Still RX70-60, RX70-70, RX70-80 Operator Manual

Original instructions
Diesel trucks
With SCR (Selective Catalytic Reduction)
RX70-60 RX70-70 RX70-80
7341 7342 7343 7344
57348011800 EN - 07/2016

Preface

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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Table of contents

1 Foreword
Your truck .......................................................... 2
General ............................................................ 2
Note regarding SCR (Selective Catalytic Reduction) as exhaust gas treatment ........ 2
CElabelling ......................................................... 3
EC declaration of conformit
Accessories ......................................................... 5
Information about the documentation ...................................... 6
Documentationscope ................................................. 6
Issuedateandtopicalityoftheoperatinginstructions ........................... 7
Copyrightandtrademarkrights ........................................... 7
Explanation of informatio
Listofabbreviations ................................................... 8
Definitionofdirections ................................................ 11
Schematicviews .................................................... 11
Environmental considerations .......................................... 13
Packaging ......................................................... 13
Disposal of components a
y in accordance with Machinery Directive ............... 4
nsymbolsused ................................... 7
ndbatteries ..................................... 13
2 Introduction
Using the truck ...................................................... 16
Proper usage ....................................................... 16
Proper use during tow
Impermissibleuse ................................................... 16
Placeofuse ........................................................ 17
Using working platf
Residual risk ....................................................... 19
Residual dangers, residual risks ......................................... 19
Special risks assoc
Overviewofhazardsandcountermeasures ................................. 22
Danger to employees . . ............................................... 25
ing .............................................. 16
orms ............................................... 18
iatedwithusingthetruckandattachments ................... 20
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3Safety
Definition of resp
Operatingcompany .................................................. 28
Specialist .......................................................... 28
Drivers ........................................................... 29
Basic principles for safe operation ....................................... 31
Insurance cover on company premises .................................... 31
onsible persons ........................................ 28
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Changes and retrofitting ............................................... 31
Changes to the overhead guard and roof loads . . . ........................... 33
Warning regarding non-origin
Damage, defects and misuse of safety systems . . . ........................... 34
Tyres ............................................................. 34
Medicalequipment ................................................... 36
Exercise caution when handling gas springs and accumulators .................. 36
Lengthoftheforkarms ................................................ 37
Safety tests ........................................................ 38
Regularsafetyinspectionofthetruck ..................................... 38
Checkingthedieselengineemissions ..................................... 38
Particlefilter ........................................................ 39
Insulationtesting .................................................... 40
Safety regulations for handling consumables ............................... 41
Permissible consumables
Oils .............................................................. 41
Hydraulicfluid ...................................................... 42
Batteryacid ........................................................ 43
Dieselfuel ......................................................... 44
Coolantandcoolingfluid .............................................. 46
Disposal of consumable
Emissions ......................................................... 48
alparts ..................................... 33
............................................. 41
s .............................................. 46
4Overviews
Overview .......................................................... 54
Overview of the driv
Operating devices and display elements ................................... 56
Display and operating unit . . . .......................................... 56
Operating devices f
Doublemini-lever .................................................... 58
Three-waymini-lever ................................................. 59
Four-way mini-lev
Joystick4Plus ...................................................... 61
Fingertip .......................................................... 62
Miniconsole ....................................................... 63
Labelling points ..................................................... 64
Overview .......................................................... 64
Nameplate ......................................................... 66
Productionnumber .................................................. 67
IV
er’s compartment ..................................... 55
orhydraulicanddrivingfunctions .......................... 57
er .................................................. 60
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Table of contents
StVZO(RoadTrafficLicensingRegulations)information ....................... 67
5 Operation
Checks and tasks to be carried out prior to commissioning ...................... 70
Visualinspections ................................................... 70
Fillingthewashersystem .............................................. 72
Checking the condition of the wheels and tyres .............................. 72
Checking the cooling fluid l
Checking the engine oil level ........................................... 74
AdjustingtheMSG65/MSG75driver’sseat ................................ 76
Adjustingthearmrest ................................................. 79
Adjustingthesteeringcolumn ........................................... 80
Cleaningthedustvalve ............................................... 81
Checking the pre-cleane
Checkingtheoiltankontheoilbathairfilter ................................. 82
Commissioning ..................................................... 83
Climbing into and out of
Unlockingtheemergencyoffswitch ...................................... 86
Switchingonthekeyswitch ............................................ 86
Access authorisation
Operating the signal horn .............................................. 99
Seatbelt .......................................................... 99
Using the driver’s cab
Starting the engine ...................................................103
Checkingthebrakesystemforcorrectfunction ..............................105
Checking the steeri
Checking the emergency off function .....................................106
Zeroadjustmentoftheloadmeasurement(variant) ...........................107
Checking the vertic
Driving ............................................................110
Safety regulations when driving .........................................110
Roadways .........................................................112
Settingthedriveprogramme ............................................114
Selectingthedrivedirection ............................................115
Actuating the driv
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 117
Actuating the drive direction switch, fingertip version ..........................117
Actuating the driv
Startingtodrive .....................................................118
Starting drive mode, dual-pedal version (variant) .............................120
edirectionswitch,mini-leverversion .........................116
edirectionswitch,mini-consoleversion ......................118
evel .......................................... 74
r .............................................. 81
thetruck ........................................ 83
withPINcode(variant) ................................ 89
.................................................102
ngsystemforcorrectfunction ............................106
alliftmastposition(variant)forcorrectfunction ................109
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Operatingtheservicebrake ............................................123
Parkingbrake ......................................................124
Actuating the mechanical park
Steering ...........................................................126
Reducing speed when turning (Curve Speed Control) .........................127
Reducing speed with a raised lo
Automatic shut-off of the internal combustion engine (variant) ...................128
Lifting ............................................................129
Liftingsystemvariants ................................................129
Automaticliftcutout(variant) ...........................................129
Liftmastverticalposition(variant) ........................................130
Typesofliftmast ....................................................134
Malfunctionsduringliftingmode .........................................135
Hydraulicblockingfunction .............................................136
Lifting system operating
Controlling the lifting system using a double mini-lever .........................138
Controllingtheliftingsystemusingatriplemini-lever ..........................139
Controlling the lifting
Controllingtheliftingsystemusingthejoystick4Plus ..........................141
Controlling the lifting system using the fingertip . . . ...........................143
Changing the fork arms ...............................................1
Forkextension(variant) ...............................................146
Operationwithreversibleforkarms(variant) ................................148
Handling loads ......................................................150
Safety regulations when handing loads ....................................150
Beforetakingupload .................................................151
Load measurement (va
Picking up loads .....................................................155
Danger area .......................................................156
Transporting pallet
Transportofswingingloads ............................................157
Loadpickup ...................................................... . 158
Transporting loads
Setting down loads ...................................................163
Driving on ascending and descending slopes ...............................165
Drivingonlifts ......................................................165
Drivingonloadingbridges .............................................166
Particle filter system ..................................................167
Particlefilter-Fu
Particle filter - Performing parked regeneration . . . ...........................169
Particlefilter-Displays ................................................173
system using a quadruple mini-lever ......................140
