Still RX60-60, RX60-70, RX60-80 Operator Manual

Original instructions

Electric forklift truck

RX60-60
RX60-70
RX60-80

6341 6342 6343 6344

56358042501 EN - 10/2016

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

g

358042501 EN- 10/2016 I

56

Table of contents

1 Foreword

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

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

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

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

Accessories ......................................................... 4

Information about the documentation ...................................... 5

Documentationscope ................................................. 5

Issue date and topicality o

Copyrightandtrademarkrights ........................................... 6

Explanation of information symbols used . . ................................. 6

Listofabbreviations ................................................... 7

Units ............................................................. 10

Definitionofdirections ................................................ 11

Schematicviews .................................................... 11

Environmental considerations .......................................... 13

Packaging ......................................................... 13

Disposal of components a

ftheoperatinginstructions ........................... 6

ndbatteries ..................................... 13

2 Introduction

Using the truck ...................................................... 16

Proper usage ....................................................... 16

Proper use during tow

Impermissibleuse ................................................... 16

Placeofuse ........................................................ 17

Parking in temperat

Usingworkingplatforms ............................................... 18

Residual risk ....................................................... 19

Residual dangers, r

Specialrisksassociatedwithusingthetruckandattachments ................... 20

Overviewofhazardsandcountermeasures ................................. 22

Danger to employee

ing .............................................. 16

uresbelow-10°C ..................................... 18

esidual risks ......................................... 19

s ................................................. 25

g

3Safety

Definition of responsible persons ........................................ 28

Operatingcompany .................................................. 28

Specialist .......................................................... 28

Drivers ........................................................... 29

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Basic principles for safe operation ....................................... 31

Insurance cover on company premises .................................... 31

Changes and retrofitting ............................................... 31

Changes to the overhead guard and roof loads . . . ........................... 34

Warning regarding non-original parts ..................................... 34

Damage, defects and misuse of s

Tyres ............................................................. 35

Medicalequipment ................................................... 36

Exercise caution when handl

Lengthoftheforkarms ................................................ 37

Safety tests ........................................................ 39

Regular safety inspection

Insulationtesting .................................................... 39

Safety regulations for handling consumables ............................... 41

Permissible consumables

Oils .............................................................. 41

Hydraulicfluid ...................................................... 42

Batteryacid ........................................................ 43

Coolantandcoolingfluid .............................................. 44

Disposalofconsumables .............................................. 45

Emissions ......................................................... 46

afetysystems .............................. 35

inggasspringsandaccumulators .................. 37

ofthetruck ..................................... 39

............................................. 41

4Overviews

Overview .......................................................... 50

Overview of the driver’s compartment ..................................... 51

Operating and displ

Display operating unit ................................................. 52

Operatingdevicesforhydraulicanddrivingfunctions .......................... 53

Doublemini-lever .................................................... 5

Three-waymini-lever ................................................. 55

Four-waymini-lever .................................................. 56

Joystick4Plus ...................................................... 57

Fingertip .......................................................... 58

Miniconsole ....................................................... 59

Identification po

Overview .......................................................... 60

Nameplate ......................................................... 62

Production numb

StVZO (Road Traffic Licensing Regulations) information ....................... 63

IV

ay elements ......................................... 52

ints .................................................. 60

er .................................................. 63

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Table of contents

5 Operation

Checks and tasks to be carried out prior to commissioning ...................... 66

Visualinspections ................................................... 66

Fillingthewashersystem .............................................. 68

Checking the condition of the wheels and tyres .............................. 69

Checkingthecoolantlevel ............................................. 7

AdjustingtheMSG65/MSG75driver’sseat ................................ 72

Adjustingthearmrest ................................................. 76

Adjusting the steering colu

Commissioning ..................................................... 78

Climbingintoandoutofthetruck ........................................ 78

Connecting the battery mal

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

Switchingonthekeyswitch ............................................ 82

Access authorisation wit

Operating the signal horn .............................................. 95

Seatbelt .......................................................... 95

Usingthedriver’scab ................................................. 98

Checkingthebrakesystemforcorrectfunction .............................. 98

Checkingthesteeringsystemforcorrectfunction ............................ 99

Checking the emergency

Zeroadjustmentoftheloadmeasurement(variant) ...........................101

Checking the vertical lift mast position (variant) for correct function . ...............102

Traction ...........................................................103

Safety regulations when driving .........................................103

Roadways .........................................................105

Setting the drive pro

Selectingthedrivedirection ............................................109

Actuatingthedrivedirectionswitch,mini-leverversion .........................110

Actuating the vertic

Actuatethedrivedirectionswitch,fingertipversion ...........................111

Actuatingthedrivedirectionswitch,mini-consoleversion ......................111

Starting drive mode

Starting drive mode, dual pedal version (variant) .............................114

Operatingtheservicebrake ............................................117

Actuating the mecha

Steering ...........................................................120

Reducing speed when turning (Curve Speed Control) .........................121

Reducing speed wit

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

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

mn ........................................... 77

e connector .................................... 81

hPINcode(variant) ................................ 85

offfunction .....................................100

gramme ............................................107

al rocker switch for the "drive direction", joystick 4Plus version . . . . 110

..................................................111

nicalparkingbrake ...................................118

haraisedload(variant) ................................122

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Automaticliftcutout(variant) ...........................................123

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

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

Malfunctionsduringliftingmode .........................................129

Hydraulicblockingfunction .............................................130

Lifting system operating devi

Controlling the lifting system using a double mini-lever .........................132

Controllingtheliftingsystemusingatriplemini-lever ..........................133

Controlling the lifting sys

Controllingtheliftingsystemusingthejoystick4Plus ..........................135

Controllingtheliftingsystemwiththefingertipconsole .........................137

Changing the fork arms ...............................................138

Forkextension(variant) ...............................................140

Operationwithreversibleforkarms(variant) ................................142

Handling loads ......................................................144

Safety regulations when handing loads ....................................144

Beforetakingupload .................................................145

Load measurement (varia

Picking up loads .....................................................149

Danger area .......................................................150

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

Transporting suspended loads ..........................................151

Loadpickup ...................................................... . 152

Transporting loads ...................................................156

Setting down loads ...................................................157

Driving on ascending and descending slopes ...............................159

Drivingonlifts ......................................................159

Drivingonloadingbridges .............................................161

Workingwithattachments .............................................162

Fitting attachments

Releasingthepressurefromthehydraulicsystem ............................164

General instructions for controlling attachments . . ...........................166

Controlling attach

Controlling attachments using the double mini-lever and the 5th function ...........170

