Original instructions
Diesel truck
RX70-40
RX70-45
RX70-50
7331 7332 7333 7334
57348011825 EN - 12/2015
Preface
Address of manufacturer and contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. +49 (0) 40 7339-0
Fax: +49 (0) 40 7339-1622
Email: info@still.de
Website: http://www.still.de
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348011825 EN- 12/2015 I
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Table of contents
1 Foreword
List of abbreviations ................................................... 2
Your truck .......................................................... 4
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformit
Information about the documentation ...................................... 7
Documentationscope ................................................. 7
Issue date and topicality o
Copyrightandtrademarkrights ........................................... 8
Explanation of information symbols used . . ................................. 8
Explanation of the cross-
Definitionofdirections ................................................. 9
Schematicviews .................................................... 10
Environmental consider
Packaging ......................................................... 11
Disposal of components and batteries ..................................... 11
y in accordance with Machinery Directive ............... 6
ftheoperatinginstructions ........................... 8
references ....................................... 9
ations .......................................... 11
2 Introduction
Using the truck ...................................................... 14
Proper usage ....................................................... 14
Proper use during towing .............................................. 14
Impermissibleuse ................................................... 14
Placeofuse ........................................................ 15
Usingworkingplatforms ............................................... 16
Residual risk ....................................................... 17
Residual dangers, residual risks ......................................... 17
Specialrisksassociatedwithusingthetruckandattachments ................... 18
Overview of hazards
Danger to employees . . ............................................... 23
andcountermeasures ................................. 20
g
3Safety
Definition of terms used for responsible persons ............................. 26
Operating compan
Specialist .......................................................... 26
Drivers ........................................................... 27
Basic principle
Insurance cover on company premises .................................... 29
Changes and retrofitting ............................................... 29
y .................................................. 26
s for safe operation ....................................... 29
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Table of contents
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Changes to the overhead guard and roof loads . . . ........................... 31
Warning regarding non-original parts ..................................... 31
Damage, defects and misuse of s
Lengthoftheforkarms ................................................ 32
Tyres ............................................................. 33
Medicalequipment ................................................... 34
Exercise caution when handling gas springs and accumulators .................. 35
Safety tests ........................................................ 36
Regular safety inspection o
Checkingthedieselengineemissions ..................................... 36
Truckswithparticlefilters .............................................. 37
Insulationtesting .................................................... 38
Safety regulations for handling consumables ............................... 39
Permissibleconsumables ............................................. 39
Oils .............................................................. 39
Hydraulicfluid ...................................................... 40
Batteryacid ........................................................ 41
Dieselfuel ......................................................... 42
Coolantandcoolingfluid .............................................. 44
Disposalofconsumables .............................................. 44
Emissions ......................................................... 46
afetysystems .............................. 32
fthetruck ..................................... 36
4Overviews
Truck overview ..................................................... 50
Overview of driver’s compartment ........................................ 51
Operating devices a
Display and operating unit . . . .......................................... 52
Operatingdevicesforhydraulicanddrivingfunctions .......................... 53
Doublemini-lever .................................................... 5
Three-waymini-lever ................................................. 55
Four-waymini-lever .................................................. 56
Joystick4Plus ...................................................... 57
Fingertip .......................................................... 58
Identification points .................................................. 59
Overview .......................................................... 59
Nameplate ......................................................... 60
Productionnumber .................................................. 61
StVZO (Road Traf
IV
nd display elements ................................... 52
fic Licensing Regulations) information ....................... 61
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Table of contents
Equipment ......................................................... 62
Accessories ........................................................ 62
5 Operation
Checks and tasks to be carrie
Visualinspections ................................................... 64
Checkingthesidecoverislocked ........................................ 66
Fillingthewashersystem .............................................. 6
Checking the condition of the wheels and tyres .............................. 67
Topping up the coolant and checking the concentration of the coolant additive ....... 68
Checking the engine oil le
AdjustingtheMSG65/MSG75driver’sseat ................................ 70
Adjustingthearmrest ................................................. 74
Adjusting the steering c
Cleaningthedustvalve ............................................... 75
Commissioning ..................................................... 76
Climbing into and out of
Climbingintoandoutofatruckwitharaiseddriver’scab ....................... 77
Shelvesandcupholders .............................................. 79
Unlocking the emergen
Switchingonthekeyswitch ............................................ 80
AccessauthorisationwithPINcode(variant) ................................ 83
Operating the signal h
Seatbelt .......................................................... 93
Usingthedriver’scab ................................................. 96
Starting the engine
Checkingthebrakesystemforcorrectfunction .............................. 99
Checkingthesteeringsystemforcorrectfunction ............................100
Checking the emerge
Zeroadjustmentoftheloadmeasurement(variant) ...........................101
Checking the vertical lift mast position (variant) for correct function . ...............103
Driving ............................................................104
Safety regulations when driving .........................................104
Roadways .........................................................106
Setting the drive p
Actuatingthedrivedirectionswitch,mini-leverversion .........................109
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 109
Actuating the driv
Startingtodrive .....................................................110
Starting drive mode, dual-pedal version (variant) .............................112
................................................... 97
rogrammes ...........................................108
e direction switch, fingertip version ..........................110
d out prior to commissioning ...................... 64
vel ........................................... 69
olumn ........................................... 75
thetruck ........................................ 76
cyoffswitch ...................................... 80
orn .............................................. 92
ncyofffunction .....................................100
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Operatingtheservicebrake ............................................115
Actuating the mechanical parking brake ...................................116
Steering ...........................................................118
Reducing speed with a raised load (variant) ................................119
Automatic shut-off of the internal combustion engine (variant) ...................119
Lifting ............................................................120
Liftingsystemvariants ................................................120
Automaticliftcutout(variant) ...........................................120
Lift mast vertical position
Typesofliftmast ....................................................125
Malfunctionsduringliftingmode .........................................126
Hydraulic blocking functi
Liftingsystemoperatingdevices .........................................128
Controlling the lifting system using a double mini-lever .........................130
Controlling the lifting s
Controlling the lifting system using a quadruple mini-lever ......................132
Controllingtheliftingsystemusingthejoystick4Plus ..........................133
Controlling the lifting
Changing the fork arms ...............................................136
Forkextension(variant) ...............................................138
Operation with reversi
Handling loads ......................................................142
Safety regulations when handing loads ....................................142
Beforetakingupload .................................................14
Loadmeasurement(variant) ...........................................144
Picking up loads .....................................................147
Danger area .......................................................148
Transportingpallets ..................................................149
Transporting suspended loads ..........................................149
Loadpickup ...................................................... . 150
Transporting loads ...................................................154
Setting down loads ...................................................155
Shake function (var
Driving on ascending and descending slopes ...............................160
Drivingonlifts ......................................................161
Drivingonloadingb
Particle filter system ..................................................163
Particlefilter-Function ................................................163
Particlefilter-Pe
Particlefilter-Displays ................................................168
(variant) ........................................121
on .............................................128
ystemusingatriplemini-lever ..........................131
system using the fingertip . . . ...........................135
bleforkarms(variant) ................................140
iant) ...............................................156
ridges .............................................162
rforming parked regeneration . . . ...........................165
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Working with attachments .............................................170
Fittingattachments ..................................................170
Releasing the pressure from th
Generalinstructionsforcontrollingattachments .............................174
Controlling attachments using a double mini-lever ............................176
Controlling attachments usin
Controllingattachmentsusingatriplemini-lever .............................180
Controlling attachments using the triple mini-lever and the 5th function .............182
Controlling attachments us
Controlling attachments using the quadruple mini-lever and the 5th function .........185
Controllingattachmentsviathejoystick4Plus ...............................186
Controlling attachments u
Controlling the attachments with the fingertip ...............................188
Controlling attachments with the fingertip and 5th function ......................189
Clamp locking mechanism (
Takingupaloadusingattachments ......................................195
Operating auxiliary equipment ..........................................196
Switching the lighting o
Switching the rotating beacon on and off . . . ................................197
Switchingthehazardwarningsystemonandoff .............................198
Switching direction in
Switching the double working spotlights on and off. ...........................201
Operatingthewindscreenwiper/washer ...................................203
FleetManager (variant
Accidentrecorder(variant) .............................................204
Driverrestraintsystems(variants) .......................................204
Cab operation ......................................................204
Opening the cab door . . ...............................................204
Closingthecabdoor ............................................... . . 205
Opening the side wind
Closing the side windows ..............................................206
Operating the rear window heating .......................................207
Radio(variant) ......................................................207
Heatingsystem(variant) ..............................................208
Air conditioning (variant) ...............................................209
Trailer operation ....................................................2
Towedload ....................................................... . 210
Coupling pin in the counterweight ........................................211
Automatic tow coup
Towingtrailers ......................................................221
dicatorsonandoff ...................................198
ling ...............................................213
ehydraulicsystem ............................172
g the double mini-lever and the 5th function ...........178
ing a quadruple mini-lever .........................183
singthejoystick4Plusandthe5thfunction ..............187
variant) ......................................191
nandoff .........................................196
) ................................................203
ows .............................................205
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Operating the display and operating unit ...................................223
Displays ..........................................................223
