Original instructions Diesel truck - MVC-Empilhadores

Original instructions

Diesel truck

RX70-16RX70-18RX70-20

7311 7312 7313

174749 EN - 11/2018

Prefaceg

Address of manufacturer andcontact detailsSTILL GmbHBerzeliusstraße 1022113 Hamburg, GermanyTel. +49 (0) 40 7339-0Fax: +49 (0) 40 7339-1622Email: [email protected]: http://www.still.de

Rules for the operatingcompany of industrial trucksIn addition to these operating instructions,a code of practice containing additionalinformation for the operating companies ofindustrial trucks is also available.

This guide provides information for handlingindustrial trucks:• Information on how to select suitableindustrial trucks for a particular area ofapplication

• Prerequisites for the safe operation ofindustrial trucks

• Information on the use of industrial trucks• Information on transport, initial commis-sioning and storage of industrial trucks

Internet address and QR codeThe information can be accessed at any timeby pasting the address https://m.still.de/vdmain a web browser or by scanning the QR code.

174749 EN - 11/2018 I

Table of contentsg

1 ForewordYour truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Description of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 6Accessories overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Labelling points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10StVZO (Road Traffic Licensing Regulations) information . . . . . . . . . . . . . . . . . . . . . . . 11

Use of truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Proper use during towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Supplementary documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Issue date and topicality of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 17Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 SafetyDefinition of responsible persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Essentials for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Insurance cover on company premises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Changes to the overhead guard and roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Damage, defects andmisuse of safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . . 32Length of the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Special risks associated with using the truck and attachments . . . . . . . . . . . . . . . . . . . 35Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Safety inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Checking the diesel engine emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Trucks with particle filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Safety regulations when handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Coolant and cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3 OverviewsGeneral view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Driver's compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Operating devices for hydraulic and driving functions . . . . . . . . . . . . . . . . . . . . . . . . . . 59Double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Three-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Four-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Mini console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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4 OperationTesting and activities before daily use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Climbing in and out of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Shelves and cup holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Adjusting the MSG 65/MSG 75 driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Adjusting the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Checking the brake system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Checking the steering system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Checking the emergency off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Zero adjustment of the load measurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Checking the vertical lift mast position (variant) for correct function . . . . . . . . . . . . . . . . 89

Switching on and starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Operation of the display operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104Adjusting the displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Setting the date or time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Resetting the daily kilometres and daily operating hours . . . . . . . . . . . . . . . . . . . . . . . 112Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Softkeys for operating various equipment variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Configuring Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Switching off additional consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116Switching efficiency mode Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Driveways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120Setting the drive programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Actuating the drive direction switch, mini-lever version . . . . . . . . . . . . . . . . . . . . . . . . . 125Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 125

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Actuating the drive direction switch, fingertip version . . . . . . . . . . . . . . . . . . . . . . . . . . 126Actuating the drive direction switch, mini-console version . . . . . . . . . . . . . . . . . . . . . . 126Starting to drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Starting drive mode, dual pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Actuating the mechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132Actuating the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139Driving on ascending and descending gradients . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140Reducing speed with a raised load (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141Automatic shut-off of the internal combustion engine (variant) . . . . . . . . . . . . . . . . . . . 141

Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Parking the truck securely and switching it off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Wheel chock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Lift mast vertical position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Types of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149Malfunctions during lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Hydraulic blocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153Controlling the lifting system using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 154Controlling the lifting system using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . 155Controlling the lifting system using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . 156Controlling the lifting system using the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 157Controlling the lifting system using the fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Operation with reversible fork arms (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Working with loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Safety regulations when handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Before taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Loadmeasurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168Picking up loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171Danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Transporting suspended loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183Releasing the pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187Controlling attachments using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189Controlling attachments using the double mini-lever and the 5th function . . . . . . . . . . . 191Controlling attachments using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Controlling attachments using the triple mini-lever and the 5th function . . . . . . . . . . . . . 195Controlling attachments using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 197Controlling attachments using the quadruple mini-lever and the 5th function . . . . . . . . . 199Controlling attachments via the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Controlling attachments using the joystick 4Plus and the 5th function . . . . . . . . . . . . . . 202Controlling the attachments with the fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Controlling attachments with the fingertip and 5th function . . . . . . . . . . . . . . . . . . . . . . 204Clamp locking mechanism (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206Taking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Switching the lighting on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210Switching the working spotlight for reverse travel on and off . . . . . . . . . . . . . . . . . . . . . 211Switching the rotating beacon on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Switching the hazard warning system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Switching the turn indicator on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Switching the double working spotlights on and off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 216STILL SafetyLight (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Operating the windscreen wiper/washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Shock recognition (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Cruise control (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Driver restraint systems (variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224Ceiling sensor (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230Opening the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230Closing the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231Closing the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Operating the interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Operating the rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

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Radio (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234Heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235Push-up roof window (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236Clipboard (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263Malfunctions in the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276Diesel fuel - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276Topping up the diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Cleaning the windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285After washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Behaviour in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Emergency hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Emergency operation of the electric parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Disconnecting the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Jump starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303Recommissioning after decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

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Table of contentsg

5 MaintenanceSafety instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312Maintenance - 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315Maintenance— 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 320Lubrication plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Opening the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325Closing the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Installing and removing the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Maintenance after first 50 operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Maintenance during the break-in period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Remaining ready for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329Checking the cooling fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Cleaning the radiator, checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Topping up the cooling fluid and checking the coolant concentration . . . . . . . . . . . . . . . 332Changing the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Draining water from the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Eberspächer particle filters - Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337Lubricating the joints and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340Maintaining the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Checking the driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Checking the door latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Servicing wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Servicing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

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Checking the hydraulic system for leak tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Lubricating the lift mast and roller track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Greasing the automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Changing the heating system fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

1000-hour maintenance / Annual maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Other tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Checking the exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Checking the lift cylinders and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 355Checking the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Checking the reversible fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

6 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

VDI datasheet for RX70-16, RX70-18 and RX70-20 . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Ergonomic dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

Fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

X 174749 EN - 11/2018

1

Foreword

1 ForewordYour truck

Your truckDescription of the truck

GeneralThe internal combustion engine-poweredtrucks in the RX70-16/18/20 series with aload capacity of up to 2 t are equipped withan internal combustion/electric drive. Theinternal combustion/electric drive combinesthe advantages of the diesel engine with theprecise control of an electric drive.

The bend-resistant and warp-resistant liftmast enables safe load handling, even withheavy loads. The comfortable driver's com-partment features the most up-to-date er-gonomic design to prevent signs of fatigueand increase safety.

The low centre of gravity of the truck providesstability, which is guaranteed if the truck isused according to its intended use.

The truck supports all of the functions ofFleetManager 4.0.

Brake system

The brake system of the truck is comprised ofthree different brakes:• Service brake• Regenerative brake• Parking brake

The service brake is based on a wear-free,oil-immersed multi-disc brake. This multi-discbrake is used as the service brake for heavybraking or emergency braking with the brakepedal. In the normal working mode, theregenerative brake of the electric tractionmotor takes effect. The regenerative brakeconverts the acceleration energy of the truckinto electrical energy. This causes the truck todecelerate as soon as the accelerator pedalis released. Completely removing your footfrom the accelerator pedal causes the truck tobrake until it comes to a standstill. A parkingbrake ensures that the truck remains securelyin place when parked.

2 174749 EN - 11/2018

Foreword 1Your truck

Hydraulic systemAll lift cylinders are hydraulically actuated.The required oil volume flow is realised via agear pump, which is connected to the internalcombustion engine. The proportional valvetechnology provides particularly sensitivemovements and safe handling of the load.The hydraulic functions can be parameterisedindividually by the authorised service centre.

Up to three hydraulic circuits can be used toactivate attachments (variant). Depending onthe equipment, a hydraulic accumulator is alsoavailable in the lifting circuit for the purpose ofdampening pressure peaks in the hydraulicsystem.

Drive conceptThe internal combustion engine drives anelectric generator. The generated currentis directed to an electric traction motor, whichdrives the truck. Anelectronic speed controllergently provides high torque for both forwardsand backwards travel.

The components for the drive unit and thelift drive are enclosed in order to prevent theingress of dust or moisture. This means thatthe truck is suitable for indoor and outdooruse. In addition, all drives for traction, steeringand lifting are maintenance-free.

The driving characteristics and lifting be-haviour can be adapted to the applicationor driving habits. Five drive programmes areavailable for this purpose. The maximumdriving speed is 22 km/h. The energy-savingmode Blue-Q reduces energy consumption byup to 10%, without impairing performance.

Operating devicesThe truck is characterised by an accessibleoperating concept. When purchasing thetruck, a variety of controls and equipmentvariants are available:

• Double mini-lever• Triple mini-lever• Quadruple mini-lever• Joystick 4Plus

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• Fingertip switch• Single pedal• Dual pedal

Hands are always kept free for steering andfor controlling the operational movements toallow efficient working. The forces that needto be applied for this purpose are reduced toa minimum thanks to the compact steeringwheel. The simple handling of the truck isassisted by the agile steering axle.

Operational information, such as the fuel levelor an indication that the Blue-Q energy-savingmode is enabled, is shown in the display-operating unit.

For drive mode, the truck features eithersingle-pedal or dual-pedal operation. Theaccelerator pedal is used to accelerate andbrake (electric brake) the truck. In emergencysituations or when carrying heavy loads,the driver can also brake the truck via theservice brake by pressing the brake pedal.In dual-pedal operation, the truck has onepedal for the "Forwards" drive direction andone pedal for the "Reverse" drive direction.Acceleration and braking behaviour can beindividually selected from five different driveprogrammes.

GeneralThe truck described in these operating instruc-tions corresponds to the applicable standardsand safety regulations.

If the truck is to be operated on public roads, itmust conform to the existing national regula-tions for the country in which it is being used.The driving permit must be obtained from theappropriate office.

The truck has been fitted with state-of-the-art technology. Following these operatinginstructions will allow the truck to be handledsafely. By complying with the specifications inthese operating instructions, the functionalityand the approved features of the truck will beretained.

4 174749 EN - 11/2018


Get to know the technology, understand itand use it safely - these operating instructionsprovide the necessary information and help toavoid accidents and to keep the truck ready foroperation beyond the warranty period.

Therefore:

– Before commissioning the truck, readthe operating instructions and follow theinstructions.

– Always follow all of the safety informationcontained in the operating instructions andon the truck.

CE-Symbol

CE labellingThe manufacturer uses CE labelling to indi-cate that the truck complies with the standardsand regulations valid at the time of marketing.This is confirmed by the issued EC declarationof conformity. The CE labelling is attached tothe nameplate.

An independent structural change or additionto the truck can compromise safety, thusinvalidating the EC declaration of conformity.

The EC declaration of conformity must becarefully stored and made available to theresponsible authorities.

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EC declaration of conformity in accordance with Machinery Directive

Declaration

STILL GmbH

Berzeliusstraße 10

D-22113 Hamburg Germany

We declare that the

Industrial truck according to these operating instructions

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 GmbH

.

6 174749 EN - 11/2018


Accessories overview• Key for key switch (2 pieces)• Key for cab (variant)• Hexagon socket wrench for emergencylowering

174749 EN - 11/2018 7


Labelling points

5

11

19

10

161920

16

1

152

15

2118

10

29

3

8

4

17

DANGER

DANGER

1615

DANGER

DANGER

DANGER

DANGER

WAL

9

8

3

18

612

4

13 14

2120

22

10 bar

7

5

11

6

7

7

12 1722

1314

Regelmäßige Prüfung(FEM 4.004)

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

Die Prüfplakette ersetzt nicht das Prüfprotokoll

Nächste Prüfung

5634

4391

019

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

23

1

23

7314_003-017_V11

xx xxxx x xxxxx

1

2

3

4

Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr

Rated capacityCapacité nominaleNenn-Tragfähigkeit

Battery voltageTension batterieBatteriespannung

Rated drive powerPuissance motr.nom.Nenn-Antriebsleist.

Unladen massMasse à videLeergewicht

max

min.*

* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung

kg kg

kg

kg

kgkW

V

*

5430 1010 1080 1080 1080

1050 1150 1310

4430 1110 1230 1250 1500

4030 1150 1260 1200 1500

3730 1180 1290 1430 1500

3430 1210 1330 1470 1500

800 700 500600

5030 1270

2

1

3

DANGER

20xx

8 174749 EN - 11/2018


1 Decal information: "Dual-pedal operation"(variant)

2 Manufacturer's label text3 Decal information: FEM audit4 Inspection sticker5 Warning sign: Passengers are not allowed6 Decal information: Lifting gear attachment

point7 Decal information: Tyre filling pressure8 Decal information: Driving dynamics9 Cable strap10 Decal information: Do not jump off if the

truck is tipping over / Lean in the oppositedirection to which the truck is tipping

11 Decal information: Caution / Read theoperating instructions / Fasten the seat belt

12 Decal information: Lifting gear attachmentpoint

13 Decal information: Parking brake released14 Decal information: Parking brake applied

15 Warning sign: Danger due to shearing /Danger due to high fluid pressure

16 Warning sign: Do not stand underneath thefork / Do not stand on the fork

17 Decal information: Sound power level18 Decal information: Caution / Read the

operating instructions / Fasten the seat belt/ Apply the parking brake when leaving thetruck / Passengers are not allowed / Do notjump off if the truck is tipping over / Lean inthe opposite direction to which the truck istipping

19 Decal information: StVZO (German RoadTraffic Licensing Regulations) information(variant)

20 Decal information: nameplate21 Decal information: Factory number22 Decal information: capacity rating plate23 Decal information: Ceiling sensor

174749 EN - 11/2018 9







maxmin.*


kg kg

kgkg

kgkW

V

*

D-22113 HamburgBerzeliusstr. 10

1 2 3

44

56

7

910

111213

6210_921-003_V3

8

1 Type2 Production number3 Year of manufacture4 Tare weight in kg5 Max. permissible battery weight in kg6 Min. permissible battery weight in kg7 Ballast weight in kg8 Address of manufacturer9 Refer to the technical data listed in these

operating instructions for more detailedinformation

10 CE labelling11 Nominal drive power in kW12 Battery voltage in V13 Rated capacity in kg

NameplateThe truck can be identified from the informa-tion on the nameplate.

The information for the battery weights (5,6) and the ballast weight (7) only applies toelectric forklift trucks.

7090_921-004

xx xxxx x xxxxx

1

2

3

4

Production number

NOTE

The production number is used to identify thetruck. It can be found on the nameplate andmust be referred to in all technical questions.

The production number contains the followingcoded information:

(1) Production location

(2) Model

(3) Year of manufacture

(4) Sequential number

10 174749 EN - 11/2018

Foreword 1Use of truck

7094_003-098

1 2

3 45

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)

StVZO (Road Traffic LicensingRegulations) informationThis label includes information on the weightand load distribution of the truck.

Use of truckProper usageThe truck described in these operating in-structions is suitable for lifting, transportingand stacking loads.

The truck may only be used for its properpurpose as set out and described in theseoperating instructions.

If the truck is to be used for purposes otherthan those specified in the operating instruc-tions, the approval of the manufacturer and, ifapplicable, the relevant regulatory authoritiesmust be obtained beforehand to prevent haz-ards.

The maximum load to be lifted is specified onthe capacity rating plate (load diagram) andmust not be exceeded; see also the chapterentitled "Before picking up a load".

174749 EN - 11/2018 11

1 ForewordUse of truck

Proper use during towingThis truck is suitable for the occasional towingof trailers and is equippedwith a towing devicefor this purpose. This occasional towing maynot exceed 2% of the daily operating time. Ifthe truck is to be used for towing on a moreregular basis, the manufacturer should beconsulted.

The regulations regarding trailer operationmust be observed; see chapter "Traileroperation".

Impermissible useThe operating company or driver, and not themanufacturer, is liable for any hazards causedby improper use.

NOTE

Please observe the definition of the followingresponsible persons: "operating company"and "driver".

Use for purposes other than those describedin these operating instructions is prohibited.

DANGERThere is a risk of fatal injury from fallingoff the truck while it is moving!– It is prohibited to carry passengers

on the truck.

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

Stacking or unstacking is not permissible oninclined surfaces or ramps.

Place of useThe truck can be used outdoors.

When using the truck with a particle filter (vari-ant) in halls, observe the national regulationsfor the country in which the truck is being used.

12 174749 EN - 11/2018

Foreword 1Use of truck

Operation on public roads is only permittedwith the "StVZO" (Road Traffic LicensingRegulations) equipment variant.

If the truck is to be operated on public roads, itmust conform to the existing national regula-tions for the country in which it is being used.

The ground must have an adequate loadcapacity (concrete, asphalt) and a roughsurface. Routes, working areas and aislewidths must conform to the specifications inthese operating instructions; see the chapterentitled "Routes".

Driving on upward and downward gradientsis permitted provided the specified data andspecifications are observed; see the chapterentitled "Routes".

The truck is suitable for use in many differentcountries, ranging from those situated in theTropics to those in Nordic regions (tempera-ture range: -20°C to +40°C).

This truck is not designed to be operated incold stores.

The operating company must ensure suitablefire protection for the relevant application inthe truck's surroundings. Depending on theapplication, additional fire protection must beprovided on the truck. If in doubt, contact therelevant authorities.

NOTE

Please observe the definition of the followingresponsible person: "operating company".

174749 EN - 11/2018 13

1 ForewordUse of truck

DANGERRisk to health from exhaust gases!Exhaust gases from internal combustion enginesare harmful to your health. In particular, the sootparticles contained in the diesel exhaust gas cancause cancer. When the internal combustionengine is left running, there is a risk of poisoningdue to the CO, CH and NOx components containedin the exhaust gas.Modern exhaust gas treatment systems (e.g.catalytic converters, particle filters or comparablesystems) can clean exhaust gases in a way thatreduces the health hazard and risk of poisoningwhen operating the truck.– Observe the national laws and regulations when

using trucks with an internal combustion enginein entirely or partially enclosed working areas.

– Always ensure sufficient ventilation.

Using working platforms

WARNINGThe use of working platforms is regulated by na-tional law. The use of working platforms is onlypermitted by virtue of the jurisdiction in the countryof use.– Observe national legislation.– Before using working platforms, consult the

national regulatory authorities.

14 174749 EN - 11/2018

Foreword 1Information about documentation

Information about documentationDocumentation scope• Original operating instructions• Original operating instructions for attach-ments (variant)

• Spare parts list• Depending on the truck equipment, "UPA"operating instructionsmay also be provided

NOTE

Refer to the additional information in thesection entitled "Rules for the operatingcompany of industrial trucks".

These operating instructions describe allmeasures necessary for the safe operationand proper maintenance of the truck in allpossible variants available at the time ofprinting. Special versions to meet customerrequirements (UPA) are documented inseparate operating instructions. If you haveany questions, please contact your authorisedservice centre.

Enter the production number and year ofmanufacture from the nameplate in the spaceprovided:

Production number:

Year of manufacture:

Please quote the production number in alltechnical enquiries.

Each truck comes with a set of operatinginstructions. These instructions must bestored carefully and must be available to thedriver and operating company at all times.The storage location is specified in the chapterentitled "Overviews".

If the operating instructions are lost, the op-erating company must obtain a replacementfrom the manufacturer immediately.

The operating instructions are included in thespare parts list and can be reordered as aspare part.

174749 EN - 11/2018 15

1 ForewordInformation about documentation

The personnel responsible for operating andmaintaining the equipment must be familiarwith these operating instructions.

The operating company must ensure that allusers have received, read and understoodthese operating instructions.

Safely store the complete documentation andpass on to the subsequent operating companywhen transferring or selling the truck.

NOTE


Thank you for reading and complying withthese operating instructions. If you have anyquestions or suggestions for improvements,or if you have found any errors, please contactthe authorised service centre.

Supplementary documentationThis industrial truck can be fitted with un-planned equipment (UPA) that deviates fromthe standard equipment and/or the variants.

The UPAmay be, for example:• Special sensors• Special attachments• Towing devices• Customised attachments

In this case, the industrial truck has additionaldocumentation. This may be in the form of aninsert or separate operating instructions.

The original operating instructions for thisindustrial truck are valid for the operationof standard equipment and variants withoutrestriction. The operational and safety infor-mation in the original operating instructionscontinues to be valid in its entirety unless it iscountermanded in this additional documenta-tion.

The requirements for the qualification ofpersonnel as well as the time for maintenance

16 174749 EN - 11/2018


may vary. This is defined in the additionaldocumentation.

– If you have any questions, please contactyour authorised service centre.

Issue date and topicality of theoperating instructionsThe issue date of these operating instructionscan be found on the title page.

STILL is constantly engaged in the furtherdevelopment of trucks. These operatinginstructions are subject to change, and anyclaims based on the information and/orillustrations contained in them cannot beasserted.

Please contact your authorised service centrefor technical support relating to your truck.

Copyright and trademark rightsThese instructions must not be reproduced,translated or made accessible to third par-ties—including as excerpts—except with theexpress written approval of the manufacturer.

Explanation of information symbolsused

DANGERIndicates procedures that must be strictly adheredto in order to prevent the risk of fatalities.

WARNINGIndicates procedures that must be strictly adheredto in order to prevent the risk of injuries.

CAUTIONIndicates procedures that must be strictly adheredto in order to prevent material damage and/ordestruction.

174749 EN - 11/2018 17


NOTE

For technical requirements that requirespecial attention.

ENVIRONMENT NOTE

To prevent environmental damage.

List of abbreviations

NOTE

This list of abbreviations applies to all typesof operating instructions. Not all of the abbre-viations that are listed here will necessarilyappear in these operating instructions.

Abbrevi-ation

Meaning Explanation

ABE Display operating unit

ArbSchG Arbeitsschutzgesetz German implementation of EU occupa-tional health and safety directives

Betr-SichV

Betriebssicherheitsverordnung German implementation of the EU workingequipment directive

BG Berufsgenossenschaft German insurance company for the com-pany and employees

BGG Berufsgenossenschaftlicher Grundsatz German principles and test specificationsfor occupational health and safety

BGR Berufsgenossenschaftliche Regel German rules and recommendations foroccupational health and safety

DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations

CE Communauté Européenne Confirms conformity with product-specificEuropean directives (CEmark)

CEECommission on the Rules for the Approvalof the Electrical Equipment

International commission on the rules forthe approval of electrical equipment

DC Direct Current Direct current

DFÜ Datenfernübertragung Remote data transmission

DIN Deutsches Institut für Normung German standardisation organisation

EG European Community

EN European standard

FEM Fédération Européene de la Manutention European Federation of Materials Han-dling and Storage Equipment

Fmax maximum Force Maximum power

18 174749 EN - 11/2018


Abbrevi-ation

Meaning Explanation

GAA Gewerbeaufsichtsamt

German authority for monitoring/issuingregulations for worker protection, environ-mental protection, and consumer protec-tion

GPRS General Packet Radio Service Transfer of data packets in wirelessnetworks

ID no. ID number

ISO International Organization for Standard-ization

International standardisation organisation

LAN Local Area Network Local area network

KpAUncertainty of measurement of soundpressure levels

LED Light Emitting Diode Light emitting diode

Lp Sound pressure level at the workplace

LpAZAverage continuous sound pressure levelin the driver's compartment

LSP Load centre of gravity Distance of the centre of gravity of the loadfrom the front face of the fork backs

MAK Maximumworkplace concentration Maximum permissible air concentrationsof a substance at the workplace

Max. Maximum Highest value of an amount

Min. Minimum Lowest value of an amount

PIN Personal Identification Number Personal identification numberPPE Personal protective equipment

SE Super-Elastic Superelastic tyres (solid rubber tyres)

SIT Snap-In Tyre Tyres for simplified assembly, withoutloose rim parts

StVZO Straßenverkehrs-Zulassungs-Ordnung German regulations for approval of vehi-cles on public roads

TRGS Technische Regel für Gefahrstoffe Ordinance on hazardous materials appli-cable in the Federal Republic of Germany

VDE Verband der Elektrotechnik ElektronikInformationstechnik German technical/scientific association

VDI Verein Deutscher Ingenieure German technical/scientific association

VDMAVerband Deutscher Maschinen- undAnlagenbau e.V.

GermanMechanical Engineering IndustryAssociation

WLAN Wireless LAN Wireless local area network.

174749 EN - 11/2018 19


6210_001-031

4 2

3

1Definition of directionsThe directions "forwards" (1), "backwards" (3),"right" (2) and "left" (4) refer to the installationposition of the parts as seen from the driver'scompartment; the load is to the front.

Schematic views

6210_003-062

View of functions and operationsThis documentation explains the (usuallysequential) chain of certain functions or oper-ations. Schematic diagrams of a counterbal-ance truck are used to illustrate these proce-dures.

NOTE

These schematic diagrams are not represen-tative of the structural state of the documentedtruck. The diagrams are used solely for thepurpose of clarifying procedures.

20 174749 EN - 11/2018


View of the display operating unit

NOTE

Views of operating statuses and values inthe display of the display operating unit areexamples and partly dependent on the truckequipment. As a result, the displays shownof the actual operating statuses and valuescan vary. Information that is not relevant fordescriptions is not shown.

174749 EN - 11/2018 21

1 ForewordEnvironmental considerations

Environmental considerationsPackagingDuring delivery of the truck, certain partsare packaged to provide protection duringtransport. This packaging must be removedcompletely prior to initial start-up.

ENVIRONMENT NOTE

The packaging material must be disposed ofproperly after delivery of the truck.

Disposal of components andbatteriesThe truck is composed of different materials. Ifcomponents or batteries need to be replacedand disposed of, they must be:• disposed of,• treated or• recycled in accordance with regional andnational regulations.

NOTE

The documentation provided by the batterymanufacturer must be observed when dispo-sing of batteries.

ENVIRONMENT NOTE

We recommend working with a waste mana-gement company for disposal purposes.

22 174749 EN - 11/2018

2

Safety

2 SafetyDefinition of responsible persons

Definition of responsible personsOperating companyThe operating company is the natural or legalperson or group who operates the truck or onwhose authority the truck is used.

The operating company must ensure that thetruck is only used for its proper purpose and incompliance with the safety regulations set outin these operating instructions.

The operating company must ensure thatall users read and understand the safetyinformation.

The operating company is responsible for thescheduling and correct performance of regularsafety checks.

We recommend that the national performancespecifications are adhered to.

SpecialistA qualified person is defined as a serviceengineer or a person who fulfils the followingrequirements:• A completed vocational qualification thatdemonstrably proves their professionalexpertise. This proof should consist ofa vocational qualification or a similardocument.

• Professional experience indicating thatthe qualified person has gained practicalexperience of industrial trucks over aproven period during their career Duringthis time, this person has become familiarwith a wide range of symptoms that requirechecks to be carried out, such as basedon the results of a hazard assessment or adaily inspection

• Recent professional involvement in thefield of the industrial truck test in questionand an appropriate further qualificationare essential. The qualified person musthave experience of carrying out the testin question or of carrying out similar tests.Moreover, this person must be aware ofthe latest technological developments

24 174749 EN - 11/2018

Safety 2Definition of responsible persons

regarding the industrial truck to be testedand the risk being assessed

DriversThis truck may only be driven by suitable per-sons who are at least 18 years of age, havebeen trained in driving, have demonstratedtheir skills in driving and handling loads tothe operating company or an authorised rep-resentative, and have been specifically in-structed to drive the truck. Specific knowledgeof the truck to be operated is also required.

The training requirements under §3 of theHealth and Safety at Work Act and §9 of theplant safety regulations are deemed to havebeen satisfied if the driver has been trained inaccordance with BGG (General Employers'Liability Insurance Association Act) 925.Observe the national regulations for yourcountry.

Driver rights, duties and rules of be-haviourThe driver must be trained in his rights andduties.

The drivermust be granted the required rights.

The driver must wear protective equipment(protection suit, safety footwear, safetyhelmet, industrial goggles and gloves) thatis appropriate for the conditions, the job andthe load to be lifted. Solid footwear should beworn to ensure safe driving and braking.

The driver must be familiar with the operatinginstructions and have access to them at alltimes.

The driver must:• have read and understood the operatingmanual

• have familiarised himself with safe opera-tion of the truck

• be physically and mentally able to drive thetruck safely

174749 EN - 11/2018 25

2 SafetyDefinition of responsible persons

DANGERThe use of drugs, alcohol or medications that affectreactions impair the ability to drive the truck!Individuals under the influence of the aforementio-ned substances are not permitted to perform workof any kind on or with the truck.

Prohibition of use by unauthorisedpersonsThe driver is responsible for the truck duringworking hours. He must not allow unautho-rised persons to operate the truck.

When leaving the truck, the drivermust secureit against unauthorised use, e.g. by pulling outthe key.

26 174749 EN - 11/2018

Safety 2Essentials for safe operation

Essentials for safe operationInsurance cover on companypremisesIn many cases, company premises arerestricted public traffic areas.

NOTE

The business liability insurance should bereviewed to ensure that, in the event of anydamage caused in restricted public trafficareas, there is insurance cover for the truck inrespect of third parties.

Changes and retrofittingIf the truck will be used for work that is notlisted in the directives or in these instructions,convert or retrofit the truck for this purposeas required. Any structural modification canimpair the handling and stability of the truck,and can result in accidents.

Any modifications that adversely affect thestability, the load capacity or the circumferen-tial view of the truck require written approvalfrom the manufacturer.

The following components may only bemodified with prior written approval from themanufacturer:• Brakes• Steering• Operating devices• Safety systems• Equipment variants• Attachments

The truck may only be converted with writtenapproval from the manufacturer. If necessary,obtain approval from the relevant authorities.

Only the authorised service centre is permittedto perform welding work on the truck.

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

– Contact the authorised service centrebefore converting or retrofitting the truck.

174749 EN - 11/2018 27

2 SafetyEssentials for safe operation

DANGERRisk of injury if the truck tips over!Even if an approved restraint systemis in use, there is still a residual riskthat the driver could be injured if thetruck tips over. The risk of injury canbe reduced by using the restraintsystem in conjunction with the seatbelt. In addition, the seat belt protectsagainst the consequences of rear-endcollisions and falling off ramps.– Use the seat belt too.

DANGERRisk of fatal injury from falling load!There is a risk to the driver's life if the truck is notequipped with an overhead guard, as the drivermay be struck by a load falling from a lift height of1800 mm or greater.Operation of the forklift truck without an overheadguard is prohibited with a lift height greater than1800 mm.– At lift heights of 1800 mm and above, only use

the truck in conjunction with an overhead guard.

The operating company is only permitted tomakemodifications to the truck independentlyif the manufacturer goes into liquidation andthe company is not taken over by another legalperson.

The operating company must also fulfil thefollowing prerequisites:• Design documents, test documents andassembly instructions associated with themodification must be permanently archivedand remain accessible at all times.

• The capacity rating plate, the decal informa-tion, the hazard warnings and the operatinginstructions must be checked to ensure thatthey are consistent with the modificationsand must be amended if required.

• Modifications must be designed, checkedand implemented by a design office thatspecialises in industrial trucks. The designoffice must comply with the standards anddirectives valid at the time thatmodificationsare made.

28 174749 EN - 11/2018


Decal information with the following data mustbe permanently affixed to the truck so that it isclearly visible:• Type of modification• Date of modification• Name and address of the company thatcarried out the modification

Changes to the overhead guard androof loads

DANGERIn the event of the overhead guard failing due toa falling load or the truck tipping over, there arepotentially fatal consequences for the driver. Thereis a risk to life!Welding and drilling on the overhead guard chan-ges the material characteristics and the structuraldesign of the overhead guard. Excessive forcescaused by falling loads or the truck tipping overmayresult in buckling of the modified overhead guardand no protection for the driver.– Do not perform welding on the overhead guard.– Do not perform drilling on the overhead guard.

CAUTIONHeavy roof loads damage the overhead guard!To ensure the stability of the overhead guard atall times, a roof load may only be mounted on theoverhead guard if the structural design has beentested and the manufacturer has given approval.– Seek advice from the authorised service centre

for the mounting of roof loads.

Warning regarding non-original partsOriginal parts, attachments and accessoriesare specially designed for this truck. Wespecifically draw your attention to the fact thatparts, attachments and accessories suppliedby other companies have not been tested andapproved by STILL.

174749 EN - 11/2018 29


CAUTIONInstallation and/or use of such products may there-fore have a negative impact on the design featuresof the truck and thus impair active and/or passivedriving safety.We recommend that you obtain approval from themanufacturer and, if necessary, from the relevantregulatory authorities before installing such parts.The manufacturer accepts no liability for any da-mage caused by the use of non-original parts andaccessories without approval.

Damage, defects and misuse ofsafety systemsDamage or other defects on the truck orattachment must be reported to the supervisoror responsible fleet manager immediately sothat they can have the defect rectified.

Trucks and attachments that are not functionalor safe to drivemay not be used until they havebeen properly repaired.

Do not remove or deactivate safety systemsand switches.

Fixed set valuesmay only be changedwith theapproval of the manufacturer.

Work on the electrical system (e.g. connectinga radio, additional headlights etc.) is onlypermitted with the manufacturer's writtenapproval. All electrical system interventionsmust be documented.

Even if they are removable, roof panels maynot be removed, as they are designed toprotect against small falling objects.

Tyres

DANGERRisk to stability!Failure to observe the following information andinstructions can lead to a loss of stability. The truckmay tip over, risk of accident!

30 174749 EN - 11/2018


The following factors can lead to a loss ofstability and are therefore prohibited:• Different tyres on the same axle, e.g.pneumatic tyres and superelastic tyres

• Tyres not approved by the manufacturer• Excessive tyre wear• Tyres of inferior quality• Changing rim wheel parts• Combining rim wheel parts from differentmanufacturers

The following rules must be observed toensure stability:• Only use tyres with equal and permittedlevels of wear on the same axle

• Only use wheels and tyres of the same typeon the same axle, e.g. only superelastictyres

• Only use wheels and tyres approved by themanufacturer

• Only use high-quality products

Wheels and tyres approved by the manu-facturer can be found on the spare parts list.If other wheels or tyres are to be used, au-thorisation from the manufacturer must beobtained beforehand.