Controllingattachmentsusingatriplemini-lever .............................172

Controlling attach

Controlling attachments using a quadruple mini-lever .........................176

Controlling attachments using the four-way mini-lever and the 5th function ..........178

Controlling attac

Controlling attachments using the joystick 4Plus and the 5th function . . . ...........181

Controllingtheattachmentswithfingertip ..................................182

ments using a double mini-lever . ...........................168

mentsusingthethree-waymini-leverandthe5thfunction .........174

hmentsviathejoystick4Plus ...............................180

ces .........................................131

tem using a quadruple mini-lever ......................134

nt) ...........................................146

..................................................162

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Controlling attachments with fingertip and the 5th function ......................183

Clamp locking mechanism (variant) ......................................185

Taking up a load using attachme

Operating auxiliary equipment ..........................................190

Switchingthelightingonandoff .........................................190

Switching the rotating beac

Switchingthehazardwarningsystemonandoff .............................192

Switchingthedirectionindicatorsonandoff ................................192

Switching the double workin

Operatingthewindscreenwiper/washer ...................................196

FleetManager (variant) . ...............................................196

Accident recorder (varian

Driverrestraintsystems(variants) .......................................197

Cab operation ......................................................197

Opening the cab door . . ...............................................197

Closingthecabdoor ............................................... . . 198

Openingthesidewindows ........................................... . . 198

Closing the side windows

Operatingtheinteriorlighting ...........................................200

Operating the rear window heating .......................................201

Radio(variant) ......................................................201

Heatingsystem(variant) ..............................................202

Push-up roof window (variant) ..........................................204

Clipboard (variant) ...................................................20

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

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

Coupling pin in the co

Automatic tow coupling ...............................................208

Towingtrailers ......................................................216

Operating the displa

Indicators .........................................................217

Adjustingthedisplays ................................................220

Symbols in the displ

Settingthedateortime ................................................225

Resetting the daily kilometres and daily operating hours .......................225

Setting the languag

Soft key button for operating various equipment variants .......................226

Blue-Q efficiency mode ...............................................228

Functional descr

Effects on additional consumers .........................................228

SwitchingefficiencymodeBlue-Qonandoff ................................229

unterweight ........................................206

y and operating unit ...................................217

ay ................................................220

e .................................................226

iption ................................................228

nts ......................................189

ononandoff ...................................191

gspotlightsonandoff. ...........................194

t) .............................................197

..............................................199

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ConfiguringBlue-Qefficiencymode ......................................230

Display messages ...................................................232

Displaycontent .....................................................232

Errorcodetable .....................................................232

General messages ...................................................235

Drive-specificmessages ..............................................244

Operating in special operating situations ...................................247

Transportation ......................................................247

Towing .......................................................... . 250

Craneloading ......................................................252

Procedure in emergencies .............................................257

Emergency shutdown ................................................257

Procedureiftrucktipsover .............................................258

Emergency hammer ..................................................259

Emergency lowering .................................................259

Releasing the spring-operated brake .....................................261

Handling the battery ..................................................265

Safety regulations when

Changing to a different battery type .......................................267

Opening and closing the battery cover ....................................268

Disconnecting the batt

Checkingthebatterychargestatus .......................................272

Chargingthebattery ..................................................272

Equalising charge to p

Replacingthebatteryusingatruck .......................................277

PowerPlusLife battery ................................................283

PowerPlusLife
PowerPlusLife
PowerPlusLife

®

®

®

Decommissioning ...................................................286

Parkingthetrucksecurelyandswitchingitoff ...............................286

Wheel chock (variant) ................................................288

Shutting down and st

Re-commissioningaftershutdown .......................................290

Cleaning ..........................................................292

Cleaning the truck

Cleaning the electrical system ..........................................294

Cleaning load chains .................................................295

Cleaning the wind

Afterwashing .......................................................296

handling the battery ...............................265

ery male connector ..................................270

reventadeepdischargeofthebattery ....................275

ery ...............................................283

batt

temperaturemonitoring ...................................284

error messages . ........................................285

oringthetruck ......................................288

...................................................292

ows ................................................295

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Table of contents

6 Maintenance

General maintenance information ........................................298

Personnel qualifications ...............................................298

Informationforcarryingoutmaintenance ..................................298

Maintenance - 1000 hours/annually ......................................301

Maintenance - 3000 hours/ev

Orderingsparepartsandwearingparts ....................................304

Quality and quantity of the required operating materials ........................304

Lubricationplan .....................................................306

Maintenance data table ...............................................307

Safety regulations for maintenance .......................................310

Generalinformation ..................................................310

Workingonthehydraulicequipment ......................................310

Working on the electrical equipment ......................................310

Safetydevices ......................................................311

Setvalues ....................................................... . . 311

Liftingandjackingup .................................................311

Workingatthefrontofth

Providing access to maintenance points ...................................314

Removingandattachingtheleftsidecover .................................314

Installing and removin

Opening/closingthefrontrightcover ......................................316

Removingandattachingtherearcover ....................................317

Servicing ..........................................................318

Cleaningtheradiatorandcheckingforleaks ................................318

Topping up cooling fluid and checking coolant content .........................319

Servicing wheels and

Replacingthefuses ..................................................323

Checking the battery condition, acid level and acid density ......................326

Checking the hydraul

Changing the heating system fresh air filter . ................................328

Replacingtherecirculatedairfilterfortheheatingsystem ......................330

1000-hour maintena

Othertasks ...................................................... . . 331

Checkingthedriver’sseat .............................................331

Maintaining the se

Checking the door latch ...............................................333

Lubricatingthejointsandcontrols ........................................333

Lubricating the l

Checkingtheliftcylindersandconnectionsforleaks ..........................334

Checkingthehydraulicsystemforleaks ...................................334

nce/annual maintenance ...............................331

atbelt ...............................................331

iftmastandrollertrack ....................................333

erytwoyears .................................304

etruck ..........................................312

gthebottomplate ...................................314

tyres .............................................321

icoillevel ..........................................327

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Checkingtheforkarms ................................................335

Checkingthereversibleforkarms ........................................335

Greasing the automatic tow cou

pling ......................................336

7 Technical data

Dimensions ........................................................340

VDI datasheet ......................................................342

Ergonomic dimensions ................................................346

Battery specifications .................................................347

Fuse assignment ....................................................349

X5

6358042501 EN - 10/2016

1

Foreword

1 Foreword

Your truck

Your truck

General

The truck described in these operatinginstruc­tions 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 is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.

