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

Download

Original instructions

Diesel trucks

With SCR (Selective Catalytic Reduction)

RX70-60 RX70-70 RX70-80

7341 7342 7343 7344

57348011800 EN - 07/2016

Preface

Address of manufacturer and contact details

STILL GmbH Berzeliusstraße 10 22113 Hamburg, Germany Tel. +49 (0) 40 7339-0 Fax: +49 (0) 40 7339-1622 Email: info@still.de Website: http://www.still.de

348011800 EN- 07/2016 I

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

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

348011800 EN - 07/2016 III

Table of contents

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

er’s compartment ..................................... 55

orhydraulicanddrivingfunctions .......................... 57

er .................................................. 60

57348011800 EN - 07/2016

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

348011800 EN - 07/2016 V

Table of contents

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

57348011800 EN - 07/2016

Table of contents

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

348011800 EN - 07/2016 VII

Table of contents

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

II 57348011800 EN - 07/2016

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

348011800 EN - 07/2016 IX

Table of contents

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

7348011800 EN - 07/2016

Foreword

1 Foreword

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.

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

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

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

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

1 Foreword

Information about the documentati

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

7348011800 EN - 07/2016

Foreword 1

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.

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

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.

Abbreviation

°C

°F

ABE

ArbSchG

BetrSichV

BGG

BGR German Social

Accident Insurance

Approx.

CEE

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

Abbreviation

Meaning

Cubic centimetres

dB Decibels

DFÜ

Remote data transmission

DIN German standard

EN FEM F

max

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

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

pAZ

LSP

o.s.

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

1 Foreword

Information about the documentati

Abbreviation

m/s

MAK

Meaning

Metres per second

Metres per second squared

Maximum workplace concentration

Max. Maximum

Min. Minimum

min Minutes rpm

Revolution(s) per minute

Millimetres N Newtons Nm Newton metres PIN

SIT

StVZO

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

57348011800 EN - 07/2016

Foreword 1

Information about the documentati

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.

6210_001-031

6210_003-062

348011800 EN - 07/2016 11

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.

57348011800 EN - 07/2016

Foreword 1

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.

348011800 EN - 07/2016 13

1 Foreword

Environmental considerations

57348011800 EN - 07/2016

Introduction

2 Introduction

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.

57348011800 EN - 07/2016

Introduction 2

Using the truck

DANGER

There is a risk of fatal injury from falling off the truck while it is moving!

– It is prohibited to carry passengers

on the truck.

The truck may not be operated in areas where there is a risk of ﬁre, explosion or corrosion, or in areas that are particularly dusty.

Stacking or unstacking is not permissible on inclined surfaces or ramps.

Place of use

The truck can be used 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

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.

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Introduction 2

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

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

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

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 German Ordinance on

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)

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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

Notes

Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG)

348011800 EN - 07/2016 23

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

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

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)

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)

348011800 EN - 07/2016 25

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.

57348011800 EN - 07/2016

Safety

3 Safety

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

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

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.

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Safety 3

Basic principles for safe operatio

Basic principles for safe operation

Insurance cover on company premises

In many cases, company premises are restricted public trafﬁc areas.

NOTE

The business liability insurance should be reviewed to ensure that, in the event of any damage caused in restricted public trafﬁc areas, there is insurance cover for the truck in respect of third parties.

Changes and retroﬁtting

If the truck is used for work that is not listed in the guidelines or in these instructions and has to be converted or retroﬁtted accordingly, you must note that any change to its structural state can affect the handling and stability of the truck, which in turn can lead to accidents.

You should therefor centre beforehand.

Changes that will adversely affect stability, load capacity and safety systems, among other things, must not be made without the manufacturer’s approval.

Thetruckmayonlybeconvertedwithwritten approval from the manufacturer. Approval from the responsible authority must be obtained if necessary.

Changes to the bra elements, circum variants and atta made without the p manufacturer.

We warn against installing and using restraint systems not approved by the manufacturer.

e contact your service

kes, steering, control

ferential view, equipment

chments must also not be

rior written approval of the

348011800 EN - 07/2016 31

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:

57348011800 EN - 07/2016

Safety 3

Basic principles for safe operatio

– Type of change

– Date of change

– Name and address of the company

menting the change.

imple-

Changes to the overhead gua

rd and

roof loads

DANGER

In the event of the overhead guard failing due to a falling load or the truck tipping over, there are potentially fatal consequences for the driver. There isarisktolife!

Welding and drilling on the overhead guard changes the material characteristics and the structural design of the overhead guard. Excessive forces caused by 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

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.

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!

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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

348011800 EN - 07/2016 35

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.

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.

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Safety 3

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.

348011800 EN - 07/2016 37

3 Safety

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

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.

– 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

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

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.

/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

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.

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

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!

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.

348011800 EN - 07/2016 45

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.

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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

3 Safety

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

pAZ

< 75.0 dB(A) 4 dB(A)

lowing sound

Measurement

uncertainty K

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

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

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

2.5 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

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

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.

– 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.