– Contact the authorised service centre onthis matter.

When changing wheels or tyres, alwaysensure that this does not cause the truck totilt to one side (e.g. always replace right-hand and left-hand wheels at the sametime). Changes must only be made followingconsultation with the manufacturer.

If the type of tyre used on an axle is changed,for example from superelastic tyres to pneu-matic tyres, the loaddiagrammust be changedaccordingly.


174749 EN - 11/2018 31


Medical equipment

WARNINGElectromagnetic interferencemayoccur onmedicaldevices!Only use equipment that is sufficiently protectedagainst electromagnetic interference.

Medical equipment, such as pacemakers orhearing aids, may not work properly when thetruck is in operation.

– Ask your doctor or the manufacturer ofthe medical equipment to confirm that themedical equipment is sufficiently protectedagainst electromagnetic interference.

Exercise caution when handling gassprings and accumulators

WARNINGGas springs are under high pressure. Improperremoval results in an elevated risk of injury.For ease of operation, various functions on thetruck can be supported by gas springs. Gas springsare complex components that are subject to highinternal pressures (up to 300 bar). They may underno circumstances be opened unless instructed todo so, and may be installed only when not underpressure. If required, the authorised service centrewill depressurise the gas spring in accordance withthe regulations before removal. Gas springs mustbe 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.

WARNINGAccumulators are under high pressure. Improperinstallation of an accumulator results in an elevatedrisk of injury.Before starting work on the accumulator it must bedepressurised.– Contact the authorised service centre.

32 174749 EN - 11/2018


Length of the fork arms

DANGERRisk of accident due to the incorrect selection offork arms!– The fork armsmust match the depth of the load.

If the fork arms are too short, the load mayfall off the arms after it has been picked up.In addition, be aware that the load centre ofgravity may shift as a result of dynamic forces,such as braking. A load that is otherwiseresting safely on the fork arms may moveforwards and fall.

If the fork arms are too long, they can catchon loading units behind the load that is to bepicked up. These other loading units then fallover when the load is raised.

– For helpwith selecting the correct fork arms,contact the authorised service centre.

174749 EN - 11/2018 33

2 SafetyResidual risk

Residual riskResidual dangers, residual risksDespite careful working and compliance withstandards and regulations, the occurrenceof other risks when using the truck cannot beentirely excluded.

The truck and all other system componentscomply with current safety requirements.Nevertheless, even when the truck is usedfor its proper purpose and all instructionsare followed, some residual risk cannot beexcluded.

Even beyond the narrow danger areas of thetruck itself, a residual risk cannot be excluded.Persons in this area around the truck mustexercise a heightened degree of awareness,so that they can react immediately in the eventof any malfunction, incident or breakdown etc.

WARNINGAll persons that are in the vicinity of the truckmust be instructed regarding these risks that arisethrough use of the truck.In addition, we draw attention to the safety regulati-ons in these operating instructions.

Risks can include:• Escape of consumables due to leakages,rupture of lines and containers etc.

• Risk of accident when driving over difficultground such as gradients, smooth orirregular surfaces, or with poor visibilityetc.

• Falling, tripping etc. when moving onthe truck, especially in wet weather, withleaking consumables or on icy surfaces

• Fire and explosion risks due to batteries andelectrical voltages

• Human error resulting from failure toobserve the safety regulations,

• Unrepaired damage or defective and worncomponents,

• Insufficient maintenance and testing• Use of incorrect consumables• Exceeding test intervals

34 174749 EN - 11/2018

Safety 2Residual risk

The manufacturer is not held responsible foraccidents involving the truck caused by thefailure of the operating company to complywith these regulations either intentionally orcarelessly.

StabilityThe stability of the truck has been tested to thelatest technological standards and is guaran-teed provided that the truck is used properlyand according to its intended purpose. Thesestandards only take into account the dynamicand static tipping forces that can arise duringspecified use in accordance with the operat-ing rules and intended purpose. However, thedanger of exceeding the moment of tilt due toimproper use or incorrect operation and losingstability can never be excluded.

The loss of stability can be avoided or min-imised by the following actions:

– Always secure the load against slipping,e.g. by lashing.

– Always transport unstable loads in suitablecontainers.

– Always drive slowly when cornering.

– Drive with the load lowered.

– Even with sideshifts, align the load ascentrally as possible with the truck andtransport in this position.

– Avoid turning and diagonally driving acrossslopes or gradients.

– Never have the load facing downhill whentravelling on slopes or gradients.

– Pick up only loads of the approved width.

– Always take great care when transportingsuspended loads.

– Do not drive over ramp edges or steps.

Special risks associated with usingthe truck and attachmentsApproval from the manufacturer and attach-ment manufacturer must be obtained each

174749 EN - 11/2018 35


time the truck is used in a manner that fallsoutside the scope of normal use, and in caseswhere the driver is not certain that he can usethe truck correctly and without the risk of acci-dents.

36 174749 EN - 11/2018


174749 EN - 11/2018 37


Overview of hazards and counter-measures

NOTE

This table is intended to help evaluate thehazards in your facility and applies to all drivetypes. It does not claim to be complete.

– Observe the national regulations for thecountry in which the truck is being used.

Hazard Measure Check note√ Complete- Not applicable

Notes

Truck equipment doesnot comply with localregulations

Test O If in doubt, consultcompetent factoryinspectorate oremployers' liabilityinsurance association

Lack of skills andqualification of driver

Driver training (sit-onand stand-on)

O BGG 925VDI 3313 driver permit

Usage by unauthorisedpersons

Access with key onlyfor authorised persons

O

Truck not in a safecondition

Recurrent testing andrectification of defects

O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Risk of falling whenusing workingplatforms

Compliance withnational regulations(different national laws)

O German Ordinanceon Industrial Safetyand Health (BetrSichV)and employer's liabilityinsurance associations

Impaired visibility dueto load

Resource planning O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Assessment of dieselexhaust gases

O Technical Regulationsfor HazardousSubstances (TRGS)554 and the GermanOrdinance on IndustrialSafety and Health(BetrSichV)

Contamination ofrespiratory air

Assessment of LPGexhaust gases

O German threshold limitvalues list (MAK-Liste)and the GermanOrdinance on IndustrialSafety and Health(BetrSichV)

38 174749 EN - 11/2018



Notes

Issuing of operatinginstructions

O German Ordinance onIndustrial Safety andHealth (BetrSichV) andGerman Health andlabour protection law(ArbSchG)

Written notice ofinstruction to driver

O German Ordinance onIndustrial Safety andHealth (BetrSichV) andGerman Health andlabour protection law(ArbSchG)

Impermissible usage(improper usage)

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O

When fuelling

a) Diesel Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O

b) LPG Note German SocialAccident Insurance(DGUV) regulationD34, the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O

174749 EN - 11/2018 39



Notes

When charging thetraction battery

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),the operatinginstructions and theGerman EngineeringFederation (VDMA)rules

O Association forElectrical, Electronicand InformationTechnologies (VDE)regulation 0510: Inparticular- Ensure adequateventilation- Insulation value withinthe permissible range

When using batterychargers

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),employers' liabilityinsurance associationregulation 104 and theoperating instructions

O German Ordinanceon Industrial Safetyand Health (BetrSichV)and employers' liabilityinsurance associationregulation 104

When parking LPGtrucks

Note the GermanOrdinance onIndustrial Safety andHealth (BetrSichV),employers' liabilityinsurance associationregulation 104 and theoperating instructions

O German Ordinanceon Industrial Safetyand Health (BetrSichV)and employers' liabilityinsurance associationregulation 104

With driverless transport systems

Roadway qualityinadequate

Clean/clear driveways O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Load carrierincorrect/slipped

Reattach load to pallet O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Drive behaviourunpredictable

Employee training O German Ordinance onIndustrial Safety andHealth (BetrSichV)

Driveways blocked Mark drivewaysKeep driveways clear


Driveways intersect Announce right-of-wayrule


No person detectionduring depositing andretrieval

Employee training O German Ordinance onIndustrial Safety andHealth (BetrSichV)

.

40 174749 EN - 11/2018


Danger to employeesAccording to the GermanOrdinance on Indus-trial Safety and Health (BetrSichV) and labourprotection law (ArbSchG), the operating com-pany must determine and assess hazardsduring operation, and establish the labourprotection measures required for employ-ees (BetrSichVO). The operating companymust therefore draw up appropriate operatinginstructions (§ 6 ArbSchG) and make themavailable to the driver. A responsible personmust be appointed.

NOTE


The construction and equipment of thetruck correspond to the Machinery Directive2006/42/EC and are therefore marked withCE labelling. These elements are thereforenot included in the hazard assessment. At-tachments possess their own CE labelling andlikewise are not included for that reason. Theoperating company must, however, select thetype and equipment of the trucks so as to com-ply with the local provisions for deployment.

The result must be documented (§ 6 Arb-SchG). In the case of truck applications involv-ing similar hazard situations, the results maybe summarised. This overview (see chapter"Overview of hazards and countermeasures")provides help on complying with this regula-tion. The overview specifies the main hazardsthat are the most frequent cause of accidentsin the event of non-compliance. If other majoroperational hazards are involved, they mustalso be taken into consideration.

The conditions of use for trucks are broadlysimilar in many plants, so the hazards canbe summarised in one overview. Observethe information provided by the relevantemployers' liability insurance association onthis subject.

174749 EN - 11/2018 41

2 SafetySafety inspections

Safety inspectionsRegular safety inspection of the truck

Safety inspection based on time andextraordinary incidentsThe operating company must ensure that thetruck is checked by a specialist at least once ayear or after particular incidents.

As part of this inspection, a complete checkof the technical condition of the truck must beperformed with regard to accident safety.In addition, the truck must be thoroughlychecked for damage that could potentiallyhave been caused by improper use. A testlog must be created. The results from theinspection must be retained until a further twoinspections have been carried out.

The inspection date is indicated by an adhe-sive label on the truck.

– Arrange for the service centre to performperiodic safety inspections on the truck.

– Observe guidelines for checks carried outon the truck in accordance with FEM 4.004.

The operator is responsible for ensuring anydefects are remedied without delay.

– Contact your service centre.

NOTE

Observe the national regulations for yourcountry!

Checking the diesel engine emis-sions– Check the diesel engine emissions yearly inaccordance with TRGS 554.

The exhaust-gas checkmust be carried out bya "competent person" and must be recordedin writing.

– Notify the authorised service centre.

42 174749 EN - 11/2018

Safety 2Safety inspections

NOTE

Observe the national regulations for thecountry in which the truck is being used.

Trucks with particle filters

DANGERRisk to health from exhaust gases!Exhaust gases from internal combustion enginesare harmful to your health. In particular, the sootparticles contained in the diesel exhaust gas cancause cancer.When the internal combustion engine is running,there is a risk of poisoning from the CO, CH andNOx components contained in the exhaust gas.Modern exhaust gas treatment systems (e.g.catalytic converters, particle filters or comparablesystems) can clean exhaust gases in a way thatreduces the health hazard and risk of poisoningwhen operating the truck.– Observe the national laws and regulations when



Trucks with a particle filter (variant) complywith the essential technical requirements foruse in buildings and halls. In addition, theoperating company must also comply with thefollowing requirements:• Usage must be reported to the responsibleoccupational health and safety authorities

• Operating instructions must be displayed inthe working areas

• Danger areas should be confined andindicated by appropriate warning and safetysigns

• Employeesmust bemadeaware of dangersand protective measures

• The particle filter must be checked andserviced every 12 months or after every1000 operating hours. The exhaust-gascheck must be carried out by a competentperson and must be recorded in writing

• Observe the TRGS 554 regulations andnational regulations of the country of use.

174749 EN - 11/2018 43

2 SafetySafety inspections

NOTE

Please observe the definition of the followingresponsible persons: "operating company"and "competent person".

Insulation testingThe truck insulation must have sufficient insu-lation resistance. For this reason, insulationtesting in accordance with DIN EN 1175 andDIN 43539, VDE 0117 and VDE 0510must beconducted at least once every year.

NOTE

Contact your service centre to arrange for aninsulation test.

Measuring the insulation resistance ofthe electrical system

NOTE

Nominal battery voltage < test voltage < 500V.

– Ensure that all voltage sources have beendisconnected from the circuit to be tested.

– Measure the insulation resistance with asuitable measuring device.

The insulation resistance can be consideredsufficient if it measures at least 1000 Ω/V fornominal battery voltage against ground.

– Contact the authorised service centre.

44 174749 EN - 11/2018

Safety 2Safety regulations when handling consumables

Safety regulations when handling consumablesPermissible consumables

DANGERFailure to observe the safety regulations relating toconsumables may result in a risk of injury, death ordamage to the environment.– Observe the safety regulations when handling

such materials.

Refer to the maintenance data table for thepermissible substances that are necessary foroperation (see ⇒ Chapter "Maintenance datatable", P. 5-322).

Oils

DANGEROils are flammable!– Follow the statutory regulations.– Do not allow oils to come into

contact with hot engine parts.– No smoking, fires or naked flames!

DANGEROils 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 least10 minutes) with water and thenconsult an eye specialist.

– If swallowed, do not inducevomiting. Seek immediate medicalattention.

174749 EN - 11/2018 45

2 SafetySafety regulations when handling consumables

WARNINGProlonged intensive contact with theskin can result in dryness and irritatethe skin!– Avoid contact and consumption.– Wear protective gloves.– After any contact, wash the skin

with soap andwater, and thenapplya skin care product.

– Immediately change soakedclothing and shoes.

WARNINGThere is a risk of slipping on spilled oil, particularlywhen combined with water!– Spilt oil should be removed immediately with

oil-binding agents and disposed of according tothe regulations.

ENVIRONMENT NOTE

Oil is a water-polluting substance!• Always store oil in containers that complywith the applicable regulations.

• Avoid spilling oils.• Spilt oil should be removed immediatelywith oil-binding agents and disposed ofaccording to the regulations.

• Dispose of old oils according to the regula-tions.

Hydraulic fluid

WARNINGThese fluids are pressurised duringoperation of the truck and are hazar-dous to your health.– Do not spill the fluids.– Follow the statutory regulations.– Do not allow the fluids to come into

contact with hot engine parts.

46 174749 EN - 11/2018


WARNINGThese fluids are pressurised duringoperation of the truck and are hazar-dous 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 danger-ous if these fluids escape at highpressure due to leaks in the hydrau-lic system. In case of such injury,immediate medical assistance isrequired.

– To avoid injury, use appropriatepersonal protective equipment(e.g. protective gloves, industrialgoggles, skin protection and skincare products).

ENVIRONMENT NOTE

Hydraulic fluid is a water-polluting substance.• Always store hydraulic fluid in containersthat comply with regulations

• Avoid spills• Spilt hydraulic fluid should be removedimmediately with oil-binding agents anddisposed of according to the regulations

• Dispose of old hydraulic fluid according tothe regulations

Battery acid

WARNINGBattery acid contains dissolvedsulphuric acid. This is toxic.– Avoid touching or swallowing the

battery acid at all costs.– In case of injury, seek medical

advice immediately.

174749 EN - 11/2018 47


WARNINGBattery acid contains dissolvedsulphuric acid. This is corrosive.– When working with battery acid,

use appropriate PSA (rubbergloves, apron, protection goggles).

– When working with battery acid,never wear a watch or jewellery.

– Do not allow any acid to getonto clothing or skin or into theeyes. If this does happen, rinseimmediately with plenty of cleanwater.

– In case of injury, seek medicaladvice immediately.

– Immediately rinse away spiltbattery acid with plenty of water.

– Follow the statutory regulations.

ENVIRONMENT NOTE

– Dispose of used battery acid in line with theapplicable regulations.

Diesel fuel

WARNINGDiesel fuel is combustible.– Observe statutory regulations.– Do not allow diesel fuel to come

into contact with hot enginecomponents.

Do not smoke!

WARNINGDiesel 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 eyespecialist.

– If swallowed, do not inducevomiting. Seek immediate medicalattention.

48 174749 EN - 11/2018


WARNINGProlonged intensive contact with theskin can result in loss of skin oils andcan irritate the skin!– Avoid contact and swallowing.– Wear protective gloves.– After any contact, wash the skin

with soap andwater, and then applya skin care product.

– Immediately change soakedclothing and shoes.

WARNINGRisk of slipping due to spilled diesel fuel, particularlyin combination with water.– Immediately collect spilled diesel fuel using an

oil-binding agent and dispose of it in accordancewith regulations.

ENVIRONMENT NOTE

Diesel fuel is a water-polluting substance!

– Always store in regulation containers.

– Avoid spilling diesel fuel.

– Immediately collect spilled diesel fuel usingan oil-binding agent and dispose of it inaccordance with regulations.

174749 EN - 11/2018 49


Coolant and cooling fluid

WARNINGCoolant and cooling fluid can behazardous to your health and theenvironment!Coolants are chemical corrosion inhi-bitors and cooling system protectingagents such as Glysantin. The coo-ling fluid is an appropriate mixture ofwater and coolant. Coolant in bothconcentrated and dilute form can behazardous to your health if swallowed,or hazardous to the environment ifspilled.– Store coolant and cooling fluid only

in their original containers and donot spill them.

– Never store coolant or cooling fluidin empty food containers, bottles orother containers.

– Observe the national regulationsfor the country of use.

ENVIRONMENT NOTE

– Soak up any spilt coolant or cooling fluidimmediately using an oil binding agent anddispose of it in accordance with the nationalregulations for the country of use.

– Dispose of old coolant or cooling fluid inaccordance with the national regulations forthe country of use.

Disposal of consumables

ENVIRONMENT NOTE

Materials that accumulate during repair,maintenance and cleaning must be collectedproperly and disposed of in accordance withthe national regulations for the country inwhich the truck is being used. Work mustonly be carried out in areas designated for thatpurpose. Care must be taken to minimise anyenvironmental pollution.

– Soak up any spilt fluids such as hydraulicoil or gearbox oil immediately using anoil-binding agent.

50 174749 EN - 11/2018


– Neutralise any spilt battery acid immedi-ately.

– Always observe national regulations con-cerning the disposal of used oil.

174749 EN - 11/2018 51

2 SafetyEmissions

EmissionsThe values specified apply to a standard truck(compare the specifications in the "Technicaldata" chapter). Different tyres, lift masts,additional units etc. may produce differentvalues.

Noise emissionsThe values were determined based onmeasuring procedures from the standardEN 12053 "Safety of industrial trucks. Testmethods for measuring noise emissions",based on EN 12001, EN ISO 3744 and therequirements of EN ISO 4871.

This machine emits the following soundpressure level:

Continuous sound pressure level in thedriver's compartment

LpAZMeasurementuncertainty KpA

< 74.0 dB(A) 4 dB(A)

The values were determined in the test cycleon an identical machine from the weightedvalues for operating conditions and idling.

Time proportions:• Lifting 18%• Idling 58%• Driving 24%

However, the indicated noise levels at thetruck cannot be used to determine the noiseemissions atworkplacesaccording to themostrecent version of Directive 2003/10/EC (dailypersonal noise pollution). If necessary, thesenoise emissions should be determined by theoperating company directly at the workplaceunder the actual conditions there (additionalnoise sources, special application conditions,sound reflections).

NOTE

Please note the definition of "operating com-pany" in the sense of responsible persons!

52 174749 EN - 11/2018

Safety 2Emissions

VibrationsThe vibrations of the machine have beendetermined on an identical machine in ac-cordance with the standards DIN EN 13059"Safety of industrial trucks - Test methodsfor measuring vibration" and DIN EN 12096"Mechanical vibration - Declaration and verifi-cation of vibration emission values".

Frequency-weighted effective value of accel-eration on the seat

MSG 65 driver's seatMeasurementuncertainty

< 0.71 m/s2 0.177 m/s2

Tests have indicated that the amplitude of thehand and arm vibrations on the steering wheelor on the operating devices in the truck is lessthan 2.5 m/s 2. There are therefore no mea-surement guidelines for thesemeasurements.

The personal vibration load on the driver overa working day must be determined by theoperating company at the actual place of usein accordance with Directive 2002/44/EC, inorder to consider all additional influences,such as driving route, intensity of use etc.

NOTE


174749 EN - 11/2018 53

2 SafetyEmissions

Exhaust gases

DANGERRisk to health from exhaust gases!Exhaust gases from internal combustion enginesare harmful to your health. In particular, the sootparticles contained in the diesel exhaust gas cancause cancer.When the internal combustion engine is running,there is a risk of poisoning from the CO, CH andNOx components contained in the exhaust gas.Modern exhaust gas treatment systems (e.g.catalytic converters, particle filters or comparablesystems) can clean exhaust gases in a way thatreduces the health hazard and risk of poisoningwhen operating the truck.– Observe the national regulations for the country

of use when using trucks with an internal com-bustion engine in entirely or partially enclosedworking areas.


Heat

DANGERRisk of burns due to hot exhaustgases!Exhaust gases or components thatcarry exhaust gases (e.g. exhaustpipes) can become so hot that directbody contact can cause burns to theskin and materials that are too closecan be burned or singed.– Do not grasp or touch hot exhaust

pipes.– Keep combustible materials away

from the exhaust pipe.– In the event of burns, seek first aid

immediately.– If materials are burning, take fire

protection measures immediately.

54 174749 EN - 11/2018

3

Overviews

3 OverviewsGeneral view

General view

7312_003-172_V2

1 2 3

4

5

6

7

8

9

10

1 Lift mast2 Overhead guard3 Driver's compartment4 Fuel tank5 Towing device

6 Steering axle7 Drive axle8 Fork arms9 Fork carriage10 Lift cylinders

56 174749 EN - 11/2018

Overviews 3Driver's compartment

Driver's compartment

9

0

7

8

5

3

1

24

6

100 % +-

5

12890

15:23

F1 F2

1 2 3 4 5

6

7

810

11

12

13

7314_003-048 9

1 Parking brake lever2 Steering wheel3 Key switch4 Display and operating unit5 Document holder6 Operating devices for hydraulic and traction

functions7 Compartment (variant)

8 Cup holder for max. 0.5-l bottles9 Driver's seat10 Compartment and storage location for

operating instructions11 Accelerator pedal12 Brake pedal13 Steering column adjustment lever

NOTE

The truck equipment may differ from theequipment shown.

174749 EN - 11/2018 57

3 OverviewsOperating and display elements

Operating and display elementsDisplay and operating unit

8

9

6

72

0

13

5

4

%75

2

234,7 h12:15

12

3 4 5 6 7 8 9 10 11

12

13

14

1516

1718192021222324

25

26

1 Hazard warning system button2 Front windscreen wiper button3 Working spotlight button4 Drive programme selector button5 Softkey Lighting6 Lighting symbol7 Not assigned8 Fuel level display (percentage)9 Drive programme display (numerical)10 Left turn indicator display11 Forward travel indicator12 Right turn indicator display13 Malfunction display14 Reverse travel indicator

15 Operating hours display16 Time display (digital)17 Particle filter display18 Rotating beacon display19 Interior lighting display20 Rear window heating display21 Softkey Interior light/rotating beacon22 Softkey Rear window heating/particle filter

regeneration23 Menu change button24 Lighting button25 Blue-Q button26 Rear window wiper button

NOTE

The Softkeys (5, 21, 22) and the accompa-nying display elements (6, 7, 17, 18, 19, 20)are assigned according to the equipment va-riants in use.

The assignment shown here is an exampleand may differ from the assignment actuallyprogrammed on the truck. Softkeys can beassigned multiple functions that are calledup according to the menu navigation. Forfurther information, see the section entitled"Operating the display-operating unit".

58 174749 EN - 11/2018

Overviews 3Operating and display elements


Operating devices for hydraulic anddriving functionsDifferent versions of the operating devices areavailable for operating the truck's hydraulicand traction functions.

The truck can be equipped with the followingoperating devices:• Double mini-lever• Triple mini-lever• Quadruple mini-lever• Joystick 4Plus• Fingertip switch• Mini-console

174749 EN - 11/2018 59


Double mini-lever

F1 F2

1

23 4

5

6

7

1 "Lift mast" 360° lever2 Function key "F1"3 Function key "F2"4 "Drive direction/turn indicator" cross lever5 Function key "5th function"6 "Attachments" cross lever7 Signal horn button

NOTE

Depending on the specification, variouselectric attachment parts can be controlledvia function keys (2) and (3).• For alterations, contact the authorisedservice centre.

60 174749 EN - 11/2018


Three-way mini-lever

1

2

3 45

6

7

87325_003-026

1 "Lift mast" 360° lever2 Function key "F1"3 Function key "F2"4 "Drive direction/turn indicator" cross lever

5 Function key "5th function"6 "Auxiliary hydraulics 1" operating lever7 "Auxiliary hydraulics 2" operating lever8 Signal horn button

NOTE


174749 EN - 11/2018 61


Four-way mini-lever

7325_003-027

1

2

34 5

6

7

8

9

1 "Lift/lower" operating lever2 "Tilt" operating lever3 Function key "F1"4 Function key "F2"5 "Drive direction/turn indicator" cross lever

6 Function key "5th function"7 "Auxiliary hydraulics 1" operating lever8 "Auxiliary hydraulics 2" operating lever9 Signal horn button

NOTE


62 174749 EN - 11/2018


Joystick 4Plus

1

2

3

4

5

9

8

7

6

6210_003-087

1 Horizontal rocker button for "3rd hydraulicfunction", tilt the lift mast

2 Pictograms for the basic hydraulic functions3 Pictograms for the 5th hydraulic function and

the clamp locking mechanism (variant)4 Pictograms for the 3rd & 4th hydraulic

functions

5 LED for clamp locking mechanism (variant)6 Slider for the "4th hydraulic function", e.g.

reach frame forwards/backwards7 Vertical rocker button for the "drive direction"8 Shift key "F"9 Signal horn button

174749 EN - 11/2018 63


Fingertip

F1F1 F2F2

7325_003-028

1 2 3 4 5 6

7891011

1 Function key "F1"2 Function key "F2"3 Left turn indicator button4 Signal horn button5 Right turn indicator button6 Function key "5th function"

7 "Attachments" operating lever8 "Attachments" operating lever9 "Tilt" operating lever10 "Lift/lower" operating lever11 Drive direction switch

NOTE


64 174749 EN - 11/2018


7311_003-0561

2

1 Travel direction switch2 Direction indicator switch

Mini consoleThe mini console is located on the steeringcolumn below the steering wheel.

174749 EN - 11/2018 65


66 174749 EN - 11/2018

4

Operation

4 OperationTesting and activities before daily use

Testing and activities before daily useVisual inspections

WARNINGRisk of injury from falling off the truck!When climbing onto the truck, thereis a risk of getting stuck or slippingand falling. Use suitable equipment toreach higher points on the truck.– Use only the steps provided for this

purpose to climb onto the truck.– Use equipment such as steplad-

ders or platforms to reach inacces-sible areas.

Damage to the truck or the attachment(variant), non-functional switches or safetysystems and modification of predefinedset values can lead to unpredictable anddangerous situations.The following checks and tasks enablecauses of this type to be identified in goodtime. It is important to run through all thechecks and tasks listed in the followingtable from top to bottom before daily use ofthe truck.If damage or other defects are identifiedon the truck or the attachment (variant),the truck must not be used until it has beenproperly repaired.

Ensure that the truck is safe for operation each day before it is used:

Component Course of action

Fork arms, general lifting accessories

Perform a visual inspection to check for deformationand wear (e.g. to check if they are bent, broken orfeature significant wear).Check the condition and function of the fork lockingdevices for preventing lifting and shifting.

Lift mast roller tracks Make sure that there is a film of grease.

Load chainsPerform a visual inspection to ensure that the chainsare intact and have adequate and even tension.

Attachments (variant)

Ensure correct mounting in accordance with theoperating instructions of the manufacturer.Perform a visual inspection to ensure the attach-ments are intact and not leaking.Perform checks to ensure the attachments areworking correctly.

68 174749 EN - 11/2018

Operation 4Testing and activities before daily use


Underside Check the area under the forklift truck for leakingconsumables.

Overhead guard, guard grille (variant) Perform a visual inspection for integrity.Check for secure mounting.

Steps Make sure they are clean (free of ice, not slippery).

Panes of glass (variant) Perform a visual inspection for integrity.Make sure they are clean (also free of ice).

Handholds Check for secure mounting.

Maintenance lids Check the close function and close the lids.

Fuel system, fuel tank

Perform a visual inspection for damage and leak-ages.Have damaged components replaced only by theauthorised service centre.

Battery Perform a visual inspection for integrity and defor-mation.

Bonnet and side flap

Perform a visual inspection for integrity and defor-mation.Check that the interlock is in good condition and isworking correctly.Check the close function and close the cover.

Coupling pin, tow coupling (variant)

Perform a visual inspection for deformation andwear (for example, bent, torn, broken).Check the securing bush in the counterweight forintegrity and that it is working correctly.Check that the linchpin is present and workingcorrectly (chain, rope, split pin).

Labelling, adhesive label

Check for presence, integrity and legibility.Replace damaged or missing adhesive labels inaccordance with the section entitled "Labellingpoints".

Driver's seat, seat belt Check the integrity and function.

Lighting, warning units Check the integrity and function.

Antistatic belt

Perform a visual inspection for integrity.Ensure cleanliness.The antistatic belt must be long enough to touch theground adequately.

Lift and tilt cylinders, tank, valve block,hoses, pipes, connections

Perform a visual inspection for damage and leak-ages.Check the area under the truck for leaking consum-ables.Have damaged components replaced only by theauthorised service centre.

174749 EN - 11/2018 69



Wheels, tyres

Perform a visual inspection for wear and damage.Make sure that only rims of the same type from thesamemanufacturer are fitted.In the event of uneven tyre wear, replace both tyres.Observe the safety regulations in the section entitled"Tyres".

Axle Make sure that no consumables are escaping fromthe axle.

Engine Check the engine oil level. Top up if necessary.Check the cooling fluid level. Top up if necessary.

– Do not use the truck if there is any damageor defects.

– Contact your authorised service centre.

70 174749 EN - 11/2018


Climbing in and out of the truck

WARNINGRisk of injury when climbing into and out of thetruck due to slipping, striking parts of the truck orbecoming stuck!If the footwell cover is very dirty or smeared with oil,there is a risk of slipping. There is a risk of hittingyour head on the post of the overhead guard or ofyour clothes becoming stuck when climbing out ofthe 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.

WARNINGRisk of injury when jumping out of the truck!If your clothing or jewellery (e.g. watch, ring etc.)become stuck on a component while you arejumping out of the truck, this can lead to seriousinjuries (e.g. from falling, loss of fingers etc.). It isforbidden 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.

CAUTIONComponents may become damaged throughincorrect use!Truck components, such as the driver's seat,steering wheel, parking brake lever etc., are notdesigned to be used for climbing in and out of thetruck and can be damaged due to misuse.– Only use the fittings specifically designed for the

purpose of climbing in and out of the truck.

174749 EN - 11/2018 71


7314_003-051

1 2

35

4

Toassistwith climbing into andout of the truck,the footwell must be used as a step (5) and thehandle (2) must be used for support. The postof the overhead guard (1) can also be used forsupport.

Always climb into the truck in a forwardsmotion:

– Grip the handle (2) with your left hand andhold on.

– Put your left foot on the step (4).

– Enter the truck with your right foot first andsit down on the driver's seat (3).

Always climb out of the truck backwards:

– Grip the handle (2) with your left hand andhold on.

– Stand up from the driver's seat and placeyour left foot on the step (4).

– Climb out of the truck right foot first.

0

7

8

5

3

1

6

5

12890

15:23

F1 F2

7314_003-050

1

2

3

Shelves and cup holders

WARNINGRisk of accident!Objects that fall into the footwell during travel as aresult of steering or braking may slip between thepedals (3) and prevent them fromworking correctly.It may then become impossible to brake the truck.– The storage compartment must only be used for

objects that cannot fall out.

– Make sure that stored objects cannot fallfrom the shelves (1) when the truck sets off,is steered or braked.

– Bottles with a maximum size of 0.5 l may bestored in the cup holder (2).

72 174749 EN - 11/2018


Adjusting the MSG 65/MSG 75driver's seat

DANGERThere is a risk of accident if the seat or seat backrestshifts suddenly, which could cause the driver tomove in an uncontrolled manner. This may result inunintentional actuation of the steering or operatingdevices and thus cause the truck or load to move inan uncontrolled fashion.– Do not adjust the seat or seat backrest while

driving– Adjust the seat and the seat backrest so that all

operating devices can be actuated safely– Ensure that the seat and seat backrest are

securely engaged

WARNINGOn some equipment variants, theamount of head clearance on the truckmay be restricted.On these specific equipment variants,the distance between the head andthe lower edge of the roofing sheetmust be at least 40 mm.

NOTE

If there are separate operating instructions forthe seat, they must be followed.

WARNINGTo obtain optimum seat cushioning, you must ad-just the seat suspension to your own body weight.This is better for your back and protects your health.– To prevent injury, make sure that there are no

objects within the swivel area of the seat

174749 EN - 11/2018 73


7094_003-0061

Moving the driver's seat– Lift and hold the lever (1)

– Push the driver's seat into the desiredposition.

– Release the lever.

– Ensure that the driver's seat is securelyengaged.

7094_003-008

2

Adjusting the seat backrestDo not put pressure on the seat backrest whileengaging it.

– Lift and hold the lever (2)

– Push the seat backrest into the desiredposition.

– Release the lever.

– Ensure that the seat backrest is securelyengaged.

NOTE

The backwards tilt angle of the seat backrestcan be restricted by the structural condition ofthe truck.

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6321_003-038

3

4

Adjusting the seat suspension

NOTE

The driver's seat can be adjusted to suit theweight of the individual driver. In order toachieve the best seat suspension setting, thedriver should perform the adjustment whilstsitting in the seat.

NOTE

The driver's seatMSG 65/MSG 75 is designedfor people weighing between 45 kg and170 kg.

NOTE

The MSG 75 seat is equipped with electric airsuspension that is activated using an electricswitch instead of the lever (3).

– Fully extend the weight-adjusting lever (3)

– Pump it up or down to set the driver'sweight.

