Original instructions
Diesel truck
RX70-16
RX70-18
RX70-20
7311 7312 7313
174749 EN - 03/2017
Preface
Address of manufacturer and contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. +49 (0) 40 7339-0
Fax: +49 (0) 40 7339-1622
Email: info@still.de
Website: http://www.still.de
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749 EN - 03/2017 I
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Table of contents
1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformit
Accessoriesoverview ................................................. 7
Overview ........................................................... 8
Nameplate ......................................................... 10
Production number . . . ............................................... 11
StVZO(RoadTrafficLicensingRegulations)information ....................... 11
Use of truck ........................................................ 11
Proper usage ....................................................... 11
Proper use during towing .............................................. 12
Impermissibleuse ................................................... 12
Placeofuse ........................................................ 13
Usingworkingplatforms ............................................... 14
Information about docum
Documentationscope ................................................ 15
Supplementarydocumentation .......................................... 16
Issue date and topicali
Copyrightandtrademarkrights .......................................... 17
Explanation of information symbols used . . ................................ 17
List of abbreviations
Definitionofdirections ................................................ 20
Schematicviews .................................................... 20
Environmental con
Packaging ......................................................... 22
Disposal of components and batteries ..................................... 22
y in accordance with Machinery Directive ............... 6
entation ........................................ 15
tyoftheoperatinginstructions .......................... 17
.................................................. 18
siderations .......................................... 22
g
2Safety
Definition of respon
Operatingcompany .................................................. 24
Specialist .......................................................... 24
Drivers ........................................................... 25
Essentials for safe operation ........................................... 27
Insurance cover on company premises .................................... 27
Changes and retrofi
Changes to the overhead guard and roof loads .............................. 29
Warning regarding non-original parts ..................................... 29
sible persons ........................................ 24
tting ............................................... 27
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Table of contents
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Damage, defects and misuse of safety systems . . . ........................... 30
Tyres ............................................................. 30
Medicalequipment ................................................... 32
Exercise caution when handling gas springs and accumulators .................. 32
Lengthoftheforkarms ................................................ 33
Residual risk ....................................................... 34
Residual dangers, residual risks ......................................... 34
Specialrisksassociatedwithusingthetruckandattachments ................... 35
Overview of hazards and coun
Danger to employees ................................................. 41
Safety inspections ................................................... 42
Regular safety inspection
Checkingthedieselengineemissions ..................................... 42
Truckswithparticlefilters .............................................. 43
Insulationtesting .................................................... 44
Safety regulations when handling consumables ............................. 45
Permissibleconsumables ............................................. 45
Oils .............................................................. 45
Hydraulicfluid ...................................................... 46
Batteryacid ........................................................ 47
Dieselfuel ......................................................... 48
Coolantandcoolingfluid .............................................. 50
Disposalofconsumables .............................................. 50
Emissions ......................................................... 52
termeasures ................................. 38
ofthetruck ..................................... 42
3Overviews
General view ....................................................... 56
Driver's compartment ................................................. 57
Operating and displ
Display and operating unit . . . .......................................... 58
Operatingdevicesforhydraulicanddrivingfunctions .......................... 59
Double mini-lever
Three-waymini-lever ................................................. 61
Four-waymini-lever .................................................. 62
Joystick4Plus ...................................................... 63
Fingertip .......................................................... 64
Miniconsole ....................................................... 65
IV 1
ay elements ......................................... 58
.................................................... 60
74749 EN - 03/2017
Table of contents
4 Operation
Testing and activities before daily use ..................................... 68
Visualinspections ................................................... 68
Checkingthecoolingfluidlevel .......................................... 71
Checking the engine oil level ........................................... 72
Climbing in and out of the tru
Shelvesandcupholders .............................................. 74
AdjustingtheMSG65/MSG75driver'sseat ................................ 75
Adjustingthearmrest ................................................. 79
Adjustingthesteeringcolumn ........................................... 80
Unlockingtheemergencyoffswitch ...................................... 80
Switchingonthekeyswitch
AccessauthorisationwithPINcode(variant) ................................ 84
Operating the signal horn .............................................. 94
Seatbelt .......................................................... 94
Driver'scab ........................................................ 97
Starting the engine ................................................... 98
Checking the brake syste
Checkingthesteeringsystemforcorrectfunction ............................101
Checking the emergency off function .....................................101
Zero adjustment of the l
Checking the vertical lift mast position (variant) for correct function . ...............104
Operation of the display operating unit ....................................105
Displays ........................................................ . . 105
Adjustingthedisplays ................................................106
Symbolsinthedisplay ................................................106
Setting the date or time
Resetting the daily kilometres and daily operating hours .......................111
Setting the language . . ...............................................112
Soft key button for operat
ConfiguringBlue-Qefficiencymode ......................................113
Blue-Q efficiency mode ...............................................115
Functional description . ...............................................1
Effects on additional consumers .........................................115
SwitchingefficiencymodeBlue-Qonandoff ................................116
Driving ............................................................117
Safety regulations when driving .........................................117
Driveways ....................................................... . . 119
Setting the drive prog
Selectingthedrivedirection ............................................122
Actuatingthedrivedirectionswitch,mini-leverversion .........................123
ck .......................................... 73
............................................ 81
mforcorrectfunction ..............................100
oadmeasurement(variant) ...........................102
................................................111
ing various equipment variants .......................112
rams .............................................122
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Actuating the vertical rocker switch for the "drive direction", joystick 4Plusversion ....124
Actuating the drive direction switch, fingertip version ..........................124
Actuating the drive direction
Startingtodrive .....................................................125
Starting drive mode, dual-pedal version (variant) . . ...........................127
Operatingtheservicebrake ............................................13
Parkingbrake ......................................................131
Actuating the mechanical parking brake ...................................131
Actuating the electric park
Steering ...........................................................138
Driving on ascending and descending gradients . . ...........................139
Reducing speed with a raise
Automatic shut-off of the internal combustion engine (variant) ...................140
Parking ...........................................................141
Parking the truck securel
Wheel chock (variant) ................................................142
Lifting ............................................................143
Lifting system variants
Automaticliftcutout(variant) ...........................................143
Liftmastverticalposition(variant) ........................................144
Typesofliftmast ....................................................148
Malfunctionsduringliftingmode .........................................150
Hydraulicblockingfunction .............................................151
Lifting system operati
Controlling the lifting system using a double mini-lever .........................153
Controllingtheliftingsystemusingatriplemini-lever ..........................154
Controlling the lift
Controllingtheliftingsystemusingthejoystick4Plus ..........................156
Controlling the lifting system using the fingertip . . . ...........................158
Changing the fork arm
Forkextension(variant) ...............................................161
Operationwithreversibleforkarms(variant) ................................163
Workingwithloads ...................................................165
Safety regulations when handing loads ....................................165
Beforetakingupload .................................................166
Load measurement (va
Picking up loads .....................................................170
Danger area .......................................................171
Transportingpallets ..................................................17
Transporting suspended loads ..........................................172
Loadpickup ...................................................... . 173
ing system using a quadruple mini-lever ......................155
switch,mini-consoleversion ......................125
ingbrake ......................................133
dload(variant) ................................140
yandswitchingitoff ...............................141
................................................143
ngdevices .........................................152
s ...............................................159
riant) ...........................................167
0
2
VI 1
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Table of contents
Transportingloads ...................................................177
Settingdownloads ...................................................178
Drivingonlifts ......................................................180
Driving on loading bridges .............................................181
Attachments .......................................................182
Fittingattachments ..................................................182
Releasingthepressurefromthehydraulicsystem ............................184
Generalinstructionsforcontrollingattachments .............................186
Controlling attachments us
Controlling attachments using the double mini-lever and the 5th function ...........190
Controllingattachmentsusingatriplemini-lever .............................192
Controlling attachments u
Controlling attachments using a quadruple mini-lever .........................196
Controlling attachments using the quadruple mini-lever and the 5th function .........198
Controlling attachments
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........201
Controlling the attachments with the fingertip ...............................202
Controlling attachment
Clamp locking mechanism (variant) ......................................205
Takingupaloadusingattachments ......................................208
