Original instructions
Diesel trucks
Pilot series
RX70-20/600
RX70-25
RX70-25/600
RX70-30
RX70-30/600
RX70-35
7381 7382 7383 7384 7389
7390
57368011501 EN - 10/2017
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
Rules for the operating company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commissioning and storage of industrial trucks
thesafeoperationof
g
Internet address and QR code
The information c
by pasting the add
in a web browser or
an be accessed at any time
ress https://m.still.de/vdma
by scanning the QR code.
68011501 EN - 10/2017 I
573
Table of contents
1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformit
Accessories ......................................................... 7
Labelling points ...................................................... 8
Nameplate ......................................................... 10
Production number . . . ............................................... 10
StVZO(RoadTrafficLicensingRegulations)information ....................... 11
Using the truck ...................................................... 11
Proper usage ....................................................... 11
Proper use during towing .............................................. 12
Impermissibleuse ................................................... 12
Placeofuse ........................................................ 12
Usingworkingplatforms ............................................... 14
Information about the do
Scopeofthedocumentation ............................................ 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
cumentation ..................................... 15
tyoftheoperatinginstructions .......................... 17
.................................................. 18
siderations .......................................... 22
g
2Safety
Definition of respon
Operatingcompany .................................................. 24
Specialist .......................................................... 24
Drivers ........................................................... 25
Basic principles 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
g
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 tests ........................................................ 42
Regular safety inspection
Checkingthedieselengineemissions ..................................... 42
Truckswithparticlefilters .............................................. 43
Insulationtesting .................................................... 44
Safety regulations for handling consumables ............................... 45
Permissibleconsumables ............................................. 45
Oils .............................................................. 45
Hydraulicfluid ...................................................... 46
Batteryacid ........................................................ 47
Dieselfuel ......................................................... 48
Coolantandcoolingfluid .............................................. 50
Disposalofconsumables .............................................. 50
Emissions ......................................................... 52
termeasures ................................. 38
ofthetruck ..................................... 42
3Overviews
Overview .......................................................... 56
Driver's compartment ................................................. 57
Operating devices a
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 5
nd display elements ................................... 58
.................................................... 60
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Table of contents
4 Operation
Testing and activities before daily use ..................................... 68
Visualinspections ................................................... 68
Climbinginandoutofthetruck .......................................... 71
Shelvesandcupholders .............................................. 72
Adjusting the MSG 65/MSG 75 d
Adjustingthearmrest ................................................. 77
Adjustingthesteeringcolumn ........................................... 78
Unlocking the emergency off
Switchingonthekeyswitch ............................................ 79
AccessauthorisationwithPINcode(variant) ................................ 82
Operating the signal horn .............................................. 9
Seatbelt .......................................................... 92
Driver'scab ........................................................ 95
Starting the engine ................................................... 96
Checkingthebrakesystemforcorrectfunction .............................. 97
Checkingthesteeringsystemforcorrectfunction ............................ 98
Checking the emergency o
Zeroadjustmentoftheloadmeasurement(variant) ........................... 99
Checking the vertical lift mast position (variant) for correct function . ...............101
Operating the display-
Displays ........................................................ . . 102
Adjustingthedisplays ................................................103
Symbolsinthedisplay ................................................1
Settingthedateortime ................................................109
Resetting the daily kilometres and daily operating hours .......................110
Setting the language
Softkeys for operating various equipment variants ............................111
ConfiguringBlue-Qefficiencymode ......................................111
Blue-Q efficiency mod
Functional description . ...............................................113
Switching off additional consumers .......................................114
Switching efficiency m
Driving ............................................................116
Safety regulations when driving .........................................116
Roadways .........................................................118
Settingthedriveprogramme ............................................121
Selectingthedrivedirection ............................................121
Actuating the drive dir
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 123
Actuating the drive direction switch, fingertip version ..........................123
operating unit ......................................102
.................................................110
e ...............................................113
odeBlue-Qonandoff ................................114
ectionswitch,mini-leverversion .........................122
river'sseat ................................ 73
switch ...................................... 79
fffunction ..................................... 99
g
2
04
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Table of contents
g
Actuatingthedrivedirectionswitch,mini-consoleversion ......................124
Startingtodrive .....................................................124
Starting drive mode, dual-ped
Operatingtheservicebrake ............................................129
Parkingbrake ......................................................130
Actuating the mechanical park
Steering ...........................................................132
Driving on ascending and descending gradients . . ...........................133
Reducing speed with a raised
Automatic shut-off of the internal combustion engine (variant) ...................134
Parking ...........................................................135
Parking the truck securely
Wheel chock (variant) ................................................136
Lifting ............................................................137
Liftingsystemvariants ................................................1
Automaticliftcutout(variant) ...........................................137
Liftmastverticalposition(variant) ........................................138
Typesofliftmast ....................................................142
Malfunctionsduringliftingmode .........................................144
Hydraulicblockingfunction .............................................145
Lifting system operati
Controlling the lifting system using a double mini-lever .........................147
Controllingtheliftingsystemusingatriplemini-lever ..........................148
Controlling the liftin
Controllingtheliftingsystemusingthejoystick4Plus ..........................150
Controlling the lifting system using the fingertip . . . ...........................152
Changing the fork arm
Forkextension(variant) ...............................................155
Operationwithreversibleforkarms(variant) ................................157
Handling loads ......................................................159
Safety regulations when handing loads ....................................159
Beforetakingupload .................................................160
Load measurement (v
Picking up loads .....................................................164
Danger area .......................................................165
Transportingpallets ..................................................1
Transporting suspended loads ..........................................166
Pickingupaload ....................................................167
Transporting loads ...................................................171
Setting down loads ...................................................172
Shakefunction(variant) ...............................................173
g system using a quadruple mini-lever ......................149
alversion(variant) .............................126
ingbrake ...................................130
load(variant) ................................134
andswitchingitoff ...............................135
ngdevices .........................................146
s ...............................................153
ariant) ...........................................161
37
66
VI 5
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Table of contents
Drivingonlifts ......................................................177
Driving on loading bridges .............................................178
Attachments .......................................................180
Fittingattachments ..................................................180