– Return the weight adjusting lever to thecentral initial position before each new lift(audible click).

– Fully fold in the weight adjusting lever onceadjustment is complete.

NOTE

The driver's weight has been selected cor-rectly when the arrow (4) is in the centre of theinspection window. If the seat does not moveany further when you pump the weight adju-sting lever, the minimum or maximum weightsetting has been reached.

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6321_003-039

5

Adjusting the lumbar support (variant)

NOTE

The lumbar support can be adjusted to suitthe contours of the individual driver's spine.Adjusting the lumbar support moves a convexsupport cushion into the upper or lower part ofthe backrest.

– Turn the turning knob (5) up or down untilthe lumbar support is in the desired position

6321_003-040

6Adjusting the backrest extension(variant)– Adjust the backrest extension (6) by pullingit out or pushing it into the desired position.

To remove the backrest extension, move itpast the end stop by jolting it upwards.

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6321_003-041

7

Switching the seat heater (variant) onand off

NOTE

The seat heater only functions if the seatcontact switch is active, i.e. when the driver issitting on the driver's seat.

– Switch the seat heater (7) on or off using theswitch.

Adjusting the armrest

DANGERThere is a risk of accident if the armrest lowers sud-denly, causing the driver tomove in an uncontrolledmanner. This can result in unintentional actuationof the steering or the operating devices and thuscause uncontrolled movements of the truck or load.– Do not adjust the armrest while driving.– Adjust the armrest so that all operating devices

can be actuated safely.– Ensure that the armrest is securely tightened.

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7331_342-001

3 1 2

Adjusting the length of the armrest– Release the star-grip handle (1) by turningit anti-clockwise.

– Shift the armrest (2) into the desired posi-tion.

– Tighten the star-grip handle by turning itclockwise.

– Check that the armrest is firmly attached.

Adjusting the height of the armrest– Release hand wheel (3) by turning it anti-clockwise.

– Shift the armrest (2) into the desired posi-tion.

– Tighten the hand wheel by turning it clock-wise.

– Check that the armrest is firmly attached.

6210_424-001

1

2

Adjusting the steering column

DANGERRisk of accidents!Adjusting the steering column during travel maycause the truck to career out of control.– Adjust the steering column only when the truck is

at a standstill.– Ensure that the steering column is engaged.

– Press down and hold the lever (2) forsteering column adjustment.

– Position the steering column (1) and releasethe lever.

When the steering column engages, the leversnaps back to the initial position.

– Gently push and pull on the steering columnto make sure that the steering column isengaged.

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Unlocking the emergency off switch

NOTE

Only diesel trucks with a particle filter system(variant) or a joystick 4Plus (variant) have anemergency off switch.

7312_003-183

F1F1 F2F2

1

1

1

– Pull the emergency off switch (1) until itunlatches.

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F1F1 F2F2

7314_003-058

1

1

1

1

Operating the signal horn– Push the signal horn button (1).

The signal horn sounds.

NOTE

The signal horn is used to warn people againstimminent danger or to announce your intentionto overtake.

Seat belt

DANGEREven when using an approvedrestraint system, there is someresidual risk that the driver might beinjured if the truck tips over.This risk of injury can be reducedthrough the combined use of therestraint system and the seat belt.In addition, the seat belt protectsagainst the consequences of rear-endcollisions and falling off a ramp.– We therefore recommend that you

also use the seat belt.

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DANGEROnly bracket doors (variant) or the driver's cab(variant) with closed, fixed doors constitute a driverrestraint system. Plastic doors (weather protection)do not constitute a restraint system!If you need to open or remove the doors, you mustuse an alternative suitable restraint system (e.g. aseat belt).

7311_003-048

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23

Fastening the seat belt

DANGERRisk to life when driving without a seat belt!If the truck tips over or crashes into an obstacleand the driver is not wearing the seat belt, the drivermay be thrown from the truck. The driver could slideunder the truck or collide with an obstacle.There is a risk of fatal injury!– Fasten the seat belt before every trip.– Do not twist the seat belt when fastening it.– Only use the seat belt to secure one person.– Have any malfunctions repaired by the authori-

sed service centre.

NOTE

The buckle has a buckle switch (variant). Inthe event of an operating error or malfunction,the message SAFETY BELT appears in thedisplay and operating unit, see the chapterentitled "Display messages".

– Pull the seat belt (3) out of the belt retractorwithout jerking and fasten closely aroundthe body over the thighs.

NOTE

Sit as far back as possible so that your backis leaning against the seat backrest. Theautomatic blocking mechanism permitssufficient freedom of movement on the seat.

– Click the belt tongue (2) into buckle (1).

– Check tension of the seat belt. It should beclose to the body.

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6210_342-005

Fastening on a steep slopeThe automatic blocking mechanism preventsthe belt from being extended whenever thetruck is on a steep gradient. It is not possibleto pull the seat belt any further out of the beltretractor.

– Move away carefully on the slope.

– Fasten the seat belt.

Releasing the seat belt

7090_342-0051

4

– Push the red button (4) on the buckle (1).

– Manually guide the belt tongue slowly backto the retractor.

NOTE

Do not allow the seat belt to retract too quickly.The automatic blocking mechanism may betriggered if the belt tongue strikes the housing.It will then no longer be possible to pull the seatbelt out with the usual force.

– Using increased force, pull the seat beltaround 10-15 mm out of the retractor todisengage the blocking mechanism.

– Slowly allow the seat belt to retract again.

– Protect the seat belt from dirt (for example,by covering it).

Malfunction due to cold– If the buckle or belt retractor is frozen, thawthemout anddry them thoroughly to preventrecurrence.

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CAUTIONThe seat belt may be damaged by heat!Do not subject the buckle or belt retractor to exces-sive heat when thawing.– Do not use air warmer than 60°C when thawing.

6321_003-094

Driver's cab

DANGERRisk of fatal injury in the event of falling from thetruck if it tips over!In order to prevent the driver from sliding under-neath the truck and being crushed if the truck tipsover, a restraint systemmust be in place and mustbe used. The restraint system prevents the driverfrom being thrown from the truck if it tips over. Thedriver's cab constitutes a driver restraint systemonly if the cab door is sturdy and closed. Fabric-co-vered cabs (variant) with doors made of plastic orcanvas do not constitute a driver restraint systemand offer no protection from the consequences ofthe truck tipping over!– Close the cab door before operation– If the door is open or has been removed, use a

comparably secure restraint system– We recommend that you always use the seat belt

Checking the brake system forcorrect function

DANGERRisk of accident due to failure of the brake system!If the brake system fails, the truck will be insuffici-ently braked or will not be braked at all.– Do not commission trucks with a defective brake

system.

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1

5060_003-015

Checking the service brake– Release the parking brake.

– Depress the brake pedal (1).

There must be a slight pedal clearance andthen a noticeable pressure point at the brake.

– Accelerate the unladen truck in a clear area.

– Press the brake pedal firmly.

The truck must decelerate noticeably.

Checking the parking brakeOn a gradient or ramp:

DANGERRisk to life if the truck rolls away!The truck could run people over if theparking brake is not applied.– Do not exit the truck during the

following check.

– Stop the truck on a steep gradient (e.g. aramp) and actuate the parking brake.

The parking brake must hold the truck on theincline.

If the truck rolls back despite the parking brakebeing applied:

– Secure the truck using the service brake.

– Secure the truck with wedges so that thetruck does not roll away.


On level ground:

WARNINGRisk of accident!The truck may decelerate abruptly.– Fasten the seat belt.– Activate the available restraint systems.

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WARNINGThere is no electrical braking assistance when thekey switch is switched off!Switching off the key switch will de-energise theentire electrical system. The regenerative brakewill not be available.

CAUTIONThere is no power steering when the key switch isswitched off!The truck is equipped with hydraulic power stee-ring. Switching off the key switch shuts down thehydraulics completely. Steering forces are increa-sed by the remaining emergency steering function.– Steer with a higher level of force.

– Find a sufficiently large, open area in whichnobody will be obstructed.

– Accelerate the truck to walking speed.

– Use the key switch to switch off the engine.

– Apply the parking brake.

The truck must decelerate and remain station-ary.

If the truck only coasts and does not deceler-ate or decelerates only slightly:

– Secure the truck using the service brake.

– Secure the truck with wedges so that thetruck does not roll away.


1

2

Checking the regenerative brake

DANGERRisk of accident due to reduced braking power!The regenerative brake may not be sufficient foremergency braking.– Always actuate the brake pedal (1) for emer-

gency braking.

If the driving speed is restricted or if theopposite drive direction is selected, the truckbrakes electrically.

– Release the accelerator pedal (2).

– The truck must brake to a standstill.

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5060_003-031

1Checking the steering system forcorrect function

DANGERIf the hydraulics fail, there is a risk of accident as thesteering characteristics have changed.– Do not operate the truck if it has a defective

steering system.

– Operate steering wheel (1). The steeringplay while stationary must not be more thantwo finger widths.

NOTE

If the truck is switched on with the steeringwheel turned, the maximum driving speed islimited. Travel speed limitation is removedas soon as the steering wheel is moved outof a cornering position into the straight-aheadposition. This requires a change in steeringangle of about half a revolution.

Checking the emergency off function

NOTE

Only diesel trucks with a particle filter system(variant) or a joystick 4Plus (variant) have anemergency off switch.

WARNINGNo electric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will de-energisethe entire electrical system.– To brake, actuate the service brake.

– Slowly drive the truck forwards.

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7312_003-183

F1F1 F2F2

1

1

1

– Press the emergency off switch (1).

The truck will coast

– Brake the truck to a standstill by actuatingthe brake pedal.

NOTE

In trucks with an electric parking brake, theelectric parking brake will be applied as soonas the truck comes to a stop.

– Pull out the emergency off switch (1).

The knob is unlocked and pops out. The truckperforms an internal self-test and is then readyfor operation again.

Zero adjustment of the load mea-surement (variant)

NOTE

A zero adjustment must be carried out inorder to guarantee the accuracy of the loadmeasurement (variant) at all times. Zeroadjustment is required• Before daily use• after changing the fork arms• after fitting or changing attachments.

NOTE

Accurate zero adjustment is only possible ifthe fork is not carrying a load. Do not take up aload yet.

NOTE

Accurate zero adjustment is only possiblewithin the first lifting stage of the lift mast.When carrying out the zero adjustment, do not

174749 EN - 11/2018 87


raise the fork more than 800 mm above theground.

NOTE

The way in which the lifting system is operateddepends on the operating devices included inthe truck's equipment; see the chapter entitled"Lifting system operating devices".

– Set lift mast to vertical.

– Raise the fork to a height of 300-800 mm.

6210_003-071_V2

21

– Press the Softkey (1).

The zero adjustment of the loadmeasurementis switched on. The symbol is displayed.The message LOWER FORKS appears on thedisplay.

NOTE

During the following process, the fork carriagemust be lowered slightly and then stoppedabruptly. While doing so, the fork mustnot touch the ground, otherwise the zeroadjustment will not be accurate. To stopthe lowering procedure quickly, release theoperating device for lowering so that it jumpsinto the zero position.

– Lower the fork carriage slightly and releasethe operating device.

When the zero adjustment has been carriedout correctly, the value "0 kg" appears on thedisplay.

– The zero adjustment of the load measure-ment is completed. The symbol (2) isdisplayed.

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Operation 4Switching on and starting

6210_003-067_V2

21

Checking the vertical lift mastposition (variant) for correct function

NOTE

The function check of the lift mast verticalposition (variant) must be carried out everytime a truck is commissioned.


The comfort feature "lift mast vertical posi-tion" is switched on. The symbol (2) isdisplayed.

– Tilt the lift mast backwards.

The lift mast must tilt back fully and movegently as far as the end stop.

– Tilt the lift mast forward.

The lift mast must tilt forwards and stop in thevertical position.

– Release the operating device to tilt andactuate again.

The lift mast must tilt forwards fully and movegently as far as the end stop.

Switching on and startingSwitching on the key switch

WARNINGBefore switching on the key switch, all tests prior tostart-up must be performed without detecting anydefects.– Perform the tests prior to commissioning.– Do not operate the truck if defects have been

detected– Notify the authorised service centre.

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4 OperationSwitching on and starting

7090_001-002

0 I

1

– Insert the switch key (1) into the key switchand turn to position "I"

7312_003-085

This initiates a self-test. All lamps in the drivedirection and turn indicator displays light upbriefly.

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When the key switch is switched on, thedisplay shows the welcome screen in theset language until the truck controls havecompletely started up.

If the truck has the "access authorisation withPIN code" variant, the display initially changesto the input menu for access authorisation.

If the truck is ready for operation, the standarddisplays are shown.

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34

Standard display elements

In the factory setting, the following indicatorscan be seen in the display and operating unit:1 Fuel level

Shows the fuel level in the fuel tank as apercentage (%).

2 Drive programmeDisplays the current drive programmenumerically (1-5). The drive programmecan be changed; see the chapter entitled"Setting the drive programme".

3 Operating hoursDisplays the total operating hourscompleted by the truck. The hour meteroperates as soon as the engine is started.

4 TimeDisplays the current time digitally in hoursand minutes. The time can be adjusted;see the chapter entitled "Setting thetime".

CAUTIONLack of fuel can cause malfunctions!If the fuel tank has been run empty, the fuel injectionsystem can draw in air bubbles. This can lead tomalfunctions in the fuel injection system.– Never run the fuel tank empty.

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NOTE

Additional information may appear on thedisplay.• Refer to the information in the chapterentitled "Display messages".

Access authorisation with PIN code(variant)

DescriptionTrucks equipped with the "Access authori-sation with PIN code" variant are protectedagainst unauthorised use by a five-digit driverPIN. Up to fifty different driver PINs can bedefined so that the same truck can be usedby different drivers, each with their own driverPIN.

NOTE

The driver PINs are defined in a truck controlunit menu that can only be accessed bypersons with the corresponding accessauthorisation, e.g. fleet managers.

Once the key switch has been switched on,the input menu for the driver PIN appearson the display and operating unit screen. Allof the truck's functions (driving, hydraulics,additional electrical installations and thedisplay and operating unit displays) areblocked. The function of the hazard warningsystem (variant) is guaranteed. Enter the five-digit driver PIN (possible entries from 00000 to99999) to enable the blocked functions. Oncethe correct driver PIN has been entered, thestandard displays are shown. All of the truckfunctions are available.

The access authorisation can be configuredin such a way that the driver PIN has to bere-entered each time the driver steps off thetruck, in order for the truck to be operatedagain.


The first driver PIN is preset to "11111" at thefactory. All others are preset to "0xFFF" but

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have no function as the highest valid driverPIN is "99999". Persons with the appropriateaccessauthorisation, e.g. fleetmanagers, canchange the driver PINs in the correspondingmenu.

NOTE

When first commissioning the truck, we re-commend you change the access authorisa-tion set at the factory. This is the only way toguarantee that the driver PIN is only known topersons with corresponding access authori-sation.

The driver PINs are stored in the truck controlunit. These are still available if the displayand operating unit has been changed. Theauthorised service centre can use a diagnosticdevice to read out the driver PIN and, ifnecessary, restore the factory default driverPIN.

ACCESS CODE input menuThe driver enters the five-digit driver PIN(00000 to 99999) in this input menu.

The driver PIN is entered using the buttons orSoftkeys (1). The digits entered for the driverPIN (2) are not visible but are represented bycircles instead. If the driver PIN entered iscorrect, the familiar screen appears with thestandard display, and all truck functions areavailable.

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4

2

0

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5

BQ_023_en_V2

If an incorrect driver PIN is entered, themessage INVALID appears for a short time.When the message goes out, the driver PINcan be re-entered.

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BQ_024_en_V2

After three invalid entry attempts, the mes-sage CODE DENIED appears. The input isthen locked for five minutes before anotherattempt can be made.

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Blue-Q_029_V2

1

2

Defining the driver PIN

NOTE

The driver PINs can be defined only by per-sons with the appropriate access authorisa-tion, e.g. fleet managers. To set the driverPIN, the fleet manager must access the con-figuration menu. The configuration menu ispassword-protected. After entering the pass-word, the fleet manager can configure generalsettings for the truck. To change the pass-word, see the chapter entitled "Changing thepassword".

– Push the drive program selection button (1)and themenu change button (2) at the sametime.

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BQ_030_en_V2

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5

ESC

PASSWORD appears in the display.

– Enter the four-digit password (factorydefault: 2777) using the buttons (1).

– Confirm the input using Softkey (2).

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BQ_31_en

1

3 2

CONFIGURATION appears in the display.

– Use the drive program selection button (1)and the menu change button (3) to selectthe ACCESS CODEmenu.

– Confirm your selection using Soft-key (2).

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BQ_025_en_V3

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34 2

Selecting the driver PINIn the ACCESS CODEmenu, there are fiftypossible driver PINs to choose from.

The digit sequences can be set or changed inthe NEW CODE submenu.

Once the ACCESS CODEmenu has been ac-cessed, the CODE selection field (2) containsthe number 1. The first of the fifty driver PINscan now be defined.

– Use the drive program selection button (1)and the menu change button (4) to selectthe desired driver PIN (1 to 50).


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NEW CODE appears in the display.

– Enter the desired driver PIN using thebuttons or Softkeys (5).

Thedigits entered do not appear in the display.Instead they are represented by circles in theNEW CODE field (6).

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BQ_026_en

CONFIRM appears in the display.

The CONFIRM submenu is used to confirmthe new driver PIN.

– Enter the new driver PIN for a second timein the CONFIRM field (8) using the buttonsor Softkeys (7).

If the entry matches the new driver PINpreviously entered, the system will acceptthe new driver PIN once the last digit hasbeen entered. The display switches back tothe ACCESS CODEmenu.

Another driver PIN can be defined here.

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BQ_023_en_V2

If the driver PIN entered in the CONFIRM sub-menu does not match the driver PIN enteredpreviously in the NEW CODE submenu, themessage INVALIDwill appear.

The message will then disappear after a shorttime. The new driver PIN can be entered inthe CONFIRM submenu for further confirma-tion.

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BQ_024_en_V2

After three incorrect entries, the CODE DE-NIEDmessage appears.

The display switches back to the ACCESSCODEmenu. The desired driver PIN must bere-defined.

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Blue-Q_029_V2

1

2

Changing the passwordIt is recommended that you change the factorydefault password.

NOTE

The password can only be changed when theparking brake is applied.

– Push the drive program selection button (1)and themenu change button (2) at the sametime.

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BQ_030_en_V2

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ESC

PASSWORD appears in the display.

– Enter the current password using thebuttons (1).

– Confirm the input using Softkey (2).

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BQ_032_en

CONFIGURATION appears in the display.

– Use the drive program selection button (1)and the menu change button (3) to selectthe PASSWORDmenu.


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BQ_033_en

2

1

PASSWORD/PASSWORD LEVEL appears inthe display.

– Use the drive program selection button (1)and the menu change button (4) to selectthe desired PASSWORD LEVEL (2).


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ESC

BQ_034_en_V2

1 2 3

4

NEW CODE appears in the display.

The four-digit password can be entered usingthe buttons (1).

CAUTIONDo not enter the password 1777!If this password is entered, the configuration op-tions for the fleet manager are restricted to driverauthorisations and cannot be reset independently.The authorisations can only be reset by the autho-rised service centre!

– Enter the new desired password using thebuttons (1).

The digits entered are shown in plain text inthe NEW CODE field (4).


In the NEW CODE field, -??- appears briefly.The new password is confirmed.

– Press Softkey (2) to correct the newpassword.

The display switches back to PASS-WORD/PASSWORD LEVEL.

– Repeat the process steps from PASS-WORD/PASSWORD LEVEL.

– To exit the configuration menu, pressSoftkey (2) repeatedly until the standarddisplay appears.

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Starting the engine

DANGERRisk to health from exhaust gases!Exhaust gases from internal combustion enginesare harmful to your health. In particular, the sootparticles contained in the diesel exhaust gas cancause cancer.When the internal combustion engine is running,there is a risk of poisoning from the CO, CH andNOx components contained in the exhaust gas.Modern exhaust gas treatment systems (e.g.catalytic converters, particle filters or comparablesystems) can clean exhaust gases in a way thatreduces the health hazard and risk of poisoningwhen operating the truck.– Observe the national laws and regulations when




7071_003-101

0 I

1

II– Insert the switch key (1) into the key switchand turn to position "I"

The truck controller starts, see the sectionentitled "Switching on the key switch".

– Turn the key switch to position "II" and holdthere until the engine starts.

– Release the key switch as soon as theengine has started.

If the engine does not start after 20 seconds,stop the starting procedure and repeat afterone minute.

CAUTIONRisk of engine damage!If the OIL PRESSUREmessage appears on thedisplay after starting the motor, there may be in-sufficient engine lubrication. Insufficient lubricationmay cause engine damage.– Immediately switch off the engine.– Check the engine oil level and top up if neces-

sary.– If the message continues to appear, notify the

authorised service centre.

– Refer to the information in the chapterentitled "Display messages".

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NOTE

If the engine does not start due to a dischargedbattery, it can be jump-started.

NOTE

If the truck is left turned off for a lengthy periodin ambient temperatures below -5°C, the truckwill need to pre-heat at the next start-up.The message GLOW flashes on the display.Preheating can take up to 22 seconds. Ifthe message START is displayed, start theengine.

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4 OperationOperation of the display operating unit

Operation of the display operating unitDisplays

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Standard display elements

In the factory setting, the following indicatorscan be seen in the display and operating unit:1 Fuel level

Shows the fuel level in the fuel tank in %.2 Drive programme

Displays the current drive programmenumerically (1-5). The drive programmecan be changed; see the chapter entitled"Setting the drive programme".

3 Operating hoursDisplays the total operating hourscompleted by the truck. The hour meteroperates as soon as the engine is started.

4 TimeDisplays the current time digitally in hoursand minutes. The time can be adjusted;see the chapter entitled "Setting thetime".

990h

0.0km

0.0km/T

1.2h/T

6 75

89

Additional indicators5 Menu change button

When the menu change button ispressed, the following additional indi-cators appear:

6 "Service in" indicatorDisplays the remaining time in hours untilthe next servicework has to be carried outaccording to the maintenance schedulein the maintenance instructions. Contactthe authorised service centre in goodtime.

7 Total distanceDisplays the total distance driven inkilometres.

8 Daily kilometresDisplays the kilometres driven for theday.

9 Daily driving timeDisplays the hours driven for the day.

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Operation 4Operation of the display operating unit

Adjusting the displays

NOTE

The parking brake must always be engagedwhen you adjust the displays. The displayscannot be adjusted if the parking brake is notengaged.

NOTE

When adjusting the displays, do not actuatethe hydraulic system operating devices. If youdo, entry is interrupted and the display returnsto the operating display.

The displays are adjusted in the CONFIGU-RATIONmenu.

– Turn the key switch to position "I".

Blue-Q_029_V2

1

2

– Press the drive program button (1) and themenu change button (2) at the same time.

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5

ESC

The display changes to thePASSWORDmenu.

NOTE

It may be necessary to enter a password inorder to configure the displays. This dependson the configuration of the display-operatingunit.• For configuration of the display-operatingunit, contact the authorised service centre

7312_003-056_en_V3

ESC

1 2 3– Press the Softkey (3).

The display changes to the CONFIGURA-TIONmenu.

The following settings are possible and can befound in the corresponding chapter:• Setting the date and time• Resetting the daily kilometres and dailyoperating hours

• Setting the language• Configure Blue-Q

Symbols in the display

MessagesTo show operating messages, warningmessages or error messages in the display,text messages and symbols are used.

Symbols for operating messages

Description Symbol

Empty field No display

Please wait

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Description Symbol

Service required

Lift limitation

Reference cycle

Battery charging

Drive program

Hour meter

Odometer

Daily hour meter

Daily odometer

Speed

Steering angle

Load

Time

Hydraulic system

Exh.gas purifier

Coolant temperature

Fuel level

Blue-Q

Power rating (average)

Power rating (trend).

Symbols for warning messages

Description Symbol

Parking brake

Actuate seat switch

Safety belt

Battery acid level

Neutral warning message

Are you sure?

Oil pressure.

174749 EN - 11/2018 107


Symbols for error messages

Description Symbol

Brake systemmalfunction

Overheating of the engine

Overheating

Malfunction in the electrical system

General malfunction.

Symbols for softkey functions of auxiliaryequipmentThe following symbols for softkey functionsare used on the left of the display for auxiliaryequipment:

Description Symbol


General function OFF

General function ON

Rear working spotlight OFF

Rear working spotlight ON

Front working spotlight OFF

Front working spotlight ON

Windscreen heating OFF

Windscreen heating ON

Rear window heating OFF

Rear window heating ON

Interior lighting OFF

Interior lighting ON

Roof wiper/washer OFF

Roof wiper/washer ON

Heater blower OFF

Heater blower ON

Rotating beacon OFF

Rotating beacon ON

108 174749 EN - 11/2018


Description Symbol

Seat heater OFF

Seat heater ON

Signal horn OFF

Signal horn ON

Cruise control OFF

Cruise control ON

Automatic mast vertical positioning OFF

Automatic mast vertical positioning ON

Loadmeasurement zero adjustment OFF

Load measurement zero adjustment ON

Load measurement OFF

Load measurement ON.

Symbols for softkey functions for menunavigation and for acknowledgingmessagesThe following symbols for the softkey functionsare used on the left of the display for menunavigation and to acknowledge messages:

Description Symbol


Cancel input

Confirm input

Confirm information

Reset

Back by one menu level

Back to the previous edit field

Scroll up

Scroll down

Count up

Count down.

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Status LEDs of the function keys foradditional electrical installationsThe current switch status of a button is indi-cated with LEDs next to the relevant functionkey for the additional electrical installation.

Description LED

Function off LED OFF

Function on LED ON.

Symbols for numeric keypadThe buttons and Softkeys that can be used toenter numbers and to cancel or confirm inputvalues are shown in the display.

BQ_037

1

2

6

7

3

4

5

ESC

Screen for entering the fleet manager pass-word:

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1

2

6

7

3

4

5

8

9

0

BQ_038

Screen for entering the driver PIN (accesscode):

8

9

0

6

7

4

3

5

7312_003-054_en_V3

1 2 3 4Setting the date or time– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Press the Drive programme button (1) orthe Menu change button (2) repeatedly untilthe TIME option appears.

– Confirm your selection using the Soft-key (4).

The TIMEmenu appears.

– Press and hold down the Drive programmebutton (1) or Menu change button (2) untilthe desired time appears on the display.

As the buttons are held down for longer, thescrolling speed increases in three levels.

– Confirm the set time using Softkey (4).

– Use the Softkey (3) to exit themenu andreturn to the next level up.

NOTE

The date is set in a similar manner.

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8

9

0

6

7

4

3

5

7312_003-055_en_V4

1 2 3 4Resetting the daily kilometres anddaily operating hoursThe daily number of kilometres and dailyoperating hours displays can be reset to zero:

– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Press the Drive programme button (1) orthe Menu change button (2) repeatedly untilthe DAY KM option appears.


The DAY KMmenu appears.

– Reset the displayed mileage using Soft-key (4).


NOTE

The daily operating hours are reset in thesamemanner.

8

9

0

6

7

4

3

5

7312_003-058_en_V4

1 2 3 4Setting the languageThe displays can be shown in additionallanguages:

– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Press the drive programme button (1) or themenu change button (2) repeatedly until theLANGUAGE option appears.


The LANGUAGEmenu appears.

– Press drive program button (1) or menuchangebutton (2) until the desired languageappears in the display.


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Softkeys for operating variousequipment variantsAdditional functions can be displayed on thedisplay-operating unit. These additionalfunctions, e.g. a rotating beacon, can beswitched on and off using Softkeys.

1 2 3

ABE_Softkeytasten_V2

Changing the Softkey functions:

A grey bar (3) highlights the Softkey column.This is the right-hand column in the exampleshown here. These additional functionscan now be switched on and off via thecorresponding Softkeys (2). The right-handcolumn is only populated with additionalfunctions if the truck has more than threeequipment variants that can be switched onand off using Softkeys.

In this case, proceed as follows to switchbetween the two columns:

– Briefly press the Menu change button (1).

The grey bar jumps to the left-hand col-umn. These additional functions can nowbe switched on and off via the correspondingSoftkeys (2).

NOTE

Press the Menu change button (1) for approx.1 second to switch between the individualmenus on the display-operating unit.

NOTE

The additional functions depend on theindividual equipment of the truck and mayvary from those shown here.

Configuring Blue-Q efficiency modeThe following operating modes can be se-lected to activate the Blue-Q efficiency mode:

174749 EN - 11/2018 113


STANDARD

• Blue-Q is turned off whenever the truckis commissioned. The driver can use theBlue-Q button to switch efficiency mode onand off at any time while the truck is beingoperated

FIXED

• Blue-Q is switched on permanently when-ever the truck is commissioned and duringtruck operation. The driver cannot turn effi-ciency mode off

FIXED-FLEX

• Blue-Q is turned on whenever the truckis commissioned. The driver can use theBlue-Q button to switch efficiency mode onand off at any time while the truck is beingoperated

8

9

0

6

7

4

3

5

7312_003-179_en

1 2 3 4– Switch to the CONFIGURATIONmenu;see the chapter entitled "Adjusting thedisplays".

– Keep pressing the drive programme button(1) or the menu change button (2) until op-tion BLUE Q CONFIGURATION appears.

– Confirm your selection with Softkey (4).

The BLUE-Q CONFIGURATION menuappears.

– Press drive program button (1) or menuchange button (2) until the desired effi-ciency mode appears in the display.

– Confirm the set efficiency mode usingSoftkey (4).


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Operation 4Blue-Q efficiency mode

Blue-Q efficiency modeFunctional descriptionThe Blue-Q efficiency mode affects both thedrive unit and the activation of the additionalconsumers, and reduces the truck's energyconsumption.

If the efficiency mode has been activated, theacceleration behaviour of the truck changes tomake acceleration more moderate.

When travelling at low speeds—normallywhen manoeuvring—no reduction is notice-able despite the activated efficiency mode.For moderate speeds of at least approx.7 km/h, acceleration is gentler. Therefore,on distances of up to approx. 40 m, lowerspeeds are reached than would be the case ifthe efficiency mode was not activated.

Blue-Q has no influence on:• Maximum speed• Climbing capability• Traction• Braking characteristics

NOTE

The Blue-Q efficiency mode can be swit-ched on and off in the STANDARD and FI-XED-FLEX operating modes. If the FIXEDoperating mode is configured in the displayoperating unit, the Blue-Q button has no func-tion and the Blue-Q efficiency mode is swit-ched on permanently; see also chapter "Con-figuring Blue-Q efficiency mode".

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4 OperationBlue-Q efficiency mode

Switching off additional consumersIf the Blue-Q efficiency mode is activated,the controller switches off various additionalconsumers after a few seconds in certain con-ditions. The additional consumers availabledepend on the truck equipment. The followingtable shows the conditions that cause addi-tional consumers to be switched off. Only oneof the conditions listed must be met.

ConditionAdditional consumers

Seat switch notactuated

Truck stopped Truck is in motion

Front workingspotlights X X Backwards > 3 km/h

Rearworking spotlights X X ForwardsTop double workingspotlight X X > 3 km/h

Headlights X X -

Front wiper X X Backwards > 3 km/h

Rear wiper X X Forwards

Seat heater X - -

Cab heating X - -

NOTE

On the version with StVZO (German RoadTraffic Licensing Regulations) equipment, theBlue-Q efficiency mode does not switch offthe lighting devices headlights and workingspotlights, side lights, rear lights and licenseplate lamps.

Switching efficiencymode Blue-Q onand off

NOTE

The Blue-Q efficiency mode can be swit-ched on and off in the STANDARD and FI-XED-FLEX operating modes. If the FI-XED operating mode is configured in thedisplay-operating unit, the Blue-Q button isdisabled and the Blue-Q efficiency mode isswitched on permanently. For information on

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Operation 4Blue-Q efficiency mode

configuring the Blue-Q operating modes, seethe "Configuring Blue-Q efficiency mode" sec-tion.

2

2

1

3

– Press the Blue-Q button (2) to switch onBlue-Q.

The Blue-Q symbol (1) is displayed. TheLED (3) illuminates in blue. Blue-Q efficiencymode is switched on.

– To switch it off, press the Blue-Q button (2)again.

The Blue-Q symbol (1) and the LEDs (3) goout. Blue-Q efficiency mode is switched off.

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4 OperationDriving

DrivingSafety regulations when driving

Driving conductThe driver must follow the public rules of theroad when driving in company traffic.

The speed must be appropriate to the localconditions.

For example, the driver must drive slowlyaround corners, in tight passageways, whendriving through swing-doors, at blind spots, oron uneven surfaces.

The driver must always maintain a safebraking distance from vehicles and persons infront, and must always have the truck undercontrol. Stopping suddenly, turning quicklyand overtaking at dangerous or blind spotsmust be avoided.

– Initial driving practice must be carried out inan empty space or on a clear roadway.

The following are forbidden during driving:• Allowing arms and legs to hang outside thetruck

• Leaning the body over the outer contour ofthe truck

• Climbing out of the truck• Moving the driver's seat• Adjusting the steering column• Releasing the seat belt• Disabling the restraint system• Raising the load higher than 300 mmabove the ground (with the exceptionof manoeuvring processes during theplacement into stock/removal from stockof loads)

• Using electronic devices, for exampleradios, mobile phones etc.

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Operation 4Driving

WARNINGThe use of multimedia and communication equip-ment as well as playing these devices at an exces-sive volume during travel or when handling loadscan affect the operator's attention. There is a risk ofaccident!– Do not use devices during travel or when hand-

ling loads.– Set the volume so that warning signals can still

be heard.

WARNINGIn areas where use of mobile phones is prohibited,use of a mobile phone or radio telephone is notpermitted.– Switch off the devices.

Visibility when drivingThe driver must look in the drive direction andhave a sufficient view of the driving lane.

Particularly for reverse travel, the driver mustbe sure that the driving lane is clear.

When transporting goods that impair visibility,the driver must drive the truck in reverse.