Auxiliary equipment ..................................................20
Switchingthelightingonandoff .........................................209
Switching the rotating beacon on and off . . . ................................210
Switching the hazard wa
Switchingdirectionindicatorsonandoff ...................................211
Switching the double working spotlights on and off. ...........................214
STILL SafetyLight (v
Operatingthewindscreenwiper/washer ...................................217
Fillingthewashersystem ..............................................217
FleetManager (variant
Shock recognition (variant) .............................................218
Cruisecontrol(variant) ................................................218
Driver restraint syst
Cab ..............................................................223
Opening the cab door . . ...............................................223
Closing the cab door
Openingthesidewindows ........................................... . . 224
Closing the side windows ..............................................225
Operating the inte
Operating the rear window heating .......................................227
Radio(variant) ......................................................227
riorlighting ...........................................226
ing a double mini-lever ............................188
singthetriplemini-leverandthe5thfunction .............194
viathejoystick4Plus ...............................200
s with the fingertip and 5th function ......................203
rningsystemonandoff .............................210
ariant) .............................................216
) ................................................217
ems(variants) .......................................222
.................................................224
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Heatingsystem .....................................................228
Push-up roof window (variant) ..........................................229
Clipboard (variant) ...................................................230
Trailer operation ....................................................231
Towedload ....................................................... . 231
Coupling pin in the counterw
Automatictowcoupling ...............................................234
Towingtrailers ......................................................242
Display messages ...................................................244
Displaycontent .....................................................244
Errorcodetable .....................................................245
General messages ...................................................247
Drive-specificmessages ..............................................256
Malfunctionsintheelectricparkingbrake ..................................263
Refuelling .........................................................269
Dieselfuel-Specifications .............................................269
Topping up the diesel fuel ..............................................273
Cleaning ..........................................................275
Cleaning the truck ...................................................275
Cleaning the electrical system ..........................................277
Cleaning load chains .................................................27
Cleaning the windows ................................................278
Afterwashing .......................................................279
Behaviour in emergenc
Emergency shutdown ................................................279
Procedureiftrucktipsover .............................................281
Emergency hammer ..................................................282
Emergency lowering .................................................282
Emergency operation of the electric parking brake . ...........................284
Disconnecting the batte
Jumpstarting .......................................................286
Towing .......................................................... . 288
Transporting the truck ................................................290
Transport ..........................................................290
Craneloading ......................................................292
Shutdown .........................................................295
Shuttingdownandstoringthetruck ......................................295
Returningtoserviceafterstorage ........................................297
eight ........................................232
ies .............................................279
ry ..............................................285
8
I 174749 EN - 03/2017
VII
Table of contents
5 Maintenance
Safety instructions for maintenance ......................................300
Generalinformation ..................................................300
Workingonthehydraulicequipment ......................................300
Working on the electrical equipment ......................................301
Working on the ignition syst
Safetydevices ......................................................302
Setvalues ....................................................... . . 302
Liftingandjackingup .................................................302
Workingatthefrontofthetruck ..........................................302
General maintenance information ........................................304
Personnel qualifications ...............................................3
Informationforcarryingoutmaintenance ..................................304
Maintenance - 1000 hours/annually ......................................307
Maintenance — 3000 hours/
Orderingsparepartsandwearingparts ....................................311
Quality and quantity of the required operating materials ........................312
Lubricationplan .....................................................313
Maintenance data table ...............................................314
Providing access to maintenance points ...................................317
Openingthebonnet ................................................ . . 317
Closing the bonnet ...................................................317
Installingandremovingthebottomplate ...................................318
Maintenance after first 5
Maintenance during the break-in period . . . ................................320
Remaining ready for operation ..........................................321
Cleaning the radiator,
Topping up the cooling fluid and checking the coolant concentration ...............321
Changing the air filter insert ............................................323
Draining water from the
Eberspächer particle filters - Regeneration . ................................326
Lubricatingthejointsandcontrols ........................................329
Maintaining the seat belt
Checkingthedriver'sseat .............................................331
Checking the door latch ...............................................332
Servicing wheels and tyre
Servicingthebattery .................................................334
Replacingfuses .....................................................336
Checking the hydraulic
Checkingthehydraulicsystemforleaks ...................................337
Lubricatingtheliftmastandrollertrack ....................................338
em ..........................................301
everytwoyears ................................311
0 operating hours ..................................320
checkingforleaks ...................................321
fuelfilter .........................................325
...............................................330
s .............................................332
oillevel ..........................................336
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Greasingtheautomatictowcoupling ......................................339
Changing the heating system fresh air filter .................................341
1000-hour maintenance / Annua
Othertasks ........................................................343
Checking theribbed V-belt . . . ..........................................343
Checking the exhaust gas sys
Changing the fuel filter ................................................344
Changing the fuel filter for Eberspächer particle filters .........................345
Checking the lift cylinders
Checkingtheforkarms ................................................346
Checkingthereversibleforkarms ........................................346
l maintenance ..............................343
tem .......................................343
and connections for leaks ..........................345
6 Technical data
Dimensions ........................................................348
VDI datasheet for RX70-16, RX70-18 and RX70-20 ..........................350
Ergonomic dimensions ................................................354
Fuse assignment ....................................................356
X17
4749 EN - 03/2017
1
Foreword
1 Foreword
Your truck
Your truck
Description of the truck
General
The internal combustion engine-powered
trucks of series RX70-16/18/20 with a load
capacity of up to 2 t are equipped with a
diesel-electric drive. The diesel-electric drive
combines the advantages of the diesel engine
with the precise control of an electric drive.
The bend-resistant and war
mast enables safe load hand
heavy loads. The comfortab
partment features the mo
gonomic design to preven
and increase safety.
The low centre of gravity of the truck provides
stability, which is guaranteed if the truck is
used according to its intended use.
Brake system
The brake system of the truck is comprised of
three different brakes:
• Service brake
• Regenerative brake
• Parking brake
The service brake is based on a wear-free,
oil-immersed multi-disc brake. This multi-disc
brake is used as the service brake for heavy
braking or emergency braking with the brake
pedal. In the normal working mode, the
regenerative brake of the electric traction
motor takes effect. The regenerative brake
converts the acceleration energy of the truck
into electrical energy. This causes the truck to
decelerate as soon as the accelerator pedal
is released. Completely removing your foot
from the accelerator pedal causes the truck to
brake until it comes to a standstill. A parking
brake ensures that the truck remains securely
in place when parked.
p-resistant lift
ling, even with
le driver's com-
st up-to-date er-
t signs of fatigue
Engine
The truck is equipped with
four-stroke diesel engin
217
a four-cylinder,
e. The engine is
4749 EN - 03/2017
Foreword 1
Your truck
cooled by means of a closed coolant circuit.
The engine is lubricated via forced circulation
lubrication. The combustion air is drawn in and
cleaned by a dry air filter. Different equipment
variants are available, for example a diesel
particle filter.
Hydraulic system
All lift cylinders are hydraulically actuated.
The required oil volume flow is realised via a
gear pump, which is connected to the internal
combustion engine. The proportional valve
technology provides particularly sensitive
movements and safe handling of the load.
The hydraulic functions can be parameterised
individually by the authorised service centre.
Up to three hydraulic circ
activate attachments (va
the equipment, a hydrauli
available in the lifting c
dampening pressure peaks
system.
uitscanbeusedto
riant). Depending on
c accumulator is also
ircuit for the purpose of
in the hydraulic
Drive concept
The internal combustion engine drives an
electric generator. The generated current
is directed to an electric traction motor, which
drives the truck. An electronic speed controller
gently provides high torque for both forwards
and backwards travel.
The components for the drive unit and the
lift drive are enclosed in order to prevent the
ingress of dust or moisture. This means that
the truck is suitable for indoor and outdoor
use. In addition, all drives for traction, steering
and lifting are maintenance-free.
The driving characterist
haviour can be adapted to t
or driving habits. Five d
available for this purpo
driving speed is 22 km/h.
mode Blue-Q reduces ener
up to 10%, without impair
ics and lifting be-
he application
rive programmes are
se. The maximum
The energy-saving
gy consumption by
ing performance.
749 EN - 03/2017 3
174
1 Foreword
Your truck
Operating devices
The truck is characterised by an accessible
operating concept. When purchasing the
truck, a variety of controls and equipment
variants are available:
• Double mini-lever
• Triple mini-lever
• Quadruple mini-lever
• Joystick 4Plus
• Fingertip switch
• Single pedal
• Dual pedal
Hands are always kept free for steering and
for controlling the operational movements to
allow efficient working. The forces that need
to be applied for this purpose are reduced to
a minimum thanks to the compact steering
wheel. The simple handling of the truck is
assisted by the agile steering axle.
General
The truck described in these operating instructions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regulations for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
Thetruckshavebeenfitt
art technology. All tha
the truck safely and mai
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.
ed with state-of-the-
t remains is to handle
ntain its functionality.