Releasingthepressurefromthehydraulicsystem ............................182
General instructions for co
Controlling attachments using a double mini-lever ............................186
Controlling attachments using the double mini-lever and the 5th function ...........188
Controlling attachments us
Controlling attachments using the triple mini-lever and the 5th function .............192
Controlling attachments using a quadruple mini-lever .........................194
Controlling attachments u
Controllingattachmentsviathejoystick4Plus ...............................198
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........199
Controlling the attachme
Controlling attachments with the fingertip and 5th function ......................201
Clamp locking mechanism (variant) ......................................203
Taking up a load using att
Auxiliary equipment ..................................................207
Switchingthelightingonandoff .........................................207
Switching the rotating
Switchingthehazardwarningsystemonandoff .............................209
Switchingdirectionindicatorsonandoff ...................................209
Switching the double wo
STILLSafetyLight(variant) .............................................214
Operatingthewindscreenwiper/washer ...................................215
Filling the washer syst
FleetManager (variant) . ...............................................216
Shock recognition (variant) .............................................216
Cruise control (varian
Driverrestraintsystems(variants) .......................................220
Cab ..............................................................221
Opening the cab door
Closingthecabdoor ............................................... . . 222
Openingthesidewindows ........................................... . . 223
Closing the side win
Operatingtheinteriorlighting ...........................................224
Operating the rear window heating .......................................225
Radio(variant) ......................................................22
RadiowithBluetoothinterface(variant) ....................................227
Heatingsystem ................................................... . . 229
ntrollingattachments .............................184
ingatriplemini-lever .............................190
sing the quadruple mini-lever and the 5th function .........196
nts with the fingertip ...............................200
achments ......................................206
beacon on and off . . . ................................208
rkingspotlightsonandoff. ...........................212
em ..............................................215
t) ................................................216
.................................................221
dows ..............................................223
g
6
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Table of contents
g
Push-up roof window (variant) ..........................................230
Clipboard (variant) ...................................................231
12Vsocket ....................................................... . 231
Trailer operation ....................................................232
Towedload ....................................................... . 232
Coupling pin in the counterw
Automatictowcoupling ...............................................235
Towingtrailers ......................................................243
Display messages ...................................................245
Displaycontent .....................................................245
Errorcodetable .....................................................246
General messages ...................................................248
Drive-specificmessages ..............................................257
Refuelling .........................................................264
Diesel fuel - Specificati
Fillingupwithdieselfuel ...............................................267
Cleaning ..........................................................269
Cleaning the truck ...................................................269
Cleaning the electrical system ..........................................271
Cleaning load chains .................................................272
Cleaning the windows ................................................27
Afterwashing .......................................................273
Procedure in emergencies .............................................273
Emergency shutdown ................................................273
Procedureiftrucktipsover .............................................275
Emergency hammer ..................................................276
Emergency lowering .................................................276
Disconnectingthebattery ..............................................278
Jumpstarting .......................................................279
Towing .......................................................... . 281
Transporting the truck ................................................283
Transport ..........................................................283
Craneloading ......................................................285
Shutdown .........................................................289
Shuttingdownandstoringthetruck ......................................289
Recommissioningafterstorage .........................................290
eight ........................................233
ons .............................................264
2
I 57368011501 EN - 10/2017
VII
Table of contents
5 Maintenance
Safety regulations for maintenance .......................................294
Generalinformation ..................................................294
Workingonthehydraulicequipment ......................................294
Working on the electrical equipment ......................................295
Working on the ignition syst
Safetydevices ......................................................296
Setvalues ....................................................... . . 296
Liftingandjackingup .................................................296
Workingatthefrontofthetruck ..........................................296
General maintenance information ........................................298
Personnel qualifications ...............................................2
Informationforcarryingoutmaintenance ..................................298
Maintenance - 1000 hours/annually ......................................301
Maintenance - 3000 hours/
Orderingsparepartsandwearingparts ....................................305
Quality and quantity of the required operating materials ........................306
Lubricationplan .....................................................307
Maintenance data table ...............................................308
Providing access to maintenance points ...................................311
Openingthebonnet ................................................ . . 311
Closing the bonnet ...................................................313
Removingandattachingtherearcover ....................................315
Installing and removing th
Remaining ready for operation ..........................................317
Checking the engine oil level ...........................................317
Fillingthewashersystem ..............................................31
Cleaningtheradiator,checkingforleaks ...................................320
Topping up the cooling fluid and checking the coolant concentration ...............320
Draining water from the fue
Replacing the air filter cartridges .........................................323
ServicingtheETBparticlefilter ..........................................326
Eberspächer particle filt
Lubricatingthejointsandcontrols ........................................333
Maintainingtheseatbelt ...............................................334
Checkingthedriver'sseat .............................................33
Checking the door latch ...............................................336
Maintainingwheelsandtyres ...........................................336
Servicingthebattery .................................................339
Replacingfuses .....................................................342
Checkingthehydraulicoillevel ..........................................342
em ..........................................295
everytwoyears .................................305
ebottomplate ...................................316
lfilter .........................................322
ers - Regeneration . ................................330
g
98
8
6
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Table of contents
g
Checkingthehydraulicsystemforleaks ...................................343
Lubricatingtheliftmastandrollertrack ....................................344
Greasing the automatic tow cou
1000-hour maintenance/annual maintenance ...............................349
Othertasks ........................................................349
Checking the exhaust gas sys
Checking the lift cylinders and connections for leaks ..........................349
Checkingtheforkarms ................................................349
Checking the reversible for
pling ......................................345
tem .......................................349
karms ........................................350
6 Technical data
Dimensions ........................................................352
VDI datasheet for RX70-20/600 and RX70-25 ...............................354
VDI datasheet for RX70-
VDI datasheet for RX70-30/600 and RX70-35 ...............................362
Ergonomic dimensions ................................................366
Fuse assignment ....................................................367
25/600 and RX70-30 ...............................358
X57
368011501 EN - 10/2017
1
Foreword
1 Foreword
Your truck
Your truck
Description of the truck
General
Counterbalanced trucks of the series RX7020/25/30/35 with a load capacity of up to
3.5 t are equipped with an internal combustion/electric drive. The internal combustion/electric drive combines the advantages of
an internal combustion engine with the precise
control of an electric drive.