If this is not possible, a second person actingas a guide must walk in front of the truck.

In this case the driver must only move atwalking pace and with extra care. The truckmust be stopped immediately if eye contactwith the guide is lost.

Rear-view mirrors are only to be used forobserving the road area behind the truck andnot for reverse travel. If visual aids (mirror,monitor) are necessary to achieve sufficientvisibility, it is necessary to practise using them.For reverse travel using visual aids, extra careshould be taken.

When using attachments, special conditionsapply; see the chapter entitled "Fitting attach-ments".

Any glass (variant, e.g. windscreen) andmirrors must always be clean and free of ice.

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4 OperationDriving

Driveways

Dimensions of roadways andaislewidthsThe following dimensions and aisle widthrequirements apply under the specifiedconditions to ensure safe manoeuvring. Ineach case, a check must be performed todetermine whether a larger aisle width isnecessary, e.g. in the case of deviating loaddimensions, attachments or lift masts.

Within the EU, Directive 89/654/EEC (mini-mum safety and health requirements for theworkplace) must be observed. The respectivenational guidelines apply for areas outside ofthe EU.

The required aisle widths depend on thedimensions of the load.

For pallets, these are:

Aisle width [mm]

Model Type With pallet1000x1200crosswise

With pallet800x1200lengthwise

7311RX70-16

73143523 3727

7312RX70-18

73153557 3762

7313RX70-20

73163603 3810

The truck may only be used on roadwaysthat do not have excessively sharp bends,excessively steep gradients or excessivelynarrow or low entrances.

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Operation 4Driving

Driving on ascending and descendinggradients

CAUTIONIt is not permitted to drive on long ascending anddescending gradients greater than 15% due to thespecifiedminimum braking and stability values.The climbing capability values given below onlyapply to overcoming obstacles on the roadway andto short differences in level, e.g. ramps.– Before driving on long ascending and descen-

ding gradients greater than 15%, consult theauthorised service centre.

The truck may be driven on the followingascending and descending gradients:

Maximum gradient [%]Model Type

With load There is no load on the truck

7311RX70-16

731427.0

7312RX70-18

7315

7313RX70-20

7316

26.0

28.0

The stated values are used only to compareperformance of trucks in the same category.The gradient values in no way represent thenormal daily operating conditions.

CAUTIONTo use the truck safely—with or without a load—themaximum ascending or descending gradient per-mitted for travel is 15%.– If you have any questions, contact your authori-

sed service centre.

The upwards and downwards gradients mustnot exceed themaximum gradients above andmust feature a rough surface.

The top and bottom of the gradient mustfeature smooth and gradual transitions toprevent the load from falling to the ground orthe truck being damaged.

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4 OperationDriving

Warning in case components projectbeyond the truck contour

Trucks are often required to drive throughvery narrow or very low spaces such as aislesor containers. The trucks are dimensionedfor this purpose. However, movable partsmay project beyond the truck contour andbe damaged or torn off. Examples of suchcomponents include:• A folding roof panel in the driver's cab• Cab doors• Folding LPG cylinders

Condition of the roadwaysRoadways must be sufficiently firm, level andfree from dirt and fallen objects.

Drainage channels, level crossings andsimilar obstacles must be evened out and,if necessary, ramps must be provided so thattrucks can drive over these obstacles with asfew bumps as possible.

Note the load capacity of manhole covers,drain covers etc.

There must be sufficient distance between thehighest points of the truck or the load and thefixed elements of the surrounding area. Theheight is based on the overall height of the liftmast and the dimensions of the load; see thechapter entitled "Technical data".

Rules for roadways and the working areaIt is only permitted to drive on routes autho-rised for traffic by the operating company or itsrepresentatives. Traffic routes must be freeof obstacles. The load may only be set downand stored in the designated locations. Theoperating company and its representativesmust ensure that unauthorised third parties donot enter the working area.

NOTE


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Operation 4Driving

Hazard areasHazard areas on roadways must be markedby standard traffic signs or, if necessary, byadditional warning signs.

2

5060_003-092_V2

1 2

Setting the drive programsThe driving and braking characteristics of thedrive can be set on the display and operatingunit.

– Push the drive program button (1) repeat-edly until the number of the required driveprogram appears on the drive program dis-play (2).

Drive programs 1-5 are available.

The basic principle is that the higher the driveprogram number is, the greater the drivingdynamics.

The following drive programs are possible:

Drive program 1 2 3 4 5

Speed (km/h) 22 22 22 22 22

Acceleration (%) (forwards/backwards) 50 100 120 140 160

Deceleration (%) (forwards/backwards) 50 100 120 140 160

Reversing (%) (forwards/backwards) 50 100 120 140 160

Brake retardation (%) (electric brake booster) 60 70 80 90 100.

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4 OperationDriving

5060_003-082

1

2

Selecting the drive directionThe desired drive direction of the truck mustbe selected using the drive direction switchbefore attempting to drive. The method ofactuating the drive direction switch dependson the operating devices included in the truck'sequipment.

Possible equipment variants include:• Mini-lever• Joystick 4Plus• Fingertip switch• Mini-console

NOTE

The drive direction can also be changedduring travel. Your foot can remain on theaccelerator pedal while doing so. The truck isthen decelerated and accelerated again in theopposite direction (reversing).The indicator for the selected drive direction("forwards" (1) or "reverse" (2)) lights up on thedisplay and operating unit.

Neutral positionIf the truck is stopped for an extended period,select the neutral position to prevent the truckfrom suddenly starting if the accelerator pedalis inadvertently pressed.

– Briefly select the drive direction switchfor the direction opposite to the currentdirection.

The drive direction indicator on the display andoperating unit goes out.

NOTE

When the seat is vacated, the drive directionswitch is set to "Neutral". To drive, the drivedirection switch must be actuated again.

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Operation 4Driving

5060_003-096

F1 F2

1

Actuating the drive direction switch,mini-lever version– Push the cross lever (1) forwards to drive"forward".

– Pull the cross lever backwards to drive"backward".

1

6210_003-101

A

B

Actuating the vertical rockerswitch for the "drive direction", joy-stick 4Plus version– For the "forwards" drive direction, pushthe vertical rocker button for the "drivedirection"(1) upwards (A).

– For the "reverse" drive direction, pushthe vertical rocker button for the "drivedirection"(1) downwards (B).

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4 OperationDriving

F1F1 F2F2

7325_003-031

1

Actuating the drive direction switch,fingertip version– For the "forwards" drive direction, push thedrive direction switch (1) forwards

– For the "backwards" drive direction, pushthe drive direction switch backwards

5060_003-005

1

Actuating the drive direction switch,mini-console version– For the "forwards" drive direction, push thedrive direction switch (1) forwards.

– For the "backwards" drive direction, pushthe drive direction switch to the rear.

NOTE

Alternatively, the drive direction can also beselected using the drive direction switches onthe operating devices.

Starting to drive

DANGERRisk to life if the truck rolls away or tips over!– Sit on the driver's seat.– Fasten the seat belt.– Activate the available restraint systems.

Observe the information in the chapter entitledSafety regulations when driving.

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Operation 4Driving

The driver's seat has a seat switch thatchecks whether the driver's seat is occupied.The truck cannot be moved if the driver'sseat is not occupied or if the seat switchmalfunctions. All lifting functions are disabled.The SEAT SWITCHmessage appears on thedisplay-operating unit.

– Lift the fork carriage until the necessaryground clearance is achieved.


– Release the parking brake.

– Select the desired drive direction.

5060_003-082

1

2

The indicator for the selected drive direction("forwards" (1) or "backwards" (2)) lights up onthe display and operating unit.

NOTE

Depending on the equipment, an acousticsignal (variant) may sound a warning duringreverse travel, the warning light (variant) maylight up or the hazard warning system (variant)may flash.

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4 OperationDriving

3

5060_003-084

– Press the accelerator pedal (3).

The truck will travel in the selected drive direc-tion. The accelerator pedal position controlsthe speed. When the accelerator pedal is re-leased, the truck brakes automatically via theregenerative brake.

NOTE

The regenerative brake holds the truck briefly,even on ascending or descending gradients,without the parking brake being actuated. Thetruck will then begin to creep downhill slowly.

DANGERRisk of accident due to brake failure!The electric brake only functions while the keyswitch is switched on, the emergency off switch(variant) has not been actuated and the parkingbrake is released.– Use the brake pedal if the electrical brake

malfunctions– Only leave the truck when the parking brake is

applied.

Changing the drive direction– Remove foot from accelerator pedal.

– Select the desired drive direction.

– Press the accelerator pedal.

The truck will travel in the selected drivedirection.

NOTE

You can also change the drive direction whilethe truck is in motion. Your foot can remainon the accelerator pedal while you do so. Thetruck will brake and then accelerate in theopposite direction (reversing).

NOTE

If an electrical fault occurs in the accelerator,the drive unit switches off. The truck is brakedby the regenerative brake. Once the electricalfault has been corrected, it will be possibleto drive the truck again by releasing theaccelerator pedal and then actuating the

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Operation 4Driving

accelerator pedal again. If the truck stillcannot be operated, park the truck securelyand contact your authorised service centre.

Starting drive mode, dual pedalversion (variant)

DANGERRisk to life if the truck rolls away or tips over!– Sit on the driver's seat.– Fasten the seat belt.– Activate the available restraint systems.

Observe the information in the chapter entitledSafety regulations when driving.

The driver's seat has a seat switch thatchecks whether the driver's seat is occupied.The truck cannot be moved if the driver'sseat is not occupied or if the seat switchmalfunctions. All lifting functions are disabled.The SEAT SWITCHmessage appears on thedisplay-operating unit.

– Lift the fork carriage until the necessaryground clearance is achieved.



5060_003-085

2 1

– Actuate the right-hand accelerator pedal (1)to drive "forward" and actuate the left-handaccelerator pedal (2) to drive "backward".

NOTE

In the dual pedal version, the drive directionswitches on the operating devices do notfunction.

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4 OperationDriving

5060_003-083

3

4

The indicator for the selected drive direction("forwards" (3) or "backwards" (4)) lights up onthe display and operating unit.

NOTE

Depending on the equipment, an acousticsignal (variant) may sound a warning duringreverse travel, the warning light (variant) maylight up or the hazard warning system (variant)may flash.

The truck will travel in the selected drive direc-tion. The accelerator pedal position controlsthe speed. When the accelerator pedal is re-leased, the truck brakes automatically via theregenerative brake.

NOTE

The regenerative brake holds the truck briefly,even on ascending or descending gradients,without the parking brake being actuated. Thetruck will then begin to creep downhill slowly.

DANGERRisk of accident due to brake failure!The electric brake only functions while the keyswitch is switched on, the emergency off switch(variant) has not been actuated and the parkingbrake is released.– Use the brake pedal if the electric brakemalfunc-

tions.– Only leave the truck when the parking brake is

applied.

Changing the drive direction– Remove your foot from the acceleratorpedal.

– Actuate the accelerator pedal for the otherdirection.

The truck will travel in the selected drivedirection.

NOTE

If an electrical fault occurs in the accelerator,the drive unit switches off. The truck is brakedby the regenerative brake. Once the electrical

130 174749 EN - 11/2018

Operation 4Driving

fault has been corrected, it will be possibleto drive the truck again by releasing theaccelerator pedal and then actuating theaccelerator pedal again. If the truck stillcannot be operated, park the truck securelyand contact your authorised service centre.

1

2

5060_003-006

Operating the service brakeThe electric brake converts the accelerationenergy of the truck into electrical energy. Thiscauses the truck to decelerate.

In addition, the truck can be braked using theservice brake:

– Press the brake pedal (2).

In the first section of the brake pedal's travel,only the regenerative braking takes effect. Asthe pedal is depressed further, the servicebrake is also activated and acts on the drivewheels.

DANGERRisk of accident!If the service brake fails, the truck cannot brakesufficiently.– Bring the truck to a standstill by applying the

parking brake.– Do not operate the truck again until the service

brake has been repaired.

DANGERRisk of tipping and risk of slipping!The braking distance of the truck depends on theweather conditions and the level of contaminationon the roadway. The braking distance increaseswith the square of the speed. There is a danger thatthe truck could slip or overturn.– Adapt your driving and braking style to suit the

weather conditions and the level of contamina-tion on the roadway.

– Always choose a driving speed that will providea sufficient stopping distance.

– Brake the truck by releasing the acceleratorpedal (1).

– If the braking effect is inadequate, brakeusing the service brake (2) as well.

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4 OperationDriving

Zero braking (variant)

DANGERRisk of accident!Trucks with zero braking (variant) are not brakedwhen the accelerator pedal is released.– Bring the truck to a standstill by actuating the

brake pedal.

If your truck features the zero braking equip-ment variant, the electric brake function isdisabled. Taking your foot off the acceleratorpedal does not brake the truck.

In this case, the truck can only be slowed byapplying the service brake via the brake pedal.

Parking brakeOperation of the parking brake depends onwhich parking brake the truck is fitted with.

Possible equipment variants are as follows:• Mechanical parking brake; see ⇒ Chap-ter "Actuating the mechanical parkingbrake", P. 4-132

• Electric parking brake; see ⇒ Chapter "Ac-tuating the electric parking brake", P. 4-134

Actuating the mechanical parkingbrake

DANGERThere is a risk of being run over if the truck rollsaway, and therefore a danger to life.– The truck must not be parked on a slope.– In emergencies, secure with wedges on the side

facing downhill.– Only leave the truck when the parking brake is

applied.

NOTE

Once the parking brake is released, thepreviously selected drive direction is retainedand is shown on the drive direction indicator.

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Operation 4Driving

NOTE

If you operate the accelerator pedal while theparking brake is applied and a drive directionis selected, the message PARKING BRAKEappears in the display.

8

9

6

72

0

13

5

%75

h

2

234,712:15

1 2

7312_003-044_V2

Apply the parking brake– Pull the parking brake lever (1) down fullyand release.

The parking brake lever swivels back half thedistance into the middle position automati-cally.

The parking brake is engaged and the wheelsare blocked. Driving is no longer possible.The drive direction indicator (2) on the displayand operating unit goes out.

6210_494-002

Releasing the parking brake– Pull the parking brake lever (1) down fullyout of the middle position.

– In the lower lever position, pull out the leverknob and then guide the parking brake leverup fully.

NOTE

The parking brake lever swivels to the upperposition automatically by means of springforce and should be guided only lightly byhand. If the adjustment is stiff, notify theauthorised service centre.

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4 OperationDriving

6210_003-050_V421

Actuating the electric parking brakeThe electric parking brake helps the driverto park the truck safely thanks to the simpleactuation of the push button (1) and theadditional automatic functions. Despitethese automatic aids, the driver is alwaysresponsible for parking the truck safely. Thesafety information about safe parking applies.

DANGERThere is a risk of being run over ifthe truck rolls away and therefore adanger to life.– The truck should not be parked on

a slope.– In emergencies, secure with

wedges on the side facing downhill.– Only leave the truck if the parking

brake is applied.

NOTE

To electrically activate the parking brake, thebattery male connector must be connectedand the key switch must be switched on.

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Operation 4Driving

6210_003-050_V421

Functions at truck standstillActuation by the driver

– Press push button (1).

The parking brake will audibly engage and theLED (2) illuminates with a steady light.

Actuation triggered automatically

Cause Effect

When the driverleaves the driver'sseat:

After a short waitingperiod, the parkingbrake will audiblyengage and the LED(2) will illuminate witha steady light.

When the acceleratorpedal is released:

After a short waitingperiod, the parkingbrake will audiblyengage and the LED(2) will illuminatewith a steady light.The truck is held ona gradient by thetraction motor untilthe parking brake isapplied.

When the key switchis turned off:

The parking brakewill audibly engageimmediately and theLED (2) will illuminatebriefly with a steadylight until the controlunits switch off.

If the emergency offswitch (variant) isactuated, followingthe emergency offfunction:

The parking brake isapplied.

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4 OperationDriving

6311_003-031_en_V2

If the electric parking brake is applied, thePARKING BRAKE ACTIVEmessage ap-pears in the display for 5 seconds.

6210_003-050_V421

Releasing the parking brake by pressing thebutton

NOTE

When the truck is ready for operation, theelectric parking brake can be released at anytime by pressing the button.

– Sit down on the driver's seat.


The parking brake will audibly release and theLED (2) will go out.

Releasing the parking brake by starting todrive

NOTE

The electric parking brake can be releasedby starting to drive only if the electric parkingbrake is applied automatically by releasing theaccelerator pedal or vacating the driver's seat.


– Select the drive direction (single-pedalversion only).

– Actuate the accelerator pedal.

The parking brake will audibly release and theLED (2) will go out.

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6311_003-032_en_V2

If the parking brake has not been appliedby the accelerator pedal being released orthe driver's seat being vacated, then it is notpossible to drive the truck until the parkingbrake has been released by pressing thebutton. The RELEASE PARKING BRAKEmessage appears in the display.

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4 OperationDriving

6210_003-050_V421

Functions available when the truck ismovingActuation by the driver


The truck is brakedmoderately. Depending onthe situation, it is possible to drive again afterthe button has been released. If the truck is ata standstill, the parking brake audibly engagesand the LED (2) illuminates with a steady light.

Actuation triggered automatically

Cause Effect

When the driverleaves the driver'sseat:

After a short wait,the truck rolls to astop or deceleratesmoderately. If thetruck is at a standstill,the parking brakeaudibly engagesand the LED (2)illuminates with asteady light.

When the key switchis turned off:

The truck will roll toa stop. If the truckis at a standstill, theparking brake audiblyengages and the LED(2) illuminates with asteady light until thecontrol units switchoff.

If the emergency offswitch (variant) isactuated, followingthe emergency offfunction:

The truck will roll toa stop. If the truckis at a standstill, theparking brake audiblyengages and the LED(2) illuminates brieflywith a steady light.

Automatic braking:

With the drivedeactivated and theseat not occupied,or if the truck beingaccelerated heavily,the parking brake isapplied withmoderatebraking force.

.

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Operation 4Driving

A

A B

A B

B

5060_003-007

1

Steering

DANGERIf the hydraulics fail, there is a risk of accident as thesteering characteristics have changed.– Do not operate the truck if it has a defective

steering system.

– Steer the truck by turning the steeringwheel(1) accordingly.

Turning the steering wheel in the direction ofarrow (A) steers the truck in drive direction (A).

Turning the steering wheel in the direction ofarrow (B) steers the truck in drive direction (B).

For turning radius information, see ⇒ Chap-ter "VDI datasheet for RX70-16, RX70-18 andRX70-20", P. 6-360.

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4 OperationDriving

6210_001-008

Driving on ascending and descend-ing gradients

DANGERDanger to life!Driving on ascending and descending gradientscarries special dangers!– Always follow the instructions below.

– On ascending and descending gradients,the load must be carried facing uphill.

– It is only permitted to drive on ascendingand descending gradients that are markedas traffic routes and that can be used safely.

– Ensure that the ground to be traversed isclean and provides a good grip.

– Do not turn on ascending and descendinggradients.

– Do not drive onto or along ascending anddescending gradients at an angle.

– Do not park the truck on ascending ordescending gradients.

– In case of emergency, secure the truck withwedges so that the truck does not roll away.

– Reduce the driving speed on descendinggradients.

It is not permitted to drive on long ascendingand descending gradients greater than 15%due to the specified minimum braking andstability values.

– Before driving on ascending and descend-ing gradients greater than 15%, consult theauthorised service centre.

The process of placing loads into stockand removing loads from stock while onan ascending or descending gradient is notpermitted!

– Always place loads into stock and removeloads from stock on a horizontal plane.

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7321_003-052_en_V2

Reducing speed with a raised load(variant)This function (variant) reduces the speed ofthe truck with a raised load.

7300_003-017_en

CUTOUT MODE

STOP

Automatic shut-off of the internalcombustion engine (variant)The truck is equipped with an automaticshut-off function that shuts off the internalcombustion engine when certain conditionsapply simultaneously after a preset waitingtime has elapsed.

The message CUTOUT MODE appears in thedisplay.

Conditions that apply simultaneously:• The truck is stationary.• The parking brake is applied.• The driver's seat is not occupied.• Particle filter regeneration is not in progress.• There are no consumers switched on thatrequire a significant amount of energy, suchas the air conditioning.

The waiting time only starts when all condi-tions apply simultaneously. If one of the con-ditions is no longer fulfilled, the waiting timestops and is restored to the preset value.

NOTE

The waiting time is set to 120 seconds at thefactory, but can be changed at a later date.• Contact the authorised service centre.

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4 OperationParking

Parking

5060_003-130

Parking the truck securely andswitching it off

DANGERRisk of fatal injury from being run overif the truck rolls away!– The truck must not be parked on a

slope.– In emergencies, secure the truck

using wedges on the side facingdownhill.

– Only leave the truck when theparking brake has been applied.

DANGERThere is a risk of fatal injury from a falling load orparts of the truck being lowered!– Lower the load fully before leaving the truck.


– Lower the fork carriage to the ground.

– Tilt the lift mast forwards until the tips of thefork arms rest on the ground.

– If attachments (variant) are fitted, retractthe working cylinders; see the chapterentitled "General instructions for controllingattachments".

– Take your foot off the accelerator pedal andallow the engine to continue idling for a shortwhile.

– Turn the switch key to the left and remove it.

NOTE

Switch keys, FleetManager cards (variant),FleetManager transponder chips (variant) andthe PIN code for access authorisation (variant)must not be handed over to other personsunless explicit instructions to this effect havebeen given.

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Operation 4Parking

7321_003-039_V2

2

1

1

Wheel chock (variant)The wheel chock (variant) is used to preventthe truck from rolling away on a slope.

– Lift handle (2) on the support mounting.

– Remove wheel chock (1) from the supportmounting.

– Push the wheel chock under a front axlewheel on the side facing the downhill slope.

NOTE

After use, return the wheel chock to thesupport mounting and press the handle (2)down again.

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4 OperationLifting

LiftingLifting system variantsThe movement of the fork carriage and thelift mast heavily depends on the followingequipment:• The lift mast with which the truck isequipped, see ⇒ Chapter "Types of liftmast", P. 4-149

• The operating device with which thehydraulic functions are controlled, see⇒ Chapter "Lifting system operating de-vices", P. 4-153

Regardless of the equipment variants of thetruck, the basic specifications and proceduresmust be complied with, see ⇒ Chapter "Safetyregulations when handing loads", P. 4-166.

Automatic lift cut out (variant)

Description:The automatic lift cut out (variant) means thatthe load cannot be lifted above a preset height.This function uses a sensor that is welded onat the factory at the required lift mast limitheight. Once attached, the height cannot beeasily changed.

Application:• If the ceiling of the building is lower thanthe maximum lift height of the truck, thisvariant can prevent the lift mast fromaccidentally hitting the ceiling, which canresult in damage.

• If the truck is frequently used at a particularheight, the work is simplified by the auto-matic lift cut out at this height.

NOTE

If a load is lifted very quickly, the fork carriageand load are moved approximately 15 cmabove the position of the sensor due toinertia. This deviation is already taken intoconsideration at the factory when determiningthe position of the sensor.

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Operation 4Lifting

Overriding and reactivating the auto-matic lift cut outIf a load needs to be lifted to the truck'smaximum lift height and the automatic liftcut out function is not required, it is possibleto override the lift cut out. It is automaticallyreactivated when the truck is switched off andback on again.

To override the automatic lift cut out:

F1

1

7312_003-160_V3

– Press Softkey (1).

Automatic lift cut out is switched off.The symbol is displayed. Loads can belifted to the maximum lift height for the truck.

To switch the automatic lift cut out back on:


Automatic lift cut out is switched on.The symbol is displayed. Loads can belifted only to the set lift height for the truck.

Lift mast vertical position (variant)

DescriptionIf the truck is equipped with the "automaticmast vertical positioning" comfort feature(variant), the driver can lower goods, suchas paper rolls, vertically with precision andtherefore avoid damage when unloading.The tilt cylinders run into the end stops gentlyto prevent hard vibrations and impacts.Oscillating motions of the truck are minimised,thus increasing work safety. The automaticmast vertical positioning reduces wear onvarious components and therefore reducesrepair costs.

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4 OperationLifting

CAUTIONRisk of damage to property due to the lift mastcolliding with racks or other objects!– Before using the "lift mast vertical position"

comfort feature, position the truck at a sufficientdistance from racks and other objects.

The "lift mast vertical position" comfort featureconsists of the following individual functions:• Display of the "lift mast vertical position"• Automatic movement into the "automaticmast vertical position"

• End stops are approached gently

F1F1 F2F2

F1 F2

7314_003-059

2

1

4 5

3

The "lift mast vertical position" comfort featureis only available as a variant if the truck isequipped with one of the following operatingdevices:

• Double mini-lever (1)• Triple mini-lever (2)• Quadruple mini-lever (3)• Fingertip (4)• Joystick 4Plus (5)

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Operation 4Lifting

6210_003-069_en_V2

1

Display of the "lift mast vertical position"The driver can see the mast tilt on the displayand operating unit screen. The bar in thedisplay shows the current mast tilt relativeto the "lift mast vertical position". The arrowabove the barmarks the vertical position of thelift mast.

Automatic approach towards the "liftmast vertical position"

6210_003-067_V2

21


The "automatic mast vertical positioning"comfort feature is switched on. The (2)symbol is displayed.

– Tilt the lift mast forwards.

The lift mast stops automatically as soon asthe preselected setting for "automatic mastvertical positioning" is reached.

If the comfort feature is switched off, the liftmast tilts forwards past the "automatic mastvertical positioning" without stopping.

If the lift mast is tilted backwards, it movespast the "lift mast vertical position" withoutstopping, regardless of whether the comfortfeature is switched on or not.

Gentle running-in to the end stopsThe lift mast is braked gently at the end of thetilt range. This prevents the lift mast fromstopping harshly in the end position andreduces severe oscillating motions of thetruck.

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4 OperationLifting

Tilting the lift mast forwards with the "liftmast vertical position"

6210_003-067_V2

21


The "automatic mast vertical positioning"comfort feature is switched on. The (2)symbol is displayed.

– Tilt the lift mast forwards.

NOTE

The way in which the lifting system is operateddepends on the operating devices included inthe truck's equipment; see the chapter entitled"Lifting system operating devices".

6210_003-069_en_V2

1

The lift mast is tilted forwards and stops assoon as the vertical position is reached. Thearrow above the bar shown on the screen ofthe display and operating unit represents the"lift mast vertical position".

Tilting the lift mast forwards beyond thevertical position:

– Release the operating device to tilt andactuate again.

The lift mast is tilted beyond the verticalposition up to the end stop. The current masttilt is shown in the display and operating unit.

– To switch off the "automatic mast verticalpositioning", press Softkey (1).

The "automatic mast vertical positioning"comfort feature is switched off. Thesymbol is displayed.

Tilting the lift mast backwards with the"lift mast vertical position"– Tilt the lift mast backwards.

The lift mast is tilted backwards withoutstopping in the vertical position.

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Operation 4Lifting

Possible restrictions on the "lift mastvertical position"

In some circumstances, the lift mast cannotmove exactly into the preset vertical position.Possible causes include:• Uneven ground• Bent fork• Bent attachment• Worn tyres• Severely deformed lift mast

The vertical position can be corrected by tiltingthe lift mast using the relevant operatingdevice. If the vertical position has to becorrected frequently, the "lift mast verticalposition" should be calibrated.

6210_003-070_en_V2

12

3

Calibrating the "lift mast vertical position"– Set the lift mast to the required position.

– Press and hold down Softkey (1) for atleast five seconds.

The message ? VERTICAL POSITIONappears on the display.

Storing the mast position:

– Press the Drive programme selectionbutton (3) to confirm .

The current mast position is stored.

Cancelling calibration:

– Press the Menu change button (2) to cancelthe input .

The calibration is cancelled.

Types of lift mastOne of the following lift masts may be installedin the truck:

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4 OperationLifting

6210_810-001

1

Telescopic mastDuring lifting, the lift mast rises over the outerlift cylinders, bringing the fork carriage with itvia the chains (fork carriage rises twice as fastas the inner lift mast). The top edge (1) of theinner lift mast can therefore be higher than thefork carriage.

DANGERRisk of accident due to collision of the lift mast orload with low ceilings or entrances.– Note that the inner lift mast or loadmay be higher

than the fork carriage.– Note the heights of ceilings and entrances.

6210_810-002

2

3

Hi-Lo lift mast (variant)During lifting, the inner lift cylinder moves upto free lift (3), and then the outer lift cylindersraise the inner lift mast up to the max. height(2).

NOTE

When lifting above the free lift, the fork car-riage always remains at the upper edge of theextending lift mast.



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Operation 4Lifting

6210_810-002

2

3

Triplex lift mast (variant)During lifting, the inner lift cylinder moves upto free lift (3), and then the outer lift cylindersraise the inner lift mast up to the max. height(2).



Malfunctions during lifting mode

Incorrect extension sequence

DANGERRisk of accidents!In the case of Hi-Lo lift masts (variant) and triplex liftmasts (variant), an incorrect extension sequencemay occur, i.e. the inner lift mast may extendbefore the free lift is complete. As a result, theoverall height is exceeded and damage may occurin passageways or from low ceilings.

An incorrect extension sequence may, forinstance, result from:• The hydraulic oil temperature being too low.• Blocking of the fork carriage in the inner liftmast.

• Blocking of the free lift cylinder.• Blocking of the chain roller on the free liftcylinder.

– If the hydraulic oil temperature is too low,slowly actuate the lift mast functions severaltimes in order to raise the oil temperature.

In the event that the fork carriage is blockedin the inner lift mast, or the free lift cylinderor chain roller are blocked, the cause of theblockage must be eliminated before resumingwork.

– Notify your service centre

174749 EN - 11/2018 151

4 OperationLifting

Load chains not under tension

DANGERDanger caused by a falling load!– Make sure that the chain(s) does (do) not

become slack when lowering the load.

Slack chains can, for instance, result from:• Resting the fork carriage or the load on theracking.

• Fork carriage rollers blocking in the lift mastdue to contamination.

– If the fork carriage or the load comes to anunexpected stop, lift the fork carriage untilthe chains are under tension again andlower the load at another suitable location.

– If the fork carriage rollers in the lift mastbecome blocked due to contamination, liftthe fork carriage until the chains are undertension again. Remove the contaminationbefore resuming work.

WARNINGRisk of injury!– Observe the safety regulations for working on

the lift mast, see the chapter entitled "Working atthe front of the truck".

Hydraulic blocking functionThe hydraulic blocking function ensures thatall the functions of the working hydraulicsare disabled whenever the seat switch in thedriver's seat is unloaded.

If the driver stands up from the driver's seat,the blocking function prevents the hydraulicfunctions that:• Lift the load• Lower the load• Tilt the lift mast• Additional functions

Releasing the block on the hydraulicsProceed as follows to release the block on thehydraulics:

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Operation 4Lifting


All the relevant functions of the workinghydraulics will be available again.

NOTE

If it is not possible to release the block on thehydraulics when the load is raised becauseof a technical fault, the load must be loweredusing the "emergency lowering" mechanismbefore any further action is taken. Do notoperate the truck again until the fault has beenrectified by the authorised service centre.

Lifting system operating devicesThe method of operating the lifting systemdepends on the operating devices included inthe truck's equipment.

Possible equipment variants include:• Double mini-lever• Triple mini-lever• Quadruple mini-lever• Joystick 4Plus• Fingertip switch

– The following informationmust be observedregardless of the equipment variant:

DANGERReaching into or climbing between moving partsof the truck (e.g. lift mast, sideshifts, workingequipment, load carrying devices etc.) can lead toserious injury or death and is therefore prohibited.– Observe the safety regulations for handling

loads.– Only operate the lifting system from the driver's

seat.

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4 OperationLifting

F1 F2

7325_003-035

A

C

D

B

1

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using adouble mini-lever


loads.– Operate the lifting system from the driver's seat

only.

Lifting/lowering the fork carriageTo lift the fork carriage:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (B).

To lower the fork carriage:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (A).

Tilting the lift mastTo tilt the lift mast forwards:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (C).

To tilt the lift mast backwards:

– Move the "lift mast" 360° lever (1) in thedirection of arrow (D).

NOTE

The symbols on the 360° lever show thedirection of movement of the lift mast and thefork carriage when the 360° lever is moved.

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Operation 4Lifting

7325_003-036

A

C

D

B

1

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using atriple mini-lever



only.


– Move the "lift mast" 360° lever (1) in thedirection of arrow (B)


– Move the "lift mast" 360° lever (1) in thedirection of arrow (A)


– Move the "lift mast" 360° lever (1) in thedirection of arrow (C)


– Move the "lift mast" 360° lever (1) in thedirection of arrow (D)

NOTE

The symbols on the 360° lever show thedirection of movement of the lift mast and thefork carriage when the 360° lever is moved.

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4 OperationLifting

7325_003-037

1 C

D

2

A

B

7312_003-114

7312_003-022_V2

DC

B

A

Controlling the lifting system using aquadruple mini-lever



only.


– Move the "lift mast" operating lever (1) in thedirection of arrow (A).


– Move the "lift mast" operating lever (1) in thedirection of arrow (B).


– Move the "lift-lower" operating lever (2) inthe direction of arrow (D).


– Move the "lift-lower" operating lever (2) inthe direction of arrow (C).

NOTE

The symbols on the operating levers show thedirection of movement of the lift mast or forkcarriage when the operating lever is moved.

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Operation 4Lifting

Controlling the lifting system usingthe joystick 4Plus


loads.– Only operate the lifting system from the driver's

seat.

6210_003-089

1

A

B


– Pull the joystick 4Plus (1) backwards (B).


– Push the joystick 4Plus (1) forwards (A).

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4 OperationLifting

6210_003-090

DC

2

7312_003-022_V2

DC

B

A


– Tilt the horizontal rocker button (2) to the left(C).


– Tilt the horizontal rocker button (2) to theright (D).

1

6210_003-091

E

F

Fork-carriage sideshiftTo move the fork carriage to the left.

– Push the joystick 4Plus (1) to the left (E).

To move the fork carriage to the right:

– Push the joystick 4Plus (1) to the right (F).