417
4749 EN - 03/2017
Foreword 1
Your truck
CE labelling
The manufacturer uses CE labe
cate that the truck complies w
and regulations valid at the t
This is confirmed by the issued
of conformity. The CE labelli
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
llingtoindi-
ith the standards
ime of marketing.
EC declaration
ng is attached to
CE-Symbol
749 EN - 03/2017 5
174
1 Foreword
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
.
617
H
4749 EN - 03/2017
Foreword 1
Your truck
Accessories overview
• Key for key switch (2 pieces)
• Key for cab (variant)
• Hexagon socket wrench for emer
lowering
gency
749 EN - 03/2017 7
174
1 Foreword
Your truck
Overview
15
DANGER
DANGER
L
WA
16
DANGER
DANGER
18
22
17
11
21
12
8
9
2
15
10
5
6
16
1
5
11
17
10 bar
DANGER
9
8
19
2
5430
5030 1270
4430
4030 1150 1260 1200 1500
3730 1180 1290 1430 1500
3430 1210 1330 1470
7
D
A
N
G
E
R
1080
1080
1010
1050
1150 1310
1110 1230 1250 1500
3
800 700
1
13
14
2
15
7
Regelmäßige Prüfung
(FEM 4.004)
Nächste Prüfung
12
16
19
20
3
6
4
STILL GmbH Hamburg
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
2009/104/EG, 99/92/EG
20xx
10
Die Prüfplakette ersetzt nicht das Prüfprotokoll
Mitglied der:
Fédération
Européene
de la Manutention
13
1080
22
1500
600
500
1
14
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
max
min.*
*
20
kg
kg
kg
kg
21
xx xxxx x xxxxx
3
4
56344391019
1
2
3
4
7
18
DANGER
7314_003-017_V11
817
4749 EN - 03/2017
Foreword 1
Your truck
1 Decal information: "Dual-pedal operation"
(variant)
2 Manufacturer's label text
3 Decal information: FEM audit
4 Inspection sticker
5 Warning sign: Passengers are not allowed
6 Decal information: Lifting gear attachment
point
7 Decal information: Tyre filling pressure
8 Decal information: Driving dynamics
9 Cable strap
10 Decal information: Do not jump off if the
truck is tipping over / Lean in the opposite
direction to which the truck is tipping
11 Decal information: Caution / Read the
operating instructions / Fasten the seat belt
12 Decal information: Lifting gear attachment
point
13 Decal information: Parking brake released
14 Decal information: Parking brake applied
15 Warning sign: Danger due to shearing /
Danger due to high fluid pressure
16 Warning sign: Do not stand underneath the
fork / Do not stand on the fork
17 Decal information: Sound power level
18 Decal information: Caution / Read the
operating instructions / Fasten the seat belt
/ Apply the parking brake when leaving the
truck / Passengers are not allowed / Do not
jump off if the truck is tipping over / Lean in
the opposite direction to which the truck is
tipping
19 Decal information: StVZO (German Road
Traffic Licensing Regulations) information
(variant)
20 Decal information: nameplate
21 Decal information: Factory number
22 Decal information: capacity rating plate
749 EN - 03/2017 9
174
1 Foreword
Your truck
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
max
min.*
*
8
kg
kg
kg
kg
6210_921-003_V2
4
5
6
7
1 Type
2 Production number
3 Year of manufacture
4 Tare weight in kg
5 Max. permissible battery weight in kg (for
electric forklift trucks only)
6 Min. permissible battery weight in kg (for
electric forklift trucks only)
7 Ballast weight in kg (for electric forklift trucks
only)
8 Refer to the technical data listed in these
operating instructions for more detailed
information
9 CE labelling
10 Nominal drive power in kW
11 Battery voltage in V
12 Rated capacity in kg
10 1
74749 EN - 03/2017
Foreword 1
Use of truck
Production number
NOTE
The production number is used to identify the
truck. It can be found on the nameplate and
must be referred to in all technical questions.
The production number contains the following
coded information:
(1) Production location
(2) Model
(3) Year of manufacture
(4) Sequential number
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
Use of truck
Proper usage
The truck described in these operating instructions is suitable for lifting, transporting
and stacking loads.
749 EN - 03/2017 11
174
1 Tare weig
2 Permitte
3 Permi
4Per
5 Payload (in kg)
ht (in kg)
d total weight (in kg)
tted front axle weight (in kg)
mitted rear axle weight (in kg)
5
34
7094_003-098
1 Foreword
Use of truck
The truck may only be used for its proper
purpose as set out and described in these
operating instructions.
If the truck is to be used for purposes other
than those specified in the operating instructions, the approval of the manufacturer and, if
applicable, the relevant regulatory authorities
must be obtained beforehand to prevent hazards.
The maximum load to be lifted
the capacity rating plate (l
must not be exceeded; see als
entitled "Before picking up
Proper use during towing
This truck is suitable fo
of trailers and is equipp
for this purpose. This oc
not exceed 2% of the daily
the truck is to be used for
regular basis, the manu
consulted.
The regulations regarding trailer operation
must be observed; see chapter "Trailer
operation".
is specified on
oad diagram) and
o the chapter
a load".
r the occasional towing
ed with a towing device
casional towing may
operating time. If
towing on a more
facturer should be
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.
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.
12 1
74749 EN - 03/2017
Foreword 1
Use of 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 outdoors.
If the truck is equipped wi
filter" equipment variant
prerequisites for use in v
national regulations for
must be observed.
Operation on public roads is only permitted
with the "StVZO" (Road Traffic Licensing
Regulations) equipment variant.
If the truck is to be operated on public roads, it
must conform to the existing national regulations for the country in which it is being used.
The ground must have an
capacity (concrete, a
surface. Routes, work
widths must conform to
these operating instr
entitled "Routes".
Driving on upward and downward gradients
is permitted provided the specified data and
specifications are observed; see the chapter
entitled "Routes".
The truck is suitable for use in many different
countries, ranging from those situated in the
Tropics to those in Nordic regions (temperature range: -20°C to +40°C).
This truck is not designed to
cold stores.
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.
th the "particle
, it fulfils the essential
entilated halls. The
the country of use
adequate load
sphalt) and a rough
ing areas and aisle
the specifications in
uctions; see the chapter
be operated in
749 EN - 03/2017 13
174
1 Foreword
Use of truck
NOTE
Please observe the definition of the following
responsible person: "operating company".
DANGER
Risk to health from exhaust gases!
Exhaust gases from internal combustion engines
are harmful to your health. In particular, the soot
particles contained in the diesel exhaust gas can
cause cancer. When the internal combustion
engine is left running, there is a risk of poisoning
due to the CO, CH and NOx components contained
in the exhaust gas.
Modern exhaust gas treatment systems (e.g.
catalytic converters, particle filters or comparable
systems) can clean exhaust gases in a way that
reduces the health hazard and risk of poisoning
when operating the truck.
– Observe the national laws and regulations when
using trucks with an internal combustion engine
in entirely or partially enclosed working areas.
– Always ensure sufficient ventilation.
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.
14 1
74749 EN - 03/2017
Foreword 1
Information about documentation
Information about documentation
Documentation scope
• Original operating instructions
• Original operating instructions for attachments (variant)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
• Depending on the truck equipment, "UPA"
operating instructions may also be provided
These operating instructi
measures necessary for the
and proper maintenance o
possible variants avail
printing. Special versi
requirements (UPA) are d
separate operating inst
any questions, please co
service centre.
Enter the production number and year of
manufacture from the nameplate in the space
provided:
Production number:
Year of manufacture:
ons describe all
safe operation
fthetruckinall
able at the time of
ons to meet customer
ocumented in
ructions. If you have
ntact your authorised
Please quote the product
technical enquiries
Each truck comes with a set of operating
instructions. These instructions must be
stored carefully and must be available to the
driver and operating company at all times.
The storage location is specified in the chapter
entitled "Overviews".
If the operating instructions are lost, the operating company must obtain a replacement
from the manufacturer immediately.
The operating inst
spare parts list and c
spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
ion number in all
.
ructions are included in the
an be reordered as a
749 EN - 03/2017 15
174
1 Foreword
Information about documentation
The operating company must ensure that all
users have received, read and understood
these operating instructions.
NOTE
Please observe the definition of the following
responsible persons: "operating 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.
Supplementary documentation
This industrial truck may deviate from the
standard equipment or from the variants and
be fitted with unplanned equipment (UPA).