Adjustingthedisplays ................................................224
Symbolsinthedisplay ................................................224
Settingthedateortime ................................................229
Resetting the daily kilometre
Setting the language .................................................230
Soft key button for operating various equipment variants .......................230
Configuring Blue-Q efficienc
Additional settings ...................................................232
Blue-Q efficiency mode ...............................................233
Functionaldescription ................................................23
Effects on additional consumers .........................................233
SwitchingefficiencymodeBlue-Qonandoff ................................234
Display messages ...................................................236
Displaycontent .....................................................236
Errorcodetable .....................................................237
General messages ...................................................239
Drive-specificmessages ..............................................248
Operation in special operating situations ...................................256
Transport ..........................................................256
Towing .......................................................... . 258
Craneloading ......................................................260
Jump-starting ......................................................263
Procedure in emergencies .............................................264
Emergency shutdown ................................................264
Procedure if truck ti
Emergency hammer ..................................................266
Emergency lowering .................................................267
Disconnecting the ba
Refuelling .........................................................270
Dieselfuel-Specifications .............................................270
Filling up with dies
Cleaning ..........................................................276
Cleaning the truck ...................................................276
Cleaning the elect
Cleaning load chains .................................................279
Cleaning the windows ................................................279
Afterwashing .......................................................280
psover .............................................265
elfuel ...............................................274
ricalsystem ..........................................278
s and daily operating hours .......................229
ymode ......................................231
ttery ..............................................269
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Table of contents
Decommissioning ...................................................281
Parkingthetrucksecurely .............................................281
Wheelchock(variant) ................................................282
Shuttingdownandstoringthetruck ......................................282
Recommissioningaftershutdown ........................................284
6 Maintenance
General maintenance infor
Personnel qualifications ...............................................286
Informationforcarryingoutmaintenance ..................................286
Maintenance instruction
Orderingsparepartsandwearingparts ....................................289
Quality and quantity of the required operating materials ........................289
Lubricationplan .....................................................290
Maintenance data table ...............................................291
Intervals for maintenance and inspection ..................................295
Maintenance — 1000 hour
Maintenance - 3000 hours/every two years . ................................299
Safety regulations for maintenance .......................................300
Generalinformation ..................................................3
Workingonthehydraulicequipment ......................................300
Working on the electrical equipment ......................................301
Working on the ignitio
Safetydevices ......................................................302
Setvalues ....................................................... . . 302
Lifting and jacking
Workingatthefrontofthetruck ..........................................302
Providing access to maintenance points ...................................304
Opening the side ser
Closingthesideserviceflap ............................................305
Openingthebonnet ................................................ . . 306
Closing the bonnet
Installingandremovingthebottomplate ...................................307
Maintenance .......................................................309
Cleaning the radia
Replacing the air filter cartridges .........................................309
Drainingwaterfromthefuelfilter .........................................311
Lubricating the j
Checking the door latch ...............................................313
Maintainingtheseatbelt ...............................................313
ointsandcontrols ........................................312
mation ........................................286
s ..............................................289
s/annually .....................................295
nsystem ..........................................301
up .................................................302
viceflap ...........................................304
...................................................307
tor,checkingforleaks ...................................309
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Checkingthedriver’sseat .............................................315
Greasingtheautomatictowcoupling ......................................315
Servicingwheelsandtyres .............................................318
Servicingthebattery .................................................320
Replacingfuses .....................................................322
Lubricating the lift mast and r
ollertrack ....................................322
7 1000 hour maintenance/ann
Other tasks ........................................................324
Checking the hydraulic system for leaks ...................................324
Checking the hydraulic oi
Checking the lift cylinders and connections for leaks ..........................326
Checking the fork arms ................................................326
Checking the reversibl
l level ..........................................325
e fork arms ........................................327
ual maintenance
8 Technical data
Dimensions ........................................................330
VDI datasheet ......................................................332
Fuse assignment ....................................................335
X5
7348011825 EN - 12/2015
1
Foreword
1 Foreword
List of abbreviations
List of abbreviations
NOTE
This list of abbreviations applies to all types
of operating instructions. Not all of the abbreviations that are listed here will necessarily
appear in these operating instructions.
Abbreviation
°C
°F
A
ABE
ArbSchG
BetrSichV
BG
BGG
BGR
German Social
Accident
Insurance
Approx.
CE
CEE
cm
3
cm
dB Decibels
DFÜ
DIN
EG
EN
FEM
F
max
g
GAA
Meaning
Degrees Celsius
Degrees Fahrenheit
Amperes
Display operating unit
German labour protec
German Ordinance on Industrial Safety and Health
Employers’ liability insurance association
Employers’ liability insurance association act
Employers’ liability insurance association rule
Employers’ liability insurance association regulation
Approximately
Symbol that confirms conformity with the valid product-specific European
directives
International Commission on the Rules for the Approval of Electrical Equipment
Centimetres
Cubic centimetres
Remote data transmission
German standard
European Community
European standard
Fédération Européene de la Manutention
Maximum power
Grams
trial inspectorate
Indus
tion law
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7348011825 EN - 12/2015
Foreword 1
List of abbreviations
Abbreviation
Meaning
If applicable If applicable
GPRS General Packet Radio Service
h/d
Hours per day (time driven each day in hours)
ID no. ID number
ISO
International standard
kg Kilograms
3
kg/m
km/h
km/d
Kilograms per cubic metre
Kilometres per hour
Kilometres per day (kilometres driven each day)
kN Kilonewtons
kW Kilowatts
kWh/h
Energy consumption
lLitres
l/h
l/min
LAN Local area ne
LED
L
p
L
pAZ
LSP
o.s.
m
m/s
2
m/s
MAK
Litres per hour
Litres per minute
twork
Light emitting diode
Sound pressure level
Continuous sound pressure level in driver’s compartment
Load centre of gravity
Or similar
Metres
Metres per second
Metres per second squared
Maximum workplace concentration
Max. Maximum
Min. Minimum
min Minutes
rpm
mm
Revolution(s) per minute
Millimetres
N Newtons
Nm New
ton metres
348011825 EN - 12/2015 3
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1 Foreword
Your truck
Abbreviation
PIN
SE
SIT
StVZO
t
TRGS
a.s.
VVolts
VDE
VDI
VDMA
W Watts
WLAN Wireless local area network
e.g.
.
Meaning
Personal identification number
Superelastic
Snap-in tyre for simplified ass
German Road Traffic Licensing
Tonnes
Technical Regulations fo
And similar
Association for Electr
Association of Germa
German Engineering
For example
ical, Electronic & Information Technologies
n Engineers
Federation
Your truck
General
The truck des
tions corre
and safety r
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 oper
necessary
observe th
commissio
accidents
remains va
cribed in these operating instruc-
sponds to the applicable standards
egulations.
ating instructions provide the
information to do this. Read and
e information provided before
ning the truck. This will prevent
and ensure that the warranty
lid.
embly
Regulations
r Hazardous Substances
45
7348011825 EN - 12/2015
Foreword 1
Your truck
CE labelling
The manufacturer uses CE labelling to indicate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of confo
carefully stored and made a
responsible authorities.
rmity must be
vailable to the
CE-Symbol
348011825 EN - 12/2015 5
57
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
.
65
H
7348011825 EN - 12/2015
Foreword 1
Information about the documentati
on
Information about the documentation
Documentation scope
• Original operating instructions
• Original operating instructions for attachments (variant)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all measures necessary for the safe operation and
proper maintenance of your truck in all possible variants available at the time of printing.
Special versions to meet customer requirements are documented in separate operating
instructions. If you have any questions, please
contact your authorised service centre.
Enter the production num
manufacturer from the na
provided:
Production number
...............................................
Year of manufacture
...................................................
Please quote the produ
technical enquiries.
Each truck comes with a set of operating
instructions. These instructions must be
stored carefully and must be available to the
driver and operatingcompany at any time. The
storage location isspecified in the "Overviews"
chapter.
If the operating instructions are lost, the
operator must obtain a replacement from the
manufacturer immediately.
The operating instr
spare parts list and
a spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company must ensure that all
users have received, read and understood
these operating instructions.
ber and year of
meplate in the space
ction number during all
uctions are included in the
can be reordered there as
348011825 EN - 12/2015 7
57
1 Foreword
Information about the documentati
NOTE
Please observe the definition o
responsible persons: "operat
ing company"
and "driver".
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any errors, please contact
the authorised service centre.
Issue date and topicality of the operating instructions
The issue date of these operating instructions
can be found on the title page.
STILL is constantly engaged in the further
development of trucks. These operating
instructions are subject to change, and any
claims based on the information and/or
illustrations contained in them cannot be
asserted.
Please contact your au
for technical support
thorised service centre
relating to your truck.
on
f the following
Copyright and tradem
These instruction
translated or made
ties—including as
express written ap
s must not be reproduced,
excerpts—except with the
proval of the manufacturer.
Explanation of in
ark rights
accessible to third par-
formation symbols
used
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures that must be strictly adhered
to in order to prevent the risk of injuries.
85
7348011825 EN - 12/2015
Foreword 1
on
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
NOTE
Information about the documentati
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to a section: ⇒ Chapter "Explanation of the cross-references",P.1-9
• Cross reference to a chapter: ⇒ Chapter "Definition of terms used for responsible
persons", P. 26
Definition of directions
The directions "forwards" (1), "backwards" (3),
"right" (2) and "left" (4) refer to the installation
position of the parts as seen from the driver’s
compartment; the load is to the front.
348011825 EN - 12/2015 9
57
1
4
2
3
6210_001-031
1 Foreword
Information about the documentati
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.
View of the display operating unit
NOTE
Views of operating statuses and values in
the display of the display operating unit are
examples and partly dependent on the truck
equipment. As a result, the displays shown
of the actual operating statuses and values
can vary. Information that is not relevant for
descriptions is not shown.
on
6210_003-062
10
57348011825 EN - 12/2015
Foreword 1
Environmental considerations
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material mu
properly after delivery o
st be disposed of
f the truck.
Disposal of component
s and
batteries
The truck is composed
components or batter
and disposed of, they
• disposed of,
• treated or
• recycled in accorda
national regulatio
NOTE
The documentation provided by the battery
manufacturer must be observed when disposing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste management company for disposal purposes.
of different materials. If
ies need to be replaced
must be:
nce with regional and
ns.
348011825 EN - 12/2015 11
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1 Foreword
Environmental considerations
12
57348011825 EN - 12/2015
2
Introduction
2 Introduction
Using the truck
Using the truck
Proper usage
The truck described in these operating instructions is suitable for lifting, transporting
and stacking loads.
The truck may only be used for its proper
purpose as set out and described in these
operating instructions.
If the truck is to be used for
than those specified in the o
tions, the approval of the m
applicable, the relevant r
must be obtained beforeha
ards.