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

The EC declaration o
carefully stored an
responsible author

dmadeavailabletothe
ities.

ith state-of-the-

mains is to handle

ain its functionality.

f conformity must be

25

6358042501 EN - 10/2016

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

358042501 EN - 10/2016 3

56

1 Foreword

Your truck

Accessories

• Key for key switch (two pieces)

• Key for cab (variant)

• Hexagon socket wrench for emer
lowering

gency

45

6358042501 EN - 10/2016

Foreword 1

Information about the documentati

on

Information about the 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 describe all 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 operatingcompany at any time. The
storage location isspecified 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

358042501 EN - 10/2016 5

56

1 Foreword

Information about the documentati

NOTE

Please observe the definition o
responsible persons: "operat

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.

on

f the following

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

WARNING

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

65

6358042501 EN - 10/2016

Foreword 1

on

CAUTION

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

NOTE

Information about the documentati

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

ABE
Arb-

SchG
Betr-

SichV

BG

BGG

BGR

DGUV

CE

CEE

DC Direct Current

DFÜ

DIN

EG

Meaning

Display operating unit

Arbeitsschutzgesetz

Betriebssicherheitsverordnung

Berufsgenossenschaft

Berufsgenossenschaftlicher Grundsatz

Berufsgenossenschaftliche Regel

Berufsgenossenschaftliche Vorschrift German accident prevention regulations

Communauté Européenne

Commission on theRules forthe Approval
of the Electrical Equipment

Datenfernübertragung

Deutsches Institut für Normung German standardisation organisation

European Community

Explanation

German implementation of EU occupa­tional health and safety directives

German implementation of the EU work­ing equipment directive

German insurance company for the
company and employees

German principles and test specifications
for occupational health and safety

German rules and recommendations for
occupational health and safety

Confirms conformity with product-specific
European directives (CE mark)

International commission on the rules for
the approval of electrical equipment

Direct current

Remote data transmission

358042501 EN - 10/2016 7

56

1 Foreword

Information about the documentati

on

Abbrevi­ation

EN

FEM

F

max

Meaning

European standard

Fédération Européene de la Manutention

maximum Force

Explanation

European Federation of Materials Han­dling and Storage Equipment

Maximum power
German authority for monitoring/issuing

GAA Gewerbeaufsichtsamt

regulations for worker protection, environ­mental protection, and consumer protec­tion

GPRS General Packet Radio Service

Transfer of data packets in wireless
networks

ID no. ID number

ISO

International Organization for Standard­ization

International sta

ndardisation organisation

LAN Local Area Network Local area network

K

pA

LED

L

p

L

pAZ

LSP

MAK

Max

Min
PIN

PP
SE

SIT

StVZO

TRGS

VDE

Uncertainty of measurement of sound
pressure levels

Light Emittin

g Diode

Light emittin

g diode

Sound pressure level at the workplace

Average co
in the driv

Load centre of gravity

Maximum workplace concentration

.

Max

.

Min

ntinuous sound pressure level

er’s compartment

imum

imum

e of the centre of gravity of the load

Distanc

e front face of the fork backs

from th
Maximum permissible air concentrations
of a substance at the workplace

Highest value of an amount

Lowest value of an amount

Personal Identification Number Personal identification number
Personal protective equipment

E

Super-Elastic Superelastic tyres (solid rubber tyres)

Snap-In Tyre

Straßenverkehrs-Zulassungs-Ordnung

Technische Regel für Gefahrstoffe

Verband der Elektrotechnik Elektronik
Informationstechnik

Tyres for simplified assembly, without
loose rim parts

German regulations for approval of
vehicles on public roads

Ordinance on hazardous materials appli­cable in the Federal Republic of Germany

German technical/scientific association

85

6358042501 EN - 10/2016

Foreword 1

Information about the documentati

on

Abbrevi­ation

VDI

VDMA

Meaning

Verein Deutscher Ingenieure
Verband Deutscher Maschinen- und

Anlagenbau e.V.

Explanation

German technical/scientifica
German Mechanical Enginee

Association

WLAN Wireless LAN Wireless local area network

.

ssociation
ring Industry

358042501 EN - 10/2016 9

56

1 Foreword

Information about the documentati

Units

on

Unit symbol

°C

°F

A

Ah

Unit name

Degree Celsius Unit of temperature

Degree Fahrenheit

Ampere

Ampere hour

dB Decibel

cm

cm

g

h/d

3

Centimetre

Cubic centimetres Unit of volume

Gram Unit of mass

Hours per day Hours driven per day

kg Kilogram

kg/m

km/h

3

Kilograms per cubic
metre

Kilometres per hour Unit of speed

kN Kilonewton

kW Kilowatt

kWh/h Kilowatt hour/hour

lLitre

l/h

l/min

m

2

s

m/

n

mi
rpm

mm
NN

Litres per hour

Litres per minute

Metre

res per second

Met

ared

squ

nute

Mi
Revolution(s) per minute

Millimetre

ewton
Nm Newton metre

s

Second Base unit for time

Explanation

Unit of temperature

Unit of electrical current

Unit of electrical char

ge storage capacity (nominal

capacity)

Unit of sound intensity

Unit of length (1 cm = 10 mm)

Unit of mass (1 kg = 1000 g)
Unit of density (ratio of the mass of a body to its

volume)

Unit of force (1 kN = 1000 N)

Unit of electrical power

Energy consumption

Unit of volume

Unit of consumption

Unit of consumption

Unit of length (1 m = 100 cm)

Unit of acceleration

Unit of time (1 min. = 60 s)
Unit of revolution speed
Unit of length (1 mm = 10
Unitofforce(1N=10

nit of torque

U

-3

m)

-3

kN)

10

56358042501 EN - 10/2016

Foreword 1

Information about the documentati

on

Unit symbol

t

Unit name

Tonne

VVolt
WWatt
W/kg Watt/kilogram
Wh Watt-hours
Wh/kg Watt-hours/kilogram Stored energy per kilogram of mass (energy density)

.

Definition of directions

The directions "forward
"right" (2) and "left"
position of the parts a
compartment; the load

s" (1), "backwards" (3),

(4) refer to the installation

s seen from the driver’s

is to the front.

Explanation

Unit of mass (1 t = 1000 kg)
Unit of electrical voltage

Unit of electrical power
Performance by mass (power de

nsity)

Unit of electrical work (nominal energy)

1

4

3

2

6210_001-031

Schematic views

View of functions and operations

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

NOTE

These schematic diagrams are not represen­tative of the structural state of the documented
truck. The diagrams are used solely for the
purpose of clarifying procedures.

358042501 EN - 10/2016 11

56

6210_003-062

1 Foreword

Information about the documentati

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.

on

12

56358042501 EN - 10/2016

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 truck is 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.