s ..................................................157
...................................................162
nction ................................................167
ingbrake ...................................124
ad(variant) ................................128
devices .........................................137
riant) ...........................................152
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Working with attachments .............................................175
Fittingattachments ..................................................175
Releasing the pressure from th
Generalinstructionsforcontrollingattachments .............................179
Controlling attachments using a double mini-lever ............................181
Controlling attachments usin
Controllingattachmentsusingatriplemini-lever .............................185
Controlling attachments using the triple mini-lever and the 5th function .............187
Controlling attachments us
Controlling attachments using the quadruple mini-lever and the 5th function .........190
Controllingattachmentsviathejoystick4Plus ...............................191
Controlling attachments u
Controlling the attachments with the fingertip ...............................193
Controlling attachments with the fingertip and 5th function ......................194
Clamp locking mechanism (
Takingupaloadusingattachments ......................................200
Operating auxiliary equipment ..........................................201
Switching the lighting o
Switching the rotating beacon on and off . . . ................................202
Switchingthehazardwarningsystemonandoff .............................203
Switching the directio
Switching the double working spotlights on and off. ...........................205
Operatingthewindscreenwiper/washer ...................................207
FleetManager (variant
Accidentrecorder(variant) .............................................208
Cruisecontrol(variant) ................................................208
Driver restraint sys
Cab operation ......................................................212
Opening the cab door . . ...............................................212
Closingthecabdoor .................................................2
Openingthesidewindows ........................................... . . 213
Closing the side windows ..............................................214
Operating the inter
Operating the rear window heating .......................................215
Radio(variant) ......................................................216
Heating system (var
Air conditioning (variant) ...............................................218
Push-up roof window (variant) ..........................................219
Clipboard (varian
Trailer operation ....................................................220
Towedload ....................................................... . 220
nindicatorsonandoff ................................203
tems(variants) .......................................212
iorlighting ...........................................214
iant) ..............................................216
t) ...................................................219
ehydraulicsystem ............................177
g the double mini-lever and the 5th function ...........183
ing a quadruple mini-lever .........................188
singthejoystick4Plusandthe5thfunction ..............192
variant) ......................................196
nandoff .........................................201
) ................................................207
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Coupling pin in the counterweight ........................................221
Automatictowcoupling ...............................................223
Towingtrailers ......................................................231
Operating the display and operating unit ...................................232
Displays ..........................................................232
Adjustingthedisplays ................................................233
Symbolsinthedisplay ................................................233
Settingthedateortime ................................................238
Resetting the daily kilomet
Setting the language .................................................239
Soft key button for operating various equipment variants .......................239
Configuring Blue-Q efficien
Blue-Q efficiency mode ...............................................242
Functionaldescription ................................................242
Effects on additional con
SwitchingefficiencymodeBlue-Qonandoff ................................243
Display messages ...................................................245
Displaycontent .....................................................245
Errorcodetable .....................................................246
General messages ...................................................249
Drive-specific message
Operating in special operating situations ...................................266
Transport ..........................................................266
Towing .......................................................... . 268
Craneloading ......................................................271
Jump-starting ......................................................274
Procedure in emergen
Emergency shutdown ................................................276
Procedureiftrucktipsover .............................................277
Emergency hammer ..................................................278
Emergency lowering .................................................278
Releasing the spring-operated brake .....................................280
Disconnecting the b
Refuelling .........................................................283
Dieselfuel—Specifications ............................................283
Filling up with die
Usingthefuelhandpump ..............................................288
Topping up AdBlue ..................................................290
Decommissioning
Parkingthetrucksecurelyandswitchingitoff ...............................291
selfuel ...............................................287
res and daily operating hours .......................238
cymode ......................................240
sumers .........................................242
s ..............................................258
cies .............................................276
attery ..............................................283
...................................................291
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Table of contents
Wheelchock(variant) ................................................292
Shuttingdownandstoringthetruck ......................................292
Recommissioning after shutdo
Cleaning ..........................................................295
Cleaningthetruck ...................................................295
Cleaning the electrical sys
Cleaningloadchains .................................................298
Cleaningthewindows .............................................. . . 298
Afterwashing .......................................................299
wn ........................................294
tem ..........................................297
6 Maintenance
General maintenance information ........................................302
Personnel qualifications ...............................................302
Information for carryin
Maintenance instructions ..............................................305
Maintenance - 500 hours/half-yearly ......................................305
Maintenance - 1000 hour
Maintenance - 3000 hours/every two years . ................................311
Orderingsparepartsandwearingparts ....................................311
Quality and quantity o
Maintenance data table ...............................................313
Safety regulations for maintenance .......................................316
Generalinformation ..................................................3
Workingonthehydraulicequipment ......................................316
Working on the electrical equipment ......................................317
Working on the ignit
Safetydevices ......................................................318
Setvalues ....................................................... . . 318
Lifting and jacking
Workingatthefrontofthetruck ..........................................318
Providing access to maintenance points ...................................320
Opening the bonnet
Closing the bonnet ...................................................321
Removingandattachingtheleftsidecover .................................322
Installing and rem
Opening and closing the right-hand service flap ..............................324
Service work .......................................................326
Cleaning the radi
Topping up the cooling fluid and checking the coolant concentration ...............327
Drainingwaterfromthefuelfilter .........................................329
goutmaintenance ..................................302
s/annually ......................................307
f the required operating materials ........................312
ionsystem ..........................................317
up .................................................318
..................................................320
ovingthebottomplate ...................................322
atorandcheckingforleaks ................................326
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Cleaning the pre-cleaner ..............................................331
Cleaning the oil tank on the oil bath air filter .................................331
Replacing the air filter cartri
Lubricatingthejointsandcontrols ........................................334
Checking the door latch ...............................................334
Maintainingtheseatbelt ...............................................335
Checkingthedriver’sseat .............................................336
Changing the heating system fresh air filter .................................337
Replacing the recirculated
Greasingtheautomatictowcoupling ......................................338
Servicingwheelsandtyres .............................................341
Replacingthefuses ..................................................343
Checkingthehydraulicoillevel ..........................................343
Checkingthehydraulicsystemforleaks ...................................345
Lubricating the lift mast
dges .........................................332
air filter for the heating system ......................338
androllertrack ....................................346
7 1000-hour maintenance/
Other tasks ........................................................348
Checking the exhaust gas system .......................................348
Checking the lift cyli
Checking the fork arms ................................................348
Checking the reversible fork arms ........................................349
nders and connections for leaks ..........................348
annual maintenance
8 Technical data
Dimensions ........................................................352
VDI datasheet ......................................................353
Ergonomic dimensions ................................................358
Fuse assignment ....................................................36
0
X5
7348011800 EN - 07/2016
1