The maximum load to be lifted is specified on
the capacity rating plate (load diagram) and
must not be exceeded; see also the chapter
entitled "Before picking up a load".
Proper use during towing
This truck is suitable for the occasional towing
of trailers and is equipped with a towing device
for this purpose. This occasional towing may
not exceed 2% of the daily operating time. If
the truck is to be used for towing on a more
regular basis, the manufacturer should be
consulted.
The regulations regarding trailer operation
must be observed; see chapter "Trailer
operation".
purposes other
perating instruc-
anufacturer and, if
egulatory authorities
nd to prevent haz-
Impermissible use
The operating company or driver, and not the
manufacturer, is liable for any hazards caused
by improper use.
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "driver".
Use for purposes other than those described
in these operating instructions is prohibited.
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57348011825 EN - 12/2015
Introduction 2
Using the truck
DANGER
There is a risk of fatal injury from
falling off the truck while it is moving!
– It is prohibited to carry passengers
on the truck.
The truck may not be operated in areas where
there is a risk of fire, explosion or corrosion, or
in areas that are particularly dusty.
Stacking or unstacking is not permissible on
inclined surfaces or ramps.
Place of use
The truck can be used outdoors.
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.
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 adequate load
capacity (concrete, asphalt) and a rough
surface. Routes, working areas and aisle
widths must conform to the specifications in
these operating instructions; see the chapter
entitled "Routes".
Driving on upward and downward gradients
is permitted provided the specified data and
specifications are observed; see the chapter
entitled "Routes".
The truck is suitable for use in many different
countries, ranging from those situated in the
Tropics to those in Nordic regions (temperature range: -20°C to +40°C).
This truck is not designed to be operated in
cold stores.
The operating company must ensure suitable
fire protection for the relevant application in
348011825 EN - 12/2015 15
57
2 Introduction
Using the truck
the truck’s surroundings. Depending on the
application, additional fire protection must be
provided on the truck. If in doubt, contact the
relevant authorities.
NOTE
Please observe the definition of the following
responsible person: "operating company".
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.
16
57348011825 EN - 12/2015
Introduction 2
Residual risk
Residual risk
Residual dangers, residual risks
Despite careful working and compliance with
standards and regulations, the occurrence
of other risks when using the truck cannot be
entirely excluded.
The truck and all other system components
comply with current safety requirements.
Nevertheless, even when the truck is used
for its proper purpose and all instructions
are followed, some residual risk cannot be
excluded.
Even beyond the narrow dan
truck itself, a residual r
Persons in this area aroun
exercise a heightened deg
so that they can react imme
of any malfunction, incid
WARNING
All persons that are in the vicinity of the truck
must be instructed regarding these risks that arise
through use of the truck.
In addition, we draw attention to the safety regulations in these operating instructions.
ger areas of the
isk cannot be excluded.
d the truck must
ree of awareness,
diately in the event
ent or breakdown etc.
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
348011825 EN - 12/2015 17
57
2 Introduction
Residual risk
The manufacturer is not held responsible for
accidents involving the truck caused by the
failure of the operating company to comply
with these regulations either intentionally or
carelessly.
Stability
The stability of the truck has been tested to the
latest technological standards and is guaranteed provided that the truck is used properly
and according to its intended purpose. These
standards only take into account the dynamic
and static tipping forces that can arise during
specified use in accordance with the operating rules and intended purpose. However, the
danger of exceeding the moment of tilt due to
improper use or incorrect operation and losing
stability can never be excluded.
The loss of stability can b
imised by the following ac
– Always secure the load against slipping,
e.g. by lashing.
– Always transport unstable loads in suitable
containers.
– Always drive slowly whe
– Drive with the load lowered.
– Even with sideshifts, align the load as
centrally as possible with the truck and
transport in this position.
– Avoid turning and dia
slopes or gradients.
– Never have the load facing downhill when
travelling on slopes or gradients.
– Pick up only loads of the approved width.
– Always take great ca
suspended loads.
– Do not drive over ramp edges or steps.
e avoided or mintions:
n cornering.
gonally driving across
re when transporting
Special risks associated with using the truck and attachments
Approval from the manufacturer and attachment manufacturer must be obtained each
18
57348011825 EN - 12/2015
Introduction 2
Residual risk
time the truck is used in a manner that falls
outside the scope of normal use, and in cases
where the driver is not certain that he can use
the truck correctly and without the risk of accidents.
348011825 EN - 12/2015 19
57
2 Introduction
Residual risk
Overview of hazards and countermeasures
NOTE
This table is intended to help evaluate the
hazards in your facility and applies to all drive
types. It does not claim to be complete.
– Observe the national regulations for the
country in which the truck is being used.
Hazard Measure
Truck equipment does
not comply with local
regulations
Lack of skills and
qualification of driver
Usage by unauthorised persons
Truck not in a safe
condition
Risk of falling when
using working
platforms
Impaired visibility due
to load
Contamination of
respiratory air
Test
Driver training (sit-on
and stand-on)
Access with key only
for authorised persons
Recurrent testing and
rectification of defects
Compliance with
national regulations
(different national
laws)
Resource planning
Assessment of diesel
exhaust gases
Assessment of LPG
exhaust gases
Check note
√ Complete
- Not applicable
O If in doubt, consult
O BGG 925
O
O German Ordinance on
O German Ordinance on
O German Ordinance on
O
O German threshold
Notes
competent factory
inspectorate or
employers’ liability
insurance association
VDI 3313 driver permit
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
and employer’s
liability insurance
associations
Industrial Safety and
Health (BetrSichV)
Technical Regulations
for Hazardous
Substances (TRGS)
554 and the German
Ordinance on
Industrial Safety and
Health (BetrSichV)
limit values list
(MAK-Liste) and the
German Ordinance on
Industrial Safety and
Health (BetrSichV)
20
57348011825 EN - 12/2015
Introduction 2
Residual risk
Hazard Measure
Impermissible usage
(improper usage)
When fuelling
a) Diesel Note the German
b) LPG Note German Social
Issuing of operating
instructions
Written notice of
instruction to driver
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Accident Insurance
(DGUV) regulation
D34, the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Check note
√ Complete
- Not applicable
O German Ordinance on
O German Ordinance on
O
O
O
Notes
Industrial Safety and
Health (BetrSichV)
and German Health
and labour protection
law (ArbSchG)
Industrial Safety and
Health (BetrSichV)
and German Health
and labour protection
law (ArbSchG)
348011825 EN - 12/2015 21
57
2 Introduction
Residual risk
Hazard Measure
When charging the
traction battery
When using battery
chargers
When parking LPG
trucks
With driverless transport systems
Roadway quality
inadequate
Load carrier
incorrect/slipped
Drive behaviour
unpredictable
Driveways blocked Mark driveways
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
the operating
instructions and the
German Engineering
Federation (VDMA)
rules
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers’ liability
insurance association
regulation 104 and the
operating instructions
Note the German
Ordinance on
Industrial Safety and
Health (BetrSichV),
employers’ liability
insurance association
regulation 104 and the
operating instructions
Clean/clear driveways O German Ordinance on
Reattach load to pallet
Employee training
Keep driveways clear
Check note
√ Complete
- Not applicable
O Association for
O German Ordinance on
O German Ordinance on
O German Ordinance on
O German Ordinance on
O German Ordinance on
Notes
Electrical, Electronic
and Information
Technologies (VDE)
regulation 0510: In
particular
- Ensure adequate
ventilation
- Insulation value
within the permissible
range
Industrial Safety and
Health (BetrSichV)
and employers’
liability insurance
association regulation
104
Industrial Safety and
Health (BetrSichV)
and employers’
liability insurance
association regulation
104
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
22
57348011825 EN - 12/2015
Introduction 2
Residual risk
Hazard Measure
Driveways intersect
Announce right-ofway rule
No person detection
Employee training
during depositing and
retrieval
.
Danger to employees
According to the German Ordinance on Industrial Safety and Health (BetrSichV) and labour
protection law (ArbSchG), the operating company must determine and assess hazards
during operation, and establish the labour
protection measures required for employees (BetrSichVO). The operating company
must therefore draw up appropriate operating
instructions (§ 6 ArbSchG) and make them
available to the driver. A responsible person
must be appointed.
NOTE
Please observe t
responsible per
and "driver".
The construction and equipment of the
truck correspond to the Machinery Directive
2006/42/EC and are therefore marked with
CE labelling. These elements are therefore
not included in the hazard assessment. Attachments possess their own CE labelling and
likewise are not included for that reason. The
operating company must, however, select the
type and equipment of the trucks so as to comply with the local provisions for deployment.
The result must be documented (§ 6 ArbSchG). In the case of truck applications involving similar hazard situations, the results may
be summarised. This overview (see chapter
"Overview of hazards and countermeasures")
provides help on complying with this regulation. The overview specifies the main hazards
that are the most frequent cause of accidents
in the event of non-compliance. If other major
he definition of the following
sons: "operating company"
Check note
√ Complete
- Not applicable
O German Ordinance on
O German Ordinance on
Notes
Industrial Safety and
Health (BetrSichV)
Industrial Safety and
Health (BetrSichV)
348011825 EN - 12/2015 23
57
2 Introduction
Residual risk
operational hazards are involved, they must
also be taken into consideration.
The conditions of use for trucks are broadly
similar in many plants, so the hazards can
be summarised in one overview. Observe
the information provided by the relevant
employers’ liability insurance association on
this subject.
24
57348011825 EN - 12/2015
3
Safety
3 Safety
Definition of terms used for respons
ible persons
Definition of terms used for 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
26
57348011825 EN - 12/2015
Safety 3
Definition of terms used for respons
regarding the industrial truck to be tested
and the risk being assessed
ible persons
Drivers
This truck may only be driven by suitable persons who are at least 18 years of age, have
been trained in driving, have demonstrated
their skills in driving and handling loads to
the operating company or an authorised representative, and have been specifically instructed to drive the truck. Specific knowledge
of the truck to be operated is also required.