358042501 EN - 10/2016 13

56

1 Foreword

Environmental considerations

14

56358042501 EN - 10/2016

2

Introduction

2 Introduction

Using the truck

Using the 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 trailers and 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.

16

56358042501 EN - 10/2016

Introduction 2

Using the 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 outdoors 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 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 truck is suitable for indoor and outdoor
use in countries ranging from the Tropics to
Nordic regions (temperature range: -20 °C to
+40 °C).

This truck is not designed to be operated in
cold stores.

358042501 EN - 10/2016 17

56

2 Introduction

Using the truck

CAUTION

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

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

– When the ambient temperature is below -10 °C,

only park the truck for short periods of time.

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 note the definition of "operating com­pany" in the sense of responsible persons!

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 ambient temperature 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.

18

56358042501 EN - 10/2016

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.

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 due to 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

358042501 EN - 10/2016 19

56

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

suspended 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

20

56358042501 EN - 10/2016

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.

358042501 EN - 10/2016 21

56

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)

22

56358042501 EN - 10/2016

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)

358042501 EN - 10/2016 23

56

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)

24

56358042501 EN - 10/2016

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 the trucks 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)

358042501 EN - 10/2016 25

56

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.

26

56358042501 EN - 10/2016

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 and correct 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

28

56358042501 EN - 10/2016

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 driver must be granted the 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

358042501 EN - 10/2016 29

56

3 Safety

Definition of responsible persons

DANGER

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

Individuals under the influence of the aforementio­ned substances are 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, the driver must secure
it against unauthorised use, e.g. by pulling out
the key.

30

56358042501 EN - 10/2016

Safety 3

Basic principles for safe operatio

Basic principles 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

n

358042501 EN - 10/2016 31

56

3 Safety

Basic principles for safe operatio

DANGER

Risk of injury 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 falling off 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 holes in the battery

hood.

n

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 whilst driving.

– Do not drill any holes in the battery hood.

32

56358042501 EN - 10/2016

Safety 3

Basic principles for safe operatio

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 withoutan overhead guard at
a lift height of over 1800 mm is prohibited.

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

trucks with an 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.

n

358042501 EN - 10/2016 33

56

3 Safety

Basic principles for safe operatio

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 fallingloads or the truck tipping 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 manufacturer has given approval.

– Seek advice from the authorised service centre

for the mounting of roof loads.

n

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 of such 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.

34

56358042501 EN - 10/2016

Safety 3

Basic principles for safe operatio

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 and attachments thatare not functional
or safe to drive may not be used until theyhave
been properly repaired.

Do not remove or deactivate
and switches.

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

Work on the electricalsystem (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

n

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

358042501 EN - 10/2016 35

56

3 Safety

Basic principles for safe operatio

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.

o be used, au-

facturer must be

an axle is changed,

astic tyres to pneu-

gram must bechanged

n

same type

relastic

the manu-

pare parts list.

Medical equipment

WARNING

Electromagneticinterference may occur on 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.

36

56358042501 EN - 10/2016

Safety 3

Basic principles for safe operatio

Exercise caution when handling gas springs and accumulators

WARNING

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

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

– Avoid damage, lateral forces, buckling, tempe-

ratures over 80°C and heavy contamination.

– Damaged or defective gas springs must be

changed immediately.

– Contact the authorised service centre.

WARNING

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

Before starting work on the accumulator it must be
depressurised.

– Contact the authorised service centre.

n

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 shift as 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

358042501 EN - 10/2016 37

56

3 Safety

Basic principles for safe operatio

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

– For help with selecting thecorrect fork arms,

contact the authorised service centre.

n

38

56358042501 EN - 10/2016

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 insulation of the truck 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 as part
of the FEM testing.

The insulation testing results must be at least
the test values given in the following two
tables.

358042501 EN - 10/2016 39

56

3 Safety

Safety tests

– For insulation testing, contact the autho-

rised service centre.

The exact procedure for this insulation testing
is described in the workshop manual for this
truck.

NOTE

The truck’s electrical system and drive batte­ries must be checked separately.

Test values for the drive battery

Component

Battery

.

Recommended

test voltage

50 VDC

100 VDC

100 VDC

Measurements

Batt+
Batt-

Battery tray

Nominal

voltage U

Batt

24 V > 1200

48 V > 2400

80 V > 4000

Test values

Test values for the

Nominal
voltage

entire truck

Test voltage

Test values for new trucks

Minimum values over the
duration of the service life

24 V 50 VDC Min. 50 k >24k

48 V 100 VDC Min. 100 k >48k

80 V 100 VDC Min. 200 k >80k

.

40

56358042501 EN - 10/2016

Safety 3

Safety regulations for handling co

nsumables

Safety regulations for handling consumables

Permissible consumables

DANGER

Failure to observe the safety regulations relating to
consumables may result in a risk of injury, death or
damage to the environment.

– Observe the safety regulations when handling

such materials.

Refer to the maintenance data table for the
permissible substances that are necessary for
operation (see ⇒ Chapter "Maintenance data
table", P. 6-307).

Oils

DANGER

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

contact with hot engine parts.

– No smoking,fires or naked flames!

DANGER

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

move to fresh air immediately.

– In the event of contact with the

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

– If swallowed, do not induce

vomiting. Seek immediate medical
attention.

358042501 EN - 10/2016 41

56

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 thefluids to come into

contact with hot engine parts.

42

WARNING

56358042501 EN - 10/2016

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.

358042501 EN - 10/2016 43

56

3 Safety

Safety regulations for handling co

WARNING

Battery acid contains dissolved
sulphuric acid. This is corrosive.

– When working with battery acid,

use appropriate PSA (rubber
gloves, apron, protection goggles).

– When working with battery acid,

never wear a watch or jewellery.

– Do not allow any acid to get

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

– In case of injury, seek medical

advice immediately.

– Immediately rinse away spilt

battery acid with plenty of water.

– Follow the statutory regulations.

ENVIRONMENT NOTE

– Dispose of used battery acid in line with the

applicable regulations.

Coolant and cooling fluid

nsumables

WARNING

Coolant and cooling fluid can be
hazardous to your health and the
environment!

Coolants are chemical corrosion
inhibitors and cooling system
protecting agents such as Glysantin.
Cooling fluid is an appropriate
mixture of water and coolant. Coolant
in both concentrated and dilute form
can be hazardous to your health
if swallowed, or hazardous to the
environment if spilled.

– Store coolant and cooling fluid

only in their original containers and
do not spill them.

– Never store coolant or coolingfluid

in empty food containers, bottles
or other containers.