The bend-resistant and war
mast enables safe load hand
heavy loads. The comfort
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.
The truck is suitable for outdoor use. When
fitted with a particle filter, the truck is also
equipped for unrestricted indoor use. The
series is suitable for use multi-shift operation
and supports all of the FleetManager 4.x
functions.
p-resistant lift
ling, even with
able driver's comst up-to-date er-
t signs of fatigue
Brake system
The brake system of the truck is comprised of
three different brakes:
• Service brake
• Regenerative brake
• Parking brake
The service brake
oil-immersed mul
brake is used as th
braking or emerge
pedal. In the norma
regenerative brak
motor takes effect
converts the accel
into electrical en
decelerate as soon a
is released. Comple
from the accelerato
brake until it come
257
is based on a wear-free,
ti-discbrake. Thismulti-disc
e service brake for heavy
ncy braking with the brake
l working mode, the
e of the electric traction
. The regenerative brake
eration energy of the truck
ergy. This causes the truck to
s the accelerator pedal
tely removing your foot
r pedal causes the truck to
s to a standstill. A parking
368011501 EN - 10/2017
Foreword 1
Your truck
brake ensures that the truck remains securely
in place when parked.
Steering
The truck is equipped with a swing axle and
has kickback-free hydraulic rear-wheel steering. Stability is guaranteed when cornering
thanks to speed limitation based on the steering angle. Simple handling of the truck is assisted by the manoeuvrable steering axle.
Hydraulic system
All lift cylinders are hyd
oil volume required for t
mast is provided by a gear
to the internal combusti
directional control val
proportional technolog
sensitive movements and
the load. The hydraulic f
parameterised individu
service centre.
Uptothreehydrauliccircuitscanbeusedto
activate attachments (variant). Depending on
the equipment, a hydraulic accumulator is also
available in the lifting circuit for the purpose of
dampening pressure peaks in the hydraulic
system.
raulically actuated. The
he steering and the lift
pump connected
on engine. The
ve block with electrical
y ensures extremely
safe handling of
unctions can be
ally by the authorised
Drive concept
The internal combustion engine drives an
electric three-phase generator. The generated current is routed to a maintenance-free,
electrical 22-kW three-phase AC traction motor, which drives the truck using the two front
wheels. An electronic speed controller gently
provides high torque for both forwards and
backwards travel.
The components for t
lift drive are enclose
ingress of dust or moistu
the truck is suitable for
use. In addition, all dri
and lifting are mainten
The driving characteristics and lifting behaviour can be adapted to the application
he drive unit and the
d in order to prevent the
re. This means that
indoor and outdoor
ves for traction, steering
ance-free.
68011501 EN - 10/2017 3
573
1 Foreword
Your truck
or driving habits. Five drive programmes are
available for this purpose. The maximum driving speed is 22 km/h. The Blue-Q energy-saving mode reduces energy consumption by up
to 10%, without impairing performance.
Operating devices
The truck is characterised by an accessible
operating concept. When purchasing the
truck, a variety of operating devices 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.
Operational information, such as the fuel level
or the current energy-saving modeBlue-Q are
shown in the display-operating unit.
For drive mode, the tru
single-pedal or dualaccelerator pedal is use
brake (electric brake) t
situations or when carry
driver can also brake the tr
service brake by pressing the
In dual-pedal operation, the tr
pedal for the "Forwards" driv
one pedal for the "Reverse" driv
Acceleration and braking behav
individually selected from five
programmes.
ck features either
pedal operation. The
d to accelerate and
he truck. In emergency
ing heavy loads, the
uck using the
brake pedal.
uck has one
e direction and
e direction.
iour can be
different drive
General
The truck described in thes
tions corresponds to the app
and safety regulations.
457
e operating instruc-
licable standards
368011501 EN - 10/2017
Foreword 1
Your truck
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.
The trucks have been fitted with state-of-theart technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructio
necessary information to do
observe the information pro
commissioning the truck. Th
accidents and ensure that th
ns provide the
this. Read and
vided before
is will prevent
e warranty
remains valid.
CE labelling
The manufacturer uses CE
cate that the truck compl
and regulations valid at
This is confirmed by the is
of conformity. The CE la
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.
labellingtoindi-
ies with the standards
the time of marketing.
sued EC declaration
belling is attached to
68011501 EN - 10/2017 5
573
CE-Symbol
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
.