The training requirements under §3 of the
Health and Safety at Work Act and §9 of the
plant safety regulations are deemed to have
been satisfied if the driver has been trained in
accordance with BGG (General Employers’
Liability Insurance Association Act) 925.
Observe the national regulations for your
country.
Driver rights, duties and rules of behaviour
The driver must be trai
duties.
The driver must be granted the required rights.
The driver must wear protective equipment
(protection suit, safety footwear, safety
helmet, industrial goggles and gloves) that
is appropriate for the conditions, the job and
the load to be lifted. Solid footwear should be
worn to ensure safe driving and braking.
Thedrivermustbefa
instructions and ha
times.
The driver must:
• have read and understood the operating
manual
• have familiarised himself with safe operation of the truck
• be physically and m
truck safely
ned in his rights and
miliar with the operating
ve access to them at all
entally able to drive the
348011825 EN - 12/2015 27
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3 Safety
Definition of terms used for respons
DANGER
The use of drugs, alcohol or medications that affect
reactions impair the ability to drive the truck!
Individuals under the influence of the aforementioned substances are not permitted to perform work
of any kind on or with the truck.
Prohibition of use by unauthorised
persons
The driver is responsible for the truck during
working hours. He must not allow unauthorised persons to operate the truck.
When leavingthe truck, the driver must secure
it against unauthorised use, e.g. by pulling out
the key.
ible persons
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57348011825 EN - 12/2015
Safety 3
Basic principles for safe operatio
Basic principles for safe operation
Insurance cover on company premises
In many cases, company premises are
restricted public traffic areas.
NOTE
The business liability insurance should be
reviewed to ensure that, in the event of any
damage caused in restricted public traffic
areas, there is insurance cover for the truck in
respect of third parties.
Changes and retrofitting
If the truck is used for work that is not listed
in the guidelines or in these instructions and
has to be converted or retrofitted accordingly,
you must note that any change to its structural
state can affect the handling and stability of
the truck, which in turn can lead to accidents.
You should therefor
centre beforehand.
Changes that will adversely affect stability,
load capacity and safety systems, among
other things, must not be made without the
manufacturer’s approval.
Thetruckmayonlybeconvertedwithwritten
approval from the manufacturer. Approval
from the responsible authority must be obtained if necessary.
Changes to the bra
elements, circum
variants and atta
made without the p
manufacturer.
We warn against installing and using restraint
systems not approved by the manufacturer.
e contact your service
kes, steering, control
ferential view, equipment
chments must also not be
rior written approval of the
n
348011825 EN - 12/2015 29
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3 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 trucktips over. This riskof injury canbe
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 tothe driver’s life, as hemay 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
30
57348011825 EN - 12/2015
Safety 3
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 fallingloads or the truck tippingover 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 regardingnon-original parts
Original parts, attachments and accessories
are specially designed for this truck. We
specifically draw your attention to the fact that
parts, attachments and accessories supplied
by other companies have not been tested and
approved by STILL.
348011825 EN - 12/2015 31
57
3 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 attachments thatare notfunctional
or safe to drive may notbe useduntil theyhave
been properly repaired.
Do not remove or deactivate safety systems
and switches.
Fixed set values may only be changed with the
approval of the manufacturer.
Work on the electricalsystem (e.g. connecting
a radio, additional headlights etc.) is only
permitted with the manufacturer’s written
approval. All electrical system interventions
must be documented.
Even if they are removable, roof panels may
not be removed, as they are designed to
protect against small falling objects.
n
Length of the fork arms
DANGER
Risk of accident due to the incorrect selection of
fork arms!
– The fork arms must match the depth of the load.
If the fork arms are too short, the load may
fall off the arms after it has been picked up.
In addition, be aware that the load centre of
32
57348011825 EN - 12/2015
Safety 3
Basic principles for safe operatio
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 thec
contact the authorised serv
orrect forkarms,
ice centre.
Tyres
DANGER
Risk to stability!
Failure to observe the following information and
instructions can lead to a loss of stability. The truck
may tip over, risk of accident!
Thefollowingfactorscanleadtoalossof
stability and are therefore prohibited:
• Different tyres on the same axle, e.g.
pneumatic tyres and superelastic tyres
• Tyres not approved by the manufacturer
• Excessive tyre wear
• Tyres of inferior quality
• Changing rim wheel parts
• Combining rim wheel parts from different
manufacturers
The following rules must be observed to
ensure stability:
• Only use tyres with equal and permitted
levels of wear on the same axle
• Only use wheels and tyres of the same type
on the same axle, e.g. only superelastic
tyres
• Only use wheels and tyres approved by the
manufacturer
• Only use high-quality products
Wheels and tyres approved by the manufacturer can be found on the spare parts list.
If other wheels or tyres are to be used, authorisation from the manufacturer must be
obtained beforehand.
n
348011825 EN - 12/2015 33
57
3 Safety
Basic principles for safe operatio
– 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.
Ifthetypeoftyreusedonana
for example from superelast
matic tyres, the load diagra
accordingly.
– Contact the authorised service centre on
this matter.
ic tyres to pneu-
m must bechanged
Medical equipment
WARNING
Electromagneticinterference may occur on medical
devices!
Only use equipment that is sufficiently protected
against electromagnetic interference.
Medical equipment, such as pacemakers or
hearing aids, may not work properly when the
truck is in operation.
– Ask your doctor or the manufacturer of
the medical equipment to confirm that the
medical equipment is sufficiently protected
against electromagnetic interference.
n
xle is changed,
34
57348011825 EN - 12/2015
Safety 3
Basic principles for safe operatio
Exercise caution when handling gas springs and accumulators
WARNING
Gas springs are under high pressure. Improper
removal results in an elevated risk of injury.
For ease of operation, various functions on the
truck can be supported bygas springs. Gas springs
are complex components that are subject to high
internal pressures (up to 300 bar). They may under
no circumstances be opened unless instructed to
do so, and may be installed only when not under
pressure. If required, the authorised service centre
will depressurise the gas spring in accordance with
the regulations before removal. Gas springs must
be depressurised before recycling.
– Avoid damage, lateral forces, buckling, tempe-
ratures over 80°C and heavy contamination.
– Damaged or defective gas springs must be
changed immediately.
– Contact the authorised service centre.
WARNING
Accumulators are under high pressure. Improper
installation of an accumulator results in an elevated
risk of injury.
Before starting work on the accumulator it must be
depressurised.
– Contact the authorised service centre.
n
348011825 EN - 12/2015 35
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3 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
terms used for responsible persons", P. 26)
and must be recorded in writing.
– Contact your ST
36
ILL service centre.
57348011825 EN - 12/2015
Safety 3
Safety tests
NOTE
Observe the national regulati
ons for your
country!
Trucks with particle filter
Trucks with particle filte
operated in entirely or pa
s
rs (variant) may be
rtially 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 left
running, there is a risk of poisoning due to the CO,
CH and NO
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 fitted with an internal combustion
engine in entirely or partially enclosed working
areas.
– Always ensure sufficient ventilation.
components present in the exhaust
x
NOTE
Observe the national regulations of the
country in which the truck is being used!
The operating company must ensure that
the following requirements are met; see
chapter entitled "Definition of terms used for
responsible persons":
• Usage must be reported to the responsible
occupational 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 mustbe madeaware of dangers
and protective measures.
• The particle filter must be changed every
6000 operating hours. The exhaust-gas
348011825 EN - 12/2015 37
57
3 Safety
Safety tests
check must be carried out by a specialist
(see chapter entitled "Definition of terms
used for responsible persons") and must be
recorded in writing.
NOTE
Observe the TRGS 554 regula
national regulations of th
truck is being used.
Insulation testing
The truck insulation mus
lation resistance. For
testing in accordance w
DIN 43539, VDE 0117 and V
conducted at least once
NOTE
Contact your service centre to arrange for an
insulation test.
Measuring the insulation resistance of
the electrical system
tions and the
e country in which the
t have sufficient insu-
this reason, insulation
ith DIN EN 1175 and
DE 0510 must be
every year.
NOTE
Nominal battery voltage < test voltage < 500 V.
– Ensure that all voltage sources have been
disconnected from the circuit to be tested.
– Measure the insulation resistance with a
suitable measuring device.
The insulation resistance can be considered
sufficient if it measures at least 1000
nominal battery voltage against ground.
– Contact the authorised service centre.
38
/V for
57348011825 EN - 12/2015
Safety 3
Safety regulations for handling co
nsumables
Safety regulations for handling consumables
Permissible consumables
DANGER
Failure to observe the safety regulations relating to
consumables may result in a risk of injury, death or
damage to the environment.
– Observe the safety regulations when handling
such materials.
Refer to the maintenance data table for the
permissible substances that are necessary for
operation (see ⇒ Chapter "Maintenance data
table", P. 6-291).
Oils
DANGER
Oils are flammable!
– Follow the statutory regulations.
– Donotallowoilstocomeinto
contact with hot engine parts.
– No smoking, fires or naked flames!
DANGER
Oils are toxic!
– Avoid contact and consumption.
– If vapour or fumes are inhaled,
move to fresh air immediately.
– In the event of contact with the
eyes, rinse thoroughly (for at least
10 minutes) with water and then
consult an eye specialist.
– If swallowed, do not induce
vomiting. Seek immediate medical
attention.
348011825 EN - 12/2015 39
57
3 Safety
Safety regulations for handling co
WARNING
Prolonged intensive contact with the
skin can result in dryness and irritate
the skin!
– Avoid contact and consumption.
– Wear protective gloves.
– After any contact, wash the skin
with soap and water, and then
apply a skin care product.
– Immediately change soaked
clothing and shoes.
WARNING
There is a risk of slipping on spilled oil, particularly
when combined with water!
– Spilt oil should be removed immediately with
oil-binding agents and disposed of according to
the regulations.
ENVIRONMENT NOTE
Oil is a water-polluting substance!