– Observe the national regulations

for the country of use.

ENVIRONMENT NOTE

44

56358042501 EN - 10/2016

Safety 3

Safety regulations for handling co

– Soak up any spilt coolant or cooling fluid

immediately using an oil binding agent and
dispose of it in accordance with the national
regulations for the country of use.

– Dispose of old coolant or cooling fluid in

accordance with the national regulations for
the country of use.

nsumables

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 that
purpose. Care must be taken to minimise any
environmental pollution.

– Soak up any spilt fluids s

oil or gearbox oil imme
oil-binding agent.

– Neutralise any spilt battery acid immedi-

ately.

– Always observe national regulations con-

cerning the disposal of used oil.

uch as hydraulic

diately using an

358042501 EN - 10/2016 45

56

3 Safety

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, EN ISO 3744 and the
requirements of EN ISO 4871.

This machine emits the fol
pressure level:

Continuous sound pressure level in the

driver’s compartment

L

pAZ

< 70 dB(A) 4 dB(A)

lowing sound

Measurement

uncertainty K

pA

The values were dete
on an identical mach
values for operatin

Time proportions:

• Lifting 18%

• Idling 58%

• Driving 24%

However, the noise levels indicated on the
truck cannot be used to determine the noise
emissionsat workplaces accordingto the most
recent version of Directive 2003/10/EC (daily
personal noise pollution). If necessary, these
noise emissions should be determined by the
operating company directly at the workplace
under the actual conditions there (additional
noise sources, special application conditions,
sound reflections).

NOTE

rmined in the test cycle

ine from the weighted

g statuses and idling.

Please note the definition of "operating com­pany" in the sense of responsible persons!

46

56358042501 EN - 10/2016

Safety 3

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

0.31 m/s

2

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

2.5 m/s

. There are therefore no measure-

ment guidelines for these measurements.

The personal vibration
a working day must be det
operating company at t
in accordance with Dir
order to consider all a
such as driving route,

Measurement

uncertainty

0.093 m/s

2

load on the driver over

ermined by the

he actual place of use

ective 2002/44/EC,in

dditional influences,

intensity of use etc.

NOTE

Please note the definition of "operating com­pany" in the sense of responsible persons!

358042501 EN - 10/2016 47

56

3 Safety

Emissions

Battery

DANGER

Risk of explosion due to flammable
gases!

During charging, the battery releases
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.

48

56358042501 EN - 10/2016

4

Overviews

4 Overviews

Overview

Overview

10

9

8

1Liftmast
2 Driver’s compartment
3 Overhead guard
4 Left side cover
5 Steering axle

1

2

3

4

5

6341_003-019_V2

7

6

6Driveaxle
7 Tilt cylinder
8 Fork arms
9 Fork carriage
10 Lift cylinder

50

56358042501 EN - 10/2016

Overviews 4

Overview of the driver’s compartme

Overview of the driver’s compartment

nt

16

15

14

13

3

1

2

4

9

1

0

0

%

2

7

5

1

5

0

1

2
8

9

0

8

3

6

1

5
:2

3

5

4

­+

F

1

F2

6

7

8

12

11

10

9

6341_003-020

1Parking
2 Steeri
3Keysw
4 Displ
5Docu
6Ope

7Em
8C

brake lever

ng wheel

itch

ay and operating unit

ment holder

rating devices for hydraulic and traction

nctions

fu

ergency off switch

ompartment

NOTE

The truck equipment may differ from the
equipment shown.

358042501 EN - 10/2016 51

56

9Bottleh
10 Driver
11 Compa

12 Comp
13 Fil
14 Ac
15 Br

6

1

older for max. 1.5 l bottles

’s seat

rtment and potential storage location

erating instructions

for op

artment

ler cap for windscreen washer reservoir

celerator pedal

ake pedal

teering column adjustment

S

4 Overviews

Operating and display elements

Operating and display elements

Display operating unit

4

3

56

2

1

26

25

21

20

6210_003-082_V3

1 Hazard warning system button
2 Front windscreen wiper button
3 Working spotlight button
4 Drive programme selector button
5 Lighting button
6 Lighting symbol
7 Not assigned
8 Battery charge display
9 Drive programme display (numerical)
10 Left direction indicator light
11 Forward travel display
12 Right direction indicator light
13 Malfunction display

24

22

23

7

19

17

18

14 Reverse travel display
15 Power rating display
16 Time display (digital)
17 Not assigned
18 Rotating beacon display
19 Interior light display
20 Rear window heating display
21 Interior light/rotating beacon button
22 Rear window heating button
23 Menu change button
24 Lighting button
25 Blue-Q button
26 Rear window wiper button

8

9

10

11

12

13

14

15

16

NOTE

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

e assignment shown here is an example

Th

d may differ from the assignment actually

an

ogrammed on the truck. Buttons may be

pr

signed multiple functions that are called

as

according to the menu navigation. For

up

rther information, see the section entitled

fu

perating the display and operating unit".

"O

52

56358042501 EN - 10/2016

Overviews 4

Operating and display elements

– If you have any questions, please contact

your authorised service centre.

Operating devices for hydraulic and driving 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:

• Double mini-lever

• Triple mini-lever

• Quadruple mini-lever

• Joystick 4Plus

• Fingertip switch

• Mini-console

358042501 EN - 10/2016 53

56

4 Overviews

Operating and display elements

Double mini-lever

3

2

1

8

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

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 bythe authorisedservice centre.

54

56358042501 EN - 10/2016

Overviews 4

Operating and display elements

Three-way mini-lever

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

358042501 EN - 10/2016 55

56

4 Overviews

Operating and display elements

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 bythe authorisedservice centre.

operating lever

ting lever

yF1

ey F2

ection / turn indicator" cross lever

5

6

7

5060_003-088

6Functionkey"
7 "Auxiliary h
8 "Auxiliary
9 Emergency
10 Signal hor

9

5th function"

ydraulics 1" operating lever

hydraulics 2" operating lever

stop switch

n button

8

56

56358042501 EN - 10/2016

Overviews 4

Operating and display elements

Joystick 4Plus

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 the 5th hydraulic function and

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

functions

2

3

6210_003-087

4

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

reach frame forwards/backwards
7 Vertical rocker button for the "drive direction"
8Shiftkey"F"
9 Signal horn button

358042501 EN - 10/2016 57

56

4 Overviews

F1

F2

Operating and display elements

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 bythe authorisedservice centre.