Foreword

1 Foreword

Your truck

Your truck
General
The truck described in these operatinginstruc­tions corresponds to the applicable standards and safety regulations.
If the truck is to be operated on public roads, it must conform to the existing national regula­tions for the country in which it is being used. The driving permit must be obtained from the appropriate office.
Thetruckshavebeenfittedw art technology. All that re the truck safely and maint
These operating instructions provide the necessary information to do this. Read and observe the information provided before commissioning the truck. This will prevent accidents and ensure that the warranty remains valid.
Note regarding SCR (Selective Catalytic Reduction) as exhaust gas treatment
This truck uses the Selective Catalytic Reduc­tion (SCR) process of exhaust gas treatment.
To enable the SCR process to be performed, the truck uses AdBlue (32.5% urea solution, in accordance with DIN 70070 / ISO 22241).
It is recommended t refilled with AdBlu is topped up; see th AdBlue".
The applicable European emission require­ments (97/68/EC) state that new engines must have an SCR system.
hattheAdBluetankbe
e every time the diesel fuel
e section "Topping up
ith state-of-the-
mains is to handle
ain its functionality.
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7348011800 EN - 07/2016
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
348011800 EN - 07/2016 3
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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
.
45
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7348011800 EN - 07/2016
Foreword 1
Your truck
Accessories
• Key for key switch (two pieces)
• Key for cab (variant)
• Hexagon socket wrench for emer lowering
gency
348011800 EN - 07/2016 5
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1 Foreword
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 is specified inthe "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
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7348011800 EN - 07/2016
Foreword 1
on
NOTE
Please observe the definition o responsible persons: "operat
Information about the documentati
f the following
ing company"
and "driver".
Thank you for reading and complying with these operating instructions. If you have any questions or suggestions for improvements, or if you have found any errors, please contact the authorised service centre.
Issue date and topicality of the operating instructions
The issue date of these operating instructions can be found on the title page.
STILL is constantly engaged in the further development of trucks. These operating instructions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.
Please contact your au for technical support
thorised service centre
relating to your truck.
Copyright and tradem
These instruction translated or made ties—including as express written ap
s must not be reproduced,
excerpts—except with the proval of the manufacturer.
Explanation of in
ark rights
accessible to third par-
formation symbols
used
DANGER
Indicates 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.
348011800 EN - 07/2016 7
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1 Foreword
Information about the documentati
CAUTION
Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruction.
NOTE
For technical requirements that require special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
List of abbreviations
NOTE
This list of abbreviations applies to all types of operating instructions. Not all of the abbre­viations that are listed here will necessarily appear in these operating instructions.
on
Abbreviation
°C
°F
A
ABE
ArbSchG
BetrSichV
BG
BGG
BGR German Social
Accident Insurance
Approx.
CE
CEE
cm
85
Meaning
Degrees Celsius
Degrees Fahrenheit
Amperes
Display operating unit
German labour protection law
German Ordinance on Industrial Safety and Health
Employers’ liability insurance association
Employers’ liability insurance association act
Employers’ liability insurance association rule
Employers’ liability insurance association regulation
Approximately Symbol that confirms conformity with the valid product-specific European
directives International Commission on the Rules for the Approval of Electrical Equip­ment
Centimetres
7348011800 EN - 07/2016
Foreword 1
Information about the documentati
on
Abbreviation
3
cm
Meaning
Cubic centimetres
dB Decibels
DFÜ
Remote data transmission
DIN German standard
EG
EN FEM F
max
g
GAA
European Community
European standard
Fédération Européene de Maximum power
Grams Industrial inspectorate
la Manutention
If applicable If applicable
GPRS General Packet Radio Service
h/d
Hours per day (time driven each day in hours)
ID no. ID number
ISO International standard
kg Kilograms
3
kg/m km/h km/d
Kilograms per cubic metre Kilometres per hour Kilometres per day (kilometres driven each day)
kN Kilonewtons
kW Kilowatts
kWh/h
Energy consumption
lLitres
l/h
l/min
Litres per hour
Litres per minute
LAN Local area network
LED L
p
L
pAZ
LSP
o.s.
m
Light emitting diode
Sound pressure level Continuous sound pressure level in driver’s compartment
Load centre of gravity
milar
Or si
Metres
348011800 EN - 07/2016 9
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1 Foreword
Information about the documentati
on
Abbreviation
m/s
2
m/s
MAK
Meaning
Metres per second
Metres per second squared
Maximum workplace concentration
Max. Maximum
Min. Minimum
min Minutes rpm
mm
Revolution(s) per minute
Millimetres N Newtons Nm Newton metres PIN
SE
SIT
StVZO
t
TRGS
a.s.
Personal identifica
Superelastic
Snap-in tyre for simplified assembly
German Road Traffic Licensing Regulations
Tonnes
Technical Regulations for Hazardous Substances
And similar
tion number
VVolts
VDE
VDI
VDMA
Association for Electrical, Electronic & Information Technologies
Association of German Engineers
German Engineering Federation
W Watts
WLAN Wireless e.g.
.
For example
local area network
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Foreword 1
Information about the documentati
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Definition of directions
The directions "forwards" (1), "backwards" (3), "right" (2) and "left" (4) refer to the installation position of the parts as seen from the driver’s compartment; the load is to the front.
Schematic views
View of functions and operations
This documentati sequential) cha ations. Schemat ance truck are us dures.
NOTE
These schemati tative of the s truck. The dia purpose of cla
on explains the (usually
in of certain functions or oper-
ic diagrams of a counterbal-
ed to illustrate these proce-
c diagrams are not represen-
tructural state of the documented
grams are used solely for the rifying procedures.
1
4
2
3
6210_001-031
6210_003-062
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1 Foreword
Information about the documentati
View of the display operating unit
NOTE
Views of operating statuses and values in the display of the display operating unit are examples and partly dependent on the truck equipment. As a result, the displays shown of the actual operating statuses and values can vary. Information that is not relevant for descriptions is not shown.
on
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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.
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Environmental considerations
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57348011800 EN - 07/2016
2

Introduction

2 Introduction

Using the truck

Using the truck
Proper usage
The truck described in these operating in­structions is suitable for lifting, transporting and stacking loads.
The truck may only be used for its proper purpose as set out and described in these operating instructions.
If the truck is to be used for than those specified in the o tions, the approval of the m applicable, the relevant r must be obtained beforeha ards.
The maximum load to be lifted is specified on the capacity rating plate (load diagram) and must not be exceeded; see also the chapter entitled "Before picking up a load".
Proper use during towing
This truck is suitable for the occasional towing of trailers and is equipped with a towing device for this purpose. This occasional towing may not exceed 2% of the daily operating time. If the truck is to be used for towing on a more regular basis, the manufacturer should be consulted.
The regulations regarding trailer operation must be observed; see chapter "Trailer operation".
purposes other
perating instruc-
anufacturer and, if
egulatory authorities
nd to prevent haz-
Impermissible use
The operating company or driver, and not the manufacturer, is liable for any hazards caused by improper use.
NOTE
Please observe the definition of the following responsible persons: "operating company" and "driver".
Use for purposes other than those described in these operating instructions is prohibited.
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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.
The truck has a closed particle filter system and therefore 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 national regulations for the country in which it is being used.
The ground must have an adequate load capacity (concrete, asphalt) and a rough surface. Routes, work areas and aisle widths must conform to the specifications in these operating instructions, see the "Routes" chapter.
Driving on upward and downward gradients is permitted provided the specified data and specifications are observed, see the "Routes "chapter.
The truck is suitable for 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
348011800 EN - 07/2016 17
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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 note the definition of "operating com­pany" in the sense of responsible persons!
DANGER
Risk to health from exhaust gases! Exhaust gases from internal combustion engines
are harmful to your health. In particular, the soot particles contained in the diesel exhaust gas can cause cancer.
When the internal combustion engine is running, there is a risk of poisoning from the CO, CH and NOx components contained in the exhaust gas.
Modern exhaust gas treatment systems (e.g. catalytic converters, particle filters or comparable systems) can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck.
– Observe the national laws and regulations when
using trucks with an internal combustion engine in entirely or partially enclosed working areas.
– Always ensure sufficient ventilation.
Using working platforms
WARNING
The use of working platforms is regulated by na­tional law. The use of working platforms is only permitted by virtue of the jurisdiction in the country of use.
– Observe national legislation. – Before using working platforms, consult the
national regulatory authorities.
18
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Introduction 2