•
Always store oil in containers that comply
with the applicable regulations.
•
Avoid spilling oils.
•
Spilt oil should be removed immediately
with oil-binding agents and disposed of
according to the regulations.
•
Dispose of old oils according to the regulations.
nsumables
Hydraulic fluid
These fluids are pressurised during
operation of the truck and are
hazardous to your health.
– Do not spill the fluids.
– Follow the statutory regulations.
– Do not allow the fluids to come into
contact with hot engine parts.
40
WARNING
57348011825 EN - 12/2015
Safety 3
nsumables
WARNING
These fluids are pressurised during
operation of the truck and are
hazardous to your health.
– Do not allow the fluids to come into
contact with the skin.
– Avoid inhaling spray.
– Penetration of pressurised
fluids into the skin is particularly
dangerous if these fluids escape
at high pressure due to leaks in
the hydraulic system. In case of
such injury, immediate medical
assistance is required.
– To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).
ENVIRONMENT NOTE
Safety regulations for handling co
Hydraulic fluid is a water-polluting substance.
•
Always store hydraulic fluid in containers
that comply with regulations
•
Avoid spills
•
Spilt hydraulic fluid should be removed
immediately with oil-binding agents and
disposed of according to the regulations
•
Dispose of old hydraulic fluid according to
the regulations
Battery acid
Battery acid contains dissolved
sulphuric acid. This is toxic.
– Avoid touching or swallowing the
– In case of injury, seek medical
WARNING
battery acid at all costs.
advice immediately.
348011825 EN - 12/2015 41
57
3 Safety
Safety regulations for handling co
WARNING
Battery acid contains dissolved
sulphuric acid. This is corrosive.
– When working with battery acid,
always wear a protection suit and
eye protection.
– When working with battery
acid, never wear a watch or any
jewellery.
– Do not allow any acid to get
onto clothing or skin or into the
eyes; if this does happen, rinse
immediately with plenty of clean
water.
– In case of injury, seek medical
advice immediately.
– Immediately rinse away spilt
battery acid with plenty of water.
– Follow the statutory regulations.
ENVIRONMENT NOTE
– Dispose of used battery acid in line with the
applicable regulations.
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!
42
57348011825 EN - 12/2015
Safety 3
nsumables
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.
WARNING
Prolonged intensive contact with the
skin can result in loss of skin oils and
can irritate the skin!
– Avoid contact and swallowing.
– Wear protective gloves.
– After any contact, wash the skin
with soap and water, and then
apply a skin care product.
– Immediately change soaked
clothing and shoes.
Safety regulations for handling co
WARNING
Risk of slipping dueto spilled diesel fuel,particularly
in combination with water.
– Immediately collect spilled diesel fuel using an
oil-binding agent and dispose of it in accordance
with regulations.
ENVIRONMENT NOTE
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.
348011825 EN - 12/2015 43
57
3 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 coolant or cooling fluid in
accordance with the national regulations for
the country of use.
nsumables
Disposal of consumables
ENVIRONMENT NOTE
Materials that accumulate during repair,
maintenance and cleaning must be collected
properly and disposed of in accordance with
the national regulations for the country in
which the truck is being used. Work must
only be carried out in areas designated for the
purpose. Care must be taken to minimise any
environmental pollution.
– Soak up any spilt fluids such as hydraulic
oil, brake fluid or gearbox oil using an
oil-binding agent.
44
57348011825 EN - 12/2015
Safety 3
Safety regulations for handling co
– Neutralise any spilt battery acid immedi-
ately.
– Always observe national regulations con-
cerning the disposal of used oil.
nsumables
348011825 EN - 12/2015 45
57
3 Safety
Emissions
Emissions
The values specified apply to a standard truck
(see technical datasheet). Different tyres,
lift masts, additional units etc. may produce
different values.
Noise emissions
The values were determined on the basis of
measuring procedures from the EN 12053
standard (noise measurement for industrial
trucks based on EN 12001 and EN ISO 3744
and the requirements of EN ISO 4871).
Continuous sound pressure level in driver’s
compartment
1
L
pAZ
Uncertainty K
1
: higher continuous sound pressure level with
pA
< 75 dB(A)
4 dB(A)
cab/without cab
The values were dete
on an identical mach
values for operatin
rmined in the test cycle
ine from the weighted
g statuses and idling.
Time proportions:
• Lifting 18%
• Idling 58%
• Driving 24%
However, the specifiednoise levels in the truck
cannot be used to determine the noise emissions in the workplace in accordance with the
most recent version of Directive 2003/10/EC
(daily personal noise pollution). If necessary,
these should be determined directly at the
workplace under the actual conditions there
(additional noise sources, special application
conditions, sound reflections) by the operating
company; (see ⇒ Chapter "Definition of terms
used for responsible persons", P. 26).
Vibrations
The vibrations o
determined on an
cordance with th
"Safety of indus
for measuring vi
f the machine have been
identical machine in ac-
e standards DIN EN 13059
trial trucks - Test methods
bration" and DIN EN 12096
"Mechanical vibration - Declaration and verification of vibration emission values".
Weighted effective value
of acceleration to which
the body (feet or seat
< 0.59 m/s
surface) is subjected
Uncertainty K
Tests have indicated that
hand and arm vibrations on
or on the controls in the tr
2
m/s
. There are therefore
guidelines for these mea
surements.
0.177 m/s
the amplitude of the
the steering wheel
uck is less than 2.5
no measurement
The personal vibration load on the driver over
a working day shall be determined in accordance with the Directive 2002/44/EC by the
operating company (see ⇒ Chapter "Definition
of terms used for responsible persons", P. 26)
at the actual place of use, in order to consider
all additional influences, such as driving route,
intensity of use etc.
Exhaust gases
CAUTION
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 engineis left
running, there is a risk of poisoning due to the CO,
CH and NO
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
usingtrucksfittedwithaninternalcombustion
engine in entirely or partially enclosed working
areas.
– Always ensure sufficient ventilation.
The engine releases exhaust gases into the
surrounding environment during operation.
The exhaust gases consist mainly of steam,
carbon dioxide (CO
hydrocarbons (CH), aldehydes, nitrogen oxide
components present in the exhaust
x
), carbon monoxide (CO),
2
2
2
46
57348011825 EN - 12/2015
Safety 3
Emissions
(NOX) and soot. The components CO, CH,
NO
and soot are poisonous or are health
X
hazards, and should not be inhaled at high
concentrations.
Diesel engine emissions
DANGER
Health risk as a result of inhaling exhaust gases
that have not been filtered!
A particle filter (exhaust gas purifier for diesel
engines) can be used to clean exhaust gases so
that during truck operation there is no direct health
risk or risk of poisoning as a result of the exhaust
gas.
– In working areas that are fully or partially enclo-
sed, only operate the truck with the particlefilter.
Diesel engine emissions are harmful to
your health. The particles contained in the
exhaust gases in particular are classified as
carcinogenic.
NOTE
Observe the national regulations for your
country.
Heat
Battery
DANGER
Risk of burns caused by hot exhaust
gases!
Exhaust gases or components that
carry exhaust gases (e.g. exhaust
pipes) can become so hot that direct
body contact can cause burns to the
skin and materials that are too close
can be burned or singed.
– Do not grasp or touch hot exhaust
pipes.
– Keep combustible materials away
from the exhaust pipe.
– In the event of burns, seek first aid
immediately.
– If materials start to burn, take fire
protection measures immediately.
DANGER
Risk of explosion due to flammable
gases!
During charging, the battery releases
a mixture of oxygen and hydrogen
(detonating gas). This gas mixture is
explosive and must not be ignited.
– Make sure that there is always
sufficient ventilation in working
areas that are fully or partially
enclosed.
– Keep away from open flames and
flying sparks.
– Observe the safety regulations for
handling the battery.
348011825 EN - 12/2015 47
57
3 Safety
Emissions
48
57348011825 EN - 12/2015
4
Overviews
4 Overviews
Truck overview
Truck overview
1
10
9
8
1Liftmast
2 Overhead guard
3 Driver’s compartment
4 Towing device
5 Steering axle
2
3
4
7
6
5
6 Fuel tank locking cap
7 Bonnet
8Driveaxle
9 Fork arms
10 Fork carriage
7331_003-001
50
57348011825 EN - 12/2015
Overviews 4
Overview of driver’s compartment
Overview of driver’s compartment
1 Parking brake lever
2 Steering wheel
3 Key switch
4 Display and operating unit
5 Compartment for the operating instructions
6 Operating devices for hydraulic and drive
functions
7 Compartment
OTE
N
he truck equipment may differ from the
T
quipment shown.
e
348011825 EN - 12/2015 51
57
8 Bottle holder for max. 1.5 l bottles
9 Driver’s seat
10 Compartment
11 Filler cap for windscreen washer reservoir
12 Accelerator pedal
13 Brake pedal
14 Steering column adjustment lever
4 Overviews
4
Operating devices and display elem
ents
Operating devices and display elements
Display and operating unit
4
3
56
2
1
3
1
2
6
9
7
5
26
25
21
20
7314_003-043
1 Hazard warning system button
2 Front windscreen wiper button
3 Working spotlight button
4 Drive programme selector button
5 Lighting button
6 Lighting symbol
7 Not assigned
8 Fuel level display (percentage)
9 Drive programme display (numerical)
10 Left turn indicator display
11 Forward travel indicator
12 Right turn indicator display
13 Malfunction display
14 Reverse travel indicator
24
22
23
7
8
0
75
%
2
234,7 h
12:15
8
9
10
11
12
13
1
15
19
17
18
15 Operating hours display
16 Time display (digital)
17 Particle filter display
18 Rotating beacon display
19 Interior lighting display
20 Rear window heating display
21 Interior lighting/rotating beacon button
22 Rear window heating/particle filter regener-
ation button
23 Menu change button
24 Lighting button
25 Blue-Q button
26 Rear window wiper button
16
NOTE
Buttons (5, 21, 22) and the accompanying
display elements (6, 7, 17, 18, 19, 20) are
assigned according to the equipment variants
in use.
he assignment shown here is an example
T
nd may differ from the assignment actually
a
rogrammed on the truck. Buttons may be
p
ssigned multiple functions that are called up
a
ccording to the menu navigation. For further
a
nformation, see the "Operating the display
i
nd operating unit" chapter.
a
52
57348011825 EN - 12/2015
Overviews 4
Operating devices and display elem
– If you have any questions, please contact
your authorised service centre.