657
H
368011501 EN - 10/2017
Foreword 1
Your truck
Accessories
• Key for key switch (two pieces)
• Key for cab (variant)
• Hexagon socket wrench for emer
lowering
gency
68011501 EN - 10/2017 7
573
1 Foreword
Your truck
Labelling points
16
DANGER
DANGER
18
17
DANGER
DANGER
12
16
10
17
24
11
18
25
5
8
9
2
15
5
6
L
WA
1
25
5
DANGER
9
8
20
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.*
*
12
kg
kg
kg
kg
1
7
4
20xx
10 bar
16
7
STILL GmbH Hamburg
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
2009/104/EG, 99/92/EG
Die Prüfplakette ersetzt nicht das Prüfprotokoll
17
24
6
10
D
A
N
G
E
R
11
13
14
23
13
14
3
4
2
3
Regelmäßige Prüfung
(FEM 4.004)
Nächste Prüfung
Mitglied der:
Fédération
Européene
de la Manutention
2
1080
1080
5430
1080
1010
1050
1150 1310
5030 1270
4430
1110 12301250 1500
3
4030 1150 1260 12001500
3730 1180 1290 14301500
1500
3430 1210 1330 1470
800 700
600
500
1
22
15
DANGER
56344391019
19
1
2
3
4
21
73XX_003-002
7
857
368011501 EN - 10/2017
Foreword 1
Your truck
1 Decal information: "Dual-pedal operation"
(variant)
2 Manufacturer's label text
3 Decal information: FEM test
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: Traction 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 seat belt
12 Decal information: Lifting gear attachment
point
13 Decal information: Parking brake released
14 Decal information: Parking brake applied
15 Decal information: Caution / Read the
operating instructions / Fasten seat belt
/ Apply 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
16 Warning sign: Danger due to shearing /
Danger due to high fluid pressure
17 Warning sign: Do not stand underneath the
fork / Do not stand on the fork
18 Decal information: Sound power level
19 Capacity rating plate
20 Decal information: Nameplate
21 Factory number
22 Capacity rating plate: Attachment (variant)
23 Decal information: StVZO (German Road
Traffic Licensing Regulations) information
(variant)
24 Decal information: Microphone for hands-
free device (variant)
25 Decal information: Radio with Bluetooth
interface (variant)
68011501 EN - 10/2017 9
573
1 Foreword
4
Your truck
Nameplate
The truck can be identified from the information on the nameplate.
The information for the battery weights (5,
6) and the ballast weight (7) only applies to
electric forklift trucks.
1
Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
13
Rated capacity
Capacité nominale
Nenn-Tragfähigkeit
12
Battery voltage
Tension batterie
Batteriespannung
11
Rated drive power
Puissance motr.nom.
Nenn-Antriebsleist.
2
Unladen mass
kg
Masse à vide
Leergewicht
V
kW
* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung
max
min.*
*
D-22113 Hamburg
Berzeliusstr. 10
3
4
kg
5
kg
kg
6
kg
7
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
10
9
8
6210_921-003_V3
1 Type
2 Production number
3 Year of manufacture
4 Tare weight in kg
5 Max. permissible battery weight in kg
6 Min. permissible battery weight in kg
7 Ballast weight in kg
8 Address of manufacturer
9 Refer to the technical data listed in these
operating instructions for more detailed
information
10 CE labelling
11 Nominal drive power in kW
12 Battery voltage in V
13 Rated capacity in kg
xx xxxx x xxxxx
1
2
3
4
7090_921-004
10 5
7368011501 EN - 10/2017
Foreword 1
Using the truck
StVZO (Road Traffic Licensing
Regulations) information
This label includes informa
and load distribution of the
tion on the weight
truck.
12
Using the truck
Proper usage
The truck described in these operating instructions is suitable for lifting, transporting
and stacking loads.
k may only be used for its proper
The truc
purpose
opera
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 is specified on
the capacity rating plate (load diagram) and
must not be exceeded; see also the chapter
entitled "Before picking up a load".
as set out and described in these
ting instructions.
5
1 Tare weight (in kg)
2 Permitted total weight (in kg)
3 Permitted front axle weight (in kg)
4 Permitted rear axle weight (in kg)
5 Payload (in kg)
3 4
7094_003-098
68011501 EN - 10/2017 11
573
1 Foreword
Using the truck
Proper use during towing
This truck is suitable for the occasional towing
of trailers and is equipped with a towing device
for this purpose. This occasional towing may
not exceed 2% of the daily operating time. If
the truck is to be used for towing on a more
regular basis, the manufacturer should be
consulted.
The regulations regarding trailer operation
must be observed; see chapter "Trailer
operation".
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.
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 unstac
inclined surface
king is not permissible on
sorramps.
Place of use
The truck can b
If the truck is equipped with the "particle
filter" equipment variant, it fulfils the essential
prerequisites for use in ventilated halls. The
national regulations for the country of use
must be observed.
12 5
e used outdoors.
7368011501 EN - 10/2017
Foreword 1
Using the truck
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 adequ
capacity (concrete, asphal
surface. Routes, working ar
widths must conform to the sp
these operating instructio
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 designe
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.
ate load
t) and a rough
eas and aisle
ecifications in
ns; see the chapter
dtobeoperatedin
NOTE
Please observe the definition of the following
responsible person: "operating company".
68011501 EN - 10/2017 13
573
1 Foreword
Using the truck
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 5
7368011501 EN - 10/2017
Foreword 1
Information about the documentati
on
Information about the documentation
Scope of the documentation
• Original operating instructions
• Original operating instructions for attachments (variant)
• Depending on the truck equi
operating instructions ma
NOTE
Refer to the additional information in the
section entitled "Rules for the operating
company of industrial trucks".
These operating instructions describe all
measures necessary for the safe operation
and proper maintenance of the truck in all
possible variants available at the time of
printing. Special versions to meet customer
requirements (UPA) are documented in
separate operating instructions. If you have
any questions, please contact your authorised
service centre.