NOTE

The symbols on the joystick 4Plus indicate thedirection of movement of the lift mast or thefork carriage.

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Operation 4Lifting

F1F1 F2F2

7325_003-038

1

2

1 2

6210_003-043

6210_713-002_V2

2

1

Controlling the lifting system usingthe fingertip



only.


– Pull the "lift/lower" operating lever (1)backwards.


– Push the "lift/lower" operating lever (1)forwards.


– Push the "tilt" operating lever (2) forwards.


– Pull the "tilt" operating lever (2) backwards.

NOTE

The symbols on the operating levers show thedirection of movement of the lift mast or forkcarriage when the operating lever is moved.

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4 OperationLifting

Changing the fork arms

DANGERRisk of fatal injury from being run over if the truckrolls away!– Do not park the truck on a gradient.– Apply the parking brake.– Change the fork arms in a separate, safe location

on a level surface.

WARNINGThere is a risk of injury when changing the forkarms; the weight of the fork arms could cause themto fall on your legs, feet or knees. The space to theleft and right of the fork is a danger area.– Always wear protective gloves and safety

footwear when changing the fork arms.– Ensure that no one stands in the danger area!– Do not pull on the fork arms.– The fork arms must always be carried by two

people; if necessary, use a hoist.

NOTE

• For installation and removal, a transportpallet is recommended for supportingthe fork arms. The pallet size dependson the fork arm size used and should bedimensioned such that the fork arms do notprotrude after being placed on the pallet.This means the fork arms can be safelyplaced down and transported.

• Both fork arms can be pushed over to thesame side. It is possible to choose the sidevia which the forks are removed

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Operation 4Lifting

1

2

6210_003-027

Removal– Select a pallet corresponding to the fork armsize.

– Set down the pallet next to the fork carriageon the side chosen for removal.

– Lift the fork carriage until the fork arms areapprox. 3 cm above the pallet.


– Remove the switch key.

– Unscrew the locking screw (2) on the sidechosen for removal.

– Pull up the locking lever (1) and push thefork arms onto the pallet one after the other.

Installation– Make sure that the locking screw is un-screwed on the side chosen for installation.

– Place the fork arms on a pallet next tothe fork carriage on the side chosen forinstallation.

– Pull up the locking lever (1) and push thefork arms onto the fork carriage one afterthe other.

– Place the fork arms in the required positionand push down the locking lever. Ensurethat the locking lever snaps into place.

– Screw in and tighten the locking screw (2).

DANGERThere is a risk of fatal injury from a falling load orfork!– Tighten the locking screw each time a fork is

changed.– Driving and moving loads without the locking

screw is prohibited.

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, a "zero adjustment ofthe load measurement" must always be per-formed after the fork arms have been chan-

174749 EN - 11/2018 161

4 OperationLifting

ged. Otherwise, correct load measurementcannot be guaranteed.

Fork extension (variant)

DANGERThere is a risk of being run over if the truck rollsaway and therefore a danger to life.– Do not park the truck on a slope.– Apply the parking brake.– Change the fork extension in a separate, safe

location on a level surface.

WARNINGThere is a risk of crushing!Theweight of the fork extension can cause crushingor cuts on sharp edges or burrs.– Always wear protective gloves and safety

footwear.

WARNINGThere is a risk of tipping!The weight and dimensions of the fork extensionaffect the stability of the truck. The permissibleweights stated on the capacity rating plate must bereduced in proportion to the actual load distance.The truck is equipped with a fork extension exworks, the capacity rating plate is already adjustedaccordingly.– Observe load capacity, see the "Before picking

up a load" chapter.

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, a "zero adjustment ofthe load measurement" must always be per-formed after the fork extensions have beenchanged. Otherwise, correct load measure-ment cannot be guaranteed.

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Operation 4Lifting

7071_003-104_V2

1

2

3

Attachment

DANGERRisk to life from falling load!At least 60%of the length of the fork extensionmustlie on the fork arm. Amaximum 40% overhang overthe fork arm end is permissible. The fork extensionmust also be secured against slipping from the forkarm.If the fork extension (1) is not secured with a secu-ring bolt (2) and linch pin (3), the load with the forkextension may fall.– Push the fork extension completely to the back

of the fork.– Make sure that 60% of the length of the fork

extension is on the fork arm.– Always secure the fork extension with a securing

bolt.– Always secure the securing bolt with a linch pin.

– Remove the linch pin (3) from the securingbolt (2).

– Remove the securing bolt from the forkextension (1).

– Push the fork extension onto the fork armsuntil it is flush with the fork back.

– Insert the securing bolts located behind thefork back fully into the fork extension.

– Insert the linch pin into the securing bolt andsecure.

Removal– Remove the linch pin (3) from the securingbolt (2).

– Remove the securing bolt from the forkextension (1).

– Pull the fork extension from the fork arms.

– Insert the securing bolt fully into the forkextension.

– Insert the linch pin into the securing bolt andsecure.

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4 OperationLifting

Operation with reversible fork arms(variant)

DANGERRisk to life from falling load!Standard fork arms are not structurally designed forreverseoperation. If this instruction is not observed,it can lead to material failure and the load falling.– Only work in reverse operation using reversible

fork arms (1)

WARNINGRisk of accident from slipping load!Loadsmay slip on the reversible fork arms if there isno load support. A fork extension (variant) cannotbe secured against slipping.– Do not use a fork extension (variant)

WARNINGRisk of accident from the truck tipping over.When driving, the centre of gravity of the load (2)must not be higher than 600 mm above the ground.The truck may tip forwards when driving or braking.– Only drive with a load centre of gravity up to a

max. of 600 mm above the ground

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, a "zero adjustmentof the load measurement" must always beperformed after the reversible fork arms havebeen changed. Otherwise, correct load mea-surement cannot be guaranteed.

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Operation 4Lifting

6341_862-001

Reversible fork arms (1) can be used to reachan additional lift height. The reversible forkarms are installed on the fork carriage in thesame manner as standard fork arms. Loadsmay be lifted on and beneath the reversiblefork arms. The mast is lifted and tilted in thesame manner.

– Only work in reverse operation usingreversible fork arms

– Do not use a fork extension (variant)

– If the "load measurement" comfort featureis available, perform a "zero adjustment ofthe load measurement"

– To drive, raise the load centre of gravity (2)to a max. of 600 mm above the ground

– Observe the information in the sectionentitled "Transporting suspended loads"

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4 OperationWorking with loads

Working with loads

6210_003-030

Safety regulations when handingloadsThe safety regulations for handling loads areshown in the following sections.

DANGERThere is a risk to life caused by falling loads or ifparts of the truck are being lowered.– Never walk or stand underneath suspended

loads or raised fork arms.– Never exceed the maximum load indicated on

the capacity rating plate. Otherwise stabilitycannot be guaranteed!

DANGERRisk of accident from falling or crushing!– Do not step onto the forks.– Do not lift people.– Never grab or climb on moving parts of the truck.

DANGERRisk of accident from a falling load!– When transporting small items, attach a load

safety guard (variant) to prevent the load fromfalling on the driver.

– Use a closed roof covering (variant) in addition.

166 174749 EN - 11/2018

Operation 4Working with loads

Before taking up load

2

1

780

9101310

93012306801500

95012606901500

970860710150010008807301500

600500

6401080

4830

4630

4230

3830

kg

3

5051_003-006

800

800 5030660

5230

500

880

Load capacityThe load capacity indicated for the truck on thecapacity rating plate may not be exceeded.The load capacity is influenced by the loadcentre of gravity and the lift height as well asby the tyres, if applicable.

The position of the capacity rating plate canbe found in the chapter entitled "Identificationpoints".

WARNINGThe figures show examples.Only the capacity rating plateson the truckare valid!

The attachment of additional weights toincrease load capacity is prohibited.

DANGERRisk to life from the truck losing stability!Never exceed the maximum loads shown! Thesevalues apply to compact and homogenous loads.Otherwise, the stability as well as the rigidity of thefork arms and lift mast cannot be guaranteed.Improper or incorrect operation or the placement ofpersons to increase load capacity is prohibited.

174749 EN - 11/2018 167


5051_003-007

3

5230

500

2

880 Kg

1

ExampleWeight of load to be lifted: 880 kg (3)

Load distance from fork back: 500 mm (1)

Permitted lift height: 5230 mm (2)

WARNINGRisk of accident from the truck losing stability!The permissible load of the attachments (variant)and the reduced lifting capacity of the combinationof truck and attachment must not be exceeded.– Observe the special capacity rating plate infor-

mation shown on the truck and the attachment.

Load measurement (variant)

DescriptionKnowing the weight of the load to be trans-ported gives the driver greater security. Ifthe truck is equipped with the "load measure-ment" (variant) comfort feature, the weight ofthe lifted load can be measured and shown inthe display and operating unit.

Load measurement is possible only when thetruck is at a standstill. Before performing aload measurement, the load must be raised toa height of 300-800 mm above the ground.

168 174749 EN - 11/2018


The load measurement has an accuracy of+/-3% of the rated capacity of the truck.

NOTE

In order to ensure accuracy at all times, a zeroadjustment of the load measurement must becarried out. Zero adjustment is required.• as part of daily commissioning• after changing the fork arms• after fitting or changing attachments.

Performing the load measurement

DANGERRisk of accident from a falling load!The loadmay fall if the load centre of gravity has notbeen taken into account or the load has not beenpicked up securely.– Pick up the load securely; see the chapter

entitled "Picking up loads".

CAUTIONIf the weight determined by a load measurementexceeds the permissible residual load capacity ofthe truck, the truck cannot be operated safely.– Set down and reduce load immediately.– If necessary, use another truck with sufficient

load-bearing capacity.

NOTE

Accurate load measurement is only possibleunder the following conditions:• The hydraulic oil is at normal operatingtemperature

• The load is at rest at the beginning of theload measurement

• The load corresponds to at least 10% of thenominal load capacity in trucks with a loadcapacity of up to 2.5 t

• The load corresponds to at least 5% of thenominal load capacity in trucks with a loadcapacity of 3 t and over

• The lift mast is in the vertical position• The fork is not raised to more than 800 mmabove the ground

174749 EN - 11/2018 169


NOTE

The method of operating the lifting systemdepends on the operating devices included inthe truck's equipment.

– Ensure that the truck has been in operationfor a period of time before carrying out theload measurement.


– Raise the fork to a height of 300–800 mm.

– Ensure that the load is at rest.

6210_003-072_V2

21


Load measurement is switched on.The (2) symbol is displayed.

NOTE

If the truck is equipped with mini-levers orfingertip operation, the F1 button can also bepressed as an alternative.

NOTE

During the following process, the fork carriagemust be lowered slightly and then stoppedabruptly. While doing so, the fork mustnot touch the ground, otherwise the loadmeasurement will not be accurate. To stopthe lowering procedure quickly, release theoperating device for lowering so that it jumpsinto the zero position.

– Lower the fork carriage slightly and releasethe operating device.

NOTE

When stopping the lowering process theload must be cushioned in order to create ameasurable impulse.

170 174749 EN - 11/2018


6210_003-073_en

3

When loadmeasurement has been performedcorrectly, the determined load weight (3) isshown on the display.

NOTE

If the load measurement is invalid, the value"-9999 kg" is displayed in the operating unit.

Picking up loadsTo make sure that the load is securely sup-ported, it must be ensured that the fork armsare sufficiently far apart and are positioned asfar as possible under the load.

If possible, the load should rest on the back ofthe fork.

The load must not protrude too far over thefork tips, nor should the fork tips protrude toofar out from the load.

Loads are to be picked up and transported asclose to the middle as possible.

DANGERRisk of accident from a falling load!When transporting small items, attach a load safetyguard (variant) to prevent the load from falling onthe driver.A closed roof covering (variant) should also beused.Removable roof panels may not be removed.

174749 EN - 11/2018 171


1

6210_842-001

Adjusting the fork– Lift the locking lever (1) and move the forkarms to the desired position.

– Allow the locking lever to snap back intoplace.

The load centre of gravity must be midwaybetween the fork arms.

– Only actuate the fork prong positioner(variant) when the fork is not carrying aload.

Danger areaThe danger area is the area in which peopleare at risk due to the movements of the truck,its working equipment, its load-carryingequipment (e.g. attachments) or the load.Also included are the areas where loadscould fall or working equipment could fall orbe lowered.

DANGERRisk of injury!– Do not step on the fork.

DANGERRisk of injury!– Do not step under the raised forks.

DANGERPeople may be injured in the danger area of thetruck!The danger area of the truck must be completelyclear of all personnel, except the driver in hisnormal operating position. If persons fail to leavethe danger area despite warnings:– Cease work with the truck immediately.– Secure the truck against use by unauthorised

parties.

172 174749 EN - 11/2018


DANGERDanger of death from falling loads!– Never walk or stand underneath

suspended loads.

6327_003-009

Transporting palletsAsa rule, loads (e.g. pallets)must be transpor-ted individually. Transporting multiple loads atthe same time is only permitted:• when instructed by the supervisor and• when the technical requirements have beenmet.

The driver must ensure proper condition ofthe load. Only safely and carefully positionedloads may be transported.

6210_001-007

Transporting suspended loadsBefore transporting suspended loads, con-sult the national regulatory authorities (inGermany, the employer's liability insuranceassociations).

National regulations may place restrictionson these operations. Contact the relevantauthorities.

DANGERSuspended loads that begin to swing can result inthe following risks:

• Impaired braking and steering action• Tipping over the loadwheels or drivewheels• Tipping the truck at right angles to thedirection of travel

• Risk of crushing of guide persons• Reduced visibility.

174749 EN - 11/2018 173


DANGERLoss of stability.Slipping or swinging suspended loads can lead to aloss of stability and cause the truck to tip over.– When transporting suspended loads, observe

the following instructions

Instructions for transporting suspended loads:• Swinging loads must be prevented by usingthe proper driving speed and driving style(careful steering, braking)

• Hanging loads must be hooked on to thetruck in such a way that the harness cannotshift or release unintentionally and cannotbe damaged

• When transporting suspended loads, suit-able devices (e.g. guy wires or supportingpoles) must be available so that accompa-nying persons can guide suspended loadsand prevent the loads from swinging

• Take particular care to ensure that there isno one in the drive direction in the drivinglane

• If, despite this, the load begins to swing,ensure that no person is placed at risk

DANGERRisk of accidents!When transporting hanging loads, never perform orend driving and load movements abruptly.Never drive on slopes with a suspended load.Transporting containers holding fluids as hangingloads is not permitted.

Load pick up

DANGERThere is a risk to life caused by a falling load or ifparts of the truck are being lowered.– Never walk or stand underneath suspended

loads or raised fork arms.– Never exceed the maximum load values spe-

cified on the capacity rating plate. Otherwise,stability cannot be guaranteed.

– Only store pallets which do not exceed thespecified maximum size. Damaged loading

174 174749 EN - 11/2018


equipment and incorrectly formed loadsmust not be stored.

– Attach or secure the load to the load-carrying equipment so that the load cannotmove or fall.

– Store the load so that the specified aislewidth is not reduced by protruding parts.

6210_800-005

– Approach the racking carefully, brake gentlyand stop just in front of the racking.

6210_800-006

– Position the forks.


– Lift the fork carriage to the stacking height.

CAUTIONComponent damage possible!When inserting the fork into the racking, ensure thatthe racking and load are not damaged.

174749 EN - 11/2018 175


6210_800-007

– Insert the fork as far under the load aspossible. Stop the truck as soon as thefork back is resting on the load. The centreof gravity of the load must be positionedbetween the fork arms in the middle.

6210_800-008

– Lift the fork carriage until the load is restingentirely on the forks.

DANGERRisk of accidents!– Beware of any people in the danger area.– Ensure that the roadway behind you is clear.

DANGERNever tilt the lift mast with a raised load due to therisk of tipping!– Lower the load before tilting the lift mast.

– Move backwards carefully and slowly untilthe load is clear of the racking. Brake gently.

176 174749 EN - 11/2018


5060_003-102

– Lower the load while maintaining groundclearance.

5060_003-101


The load can be transported.

174749 EN - 11/2018 177


6210_800-011

Transporting loads

NOTE

Observe the information in the chapter entitled"Safety regulations when driving".

DANGERThe higher a load is lifted, the less stable it beco-mes. The truck can tip over or the load can fall,increasing the risk of accident!Driving with a raised load and the lift mast tiltedforward is not permitted.– Only drive with the load lowered.– Lower the load until ground clearance is reached

(not over 300 mm).– Only drive with the lift mast tilted backwards.

6210_800-013

– Drive slowly and carefully round corners!

NOTE

Observe the information in the chapter entitled"Steering".

– Always accelerate and brake gently!

NOTE

Observe the information in the chapter entitled"Operating the service brake".

178 174749 EN - 11/2018


6210_800-014

– Never drive with a load protruding to theside (e.g. with the sideshift)!

Setting down loads

DANGERRisk of accident due to changed moment of tilt!The load centre of gravity and the moment of tiltmove due to tilting the lift mast forwards with araised load or due to the load slipping. The truckmay tip forwards.– Only tilt the lift mast forwards with a raised lifting

accessory when it is directly above the stack.– When the lift mast is tilted forwards, take parti-

cular care to ensure that the truck does not tipforwards and that the load does not slip.

WARNINGRisk of accident from a falling load!If the fork or the load remains suspended duringlowering, the load may fall.– When removing from stock, move the truck far

enough back so that the load and the fork can belowered freely.

174749 EN - 11/2018 179


6210_800-015

– Drive up to the stack with the load loweredin accordance with regulations.


– Lift the load to the stacking height.

– Drive the truck towards the rack carefully.

6210_800-016

– Lower the load until it rests securely on therack.

DANGERRisk of accident!– Beware of any people in the danger area.– Ensure that the roadway behind you is clear.

– Move the truck back until the fork arms canbe lowered without touching the stack.

– Lower the fork while maintaining groundclearance.

– Tilt the lift mast backwards and drive away.

180 174749 EN - 11/2018


5060_003-071

Driving on liftsThe driver may only use this truck on liftswith a sufficient rated capacity and for whichthe operating company has been grantedauthorisation.

DANGERThere is a risk to life if you are crushed or run overby the truck.– There must be no personnel already in the lift

when the truck is driven into the lift.– Personnel are only permitted to enter the lift once

the truck is secure, and must exit the lift beforethe truck is driven out.






maxmin.*


kg kg

kgkg

kgkW

V

*

D-22113 HamburgBerzeliusstr. 10 2

1

Determining the actual total weight– Park the truck securely.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate and, ifnecessary, by weighing the load to be lifted.

– Add the determined unit weights to obtainthe actual total weight of the truck:

Tare weight (1)

+ Ballast weight (variant) (2)

+ Attachment net weight (variant)

+ Weight of the load to be lifted

+ 100 kg allowance for driver

= Actual total weight

– Drive the truck with the forks forwards intothe lift without touching the shaft walls.

– Park the truck securely in the lift to preventuncontrolled movements of the load or thetruck.

174749 EN - 11/2018 181


6210_001-010

Driving on loading bridges

DANGERRisk of accident if the truck crashes!Steering movements can cause the tail end to veeroff the loading bridge towards the edge. This maycause the truck to crash.The lorry driver and the truck driver must agree onthe lorry's departure time.– Before driving across a loading bridge, ensure

that it is properly attached and secured and hasa sufficient load capacity (lorry, bridge etc.).

– Drive slowly and with care on the loading bridge.– Ensure that the vehicle onto which you will be

driving is secured to prevent it from shifting andthat it can support the load of the truck.






maxmin.*


kg kg

kgkg

kgkW

V

*


1

Determining the actual total weight– Park the truck securely.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate and, ifnecessary, by weighing the load to be lifted.

– Add the determined unit weights to obtainthe actual total weight of the truck:

Tare weight (1)



+ Weight of the load to be lifted

+ 100 kg allowance for driver

= Actual total weight.

182 174749 EN - 11/2018

Operation 4Attachments

AttachmentsFitting attachmentsIf the truck is equipped with an integratedattachment (variant) at the factory, the specifi-cations in the STILL operating instructions forintegrated attachments must be observed.

If attachments are fitted at the place of use,the specifications in the operating instructionsof the attachment manufacturer must beobserved.

If an attachment is not delivered togetherwith the forklift truck, the specifications andoperating instructions of the attachmentmanufacturer must be observed.

Before initial commissioning, the functionof the attachment and the visibility from thedriver's position with and without a load mustbe checked by a competent person. If thevisibility is deemed insufficient, visual aidssuch asmirrors, a camera/monitor system etc.must be used.

In addition, it is essential that the warningsbelow are observed.

CAUTIONAttachments must be CE-certified. If the truck isnot fitted with an attachment-specific residual loadcapacity rating plate and the operating devices arenot marked with corresponding pictograms, thetruck must not be used.– Order the residual load capacity rating plate and

pictograms from your authorised service centrein good time.

– The authorised service centre must adapt thehydraulic system to the requirements of theattachment (e.g. by adjusting the pump motorspeed).

174749 EN - 11/2018 183

4 OperationAttachments

DANGERThere is risk to life caused by a falling load!Attachments that hold the load by exerting pressureon it (e.g. clamps)must be controlled additionally bya second operating function (lock) that is actuatedto prevent an unintentional release of the load.If such an attachment is retrofitted, a second opera-ting function for actuation must also be retrofitted.– Make sure that the additional clamp locking

mechanism function is available.

DANGERThere is risk to life caused by a falling load!During installation of a clamp with integral sideshift,ensure that the clamp does not open when thesideshift is actuated.– Notify your authorised service centre before

installation.– Never grab or climb on moving parts of the truck.

7090_900-001

Hydraulic connection– Before installing the attachment, releasethe pressure from the hydraulic system.

CAUTIONRisk of damage to components!Open connections of plug connectors can becomedirty. The plug connectors can become stiff and dirtcan enter the hydraulic system.– Once the attachment has been disassembled,

attach theprotective caps to theplug connectors.

Mounting attachmentsMounting an attachment and connectingthe energy supply for an attachment mustonly be performed by competent persons inaccordance with the information providedby the manufacturer and supplier of theattachment. After each installation, theattachment must be checked for correctfunction prior to initial commissioning.

NOTE

Please observe the definition of the followingresponsible person: "competent person".

184 174749 EN - 11/2018


Load capacity with attachmentThe permissible load capacity of the attach-ment and the allowable load (load capacityand load moment) of the truck must not be ex-ceeded by the combination of attachment andpayload. The specifications of the manufac-turer and supplier of the attachment must becomplied with.

– Observe the residual load capacity ratingplate, see the chapter entitled "Taking up aload using attachments".

7090_900-001

Releasing the pressure from thehydraulic systemPrior to assembling attachments, the plugconnectors must be depressurised.

Attachments must only be installed by au-thorised personnel in accordance with theinformation provided by the manufacturer andsupplier of the attachments. After each instal-lation, the attachment must be checked forcorrect function prior to initial commissioning.

NOTE

The pressure release procedure is dependenton the operating devices for controlling thehydraulic functions; see the section entitled"Lifting system operating devices".

NOTE

Before carrying out pressure release, lowerthe fork carriage and tilt the lift mast back tothe stop. The key switch must be switched onto release the pressure from the system, butdo not start the engine.

NOTE

In trucks with the "FleetManager" or "accessauthorisation with PIN code" equipment va-riants, access authorisation must be enabled.

– Switch on the key switch.

– Wait two to three seconds.

174749 EN - 11/2018 185


1

F1F1 F2F2

1

1

1

17312_003-184

– Actuate the operating lever (1) for control-ling the hydraulic functions repeatedly inthe direction of the arrow, as far as the endposition.

The valves open and the hydraulic system isdepressurised.

– Switch off the key switch.

186 174749 EN - 11/2018


General instructions for controllingattachmentsThe way in which attachments (variant) arecontrolled depends on the operating devicesincluded in the truck's equipment.

Essentially, a distinction is drawn between:• Double mini-lever• Double mini-lever with a 5th function(variant)

• Triple mini-lever• Triple mini-lever with a 5th function (variant)• Quadruple mini-lever• Quadruple mini-lever with a 5th function(variant)

• Joystick 4Plus• Joystick 4Plus with a 5th function (variant)• Fingertip switch• Fingertip with a 5th function (variant)

– For information on controlling attachmentswith the respective operating devices, seethe relevant sections in this chapter.

WARNINGUse of attachments can give rise to additionalhazards such as a change in the centre of gravity,additional danger areas etc.Attachments must only be used for their intendedpurpose as described in the relevant operatinginstructions. Drivers must be taught how to operatethe attachments.Loads may only be picked up and transported withattachments if the loads are securely grasped andattached. Where necessary, loads must also besecured against slipping, rolling away, falling over,swinging or tipping over. Note that any change tothe position of the load centre of gravity will affectthe stability of the truck.– Refer to the capacity rating plate for the attach-

ments being used.

NOTE

Further variants and functions are available inaddition to the functions described below. Thedirections of movement can be seen on thepictograms on the operating devices.

174749 EN - 11/2018 187


NOTE

All the attachments described fall into thecategory of equipment variants. Pleasesee the respective operating instructionsfor an exact description of the respectivemovements/actions of the attachment fitted.

188 174749 EN - 11/2018


5060_003-113

A

C B

D

1

5060_003-112_V2

A

C B D

Controlling attachments using adouble mini-leverThe attachments (variants) are controlled inthis version using the "attachments" crosslever (1).

The pictograms on the "attachments" crosslever show the respective functions that areactivated by this lever.

This essentially involves the following:

– Move the "attachments"(1) cross lever inthe direction of the arrow (A) .

The attachment moves in accordance with thepictogram in position (A).

– Move the "attachments"(1) cross lever inthe direction of the arrow (B) .

The attachment moves in accordance with thepictogram in position (B).

– Move the "attachments"(1) cross lever inthe direction of the arrow (C) .

The attachment moves in accordance with thepictogram in position (C).

– Move the "attachments"(1) cross lever inthe direction of the arrow (D) .

The attachment moves in accordance with thepictogram in position (D).

174749 EN - 11/2018 189


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8

– Note the following attachment functions andpictograms.

3 Move sideshift frame or fork forwards

4 Move sideshift frame or fork back-wards

5 Move sideshift to the left

6 Move sideshift to the right

7 Adjust fork arms: open

8 Adjust fork arms: close

9 Swivel lift mast or fork to the left

10 Swivel lift mast or fork to the right

11 Release load retainer

12 Clamp load retainer

13 Push off the load

14 Pull in the load

15 Open clamps

16 Close clamps

17 Rotate to the left

18 Rotate to the right

19 Tip shovel over

20 Tip shovel back

NOTE

The pictograms shown correspond to theattachments fitted to this truck at the factory. Ifan attachment with other functions is fitted, thepictograms must be checked for the correctrepresentation and changed if necessary.

– Contact the authorised service centre ifrequired.

190 174749 EN - 11/2018


2

E

F

13

7312_003-113_V2

E F

Controlling attachments usingthe double mini-lever and the 5thfunction

NOTE

For technical reasons, clamping attachmentsmust not be controlled via the 5th function.

NOTE

The "lift mast" 360° lever (3) and the "attach-ments" cross lever (2) control four hydraulicfunctions. The designation "5th function" re-fers to the fact that the 5th hydraulic functioncan be controlled with the cross lever by swit-ching the functions using the "5th function"function key (1).

The pictograms on the "attachments" crosslever (2) show the respective functions thatare activated by this lever.


– Actuate the "5th function" function key (1)and move the "attachments" cross lever (2)in the direction of arrow (E).

The attachment moves in accordance with thepictogram in position (E).

– Actuate the "5th function" function key (1)and move the "attachments" cross lever (2)in the direction of arrow (F).

The attachment moves in accordance with thepictogram in position (F).

NOTE

The pictograms are attached dependingon the pre-assembled attachment. If anattachment with other functions is fitted, thepictograms must be checked for the correctrepresentation and changed if necessary.


174749 EN - 11/2018 191


3 5

11

7

4 6

13

15 17

9

12 1410

16 18

8













14 Pull in the load



17 Tip shovel over

18 Tip shovel back.

192 174749 EN - 11/2018


7325_003-039

AC

BD

2

1

5060_003-109_V2

A C

B D

Controlling attachments using atriple mini-leverThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

The pictograms on the operating levers showthe respective functions that are activated bythese levers.


– Move the operating lever (1) towards (A)

The attachment moves in accordance with thepictogram in position (A).

– Move the operating lever (1) towards (B)

The attachment moves in accordance with thepictogram in position (B).

– Move the operating lever (2) towards (C)

The attachment moves in accordance with thepictogram in position (C).

– Move the operating lever (2) towards (D)

The attachment moves in accordance with thepictogram in position (D).

NOTE



174749 EN - 11/2018 193


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8

– Note the following attachment functions andpictograms!












14 Pull in the load

15 Open clamps

16 Close clamps



19 Tip shovel over

20 Tip shovel back.

194 174749 EN - 11/2018


E

F

2

1

43

5060_003-120_V2

E

F

Controlling attachments using thetriple mini-lever and the 5th function

NOTE

For technical reasons, clamping attachmentscannot be controlled via the 5th function.

NOTE

The "lift mast" 360° lever (3) and operatinglevers (1) and (2) control four hydraulicfunctions. The designation "5th function"refers to the fact that the 5th hydraulic functioncan be controlled with the operating lever (1)by switching the functions using the functionkey (4).



– Actuate the "5th function" function key (4)and move operating lever (1) towards (E).


– Actuate the "5th function" function key (4)and move operating lever (1) towards (F).


NOTE



174749 EN - 11/2018 195


5060_003-122

3

4

1

2





4 Rotate to the right.

196 174749 EN - 11/2018


7325_003-041

1

2

AC

BD

5060_003-109_V2

A C

B D

Controlling attachments using aquadruple mini-leverThe attachments (variant) are controlled inthis version using operating levers (1) and (2).

The pictograms on the operating levers showthe respective function that is activated bythese levers.


– Move the operating lever (1) towards (A)

The attachment moves in the direction shownin pictogram (A).

– Move the operating lever (1) towards (B)

The attachment moves in the direction shownin pictogram (B).

– Move the operating lever (2) towards (C)

The attachment moves in the direction shownin pictogram (C).

– Move the operating lever (2) towards (D)

The attachment moves in the direction shownin pictogram (D).

NOTE



174749 EN - 11/2018 197


7312_003-099

3 5

11

7

4 6

13

17 19

9

12 1410

15

18 2016

8













14 Pull in the load

15 Open clamps

16 Close clamps



19 Tip shovel over

20 Tip shovel back.

198 174749 EN - 11/2018


7325_003-042

4

1

25

3

E

F

5060_003-120_V2

E

F

Controlling attachments using thequadruple mini-lever and the 5thfunction

NOTE


NOTE

Operating levers (1) to (4) are used to controlfour hydraulic functions. The designation "5thfunction" refers to the fact that the 5th hydraulicfunction can be controlled with the operatinglever (3) by switching the functions using the"5th function" function key (5).



– Actuate the "5th function" function key (5)and move operating lever (3) towards (E).


– Actuate the "5th function" function key (5)and move operating lever (3) towards (F).


NOTE



174749 EN - 11/2018 199


5060_003-122

3

4

1

2





4 Rotate to the right.

200 174749 EN - 11/2018


1

6210_003-085

Controlling attachments via thejoystick 4PlusIn this equipment, the attachments (variant)are controlled via the joystick 4Plus (1).

The pictograms on the decal informationabout operation of the joystick 4Plus showthe respective functions that are activatedby the individual operating devices of thejoystick 4Plus.

6210_003-098

1

4

2

5

3


Operating device Function of theattachment

1 Joystick 4Plus Move sideshift to theleft/right

2 Joystick 4Plus orslider

Adjust fork arms:open/close

3 SliderMove reach frameor fork carriageforwards/backwards

4 Joystick 4Plus orslider

Rotate attachmentleft/right

5 Slider Tip shovel over/tipshovel back

NOTE

The pictograms on the joystick 4Plus areattached according to the attachments fitted tothis truck at the factory. If an attachment withother functions is fitted, the pictograms mustbe checked for the correct representation andchanged if necessary.


174749 EN - 11/2018 201


Controlling attachments using thejoystick 4Plus and the 5th function

NOTE


NOTE

The 5th hydraulic function can be used tocontrol an attachment. The pictograms onthe joystick 4Plus show which attachmentfunctions can be controlled using the 5thfunction.

2

1

6210_003-086

For attachments that are controlled usingthe 5th hydraulic function, the procedures foroperation are as follows:

– Press and hold shift key "F"(1) on thejoystick 4Plus.

– Simultaneously actuate the horizontalrocker button (2) in the direction shownin the pictogram.

The attachment moves in the selected direc-tion.

NOTE



202 174749 EN - 11/2018


F1F1 F2F2

7325_003-031

1

Controlling the attachments with thefingertipThe attachments (variant) are controlled inthis version using the operating levers (1).

The pictograms on the operating levers showthe functions that are activated by that lever.

– Move the operating lever (1) forwards

The attachment moves in the direction ofmovement shown in the upper part of thepictogram.

– Move the operating lever (1) backwards

The attachment moves in the direction ofmovement shown in the lower part of thepictogram.

NOTE



6210_003-031

2 3

6

4

7

9 10

5

8


2 Move side shift frame or fork for-wards/backwards

3 Move sideshift to the left/right

4 Adjust fork arms: open/close

5 Swivel lift mast or fork to the left/right

6 Release/clamp load retainer

7 Push off/pull in load

8 Open/close clamps

9 Turn to the left/right

10 Tip shovel over/tip shovel back.

174749 EN - 11/2018 203


F1F1 F2F2

7325_003-044

13

2Controlling attachments with thefingertip and 5th function

NOTE


NOTE

The designation "5th function" refers to thefact that the four operating levers controlfour functions, while the "5th function" canbe controlled by switching functions.

The attachments (variant) are controlled usingthe operating levers (1).

You can also use the switch (2) to switchfunctions, in which case the correspondingoperating lever controls the "5th function".

The upper and lower parts of the pictogram (3)behind the operating lever show the functionthat is activated with this lever.


