on, the
display shows the welcome screen in the set
language.

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Operation 5

%

75

2

90°

12:15

Commissioning

The display will indicate the warning message

TILTING / SPEED.

NOTE

The tilt speed of the lift mast in this truck is
significantly higher than for previous products
in this series.

The truck controller is now fully started up.

If the truck has the "access authorisation with
PIN code" variant, the display initially changes
to the input menu for access authorisation.

If the truck is ready for operation, the standard
displays are shown.

5060_003-176_en

Standard display elements

1 Battery charge

The useable batter
the display field as

2 Drive programme

The current drive program (1-5) appears
in the display field.

3 Steering positio

The position of the steering appears in
the display field.

4 Time

The current time
field.

NOTE

After connecti
charge status i

ng the battery, the correct

s not displayed until after being

placed under lo

y capacity appears in
a percentage.

n

appears in the display

ad for the first time by driving

1

2

3

4

5060_003-008

or lifting.

NOTE

Have all repair and maintenance work perfor­med by an authorised service centre. This is
the only way to permanently correct defects.

– Inform the au

the mainten

thorised service centre when

ance interval is reached.

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5 Operation

Commissioning

NOTE

Additional information may ap
play. If malfunctions occur, r
mation in the chapter entitled

pear on the dis-

efer to the infor-

"Malfunctions".

Access authorisation with

PIN code

(variant)

Description

Trucks equipped with the "Access authori­sation with PIN code" variant are protected
against unauthorised use by a five-digit driver
PIN. Up to fifty different driver PINs can be
defined so that the same truck can be used
by different drivers, each with their own driver
PIN.

NOTE

The driver PINs are defi
unit menu that can onl
persons with the corr
authorisation, e.g.

Once the key switch has been switched on,
the input menu for the driver PIN appears
on the display and operating unit screen. All
of the truck’s functions (driving, hydraulics,
additional electrical installations and the
display and operating unit displays) are
blocked. The function of the hazard warning
system (variant) is guaranteed. Enter the five­digit driverPIN (possible entriesfrom 00000 to

99999) to enable the blocked functions. Once
the correct driver PIN has been entered, the
standard displays are shown. All of the truck
functions are available.

The access authorisation can be configured
in such a way that the driver PIN has to be
re-entered each time the driver steps off the
truck, in order for the truck to be operated
again.

– Contact the author

this matter.

The first driver PIN is preset to "11111" at the
factory. All others are preset to "0xFFF" but
have no function as the highest valid driver PIN

ned in a truck control

y be accessed by

esponding access

fleet managers.

ised service centre on

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Operation 5

Commissioning

is "99999". Persons with the corresponding
access authorisation, e.g. fleet managers,can
change the driver PINs in the corresponding
menu.

NOTE

When first commissioning the truck, we re­commend you change the access authorisa­tion set at the factory. This is the only way to
guarantee that the driver PIN is only known to
persons with corresponding access authori­sation.

The driver PINs are stored in the truck control
unit. These are still available if the display
and operating unit has been changed. The
authorised servicecentre can use a diagnostic
device to read out the driver PIN and, if
necessary, restore the factory default driver
PIN.

ACCESS CODE input menu

The driver enters the fiv
(00000 to 99999) in this

The driver PIN isentered using the buttons (1).
The digits entered for the driver PIN (2) are not
visible, instead being represented by circles.
If the driver PIN entered is correct, the familiar
display appearswith the standard display,and
all truck functions are available.

e-digit driver PIN
input menu.

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5 Operation

8

9

6

7

4

2

0

1

3

5

8

9

6

7

4

2

0

1

3

5

Commissioning

If an incorrect driver PIN is entered, the
message
When the message goes out, the driver PIN
can be re-entered.

After three invalid entry attempts, the mes­sage
then locked for five minutes before another
attempt can be made.

INVALID appears for a short time.

BQ_023_en_V2

CODE DENIED appears. The input is

BQ_024_en_V2

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