Enter the production number and year of
manufacture from the nameplate in the space
provided:
Production number:
Year of manufacture:
pment, "UPA"
yalsobeprovided
Please quote the production number in all
technical enquiries.
Each truck comes with a set of original 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 original operating instructions are lost,
the operating company must immediately
obtain a copy of the original operating instructions from the manufacturer as a replacement.
– Contact the authorised service centre
regarding this matter.
The personnel responsible for operating,
maintaining and servicing the industrial
68011501 EN - 10/2017 15
573
1 Foreword
Information about the documentati
truck must be familiar with these operating
instructions.
The operating company must ensure that all
users have received, read and understood
these operating instructions.
Safely store the entirety of th
and pass the documentation o
quent operating company whe
or selling the truck.
NOTE
e documentation
Please note the definition of the following
responsible persons: "operating company"
and "driver".
Supplementary documentation
This industrial truck can be fitted with unplanned equipment () that deviates from the
standard equipment and/or the variants.UPA
The UPA may be, for example:
• Special sensors
• Special attachments
• Towing devices
• Customised 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
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.
on
n to the subse-
ntransferring
16 5
7368011501 EN - 10/2017
Foreword 1
Information about the documentati
on
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.
68011501 EN - 10/2017 17
573
1 Foreword
Information about the documentati
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 abbre-
d here will necessarily
ng instructions.
tenfernübertragung
eutsches Institut für Normung
uropean Community
ropean standard
on
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 5
7368011501 EN - 10/2017
Foreword 1
Information about the documentati
on
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
.
68011501 EN - 10/2017 19
573
1 Foreword
Information about the documentati
on
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 5
6210_003-062
7368011501 EN - 10/2017
Foreword 1
Information about the documentati
on
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.
68011501 EN - 10/2017 21
573
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 5
7368011501 EN - 10/2017
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 5
7368011501 EN - 10/2017
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 requiredrights.
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
68011501 EN - 10/2017 25
573
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 5
7368011501 EN - 10/2017
Safety 2
Basic principles for safe operatio
Basic principles for safe operation
Insurance cover on company premises
In many cases, company premises are
restricted public traffic areas.
NOTE
The business liability insurance should be
reviewed to ensure that, in the event of any
damage caused in restricted public traffic
areas, there is insurance cover for the truck in
respect of third parties.
Changes and retrofitting
If the truck is used for work that is not listed
in the guidelines or in these instructions and
has to be converted or retrofitted accordingly,
you must note that any change to its structural
state can affect the handling and stability of
the truck, which in turn can lead to accidents.
You should 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.
n
68011501 EN - 10/2017 27
573
2 Safety
Basic principles for safe operatio
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. This risk 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:
n
28 5
7368011501 EN - 10/2017
Safety 2
Basic principles for safe operatio
– Type of change
– Date of change
– Name and address of the company
menting the change.
imple-
n
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.
68011501 EN - 10/2017 29
573
2 Safety
Basic principles for safe operatio
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 theelectric
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
n
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 5
7368011501 EN - 10/2017
Safety 2
Basic principles for safe operatio
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
n
68011501 EN - 10/2017 31
573
2 Safety
Basic principles for safe operatio
Medical equipment
WARNING
Electromagneticinterferencemayoccur on medical
devices!
Only use equipment that is sufficiently protected
against electromagnetic interference.
Medical equipment, such as pacemakers or
hearing aids, may not work properly when the
truck is in operation.
– Ask your doctor or the manufacturer of
the medical equipment to confirm that the
medical equipment is sufficiently protected
against electromagnetic interference.
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.
n
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 5
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Safety 2
Basic principles for safe operatio
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 correct fork arms,
contact the authorised service centre.
n
68011501 EN - 10/2017 33
573
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 batteries and
electrical voltages
• Human error resulting from failure to
observe the safety regulations,
• Unrepaired damage or defective and worn
components,
• Insufficient maintenance and testing
• Use of incorrect consumables
• Exceeding test intervals
34 5
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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 min-
tions:
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
68011501 EN - 10/2017 35
573
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 5
7368011501 EN - 10/2017
Safety 2
Residual risk
68011501 EN - 10/2017 37
573
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 5
7368011501 EN - 10/2017
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)
68011501 EN - 10/2017 39
573
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 5
7368011501 EN - 10/2017
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.
68011501 EN - 10/2017 41
573
2 Safety
Safety tests
Safety tests
Regular safety inspection of the truck
Safetyinspectionbasedontimeand
extraordinary incidents
The operating company must ensure that the
truck is checked by a specialist at least once a
year or after particular incidents.
As part of this inspection
of the technical conditio
performed with regard to a
In addition, the truck mus
checked for damage that co
have been caused by impro
log must be created. The r
inspection must be retai
inspections have been ca
The inspection date is indicated by an adhesive label on the truck.
– Arrange for the service centre to perform
periodic safety inspections on the truck.
– Observe guidelines fo
on the truck in accorda
The operator is responsible for ensuring any
defects are remedied without delay.
– Contact your service centre.
, a complete check
n of the truck must be
ccident safety.
t be thoroughly
uld potentially
per use. A test
esults from the
ned until a further two
rried out.
r checks carried out
nce with FEM 4.004.
NOTE
Observe the national regulations for your
country!
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 5
7368011501 EN - 10/2017
Safety 2
Safety tests
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
68011501 EN - 10/2017 43
573
2 Safety
Safety tests
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 Ω/V for
nominal battery voltage against ground.
– Contact the authorised service centre.
44 5
7368011501 EN - 10/2017
Safety 2
Safety regulations for handling co
nsumables
Safety regulations for handling consumables
Permissible consumables
DANGER
Failure to observe the safety regulations relating to
consumables may result in a risk of injury, death or
damage to the environment.