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
348011825 EN - 12/2015 53
57
4 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
4
F1
F2
7325_003-025
5 Function key "5th function"
6 "Attachments" cross lever
7 Signal horn button
5
6
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (2) and (3). Changes must only be made
by the STILL service centre.
54
57348011825 EN - 12/2015
Overviews 4
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 equipment, various electric
attachment parts can be controlled via function
keys (2) and (3). Changes must only be made
bytheSTILLservicecentre.
0° lever
F1
yF2
ection/turn indicator" cross lever
4
5
6
7325_003-026
5 Function key "
6 "Auxiliary h
7 "Auxiliary
8 Signal hor
7
5th function"
ydraulics 1" operating lever
hydraulics 2" operating lever
n button
348011825 EN - 12/2015 55
57
4 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 dir
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (3) and (4). Changes must only be made
by the STILL service centre.
operating lever
ting lever
yF1
ey F2
ection/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
56
57348011825 EN - 12/2015
Overviews 4
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
348011825 EN - 12/2015 57
57
4 Overviews
F1
F2
Operating devices and display elem
Fingertip
ents
1
11
23456
F2
F1
10
9
78
1 Function key F1
2 Function key F2
3 Left turn indicator button
4 Signal horn button
5 Right turn indicator button
6 Function key "5th function"
NOTE
Depending on the equipment, various electric
attachment parts can be controlled via function
keys (1) and (2). Changes must only be made
by the STILL service centre.
58
57348011825 EN - 12/2015
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 4
Identification points
Identification points
Overview
1 Decal in
2 Manuf
3Warn
4War
5Na
6W
7 Decal information: Joystick functions
8 Decal information: Top up hydraulic oil
formation: Lifting gear attachment
point
acturer’s label text
ing sign: Danger due to shearing/Dan-
ue to high fluid pressure
ger d
ning sign: Do not stand underneath the
rk/Do not stand on the fork
fo
meplate
arning sign: Danger due to shearing/Danger due to high fluid pressure/and warning
sign: Do not stand underneath the fork/Do
not stand on the fork
(variant)
348011825 EN - 12/2015 59
57
9 Decal in
10 Decal
11 Deca
12 Deca
13 De
14 Decal information: Capacity rating plate/Ca-
15 Decal information: Head clearance
16 Decal information: Sound power level
formation: Tyre filling pressure
nt), on both sides of the truck
(varia
information: Top up diesel fuel
l information: Armrest adjustment
l information: Lifting gear attachment
nts
poi
cal information: Caution/Read the op-
ating instructions/Fastenseat belt/Apply
er
arking brake when leaving the truck/Pas-
p
sengers are not allowed/Do not jump off if
the truck is tipping over/Lean in the opposite
direction to which the truck is tipping
pacity rating plate: Attachment (variant)
4 Overviews
Identification points
17 Decal information: FEM test with inspection
sticker
Nameplate
The truck can be identified from the information on the nameplate.
1
2
3
Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
12
11
10
Rated capacity
Capacité nominale
Nenn-Tragfähigkeit
Battery voltage
Tension batterie
Batteriespannung
Rated drive power
Puissance motr.nom.
Nenn-Antriebsleist.
Unladen mass
kg
Masse à vide
Leergewicht
V
kW
* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung
9
max
min.*
*
8
kg
kg
kg
kg
6210_921-003_V2
4
5
6
7
1 Type
2 Production number
3 Year of manufacture
4 Tare weight in kg
5 Max. permissible battery weight in kg (for
electric forklift trucks only)
6 Min. permissible battery weight in kg (for
electric forklift trucks only)
7 Ballast weight in kg (for electric forklift trucks
only)
8 Refer to the technical data listed in these
operating instructions for more detailed
information
9 CE labelling
10 Nominal drive power in kW
11 Battery voltage in V
12 Rated capacity in kg
60
57348011825 EN - 12/2015
Overviews 4
Identification points
Production number
NOTE
The production number is used to identify the
truck. It can be found on the nameplate and
must be referred to in all technical questions.
The production number con
coded information:
(1) Production location
(2) Model
(3) Year of manufacture
(4) Sequential number
tains the following
StVZO (Road Traffic Licensing
Regulations) information
This label includes information on the weight
and load distribution of the truck.
xx xxxx x xxxxx
1
2
3
4
7090_921-004
12
5
1 Tare weight (in kg)
2 Permitted total weight (in kg)
3 Permitted front axle weight (in kg)
4 Permitted rear axle weight (in kg)
5 Payload (in kg)
348011825 EN - 12/2015 61
57
34
7094_003-098
4 Overviews
Equipment
Equipment
Accessories
• Key for key switch (two pieces)
• Key for cab (variant)
• Hexagon socket wrench for eme
lowering
rgency
62
57348011825 EN - 12/2015
5
Operation
5 Operation
Checks and tasks to be carried out pr
ior to commissioning
Checks and tasks to be carried out prior to commissioning
Visual inspections
WARNING
Risk of accident due to damage or other defects on
the truck or on the attachment (variant)!
Damage to the truck or the attachment (variant)
can lead to unpredictably dangerous situations.
If damage or other defects are identified on the
truck or attachment (variant) during the following
inspections, the truck may not be used until it has
been properly repaired.
– Do not remove or deactivate safety systems or
switches.
– Do not change any predefined set values.
– Do not use the truck until it has been properly
repaired.
WARNING
There is a risk of falling when working on high parts
of the truck.
– Use only the steps provided on the truck.
– Do not stand on truck components or use them
to help you mount the truck.
– Use suitable equipment.
Prior to start-up, ensure that the truck is safe
to be operated:
• The fork arms must be secured against
lifting and shifting.
• The locking devices (1) of the fork arms
must not be damaged or deformed.
• Fork arms and other lifting accessories
must not show any noticeable damage (e.g.
bends, cracks, significant wear).
• The roller tracks (2) must be lubricated with
a visible grease film.
• The chains must not be damaged and they
must be evenly and adequately tensioned.
• Check the area under the forklift truck for
leaking consumables.
• The guard grille (variant) and overhead
guard must be undamaged and securely
mounted.
64
57348011825 EN - 12/2015
2
1
6210_000-002
Operation 5
Checks and tasks to be carried out pr
• Attachments (variant) must be properly
mounted and function according to the
operating instructions.
• All decal information signs must be in
place and legible. Replace damaged or
missing adhesive labels in accordance with
the overview in the "Identification points"
chapter.
• Any warning units (e.g. sign
in perfect condition and fun
• Check the visible areas of the hydraulic
system and hydraulic oil tank for damage
and leaks. Damaged hoses must be
replaced by the authorised service centre
• Check the visible areas of the fuel system
and fuel tank for damage and leaks. Damaged hoses must be replaced by the authorised service centre
• The bonnet and side flap must
securely.
• Steps must be clean and free of ice.
• Any panes of glass (variant, e.g. windscreen) must be clean and free of ice.
• Depending on the tyres, t
fitted with an antistatic
belt must not be damaged.
clean and long enough to t
• The coupling pin in the counterweight must
show no noticeable damage (e.g. bends,
cracks or breaks). The securing bush in the
counterweight must be present.
• A tow coupling (variant) must show no
noticeable damage (e.g. coupling pin
bent, cracks or breaks). Every removable
coupling pin must be secured against loss
with a securing device (e.g. a chain, a split
pin or a rope).
• Damage or other defect
attachment (variant)
the supervisor or resp
immediately so that th
defect to be rectified.
al horn) must be
ction correctly
be locked
he truck may be
belt. The antistatic
It must also be
ouch the ground
s on the truck or
must be reported to
onsible fleet manager
ey can arrange for the
ior to commissioning
348011825 EN - 12/2015 65
57
5 Operation
Checks and tasks to be carried out pr
Checking the side cover is locked
– Check whether the side cover is locked,
see ⇒ Chapter "Closing the side service
flap",P.6-305.
Filling the washer system
CAUTION
Components may become damaged due to the
effects of frost!
Water expands when it freezes. If there is no
anti-freeze in the washer system, the system may
be damaged due to the build up of ice in freezing
conditions.
– Always use washer fluid containinganti-freeze.
The windscreen washer reservoir is under the
compartment behind the driver’s seat. The
sight glass (1) displays the fill level.
– Open filler cap (2) for the windscreen
washer reservoir.
– Fill the windscreen washer reservoir with
washer fluid and anti-freeze in accordance with the maintenance data table;
see ⇒ Chapter "Maintenance data table", P. 6-291.
– Close lid.
– Operate washer system until washer fluid is
discharged from the spray nozzles.
ior to commissioning
2
1
7331_341-001
66
57348011825 EN - 12/2015
Operation 5
Checks and tasks to be carried out pr
ior to commissioning
Checking the condition of the wheels and tyres
WARNING
Risk of accidents! With uneven wearor incorrect air
pressure, the stability of the forklift truck decreases
and the braking distance increases.
– Change worn or damaged tyres without delay.
WARNING
Risk of tipping!
Tyre quality affects the stability of the truck.
If you wish to use a different type of tyre on the truck
from the tyres approved by the truck manufacturer,
or tyres froma different manufacturer, you must first
obtain approval from the truck manufacturer.
WARNING
Risk to stability!
When using pneumatic tyres or solid rubber tyres,
rim wheel parts must never be changed and rim
wheel parts from different manufacturers must not
be mixed.
NOTE
Only approved types of tyre may be used; see
chapter entitled "Tyres".
– Check tyres (1) for wear or damage.