This may include the following, for example:
• Special sensors
• Special attachments
• Towing devices
• Customer-specific attachments
In this case, the industrial truck has additional
documentation. This may be in the form of an
insert or separate operating instructions.
The original operating instructions for this
industrial truck are valid for the operation
of standard equipment and variants without
restriction. The operational and safety information in the original operating instructions
continues to be valid in its entirety unless it is
specifically countermanded in this additional
documentation.
The requirements for the qualification of
personnel as well as the time for maintenance
may vary. This is defined in the additional
documentation.
– If you have any questions, please contact
your authorised service centre.
16 1
74749 EN - 03/2017
Foreword 1
Information about documentation
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 author
for technical support rela
ised service centre
ting to your truck.
Copyright and trademark
These instructions mus
translated or made acce
ties—including as exce
express written approv
al of the manufacturer.
Explanation of infor
rights
t not be reproduced,
ssible to third par-
rpts—except with the
mation 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.
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
NOTE
For technical requirements that require
special attention.
749 EN - 03/2017 17
174
1 Foreword
Information about documentation
ENVIRONMENT NOTE
To prevent environmental damage.
List of abbreviations
NOTE
This list of abbreviati
of operating instructi
viations that are liste
appear in these operati
Abbreviation
ABE
ArbSchG
BetrSichV
BG
BGG
BGR
DGUV
CE
CEE
DC Direct Current
DFÜ
DIN
EG
EN
FEM
F
max
GAA Gewerbeaufsichtsamt
Meaning
Display operating unit
Arbeitsschutzgesetz
Betriebssicherheitsverordnung
Berufsgenossenschaft
Berufsgenossenschaftlicher Grundsatz
Berufsgenossenschaftliche Regel
Berufsgenossenschaftliche Vorschrift German accident prevention regulations
Communauté Européenne
Commission on the Rules for the Approval
of the Electrical Equipment
Da
D
E
Eu
Fédération Européene de la Manutention
maximum Force
ons applies to all types
ons. Not all of the abbred here will necessarily
ng instructions.
tenfernübertragung
eutsches Institut für Normung
uropean Community
ropean standard
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
erman standardisation organisation
G
European Federation of Materials Handling and Storage Equipment
Maximum power
German authority for monitoring/issuing
regulations for worker protection, environmental protection, and consumer protection
18 1
74749 EN - 03/2017
Foreword 1
Information about documentation
Abbreviation
GPRS General Packet Radio Service
Meaning
Explanation
Transfer of data packets in wireless
networks
ID no. ID number
ISO
International Organization for Standardization
International standardisation organisation
LAN Local Area Network Local area network
K
pA
LED
L
p
L
pAZ
LSP
MAK
Max. Maximum
Min. Minimum
PIN
PPE
SE
SIT
StVZO
TRGS
VDE
VDI
VDMA
Uncertainty of measurement of sound
pressure levels
Light Emitting Diode Light emitting diode
Sound pressure level at the workplace
Average continuous sound pressure level
in the driver's compartment
Load centre of gravity
Maximum workplace concentration
Distance of the centre of gravity of the load
from the front face of the fork backs
Maximum permissible air concentrations
of a substance at the workplace
Highest value of an amount
Lowest value of an amount
nal Identification Number
Perso
nal identification number
Perso
Personal protective equipment
Super-Elastic
Snap-In Tyre
Straßenverkehrs-Zulassungs-Ordnung
chnische Regel für Gefahrstoffe
Te
Verband der Elektrotechnik Elektronik
Informationstechnik
Verein Deutscher Ingenieure
Verband Deutscher Maschinen- und
Anlagenbau e.V.
Superelastic tyres (solid rubber tyres)
for simplified assembly, without
Tyres
rim parts
loose
an regulations for approval of vehi-
Germ
on public roads
cles
inance on hazardous materials appli-
Ord
in the Federal Republic of Germany
cable
German technical/scientific association
German technical/scientific association
German Mechanical Engineering Industry
Association
WLAN Wireless LAN Wireless local area network
.
749 EN - 03/2017 19
174
1 Foreword
Information about documentation
Definition of directions
The directions "forwards" (1
"right" (2) and "left" (4) ref
position of the parts as seen f
compartment; the load is to th
), "backwards" (3),
er to the installation
rom the driver's
e front.
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.
1
4
2
3
6210_001-031
20 1
6210_003-062
74749 EN - 03/2017
Foreword 1
Information about documentation
View of the display operating unit
NOTE
Views of operating statuses and values in
the display of the display operating unit are
examples and partly dependent on the truck
equipment. As a result, the displays shown
of the actual operating statuses and values
can vary. Information that is not relevant for
descriptions is not shown.
749 EN - 03/2017 21
174
1 Foreword
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completelyprior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
Disposal of components and batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
•disposedof,
• treated or
• recycled in accordance with regional and
national regulations.
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.
22 1
74749 EN - 03/2017
2
Safety
2 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
24 1
74749 EN - 03/2017
Safety 2
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.
Thedrivermustbefami
instructions and have ac
times.
The driver must:
• have read and understood the operating
manual
• have familiarised himself with safe operation of the truck
• be physically and mentally able t
truck safely
ned in his rights and
liar with the operating
cess to them at all
odrivethe
749 EN - 03/2017 25
174
2 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 responsib
working hours. He must n
rised persons to operat
When leaving the truck, the driver must secure
it against unauthorised use, e.g. by pulling out
the key.
le for the truck during
ot allow unautho-
ethetruck.
26 1
74749 EN - 03/2017
Safety 2
Essentials for safe operation
Essentials for safe operation
Insurance cover on company premises
In many cases, company premises are
restricted public traffic areas.
NOTE
The business liability insurance should be
reviewed to ensure that, in the event of any
damage caused in restricted public traffic
areas, there is insurance cover for the truck in
respect of third parties.
Changes and retrofitting
If the truck is used for work that is not listed
in the guidelines or in these instructions and
has to be converted or retrofitted accordingly,
you must note that any change to its structural
state can affect the handling and stability of
the truck, which in turn can lead to accidents.
You should therefore contact your service
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.
Thetruckmayonlybeconvertedwithwritten
approval from the manufacturer. Approval
from the responsible authority must be obtained if necessary.
Changes to the brakes, steering, control
elements, circumferential view, equipment
variants and attachments must also not be
made without the prior written approval of the
manufacturer.
We warn against installing and using restraint
systems not approved by the manufacturer.
749 EN - 03/2017 27
174
2 Safety
Essentials for safe operation
DANGER
Risk of injury!
Even when using an approved restraint system,
there is some residual risk that the driver might be
injured if the truck tips over. Thisrisk of injury can be
reduced through the combined use of the 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 your service centre.
DANGER
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 forklift truck without an overhead
guard is prohibited with a lift height greater than
1800 mm.
– For lift heights of 1800 mm and greater, only use
trucks with on overhead guard
In the event that the manufacturer goes into
liquidation and the company is not 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:
28 1
74749 EN - 03/2017
Safety 2
Essentials for safe operation
– Type of change
– Date of change
– Name and address of the company
menting the change.
imple-
Changes to the overhead gua
rd 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
isarisktolife!
Welding and drilling on the overhead guard changes the material characteristics and the structural
design of the overhead guard. Excessive forces
caused by falling loads 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.
Warning regarding non-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.
749 EN - 03/2017 29
174
2 Safety
Essentials for safe operation
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.
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 attach
or safe to drive ma
been properly re
Do not remove or deactivate safety systems
and switches.
Fixed set values may only be changed with the
approval of the manufacturer.
Work on the electric
a radio, additional
permitted with the
approval. All elec
must be documented.
Even if they are removable, roof panels may
not be removed, as they are designed to
protect against small falling objects.
ments that are not functional
y not be used until they have
paired.
al system (e.g. connecting
headlights etc.) is only
manufacturer's written
trical system interventions
Tyres
DANGER
Risk to stability!
Failure to observe the following information and
instructions can lead to a loss of stability. The truck
may tip over, risk of accident!
30 1
74749 EN - 03/2017
Safety 2
Essentials for safe operation
Thefollowingfactorscanleadtoalossof
stability and are therefore prohibited:
• Different tyres on the same axle, e.g.
pneumatic tyres and superelastic tyres
• Tyres not approved by the manuf
• Excessive tyre wear
• Tyres of inferior quality
• Changing rim wheel parts
• Combining rim wheel parts from different
manufacturers
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 o
on the same axle, e.g. only
tyres
• Only use wheels and tyres approved by the
manufacturer
• Only use high-quality products
Wheels and tyres approv
facturer can be found on
If other wheels or tyres
thorisation from the ma
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.