– Observe the safety regulations when handling
such materials.
Refer to the maintenance data table for the
permissible substances that are necessary for
operation (see ⇒ Chapter "Maintenance data
table", P. 5-308).
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.
68011501 EN - 10/2017 45
573
2 Safety
Safety regulations for handling co
WARNING
Prolonged intensive contact with the
skin can result in dryness and irritate
the skin!
– Avoid contact and consumption.
– Wear protective gloves.
– After any contact, wash the skin
with soap and water, andthenapply
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.
nsumables
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 5
7368011501 EN - 10/2017
Safety 2
nsumables
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 for handling co
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.
68011501 EN - 10/2017 47
573
2 Safety
Safety regulations for handling co
WARNING
Battery acid contains dissolved
sulphuric acid. This is corrosive.
– When working with battery acid,
use appropriate PSA (rubber
gloves, apron, protection goggles).
– When working with battery acid,
never wear a watch or jewellery.
– Do not allow any acid to get
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
nsumables
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 5
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Safety 2
nsumables
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 andwater,andthenapply
askincareproduct.
– Immediately change soaked
clothing and shoes.
WARNING
Risk of slippingduetospilleddieselfuel,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
Safety regulations for handling co
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.
68011501 EN - 10/2017 49
573
2 Safety
Safety regulations for handling co
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.
nsumables
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 5
7368011501 EN - 10/2017
Safety 2
Safety regulations for handling co
– Neutralise any spilt battery acid immedi-
ately.
– Always observe national regulations con-
cerning the disposal of used oil.
nsumables
68011501 EN - 10/2017 51
573
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
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 workplacesaccordingto the most
recent version of Directive 2003/10/EC (daily
personal noise pollution). If necessary, these
noise emissions must be determined by the
operating company directly at the workplaces
under the actual conditions there (additional
noise sources, special application conditions,
sound reflections).
NOTE
rmined in the test cycle
ine from the weighted
ng statuses and idling.
Please observe the definition of the following
responsible person: "operating company".
52 5
7368011501 EN - 10/2017
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
Tests have indicated that the amplitude of the
hand and arm vibrations on the steering wheel
or the operating devices in trucks is less than
2
2.5 m/s
. There are therefore no measure-
ment guidelines for these measurements.
The personal vibration
a working day must be det
operating company at t
in accordance with Dir
order to consider all a
such as driving route,
Measurement
uncertainty
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 observe the definition of the following
responsible person: "operating company".
68011501 EN - 10/2017 53
573
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.
– Always observe the national laws and regulati-
ons of the country of use when using trucks with
an internal combustion engine in entirely or partially enclosed working areas.
– Always ensure that there is sufficient ventilation
available.
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 exhaustpipe.
– In the event of burns, seek first aid
immediately.
– If materials are burning, take fire
precautions immediately.
54 5
7368011501 EN - 10/2017
3
Overviews
3 Overviews
Overview
Overview
15
1
2
12
11
10
13
14
3
4
5
6
7
73XX_003-001
9
8
1 Rotating beacon (variant)
2 Rear working spotlight (variant)
3 Rear lighting (variant)
4 Driver's compartment
5 Exhaust pipe
6 Starter battery
7 Towing device
8 Steering axle
56 5
9Driveaxle
10 Fork arms
11 Fork carriage
12 Hydraulic connection for an attachment
13 Lift mast
14 Front working spotlight (variant)
15 Overhead guard
7368011501 EN - 10/2017
Overviews 3
Driver's compartment
Driver's compartment
13
12
11
7314_003-048
1
2 3 4
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.
68011501 EN - 10/2017 57
573
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
Operating devices and display elem
ents
Operating devices and display elements
Display and operating unit
56
4
3
2
1
3
1
2
5
8
6
4
9
7
0
26
25
20
22
23
24
21
7
8
9
10
11
12
75
%
2
234,7 h
12:15
13
14
15
19
17
18
16
1 Hazard warning sy
2 Front windscree
3 Working spotli
4 Drive programm
5 Softkey Light
6 Lighting sym
7 Not assigne
8 Fuel level
9Drivepro
10 Left tur
n indicator display
11 Forward
12 Right t
13 Malf
4
1
urn indicator display
unction display
everse travel indicator
R
stem button
n wiper button
ght button
e selector button
ing
bol
d
display (percentage)
gramme display (numerical)
travel indicator
NOTE
The Softkeys (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. Softkeys can be
assigned multiple functions that are called
up according to the menu navigation. For
further information, see the section entitled
"Operating the display-operating unit".
– If you have any questions, please contact
your authorised service centre.
15 Operating hours d
16 Time display (di
17 Particle filter
18 Rotating beaco
19 Interior ligh
20 Rear window h
21 Softkey Int
22 Softkey Re
regenera
23 Menu cha
24 Lightin
25 Blue-Q
26 Rear
display
n display
ting display
eating display
erior light/rotating beacon
ar window heating/particle filter
tion
nge button
g button
button
window wiper button
isplay
gital)
58 5
7368011501 EN - 10/2017
Overviews 3
Operating devices and display elem
ents
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
68011501 EN - 10/2017 59
573
3 Overviews
Operating devices and display elem
Double mini-lever
ents
3
2
1
7
1 "Lift mast" 360° lever
2 Function key "F1"
3 Function key "F2"
4 "Drive direction/turn indicator" cross lever
5 Function key "5th function"
6 "Attachments" cross lever
7 Signal horn button
4
5
F1
F2
6
NOTE
Depending on the specification, various
electric attachment parts can be controlled
via function keys (2) and (3).
•
For alterations, contact the authorised
service centre.