Residual risk

Residual risk
Residual dangers, residual risks
Despite careful working and compliance with standards and regulations, the occurrence of other risks when using the truck cannot be entirely excluded.
The truck and all other system components comply with current safety requirements. Nevertheless, even when the truck is used for its proper purpose and all instructions are followed, some residual risk cannot be excluded.
Even beyond the narrow dan truck itself, a residual r Persons in this area aroun exercise a heightened deg so that they can react imme of any malfunction, incid
WARNING
All persons that are in the vicinity of the truck must be instructed regarding these risks that arise through use of the truck.
In addition, we draw attention to the safety regulati­ons in these operating instructions.
ger areas of the
isk cannot be excluded.
d the truck must ree of awareness,
diately in the event
ent or breakdown etc.
The risks can include:
• Escape of consumables due to leakages, rupture of lines and containers etc.
• Risk of accident when driving over difficult ground such as gradients, smooth or irregular surfaces, or with poor visibility etc.
• Falling, tripping etc. when moving on the truck, especially in wet weather, with leaking consumables or on icy surfaces
• Fire and explosion risks 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
348011800 EN - 07/2016 19
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
swinging loads.
– Do not drive over ramp edges or steps.
e avoided or min-
tions:
n cornering.
gonally driving across
re when transporting
Special risks associated with using the truck and attachments
Approval from the manufacturer and attach­ment manufacturer must be obtained each
20
57348011800 EN - 07/2016
Introduction 2
Residual risk
time the truck is used in a manner that falls outside the scope of normal use, and in cases where the driver is not certain that he can use the truck correctly and without the risk of acci­dents.
348011800 EN - 07/2016 21
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2 Introduction
Residual risk
Overview of hazards and counter­measures
NOTE
This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete.
– Observe the national regulations for the
country in which the truck is being used.
Hazard Measure
Truck equipment does not comply with local regulations
Lack of skills and qualification of driver
Usage by unautho­rised persons
Truck not in a safe condition
Risk of falling when using working platforms
Impaired visibility due to load
Contamination of respiratory air
Test
Driver training (sit-on and stand-on)
Access with key only for authorised persons
Recurrent testing and rectification of defects
Compliance with national regulations (different national laws)
Resource planning
Assessment of diesel exhaust gases
Assessment of LPG exhaust gases
Check note √ Complete
- Not applicable O If in doubt, consult
O BGG 925
O
O German Ordinance on
O German Ordinance on
O German Ordinance on
O
O German threshold
Notes
competent factory inspectorate or employers’ liability insurance association
VDI 3313 driver permit
Industrial Safety and Health (BetrSichV)
Industrial Safety and Health (BetrSichV) and employer’s liability insurance associations
Industrial Safety and Health (BetrSichV)
Technical Regulations for Hazardous Substances (TRGS) 554 and the German Ordinance on Industrial Safety and Health (BetrSichV)
limit values list (MAK-Liste) and the German Ordinance on Industrial Safety and Health (BetrSichV)
22
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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)
348011800 EN - 07/2016 23
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2 Introduction
Residual risk
Hazard Measure
When charging the traction battery
When using battery chargers
When parking LPG trucks
With driverless transport systems
Roadway quality inadequate
Load carrier incorrect/slipped
Drive behaviour unpredictable
Driveways blocked Mark driveways
Note the German Ordinance on Industrial Safety and Health (BetrSichV), the operating instructions and the German Engineering Federation (VDMA) rules
Note the German Ordinance on Industrial Safety and Health (BetrSichV), employers’ liability insurance association regulation 104 and the operating instructions
Note the German Ordinance on Industrial Safety and Health (BetrSichV), employers’ liability insurance association regulation 104 and the operating instructions
Clean/clear driveways O German Ordinance on
Reattach load to pallet
Employee training
Keep driveways clear
Check note √ Complete
- Not applicable O Association for
O German Ordinance on
O German Ordinance on
O German Ordinance on
O German Ordinance on
O German Ordinance on
Notes
Electrical, Electronic and Information Technologies (VDE) regulation 0510: In particular
- Ensure adequate ventilation
- Insulation value within the permissible range
Industrial Safety and Health (BetrSichV) and employers’ liability insurance association regulation 104
Industrial Safety and Health (BetrSichV) and employers’ liability insurance association regulation 104
Industrial Safety and Health (BetrSichV)
Industrial Safety and Health (BetrSichV)
Industrial Safety and Health (BetrSichV)
Industrial Safety and Health (BetrSichV)
24
57348011800 EN - 07/2016
Introduction 2
Residual risk
Hazard Measure
Driveways intersect
Announce right-of­way rule
No person detection
Employee training during depositing and retrieval
.
Danger to employees
According to the German Ordinance on Indus­trial Safety and Health (BetrSichV) and labour protection law (ArbSchG), the operating com­pany must determine and assess hazards during operation, and establish the labour protection measures required for employ­ees (BetrSichVO). The operating company must therefore draw up appropriate operating instructions (§ 6 ArbSchG) and make them available to the driver. A responsible person must be appointed.
NOTE
Please observe t responsible per and "driver".
The construction and equipment of the truck correspond to the Machinery Directive 2006/42/EC and are therefore marked with CE labelling. These elements are therefore not included in the hazard assessment. At­tachments possess their own CE labelling and likewise are not included for that reason. The operating company must, however, select the type and equipment of the trucks so as to com­ply with the local provisions for deployment.
The result must be documented (§ 6 Arb­SchG). In the case of truck applications involv­ing similar hazard situations, the results may be summarised. This overview (see chapter "Overview of hazards and countermeasures") provides help on complying with this regula­tion. The overview specifies the main hazards that are the most frequent cause of accidents in the event of non-compliance. If other major
he definition of the following
sons: "operating company"
Check note √ Complete
- Not applicable O German Ordinance on
O German Ordinance on
Notes
Industrial Safety and Health (BetrSichV)
Industrial Safety and Health (BetrSichV)
348011800 EN - 07/2016 25
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2 Introduction
Residual risk
operational hazards are involved, they must also be taken into consideration.
The conditions of use for trucks are broadly similar in many plants, so the hazards can be summarised in one overview. Observe the information provided by the relevant employers’ liability insurance association on this subject.
26
57348011800 EN - 07/2016
3