58

56358042501 EN - 10/2016

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

Overviews 4

Operating and display elements

Mini console

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

2

1

1 Travel direction s
2 Direction indica

7311_003-056

witch

tor switch

358042501 EN - 10/2016 59

56

4 Overviews

5430

1010

1080

1080

1080

1050

1150

1310

4430

1110

1230

1250

1500

4030

1150

1260

1200

1500

3730

1180

1290

1430

1500

3430

1210

1330

1470

1500

800

700

500

2

1

3

1

Identification points

Identification points

Overview

9

1219

DANGER

4

DANGER

5

6

14

3

BATTERIESERVICE

Nächste Prüfung

Ihr STILL Service

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

15

10 bar

13

18

13

12

21

20

17

3
7

14

4

DANGER

733906

1

DANGER

2

20

17

7

20xx

17

DANGER

DANGER

19

16

11

10

6

15

16

7

11

8

8

STILL GmbH Hamburg

Regelmäßige Prüfung

(FEM 4.004)

nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
2009/104/EG, 99/92/EG

Nächste Prüfung

Die Prüfplakette ersetzt nicht das Prüfprotokoll

1080

1080

5430

1080

1010

1050

5030 1270

1150

1310

4430

1110

1230

1250

1500

4030

1150

1260

1200

1500

3730

1180

1290

1430

1500

1500

3430

1210

1330

1470

800

700

600

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

Rated capacity
Capacité nominale
Nenn-Tragfähigkeit

Battery voltage
Tension batterie
Batteriespannung

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

Unladen mass

kg

Masse à vide
Leergewicht

V

kW

* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung

Mitglied der:
Fédération
Européene
de la Manutention

500

*

20

max

min.*

15

kg

kg

kg

kg

56344391019

12

13

5

21

9

DANGER

6341_003-018_V3

60

56358042501 EN - 10/2016

Overviews 4

Identification points

1 Decal information: Caution/read the operat-

ing instructions
2 Warning sign: Danger due to shearing
3 Decal information: Battery service
4 Warning sign: Do not stand underneath the

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

shearing/Danger due to high fluid pressure
5 Decal information: Hydraulic oil tank
6 Decal information: Attachment capacity

rating plate
7 Decal information: Inspection sticker
8 Decal information: FEM test
9 Decal information: Caution/Read the op-

erating instructions/Fasten seat 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
10 Manufacturer’s label text

11 Decal information: Nameplate
12 Decal information: Capacity rating plate
13 Decal information: Lifting gear attachment

point

14 Warning sign: Actuate accumulator/brake

pedal 30x/Read operating instructions
15 Decal information: Tyre filling pressure
16 Decal information: StVZO (German Road

Traffic Licensing Regulations) information

(variant)
17 Warning sign: Danger due to shearing/Dan-

ger due to high fluid pressure
18 Manufacturer’s label text
19 Warning sign: Risk of short circuit due to

shearing
20 Warning sign: Do not stand underneath the

fork/Do not stand on the fork
21 Decal information: To unlock, turn 90° to the

right/to lock, turn 90° to the left

358042501 EN - 10/2016 61

56

4 Overviews

Identification points

Nameplate

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

1

2

3

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

12

11

10

Rated capacity
Capacité nominale
Nenn-Tragfähigkeit

Battery voltage
Tension batterie
Batteriespannung

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

Unladen mass

kg

Masse à vide
Leergewicht

V

kW

* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung

9

1 Type
2 Production numbe
3 Year of manufact
4 Tare weight in k
5 Max. permissi

electric fork

6 Min. permis

orklift trucks only)

electric f

7 Ballast we

only)

8Referto

9CElab
10 Nomi
11 Bat
12 Ra

the technical data listed in these

ing instructions for more detailed

operat

ation

inform

elling

nal drive power in kW

tery voltage in V

ted capacity in kg

r

ure

g

ble battery weight in kg (for

lift trucks only)

sible battery weight in kg (for

ight in kg (for electric forklift trucks

4

kg

max

min.*

*

5

kg

kg

6

kg

7

8

6210_921-003_V2

62

56358042501 EN - 10/2016

Overviews 4

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)

358042501 EN - 10/2016 63

56

34

7094_003-098

4 Overviews

Identification points

64

56358042501 EN - 10/2016

5

Operation

5 Operation

Checks and tasks to be carried out pr

ior to commissioning

Checks and tasks to be carried out prior to commissioning

Visual inspections

WARNING

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

Damage to the truck or the attachment (variant)can
lead to unpredictable and dangerous situations.
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 systems or

switches.
– Do not change any 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 components or use them

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

Prior to commissioning, 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

66

56358042501 EN - 10/2016

2

1

6210_000-002

Operation 5

Checks and tasks to be carried out pr

• 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

• The battery must be positioned securely in
the battery tray.

• Check the battery male conn
damage (e.g. cracks, break
of the housing, and whether
are bent or damaged). If nec
the battery male connector
authorised service centre

• The battery cover must be securely closed

• The battery lock and the indexing bolt for the
battery base frame must not be damaged or
deformed

• The battery base frame, b
battery cover must not be
deformed

• The maintenance lids must be closed

• 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

• The coupling pin in the counterweight must
show no noticeable damage (e.g. bends,
cracks or breaks). The securing bush in the
counterweight must be present

• A tow coupling (varia
noticeable damage (e
bent, cracks or break
coupling pin must be s
with a securing devic
pin or a rope)

al horn) must be

ction correctly

ector for

s or deformation

the contacts

essary, have

replaced by the

attery tray and

damaged or

ant, e.g. wind-

dfreeofice

nt) must show no

.g. coupling pin

s). Every removable

ecured against loss

e (e.g. a chain, a split

ior to commissioning

358042501 EN - 10/2016 67

56

5 Operation

Checks and tasks to be carried out pr

• The exhaust air grille on the cover of the
rear weight must not be covered. It must be
kept free of debris such as leaves or similar
deposits

• Damage or other defects on the truck or
attachment (variant) must be reported to
the supervisor or responsible fleet manager
immediately so that arrangements can be
made for the defect to be rectified

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 bores in the battery
hood. A build-up of hydrogen can
lead to explosions.

There must be no unsealed bores in
the battery hood. 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.

ior to commissioning

Filling the washer system

CAUTION

Components may become damaged due to the
effects of frost!

Water expands when it freezes. If there is no
anti-freeze in the washer system, the system may
be damaged due to the build up of ice in freezing
conditions.

– Always use washer fluid containing anti-freeze.

68

56358042501 EN - 10/2016

Operation 5

Checks and tasks to be carried out pr

The windscreen washer reservoir is under the
compartment behind the driver’s seat. The
sight glass (1) displays the fill level.