60 5
7368011501 EN - 10/2017
Overviews 3
Operating devices and display elem
ents
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 specification, various
electric attachment parts can be controlled
via function keys (2) and (3).
•
For alterations, contact the authorised
service centre.
0° lever
"F1"
y"F2"
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
68011501 EN - 10/2017 61
573
3 Overviews
Operating devices and display elem
Four-way mini-lever
ents
4
3
2
1
9
1 "Lift/lower"
2 "Tilt" opera
3 Function ke
4 Function k
5 "Drive di
NOTE
Depending on the specification, various
electric attachment parts can be controlled
via function keys (3) and (4).
•
For alterations, contact the authorised
service centre.
operating lever
ting lever
y"F1"
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 5
7368011501 EN - 10/2017
Overviews 3
Operating devices and display elem
ents
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
68011501 EN - 10/2017 63
573
3 Overviews
F1
F2
Operating devices and display elem
Fingertip
ents
1
11
2 3 456
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 specification, various
electric attachment parts can be controlled
via function keys (1) and (2).
•
For alterations, contact the authorised
service centre.
64 5
7368011501 EN - 10/2017
7325_003-028
7 "Attachments" operating lever
8 "Attachments" operating lever
9 "Tilt" operating lever
10 "Lift/lower" operating lever
11 Drive direction switch
Overviews 3
Operating devices and display elem
ents
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
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573
3 Overviews
Operating devices and display elem
ents
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7368011501 EN - 10/2017
4
Operation
4 Operation
Testing and activities before dail
yuse
Testing and activities before daily use
Visual inspections
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.
Damage to the truck or the attachment
(variant), non-functional switches or safety
devices and modification of predefined
set values can lead to unpredictable and
dangerous situations.
The following checks and tasks enable
causes of this type to be identified in good
time. It is therefore important to run through
the checks and tasks listed in the following
table from top to bottom before daily use of
the truck.
If damage or other defects are identified on
the truck or attachment (variant), the truck
must not be used until it has been properly
repaired.
Before the truck is used each day, ensure that it is safe to be operated:
Component
Fork arms, general lifting accessories
Lift mast roller
Load chains
Attachments (variant)
Underside
Overhead
tracks
guard, guard grille (variant)
Course of action
Perform a visual inspection for deformation and
wear (for example, bent, broken, significant wear).
Check the condition and function of the fork locking
devices to prevent them from lifting out or shifting.
Make sure that there is a film of grease.
Perform a visu
are intact and
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.
Check the ar
consumable
Perform a v
Check for s
al inspection to ensure that the chains
have adequate and even tension.
ea under the forklift truck for leaking
s.
isual inspection for integrity.
ecure mounting.
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Operation 4
Testing and activities before dail
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Component
Steps Make sure they are clean (free of
Panes of glass (variant)
Handholds
Maintenance lids
Fuel system, fuel tank
Bonnet and side flap
Coupling pin, tow coupling (variant)
Labelling, adhesive label
Driver's seat, seat belt
Lighting, wa
Antistatic belt
Lift and tilt cylinders, tank, valve block,
hoses, pipes, connections
Wheels, tyres
Axle
Engine
rning units
Course of action
Perform a visual inspection for integrity.
Make sure they are clean (also free of ice).
Check for secure mounting.
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.
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 chapterentitled
"Tyres".
Make sure that no consumables are escaping from
the axle.
Check the engine oil level and top up if necessary.
Check the coolant level and top up if necessary.
ice, not slippery).
68011501 EN - 10/2017 69
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4 Operation
Testing and activities before dail
– Do not use the truck if there is any damage
or defects.
– Contact your authorised service centre.
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7368011501 EN - 10/2017
Operation 4
Testing and activities before dail
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Climbing in and out of the truck
WARNING
Risk of injury when climbing in and out of the truck
due to slipping, hitting yourself on 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
becomes stuck o
jumping out of t
injuries (e.g
forbiddentoj
–Donotjumpo
–Donotwearj
– Do not wear
en jumping off the truck!
or jewellery (e.g. watch, ring etc.)
n a component while you are
he truck, this can lead to serious
. from falling, loss of fingers etc.). It is
ump off the truck.
ff 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 devices specifically designed for
the purpose of climbing in and out of the truck.
68011501 EN - 10/2017 71
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4 Operation
Testing and activities before dail
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To assist with climbing in and out of the truck,
the footwell must be used as a step (5) and the
handle (1) must be used for support. The post
oftheoverheadguard(2)canalsobeusedfor
support.
Always climb into the truck in
aforwards
motion:
– Grip the handle (1) 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 (1) 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. It may then not be possible to
brake the truck when necessary.
– Bottles with a maximum size of 0.5 l can be
stored in the cup holder.
– Make sure that stored objects cannot fall from
the shelves when the truck is started up, steered
or braked.
1 2
3
45
7
5
1
5
0
1
2890
8
3
6
15:23
F
1
2
F
3
7321_003-126_V2
1
2
7314_003-050
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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
68011501 EN - 10/2017 73
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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.
yuse
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.
68011501 EN - 10/2017 75
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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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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.
68011501 EN - 10/2017 77
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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
DANGER
Risk of accidents!
Adjusting the st
cause the truck to
– Adjust the steer
at a standstill
– Ensure that t
– Press down an
steering col
– Positionthe steering column (1) and release
the lever.
When the steering column engages, the lever
snaps back to the initial position.
– Gently push and p
to make sure that
engaged.
eering column during travel may
career out of control.
ing column only when the truck is
.
he steering column is engaged.
d hold the lever (2) for
umn adjustment.
ull on the steering column
the steering column is
yuse
3
2
1
7331_342-001
1
2
6210_424-001
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Operation 4
F1
F2
Testing and activities before dail
yuse
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.