Safety

3 Safety
Definition of responsible persons
Definition of responsible persons
Operating company
The operating company is the natural or legal person or group who operates the truck or on whose authority the truck is used.
The operating company must ensure that the truck is only used for its proper purpose and in compliance with the safety regulations set out in these operating instructions.
The operating company must all users read and understa information.
The operating company is responsible for the scheduling and correct performance of regular safety checks.
We recommend that the national performance specifications are adhered to.
Specialist
A qualified person is defined as a service engineer or a person who fulfils the following requirements:
• A completed vocation demonstrably proves expertise. This proo a vocational qualifi document.
• Professional experience indicating that the qualified person has gained practical experience of industrial trucks over a proven period during their career During this time, this person has become familiar with a wide range of symptoms that require checks to be carried out, such as based on the results of a hazard assessment or a daily inspection
• Recent professional involvement in the field of the industrial truck test in question and an appropriate further qualification are essential. The qualified person must have experience of carrying out the test in question or of carrying out similar tests. Moreover, this person must be aware of the latest technological developments
cation or a similar
ensure that
nd the safety
al qualification that their professional
f should consist of
28
57348011800 EN - 07/2016
Safety 3
Definition of responsible persons
regarding the industrial truck to be tested and the risk being assessed
Drivers
This truck may only be driven by suitable per­sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised rep­resentative, and have been specifically in­structed to drive the truck. Specific knowledge of the truck to be operated is also required.
The training requirements under §3 of the Health and Safety at Work Act and §9 of the plant safety regulations are deemed to have been satisfied if the driver has been trained in accordance with BGG (General Employers’ Liability Insurance Association Act) 925. Observe the national regulations for your country.
Driver rights, duties and rules of be­haviour
The driver must be trai duties.
The driver must be granted the required rights.
The driver must wear protective equipment (protection suit, safety footwear, safety helmet, industrial goggles and gloves) that is appropriate for the conditions, the job and the load to be lifted. Solid footwear should be worn to ensure safe driving and braking.
Thedrivermustbefa instructions and ha times.
The driver must:
• have read and understood the operating manual
• have familiarised himself with safe opera­tion of the truck
• be physically and m truck safely
ned in his rights and
miliar with the operating
ve access to them at all
entally able to drive the
348011800 EN - 07/2016 29
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3 Safety
Definition of responsible persons
DANGER
The use of drugs, alcohol or medications that affect reactions impair the ability to drive the truck!
Individuals under the influence of the aforementio­ned substances are not permitted to perform work of any kind on or with the truck.
Prohibition of use by unauthorised persons
The driver is responsible for the truck during working hours. He must not allow unautho­rised persons to operate the truck.
When leavingthe truck, the driver must secure it against unauthorised use, e.g. by pulling out the key.
30
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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
348011800 EN - 07/2016 31
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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
32
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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.
348011800 EN - 07/2016 33
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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
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!
34
57348011800 EN - 07/2016
Safety 3
Basic principles for safe operatio
Thefollowingfactorscanleadtoalossof stability and are therefore prohibited:
• Different tyres on the same axle, e.g. pneumatic tyres and superelastic tyres
• Tyres not approved by the manuf
• Excessive tyre wear
• Tyres of inferior quality
• Changing rim wheel parts
• Combining rim wheel parts from different manufacturers
The following rules must be observed to ensure stability:
• Only use tyres with equal and permitted levels of wear on the same axle
• Only use wheels and tyres o on the same axle, e.g. only tyres
• Only use wheels and tyres approved by the manufacturer
• Only use high-quality products
Wheels and tyres approv facturer can be found on If other wheels or tyres thorisation from the ma obtained beforehand.
– Contact the authorised service centre on
this matter.
When changing wheels or tyres, always ensure that this does not cause the truck to tilt to one side (e.g. always replace right­hand and left-hand wheels at the same time). Changes must only be made following consultation with the manufacturer.
If the type of tyre used for example from supe matic tyres, theload accordingly.
– Contact the authorised service centre on
this matter.
ed by the manu-
the spare parts list. aretobeused,au­nufacturer must be
on an axle is changed, relastic tyres to pneu-
diagram must bechanged
acturer
f the same type superelastic
n
348011800 EN - 07/2016 35
57
3 Safety
Basic principles for safe operatio
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.
Exercise caution when handling gas springs and accumulators
WARNING
Gas springs are under high pressure. Improper removal results in an elevated risk of injury.
For ease of operation, various functions on the truck can be supported by gas springs. Gas springs are complex components that are subject to high internal pressures (up to 300 bar). They may under no circumstances be opened unless instructed to do so, and may be installed only when not under pressure. If required, the authorised service centre will depressurise the gas spring in accordance with the regulations before removal. Gas springs must be depressurised before recycling.
– Avoid damage, lateral forces, buckling, tempe-
ratures over 80°C and heavy contamination.
– Damaged or defective gas springs must be
changed immediately.
– Contact the authorised service centre.
n
WARNING
Accumulators are under high pressure. Improper installation of an accumulator results in an elevated risk of injury.
Before starting work on the accumulator it must be depressurised.
– Contact the authorised service centre.
36
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Basic principles for safe operatio
Length of the fork arms
DANGER
Risk of accident due to the incorrect selection of fork arms!
– The fork arms must match the depth of the load.
If the fork arms are too short, the load may fall off the arms after it has been picked up. In addition, be aware that the load centre of gravity may shift as a result of dynamic forces, such as braking. A load that is otherwise resting safely on the fork arms may move forwards and fall.
If the fork arms are too long, they can catch on loading units behind the load that is to be picked up. These other loading units then fall over when the load is raised.
– For help with selecting thecorrect forkarms,
contact the authorised service centre.
n
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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 responsible persons", P. 28) and must be recorded in writing.
– Contact your ST
38
ILL service centre.
57348011800 EN - 07/2016
Safety 3
Safety tests
NOTE
Observe the national regulati
ons for your
country!
Particle filter
The truck has an SCR (Selec Reduction) exhaust gas tr part of its standard equip be operated in entirely or 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. Letting the combustion engine idle runs a risk of poisoning from the CO, CH and NO 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 that there is sufficient ventilation
available.
tive Catalytic
eatment system as
ment. The truck may
partially enclosed
x
NOTE
Observe the national regulations of the country in which the truck is being used!
The operating company must ensure that the below requirements are met; see the 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 must be confined and indi­cated by appropriate warning and safety signs
348011800 EN - 07/2016 39
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3 Safety
Safety tests
• Employees mustbe made aware ofdangers and protective measures
• The particle filter must be replaced every 6000 operating hours. The exhaust-gas check must be carried out by a competent person (see the chapter entitled "Definition of terms used for responsible persons") and the results must be recorded in writing
NOTE
Observe the TRGS 554 regulations and the national regulations of the country in which the truck is being used.
Insulation testing
The truck insulation must have sufficient insu­lation resistance. For this reason, insulation testing in accordance with DIN EN 1175 and DIN 43539, VDE 0117 and VDE 0510 must be conducted at least once every year.
NOTE
Contact your servic insulation test.
e centre to arrange for an
Measuring the insu the electrical sys
NOTE
lation resistance of
tem
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.
40
/V for
57348011800 EN - 07/2016
Safety 3
Safety regulations for handling co
nsumables

Safety regulations for handling consumables

Permissible consumables
DANGER
Failure to observe the safety regulations relating to consumables may result in a risk of injury, death or damage to the environment.
– Observe the safety regulations when handling
such materials.
Refer to the maintenance data table for the permissible substances that are necessary for operation (see ⇒ Chapter "Maintenance data table", P. 6-313).
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.
348011800 EN - 07/2016 41
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3 Safety
Safety regulations for handling co
WARNING
Prolonged intensive contact with the skin can result in dryness and irritate the skin!
– Avoid contact and consumption. – Wear protective gloves. – After any contact, wash the skin
with soap and water, and then apply a skin care product.
– Immediately change soaked
clothing and shoes.
WARNING
There is a risk of slipping on spilled oil, particularly when combined with water!
– Spilt oil should be removed immediately with
oil-binding agents and disposed of according to the regulations.
ENVIRONMENT NOTE
Oil is a water-polluting substance!
Always store oil in containers that comply with the applicable regulations.
Avoid spilling oils.
Spilt oil should be removed immediately with oil-binding agents and disposed of according to the regulations.
Dispose of old oils according to the regula­tions.
nsumables
Hydraulic fluid
These fluids are pressurised during operation of the truck and are hazardous to your health.
– Do not spill the fluids. – Follow the statutory regulations. – Do not allow thefluids to come into
contact with hot engine parts.
42
WARNING
57348011800 EN - 07/2016
Safety 3
nsumables
WARNING
These fluids are pressurised during operation of the truck and are hazardous to your health.
– Do not allow the fluids to come into
contact with the skin. – Avoid inhaling spray. – Penetration of pressurised
fluids into the skin is particularly
dangerous if these fluids escape
at high pressure due to leaks in
the hydraulic system. In case of
such injury, immediate medical
assistance is required. – To avoid injury, use appropriate
personal protective equipment
(e.g. protective gloves, industrial
goggles, skin protection and skin
care products).
ENVIRONMENT NOTE
Safety regulations for handling co
Hydraulic fluid is a water-polluting substance.
Always store hydraulic fluid in containers that comply with regulations
Avoid spills
Spilt hydraulic fluid should be removed immediately with oil-binding agents and disposed of according to the regulations
Dispose of old hydraulic fluid according to the regulations
Battery acid
Battery acid contains dissolved sulphuric acid. This is toxic.
– Avoid touching or swallowing the
– In case of injury, seek medical
WARNING
battery acid at all costs.
advice immediately.
348011800 EN - 07/2016 43
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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!
44
57348011800 EN - 07/2016
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.
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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 coolingfluid
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 that purpose. Care must be taken to minimise any environmental pollution.
– Soak up any spilt fluids such as hydraulic
oil or gearbox oil immediately using an oil-binding agent.
46
57348011800 EN - 07/2016
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
348011800 EN - 07/2016 47
57
3 Safety