If the type of tyre used on
for example from super
matic tyres, the load dia
accordingly.
– Contact the authorised service centre on
this matter.
ed by the manu-
the spare parts list.
aretobeused,au-
nufacturer must be
an axle is changed,
elastic tyres to pneugram must be changed
acturer
f the same type
superelastic
749 EN - 03/2017 31
174
2 Safety
Essentials for safe operation
Medical equipment
WARNING
Electromagneticinterferencemayoccuron 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.
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 by gas springs. Gas springs
are complex components that are subject to high
internal pressures (up to 300 bar). They may under
no circumstances be opened unless instructed to
do so, and may be installed only when not under
pressure. If required, the authorised service centre
will depressurise the gas spring in 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.
32 1
74749 EN - 03/2017
Safety 2
Essentials for safe operation
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
picked up. These other loading units then fall
over when the load is raised.
– For help with selecting the correctfork arms,
contact the authorised service centre.
749 EN - 03/2017 33
174
2 Safety
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 batteriesand
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
34 1
74749 EN - 03/2017
Safety 2
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.
Thelossofstabilitycanb
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 when
– 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 diagon
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 care wh
suspended loads.
– Do not drive over ramp edges or steps.
e avoided or mintions:
cornering.
ally driving across
en transporting
Special risks associated with using the truck and attachments
Approval from the manufacturer and attachment manufacturer must be obtained each
749 EN - 03/2017 35
174
2 Safety
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.
36 1
74749 EN - 03/2017
Safety 2
Residual risk
749 EN - 03/2017 37
174
2 Safety
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
Lackofskillsand
qualification of driver
Usage by unauthorised
persons
Truck not in a safe
condition
Risk of falli
using working
platforms
Impaired visibility due
to load
Contamination of
respiratory air
ng when
Test
Driver training (sit-on
and stand-on)
Access with key only
for authorised persons
Recurrent testing and
rectification of defects
Compliance wi
national regul
(different nat
Resource planning
Assessment of diesel
exhaust gases
Assessment of LPG
exhaust gases
th
ations
ional laws)
Check note
√ Complete
- Not applicable
O If in doubt, consult
O BGG 925
O
O German Ordinance on
O German Ordina
O German Ordi
O
O German threshold limit
Notes
competent factory
inspectorate or
employers' liability
insurance association
VDI 3313 driver permit
Industrial Safety and
Health (BetrSichV)
nce
on Industria
and Health (B
and employer's
insurance assoc
Industri
Health (B
Techn
for Ha
Sub
554
Ord
afety and Health
S
BetrSichV)
(
values list (MAK-Liste)
and the German
Ordinance on Industrial
Safety and Health
(BetrSichV)
l Safety
etrSichV)
liability
iations
nance on
al Safety and
etrSichV)
ical Regulations
zardous
stances (TRGS)
and the German
inance on Industrial
38 1
74749 EN - 03/2017
Safety 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)
749 EN - 03/2017 39
174
2 Safety
Residual risk
Hazard Measure
When charging the
traction battery
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
When using battery
chargers
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers' liability
insurance association
regulation 104 and the
operating instructions
When parking LPG
trucks
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers' liability
insurance association
regulation 104 and the
operating instructions
With driverless transport systems
Roadway quality
Clean/clear driveways O German Ordinance on
inadequate
Load carrier
Reattach load to pallet
incorrect/slipped
Drive behaviour
Employee training
unpredictable
Driveways blocked Mark driveways
Keep driveways clear
Driveways intersect
Announce right-of-way
rule
No person detection
Employee training
during depositing and
retrieval
.
Check note
√ Complete
- Not applicable
O Association for
O German Ordinance
O German Ordinance
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
on Industrial Safety
and Health (BetrSichV)
and employers' liability
insurance association
regulation 104
on 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)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
40 1
74749 EN - 03/2017
Safety 2
Residual risk
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 the definition of the following
responsible persons: "operating company"
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
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.
749 EN - 03/2017 41
174
2 Safety
Safety inspections
Safety inspections
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!
Checking the diesel engine emissions
– Check the diesel engine emissions annually
to TRGS 554.
The exhaust-gas check is to be carried out
by a specialist (see ⇒ Chapter "Definition of
responsible persons", P. 24) and must be
recorded in writing.
– Contact your STILL service centre.
42 1
74749 EN - 03/2017
Safety 2
Safety inspections
NOTE
Observe the national regulations for your
country!
Trucks with particle filters
Trucks with particle filters (variant) may be
operated in completely or partially enclosed
working areas.
DANGER
Risk to health from exhaust gases!
Exhaust gases from internal combustion engines
are harmful to your health. In particular, the soot
particles contained in the diesel exhaust gas can
cause cancer.
When the internal combustion engine is running,
there is a risk of poisoning from the CO, CH and
NOx components contained in the exhaust gas.
Modern exhaust gas treatment systems (e.g.
catalytic converters, particle filters or comparable
systems) can clean exhaust gases in a way that
reduces the health hazard and risk of poisoning
when operating the truck.
– Observe the national laws and regulations when
using trucks with an internal combustion engine
in entirely or partially enclosed working areas.
– Always ensure sufficient ventilation.
The operating company must ensure that the
following requirements are met:
• Usage must be
occupationa
reported to the responsible
l health and safety authorities
• Operating instructions must be displayed in
the working areas
• Danger areas should be confined and
indicated by appropriate warning and safety
signs
• Employees must
and protective
be made aware of dangers
measures
• The particle filter must be checked and
serviced every 12 months or after every
1000 operating hours. The exhaust-gas
check must be carried out by a competent
person and must be recorded in writing
749 EN - 03/2017 43
174
2 Safety
Safety inspections
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "competent person".
NOTE
Observe the TRGS 554 regulations and
national regulations of the country in which
the truck is being used.
Insulation testing
The truck insulation must have sufficient insulation resistance. For this reason, insulation
testing in accordance with DIN EN 1175 and
DIN 43539, VDE 0117 and VDE 0510 must be
conducted at least once every year.
NOTE
Contact your service centre to arrange for an
insulation test.
Measuring the insulation resistance of
the electrical system
NOTE
Nominal battery voltage < test voltage < 500 V.
– Ensure that all voltage sources have been
disconnected from the circuit to be tested.
– Measure the insulation resistance with a
suitable measuring device.
The insulation resistance can be considered
sufficient if it measures at least 1000
nominal battery voltage against ground.
– Contact the authorised service centre.
44 1
/V for
74749 EN - 03/2017
Safety 2
Safety regulations when handling c
onsumables
Safety regulations when 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. 5-314).
Oils
DANGER
Oils are flammable!
– Follow the statutory regulations.
– Do not allow oils to come into
contact with hot engine parts.
– No smoking, fires or naked flames!
DANGER
Oils are toxic!
– Avoid contact a
– If vapour or f
move to fres
– In the event
eyes, rins
10 minute
consult a
– If swallow
vomitin
attenti
umes are inhaled,
h air immediately.
of contact with the
e thoroughly (for at least
s) with water and then
n eye specialist.
ed, do not induce
g. Seek immediate medical
on.
nd consumption.
749 EN - 03/2017 45
174
2 Safety
Safety regulations when handling c
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
askincareproduct.
– 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.
onsumables
Hydraulic fluid
WARNING
These fluids are pressurised during
operation of the truck and are hazardous to your health.
– Donotspillthefluids.
– Follow the statutory regulations.
– Do not allow the fluids to come into
contact with hot engine parts.
46 1
74749 EN - 03/2017
Safety 2
onsumables
WARNING
These fluids are pressurised during
operation of the truck and are hazardous to your health.
– Donotallowthefluidstocomeinto
contact with the skin.
– Avoid inhaling spray.
– Penetration of pressurised fluids
into the skin is particularly danger-
ous if these fluids escape at high
pressure due to leaks in the hydrau-
lic 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 when handling c
Hydraulic fluid is a water-polluting substance.
•
Always store hydraulic fluid in containers
that comply with regulations
•
Avoid spills
•
Spilt hydrauli
immediately wit
disposed of acco
•
Dispose of old hydraulic fluid according to
c fluid should be removed
h oil-binding agents and
rding to the regulations
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.
749 EN - 03/2017 47
174
2 Safety
Safety regulations when handling c
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
ontoclothingorskinorintothe
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.