– Move the operating lever forwards

The attachment moves in the direction ofmovement shown in the upper part of thepictogram.

– Move the operating lever backwards

The attachment moves in the direction ofmovement shown in the lower part of thepictogram.

– Actuate the switch (2)

The additional function of the attachment isactivated/deactivated and can be controlledas the "5th function" using the operating lever.

204 174749 EN - 11/2018


F1F1 F2F2

7325_003-045

4

5

6

– Press function key (4)

NOTE

The arrow (5) under the function key indicateswhich operating lever is equippedwith the "5thfunction".

The "5th function" is switched to the 3rdoperating lever; see sticker (6).

F1F1 F2F2

7325_003-046

7

8

9

– Press function key (7)

NOTE

The arrow (8) under the function key indicateswhich operating lever is equippedwith the "5thfunction".

The "5th function" is switched to the 4thoperating lever; see sticker (9).

NOTE

The movement/action of this "5th function"can be found in the operating instructions ofthe fitted attachment.

NOTE



174749 EN - 11/2018 205


6210_003-035

10 11

14

12

15

17

13

16


10 Move side shift frame or fork for-wards/backwards

11 Move sideshift to the left/right

12 Adjust fork arms: open/close

13 Swivel lift mast or fork to the left/right

14 Release/clamp load retainer

15 Push off/pull in load

16 Turn to the left/right

17 Tip shovel over/tip shovel back.

Clamp locking mechanism (variant)This truck can be fitted with a clamp lockingmechanism as a variant. This prevents theclamp from opening unintentionally if theoperating function is inadvertently triggered.

DANGERThere is a risk of fatal injury from falling loads if thecorrect function of the clamp locking mechanism isnot guaranteed!If other attachments are used on this truck in addi-tion to the clamp, make sure that the clamp lockingmechanism function is reassigned to the corre-sponding operating device every time the clamp isreassembled; see the chapter entitled "Fitting at-tachments".– Make sure that the additional clamp locking

mechanism function is available.

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F1 F2

7325_003-047

1

2

Double mini-lever– To release the clamp locking mechanism,push the cross lever (1) forwards.

The LED for button F2 (2) lights up as long asthe clamp locking mechanism is released.

NOTE

The hydraulic function for opening the clampis available for one second after the clamplocking mechanism is released. After onesecond, the clamp locking mechanism isautomatically reactivated.

– To open the clamp, push the cross lever (1)forwards again.

The clamp can be closed without releasing theclamp locking mechanism.

– To close the clamp, pull the cross lever (1)backwards.

7325_003-048

1

2

Triple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE


– To open the clamp, push the operating lever(1) forwards again.


– To close the clamp, pull the operating lever(1) backwards.

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7325_003-049

1

2

Quadruple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





1

3

2

6210_003-097

Joystick 4Plus– To release the clamp locking mechanism,press and hold shift key F (3) andmove thehorizontal rocker button (1) to the right.

– Keep shift key F (3) pressed and movethe horizontal rocker button (1) back to theneutral position.

The LED (2) lights up as long as the clamplocking mechanism is released.

– To open the clamp, press and hold shift keyF (3) andmove the horizontal rocker button(1) to the right.

NOTE

The hydraulic function for opening the clampis available for one second after the clamplocking mechanism is released. After onesecond, the clamp locking mechanism isautomatically reactivated.The clamp can be closed without releasing theclamp locking mechanism.

– To close the clamp, press and hold shift keyF (3) andmove the horizontal rocker button(1) to the left.

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7325_003-050

F1F1 F2F2

1

2Fingertip switch– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





1

2

3

7090_860-002

Taking up a load using attachments

WARNINGRisk of accidents!Attachments may only be used for their intendedpurpose as described in the relevant operatinginstructions.Drivers must be instructed in the handling of theattachments.

WARNINGRisk of accidents!Loads may only be picked up and transported withattachments if they are securely attached. Wherenecessary, loads should also be secured againstslipping, rolling, falling over, swinging or tippingover. Note that any change to the position of theload's centre of gravity will affect the stability of theforklift truck.Check the capacity rating plates for theattachmentsor combination of attachments.

– The rating plates show the permissiblevalues for:

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4 OperationAuxiliary equipment

• Load capacity Q (kg) (1)• Lift height h (mm) (2)• Load distance C (mm) (3)

Auxiliary equipmentSwitching the lighting on and off

Driving lights

Blue-Q_039

1

– To switch on the parking light, press thebutton (1).

The front sidelights and the rear lights lightup. On the variant with StVZO (German RoadTraffic Licensing Regulations) equipment, thelicence plate lamp also lights up.

– To switch on the headlights, press thebutton (1) again.

The headlights light up in addition to theparking light.

– To switch off the driving lights, press thebutton (1) again.

The driving lights go out.

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Operation 4Auxiliary equipment

Working spotlights

Blue-Q_008_V3

1

– To switch on the working spotlights (frontand rear), press the button (1).

The working spotlights light up.

– To switch off the working spotlights, pressthe button (1) again.

The working spotlights go out.

NOTE

In trucks with StVZO (German Road TrafficLicensing Regulations) equipment (variant),the following lighting elements on the truck arealso activated when the working spotlights areswitched on:• Rear lights• Licence plate lamp• Sidelights

Switching the working spotlight forreverse travel on and offThe working spotlight for reverse travel isattached to the overhead guard at the rear. Itprovides optimal illumination of the roadway ifthe truck is travelling in reverse.

21

– Press the softkey (1).

The symbol (2) is displayed. The rearworking spotlight does not yet illuminate.

– Set the drive direction to "Reverse".

The rear working spotlight illuminates.

NOTE

If the drive direction is set to "Forwards", therear working spotlight goes out.

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Switching the rotating beacon on andoff

5060_003-045_V2

21

– Press the Softkey (1) to switch on therotating beacon.

The rotating beacon is switched on. Thesymbol is displayed.

– To switch off the rotating beacon, press theSoftkey .

The rotating beacon goes out. The symbol(2) is displayed.

5060_003-011_V2

1

2

Switching the hazard warningsystem on and off– To switch on the hazard warning system,press the button (1).

All turn indicators and indicator lights (2) flash.

– To switch off the hazard warning system,press the button (1) again.

The hazard warning system goes out.

NOTE

To switch on the hazard warning systemwithout the key switch being switched on,press and hold the button for three seconds.

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Switching the turn indicator on andoff

5060_003-096

F1 F2

1

Mini-lever version– Switch on the turn indicators by movingthe cross lever of the drive direction/turnindicator (1) to the left or to the right.

2 3

5060_003-012_V2

The turn indicators and the corresponding turnindicator displays (2) or (3) flash.

– Switch off the turn indicators by moving thecross lever to the centre position.

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F1F1 F2F2

7325_003-051

1Fingertip version– Switch on the turn indicators by actuationthe corresponding left-hand or right-handturn indicator button (1).

2 3

5060_003-012_V2


– Switch off the turn indicators by actuatingthe other turn indicator button.

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5060_003-046

1

Mini-console version– Switch on the turn indicators by moving theturn indicator switch (1) to the left or to theright.

2 3

5060_003-012_V2


– Switch off the turn indicators by moving theturn indicator switch to the centre position.

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6210_003-060

2

3

Switching the double workingspotlights on and off.The double working spotlights are fitted up onthe front right and left on the overhead guard.Each double working spotlight consists ofan upper working spotlight (2) and a lowerworking spotlight (3). The upper workingspotlight illuminates the working area atgreat lift heights, the lower working spotlightilluminates the working area directly in front ofthe truck.

Depending on the equipment, the upperworking spotlights can be switched on/offautomatically or manually.

Switching the upper working spotlightson/off manually

NOTE

The upper working spotlights can be switchedon/off independently of the lower workingspotlights. For information about switching onthe lower working spotlights, see the sectionentitled "Switching the lighting on and off".

NOTE

This function is not available if the truck isequipped with rear window heating.


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6311_003-030_V3

1

– Press Softkey (1) to switch on theworking spotlights.

The working spotlights are switched on. Thesymbol is displayed.

– Press Softkey to switch off the workingspotlights.

The working spotlights are switched off. Thesymbol is displayed.

Switching the upper working spotlightson/off automatically– Turn the key switch to position "I".

– For information about switching on theworking spotlights, see the chapter entitled"Switching the lighting on and off".

The lower working spotlights light up.

The upper working spotlights are switched onautomatically when the lift mast is lifted for aperiod of at least two seconds.

NOTE

During these two seconds, a maximum of twolifts can be executed to prevent the workingspotlights from switching on each time aprecise adjustment is made. If more lifts arecarried out during this time, the upper workingspotlights will remain switched off.

NOTE

The upper working spotlights are switchedoff automatically when the truck is driven forlonger than one second at a speed faster than2.1 km/h.

Lift-height-controlled switching on/off ofthe upper working spotlights

NOTE

This equipment is available only if a proximityswitch is fitted to the lift mast to record aparticular lift height of the fork carriage onthe lift mast.


174749 EN - 11/2018 217


– Switch on the working spotlights.

The lower working spotlights light up.

The upper working spotlights are switched onby the proximity switch when the fork carriagereaches or exceeds the preset lift height.

The upper working spotlights are switched offby the proximity switch when the fork carriagefalls below the preset lift height again.

CAUTIONPossible component damage caused by collision ifthe proximity switch is set incorrectly.– The proximity switch may be adjusted by trained

personnel.– If necessary, inform the authorised service

centre.

STILL SafetyLight (variant)

WARNINGDanger of damage to eyes fromlooking into the STILL SafetyLight.Do not look into theSTILLSafetyLight.

The STILL SafetyLight is a visual warning unitdesigned to enable early detection of trucksin driving areas with low visibility (such asdrive lanes, high racks), as well as at blindjunctions. The STILL SafetyLight is mountedon a support on the overhead guard suchthat it is not affected by jolts and vibrations.The STILL SafetyLight projects one or morelight-blue light spots in front of or behindthe truck and thus warns others about theapproaching truck. Several light spots areprojected as a chase light. The chase lightindicates the location of the truck with itsdirection of travel.

Depending on the configuration of the truck,the STILL SafetyLight automatically switchesitself on when the truck is moving. TheSTILL SafetyLight can also be switched onand off on the display-operating unit.

– To do so, press the corresponding button.

218 174749 EN - 11/2018


NOTE

If the truck is to be operated on public roads,the STILL SafetyLight must be switched off.

Operating the windscreenwiper/washer

7312_003-171_V3

1

2

– Push button (1) to actuate the front wind-screen wiper/washer (variant)

– Push button (2) to actuate the rear wind-screen wiper/washer (variant)

Repeated pressing of the respective buttonswitches between the operating stages in thesequence specified shown below.

Button actuation Operating stage

Off

1st time on

2nd time Interval

3rd time + hold Washer

4th time Off.

Filling the washer system

7312_003-009

1

– Open the filler cap (1) of the washer system(variant).

– Fill the washer reservoir with washer fluidcontaining anti-freeze, according to themaintenance data table; see ⇒ Chap-ter "Maintenance data table", P. 5-322.

CAUTIONComponents may become damaged due to theeffects of frost!Water expands when it freezes. If there is no anti-freeze in the washer system (variant), the systemmay become damaged due to the accumulation ofice in freezing conditions.– Always use washer fluid containing anti-freeze.

– Close the filler cap.

– Operate washer system until washer fluid isdischarged from the spray nozzles.

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FleetManager (variant)FleetManager is an equipment variant andcan be fitted to the truck in different versions.The description and operation information canbe found in the separate operating instructionsfor the corresponding FleetManager versions.

Shock recognition (variant)The shock recognition is an equipment variantof the FleetManager (variant) in which anacceleration sensor is installed in the truck.The acceleration sensor records data arisingfrom rapid accelerations or decelerations ofthe truck, e.g. in the event of an accident.This data can be electronically read out andevaluated.


Cruise control (variant)Using the cruise control function, the drivercan save the speed in forwards travel when it is> 6.0 km/h by pressing a button, and continuedriving without actuating the acceleratorpedal.

NOTE

The cruise control function cannot be usedfor reverse travel or when travelling at speedsbelow 6.0 km/h.

Depending on the truck equipment, the cruisecontrol can be switched on and off via the drivedirection switch or the display and operatingunit.

220 174749 EN - 11/2018


7325_003-057

F1F1 F2F2

F1 F2

1

11

Switching on and off via the drive directionswitch (1).

8

9

0

6

7

4

3

5

2

7312_003-150

Switching on and off using the Softkeys on thedisplay-operating unit.

Switching on cruise control

WARNINGRisk of accident from failing to adjust speed!Driving at excessive speeds can cause accidents,e.g. the truck could tip over when cornering.– Adjust speed along the entire distance being

travelled– Pay particular attention to cornering speed– Observe safety regulations when driving– Observe the special behaviour of the cruise

control function and the dangers associated withit

– Start drive mode.

– Accelerate the truck to the required speed(at least 6.0 km/h)

174749 EN - 11/2018 221


7325_003-057

F1F1 F2F2

F1 F2

1

11

– Press the drive direction switch (1) forforward travel again for at least one second,or press the corresponding Softkey on thedisplay-operating unit.

8

9

0

6

7

4

3

5

2

7312_003-150

The current speed is saved. The forward travelindicator (2) flashes.

Cruise control is switched on. The symbolis displayed.

– Remove your foot from the acceleratorpedal.

The truck continues to drive at the selectedspeed until the cruise control function isswitched off again.

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7325_003-057

F1F1 F2F2

F1 F2

1

11

Switching off cruise control

The cruise control function is switched off bymeans of one of the following actions:• Actuate the foot brake• Actuate the parking brake• Actuate the accelerator pedal• Move the drive direction switch (1) into theneutral position or reverse

• Actuate the corresponding Softkey (seearrows, previous picture) on the display-operating unit.

NOTE

If the seat switch is not actuated, the truck'scruise control function and drive function areswitched off.

The accelerator pedal can be used to switchoff the cruise control function, depending onwhich function type is programmed:• Type 1:Even slightly depressing the acceleratorpedal switches off the cruise control func-tion

• Type 2:To switch off the cruise control function, theaccelerator pedal must be depressed atleast as far as it was when saving the speed

– Switch off cruise control

8

9

0

6

7

4

3

5

2

7312_003-150

The forward travel indicator (2) illuminates.

Cruise control is switched off. The symbolis displayed.

NOTE

If the truck is configured with automaticfunctions that reduce the driving speed to 6km/h or less in certain situations, then thesefunctions will also switch the cruise control offautomatically.

174749 EN - 11/2018 223


Driver restraint systems (variants)Different driver restraint systems are availableas variants for this truck. The description andoperation for these systems can be foundin the separate "Driver restraint systems"operating instructions.

Ceiling sensor (variant)

Description

1

The ceiling sensor (1) on the overhead guardis an assistance system that automaticallyreduces the driving speed of the truck withinhalls. However, this assistance system doesnot release the driver from the responsibilityof observing the speed limits on companypremises.

Depending on the system setting, the ceilingsensor can detect overhead structures abovethe truck at a height of 2 m to 24 m above thesensor.

Operating the ceiling sensor systemThe drivers are to be instructed on the useof the ceiling sensor system by the operatingcompany.

When the driver enters a hall for the firsttime after starting work, he must be certainthat the ceiling sensor system is functioningcorrectly. Despite the ceiling sensor systembeing installed, the driver must also check thespeed indicator on the display-operating uniton a regular basis to ensure that he does notexceed the maximum speed permitted for theenvironment.

• Entering a hallThe ceiling detector system automaticallydetects whether the truck enters a hall. Thesystem then automatically slows the truck tothe maximum speed that is set for the hall.

• Leaving a hallIf the truck leaves the hall again, the ceilingdetector system enables the maximumspeed set for areas outside the hall. Dueto the range of the sensor, this may not

224 174749 EN - 11/2018


happen until the truck is a fewmetres awayfrom the hall exit. Before the truck is able toaccelerate to themaximumspeedpermittedfor outdoor areas, the speed limitation muststill be unlocked. To do this, release theaccelerator briefly and then operate theaccelerator again.

• Switching on the truck in a hallIf the truck is switched on inside a hall, theceiling detector system detects the hallceiling and reduces the driving speed to themaximum speed that is set for halls.

Possible limitations for object recognition• If the truck moves under larger overheadstructures outdoors, e.g. a pedestrianbridge, the ceiling sensor system mayinterpret this overhead structure to be a hallceiling and reduce the maximum speed.

• In rare cases, it may occur that the ceilingsensor system does not recognize a ceilingand does not then reduce the speed. Thiscan happen if the signals from the ceilingsensor are insufficiently reflected due to theceiling geometry; for example, if there arelarge window areas at a 45° angle.

In these cases, the sensitivity and the range ofthe ceiling sensor system must be adjusted.Formore information, refer to the next chapter.

Changing the sensor settingsThe ceiling sensor system is supplied bySTILL with the following factory settings:

Sensitivity: High

Ceiling height: 24 m

– Pull out the connecting cable from thesensor.

174749 EN - 11/2018 225


1

– On the underside of the assembly baseplateon the overhead guard, loosen the four nuts(1) on the sensor.

– Carefully remove the sensor.

2

– Using the supplied key (2), open the sensorhousing to gain access to the DIP switches.

226 174749 EN - 11/2018


1 2 3 4 5 6 7 8

3

– Using the DIP switches "1" to "5" (3), adjustthe range and the sensitivity of the sensor.The DIP switches can be adjusted using asmall screwdriver.

CAUTIONThe settings for DIP switches "6" to "8" are thefactory settings of the manufacturer.They must not be changed!

Factory settings of the manufacturer - do notchange

DIP switch

6 7 8

1 1 0

The possible settings for DIP switches "1" to"5" are shown in the following tables:

DIP switch

1 2 3 Range

0 0 0 2 m

0 0 1 3 m

0 1 0 4 m

0 1 1 6 m

1 0 0 8 m

1 0 1 12 m

1 1 0 16 m

1 1 1 24 m

4 5 Sensitivity

0 0 Very high

0 1 High

1 0 Medium

1 1 Low

The sensor has different beam angles de-pending on the combination of range and

174749 EN - 11/2018 227


sensitivity that has been set. See the followingtable:

Sensitivity Range Beam angle

2 m 22.5°

4 m 22.5°

8 m 20°

16 m 15°

Low (1)

24 m 5°

2 m 35°

4 m 30°

8 m 25°

16 m 22.5°

Medium (2)

24 m 10°

Sensitivity Range Beam angle

2 m 42°

4 m 33°

8 m 22.5°

16 m 20°

High (3)

24 m 15°

2 m 45°

4 m 43°

8 m 30°

16 m 22.5°

Very high (4)

24 m 18°

228 174749 EN - 11/2018


2 3 41234

Representation of the beam angle dependingon the sensitivity of the sensor that has beenset, from (1)"low" to (4)"very high".

Additional labellingAdhesive label next to the display-operatingunit

174749 EN - 11/2018 229

4 OperationCab

Cab

7314_003-0394 5

2

1

3

Opening the cab door

DANGERThere is risk of damage caused by collision if thecab door opens while driving.– The cab door must be securely engaged in the

detent position.

Opening the cab door from the outside:– Insert the key in the door lock (1), unlockand remove the key again.

– Pull the door handle (2) and release thedoor lock.

– Open the cab door (3) by pulling outwards.

Opening the cab door from the inside:– Take hold of the handlebar (4) and latch (5).

– Press the latch in and push the cab dooroutwards.

230 174749 EN - 11/2018

Operation 4Cab

7314_003-04112

Closing the cab door

DANGERThere is risk of damage caused by collision if thecab door opens while driving.– The cab door must be securely engaged in the

detent position.

Closing the cab door from the outside:– Push the cab door (2) inwards until the doorlock engages.

– Make sure that the cab door is fully closed.

Closing the cab door from the inside:– Take hold of the handlebar (1).

– Pull the cab door inwards until the door lockengages.

– Make sure that the cab door is fully closed.

7314_003-040

4

5

2

1

3

Opening the side windows

WARNINGThere is risk of crushing between the window frameand side window caused by the side windowsslipping inadvertently during travel.– Make sure that the handle engages securely in

the corresponding stop slot.

Opening the rear side window:– Press the handle (2) together and slide therear side window (1) forwards.

– Make sure that the handle engages in thestop slot (3).

Opening the front side window:– Press the handle (4) together and slide thefront side window (5) to the rear.


174749 EN - 11/2018 231

4 OperationCab

7314_003-040

4

5

2

1

3

Closing the side windows

WARNINGThere is risk of crushing between the window frameand side window caused by the side windowsslipping inadvertently during travel.– Make sure that the handle engages securely in

the corresponding stop slot.

Closing the rear side window:– Press the handle (2) together and pull therear side window (1) to the rear.


Closing the front side window:– Press the handle (4) together and slide thefront side window (5) forwards.


232 174749 EN - 11/2018

Operation 4Cab

7312_003-013

7 8Operating the interior lighting

6311_003-013_V2

21

– Switch the interior lighting (7) on or off usingthe switch (8) or button (1).

The "interior lighting" symbol (2) appears inthe display.

174749 EN - 11/2018 233

4 OperationCab

Operating the rear window heating

6311_003-014_V2

21

– Press Softkey (1) to switch on the rearwindow heating.

Rear window heating is switched on.The symbol is displayed.

– Press Softkey (1) to switch off the rearwindow heating.

Rear window heating is switched off.The (2) symbol is displayed.

NOTE

Rear window heating will switch off automati-cally after approximately 10 minutes.

6321_003-015

1

2

Radio (variant)The radio (1) and the loudspeakers (2) are anequipment variant. If the truck is equippedwitha radio and loudspeakers, they are integratedinto the roof lining.

The description and operation can be foundin the separate operating instructions for theradio.

WARNINGThe driver's attention is adversely affected byoperating the radio or listening to excessive volumewhile driving or handling loads. There is a risk ofaccident!– Do not use the radio when driving or when

handling loads.– Set the radio volume so that you can still hear

warning signals.

234 174749 EN - 11/2018

Operation 4Cab

Heating system

DANGERRisk of explosion!Do not expose spray cans or gascartridges to the flow of hot air.The heater should not be operatednear storage rooms or similar facilitieswhere fuel vapours or coal, wood orgrain dust could accumulate.

Switching on the blower

12

7314_003-034

– To switch on the blower, turn on the blowerswitch (1).

The blower runs at the speed level set at theswitch.

Switching on the heating system

DANGERRisk of fire!Do not cover the heater!

DANGERRisk of burns!Do not touch housing during opera-tion!

NOTE

Only switch on the heating system when theblower is running.

– To switch on the heating system, turn on theheating switch (2).

The heating system is in operation. The airis heated up to the heater power set at thevariable switch (2).

174749 EN - 11/2018 235

4 OperationCab

01 2

3

01 2

3

7314_003-035

34

Air circulation– To allow the air to circulate, open the aircirculation vent (3) (50% air circulation).

Defrost– To defrost the windscreen, close thefootwell vent (4) and direct both front airvents towards the windscreen.

– Turn the blower to the highest setting.

6210_003-105_V2

1

2

3

3

Push-up roof window (variant)

WARNINGRisk of crushing!– When closing the roof window, do not reach

between the roof window and the overheadguard.

– Do not reach in to touch components as they arebeing closed.

The push-up roof window (1) is an equipmentvariant.

– To unlock and open the roof window, rotatethe handle (2) in an anti-clockwise directionand use it to push the roof window upwards.

The roof window is held in the open position bymeans of gas springs (3).

– To close and lock the roof window, pullthe roof window downwards using thehandle and rotate the handle in a clockwisedirection

236 174749 EN - 11/2018

Operation 4Cab

6210_003-107

21

Clipboard (variant)The clipboard (1) with reading lamp (2) is anequipment variant.

174749 EN - 11/2018 237

4 OperationTrailer operation

Trailer operation

6210_313-001

Towed load

DANGERThere is an increased risk of accident when using atrailer.Using a trailer changes the truck handling charac-teristics. When towing, operate the truck such thatthe trailer train can be safely driven and braked atall times. The maximum permissible speed whentowing is 5 km/h.– Do not exceed the permissible speed of 5 km/h.– Do not couple the truck in front of rail vehicles.– The truck must not be used to push any kind of

trolley.– It must be possible to drive and brake at all times.

CAUTIONRisk of damage to components!The maximum towed load for occasional towingis the rated capacity specified on the nameplate.Overloading can lead to component damage on thetruck. The sum of the actual towed load and theactual load on the fork must not exceed the ratedcapacity. If the existing towed load correspondsto the rated capacity of the truck, no load may betransported on the fork at the same time. The loadcan be distributed between the fork and the trailer.– Check the load distribution and adjust it to

correspond to the rated capacity.– Observe the permissible rigidity value of the tow

coupling.

CAUTIONRisk of damage to components!Themaximum towed load only applies when towingunbraked trailers on a level surface (maximumdeviation +/- 1%) and on firm ground. The towedload must be reduced if towing on gradients. Ifnecessary, notify the authorised service centre ofthe application conditions. The service centre willprovide the required data.– Inform the authorised service centre.

238 174749 EN - 11/2018

Operation 4Trailer operation

CAUTIONRisk of damage to components!A support load is not permitted.– Do not use trailers with tillers supported by the

tow coupling.

This truck is suitable for the occasional towingof trailers. If the truck is equipped with atowing device, this occasional towing mustnot exceed 2% of the daily operating time. Ifthe truck is to be used for towing on a moreregular basis, the manufacturer should beconsulted.

Coupling pin in the counterweight

Coupling the trailer

DANGERIf you briefly leave the truck to couple or uncouplethe trailer, there is a risk to life caused by the truckrolling away and running you over.– Apply the parking brake.– Lower the forks to the ground.– Switch off the key switch and remove the key.

1 7090_900-008

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks (1).

– Push the coupling pin (2) down, turn 90°and pull out.

174749 EN - 11/2018 239


7312_003-103_V2

2 3

– Adjust the tiller height.

DANGERPeople can become trapped between the truck andtrailer.When hooking up, ensure that no one is betweenthe truck and trailer.

– Slowly move the truck backwards.

– Bymoving the truck back, introduce the tillerinto the recess (3) in the counterweight.

DANGERIn the event of loss or destruction of the coupling pinor the securing bush during towing, the trailer worksloose and becomes uncontrollable, meaning thereis a risk of accident!– Use only original coupling pins that have been

checked carefully.

– Ensure that the coupling pin is correctly insertedand secured.

– Insert the coupling pin into the counter-weight, press downwards against the springpressure and turn 90° (the coupling pin islocked in this position).

– Remove any items used to prevent thetrailer from rolling away.

Uncoupling the trailer– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

7312_003-103_V2

2 3

– Push the coupling pin (2) down, turn 90°and pull out.

– Slowly move the truck forwards and guidethe tow-bar eye completely out of thecounterweight.

– Insert the coupling pin into the counter-weight, press downwards against the springpressure and turn 90° (the coupling pin islocked in this position).

240 174749 EN - 11/2018


Automatic tow coupling

DANGERPeople may be trapped between the truck andtrailer.When hooking up, ensure that no one is betweenthe truck and trailer.

DANGERNever jack up the truck on the tow coupling or useit for crane lifting. The tow coupling is not designedfor this and could be deformed or damaged. Thiscould cause the truck to fall, with potentially fatalconsequences!– Use the tow coupling only for towing.– For jacking up and crane loading, use only the

designated lifting points.

DANGERThe tow coupling is not designed to support loadsand could become deformed or destroyed. Thiscould cause the supported load to fall, with poten-tially fatal consequences!– The tow coupling should be subjected only to

horizontal loads, i.e. the tiller must be horizontal.

DANGERIf you briefly leave the truck to couple or uncouplethe trailer, there is a risk to life caused by the truckrolling away and running you over.– Apply the parking brake.– Lower the forks to the ground.– Switch off the key switch and remove the key.

WARNINGNever reach between the coupling pins and thetowing jaws. If the component moves suddenlythere is a risk of injury!– To release the coupling pin, actuate the corre-

sponding lever or use a suitable device (e.g.assembly lever).

– When not in use, close the automatic towcoupling.

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WARNINGRisk of damage due to component collision.A truck with tow coupling needs more room formanoeuvring due to its overhang. The tow couplingcan damage the racking or the tow coupling itselfwhen manoeuvring. If there is a collision with thetow coupling, test the tow coupling for damagesuch as cracks. A damaged tow coupling must notbe used again.– Always manoeuvre carefully and with sufficient

room.– In the case of a collision, test the tow coupling for

damage.– Replace tow coupling if damaged, if necessary

contact the authorised service centre.

WARNINGRisk of damage to the tow bar eye or tiller!Due to the truck's rear wheel steering, the sideslewing angle of the tiller may not be adequate. Thecoupling or the tiller may be damaged! The tow bareye of the tiller must fit the tow coupling in terms ofshape and size.– Ensure that the tow bar eye and tiller fit correctly.– Avoid sharp cornering.– Exercise care when travelling and manoeuvring

in reverse.

WARNINGRisk of component damage if the tiller in the towcoupling is tilted!The tiller should be kept as horizontal as possiblewhen towing. This ensures that the rotation rangeis sufficient at the top and bottom. The authorisedservice centre can adjust the assembly height forthe tow coupling to the tiller height if necessary.– Make sure that the tiller is level.– To change the coupling height, contact the


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1 7090_900-008

Coupling model RO*243

NOTE

Tow coupling RO 243 is intended for a tow-bareye in accordance with DIN 74054 (borediameter: 40 mm).

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks (1).

– Adjust the tow bar eye of the tiller so that it isat the centre of the towing jaws.

3

7321_003-064

2

– Pull out the safety handle (3).

– Push the hand lever (2) upwards.

DANGERPersons may become trapped between the truckand trailer.When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTIONWhen being coupled, the tow-bar eye must engagein the middle of the coupling jaw. Failure to followthese instructions could result in damage to thecoupling jaw or to the tow-bar eye!– Ensure that the tow-bar eye enters the coupling

jaw centrally.

– Slowly move the truck back.

DANGERIf the coupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Ensure that the safety handle is flush with the

securing bush.– If the safety handle protrudes, repeat the coup-

ling process.


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– Tow the trailer.

Closing model RO*243 by hand

DANGERRisk of injury from hand becoming trapped!Do not reach into the coupling pin area. If, forexample, a tow rope is to be secured in the towcoupling, use only a suitable device to close the towcoupling (e.g. assembly lever).

– Use a suitable device (e.g. assembly lever)to push the coupling pin up.

The coupling pin is released from the latch andthe tow coupling then closes automatically.

3

7321_003-064

2

Uncoupling model RO*243– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

– Pull out the safety handle (3).


– Slowly drive the truck forwards until the tow-bar eye and towing jaws are disconnected.

– Close the tow coupling by hand.

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Coupling model RO*244 A

NOTE

Trailer coupling RO 244 is intended for a towbar eye in accordance with DIN 74054 (borediameter 40 mm) or DIN 8454 (bore diameter35 mm).

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.


– Push the hand lever (2) upwards until itsnaps into place.

The tow coupling is opened.

DANGERPeople can become trapped between the truck andtrailer!When hooking up, ensure that no one is betweenthe truck and trailer.


jaw centrally.

– Move the truck back slowly until the tow bareye is inserted centrally into the couplingjaw of the tow coupling and the coupling pinengages.

NOTE

The coupling pin is correctly engaged if thecontrol pin (3) does not protrude out of itsguide.

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DANGERIf thecoupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!The control pin (3)must not protrude out of its guide.– Ensure that the coupling pin is engaged cor-

rectly.If the coupling pin is not correctly engaged:– Remove any items used to prevent the trailer

from rolling away.– Move the truck with the trailer forwards approx.

1 m and then move it back slightly.– On the coupling pin, check again that the control

pin does not protrude out of its guide.



Closing model RO*244 A by hand

DANGERRisk of injury from hand becoming trapped!Do not reach into the coupling pin area. If, forexample, a tow rope is to be secured in the towcoupling, only actuate the tow coupling via theclosing lever (1).

– Press the closing lever (1) downwards asfar as it will go.

The tow coupling is closed.

Uncoupling model RO*244 A– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.


The tow coupling is opened.


– Close the tow coupling by actuating theclosing lever (1).

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NOTE

To protect the lower coupling pin bush againstcontamination, always keep the tow couplingclosed.

7321_003-066_V2

57

6


NOTE

Trailer coupling RO 245 is intended for atow-bar eye in accordance with DIN 74054(bore diameter 40 mm) or DIN 8454 (borediameter 35 mm).




– The tow coupling is opened.

DANGERPeople can become trapped between the truck andtrailer!When hooking up, ensure that no one is betweenthe truck and trailer.


DANGERIf the coupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Make sure that the control pin does not protrude

from the control bush.– Repeat the coupling process if necessary.



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7321_003-066_V2

57

6




– Push the closing lever (7) on the left side ofthe tow coupling down as far as it will go.

The tow coupling is closed.

7

8

7321_003-067


NOTE

Tow coupling RO 841 is intended for a tow-bareye in accordance with DIN 74054 (borediameter 40 mm).



DANGERPeople may be trapped between truck and trailer.When hooking up, ensure that no one is betweenthe truck and trailer.


jaw centrally.


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DANGERIf the coupling pin dropsout during towing, the trailerwill work loose and can no longer be controlled.There is a risk of accident!A protruding safety handle means that the tow bareye has not been coupled correctly. The trailermust not be towed in this condition.– Make sure that the control pin does not protrude

from the control bush.– Repeat the coupling process if necessary.






– Close the tow coupling.

7090_900-011Towing trailers– Drivers who are towing a trailer for the firsttime must practise driving with a trailer in asuitable area.

– When passing through narrow road areas(entrances, gates etc.), observe the dimen-sions of the trailer and load.

– When towing multiple trailers, ensurea sufficient minimum distance to fixedinstallations when turning and cornering.

The permissible length of the trailer trainsdepends on the roadways to be driven andmay need to be determined during the testdrive.

It is the responsibility of the operating com-pany to instruct the drivers regarding thepermissible number of trailers and, whererequired, any additional speed reductions onindividual sections of the route.