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

3 Safety

Emissions

57348011800 EN - 07/2016

Overviews

4 Overviews

Overview

1Liftmast 2 Driver’s compartment 3 Overhead guard 4 Bonnet 5 Battery maintenance lid 6 Steering axle

7341_003-002_V3

7Driveaxle 8 Tilt cylinder 9 Fork arms 10 Fork carriage 11 Lift cylinder

57348011800 EN - 07/2016

Overviews 4

Overview of the driver’s compartme

Overview of the driver’s compartment

9 0

1 5

F 1

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

mpartment

ottle holder for max. 1.5 l bottles

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

sseat

tment and potential storage location

erating instructions

rtment

7341_003-022

348011800 EN - 07/2016 55

4 Overviews

Operating devices and display elem

ents

Operating devices and display elements

Display and operating unit

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

234,7 h

12:15

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

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

nd may differ from the assignment actually

rogrammed on the truck. Buttons may be

ssigned multiple functions that are called up

ccording to the menu navigation. For further

nformation, see the "Operating the display

nd operating unit" chapter.

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

4 Overviews

Operating devices and display elem

Double mini-lever

ents

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

7325_003-025

5 Function key "5th function" 6 "Attachments" cross lever 7 Signal horn button

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.

57348011800 EN - 07/2016

Overviews 4

Operating devices and display elem

ents

Three-way mini-lever

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

yF2

ection/turn indicator" cross lever

7325_003-026

5 Function key " 6 "Auxiliary h 7 "Auxiliary 8 Signal hor

5th function"

ydraulics 1" operating lever

hydraulics 2" operating lever

n button

348011800 EN - 07/2016 59

4 Overviews

Operating devices and display elem

Four-way mini-lever

ents

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

7325_003-027

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

5th function"

ydraulics 1" operating lever hydraulics 2" operating lever n button

57348011800 EN - 07/2016

Overviews 4

Operating devices and display elem

ents

Joystick 4Plus

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

6210_003-087

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

4 Overviews

Operating devices and display elem

Fingertip

ents

23456

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.

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.

1 Travel direction s 2 Direction indica

7311_003-056

witch

tor switch

348011800 EN - 07/2016 63

4 Overviews

5430

1010

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

Labelling points

Overview

DANGER

STILL GmbH Hamburg

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

Regelmäßige Prüfung

(FEM 4.004)

Nächste Prüfung

20xx

1080

1310

1500

500

Mitglied der: Fédération Européene de la Manutention

max

min.*

56344391019

DANGER

7341_003-016_V5

DANGER

Die Prüfplakette ersetzt nicht das Prüfprotokoll

DANGER

10 bar

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

Masse à vide Leergewicht

* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung

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

4 Overviews

Labelling points

Nameplate

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

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

Masse à vide Leergewicht

* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung

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

ure

ble battery weight in kg (for

lift trucks only)

sible battery weight in kg (for

ight in kg (for electric forklift trucks

max

min.*

6210_921-003_V2

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

7090_921-004

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

7094_003-098

4 Overviews

Labelling points

57348011800 EN - 07/2016

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.

57348011800 EN - 07/2016

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

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

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.

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

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

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.

COOLANT LEVEL message

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.

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

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.

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.

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

7094_003-006

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

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.

57348011800 EN - 07/2016

6321_003-039

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.

6321_003-040

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.

348011800 EN - 07/2016 79

6321_003-041

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

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.

ng column

ng column adjustment

57348011800 EN - 07/2016

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

7341_003-021

348011800 EN - 07/2016 81

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

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57348011800 EN - 07/2016

Operation 5

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

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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).

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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.

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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

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

234,7 h

12:15

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

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Address of manufacturer and contact details

Table of contents

Foreword

Your truck

General

Note regarding SCR (Selective Catalytic Reduction) as exhaust gas treatment

CE labelling

EC declaration of conformity in accordance with Machinery Directive

Accessories

Information about the documentation

Documentation scope

Issue date and topicality of the operating instructions

List of abbreviations

Schematic views

Environmental considerations

Packaging

Introduction

Using the truck

Proper usage

Proper use during towing

Impermissible use

Place of use

Using working platforms

Residual risk

Residual dangers, residual risks

Special risks associated with using the truck and attachments

Danger to employees

Safety

Operating company

Specialist

Drivers

Basic principles for safe operation

Insurance cover on company premises

Warning regardingnon-original parts

Damage, defects and misuse of safety systems

Tyres

Medical equipment

Exercise caution when handling gas springs and accumulators

Length of the fork arms

Safety tests

Regular safety inspection of the truck

Insulation testing

Safety regulations for handling consumables

Permissible consumables

Oils

Battery acid

Diesel fuel

Disposal of consumables

Emissions

Overviews

Overview

Operating devices and display elements

Display and operating unit

Operating devices for hydraulic and driving functions

Double mini-lever

Three-way mini-lever

Four-way mini-lever

Joystick 4Plus

Fingertip

Mini console

Labelling points

Overview

Nameplate

Production number

Operation

Checks and tasks to be carried out prior to commissioning

Visual inspections

Filling the washer system

Checking the condition of the wheels and tyres

Checking the engine oil level

Adjusting the armrest

Cleaning the dust valve

Checking the pre-cleaner

Commissioning

Climbing into and out of the truck