Diesel fuel
onsumables
WARNING
Diesel fuel is combustible.
– Observe statutory regulations.
– Do not allow diesel fuel to come
into contact with hot engine
components.
Do not smoke!
WARNING
Diesel fuel is toxic!
– Avoid contact and swallowing.
– If vapour or fumes are inhaled,
administer fresh air immediately.
– After 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.
48 1
74749 EN - 03/2017
Safety 2
Safety regulations when handling c
WARNING
Prolonged intensive contact with the
skin can result in loss of skin oils and
can irritate the skin!
– Avoid contact and swallowing.
– Wear protective gloves.
– After any contact, wash the skin
with soap and water, and then apply
askincareproduct.
– Immediately change soaked
clothing and shoes.
WARNING
Risk of slipping due to spilled diesel fuel, particularly
in combination with water.
– Immediately collect spilled diesel fuel using an
oil-binding agent and dispose of it in accordance
with regulations.
ENVIRONMENT NOTE
onsumables
Diesel fuel is a water-polluting substance!
– Always store in regulation containers.
– Avoid spilling diesel fuel.
– Immediately collect spilled diesel fuel using
an oil-binding agent and dispose of it in
accordance with regulations.
749 EN - 03/2017 49
174
2 Safety
Safety regulations when handling c
Coolant and cooling fluid
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 cooling fluid
in empty food containers, bottles or
other containers.
– Observe the national regulations
for the country of use.
ENVIRONMENT NOTE
– Soak up any spilt coolant or cooling fluid
immediately using an oil binding agent and
disposeofitinaccordancewiththenational
regulations for the country of use.
– Dispose of old c
accordance wi
the country of
oolant or cooling fluid in
th the national regulations for
use.
onsumables
Disposal of c
onsumables
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 such as hydraulic
oil or gearbox oil immediately using an
oil-binding agent.
50 1
74749 EN - 03/2017
Safety 2
Safety regulations when handling c
– Neutralise any spilt battery acid immedi-
ately.
– Always observe national regulations con-
cerning the disposal of used oil.
onsumables
749 EN - 03/2017 51
174
2 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
< 74.0 dB(A) 4 dB(A)
lowing sound
Measurement
uncertainty K
pA
The values were dete
on an identical mach
values for operati
Time proportions:
• Lifting 18%
• Idling 58%
• Driving 24%
However, the indicated noise levels at the
truck cannot be used to determine the noise
emissionsat workplaces according to 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
ng conditions and idling.
Please note the definition of "operating company" in the sense of responsible persons!
52 1
74749 EN - 03/2017
Safety 2
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
< 0.71 m/s
2
Tests have indicated that the amplitude of the
hand and arm vibrations on the steering wheel
or on the operating devices in the truck is less
than 2.5 m/s
2
. There are therefore no mea-
surement 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
0.177 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!
749 EN - 03/2017 53
174
2 Safety
Emissions
Exhaust gases
DANGER
Risk to health from exhaust gases!
Exhaust gases from internal combustion engines
are harmful to your health. In particular, the soot
particles contained in the diesel exhaust gas can
cause cancer.
When the internal combustion engine is running,
there is a risk of poisoning from the CO, CH and
NOx components contained in the exhaust gas.
Modern exhaust gas treatment systems (e.g.
catalytic converters, particle filters or comparable
systems) can clean exhaust gases in a way that
reduces the health hazard and risk of poisoning
when operating the truck.
– Observe the national regulations for the country
of use when using trucks with an internal combustion engine in entirely or partially enclosed
working areas.
– Always ensure sufficient ventilation.
Heat
DANGER
Risk of burns due to hot exhaust
gases!
Exhaust gases or components that
carry exhaust gases (e.g. exhaust
pipes) can become so hot that direct
body contact can cause burns to the
skin and materials that are too close
can be burned or singed.
– Do not grasp or touch hot exhaust
pipes.
– Keep combustible materials away
from the exhaust pipe.
– In the event of burns, seek first aid
immediately.
– If materials are burning, take fire
protection measures immediately.
54 1
74749 EN - 03/2017
3
Overviews
3 Overviews
General view
General view
10
1
2
3
4
9
5
8
7
7312_003-172_V2
6
1Liftmast
2 Overhead guard
3 Driver's compartment
4 Fuel tank
5 Towing device
56 1
6 Steering axle
7Driveaxle
8 Fork arms
9 Fork carriage
10 Lift cylinders
74749 EN - 03/2017
Overviews 3
Driver's compartment
Driver's compartment
13
12
11
7314_003-048
1
234
4
9
100
%
2
7
5
1
5
0
12
890
8
3
6
15
:23
5
+
F
1
2
F
6
7
10
9
8
1 Parking brake lever
2 Steering wheel
3 Key switch
4 Display and operating unit
5 Document holder
6 Operating devices for hydraulic and traction
functions
7 Compartment (variant)
NOTE
The truck equipment may differ from the
equipment shown.
749 EN - 03/2017 57
174
8 Cup holder for max. 0.5-l bottles
9 Driver's seat
10 Compartment and storage location for
operating instructions
11 Accelerator pedal
12 Brake pedal
13 Steering column adjustment lever
3 Overviews
4
Operating and display elements
Operating and display elements
Display and operating unit
56
4
3
2
1
3
1
2
6
9
7
5
26
25
21
20
7314_003-043
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 Fuel level display (percentage)
9 Drive programme display (numerical)
10 Left turn indicator display
11 Forward travel indicator
12 Right turn indicator display
13 Malfunction display
14 Reverse travel indicator
24
22
23
7
8
0
75
%
2
234,7 h
12:15
8
9
10
11
12
13
1
15
19
17
18
15 Operating hours display
16 Time display (digital)
17 Particle filter display
18 Rotating beacon display
19 Interior lighting display
20 Rear window heating display
21 Interior lighting/rotating beacon button
22 Rear window heating/particle filter regener-
ation button
23 Menu change button
24 Lighting button
25 Blue-Q button
26 Rear window wiper button
16
NOTE
Buttons (5, 21, 22) and the accompanying
display elements (6, 7, 17, 18, 19, 20) are
assigned according to the equipment variants
in use.
The assignment shown here is an example
and may differ from the assignment actually
programmed on the truck. Buttons may be
assigned multiple functions that are called up
according to the menu navigation. For further
information, see the "Operating the display
and operating unit" chapter.
58 1
74749 EN - 03/2017
Overviews 3
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
749 EN - 03/2017 59
174
3 Overviews
Operating and display elements
Double mini-lever
3
2
1
7
1 "Lift mast" 360° lever
2 Function key F1
3 Function key F2
4 "Drive direction/turn indicator" cross lever
4
F1
F2
7325_003-025
5 Function key "5th function"
6 "Attachments" cross lever
7 Signal horn button
5
6
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (2) and (3). Changes must only be made
by the STILL service centre.
60 1
74749 EN - 03/2017
Overviews 3
Operating and display elements
Three-way mini-lever
3
2
1
8
1 "Lift mast" 36
2 Function key
3 Function ke
4 "Drive dir
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (2) and (3). Changes must only be made
bytheSTILLservicecentre.
0° lever
F1
yF2
ection/turn indicator" cross lever
4
5
6
7325_003-026
5 Function key "
6 "Auxiliary h
7 "Auxiliary
8 Signal hor
7
5th function"
ydraulics 1" operating lever
hydraulics 2" operating lever
n button
749 EN - 03/2017 61
174
3 Overviews
Operating and display elements
Four-way mini-lever
4
3
2
1
9
1 "Lift/lower"
2 "Tilt" opera
3 Function ke
4 Function k
5 "Drive di
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (3) and (4). Changes must only be made
by the STILL service centre.
operating lever
ting lever
yF1
ey F2
rection/turn indicator" cross lever
5
6
7
8
7325_003-027
6Functionkey"
7 "Auxiliary h
8 "Auxiliary
9 Signal hor
5th function"
ydraulics 1" operating lever
hydraulics 2" operating lever
n button
62 1
74749 EN - 03/2017
Overviews 3
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
749 EN - 03/2017 63
174
3 Overviews
F1
F2
Operating and display elements
Fingertip
1
11
23456
F2
F1
10
9
78
1 Function key F1
2 Function key F2
3 Left turn indicator button
4 Signal horn button
5 Right turn indicator button
6 Function key "5th function"
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (1) and (2). Changes must only be made
by the STILL service centre.