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NOTE


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Operation 4Display messages

Display messages

8

9

0

6

7

4

2

1

3

5

7312_003-157

2 3 4

1

Display contentOn the display of the display-operating unit,event-related messages may appear due tocertain truck conditions.

The following types of message may appearindividually or in combination:• A graphic symbol (2)• The message (3)• An error code (4) consisting of a letter and afour-digit number

NOTE

Each time a message appears, the "Malfunc-tion" display (1) also lights up.

Messages are always shown repeatedly andfor a certain period of time, according to theevent.

In the case of successive events, the respec-tivemessages are displayed one after anotheron the display.

After a few seconds, the display will alternatebetween the last shown operating display andthe message.

The frequency of alternation depends on thetype of event.

– If a message appears, follow these operat-ing instructions.

Once the event is remedied, the message willdisappear.

If a malfunction continues to occur, themessage will continue to appear.

– Park the truck safely.

– Inform the authorised service centre.

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4 OperationDisplay messages

Error code tableThe table gives an overview of possibledisplays. In the "Comment" column you willfind information on how to proceed should anyof these messages be displayed.

Message text/Error code

Comment

OVERHEATINGA5022

Traction motor(s) is/are too hot.1st phase: regulation of acceleration and speed.2nd phase: limitation of phase current in converter (emer-gency driving function is retained).The error automatically disappears as soon as the tempera-ture is below the limit.If the error occurs frequently, notify your authorised servicecentre.

ACCELERATORA3002A3003A3004A3005A3006A3007A3505

Sensor fault, truck cannot be driven.Notify your authorised service centre.

ACCELERATORA3008

Accelerator voltages (for dual pedal) do not match; truckcannot be driven.Notify your authorised service centre.

ACCELERATORA3811

Accelerator configuration is invalid; truck cannot be driven.Notify your authorised service centre.

BRAKE SENSORA3016A3017

Sensor fault; truck can only be driven at emergency modespeed.Notify your authorised service centre.

BRAKE SENSORA3035

Brake fluid level too low or switch defective; truck can only bedriven at the emergency mode speed.Notify your authorised service centre.

CONFIGURATIONA2111

Parameterisation error or defective printed circuit board;drive unit and hydraulic drive not functioning.Notify your authorised service centre.

CONFIGURATIONA3801

Parameterisation error; drive unit and hydraulic drive notfunctioning.Notify your authorised service centre.

CONFIGURATIONA3812

Drive program parameters are outside the permitted range.The drive program parameters are limited internally.Notify your authorised service centre.

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Comment

SEAT SWITCHA3027

Seat switch has not been operated for approx. 8 hours.Truck can possibly still be driven at a reduced speed andwithreduced lifting capacity.Stand up briefly and then sit down again.If this does not resolve the problem, contact your authorisedservice centre.

STEERINGA3215

Sensor fault; truck moves at emergency mode speed.Notify your authorised service centre.

DRIVE DIRECTIONA3020

Switch error; no or limited drive unit function.Notify your authorised service centre.

LIFTINGA3102A3103

Sensor fault; no or limited hydraulic drive function.Notify your authorised service centre.

TILTINGA3107A3108


AUX1A3112A3113


AUX2A3117A3118


VERTICAL MASTA3130A3131A3132

No hydraulic function.Turn off "vertical lift mast position".Notify your authorised service centre.

VERTICAL MAST ERRORA3135

No hydraulic function.Turn off "vertical lift mast position".Notify your authorised service centre.

SUPPLYA2242A2257

Transmitter power supply short circuit. Truck cannot bedriven.Notify your authorised service centre.

SURVEILLANCEA2801A2802A2808A2809A2810A2815

Drive unit not functioning.Release accelerator pedal.If this error occurs sporadically, it can be tolerated. If theoperational capacity is impaired, notify your authorisedservice centre.

SURVEILLANCEA2803A2806

Drive direction is set to neutral.Reselect the drive direction.If this error occurs sporadically, it can be tolerated. If theoperational capacity is impaired, notify your authorisedservice centre.

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Comment

SURVEILLANCEA2817

Truck is not ready for operation.Turn the key switch to the zero position and restart.If this error occurs sporadically, it can be tolerated. If theoperational capacity is impaired, notify your authorisedservice centre.

DRIVEA5041

Temperature sensor faultNotify your authorised service centre.

OIL PRESSUREA5631

Engine faulty (no oil pressure) or sensor faulty. Engine isswitched off for protection.Notify your authorised service centre.

COOLANT LEVELA5611

Fan is not running.Cooling fluid level too low, check the cooling fluid level andtop up the cooling fluid if necessary.If this does not resolve the problem, contact your authorisedservice centre.

AIR FILTERA5651

Depending on the design of the air filter, replace the filterinsert or the filter cartridges.If this does not resolve the problem, contact your authorisedservice centre.

CONTROL UNITA3305

CIO not functioning.Notify your authorised service centre.

EXHAUST GAS PURIFIERA5791

No regeneration and no intermediate glow.Notify your authorised service centre.

EXHAUST GAS PURIFIERA5792A5793A5794A5796

Regeneration cannot be started.Notify your authorised service centre.

EXHAUST GAS PURIFIERA5795A5797A5798

Regeneration has been interrupted.Notify your authorised service centre.

ALTERNATORA5811

Starter battery is not charged.Notify your authorised service centre.

.

General messages

NOTE

Some of the following messages are equip-ment-specific and may not appear on thedisplay and operating unit of every truck. Thefollowing messages are therefore intendedonly as a reference.

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SERVICE BRAKEmessageIf the message SERVICE BRAKE appearson the display, notify the authorised servicecentre.

– Park the truck securely for checking by theauthorised service centre.

– If multi-disc brakes in the drive wheel unitsare blocked, tow the truck.

APPLY HANDBRAKEmessage

DANGERRisk of fatal injury from being run over if the truckrolls away!Parking the truck without the parking brake appliedis dangerous and is not permitted.– The truck must not be parked on a slope.– Only leave the truck when the parking brake has

been applied.– In emergencies, secure the truck using wedges

on the side facing downhill.

NOTE

The truck is equipped with a negative spring-operated brake. Switching off the truck willblock the multi-disc brakes in the drive wheelunits after a few minutes. However, the truckcan still roll until the drive wheel units areblocked. For this reason, the parking brakemust always be applied before you leave thetruck!

If you park the truck without applying theparking brake and then vacate the driver'sseat, the APPLY HANDBRAKEmessage willappear in the display (variant). An optionalsignal tone sounds.


The APPLY HANDBRAKEmessage disap-pears.

If the truck moves even though the parkingbrake is applied:

– Drive the truck onto level ground and park itsafely. Secure it with wedges if necessary.


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BRAKE SENSORmessageIf the BRAKE SENSORmessage appears inthe display, themaximumdriving speedwill bereduced. The brake sensor in the brake pedalmust be checked.


CODE DENIEDmessageIf the message CODE DENIED appears onthe display, the driver PIN has been enteredincorrectly three times. The input is thenlocked for fiveminutes before another attemptcan be made.

– Enter the driverPIN again after fiveminutes.

ACCELERATORmessageIf the ACCELERATORmessage appears onthe display, the truck will remain stationary.The accelerator must be checked.


SWITCHOFF TRUCK?messageIf the message SWITCH OFF THE TRUCK?appears on the display, the switching-off of thetruck is verified.

– Press the corresponding softkey on thedisplay and operating unit to switch off thetruck or cancel the operation.

PARKING BRAKE ACTIVEmessageIf the electric parking brake is applied, thePARKING BRAKE ACTIVEmessage ap-pears on the display for 5 seconds.

– Release the parking brake to enable drivingmode.

RELEASE PARKING BRAKEmessageIf the message RELEASE PARKING BRAKEappears on the display, driving mode cannotbe enabled until the parking brake has beenreleased by pressing the button.

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– Release the parking brake by pressing thebutton.

PARKING BRAKE: APPLY HAND-BRAKE! messageIf the message PARKING BRAKE: APPLYHANDBRAKE! appears on the display, theelectric parking brake is faulty.

– Release the parking brake by pressing thebutton.

LOWER FORKSmessage

DANGERThere is a risk of fatal injury from a falling load orparts of the truck being lowered!Parking the truck with the load lifted is dangerousand is not permitted under any circumstances! Theincreased safety provided by this function must notbe misused in order to take safety risks.– Lower the load fully before leaving the truck.

7312_003-071_en_V2

The fork is not lowered.

If the fork is above the height sensor, the keyswitch is turned off and the seat vacated,the LOWER FORKS message appears inthe display (variant). An optional signal tonesounds.

– Lower the fork to the ground.

The message LOWER FORKS disappears.

STEERINGmessageIf the STEERINGmessage appears in thedisplay, the truck will only move at emergencymode speed. The steering angle sensor mustbe checked.


TILTING SPEEDmessageIf the message TILTING SPEED appearson the display after the welcome screen, thetilting speed of the lift mast on this truck issignificantly higher than on previous trucks inthis family.

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EMERGENCY SWITCHmessage

WARNINGNo electric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will disconnectthe drives from the power supply.– To brake, actuate the service brake.

The truck is equipped with an emergency offswitch. When this switch is actuated, thedriving functions and the functions of theworking hydraulics are blocked.

TheEMERGENCYSWITCHmessageappearsperiodically when the following criteria aremet:• The key switch is set to stage "I"• The emergency off switch is actuated• An operating device is actuated

? VERTICAL POSITIONIf the message ? VERTICAL POSITIONappears on the display, calibration of the"vertical lift mast position" has been activated.

– Save the mast position or cancel thecalibration.

7312_003-072_en_V3

REFERENCE CYCLEmessageIf the fork was lowered after the truck wasswitched off, the control electronics do notknow the position of the fork when the truckis restarted. The truck will only travel at areduced driving speed. Depending on thepositionof the fork, themessageREFERENCECYCLE (variant)may appear in the display. Toalign the position with the control electronics,the fork must be raised.

– Switch on the key switch.

The truck will only travel at a reduced drivingspeed. The message REFERENCE CYCLEmay appear in the display.

– Raise the fork.

The message REFERENCE CYCLE goes out,or now appears in the display for the first timeand then goes out.

258 174749 EN - 11/2018


– To drive again, lower the fork to a maximumof 300 mm above the ground.

The truck can now be driven again with nospeed limitation.

7325_003-056_en_V2

F1 F2

SAFETY BELTmessage

DANGERRisk of fatal injury in the event of fallingfrom the truck if it tips over!If the truck tips over, the driver is at riskof injury even if a restraint system isused. The risk of injury canbe reducedby using a combination of a restraintsystem and a seat belt. In addition,the seat belt protects against theconsequences of rear-end collisionsand falling off ramps.– We recommend that you always

use the seat belt.

This device (variant) ensures that if theseat belt is not being used or is being usedincorrectly, the truck will only drive slowly or(optionally) will not drive at all.

Depending on the configuration selected, theworking hydraulics functions (lifting/tilting) areeither available as normal, slowed down or notavailable at all.

The SAFETY BELTmessage with the restric-ted driving and lifting functions is triggered bythe following circumstances:• Seat belt not worn and driver's seat occu-pied

• The seat belt is constantly fastened but thedriver's seat is only occupied afterwards

• The seat belt is not fastened until after thekey switch has been switched on

• The seat belt is unfastened while driving

– If the SAFETY BELTmessage appears,fasten the seat belt in accordance with theregulations.

The truck can again be operated withoutrestrictions.

If the seat belt is released while driving, thetruck will be limited to low driving speeds or willbe braked to a halt.

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DANGERRisk of accident!– The speed must be adjusted to suit the driving

situation!The increased safety provided by this functionmustnot be misused in order to take safety risks.

ARE YOU SURE ?messageIf the message ARE YOU SURE ? appears onthe display, a prior prompt is verified.

– Press the corresponding softkey on thedisplay and operating unit to continue or tocancel the operation.

SEAT SWITCHmessageThe truck is equipped with a seat switch.

If the SEAT SWITCHmessage appears, thedriving functions and the working hydraulicsare blocked.

The SEAT SWITCHmessage is triggered bythe following situations:• The seat switch is not actuated while theaccelerator pedal or steering wheel isactuated

• The seat switch is not actuated while theoperating device for the working hydraulicsis actuated

• The shift time has been exceeded• The operating time has been exceeded

NOTE

The operating devices shown in the followingillustrations are only examples and may differfrom the equipment in your truck.

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7312_003-066_en_V2

The seat switch is not actuated while the ac-celerator pedal or steering wheel is actuated

The accelerator pedal or the steering wheel isactuated, even though no one is sitting in thedriver's seat. The message SEAT SWITCHappears on the display. The truck will notmove.

– Sit in the driver's seat and fasten the seatbelt.

The truck can be driven again without restric-tions.

7325_003-054_en_V2

F1 F2

The seat switch is not actuated while theoperating device for the working hydraulicsis actuated

An operating device for the working hydraulicsis actuated, even though no one is sittingin the driver's seat. The message SEATSWITCH appears on the display. The workinghydraulics functions cannot be executed.

– Sit in the driver's seat and fasten the seatbelt.

The working hydraulics can be operatedagain.

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7325_003-054_en_V2

F1 F2

The shift time has been exceeded

NOTE

The shift time is adjustable.

If the key switch is switched on and the driverdoes not leave the seat before the set shifttime is exceeded, SEAT SWITCH appearson the display. This is also the case if anoperating device for the working hydraulics orthe accelerator pedal is actuated. Dependingon the configuration, the working hydraulicfunctions can be executed normally, onlyslowly or not at all.

– Stand up briefly from the seat, sit back downagain and fasten the seat belt.


7325_003-055_en_V3

F1 F2

The operating time has been exceeded

NOTE

The operating time is adjustable.

If the key switch is switched on, the parkingbrake is released and the driver does notleave the seat before the set operating time isexceeded, and if neither the operating devicesfor the working hydraulics nor the acceleratorpedal are actuated during this time, SEATSWITCHappears on the display. The truckwillnotmove. Depending on the configuration, theworking hydraulic functions can be executednormally, only slowly or not at all.

– Stand up briefly from the seat, sit back downagain and fasten the seat belt.


OVERHEATINGmessageIf the message OVERHEATING appearson the display, the traction motors haveoverheated. The acceleration and the speedof the truck are reduced.

– Allow the truck to cool down.

– If the error persists, contact your authorisedservice centre.

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SURVEILLANCEmessageIf the SURVEILLANCE message appearsin the display, there is a fault in the processmonitoring.

This shuts off the drive unit.

– Switch the key switch to the "0" position andthen back to the "I" position.

– Start the engine.

– Release accelerator pedal.

– Select the drive direction again.

NOTE

If this error occurs sporadically, it can be tole-rated. If the operational capacity is impaired,notify your authorised service centre.

NOT VALID messageIf the message NOT VALID appears on thedisplay, an incorrect driver PIN has beenentered when entering the access code.

– Once the message goes out, enter thedriver PIN again.

Drive-specific messages

NOTE

Some of the following messages are equip-ment-specific and may not appear on thedisplay and operating unit of every truck. Thefollowing messages are therefore intendedonly as a reference.

EXH.GAS PURIFIERmessageIf the EXH.GAS PURIFIERmessage ap-pears on the display, the particle filter is full.

– Regenerate the particle filter.

174749 EN - 11/2018 263


NOTE

If the EXH.GAS PURIFIERmessage ap-pears during regeneration, a fault has occur-red.• Notify the authorised service centre

EXH.GAS PURIFIER PLEASE WAITmessageIf the EXH.GAS PURIFIER PLEASE WAITmessage appears on the display, the particlefilter is being regenerated.

– Wait for particle filter regeneration.

EXH.GAS PURIFIER SERVICE! ! !messageIf the message EXH.GAS PURIFIER SER-VICE! ! ! appears on the display, the par-ticle filter was not regenerated on time. Theparticle filter system must be repaired by theauthorised service centre.

– To avoid damage, take the truck out ofoperation until it is repaired.


CUTOUTMODEmessageWhen automatic shut-off is activated, themessage CUTOUT MODE appears on thedisplay; see the section entitled "Automaticshut-off of the internal combustion engine(variant)".

– Sit on the driver's seat.

The message goes out and the truck is readyfor operation again.

ADBLUE URGENT! messageIf the AdBlue® filling level drops below 2 litres,the driving speed is limited to 2 km/h.

– Maintain the quality of the AdBlue®; see thesection entitled "Maintenance data table".

– Top up the AdBlue®.

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ADBLUE FILLING LEVELmessageIf the filling level of the AdBlue® tank has fallensignificantly, the ADBLUE FILLING LEVELmessage appears on the display-operatingunit.

If an AdBlue® filling level of 2 litres is reached,the driving speed is limited to 5 km/h.



ADBLUE REFILL 5l messageIf the message ADBLUE REFILL 5l ap-pears, a maximum of 5 litres of AdBlue® mustbe added.



ADBLUEQUALITYmessageThis truck is equipped with a sensor thatmeasures the quality of the exhaust gascleaned using AdBlue®.

If the quality of the exhaust gas deteriorates,the ADBLUE QUALITYmessage appears onthe display and operating unit.

If the exhaust gas quality deteriorates further,the driving speed is limited to 5 km/h.



ADBLUEQUALITY URGENT! messageIf the quality sensor detects a deterioration inthe quality of the exhaust gas cleaned usingAdBlue®, the message ADBLUE QUALITYURGENT! appears on the display-operatingunit.

The driving speed is limited to 2 km/h.


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ASH LOADmessageIf the message ASH LOAD appears on thedisplay, the particle filter has become cloggedwith ash. Repair must be performed by theauthorised service centre.


GLOWmessageIf the GLOWmessage appears in the display,the engine is being preheated.

Preheating can take up to 22 seconds. If theengine is already at operating temperature,preheating is not performed.

– Once the message goes out, start theengine.

HYBRID SYSTEMmessageIf the message HYBRID SYSTEM is shownon the display, the energy storage system hasbeen deactivated because of an error.

The truck remains operational. However, thefuel consumption increases marginally.

– Contact the authorised service centre inorder to rectify the error.

HYDRAULIC PUMPmessageIf the HYDRAULIC PUMPmessage appearson the display, there was an error in thehydraulic-pump volume control.

The engine can be overloaded and stall asa result of the overload. This causes theassisted steering and regenerative brakingto malfunction. Further operation of the truckis therefore not permissible. Thedriving speedis limited to 5 km/h.

– Contact the authorised service centre inorder to rectify the error.

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FUEL FILTERmessageThe fuel filter is equipped with a level indicatorthat reports water aggregation in the fuelfilter on the display and operating unit. Ifthe message FUEL FILTER appears in thedisplay, the fuel filter is saturated with water.This water must be drained.

– Drain water from the fuel filter.

COOLANT LEVELmessageIf the message COOLANT LEVEL appears onthe display, the cooling fluid level is too low.

– Check the cooling fluid level and addcoolingfluid if necessary.

CAUTIONRisk of engine damage!If the cooling fluid level is low, this indicates a leakin the cooling system.– Check the cooling system for leaks; see the

chapter entitled "Cleaning the radiator, checkingfor leaks".

EMPTYmessageIf the message EMPTY flashes on the display,the gas supply is almost exhausted.

– Change the LPG cylinder or fill the LPGtank.

ALTERNATORmessageIf the ALTERNATORmessage appears in thedisplay, this means that the alternator is nolonger charging the starter battery.

This may have the following causes:• Drive belt loose or damaged• The electrics to or from the alternator arefaulty

• The alternator is faulty

NOTE

If the fault is not rectified within a short time,the starter battery will soon run out of charge

174749 EN - 11/2018 267


and it will no longer be possible to operate thetruck.


LPG AUTO. VALVEmessageIf the message LPG AUTO. VALVE ap-pears on the display when the LPG engineis switched off, and the engine does not switchoff until after approximately 60 seconds, thereis an error.

Initially, the truck can still be operated. Theerror message is shown on the display andoperating unit until the error has been rectifiedby the authorised service centre.


AIR FILTERmessageIf the AIR FILTERmessage appears on thedisplay, the filter insert or the filter cartridgemust be replaced.

– Replace the filter insert or the filter cartridge.

OIL PRESSUREmessage

CAUTIONRisk of engine damage!If the OIL PRESSUREmessage appears in thedisplay, the engine's oil pressure is too low.– Stop the engine immediately.

The message can have different causes:• The engine has overheated• Insufficient oil• The oil is insufficiently viscous• Engine damage

– Check engine oil level.

– Change the engine oil if necessary.


REGENERATION COMPLETEDmessageIf the message REGENERATION COM-PLETED appears on the display, parked re-

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generation is complete. The truck is ready foroperation again.

SCR-SYSTEMSERVICEmessageIf the message SCR-SYSTEM SERVICEappears on the display, there is a fault in theSCR exhaust gas treatment system.


SCR-SYSTEMMALFUNCTION mes-sageIf the message SCR-SYSTEM MALFUNC-TION appears on the display, there is a faultin the SCR exhaust gas treatment system.


PARK. REG. URGENT! ! ! messageIf the message PARK. REG. URGENT! ! !appears on the display, parked regenerationof the particle filter is required urgently.

– Perform parked regeneration.

Until parked regeneration has been carriedout, the maximum speed of the truck is re-duced to 2 km/h. The lifting speed is restricted.

PARK. REG. ERRORmessageIf themessagePARK.REG.ERROR appearson the display, parked regeneration wasinterrupted by applying the parking brakeor by a malfunction in the internal combustionengine.


– Restart parked regeneration.

– If the parking brake was not actuatedand the message PARK. REG. ERRORappears anyway, notify the authorisedservice centre.

START PARK. REG.? messageIf the message START PARK. REG.?appears on the display, the truck is ready forparked regeneration.

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– Perform parked regeneration.

START IC ENGINEmessageIf the message START IC ENGINE appearson the display, the internal combustion engineof the truck can be started.

– Start the engine.

Malfunctions in the electric parkingbrakeBefore leaving the truck, the driver must makesure that the electric parking brake is appliedproperly.

If the controller detects a malfunction in theelectric parking brake, the truck cannot beswitched off.

6210_003-050_V421

Possible malfunctions

Error indication Effect Remedy

LED (2) in the push button (1)flashes.

Parking brake malfunction.It cannot be guaranteed that theparking brake has been appliedproperly.It may still be possible toactuate the parking brake bypressing the push button (1).

Park the truck safely.Notify the authorised servicecentre.

LED (2) in push button (1) doesnot light up when the brake isactuated.

It cannot be guaranteed that theparking brake has been appliedproperly.


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The actuation noise is clearlydifferent to the normal noise orthere is no noise at all.



A warning signal is issued fromsignal horn or another acousticwarning unit in the truck.



The truck rolls even thoughthe parking brake has beenapplied.



Display and operating unit:Symbol: "Parking brake"Display: APPLY HAND-BRAKE!

LED flashes.Parking brake is not appliedautomatically.

Press and hold the push button(1) for five seconds and thenrelease the push button.The parking brake will make anoise when it is applied.

Display and operating unit:Symbol: "Parking brakemalfunction"Display: PARKING BRAKEError number: X6511

The LED (2) in the push button(1) flashes.The parking brake fails torelease.The drive unit is locked.The error message flashesevery 30 seconds for fiveseconds.

Try again to release the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe service centre.If the truck needs to be movedbecause it is in the way,release the parking brakemanually. See the chapterentitled "Emergency operationof the electric parking brake".Then park the truck safely in adifferent location and notify theservice centre.


The LED (2) in the push button(1) flashes.The parking brake is notapplied.The maximum speed is limitedto 5 km/h.The error message flashesevery 30 seconds for fiveseconds.

Try again to apply the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe authorised service centre.Apply the parking brakemanually. See the chapterentitled "Emergency operationof the electric parking brake".

Symbol: "Service required"Display: PARKING BRAKEError number: X6501

The LED (2) in the push button(1) flashes.Maintenance time reached.The error message flashesevery 30 seconds for fiveseconds.


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Control problemThe drive unit remains active aslong as the contactor is closed.The error message flashesevery 30 seconds for fiveseconds.

Try again to apply the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe service centre.Apply the parking brakemanually if necessary. See thechapter entitled "Emergencyoperation of the electric parkingbrake".

Display and operating unit:Symbol: "Temperature"Display: PARKING BRAKEError number: X6502

Application of the parking brakeis delayed.The system switches off in theevent of over-temperature.The error message flashesevery 30 seconds for fiveseconds.

Allow the parking brake to cooldown. If the warning appearsagain, notify the authorisedservice centre


Malfunction in the parkingbrake.The drive unit remains active aslong as the contactor is closed.Creep mode is possible oncethe parking brake has beenreleased.The error message flashesevery 30 seconds for fiveseconds.

Try again to apply the parkingbrake via the push button (1).If this solution does not work,park the truck safely and notifythe authorised service centre.Apply the parking brakemanually if necessary. See thechapter entitled "Emergencyoperation of the electric parkingbrake".

.

Actuating a faulty electric parking brake

6210_003-050_V421

If the electric parking brake is faulty, the LED(2) in the push button (1) will flash and themessage APPLY HANDBRAKE! will appearon the display and operating unit. A possiblecause of the malfunction is that the parkingbrake cannot determine whether the truck isstationary or still in motion. The brake can bethen be applied via the push button (1). Thefollowing section describes how to actuate theparking brake when it is faulty:

Actuating a faulty parking brake when thetruck is stationary

Apply the parking brake:

– Press and hold the push button (1) for atleast five seconds and then release thepush button.

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The parking brake will make a noise when it isapplied. After the push button is released, theparking brake will not make any further noise;if you hear the parking brake release again itmeans that the push button was pressed forless than five seconds. In this case, press thepush button again to apply the parking brakeagain. Repeat this process up to four times ifnecessary.

Releasing the parking brake:

– Press the push button (1) then release thepush button.

The parking brake will make a noise when itis released. If the malfunction in the parkingbrake persists, it will not be possible to releasethe parking brake.

Actuating a faulty parking brake when thetruck is in motion

– Press push button.

The parking brake is applied.

NOTE

The truck will brake more sharply if the pushbutton (1) is pressed and held for a long periodor if the push button is pressed multiple times.

Switching off the truck when the electricparking brake is faultyIf the electric parking brake cannot be appliedand the driver tries to switch off the truck,the truck will not switch off at first. Instead,the truck responds with the following errormessages:

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The red lamp (1) in the multifunction displaybegins to flash.

The LED (2) in the push button for the electricparking brake flashes.

The message PARKING BRAKE APPLYHANDBRAKE! appears on the display andoperating unit.

If the driver now leaves the truck, a warningsound will be emitted and will stop only whenthe driver has resumed his/her seat in thetruck. To switch off the truck despite theparking brake being faulty (e.g. in order totow the truck) proceed as follows:

– Switch off the key switch again.

The message APPLY HANDBRAKE! willappear on the display and operating unit.

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– Press the ESC (3) soft key.

– The message SWITCH OFF TRUCK? willappear on the display and operating unit.To continue switching off the truck, pressthe soft key (4). To abort the process forswitching off the truck, press the ESC (5)soft key.

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4 OperationRefuelling

– ThemessageARE YOU SURE? appears onthe display and operating unit. To continueswitching off the truck, press the soft key(6). The truck will now switch off. To abortthe process for switching off the truck, pressthe ESC (7) soft key.

If switching off the truck was continued, thetruck will now be switched off and the parkingbrake will not have been applied. The truckcan now be towed. If the truck is not goingto the towed, the truck must be secured withwheel chocks to prevent it from rolling away.

DANGERRisk of fatal injury from the truck rolling away!The truck is not secured against rolling away be-cause the parking brake is not applied.– Use wheel chocks to prevent the truck from

rolling away.– Notify the authorised service centre so that it can

repair the parking brake.

RefuellingDiesel fuel - Specifications

CAUTIONRisk of component damage if non-approved fuelsare used!Use only approved fuels with the following specifi-cations.

If non-approved fuels are used, compliancewith the specified emission values and the ser-vice life of the engine cannot be guaranteed!This truck is equipped with an engine that ful-fils the requirements of Directive 97/68/EClevel IIIA. The truck can also be equipped withan exhaust after-treatment system (variant).

The truck may be operated only with sulphur-free diesel fuels as defined by the followingstandards:• EN 590• ASTM D 975 Grade 2-D S15

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Operation 4Refuelling

• ASTM D 975 Grade 1-D S15• or non-road fuels (light fuel oils) in line withthe EN 590 standard

If these fuel types are not used, compliancewith the specified emission values and the ser-vice life of the engine cannot be guaranteed.

Minimum requirements for fuels in countriesin which none of the approved diesel fuels areavailable can be requested from the autho-rised service centre. The operating companyis obligated to check the permissibility of thefuel used in accordance with national regula-tions.

The following are not permitted:• Admixtures of petroleum, kerosene oradditional fluidity additives

• Distillate fuels for marine engines• Jet fuels• Biodiesel fuels• US fuels in line with the ASTM D 9751-D S500 or ASTM D 975 2-D S500 stan-dards

– If necessary, query with the authorisedservice centre.

Ensure compliance with parameters includingthe following limit values in accordance withEN 590:Parameter Unit ValueCetanenumber1) - Min. 51

Density at15 C

kg/m3 820 - 845

Sulphurcontent

mg/kg Max. 101) The use of diesel fuels with a lower cetanenumber can lead to the formation of whitesmoke and misfiring. In winter, the use ofdiesel fuels with a higher cetane number isrecommended.

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Sulphur content in the diesel fuel

CAUTIONInsufficient lubrication can lead to engine damage!– Use only sulphur-free diesel fuels in accordance

with manufacturer specifications.

Insufficient lubricating properties in dieselfuels with a sulphur content of > 500 mg/kgcan lead to serious problems due to wear,especially in common-rail injection systems.In sulphur-free diesel fuels in accordancewith EN 590 and ASTM D 975, sufficientlubrication properties are ensured by using thecorresponding fuel additives during refining.

Fuels with a sulphur content of > 0.5% (m/m)require a shortened change interval for thelubricating oil and must not be used in engineswith a particle filter system. Fuels with asulphur content of > 1.0% (m/m) are alsonot permissible due to high corrosion and asignificant lifetime reduction of the engine.

Winter operation with diesel fuel

CAUTIONAdding petrol can lead to malfunctions in the fuelinjection system!– Do not add petrol.– Do not add petroleum, kerosene or additional

fluidity additives.– If necessary, query with the authorised service

centre.

During winter operation, special demands areplaced on the low-temperature performanceoffuels. Generally, diesel fuels that can be usedat temperatures down to -44Care available onthe free market. Therefore, it is not necessaryto add additives to improve the fluidity. Addingpetrol can lead to the formation of vapourpockets (cavitation) in the fuel system. Theformation of these vapour pockets disruptsthe function of the fuel injection system and, ifcontinued over a long period of time, can leadto component damage.

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Non-road fuels

NOTE

In some European countries, non-road fuelsare defined with the same characteristicsas light fuel oil. The permissibility of fuels ishandled differently in individual countries.Light fuel oils and non-road fuels are suitablefor the engine as long as compliance with thelimit values of EN 590 is ensured.• Use only sulphur-free diesel fuels in accor-dance with manufacturer specifications.

• The operating company is obligated tocheck the permissibility of the fuel usedin accordance with national regulations.

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Topping up the diesel fuel

CAUTIONIf the diesel fuel tank has been run empty, the fuelinjection system can draw in air bubbles. This canlead to malfunctions in the fuel injection system.– Never run the diesel fuel tank empty.

The fuel reserve is shown by the fuel levelindicator (1) flashing on the display screen ofthe display operating unit.

DANGERThere is a risk of fire when filling upwith diesel fuel.– Turn off the engine before filling up.– When refuelling, smoking or the

use of an open flame is strictlyforbidden!

– Legal regulations relating to thehandling of diesel fuel must beobserved.

– Note safety regulations for workingwith diesel fuel, see⇒Chapter "Die-sel fuel", P. 2-48.

CAUTIONThe truck may only be operated with diesel fuelaccording to DIN EN 590, otherwise there is a riskof engine damage.– Use of fuel additives supporting soot burn-off is

not permitted.– Starting aids (such as "Startpilot" among others)

must not be used.– At low temperatures, winter diesel must be

used, see ⇒ Chapter "Diesel fuel - Specificati-ons", P. 4-276.

– Open the locking cap (2) on the fuel tank.

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7312_003-001_V2

2– Top up with clean diesel fuel; for the maxi-mum filling quantity, see ⇒ Chapter "Main-tenance data table", P. 5-322.

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4 OperationCleaning

CleaningCleaning the truck

WARNINGRisk of injury from falling off the truck!When climbing onto the truck, thereis a risk of getting stuck or slippingand falling. Use suitable equipment toreach higher points on the truck.– For climbing onto the truck, use

only the steps provided for thispurpose.

– For reaching inaccessible places,use devices such as stepladders orplatforms.

WARNINGRisk of fire due to flammable cleaningmaterials!Flammable cleaning materials can beignited by hot components.– Do not use any flammable cleaning

materials.

CAUTIONRisk of fire due to flammable materi-als!Deposits and solids can be ignited byhot components, e.g. drive units.– Remove deposits and solids.

CAUTIONIf water penetrates the electrical system, there is arisk of short circuit!The engine must be switched off during washing.Do not use water to clean the area around thecentral electrical system; instead, only clean with adry cloth or clean compressed air.– Adhere strictly to the following steps.

CAUTIONExcessive water pressure or water and steam thatare too hot can damage truck components.– Adhere strictly to the following steps.

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Operation 4Cleaning

CAUTIONAbrasive cleaning materials can damage the surfa-ces of components!Using abrasive cleaning materials that are unsuita-ble for plastics can cause plastic parts to dissolveor become brittle. The screen on the display-opera-ting unit could become cloudy.– Adhere strictly to the following steps.

– Park the truck securely.


– Do not spray electric motors and otherelectrical components or their coversdirectly with water.

– Use only high-pressure cleaners with amaximum output power of up to 50 bar and85°C.

– If a high-pressure cleaner is used, maintaina distance of at least 20 cm between thenozzle and the object being cleaned.

– Do not aim the cleaning jet directly atadhesive labels or decal information.

– Remove all deposits and accumulationsof foreign materials in the vicinity of hotcomponents.

– Use only non-flammable fluids for cleaning.