Emissions

Emissions
The values specified apply to a standard truck (compare the specifications in the "Technical data" chapter). Different tyres, lift masts, additional units etc. may produce different values.
Noise emissions
The values were determined based on measuring procedures from the standard EN 12053 "Safety of industrial trucks. Test methods for measuring noise emissions", based on EN 12001, EN ISO 3744 and the requirements of EN ISO 4871.
This machine emits the fol pressure level:
Continuous sound pressure level in the driver’s compartment
L
pAZ
< 75.0 dB(A) 4 dB(A)
lowing sound
Measurement
uncertainty K
pA
The values were dete on an identical mach values for operatin
Time proportions:
• Lifting 18%
• Idling 58%
• Driving 24%
However, the indicated noise levels at the truck cannot be used to determine the noise emissionsat workplaces accordingto the most recent version of Directive 2003/10/EC (daily personal noise pollution). If necessary, these noise emissions should be determined by the operating company directly at the workplace under the actual conditions there (additional noise sources, special application conditions, sound reflections).
NOTE
Please note the pany" in the sen
48
rmined in the test cycle
ine from the weighted
g statuses and idling.
definition of "operating com-
se of responsible persons!
57348011800 EN - 07/2016
Safety 3
Emissions
Vibrations
The vibrations of the machine have been determined on an identical machine in ac­cordance with the standards DIN EN 13059 "Safety of industrial trucks - Test methods for measuring vibration" and DIN EN 12096 "Mechanical vibration - Declaration and verifi­cation of vibration emission values".
Frequency-weighted effective value of accel­eration on the seat
MSG 65 driver’s seat
<0.31m/s
2
Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or the operating devices in trucks is less than
2
2.5 m/s
. There are therefore no measure-
ment guidelines for these measurements.
The personal vibration a working day must be det operating company at t in accordance with Dir order to consider all a such as driving route,
Measurement
uncertainty
0.093 m/s
2
load on the driver over
ermined by the
he actual place of use
ective 2002/44/EC,in dditional influences, intensity of use etc.
NOTE
Please note the definition of "operating com­pany" in the sense of responsible persons!
348011800 EN - 07/2016 49
57
3 Safety
Emissions
Exhaust gases
DANGER
Risk to health from exhaust gases! Exhaust gases from internal combustion engines
are harmful to your health. In particular, the soot particles contained in the diesel exhaust gas can cause cancer.
When the internal combustion engine is running, there is a risk of poisoning from the CO, CH and NOx components contained in the exhaust gas.
Modern exhaust gas treatment systems (e.g. catalytic converters, particle filters or comparable systems) can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck.
– Always observe the national laws and regulati-
ons of the country of use when using trucks with an internal combustion engine in entirely or par­tially enclosed working areas.
– Always ensure sufficient ventilation.
Heat
DANGER
Risk of burns due to hot exhaust gases!
Exhaust gases or components that carry exhaust gases (e.g. exhaust pipes) can become so hot that direct body contact can cause burns to the skin and materials that are too close can be burned or singed.
– Do not grasp or touch hot exhaust
pipes.
– Keep combustible materials away
from the exhaust pipe.
– In the event of burns, seek first aid
immediately.
– If materials are burning, take fire
protection measures immediately.
50
57348011800 EN - 07/2016
Safety 3
Emissions
Battery
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.
348011800 EN - 07/2016 51
57
3 Safety
Emissions
52
57348011800 EN - 07/2016
4

Overviews

4 Overviews

Overview

Overview
11
10
9
1Liftmast 2 Driver’s compartment 3 Overhead guard 4 Bonnet 5 Battery maintenance lid 6 Steering axle
1
2
3
4
5
6
7341_003-002_V3
8
7
7Driveaxle 8 Tilt cylinder 9 Fork arms 10 Fork carriage 11 Lift cylinder
54
57348011800 EN - 07/2016
Overviews 4
Overview of the driver’s compartme
Overview of the driver’s compartment
2
3
1
15
14
4
5
4
9
1
0
0
-
%
+
2
7
5
1
5
0
1
2
8
9 0
8
3
6
1 5
:2
3
F 1
F2
6
nt
13
12
1Parking 2 Steeri 3Keysw 4 Displ 5Docu 6Ope
7Co 8B
NOTE
The truck equipment may differ from the equipment shown.
brake lever
ng wheel
itch
ay and operating unit
ment holder
rating devices for hydraulic and traction
nctions
fu
mpartment
ottle holder for max. 1.5 l bottles
11
10
9
9 Driver’ 10 Compar
for op 11 Compa 12 Fill 13 Acc 14 Br 15 St
er cap for windscreen washer reservoir
elerator pedal ake pedal eering column adjustment
7
8
sseat
tment and potential storage location
erating instructions
rtment
7341_003-022
348011800 EN - 07/2016 55
57
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
56
57348011800 EN - 07/2016
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
348011800 EN - 07/2016 57
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.
58
57348011800 EN - 07/2016
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
348011800 EN - 07/2016 59
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
7325_003-027
6Functionkey" 7 "Auxiliary h 8 "Auxiliary 9 Signal hor
5th function"
ydraulics 1" operating lever hydraulics 2" operating lever n button
8
60
57348011800 EN - 07/2016
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
348011800 EN - 07/2016 61
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.
62
57348011800 EN - 07/2016
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
Operating devices and display elem
ents
Mini console
The mini console is located on the steering column below the steering wheel.
2
1
1 Travel direction s 2 Direction indica
7311_003-056
witch
tor switch
348011800 EN - 07/2016 63
57
4 Overviews
5430
1010
1080
1080
1080
1050
1150
1310
4430
1110
1230
1250
1500
4030
1150
1260
1200
1500
3730
1180
1290
1430
1500
3430
1210
1330
1470
1500
800
700
500
2
1
3
1

Labelling points

Labelling points
Overview
10
6
18
9
2
21
20
17
3
13
12
19
13
DANGER
DANGER
14
15
4
L
WA
4
3
DANGER
17
7
20
16
7
11
8
8
STILL GmbH Hamburg
nach nationalen Vorschriften basierend auf den EG-Richtlinien: 2009/104/EG, 99/92/EG
Regelmäßige Prüfung
(FEM 4.004)
Nächste Prüfung
5
15
20
21
9
20xx
1080
1310
1500
1500
1500
1500
500
Mitglied der: Fédération Européene de la Manutention
max
min.*
*
kg
kg
kg
kg
56344391019
12
DANGER
7341_003-016_V5
2
1
5
17
DANGER
Die Prüfplakette ersetzt nicht das Prüfprotokoll
6
DANGER
14
15
10 bar
19
13
16
11
1080
5430
1080
1010
1050
5030 1270
1150
4430
1110
1230
1250
4030
1150
1260
1200
3730
1180
1290
1430
3430
1210
1330
1470
800
700
600
Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
Rated capacity Capacité nominale Nenn-Tragfähigkeit
Battery voltage Tension batterie Batteriespannung
Rated drive power Puissance motr.nom. Nenn-Antriebsleist.
Unladen mass
kg
Masse à vide Leergewicht
V
kW
* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung
64
57348011800 EN - 07/2016
Overviews 4
Labelling points
1 Decal information: Caution/read the operat-
ing instructions 2 Decal information: Diesel fuel 3 Decal information: Sound power level 4 Warning sign: Do not stand underneath the
fork/Do not stand on the fork/Danger due to
shearing/Danger due to high fluid pressure 5 Decal information: Hydraulic oil tank 6 Decal information: Attachment capacity
rating plate 7 Decal information: Inspection sticker 8 Decal information: FEM test 9 Decal information: Caution/Read the op-
erating instructions/Fasten seat belt/Apply
parking brake when leaving the truck/Pas-
sengers are not allowed/Do not jump off if
the truck is tipping over/Lean in the opposite
direction to which the truck is tilting 10 Manufacturer’s label text 11 Decal information: Nameplate
12 Decal information: Capacity rating plate 13 Decal information: Lifting gear attachment
point
14 Warning sign: Actuate accumulator/brake
pedal 30x /read operating instructions 15 Decal information: Tyre filling pressure 16 Decal information: StVZO (German Road
Traffic Licensing Regulations) information
(variant) 17 Warning sign: Danger due to shearing/Dan-
ger due to high fluid pressure 18 Manufacturer’s label text 19 Decal information: Before opening the
bonnet, slide the seat forwards, lower the
armrest and fold the seat backrest down.
Then open the bonnet. 20 Warning sign: Do not stand underneath the
fork/Do not stand on the fork 21 Decal information: To unlock, turn 90° to the
right/to lock, turn 90° to the left
348011800 EN - 07/2016 65
57
4 Overviews
Labelling points
Nameplate
The truck can be identified from the informa­tion on the nameplate.
1
2
3
Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
12
11
10
Rated capacity Capacité nominale Nenn-Tragfähigkeit
Battery voltage Tension batterie Batteriespannung
Rated drive power Puissance motr.nom. Nenn-Antriebsleist.
Unladen mass
kg
Masse à vide Leergewicht
V
kW
* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung
9
1 Type 2 Production numbe 3 Year of manufact 4 Tare weight in k 5 Max. permissi
electric fork
6 Min. permis
orklift trucks only)
electric f
7 Ballast we
only)
8Referto
9CElab 10 Nomi 11 Bat 12 Ra
the technical data listed in these
ing instructions for more detailed
operat
ation
inform
elling
nal drive power in kW
tery voltage in V
ted capacity in kg
r
ure
g
ble battery weight in kg (for
lift trucks only)
sible battery weight in kg (for
ight in kg (for electric forklift trucks
4
kg
max
min.*
*
5
kg
kg
6
kg
7
8
6210_921-003_V2
66
57348011800 EN - 07/2016
Overviews 4
Labelling 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)
348011800 EN - 07/2016 67
57
34
7094_003-098
4 Overviews
Labelling points
68
57348011800 EN - 07/2016
5