Tyres must not be damaged or excessively
worn. They must be worn evenly on both
sides.
– In the case of pneumatic tyres, check the air
pressure. The air pressure indicated on the
adhesive labels (2) must be observed.
NOTE
Observe the safety principles outlined in the
chapter entitled "Tyres".
348011825 EN - 12/2015 67
57
1
2
7321_003-003
5 Operation
Checks and tasks to be carried out pr
Topping up the coolant and checking the concentration of the coolant additive
CAUTION
Risk of engine damage!
If the coolant level is low, this indicates a leak in the
cooling system.
– Check the cooling system for leaks; see
⇒ Chapter "Cleaning the radiator, checking for
leaks", P. 6-309.
WARNING
Risk of scalding!
Only open the radiator filler cap when the engine
has cooled down.
– Open the radiator filler cap (1) slowly and
release over pressure.
– Unscrew further and remove the radiator
filler cap.
WARNING
Coolant and coolant additives are hazardous to
your health.
Observe the safety regulationsfor handlingcoolant;
see ⇒ Chapter "Coolant and cooling fluid", P. 3-44.
ior to commissioning
– Check the concentration of the coolant
additive.
Concentration of the coolant additive
CAUTION
Risk of corrosion!
The percentage of coolant additive must always be
at least 40%, even if frost protection is not needed
in warmer climates.
If greater frost protection is required for climatic
reasons, the percentage of the coolant additive can
beincreasedtoupto60%.
The percentage of coolantadditivemust not exceed
60%, as otherwise the frost protection is reduced.
In addition, the cooling effect is also reduced.
Only use clean, softened water for the water percentage.
68
57348011825 EN - 12/2015
Operation 5
Checks and tasks to be carried out pr
ior to commissioning
Frost protection
Water percentage
up to °C
-25 60 40
-30
-35 50 50
-40 40 60
Filling quantity in the cooling system; see
⇒ Chapter "Maintenance data table", P. 6-291.
CAUTION
Coolant additive with a different specification must
not be added!
– Top up using coolant additive and corrosion
inhibitor in accordance with the maintenance
data table; see ⇒ Chapter "Maintenance data
table",P.6-291.
Only use coolant additive according to the manufacturer’s guidelines.
Checking the engine oil level
NOTE
The truck should be parked on as level ground
as is possible while this testing is carried out.
– Open the bonnet. See chapter entitled
"Opening the bonnet".
– Pull out the oil dipstick (1) and wipe it.
– Insert the oil dipstick to the stop and pull out
again.
The oil level must be between the marks
(arrows).
– If the oil level only reaches the lower mark,
unscrew the filler cap (2) and top up the oil
in accordance with the maintenance data
table; see ⇒ Chapter "Maintenance data
table", P. 6-291. Then screw the filler cap
(2) back on tightly.
– Insert the oil dipstick to the stop.
– Close the bonnet.
55
%
%
45
Coolant additive percentage
348011825 EN - 12/2015 69
57
5 Operation
Checks and tasks to be carried out pr
Adjusting the MSG 65/MSG 75
driver’s seat
DANGER
There is a riskof accident ifthe seat or seatbackrest
shifts suddenly, which could cause the driver to
move in an uncontrolled manner. This may result in
unintentional actuation of the steering or operating
devices and thus cause the truck or load to move in
an uncontrolled fashion.
– Do not adjust the seat or seat backrest while
driving
– Adjust the seat and the seat backrest so that all
operating devices can be actuated safely
– Ensure that the seat and seat backrest are
securely engaged
WARNING
On some equipment variants, the
amount of head clearance on the
truck may be restricted.
On these specific equipment variants, the distance betweenthe head
and the lower edge of the roofing
sheet must be at least 40 mm.
ior to commissioning
NOTE
If there are separate operating instructions for
the seat, they must be followed.
WARNING
To obtain optimum seat cushioning, you must adjust the seat suspension to your own body weight.
This is betterfor your backand protects yourhealth.
– To prevent injury, make sure that there are no
objects within the swivel area of the seat
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57348011825 EN - 12/2015
Operation 5
Checks and tasks to be carried out pr
ior to commissioning
Moving the driver’s seat
– Lift and hold the lever (1)
– Push the driver’s seat into the
position.
– Release the lever.
– Ensure that the driver’s seat is securely
engaged.
desired
Adjusting the seat backrest
Do not put pressure on the seat backrest while
engaging it.
– Lift and hold the l
ever (2)
– Push the seat backrest into the desired
position.
– Release the lever.
– Ensure that the s
eat backrest is securely
engaged.
NOTE
The backwards tilt angle of the seat backrest
can be restricted by the structural condition of
the truck.
1
7094_003-006
2
7094_003-008
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5 Operation
Checks and tasks to be carried out pr
Adjusting the seat suspension
NOTE
The driver’s seat can be adjusted to suit the
weight of the individual driver. In order to
achieve the best seat suspension setting, the
driver should perform the adjustment whilst
sitting in the seat.
NOTE
The driver’sseat MSG 65/MSG 75 is designed
for people weighing between 45 kg and
170 kg.
NOTE
The MSG 75 seat is equipped with electric air
suspension that is activated using an electric
switch instead of the lever (3).
– Fully extend the weight-adjusting lever (3)
– Pump it upor down to set the driver’s weight.
– Return the weight adjusting lever to the
central initial position before each new lift
(audible click).
– Fully fold in the weight adjusting lever once
adjustment is complete.
ior to commissioning
4
3
6321_003-038
NOTE
The driver’s weight has been selected correctly when the arrow (4) is in the centre of the
inspection window. If the seat does not move
any further when you pump the weight adjusting lever, the minimum or maximum weight
setting has been reached.
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Operation 5
Checks and tasks to be carried out pr
ior to commissioning
Adjusting the lumbar support (variant)
NOTE
5
The lumbar support can be adjusted to suit
the contours of the individual driver’s spine.
Adjusting the lumbar support moves a convex
support cushion into the upper or lower part of
the backrest.
– Turn the turning knob (5) up or down until
the lumbar support is in the desired position
6321_003-039
Adjusting the backrest extension
(variant)
– Adjust the backrest extension (6) by pulling
it out or pushing it into the desired position.
To remove the backrest extension, move it
past the end stop by jolting it upwards.
6
6321_003-040
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57
5 Operation
Checks and tasks to be carried out pr
Switching the seat heater (variant) on
and off
NOTE
The seat heater only functions if the seat
contact switch is active, i.e. when the driver is
sitting on the driver’s seat.
– Switch the seat heater (7) on or off using the
switch.
Adjusting the armrest
DANGER
There is a risk of accident if the armrest lowers suddenly, causing the driver to move in an uncontrolled
manner. This can result in unintentional actuation
of the steering or the operating devices and thus
cause uncontrolled movements of the truck or load.
– Do not adjust the armrest while driving.
– Adjust the armrest so that all operating devices
can be actuated safely.
– Ensure that the armrest is securely tightened.
ior to commissioning
7
6321_003-041
Adjusting the length of the armrest
– Release the star-grip handle (1) by turning
it anti-clockwise.
– Shift the armrest (2) into the desired posi-
tion.
– Tighten the star-grip handle by turning it
clockwise.
– Check that the armrest is firmly attached.
Adjusting the height of the armrest
– Release hand wheel (3) by turning it anti-
clockwise.
– Shift the armrest (2) into the desired posi-
tion.
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3
2
1
7331_342-001
Operation 5
Checks and tasks to be carried out pr
– Tighten the hand wheel by turning it clock-
wise.
– Check that the armrest is firmly attached.
ior to commissioning
Adjusting the steering column
– Press down the steering column adjustment
lever (2).
– Position the steering col
lever up again.
DANGER
Risk of accidents!
– Ensure that the steering column is secure.
The steering column must click into place.
Never adjust the steering column while driving.
umn (1) and pull the
1
Cleaning the dust valve
– Open the service flap on the right-hand
side under the driver’s cab; see ⇒ Chapter "Opening the side service flap", P. 6-304.
– Press the dust
housing betwe
dust is emitte
– Close the service flap on the right-hand side
under the driver’s cab again; see ⇒ Chapter "Closing the side service flap", P. 6-305.
valve (1) on the air filter
en your fingers until no more
d.
2
6210_424-001
1
7331_132-001
348011825 EN - 12/2015 75
57
5 Operation
Commissioning
Commissioning
Climbing into and out of the truck
WARNING
Risk of injury when climbing into and out of the
truck due to slipping, striking parts of the truck or
becoming stuck!
If the footwell cover is very dirty or smeared with oil,
there is a risk of slipping. There is a risk of hitting
your head on the overhead guard post or of your
clothes becoming stuck when climbing out of the
truck.
– Ensure that the footwell cover is non-slip.
– Do not jump into or out of the truck.
– Ensure that you have a secure grip on the truck.
WARNING
Risk of injury when jumping out of the truck!
If your clothing or jewellery (e.g. watch, ring etc.)
becomes stuck on a component while you are
jumping out of the truck, this can lead to serious
injuries (e.g. from falling, loss of fingers etc.). It is
forbidden to jump out of the truck.
– Do not jump out of the truck.
– Do not wear jewellery at work.
– Do not wear loose-fitting workwear.
CAUTION
Components may become damaged through
incorrect use!
Truck components, such as the driver’s seat,
steering wheel, parking brake lever etc., are not
designed to be used for climbing in and out of the
truck and can be damaged due to misuse.
– Only use the fittings specifically designed for the
purpose of climbing into and out of the truck.
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Operation 5
Commissioning
To assist with climbing intoand out of the truck,
the footwell must be used as a step (5) and the
handle (1) must be used for support. The post
of the overhead guard (2) can also be used for
support.
Always climb into the truck forwards:
– Grip the handle (1) with your
left hand and
hold on.
– Put your left foot on the step (4).
– Climb into the truck with your right foot first
and sit down on the driver’s seat (3).
Always climb out of the truc
k backwards:
– Grip the handle (1) with your left hand and
hold on.