64 1
7325_003-028
7 "Attachments" operating lever
8 "Attachments" operating lever
9 "Tilt" operating lever
10 "Lift/lower" operating lever
11 Drive direction switch
74749 EN - 03/2017
Overviews 3
Operating and display elements
Mini console
The mini console is located on the steering
column below the steering wheel.
2
1
1 Travel direction switch
2 Direction indicator switch
7311_003-056
749 EN - 03/2017 65
174
3 Overviews
Operating and display elements
66 1
74749 EN - 03/2017
4
Operation
4 Operation
Testing and activities before dail
yuse
Testing and activities before daily use
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 unpredictably dangerous situations.
If damage or other defects are identified on the
truck or attachment (variant) during the following
inspections, the truck may 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 mount the truck.
– Use suitable equipment.
Before the
it is safe t
68 1
truck is used each day, ensure that
o be operated:
d lift system unit
Loa
74749 EN - 03/2017
2
1
6210_000-002
Operation 4
Testing and activities before dail
yuse
Unit
Load lift system
Component
Fork arms, general lifting
accessories
Roller tracks (2) Make sure that there is a film
Load chains
Attachments (variant)
Course of action
Perform a visual inspection for defor-
mation and wear (for example, bent,
broken, significant wear).
Check the condition and function of
fuses (1) to prevent lifting and shifting.
Perform a visual inspection to ensure
that the chains are intact and have
adequate and even tension.
Ensure correct mounting in accordance
with the operating instructions of the
manufacturer.
Perform a visual inspection to ensure
the attachments are intact and not
leaking.
Perform checks to ensure the attachments are working correctly.
of grease.
749 EN - 03/2017 69
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4 Operation
Testing and activities before dail
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Unit
Chassis, bodywork
and fittings
Component
Underside
Overhead guard, guard grille
(variant)
Steps
Panes of glass (variant)
Handholds
Maintenance lids
Fuel system, fue
Bonnet and side flap
Coupling pin, tow coupling
(variant)
Labelling, adhesive label
Driver's seat, seat belt
ng, warning units
Lighti
Antistatic belt
l tank
Course of action
Check the area under the forklift truck
for leaking consumables.
Perform a visual inspection for integrity.
Check for secure mounting.
Make sure they are clean (free of ice,
not slippery).
Perform a visual inspection for integrity.
Make sure they are clean (also free of
ice).
Check for secure mo
Check the close function and close the
lids.
Perform a visual inspection for damage
and leaks.
Damaged hoses must be replaced by
the authorised service centre.
Perform a visual inspection for integrity
and deformation.
Check that the lock is in good condition
and is working correctly.
Check the close function.
Close.
Perform a visual inspection for deformation and wear (for example, bent,
torn, broken).
Check the securing bush in the
counterweight for integrity and that it
is working correctly.
Check that the linchpin is present and
working correctly (chain, rope, split pin).
Check that labels are present and
intact/legible.
Replace damaged or missing adhesive
labels in accordance with the chapter
entitled "Labelling points".
Check the integrity and function.
Check the integrity and function.
Perform a visual inspection for integrity.
Ensure cleanliness.
Make sure that the antistatic belt is still
long enough to touch the ground below
the truck.
unting.
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Testing and activities before dail
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Unit
Hydraulics
Component
Lift and tilt cylinders, tank, valve
block, hoses, pipes, connections
Wheels, tyres
Chassis frame
Axle
– Do not use the truck if there is any damage
or defects.
– Contact your authorised service centre.
Checking the cooling fluid level
The cooling fluid level is monitored by a
sensor.
As soon as the message
VEL appears on the dis
lows.
WARNING
Risk of scalding due to hot cooling fluid!
The cooling system is pressurised! Opening the
cooling fluid tank may result in hot cooling fluid
leaking out. Only open the cooling fluid tank when
the cooling system is cool.
– Switch off the engine and let it cool down.
– Do not open the cooling fluid tank until the truck
has cooled down.
COOLANT LE-
play, proceed as fol-
Course of action
Perform a visual inspection for damage
and leaks.
Check the area under the forklift truck
for leaking consumables.
Damaged hoses must be replaced by
the authorised service centre.
Perform a visual inspection for wear
and damage.
Make sure that only rims of the same
type from the same manufacturer are
fitted.
In the event of uneven tyre wear,
replace both tyres.
Observe the safety regulations in the
chapter entitled "Tyres".
Make sure that no consumables are
escaping from the axle.
1
7312_003-080
WARNING
Coolant and cooling fluid can pose a hazard to
health and the environment!
– Observe the safety regulations set out in the
chapter entitled "Coolant and cooling fluid".
– Check coolant level.
749 EN - 03/2017 71
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4 Operation
Testing and activities before dail
The level must be visible in the middle of the
coolant reservoir (1).
– Top up the cooling fluid if necessary; see the
section entitled "Topping up the cooling fluid
and checking the coolant concentration".
CAUTION
Risk of engine damage!
If the coolant level is low, this indicates a leak in the
cooling system.
– Check the cooling system for leaks; see
the section entitled "Cleaning the radiator,
checking for leaks".
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Checking the engine oil level
NOTE
The truck should be parked on as level ground
as is possible while this check is carried out.
– Open the bonnet; se
the bonnet", P. 5-317.
– Pull out the oil dipstick (1) and wipe it.
– Insert the oil dipstick to the stop and pull out
again. Make sure that the insertion marks
(2) are aligned when inserting.
The oil level mu
(arrows).
– If the oil level is only up to the lowest mark,
top up the oil according to the maintenance
data table; see ⇒ Chapter "Maintenance
data table", P. 5-314.
– Insert the oil dipstick to the stop. Make
sure that the insertion marks (2) are aligned
when inserting.
– Close the bonnet;
the bonnet", P. 5-
e ⇒ Chapter "Opening
st be between the marks
see ⇒ Chapter "Closing
317.
12
2
7094_121-001
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Operation 4
Testing and activities before dail
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Climbing in 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 post of the overhead guard 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 wh
If your clothing
become stuck on
jumping out of t
injuries (e.g
forbiddentoj
–Donotjumpo
–Donotwearj
– Do not wear
en jumping out of the truck!
or jewellery (e.g. watch, ring etc.)
a component while you are
he truck, this can lead to serious
. from falling, loss of fingers etc.). It is
ump out of the truck.
ut of the truck.
ewellery at work.
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 can be damaged due to misuse.
– Only use the fittings specifically designed for the
purpose of climbing in and out of the truck.
749 EN - 03/2017 73
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4 Operation
Testing and activities before dail
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To assist with climbing into and out of the truck,
the footwell must be used as a step (5) and the
handle (2) must be used for support. The post
oftheoverheadguard(1)canalsobeusedfor
support.
Always climb into the truck in
aforwards
motion:
– Grip the handle (2) with your left hand and
hold on.
– Put your left foot on the step (4).
– Enter the truck with your ri
sit down on the driver's sea
ght foot first and
t(3).
Always climb out of the truck backwards:
– Grip the handle (2) with your left hand and
hold on.
– Stand up from the driver'
your left foot on the step
s seat and place
(4).
– Climb out of the truck right foot first.
Shelves and cup holders
WARNING
Objects may fall into the footwell and obstruct the
pedals, which poses a risk of accident!
Objects to be stored must be of the correct size so
that they cannot fall from the shelf (1) or out of the
cup holder (2). Objects that fall into the footwell
during travel as a result of steering or braking may
slip between the pedals (3) and prevent them from
working correctly. The truck may subsequently not
be able to be braked when necessary.
– Bottles of max. 0.5 l may be stored in the cup
holder.
– Make sure that stored objects cannot fall from
the shelves when the truck is started up, steered
and braked.
1 2
5
4
7314_003-051
3
3
7
5
1
5
0
1
2890
8
3
6
15:23
F
1
2
F
1
2
7314_003-050
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74749 EN - 03/2017
Operation 4
Testing and activities before dail
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Adjusting the MSG 65/MSG 75 driver's seat
DANGER
There is a risk of accident if the seat or seat backrest
shifts suddenly, which could cause the driver to
move in an uncontrolled manner. This may result in
unintentional actuation of the steering or operating
devices and thus cause the truck or load to move in
an uncontrolled fashion.
– Do not adjust the seat or seat backrest while
driving
– Adjust the seat and the seat backrest so that all
operating devices can be actuated safely
– Ensure that the seat and seat backrest are
securely engaged
WARNING
On some equipment variants, the
amount of head clearance on the truck
may be restricted.
On these specific equipment variants,
the distance between the head and
the lower edge of the roofing sheet
must be at least 40 mm.