Operation

5 Operation
Checks and tasks to be carried out pr
ior to commissioning

Checks and tasks to be carried out prior to commissioning

Visual inspections
WARNING
Risk of accident due to damage or other defects on the truck or on the attachment (variant)!
Damage to the truck or the attachment (variant) can lead to 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.
70
57348011800 EN - 07/2016
2
1
6210_000-002
Operation 5
Checks and tasks to be carried out pr
• Attachments (variant) must be properly mounted and function according to the operating instructions.
• All decal information signs must be in place and legible. Replace damaged or missing adhesive labels in accordance with the overview in the "Identification points" chapter.
• Any warning units (e.g. sign in perfect condition and fun
• Check the visible areas of the hydraulic system and hydraulic oil tank for damage and leaks. Damaged hoses must be replaced 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
348011800 EN - 07/2016 71
57
5 Operation
Checks and tasks to be carried out pr
Filling the washer system
CAUTION
Components may become damaged due to the effects of frost!
Water expands when it freezes. If there is no anti-freeze in the washer system, the system may be damaged due to the build up of ice in freezing conditions.
– Always use washer fluid containing anti-freeze.
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. 6-313.
– Close lid.
– Operate washer system until washer fluid is
discharged from the spray nozzles.
ior to commissioning
2
1
Checking the condition of the wheels and tyres
WARNING
Risk of accidents! With uneven wear or incorrectair pressure, the stability of the forklifttruck decreases and the braking distance increases.
– Change worn or damaged tyres without delay.
72
57348011800 EN - 07/2016
7331_341-001
Operation 5
Checks and tasks to be carried out pr
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
ior to commissioning
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
1
2
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".
348011800 EN - 07/2016 73
57
7321_003-003
5 Operation
Checks and tasks to be carried out pr
ior to commissioning
Checking the cooling fluid level
The coolant level is monitored by a sensor.
As soon as the appears on the display, proceed as described below.
WARNING
Risk of scalding due to hot cooling fluid! The cooling system is pressurised! Opening the
cooling fluid tank (1) may result in hot cooling fluid leaking out. Only open the cooling fluid tank when the cooling system is cool.
– Switch off the engine and allow it to cool down. – Do not open the cooling fluid tank until the truck
has cooled down.
WARNING
Coolant and cooling fluid can pose a hazard to health and the environment!
– Observe the safety regulations set out in the
section entitled "Coolant and cooling fluid".
– Top up the cooling fluid if necessary; refer
to the section entitled "Topping up the cooling fluid and checking the coolant concentration".
CAUTION
Risk of engine damage! If the coolant level is low, this indicatesa leakage in
the cooling system.
COOLANTLEVEL message
1
7341_003-017
– Check the cooling system for leaks; see
the section entitled "Cleaning the radiator, checking for leaks".
Checking the engine oil level
NOTE
To determine the oil level exactly, the truck must be horizontal when checking.
– Ensure that the truck is parked in a horizon-
tal position.
– Open the bonnet.
74
57348011800 EN - 07/2016
Operation 5
Checks and tasks to be carried out pr
– Stand on the bottom plate of the driver’s
cab and turn your body slightly to the left as shown.
– Using both hands, pull out the oildipstick (1)
and wipe it using a cloth.
ior to commissioning
7341_003-065
7341_003-066
348011800 EN - 07/2016 75
57
5 Operation
Checks and tasks to be carried out pr
ior to commissioning
– Insert the oil dipstick (1) as far as it will go
and pull it out again.
The oil level must be between the marks (arrows).
– If the oil level reaches only up
marking, fill oil in accordance
to the lower with the
maintenance data table.
– Insert the oil dipstick to the stop.
– Close the bonnet.
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 can result in unintentional actuation of the steering or the operating devices and thus cause uncontrolled movements of the truck or load.
– Do not adjust the seat or seat backrest while
driving.
– Adjust the seat and seat backrest so that all
operating devices can be actuated safely.
– Ensure that the seat and seat backrest are
securely engaged.
1
7341_003-010
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.
NOTE
If there are separate operating instructions for the seat, they must be followed.
76
57348011800 EN - 07/2016
Operation 5
Checks and tasks to be carried out pr
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 seat’s swivel area.
ior to commissioning
Moving the driver’s seat
– Lift the lever (1) and hold.
– Push the driver’s seat into the desired
position.
– Release the lever.
– Ensure that the driver’s seat is securely
engaged.
Adjusting the seat backrest
Do not put pressure on the seat backrest while engaging it.
– Lift the lever (2) and hold.
– Push the seat backrest into the desired
position.
– Release the lever.
– Ensure that the seat backrest is securely
engaged.
NOTE
The backwards tilt angle of the seat backrest can be restricted by the structural condition of the truck.
348011800 EN - 07/2016 77
57
1
7094_003-006
2
7094_003-008
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 MSG 75 seat is equipped with electric air suspension activated with an electric switch instead of a lever (3).
– Fully extend weight adjusting lever (3).
– Pump it upor 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.
NOTE
The correct driver’s weight has been selected when the arrow (4) is in the centre of the inspection window. A noticeable empty lift on the weight adjusting lever shows that you have reached the minimum or maximum weight setting.
ior to commissioning
4
3
6321_003-038
Adjusting the lumbar support (variant)
NOTE
The lumbar support can be adjusted to suit the contours of the individual driver’s spine. Adjusting the lumbar support moves a convex support cushion into the upper or lower part of the backrest.
– Turn the turning knob (5) up or down until
the lumbar support isin the desired position.
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5
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Operation 5
Checks and tasks to be carried out pr
ior to commissioning
Adjusting the backrest extension (variant)
– Adjust the backrest extension (6) by pulling
it out or pushing it into the desired position.
To remove the backrest extens past the end stop by jolting i
ion, move it
t upwards.
Switching the seat heater (variant) on and off
NOTE
The seat heater only functions if the seat contact switch is active, i.e. when the driver is sitting on the driver’s seat.
– Switch the seat heater (7) on or off using the
switch.
6
6321_003-040
7
Adjusting the armrest
DANGER
There is a risk of accident if the armrest lowers sud­denly, causing the driver to move in an uncontrolled manner. This can result in unintentional actuation of the steering or the operating devices and thus cause uncontrolled movements of the truck or load.
– Do not adjust the armrest while driving. – Adjust the armrest so that all operating devices
canbeactuatedsafely.
– Ensure that the armrest is securely tightened.
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5 Operation
Checks and tasks to be carried out pr
Adjusting the length of the armrest
– Release the star-grip handle (1) by turning
it anti-clockwise.
– Shift the armrest (2) into the d
tion.
– Tighten the star-grip handle by turning it
clockwise.
– Check that the armrest is firmly attached.
esired posi-
Adjusting the height of the armrest
– Release hand wheel (3) by tu
clockwise.
– Shift the armrest (2) into the desired posi-
tion.
– Tighten the hand wheel by turning it clock-
wise.
– Check that the armrest is
rning it anti-
firmly attached.
ior to commissioning
3
2
1
7331_342-001
Adjusting the steeri
– Press down the steeri
lever (2).
– Position the steering column (1) and pull the
lever up again.
DANGER
Risk of accidents! – Ensure that the steering column is secure. Thesteeringcolumnmustclickintoplace. Never adjust the steering column while driving.
80
ng column
ng column adjustment
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1
2
6210_424-001
Operation 5
Checks and tasks to be carried out pr
ior to commissioning
Cleaning the dust valve
– Press the dust valve (1) on the air filter
housing between your fingers until no more dust is emitted.
Checking the pre-cleaner
The pre-cleaner is part of the "heavy dust guard" equipment variant and is mounted at the rear right of the truck. In the pre-cleaner, coarse dust and dirt are removed from the intake air.
Checking the pre-cleaner
– Check the dirt l
The pre-cleaner must be cleaned if it is filled to the upper marking (1), see the "Cleaning the pre-cleaner" chapter.
evel in the pre-cleaner (2).
7311_120-004
2
1
1
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5 Operation
Checks and tasks to be carried out pr
Checking the oil tank on the oil bath air filter
The oil bath air filter is a further variant of the "heavy dust guard" equipment variant and is mounted on the rear right of the truck. The oil bath air filter filters finer dust and dirt particles that have passed through the pre-cleaner out of the intake air.
WARNING
There is a risk of slipping on spilled oil, particularly when combined with water!
The oil tank (4) is filled with oil to the level marker (3).
– Carefully remove the oil tank. – Collect any spilt oil immediately using an oil
binding agent and dispose of it in accordance with regulations.
– Observe the safety information for handling oils,
see the "Oils" chapter.
– Fold up the four oil tank locking brackets (2).
– Remove the oil tank from the housing (1).
– Check the dirt level in the oil tank.
The oil tank must be cleaned if the deposited dirt reaches approximately halfway up to the oil level; see the "Cleaning the oil bath filter" chapter.
– Secure the oil tank with the four locking
brackets on the housing.
ior to commissioning
2
4
1
2
3
2
7341_003-020
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Operation 5