– Open filler cap (2) for the windscreen

washer reservoir.

– Fill the windscreen washer res

washer fluid and anti-freeze
dance with the maintenance d
see ⇒ Chapter "Maintenance d
ble", P. 6-307.

–Closelid.

– Operate washer system until washer fluid is

discharged from the spray nozzles.

ervoir with

in accor-

ata table;

ata ta-

ior to commissioning

2

1

7331_341-001

Checking the condition of the wheels and tyres

WARNING

Risk of accidents! With uneven wearor incorrect air
pressure, the stability of the forklift truck decreases
and the braking distance increases.

– Change worn or damaged tyres without delay.

WARNING

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

from the tyres approved by the truck manufacturer,
or tyres froma different manufacturer, 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.

358042501 EN - 10/2016 69

56

5 Operation

Checks and tasks to be carried out pr

NOTE

Only approved types of tyre may

be used; see

chapter entitled "Tyres".

– Check tyres (1) for wear or damage.

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

– In the case of pneumatic tyr

pressure. The air pressure
adhesive labels (2) must be

es, check the air
indicated on the

observed.

NOTE

Observe the safety principles outlined in the
chapter entitled "Tyres".

ior to commissioning

1

2

7321_003-003

Checking the coo

lant level

WARNING

Risk of scalding due to hot coolant!
The cooling system is pressurised! When you open

the coolant reservoir,hot coolant can leak out. Only
open the coolant reservoir when the cooling system
is cold.

– Switch off the truck and allow it to cool down.
– Do not open the coolant reservoiruntil the engine

has cooled down.

CAUTION

Risk of component damage due to overheating!
The power electronics and the hydraulic oil are

protected from overheating by a cooling system.
Loss of coolant from leaking coolant hoses or from
the radiator reduces the cooling capacity and can
cause components to overheat. If the coolant level
is low, this indicates a leak in the cooling system.

– Check the cooling system for leaks.

– Remove the left side cover.

70

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Operation 5

Checks and tasks to be carried out pr

– Pull the locking pin (1) on the coolant

reservoir (2) upwards.

– Pull out the coolant reservoir under the rear

cover.

– Check the coolant level.

ior to commissioning

2

The coolant level should be between the upper
mark (4) and the lower mark (5).

– Top up the coolant to the upper mark, but no

further, if necessary.

– Make sure that the

screwed on and tig

reservoir cap (3) is

htly sealed.

– Push the coolant reservoir (2) back in until

the locking pin (1) engages.

– Attach the left side cover.

1

6341_003-023

3

2

max

min

4

5

1

6341_003-024

358042501 EN - 10/2016 71

56

5 Operation

Checks and tasks to be carried out pr

Adjusting the MSG 65/MSG 75
driver’s seat

DANGER

There is a riskof accident ifthe seat or seatbackrest
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

WARNING

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

On these specific equipment va­riants, the distance betweenthe head
and the lower edge of the roofing
sheet must be at least 40 mm.

ior to commissioning

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 your backand protects yourhealth.

– To prevent injury, make sure that there are no

objects within the swivel area of the seat

72

56358042501 EN - 10/2016

Operation 5

Checks and tasks to be carried out pr

ior to commissioning

Moving the driver’s seat

– Lift and hold the lever (1)

– 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 and hold the l

ever (2)

– 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

358042501 EN - 10/2016 73

56

5 Operation

Checks and tasks to be carried out pr

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 driver’sseat MSG 65/MSG 75 is designed
for people weighing between 45 kg and
170 kg.

NOTE

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

– Fully extend the weight-adjusting lever (3)

– Pump it upor down to set the driver’s weight.

– 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.

ior to commissioning

4

3

6321_003-038

NOTE

The driver’s weight has been selected cor­rectly when the arrow (4) is in the centre of the
inspection window. If the seat does not move
any further when you pump the weight adju­sting lever, the minimum or maximum weight
setting has been reached.

74

56358042501 EN - 10/2016

Operation 5

Checks and tasks to be carried out pr

ior to commissioning

Adjusting the lumbar support (variant)

NOTE

5

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 lumbar support is in the desired position

6321_003-039

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

6

6321_003-040

358042501 EN - 10/2016 75

56

5 Operation

Checks and tasks to be carried out pr

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 the seat heater (7) on or off using the

switch.

Adjusting the armrest

DANGER

There is a risk of accident if the 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 uncontrolled movements of the truck or load.

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

can be actuated safely.

– Ensure that the armrest is securely tightened.

ior to commissioning

7

6321_003-041

Adjusting the length of the armrest

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

it anti-clockwise.

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

tion.

– Tighten the star-grip handle by turning it

clockwise.

– Check that the armrest is firmly attached.

Adjusting the height of the armrest

– Release hand wheel (3) by turning it anti-

clockwise.

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

tion.

76

56358042501 EN - 10/2016

3

2

1

7331_342-001

Operation 5

Checks and tasks to be carried out pr

– Tighten the hand wheel by turning it clock-

wise.

– Check that the armrest is firmly attached.

ior to commissioning

Adjusting the steering column

– Press down the steering column adjustment

lever (2).

– Position the steering col

lever up again.

DANGER

Risk of accidents!
– Ensure that the steering column is secure.
The steering column must click into place.
Never adjust the steering column while driving.

umn (1) and pull the

1

2

6210_424-001

358042501 EN - 10/2016 77

56

5 Operation

Commissioning

Commissioning

Climbing into and out of the truck

WARNING

Risk of injury when climbing into and out of the
truck due to slipping, striking parts of the truck or
becoming stuck!

If the footwell cover is very dirty or smeared with oil,
there is a risk of slipping. There is a risk of hitting
your head on the overhead guard post or of your
clothes becoming stuck when climbing out of 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 out of 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
forbidden to jump out of the truck.

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

CAUTION

Components may become damaged through
incorrect use!

Truck components, such as the driver’s seat,
steering wheel, parking brake lever etc., are not
designed to be used for climbing in and out of the
truck and may be damaged due to misuse.

– Only use the fittings specifically designed for the

purpose of climbing into and out of the truck.

NOTE

The foot that the driver starts with when
climbing into and out of the truck is crucial in
ensuring this action is carried out safely. This
will depend on the number of steps. Trucks
with a single wheel on the front axle feature
two steps. Trucks with two wheels on the front
axle feature three steps.

78

56358042501 EN - 10/2016

Operation 5

Commissioning

Climbing in and out of trucks featuring a
single wheel and two steps

When climbing into and out of the truck, use
the handles (2) and (4) for support. The
overhead guard post (1) can also be used
for support.

Always climb into the truck f

– Grip handle (2) with your left hand and hold

on.