– Pull the emergency off switch (1) until it
unlatches.
1
1
F2
F1
Switching on the key switch
WARNIN
All checks and tasks required before daily use must
have been performed without any defects being
identified before switching on the key switch.
– Carry out the checks and tasks that are to be
performed before daily use.
– Do not operate the truck if defects have been
identified.
– Notify your authorised service centre.
G
68011501 EN - 10/2017 79
573
1
7312_003-183
4 Operation
Testing and activities before dail
– Insert the switch key (1) into the key switch
and turn to position "I".
yuse
0
I
1
5060_003-029_V2
Performing this st
lamps in the driveindicators illumi
nate briefly.
ep initiates self testing. All
direction indicators and turn
7312_003-085
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7368011501 EN - 10/2017
Operation 4
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When the key switch is switched on, the
display shows the welcome screen in the set
language.
The truck controller is now fully started up.
If the truck is equipped with t
authorisation with PIN code"
display initially changes
for access authorisation.
Once the truck is ready for operation, the
standard display elements are shown.
he "access
variant, the
to the input menu
Testing and activities before dail
Standard display elements
In the factory setting, the following indicators
can be seen in the display-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 number of operating
hours completed by the truck. The hour
meter operates as soon as the engine is
started.
4 Time
Displays the current
and minutes. The time c
see the chapter entitled
time".
CAUTION
Lack of fuel can cause malfunctions!
If the fuel tank has been run empty, the fuel injection
system can draw in air bubbles. These air bubbles
can lead to malfunctions in the fuel injectionsystem.
– Never run the fuel tank empty.
evel in the fuel tank as a
.
urs
time digitally in hours
an be adjusted;
"Adjusting the
75
%
234,7 h
12:15
1
2
2
3
4
68011501 EN - 10/2017 81
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4 Operation
Testing and activities before dail
NOTE
Additional information may appear on the
display.
– Refer to the information in the chapter
entitled "Display messages".
Access authorisation with PIN code (variant)
Description
Trucks equipped with the "Access authorisation with PIN code" variant are protected
against unauthorised use by a five-digit driver
PIN. Up to fifty different driver PINs can be
defined so that the same truck can be used
by different drivers, each with their own driver
PIN.
NOTE
The driver PINs are defined in a truck control
unit menu that can only be accessed by
persons with the corresponding access
authorisation, e.g. fleet managers.
Once the key switch has been switched on,
the input menu for the driver PIN appears
on the display and operating unit screen. All
of the truck's functions (driving, hydraulics,
additional electrical installations and the
display and operating unit displays) are
blocked. The function of the hazard warning
system (variant) is guaranteed. Enter the fivedigit driver PIN (possible entriesfrom 00000 to
99999) to enable the blocked functions. Once
the correct driver PIN has been entered, the
standard displays are shown. All of the truck
functions are available.
The access authori
in such a way that th
re-entered each ti
truck, in order for th
again.
– Contact the authorised service centre on
this matter.
The first driver PIN is preset to "11111" at the
factory. All others are preset to "0xFFF" but
sation can be configured
e driver PIN has to be
me the driver steps off the
e truck to be operated
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82 5
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Operation 4
Testing and activities before dail
have no function as the highest valid driver
PIN is "99999". Persons with the appropriate
access authorisation, e.g. fleet managers, can
change the driver PINs in the corresponding
menu.
NOTE
yuse
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 or
Softkeys (1). The digits entered for the driver
PIN (2) are not visible but are represented by
circles instead. If the driver PIN entered is
correct, the familiar screen appears with the
standard display, and all truck functions are
available.
68011501 EN - 10/2017 83
573
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
yuse
Defining the driver PIN
NOTE
1
The driver PINs can be defined only by persons with the appropriate access authorisation, e.g. fleet managers. To set the driver
PIN, the fleet manager must access the configuration menu. The configuration menu is
password-protected. After entering the password, the fleet manager can configure general
settings for the truck. To change the password, see the chapter entitled "Changing the
password".
– Push the drive program selection button (1)
and the menu change button (2) at the 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 input using Softkey
(2).
1
ESC
3
126
4
7
5
2
BQ_030_en_V2
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573
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 using S
key
(2).
yuse
1
oft-
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
key
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 using Soft-
(3).
3 2
1
4
BQ_31_en
3
2
BQ_025_en_V3
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Operation 4
8
9
6
7
4
2
0
1
3
5
Testing and activities before dail
yuse
NEW CODE appears in the display.
– Enter the desired driver PIN using the
buttons or Softkeys (5).
The digits entered do not appe
Instead they are represented
ar in the display.
by circles in the
NEW CODE field (6).
CONFIRM appears in the display.
CONFIRM subme
The
the new driver PIN
– Enter the new driver PIN for a second time
in the
CONFIRM field (8) using the buttons
or Softkeys (7).
If the entry matches the new driver PIN
previously entered, the system will accept
the new driver PIN once the last digit has
been entered. The display switches back to
the
ACCESS CODE menu.
Another driver PIN
nu is used to confirm
.
can be defined here.
7
3
8
126
4
9
7
5
0
8
BQ_026_en
68011501 EN - 10/2017 87
573
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 the driver PIN entered in the CONFIRM submenu does not match the driver PIN entered
previously in the
message
The message will then disappe
time. The new driver PIN can be
the
CONFIRM submenu for furt
tion.
NEW CODE submenu, the
INVALID will appear.
yuse
ar after a short
entered in
her confirma-
BQ_023_en_V2
After three incorr
NIED
message appea
ect entries, the
The display switches back to the
CODE
menu. The desired driver PIN must be
re-defined.
rs.
CODE DE-
ACCESS
BQ_024_en_V2
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