NOTE
If there are separate operating instructions for
the seat, they must be followed.
WARNING
To obtain
just the
This is b
–Topreven
optimum seat cushioning, you must ad-
seat suspension to your own body weight.
etter for your back and protects your health.
t injury, make sure that there are no
ithin the swivel area of the seat
objects w
749 EN - 03/2017 75
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4 Operation
Testing and activities before dail
Moving the driver's seat
– Lift and hold the lever (1)
– Push the driver's seat into th
position.
– Release the lever.
– Ensure that the driver's seat is securely
engaged.
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edesired
Adjusting the seat backrest
Do not put pressure on the seat backrest while
engaging it.
– Lift and hold the l
– Push the seat backrest into the desired
position.
– Release the lever.
– Ensure that the sea
engaged.
NOTE
ever (2)
t backrest is securely
The backwards tilt angle of the seat backrest
can be restricted by the structural condition of
the truck.
1
7094_003-006
2
7094_003-008
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Operation 4
Testing and activities before dail
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Adjusting the seat suspension
NOTE
The driver's seat can be adju
weight of the individual dri
achieve the best seat suspen
driver should perform the
sted to suit the
ver. In order to
sion setting, the
adjustment whilst
4
sitting in the seat.
NOTE
The driver's seat MSG 65/MSG 75 is designed
for people weighing between 45 kg and
170 kg.
NOTE
3
6321_003-038
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 up or down t
– 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.
o set the driver's weight.
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.
749 EN - 03/2017 77
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4 Operation
Testing and activities before dail
Adjusting the lumbar support (variant)
NOTE
The lumbar support can be adjusted to suit
the contours of the individual driver's spine.
Adjusting the lumbar support moves a convex
support cushion into the upper or lower part of
the backrest.
– Turn the turning knob (5) up or down until
the lumbar support is in the desired position
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5
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 back
past the end stop b
rest extension, move it
y jolting it upwards.
6
6321_003-040
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74749 EN - 03/2017
Operation 4
Testing and activities before dail
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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
7
switch.
6321_003-041
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
canbeactuatedsafely.
– Ensure that the armrest is securely tightened.
749 EN - 03/2017 79
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4 Operation
Testing and activities before dail
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.
– Tighten the hand wheel by turning it clock-
wise.
– Check that the armrest is firmly attached.
Adjusting the steering column
– Press down the steering column adjustment
lever (2).
– Position the steering column (1) and pull the
lever up again.
DANGER
Risk of accidents
– Ensure that the ste
Thesteeringcol
Never adjust th
!
ering column is secure.
umn must click into place.
e steering column while driving.
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3
2
1
7331_342-001
1
Unlocking the emergency off switch
NOTE
Only diesel trucks with a particle filter system
(variant) or a joystick 4Plus (variant) have an
emergency off switch.
80 1
74749 EN - 03/2017
2
6210_424-001
Operation 4
F
1
F2
Testing and activities before dail
– Pull the emergency off switch (1) until it
unlatches.
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1
1
F2
1
F
Switching on the key switch
WARNING
Before switching on the key switch, all tests prior to
start-up must be performed without detecting any
defects.
– Perform the tests prior to commissioning.
– Do not operate the truck if defects have been
detected
– Notify the authorised service centre.
749 EN - 03/2017 81
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7312_003-183
4 Operation
Testing and activities before dail
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– Insert the switch key (1) into the key switch
and turn to position "I"
This initiates a se
direction and turn
lf-test. All lamps in the drive
indicator displays light up
briefly.
0 I
1
7090_001-002
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74749 EN - 03/2017
Operation 4
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When the key switch is switched on, the
display shows the welcome screen in the
set language until the truck controls have
completely started up.
If the truck has the "access authorisation with
PIN code" variant, the display initially changes
to the input menu for access authorisation.
If the truck is ready for ope
displays are shown.
ration, the standard
Testing and activities before dail
Standard display elements
In the factory setting, the following indicators
can be seen in the display and operating unit:
1 Fuel level
Shows the fuel l
percentage (%)
2 Drive programme
Displays the current drive programme
numerically (1-5). The drive programme
can be changed; see the chapter entitled
"Setting the drive programme".
3 Operating ho
Displays the total operating hours
completed by the truck. The hour meter
operates as soon as the engine is started.
4 Time
Displays the current ti
and minutes. The time can b
see the chapter entitled
time".
CAUTION
Lack of fuel can cause malfunctions!
If the fuel tank has been run empty, the fuelinjection
system can draw in air bubbles. This can lead to
malfunctions in the fuel injection system.
– Never run the fuel tank empty.
evel in the fuel tank as a
.
urs
me digitally in hours
e adjusted;
"Setting the
75
%
234,7 h
12:15
1
2
2
3
4
7312_003-057_V2
749 EN - 03/2017 83
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4 Operation
Testing and activities before dail
NOTE
Additional information may appear on the
display. If faults occur, refer to the information
in the chapter entitled "Faults".
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 de
unit menu that can onl
persons with the cor
authorisation, e.g
Once the key switch has been switched on,
the input menu for the driver PIN appears
on the display and operating unit screen. All
of the truck's functions (driving, hydraulics,
additional electrical installations and the
display and operating unit displays) are
blocked. The function of the hazard warning
system (variant) is guaranteed. Enter the fivedigit 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 authorisation can be configured
in such a way that the driver PIN has to be
re-entered each time the driver steps off the
truck, in order for the truck to be operated
again.
– Contact the author
this matter.
The first driver PIN is preset to "11111" at the
factory. All others are preset to "0xFFF" but
have no function as the highest valid driver PIN
fined in a truck control
y be accessed by
responding access
. fleet managers.
ised service centre on
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84 1
74749 EN - 03/2017
Operation 4
Testing and activities before dail
is "99999". Persons with the corresponding
access authorisation, e.g. fleet managers, can
change the driver PINs in the corresponding
menu.
NOTE
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When first commissioning the truck, we recommend you change the access authorisation set at the factory. This is the only way to
guarantee that the driver PIN is only known to
persons with corresponding access authorisation.
The driver PINs are stored in the truck control
unit. These are still available if the display
and operating unit has been changed. The
authorised service centre can use a diagnostic
device to read out the driver PIN and, if
necessary, restore the factory default driver
PIN.
ACCESS CODE input menu
The driver enters the five-digit driver PIN
(00000 to 99999) in this input menu.
The driver PIN is entered using the buttons (1).
The digits entered for the driver PIN (2) are not
visible, instead being represented by circles.
If the driver PIN entered is correct, the familiar
display appears with the standard display, and
all truck functions are available.
749 EN - 03/2017 85
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4 Operation
8
9
6
7
4
2
0
1
3
5
8
9
6
7
4
2
0
1
3
5
Testing and activities before dail
If an incorrect driver PIN is entered, the
message
When the message goes out, the driver PIN
can be re-entered.
INVALID appears for a short time.
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BQ_023_en_V2
After three invali
sage
CODE DENIED ap
then locked for five
attempt can be made
d entry attempts, the mes-
pears. The input is
minutes before another
.
BQ_024_en_V2
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Operation 4
8
9
6
7
4
2
0
1
3
5
Testing and activities before dail
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Defining the driver PIN
NOTE
1
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) atthe same
2
Blue-Q_029_V2
time.
PASSWORD appears in the display.
– Enter the four-digit password (factory
default: 2777) using the buttons (1).
– Confirm the entry by pressing the
ENTER
button (2).
1
ESC
3
126
4
7
5
2
BQ_030_en_V2
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4 Operation
8
9
6
7
4
2
0
1
3
5
8
9
6
7
4
2
0
1
3
5
Testing and activities before dail
CONFIGURATIONappears in the display.
– Use the drive program selection button (1)
and the menu change button (3) to select
the
ACCESS CODE menu.
– Confirm your selection by pres
ENTER
button (2).
yuse
1
sing the
Selecting the driver PIN
In the ACCESS CODE menu, there are fifty
possible driver PINs to choose from.
The digit seque
the
NEW CODE sub
Once the
cessed, the
the number
can now be defined.
– Use the drive program selection button (1)
and the menu change button (4) to select
the desired driver PIN (
– Confirm you
ENTER
nces can be set or changed in
menu.
ACCESS CODE menu has been ac-
CODE selection field (2) contains
1. The first of the fifty driver PINs
1 to 50).
r selection by pressing the
button (3)
.
32
1
4
3
BQ_31_en
2
BQ_025_en_V3
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74749 EN - 03/2017
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