Commissioning

Commissioning
Climbing into and out of the truck
WARNING
Risk of injury when climbing into and out of the truck due to slipping, striking parts of the truck or becoming stuck!
If the footwell cover is very dirty or smeared with oil, there is a risk of slipping. There is a risk of hitting your head on the overhead guard post or of your clothes becoming stuck when climbing out of the truck.
– Ensure that the footwell cover is non-slip. – Do not jump into or out of the truck. – Ensure that you have a secure grip on the truck.
WARNING
Risk of injury when jumping out of the truck! If your clothing or jewellery (e.g. watch, ring etc.)
becomes stuck on a component while you are jumping out of the truck, this can lead to serious injuries (e.g. from falling, loss of fingers etc.). It is forbidden to jump out of the truck.
– Do not jump out of the truck. – Do not wear jewellery at work. – Do not wear loose-fitting workwear.
CAUTION
Components may become damaged through incorrect use!
Truck components, such as the driver’s seat, steering wheel, parking brake lever etc., are not designed to be used for climbing in and out of the truck and may be damaged due to misuse.
– Only use the fittings specifically designed for the
purpose of climbing into and out of the truck.
NOTE
The foot that the driver starts with when climbing into and out of the truck is crucial in ensuring this action is carried out safely. This will depend on the number of steps. Trucks with a single wheel on the front axle feature two steps. Trucks with two wheels on the front axle feature three steps.
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5 Operation
Commissioning
Climbing in and out of trucks featuring a single wheel and two steps
When climbing into and out of the truck, use the handles (2) and (4) for support. The overhead guard post (1) can also be used for support.
Always climb into the truck f
– Grip handle (2) with your left hand and hold
on.
– Grip handle (4) with your right hand and
hold on.
– Place your right foot on the
– Place your left foot on the top step (6).
– Place your right foot into the footwell (7).
– Enter the truck and sit do
seat (3).
Always climb out of the truck backwards:
– Grip handle (2) with your left hand and hold
on.
– Stand up from the drive
your left foot on the to
– Grip the handle (4) with your right hand and
hold on.
– Place your right foot on the bottom step (5).
– Place your left foot o
down from the truck.
acing forwards:
bottom step (5).
wn on the driver’s
r’s seat and place
pstep(6).
n the ground and climb
7
21
3
4
6
5
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Operation 5
Commissioning
Climbing in and out of trucks featuring two wheels and three steps
When climbing into and out of the truck, use the handles (2) and (4) for support. The overhead guard post (1) can also be used for support.
Always climb into the truck f
– Grip handle (2) with your left hand and hold
on.
– Grip handle (4) with your right hand and
hold on.
– Place your left foot on the b
– Place your right foot on the middle step (6).
– Place your left foot on the top step (7).
– Place your right foot int
– Enter the truck and sit down on the driver’s
seat (3).
Always climb out of the truck backwards:
– Grip handle (2) with yo
on.
– Stand up from the driver’s seat and place
your left foot on the top step (7).
– Grip the handle (4) with your right hand and
hold on.
– Place your right foot
– Place your left foot on the bottom step (5).
– Place your right foot on the ground and
climb down from the truck.
acing forwards:
ottom step (5).
o the footwell (8).
ur left hand and hold
onthemiddlestep(6).
8
7
6
21
3
4
5
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5 Operation
Commissioning
Unlocking the emergency off switch
NOTE
Only trucks with a joystick 4Plus (variant) have an emergency off switch.
– Pull out the emergency of
unlatches.
f switch (1) until it
Switching on the key switch
WARNING
Before switching on the key switch, all tests prior to commissioning must be performed without any defects being detected.
– Perform the tests prior to commissioning. – Do not operate the truck if defects have been
detected.
– Notify the authorised service centre.
NOTE
If the steering is turned when switching on the truck, the truck will travel more slowly. This driving speed limitation is disabled as soon as the truck is steered out of cornering to drive in a straight line. To do this, rotate the steering wheel by approximately half a turn.
1
6321_003-142
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Operation 5
Commissioning
– Insert the switch key (1) into the key switch
and turn to position "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
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5 Operation
Commissioning
When the key switch is switched on, the display shows the welcome screen in the set language until the truck controllers have fully started up.
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 cur and minutes. The see the chapter time".
el in the fuel tank as a
rent time digitally in hours
time can be adjusted;
entitled "Setting the
75
%
234,7 h
12:15
1
2
2
3
4
7312_003-057_V2
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