– Grip handle (4) with your right hand and

hold on.

– Place your right foot on the

– Place your left foot on the top step (6).

– Place your right foot into the footwell (7).

– Enter the truck and sit do

seat (3).

Always climb out of the truck backwards:

– Grip handle (2) with your left hand and hold

on.

– Stand up from the drive

your left foot on the to

– Grip the handle (4) with your right hand and

hold on.

– Place your right foot on the bottom step (5).

– Place your left foot o

down from the truck.

acing forwards:

bottom step (5).

wn on the driver’s

r’s seat and place

pstep(6).

n the ground and climb

7

21

3

4

6

5

7341_003-001_V2

358042501 EN - 10/2016 79

56

5 Operation

Commissioning

Climbing in and out of trucks featuring
two wheels and three steps

When climbing into and out of the truck, use
the handles (2) and (4) for support. The
overhead guard post (1) can also be used
for support.

Always climb into the truck f

– Grip handle (2) with your left hand and hold

on.

– Grip handle (4) with your right hand and

hold on.

– Place your left foot on the b

– Place your right foot on the middle step (6).

– Place your left foot on the top step (7).

– Place your right foot int

– Enter the truck and sit down on the driver’s

seat (3).

Always climb out of the truck backwards:

– Grip handle (2) with yo

on.

– Stand up from the driver’s seat and place

your left foot on the top step (7).

– Grip the handle (4) with your right hand and

hold on.

– Place your right foot

– Place your left foot on the bottom step (5).

– Place your right foot on the ground and

climb down from the truck.

acing forwards:

ottom step (5).

o the footwell (8).

ur left hand and hold

on the middle step (6).

8

7

6

21

3

4

5

7341_003-061

80

56358042501 EN - 10/2016

Operation 5

Commissioning

Connecting the battery male connec­tor

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 shortens their service
life.

– Do not connect the battery male connector while

the key switch is switched on.

CAUTION

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

The battery cable must not be
crushed when closing the battery
cover.

– Ensure that the key switch is switched off.

– Open the battery cover.

– Hold the battery male connector (2) by

the handle (1) and insert the battery male
connector into the plug connection on the
truck.

– Push the fastener (3) completely to the right

to retract the battery male connector into the
plug connection and to secure the battery
male connector in position.

– Ensure that the battery cable cannot come

into contact with the battery cover.

– Close the battery cover.

1

2

3

6341_003-005_V2

358042501 EN - 10/2016 81

56

5 Operation

F

1

F2

Commissioning

Unlocking the emergency off switch

– Pull the emergency off switch (1) until it is

unlocked.

1

1

F2

1

F

Switching on t

he key switch

WARNING

Before switching on the key switch, all tests and
operations prior to commissioning must be perfor­med without any defects being detected.

– Carry out checks and operations before commis-

sioning.

– Do not operate the truck if defects have been

detected; contact the authorised service centre.

NOTE

When the truck is switched on, the maximum
driving speed is restricted. The driving speed
limitation is disabled as soon as the truck is
steered out of cornering to drive in a straight
line. To do this, rotate the steering wheel by
approximately half a turn.

82

56358042501 EN - 10/2016

1

7312_003-183

Operation 5

Commissioning

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

turn to position "I".

0

I

1

5060_003-029_V2

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

7312_003-085

358042501 EN - 10/2016 83

56

5 Operation

Commissioning

When the key switch is switched on, the
display shows the welcome screen in the
set language until the truck controller has fully
started up.

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

If the truck is equipped with
authorisation with PIN code
display initially changes t
for access authorisation.

the "access

" variant, the

o the input menu

Standard display elements

1 Battery charge

The available batt
in the display field

2 Drive program

The current traction program (1–5)
appears on the display.

3 Power rating

The average power consumption and
consumption trends are shown in the
display field.

4 Time

The current time
field.

NOTE

After connecti
charging state
the battery is
driving or lif

Additional information may appear on the
display.

– If malfunctions occur, refer to the informa-

tion in the chapter entitled "Display mes­sages".

placed under load in the form of

ting operations.

ery capacity is shown
.

appears in the display

ng the battery, the correct

may not be displayed until

1

2

3

4

6341_003-006_V3

84

56358042501 EN - 10/2016

Operation 5

Commissioning

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 defined in a truck control
unit menu that can only be accessed by
persons with the corresponding access
authorisation, e.g. fleet managers.

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 driver PIN (possible entries from 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 authorisa
in such a way that the d
re-entered each time
truck, in order for th
again.

– Contact the authorised service centre on

this matter.

The first driver PIN is preset to "11111" at the
factory. All others are preset to "0xFFF" but
have no functionas the highest valid driverPIN
is "99999". Persons with the corresponding
access authorisation, e.g. fleet managers, can
change the driver PINs in the corresponding
menu.

tion can be configured

river PIN has to be

the driver steps off the

e truck to be operated

358042501 EN - 10/2016 85

56

5 Operation

Commissioning

NOTE

When first commissioning the tr
commend you change the access a
tion set at the factory. This is
guarantee that the driver PIN i
persons with corresponding ac
sation.

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 service centre can use adiagnostic
device to read out the driver PIN and, if
necessary, restore the factory default driver
PIN.

ACCESS CODE input menu

The driver enters the five-digit driver PIN
(00000 to 99999) in this input menu.

The driver PIN is entered
The digits entered for th
visible, instead being
If the driver PIN entere
display appears with th
all truck functions are

represented by circles.

d is correct, the familiar
e standard display, and

available.

uck, we re-

uthorisa-

the only way to

s only known to

cess authori-

using the buttons (1).

edriverPIN(2)arenot

86

56358042501 EN - 10/2016

Operation 5

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

358042501 EN - 10/2016 87

56

5 Operation

8

9

6

7

4

2

0

1

3

5

Commissioning

Defining the driver PIN

NOTE

The driver PIN can only be defined by persons
with the corresponding access authorisation,
e.g. fleet managers. In order for the fleet
manager to define the driver PIN, the confi­guration menu must be accessed. The confi­guration menu is password-protected. After
entering the password, the fleet manager can
configure general settings for the truck. To
change the password, see the chapter entitled
"Changing the password".

– Push the drive program selection button (1)

and the menu change button (2)at thesame
time.

PASSWORD appears in the display.

– Enter the four-digit password (factory

default: 2777) using the buttons (1).

– Confirm the entry by pressing the

button (2).

ENTER

1

126

1

2

Blue-Q_029_V2

ESC

3

4

7

5

2

BQ_030_en_V2

88

56358042501 EN - 10/2016