– Stand up from the driver’s seat and place
your left foot on the step (4).
– Climboutofthetruckrig
Climbing into and out o
ht foot first.
fatruckwith
araiseddriver’scab
WARNING
Risk of injury when climbing into and out of the
truck due to slipping, striking parts of the truck or
becoming stuck!
If the footwell cover is very dirty or smeared with oil,
there is a risk of slipping. There is a risk of hitting
your head on the overhead guard post or of your
clothes becoming stuck when climbing out of the
truck.
– Ensure that the footwell cover is not slippery.
– Do not jump into or out of the truck.
– Ensure that you have a secure grip on the truck.
1
5 4
23
7331_003-005
348011825 EN - 12/2015 77
57
5 Operation
Commissioning
WARNING
Risk of injury when jumping out of the truck!
If your clothing or jewellery (e.g. watch, ring etc.)
becomes stuck on a component while you are
jumping out of the truck, this can lead to serious
injuries (e.g. from falling, loss of fingers etc.). It is
forbidden to jump out of the truck.
– Do not jump out of the truck.
– Do not wear jewellery at work.
– Do not wear loose-fitting workwear.
CAUTION
Components may become damaged through
incorrect use!
Truck components, such as the driver’s seat,
steering wheel, parking brake lever etc., are not
designed to be used for climbing in and out of the
truck and may be damaged due to misuse.
– Only use the fittings specifically designed for the
purpose of climbing into and out of the truck.
If the truck is equipped with a raised driver’s
cab, the driver’s compartment is significantly
higher than that of a standard truck.
For this reason, particular care must be taken
when climbing into and out of the truck. The
following section describes the bestprocedure
to adopt.
NOTE
The foot that the driver starts with when
climbing into and out of the truck is crucial
in ensuring this action is carried out safely.
This will depend on the number of steps.
To assist when climbing into and out of the
truck, use the handles (2) and (4) for support.
The post of the overhead guard (1) can also
be used for support.
Always climb into the truck facing forwards.
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Operation 5
Commissioning
– Grip the handle (2) with your left hand and
do not let go.
– Grip the handle (4) with your right hand and
do not let go.
– Place your right foot on the bot
– Place your left foot on the top step (6).
– Place your right foot into the foot well (7).
– Enter the truck and sit down
seat (3).
Always climb out of the truck backwards.
– Grip the handle (2) with your left hand and
do not let go.
– Stand up from the driver’
your left foot on the top s
– Grip the handle (4) with your right hand and
do not let go.
– Place your right foot on the bottom step (5).
– Place your left foot on
down from the truck.
tom step (5).
on the driver’s
s seat and place
tep (6).
the ground and climb
Shelves and cup holde
rs
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 do not fall from the shelves (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. Subsequently, it may not be
possible to brake the truck when necessary.
– Bottlesofmax. 1.5lmaybestoredinthecup
holder.
– Make sure that stored objects cannot fall from
the shelves when the truck is started up, steered
or braked.
348011825 EN - 12/2015 79
57
1
3
2
1
7331_344-001
5 Operation
F
1
F2
Commissioning
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 swi
unlatches.
tch (1) until it
1
1
F2
1
F
Switching o
nthekeyswitch
WARNING
Before switching on the key switch, all tests prior to
start-up must be performed without detecting any
defects.
– Perform the tests prior to commissioning.
– Do not operate the truck if defects have been
detected
– Notify the authorised service centre.
80
57348011825 EN - 12/2015
1
7312_003-183
Operation 5
Commissioning
– Insert the switch key (1) into the key switch
andturntoposition"I"
This initiates a self-test. All lamps in the drive
direction and turn indicator displays light up
briefly.
0 I
1
7090_001-002
7312_003-085
348011825 EN - 12/2015 81
57
5 Operation
Commissioning
When the key switch is switched on, the
display shows the welcome screen in the
set language until the truck controls have
completely started up.
If the truck has the "access authorisation with
PIN code" variant, the display initially changes
to the input menu for access authorisation.
If the truck is ready for oper
displays are shown.
ation, the standard
Standard display elements
In the factory setting, the following indicators
can be seen in the display and operating unit:
1 Fuel level
Shows the fuel lev
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 hours
Displays the total operating hours
completed by the truck. The hour meter
operates as soon as the engine is started.
4 Time
Displays the cu
and minutes. Th
see the chapter
time".
CAUTION
Lack of fuel can cause malfunctions!
If the fueltank has beenrun empty, thefuel injection
system can draw in air bubbles. This can lead to
malfunctions in the fuel injection system.
– Never run the fuel tank empty.
el in the fuel tank as a
rrent time digitally in hours
e time can be adjusted;
entitled "Setting the
75
%
234,7 h
12:15
1
2
2
3
4
7312_003-057_V2
82
57348011825 EN - 12/2015
Operation 5
Commissioning
NOTE
Additional information may ap
display. If faults occur, refe
in the chapter entitled "Fault
pear on the
rtotheinformation
s".
Access authorisation with
PIN code
(variant)
Description
Trucks equipped with the "Access authorisation with PIN code" variant are protected
against unauthorised use by a five-digit driver
PIN. Up to fifty different driver PINs can be
defined so that the same truck can be used
by different drivers, each with their own driver
PIN.
NOTE
The driver PINs are defi
unit menu that can onl
persons with the corr
authorisation, e.g.
Once the key switch has been switched on,
the input menu for the driver PIN appears
on the display and operating unit screen. All
of the truck’s functions (driving, hydraulics,
additional electrical installations and the
display and operating unit displays) are
blocked. The function of the hazard warning
system (variant) is guaranteed. Enter the fivedigit driver PIN (possible entries from 00000 to
99999) to enable the blocked functions. Once
the correct driver PIN has been entered, the
standard displays are shown. All of the truck
functions are available.
The access authorisation can be configured
in such a way that the driver PIN has to be
re-entered each time the driver steps off the
truck, in order for the truck to be operated
again.
– Contact the author
this matter.
The first driver PIN is preset to "11111" at the
factory. All others are preset to "0xFFF" but
have no functionas the highest valid driverPIN
ned in a truck control
y be accessed by
esponding access
fleet managers.
ised service centre on
348011825 EN - 12/2015 83
57
5 Operation
Commissioning
is "99999". Persons with the corresponding
access authorisation, e.g. fleet managers,can
change the driver PINs in the corresponding
menu.
NOTE
When first commissioning the truck, we recommend you change the access authorisation set at the factory. This is the only way to
guarantee that the driver PIN is only known to
persons with corresponding access authorisation.
The driver PINs are stored in the truck control
unit. These are still available if the display
and operating unit has been changed. The
authorised service centre can use adiagnostic
device to read out the driver PIN and, if
necessary, restore the factory default driver
PIN.
ACCESS CODE input menu
The driver enters the fiv
(00000 to 99999) in this
The driver PIN is entered using the buttons (1).
The digits entered for the driver PIN (2) are not
visible, instead being represented by circles.
If the driver PIN entered is correct, the familiar
display appears with the standard display, and
all truck functions are available.
e-digit driver PIN
input menu.
84
57348011825 EN - 12/2015
Operation 5
8
9
6
7
4
2
0
1
3
5
8
9
6
7
4
2
0
1
3
5
Commissioning
If an incorrect driver PIN is entered, the
message
When the message goes out, the driver PIN
can be re-entered.
After three invalid entry attempts, the message
then locked for five minutes before another
attempt can be made.
INVALID appears for a short time.
BQ_023_en_V2
CODE DENIED appears. The input is
BQ_024_en_V2
348011825 EN - 12/2015 85
57
5 Operation
8
9
6
7
4
2
0
1
3
5
Commissioning
Defining the driver PIN
NOTE
The driver PIN can only be defined by persons
with the corresponding access authorisation,
e.g. fleet managers. In order for the fleet
manager to define the driver PIN, the configuration menu must be accessed. The configuration menu is password-protected. After
entering the password, the fleet manager can
configure general settings for the truck. To
change the password, see the chapter entitled
"Changing the password".
– Push the drive program selection button (1)
and the menu change button (2)at thesame
time.
PASSWORD appears in the display.
– Enter the four-digit password (factory
default: 2777) using the buttons (1).
– Confirm the entry by pressing the
button (2).
ENTER
1
126
1
2
Blue-Q_029_V2
ESC
3
4
7
5
2
BQ_030_en_V2
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57348011825 EN - 12/2015
Operation 5
8
9
6
7
4
2
0
1
3
5
8
9
6
7
4
2
0
1
3
5
Commissioning
CONFIGURATION appears in the display.
– Use the drive program selection button (1)
and the menu change button (3) to select
the
ACCESS CODE menu.
– Confirm your selection by press
ENTER
button (2).
ing the
1
32
BQ_31_en
Selecting the driver PIN
In the ACCESS CODE menu, there are fifty
possible driver PINs to choose from.
The digit sequenc
the
NEW CODE subme
Once the
cessed, the
the number
es can be set or changed in
nu.
ACCESS CODE menu has been ac-
CODE selection field (2) contains
1. The first of the fifty driver PINs
can now be defined.
– Use the drive program selection button (1)
and the menu change button (4) to select
the desired driver PIN (
– Confirm your sel
ENTER
button (3).
1 to 50).
ection by pressing the
1
4
3
2
BQ_025_en_V3
348011825 EN - 12/2015 87
57
5 Operation
8
9
6
7
4
2
0
1
3
5
Commissioning
NEW CODE appears in the display.
– Enter the desired driver PIN using the
buttons (5).
The digits entered do not appea
Instead they are represented b
NEW CODE field (6).
CONFIRM appears in the display.
CONFIRM submen
The
the new driver PIN.
– Enter the new driver PIN for a second time
in the
CONFIRM field (8) using the buttons
(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 P
IN can be defined here.
rinthedisplay.
y circles in the
uisusedtoconfirm
7
3
8
126
4
9
7
5
0
8
BQ_026_en
88
57348011825 EN - 12/2015
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