– Observe the manufacturer's guidelines forworking with cleaning materials.

– Clean plastics only with cleaning materialsintended for plastics.

– Observe the manufacturer's guidelines forworking with cleaning materials.

– Clean the truck exterior using water-solublecleaning materials and water. Cleaningwith a water jet, a sponge or a cloth isrecommended.

– Clean all accessible areas.

– Before lubrication, clean the oil fillingopenings and the area around the oil fillingopenings, as well as the lubricating nipples.

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4 OperationCleaning

7071_003-091

Cleaning the electrical system

CAUTIONCleaning electrical system partswith water can damage the electricalsystem.– Cleaning electrical system parts

with water is forbidden!– Use dry cleaning materials in ac-

cordance with the manufacturer'sspecifications.

– Do not remove covers etc.

– Clean the electrical system parts with ametal-free brush and blow the dust off withlow-pressure compressed air.

6210_810-004

Cleaning load chains

WARNINGRisk of accident!Load chains are safety elements.The use of cold/chemical cleaners or fluids that arecorrosive or contain acid or chlorine can damagethe chains and is forbidden!– Observe the manufacturer's guidelines for

working with cleaning materials.

– Place a collection vessel under the lift mast.

– Clean with paraffin derivatives, such asbenzine.

– When using a steam jet, do not use addi-tional cleaning agents.

– Remove any water in the chain links usingcompressed air immediately after cleaning.Move the chain several times during thisprocedure.

– Immediately after drying the chain, spray itwith chain spray. Move the chain severaltimes during this procedure.

For chain spray specifications, see the "Main-tenance data table" chapter.

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Operation 4Cleaning

ENVIRONMENT NOTE

Dispose of any fluid that has been spilledor collected in the collection vessel in anenvironmentally friendly manner. Follow thestatutory regulations.

Cleaning the windowsAny panes of glass, e.g. cab windows (vari-ant), must always be kept clean and free of ice.This is the only means of guaranteeing goodvisibility.

CAUTIONDo not damage the rear window heater (inside)!– Take great care when cleaning the rear window

and do not use any objects with sharp edges.

– Clean the windows using a commerciallyavailable glass cleaner.

7311_003-058

After washing– Carefully dry the truck (e.g. with com-pressed air).

– Sit on the driver's seat and start up the truckin accordance with regulations.

CAUTIONRisk of short circuit!– If any moisture has penetrated into the engine

despite the precautionary measures taken, thismust first be dried with compressed air.

– The truck must then be started up to preventpossible corrosion damage.

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4 OperationBehaviour in emergencies

Behaviour in emergencies

7312_003-183

F1F1 F2F2

1

1

1

Emergency shutdown

WARNINGNo electric braking assistance is available when theemergency off switch is actuated!Actuating the emergency off switch will de-energisethe drive unit. The truck will not be held on a slopeby the electric brake.– Use the emergency off switch only there is a risk

of fire or to carry out a functional test.– To brake, actuate the service brake.

WARNINGThere is no power steering when the emergency offswitch is actuated!The truck is equipped with a hydraulic power stee-ring system. When the emergency off switch isactuated, the hydraulic system is completely shutdown. Steering forces are increased by the remai-ning emergency steering function.– Use the emergency off switch only there is a risk

of fire or to carry out a functional test.– Steer with a higher level of force.

The emergency off switch (1) is used to cancelparticle filter regeneration (variant) when a firerisk is present. The emergency off switch mayalso be used to carry out a functional test.

NOTE

Only trucks with a particle filter system (va-riant) or a joystick 4Plus (variant) have anemergency off switch.

Actuating the emergency off switch in drivemode switches off the electric brake, thehydraulic system and the drive unit. This hasthe following effect:• No reduction in truck speed when theaccelerator pedal is released, accordingto the drive program selected. The truck willcoast

• The electric brake does not function duringthe first part of brake pedal travel. To brakethe truck using the mechanical brake, thebrake pedal must be pushed down further

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Operation 4Behaviour in emergencies

• The truck can only be held on a slope usingthemechanical brake, not the electric brake

• No power steering effect. Steering forcesare increased by the remaining emergencysteering function.

• No hydraulic functions are available

Use the emergency off switch if there is arisk of fire or to carry out a functional test

7312_003-183

F1F1 F2F2

1

1

1

– Press the emergency off switch (1).

The truck will roll to a stop in drive mode.

– Brake the truck to a standstill by actuatingthe brake pedal.

DANGERThere is a risk of fire!If particle filter regeneration was interrupted be-cause of a fire risk, take the truck out of operationuntil the defect is remedied.– Notify your authorised service centre.

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7090_001-005

Procedure if truck tips over

DANGERIf the truck tips over, the driver could fall out andslide under the truck with potentially fatal conse-quences. There is a risk to life.Failure to comply with the limits specified in theseoperating instructions, e.g. driving on unacceptablysteep gradients or failing to adjust speed whencornering, can cause the truck to tip over. If thetruck starts to tip over, do not leave the truck underany circumstances. This increases the danger ofbeing hit by the truck.– Do not release your seat belt.– Never jump off the truck.– You must adhere to the rules of behaviour if the

truck tips over.

Rules of behaviour if truck tips over:

– Hold onto the steering wheel with yourhands.

– Brace your feet in the footwell.

– Bend your upper body over the steeringwheel.

– Bend your body against the direction of thefall.

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6321_003-097_V3

1

Emergency hammerThe emergency hammer is used to rescue thedriver if he is shut inside the cab in a hazardoussituation, for example if the truck has toppledover and the cab door cannot be opened.

Single-pane safety glass can be struck rela-tively safely using the emergency hammer inorder for the driver to escape or be rescuedfrom the danger area.

Using the emergency hammer

WARNINGWhen glass is smashed there is a risk of injurycaused by glass splinters!When the cab glass is smashed, splinters of glasscan shoot into the face and cause damage to skinand eyes through cuts. When a pane of glass issmashed, the face should be turned away andcovered with the crook of the free arm.– Protect the face when smashing a pane of glass.

– Pull the emergency hammer out of itssupport mounting at the handle.

– Using one of the two metal tips on the headof the emergency hammer, hit the pane ofglass with force until it breaks.

Emergency loweringIf the hydraulic control system fails whilst aload is raised, emergency lowering can beperformed. An emergency lowering screw forthis purpose is located on the valve block.

DANGERThere is a risk of fatal injury fromfalling loads or parts of the truck beinglowered.– Do not walk beneath the raised

load.– Adhere to the following steps.

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WARNINGThe load is lowered!The lowering speed is regulated by unscrewing theemergency lowering screw.– Note the following list.

Remember the following:• Tightening torque:max. 2.5 Nm

• When unscrewed a little:The load lowers slowly

• When unscrewed a lot:The load lowers quickly

NOTE

The valve block is located under the bottomplate. A hexagon socket wrench (1) is moun-ted on the valve block support. The hexagonsocket wrench must remain in the truck at alltimes.

– Remove the bottom plate

7312_003-145

2 1

– Take the hexagon socket wrench (1) out ofthe support mounting.

– Using the hexagon socket wrench, turnthe emergency lowering screw (2) on thevalve block a maximum of 1.5 revolutions toloosen it.

– Screw the emergency lowering screw backin after the load is lowered.

– Return the hexagon socket wrench to thesupport mounting.

– Install the bottom plate.

DANGERIf the truck is operated with the hydraulic controllerblocked, there is an increased risk of accidents!– After the emergency lowering procedure, have

the malfunction rectified.– Notify the authorised service centre.

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3

6210_003-051_V3

Emergency operation of the electricparking brake

WARNINGThe truck can roll away when the parking brake isreleased!Emergency operation of the parking brake can beinitiated only when the fork is lowered and the truckis switched off.

In emergency operation or during transportwithout a battery, the electric parking brakecan be operatedmanually via the hand wheel.

– Lower the forks to the ground.


– Lift cover (3) and move it to the side.

6210_003-053_V2

4

– Remove hand wheel (4) and place upsidedown on the tappet.

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656210_003-052_V3

5551

4391

001

1.2.

– Place the hand wheel with the tappet lugs(5) on the tappet (6) and press down againstthe spring force.

NOTE

Do not rotate the hand wheel to the stop,because this will trigger the relubricationdevice.

– To apply the parking brake rotate the handwheel clockwise until the force neededincreases markedly and the truck is heldsecurely. The effort required is not great.

– To release the parking brake rotate thehand wheel anticlockwise a maximum of5 revolutions until the hand wheel can beturned easily.

After manual operation, the hand wheel is tobe returned to its latch position and the coverto its normal position.

Disconnecting the batteryThe negative battery terminal is fitted with aquickly removable battery-terminal clip so thatthe battery can be quickly disconnected in theevent of a dangerous situation (e.g. a burningcable or electrical malfunction).

– Open the bonnet; see ⇒ Chapter "Openingthe bonnet", P. 5-325.

– Remove the bottom plate; see ⇒ Chap-ter "Installing and removing the bottomplate", P. 5-327.

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7071_003-123

– Disconnect the negative terminal and putthe battery-terminal clip to one side.

– Disconnect the positive terminal and put thebattery-terminal clip to one side.

– Close the bonnet; see⇒ Chapter "Closingthe bonnet", P. 5-326.

7312_003-046

- +21

+-

Jump starting

DANGERRisk of explosion due to sparkdischarge!If the electrical system on the truck isswitched on, or a live cable touches ametal part of the truck, this can causea spark discharge. Any escaping gasmay explode as a result.– If the truck has not been used for

a long period of time and beforestarting work, ensure that theclosed room is well ventilatedbefore operating the truck.

– The metal parts of the truck mustnot touch the connecting terminals.

NOTE

A 12 V power source (e.g. second truck of thesame type) must be available.

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WARNINGRisk of short circuit if the jump leads are connectedor disconnected in the incorrect order!If the batteries' negative terminals are connected tothe negative cable, both bodies are also conducti-vely connected to one another. If the positive cabletouches one of the two bodies as further cables areconnected, a short circuit can occur.– Ensure that the correct order is followed when

connecting and disconnecting the jump leads.

– Remove the bottom plate; see ⇒ Chap-ter "Installing and removing the bottomplate", P. 5-327.

– Remove the terminal protective caps fromthe battery terminals.

– Allow the engine of the current-giving truckto run.

Connecting the jump leads:

– Connect the positive cable (2) to the positiveterminal on the discharged battery.

– Connect the positive cable to the positiveterminal on the current-giving battery.

– Connect the negative cable (1) to thenegative terminal on the current-givingbattery.

– Connect the negative cable to negativeterminal on the discharged battery.

CAUTIONThe vibrations produced when the engine is startedcan cause the jump leads to slip off. There is a riskof short circuit!– Before starting the engine, check that the jump

leads are connected securely.

– Start the engine, see ⇒ Chapter "Startingthe engine", P. 4-102.

Disconnecting the jump leads:

– Disconnect the negative cable (1) from thenegative terminal on the dischargedbattery.

– Disconnect the negative cable from thenegative terminal on the current-givingbattery.

– Disconnect the positive cable (2) from thepositive terminal on the discharged battery.

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– Disconnect the positive cable from thepositive terminal on the current-givingbattery.

NOTE

Leave the engine to run because the battery isnot yet sufficiently charged.

– Refit the terminal protective caps.

– Reattach the bottom plate.

6036Ba-0265060_003-070

Towing

DANGERRisk of accident due to failure of the brake systemof the towing vehicle!If the brake system of the towing vehicle is notadequately sized, the vehicle may not brake safelyor the brakes may fail. The towing vehicle must bedesigned such that it is able to absorb the pullingand braking forces from the unbraked towed load(the actual total weight of the truck).– Check the pulling and braking forces of the

towing vehicle.

DANGERIf the towing vehicle brakes, there is a risk that thetruck will drive into the towing vehicle!If a rigid connection has not been used for powertransmission in two directions during towing, thetruck may drive into the towing vehicle when thetowing vehicle brakes. Use a tested tow bar forsafety reasons.– Use a tested tow bar.

CAUTIONIf the truck drive between the drive motor andthe drive axle is not interrupted, the drive may bedamaged.– Place the drive direction switch in the neutral

position.

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DANGERWhile manoeuvring, there is a risk of fatal injury inthe area between the truck and the towing vehicle!Inform the driver of the towing vehicle and themechanic attaching the tow bar about the risks.When you fit the tow bar, always use a secondperson to guide the towing vehicle manoeuvres.– Manoeuvre with a second person as a guide.

CAUTIONSteering is stiff! There is no power steering if thehydraulics fail!– Select a slow towing speed to ensure that the

truck and the towing vehicle can be braked andcontrolled effectively at all times.

CAUTIONIf the truck is not steered while it is being towed, thetruck may veer out in an uncontrolled manner!– The truck being towedmust also be steered by a

driver.– The driver of the truck being towed must sit in

the driver's seat and fasten the seat belt beforetowing.

– Where possible, activate the restraint systemsprovided.

– Set down the load and lower the fork armsso that they are close to the ground.

– Set the drive direction switch to the neutralposition.



– Check the pulling and braking forces of thetowing vehicle.

– With a second person as a guide, manoeu-vre the towing vehicle to the truck.

– Secure the tow bar to the tow coupling onthe towing vehicle and on the truck.

– Sit in the driver's seat of the truck beingtowed and fasten the seat belt.

– Where possible, activate the restraintsystems provided.


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– Select a slow towing speed.

– Tow the truck.

– After towing, secure the truck so that itcannot roll away (e.g. by applying theparking brake or by using wedges).

– Remove the tow bar.

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4 OperationTransporting the truck

Transporting the truckTransport

CAUTIONRisk of material damage from overloading!If the truck is driven onto a means of transport, theload capacity of the means of transport, the rampsand the loading bridges must be greater than theactual total weight of the truck. Components canbe permanently deformed or damaged due tooverloading.– Determine the total actual weight of the truck.– Only load the truck if the load capacity of the

means of transport, the ramps and the loadingbridges is greater than the actual total weight ofthe truck.

NOTE

If it is not possible to actuate the electricparking brake electrically, use the emergencyoperation function of the electric parkingbrake.






maxmin.*


kg kg

kgkg

kgkW

V

*


1

Determining the total actual weight– Park the truck securely.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment nameplate (variant).

– Add the determined unit weights to obtainthe total actual weight of the truck:

Tare weight (1)


+ Net weight of attachment (variant)

+ 100-kg allowance for driver

= Actual total weight

298 174749 EN - 11/2018

Operation 4Transporting the truck

DANGERRisk of accident from the truck falling!Steeringmovements can cause the rear of the truckto veer off the loading bridge towards the edge.This may cause the truck to crash.– Before driving across a loading bridge, ensure

that the loading bridge is properly attached andsecured.

– Ensure that the transport vehicle onto which thetruck is to be driven has been sufficiently securedto prevent it from shifting.

– Maintain a safety distance from edges, loadingbridges, ramps, working platforms etc.

– Drive slowly and carefully onto the transportvehicle.

6210_001-012_V3

Setting chocks– Use two wedges to secure each of the frontand rear wheels against rolling away.

Lashing

CAUTIONHarnesses can rub against the seating and causedamage!– Place a slip-resistant material between the

harness and the seating, e.g. rubber mats orfoam.

174749 EN - 11/2018 299


6321_003-104

1

– Attach the harness (1) to each side of thetruck.

– Lash the truck towards the rear.

7312_003-035

2

1

– Attach the harness (1) to the coupling pin (2)or loop the harness around the coupling pin.

– Lash the truck at both sides.

DANGERThe truck may slip if the harnesses slip!The truck must be lashed securely to ensure that itdoes not move during transportation.– Ensure that the harnesses are tightened secu-

rely and that the pads cannot slip off.

Crane loadingCrane loading is only intended for transportingthe complete truck, including the lift mast,for its initial commissioning. For applicationconditions that require frequent loading orthat are not presented here, please contactthe manufacturer with regard to specialequipment variants.

Only those persons with sufficient experienceof suitable harnesses and hoists may loadtrucks.

300 174749 EN - 11/2018

Operation 4Transporting the truck






maxmin.*


kg kg

kgkg

kgkW

V

*


1

Determining the loading weight– Park the truck securely; see ⇒ Chap-ter "Parking the truck securely and switch-ing it off", P. 4-142.

– Determine the unit weights by reading themoff the truck nameplate and, if necessary,the attachment (variant) nameplate.

– Add the determined unit weights to obtainthe loading weight of the truck:

Tare weight (1)



= Loading weight.

3

7321_003-012Hooking on the lifting straps

CAUTIONHarnesses may damage the truck's paintwork!Harnesses can damage paintwork by chafingand pressing on the surface of the truck. Hard orsharp-edged harnesses, such as wires or chains,can quickly damage the surface.– Use textile harnesses, e.g. lifting straps, with

edge protectors or similar protective devices ifnecessary.

DANGERThere is a risk of being hit if the hoists and harnes-ses fail and cause the truck to fall. Danger to life!– Only use hoists and harnesses with adequate

load capacity for the determined loading weight.– Only use the truck's designated lifting points.– Make sure that harnesses such as hooks,

shackles, belts etc. are only used in the indicatedload direction.

– The harnesses must not be damaged by truckparts.

– Loop the lifting straps around the maintraverse (3) on the outer mast of the liftmast.

174749 EN - 11/2018 301


NOTE

The lifting points are indicated by a hooksymbol.

7314_003-025_V2

4

– Loop the lifting straps around the counter-weight (4), as indicated.

– Determine the truck's centre of gravity; see⇒ Chapter "Dimensions", P. 6-358.

7321_003-013

5 6– Adjust the length of the harnesses so thatthe lifting eye (6) is directly above the truck'scentre of gravity.

This ensures that the truck hangs level whenlifted.

– Connect the lifting straps to the lifting eyeand insert the safety device (5).

CAUTIONIncorrectly fitted harnesses may damage attach-ment parts!Pressure from the harnesses can damage ordestroy attachment parts when the truck is lifted.Takeparticular care to ensure that the fuel system isnot damagedor destroyed. In somecircumstances,diesel fuel may leak from the damaged fuel system.– Secure harnesses so that they are not touching

any attachment parts.– Use a bridge piece if necessary.

– Check that harnesses cannot collide withattachment parts.

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Operation 4Shutdown

7314_003-047

Always use a bridge piece to prevent collisionswith attachment parts that protrude beyondthe contours of the cab, e.g. air conditioning,rotating beacon etc.

CAUTIONIncorrectly fitted harnesses may damage attach-ment parts!Harnesses may be positioned near attachmentparts even if a bridge piece is used. Pressure fromthe harnesses can damage or destroy attachmentparts when the truck is lifted.– Secure harnesses so that they are not touching

any attachment parts.

Loading the truck

DANGERIf the raised truck swings in anuncontrolled fashion, it may crushpeople. There is a risk to life!– Never walk or stand underneath

suspended loads.– Do not allow the truck to bump into

anything whilst it is being lifted, orallow it to move in an uncontrolledway.

– If necessary, hold the truck usingguide ropes.

– Carefully lift the truck and set it down at theintended location.

ShutdownShutting down and storing the truck

CAUTIONComponent damage due to incorrect storage!If the truck is stored or shut down incorrectly formore than two months, it may suffer corrosion da-mage. If the truck is parked in an ambient tempera-ture of less than –10°C for an extended period, thebattery will cool down. The electrolyte may freezeand damage the battery.– Carry out the following measures before shut-

down.

174749 EN - 11/2018 303

4 OperationShutdown

CAUTIONDanger of tyre deformation by continuously loadingon one side!Have the truck raised and jacked up by the authori-sed service centre so that all the wheels are clear ofthe ground. This prevents permanent deformationof the tyres.

CAUTIONDanger of damage from corrosion due to conden-sation on the truck!Many plastic films and synthetic materials arewatertight. Condensation water on the truck cannotescape through these covers.– Do not use plastic film as this encourages the

formation of condensation water.

NOTE

Store only fully charged batteries.

Measures before shutdown– Store the truck in a dry, clean, frost-free andwell ventilated environment.

– Clean the truck thoroughly; see the chapterentitled "Cleaning".

– Lift fork carriage to full extent several times.

– Tilt the lift mast forwards and backwardsseveral times and, if fitted,moveattachmentrepeatedly.

– To relieve the strain on the load chains,lower the fork onto a suitable supportingsurface, e.g. a pallet.

– Check the hydraulic oil level and top up ifrequired.

– Apply oil or grease thinly to all uninsulatedmoving parts.

– Lubricate the forklift truck.

– Lubricate the joints and controls.

– Fill the fuel tank.

– Remove the battery and store in awarm anddry location.

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Operation 4Shutdown

– Regularly check the charge state of thebattery and recharge if necessary.

– Apply a suitable contact spray to all exposedelectrical contacts.

– Preserve the engine as specified by themanufacturer.

– Cover the truck with vapour permeablematerials, such as cotton, in order to protectagainst dust.

– If the truck is to be shut down for evenlonger periods, contact your authorisedservice centre to find out about additionalmeasures.

Recommissioning after decommis-sioningIf the truck has been decommissioned forlonger than six months, the truck must becarefully checked before being recommis-sioned. As with the yearly safety inspection,this check must also include all safety-relatedaspects of the truck.

– Thoroughly clean the truck.

– Oil joints and controls.

– Lubricate the lubrication points.

– Check the condition and the acid density ofthe battery. Charge the battery if necessary.

– Restore engine to normal condition accord-ing to regulations of engine manufacturer.

– Check the engine oil for condensation waterand replace the oil if necessary.

– Check hydraulic oil for condensation water;change if necessary.

– Have the same checks and tasks carried outby the authorised service centre that werecarried out before initial commissioning.

– Carry out the checks and tasks that are tobe performed before daily use.

– Recommission the truck.

174749 EN - 11/2018 305

4 OperationShutdown

During recommissioning, the following pointsin particular must be checked:• Drive, control, steering• Brake system (service brake, parkingbrake, regenerative brake)

• Lifting system (load-carrying equipment,load chains, mounting)

NOTE

For further information, see the workshop ma-nual for the truck and contact the authorisedservice centre.

306 174749 EN - 11/2018

5

Maintenance

5 MaintenanceSafety instructions for maintenance

Safety instructions for maintenanceGeneral information

DANGERRisk of fatal poisoning!It is dangerous to leave the engine running inenclosed spaces. The engine consumes oxygenand emits carbon dioxide, carbon monoxide andother poisonous gases. There is a risk of fatalpoisoning!– Only operate the truck in areas that are well

ventilated.

To prevent accidents during maintenancework and repair work, all necessary safetymeasures must be taken, e.g.:


– Switch off the key switch and remove thekey.

– Ensure that the truck cannot move uninten-tionally or start up inadvertently.

– If required, have the truck jacked up by theauthorised service centre.

– Have the raised fork carriage or the ex-tended lift mast secured against accidentallowering by the authorised service centre.

– Insert an appropriately sized wooden beamas an abutment between the lift mast andthe cab, and secure the lift mast to preventit tilting backwards unintentionally.

– Observe the maximum lift height of the liftmast, and compare the dimensions fromthe technical data with the dimensions ofthe hall into which the truck is to be driven.These steps are taken to prevent a collisionwith the ceiling of the hall and to avoid anydamage caused as a result.

Working on the hydraulic equipmentThe hydraulic systemmust be depressurisedprior to all work on the system.

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Maintenance 5Safety instructions for maintenance

Working on the electrical equipmentWork may only be performed on the electricalequipment of the truck when it is in a voltage-free state. Function checks, inspectionsand adjustments on energised parts mustonly be performed by trained and authorisedpersons, taking the necessary precautionsinto account. Rings, metal bracelets etc.must be removed before working on electriccomponents.

To prevent damage to electronic systemswith electronic components, such as anelectronic driving regulator or lift control, thesecomponents must be removed from the truckprior to the start of electric welding.

Work on the electrical system (e.g. connectinga radio, additional headlights etc.) is onlypermitted with approval from the authorisedservice centre.

Working on the ignition systemTo prevent personal injury and/or destructionof the ignition system, please observe thefollowing:• Only connect and disconnect ignitionsystem lines, including high-voltage linesandmeasuring device lines, with the ignitionswitched off.

• If the engine is to be operated at startingspeed but not actually started (e.g. for acompression pressure test), disconnect theconnection assembly from the ignition coil.

• Use of a quick charger to jump start theengine is only permitted for a period of up to1 minute at max. 16.5 volts.

• The engine may only be washed when theignition is switched off.

• When performing electric or point welding,completely disconnect the battery.

• Trucks that have a fault in the ignitionsystem, or a suspected fault, may only betowed if the plug is disconnected from theignition coil.

174749 EN - 11/2018 309

5 MaintenanceSafety instructions for maintenance

Safety devicesAfter maintenance and repair work, all safetydevices must be reinstalled and tested foroperational reliability.

Set valuesThe device-dependent set values must beobserved when making repairs and whenchanging hydraulic and electrical compo-nents. These are listed in the appropriatesections.

Lifting and jacking up

DANGERThere is a risk to life if the truck tips over!If not raised and jacked up properly, the truck maytip over and fall off. Only the hoists specified in theworkshop manual for this truck are allowed and aretested for the necessary safety and load capacity.– Only have the truck raised and jacked up by the

authorised service centre.– Only jack the truck up at the points specified in

the workshop manual.

The truck must be raised and jacked up forvarious types of maintenance work. Theauthorised service centre must be informedthat this is to take place. Safe handling ofthe truck and the corresponding hoists isdescribed in the truck's workshop manual.

Working at the front of the truck

DANGERRisk of accident!If the lift mast or fork carriage is raised, no workmay be performed on the lift mast or at the front ofthe truck unless the following safety measures areobserved.– When securing, only use chains with sufficient

load-bearing capacity.– Contact the authorised service centre.

310 174749 EN - 11/2018

Maintenance 5Safety instructions for maintenance

CAUTIONPossibility of damage to the ceiling!– Note the maximum lift height of the lift mast.

Securing the lift mast against tiltingbackwardsA hardwood beam with a cross-section of120 x 120 mm is required. The length ofthe hardwood beam must approximatelycorrespond to the width of the fork carriage(b3). To avoid impact injuries, the hardwoodbeam must not protrude beyond the outercontour of the truck. A maximum lengthmatching the total width (b1) of the truck isrecommended.

– Obtain the dimensions (b1) and (b3) fromthe corresponding VDI datasheet.

1 2

3

6210_001-030_V3

– Clamp the hardwood beam (1) between thedriver protection structure (2) and the liftmast (3).

Removing the lift mast

DANGERRisk of accident!This work must only be performed by an authorisedservice technician.– Arrange for an authorised service technician to

remove the lift mast.

Securing the lift mast against falling off

DANGERRisk of accident!This work must only be performed by an authorisedservice technician.– Arrange for an authorised service technician to

secure the lift mast.

174749 EN - 11/2018 311

5 MaintenanceGeneral maintenance information

General maintenance informationPersonnel qualificationsOnly qualified and authorised personnel areallowed to perform maintenance work. Reg-ular safety checks and checks after unusualincidents must be performed by a competentperson. The competent person must conducttheir evaluation and assessment from a safetystandpoint, unaffected by operational andeconomic conditions. The competent personmust have sufficient knowledge and experi-ence to be able to assess the condition of atruck and the effectiveness of the protectivedevices in accordance with technical conven-tions and the principles for testing trucks.

Maintenance work without specialqualificationsSimple maintenance work, such as checkingthe hydraulic oil level, may be carried out byuntrained personnel. A qualification suchas those held by a competent person is notrequired to carry out this work. The requiredtasks are described in the chapter entitled"Remaining ready for operation".

Information for carrying out mainte-nanceThis section contains all information requiredto determine when the truck needs mainte-nance. Carry out maintenance work within thetime limits according to the hour meter andusing the following maintenance check lists.This is the only way to ensure that the truckremains ready for operation and provides op-timal performance and service life. It is also aprecondition for any warranty claims.

312 174749 EN - 11/2018

Maintenance 5General maintenance information

7312_003-156_V2

1Maintenance timeframe– Carry out maintenance work on the truck inaccordance with the "Service in" display (1).

– The maintenance check lists indicate themaintenance work that is due.

The intervals are defined for standard use.Shorter maintenance intervals can be definedin consultation with the operating company,depending on the application conditions of thetruck.

The following factors may necessitate shortermaintenance intervals:• Contaminated, poor quality roads• Dusty or salty air• High levels of air humidity• Extremely high or low ambient tempera-tures, or extreme changes in temperature

• Multi-shift operation with a high duty cycle• Specific national regulations for the truck orindividual components

CAUTIONRisk of component damage!Any deviating technical information in these opera-ting instructions takes precedence over the infor-mation in the original engine operating instructions.– If you have any questions, please contact your


174749 EN - 11/2018 313


314 174749 EN - 11/2018


Maintenance - 1000 hours/annuallyAt operating hours

1000 2000 4000 5000 7000 Carried out8000 10000 11000 13000 14000

Chassis, bodywork and fittings

Check chassis for cracks

Check overhead guard/cab and panes of glass for damage

Check controls, switches and joints for damage, and apply grease and oil

Check driver's seat for correct function and for damage

Check driver restraint system for correct function and for damage, and clean

Check the signal horn

Variant: Check the dual pedal for damage and correct function, and lubricate

Tyres and wheels

Check the tyres for wear and check the air pressure if necessary

Check wheels for damage and check the tightening torques

Power unit

Drive axle: Check the screw joints, check for leaks and clean the cooling fins

Check the oil level in the drive wheel unit and the multi-disc brake

Internal combustion engine

Check the condition of the internal combustion engine (visual inspection)

Change engine oil and oil filter

Check toothed belt, spur gears and V-belt

Replace the air filter (main cartridge)

Check the cooling system for leaks and correct function

Check coolant and top up if necessary

Check the exhaust system

LPG: Replace the spark plugsVariant: Maintain the particle filter; observe themanufacturer's maintenance instruc-tionsFuel system

Check the fuel system for leaks and correct function

Replace the fuel filter (yearly)

LPG system

174749 EN - 11/2018 315


At operating hours

1000 2000 4000 5000 7000 Carried out8000 10000 11000 13000 14000

Check the LPG system for damageCheck the solenoid shut-off valve, and if necessary check the high-pressure reliefvalve (1.7 bar)Check the gas cylinder valve for cleanliness and correct function, check the over-pressure safety device (30 bar)Change the LPG filter

Overhaul the evaporator (MD/Cobra) Replace the sticker

Check the screw joints for secure attachment and perform a leak test

Check the CO content in the exhaust gas

Check that the duration of engine run-on before the engine stops is acceptable

Steering

Check the steering system for correct function and for leaksCheck that the steering wheel is securely attached and check the turning handle fordamageSteering axle: Check that the steering axle is securely attached, check for leaks andapply greaseCheck the steering stop

Brake

Check the condition of all mechanical brake parts and check for correct function

Check the function of the service brake

Check the function of the parking brake

Electrical system

Check all power cable connections

Check the switches, transmitters and sensors for correct function

Check the lighting and indicator lights

Starter battery

Measure the cold-start current; recharge or replace the battery if necessary

Hydraulics

Check the condition of the hydraulic system, and check for correct function and leaks

Check the hydraulics blocking function (ISO valve)

Check the oil level

Lift mast

316 174749 EN - 11/2018


At operating hours

1000 2000 4000 5000 7000 Carried out8000 10000 11000 13000 14000

Check themast bearings for damage and lubricate themast bearings, and check thetightening torqueCheck the mast profiles for damage and wear, and lubricate the mast profiles

Check the load chains for damage andwear, and adjust and lubricate the load chains

Check the lift cylinder and connections for damage and leaks

Check the guide pulleys for damage and wear

Check the support rollers and chain rollers for damage and wear

Check the play between the fork carriage stop and the run-out barrier

Check the tilt cylinder and connections for damage and leaks

Check the fork carriage for damage and wear

Check the fork arm interlock for damage and correct function

Check the fork arms for wear and deformation

Check that there is a safety screw on the fork carriage or on the attachment

Special equipment variant

Check the fresh-air filter in the heating system and beat out the filter if necessaryCheck the heating system for damage; observe the manufacturer's maintenanceinstructionsCheck the attachments for wear and damage; observe the manufacturer's mainten-ance instructionsCheck the trailer coupling for wear and damage; observe the manufacturer's mai-ntenance instructionsGeneral

Read out error numbers and delete the list

Reset the maintenance interval

Check labelling to ensure it is complete

Perform a test drive

174749 EN - 11/2018 317


318 174749 EN - 11/2018


Maintenance— 3000 hours/every two yearsAt operating hours Carried out

3000 6000 9000 12000 15000

Note

Perform all 1000-hour maintenance work.

Power unit

Check the gearbox oil and multi-disc brake and change the gearbox oil

Replace the bleeder screws on the drive wheel units

Internal combustion engine

Replace toothed belt, spur gears and V-belt

Replace water pump, (recommendation, consult operating company)

Replace the safety cartridge in the air filter

Change the coolant (VW: every 9000 hours or every 5 years)

LPG system

Change all the hoses on the LPG system

Hydraulics

Change the hydraulic oil

Replace the return line filter and the breather filter

Variant: Replace the high-pressure filter

Ordering spare parts and wearingpartsSpare parts are provided by our spare partsservice department. The information requiredfor ordering parts can be found in the spareparts list.

Only use spare parts as per the manufac-turer's instructions. The use of unapprovedspare parts can result in an increased risk ofaccidents due to insufficient quality or incor-rect assignment. Anyone using unapprovedspare parts shall assume unlimited liability inthe event of damage or harm.

174749 EN - 11/2018 319


Quality and quantity of the requiredoperating materialsOnly the operating materials specified in themaintenance data table may be used.

– The required consumables and lubricantscan be found in themaintenance data table.

Oil and grease types of a different qualitymust not be mixed. This negatively affectsthe lubricity. If a change between differentmanufacturers cannot be avoided, drain theold oil thoroughly.

Before carrying out lubricating work, filterchanges or any work on the hydraulic system,carefully clean the area around the partinvolved.

When topping up working materials, use onlyclean containers!

320 174749 EN - 11/2018


Lubrication plan

Code1 Lubrication point

(A) Four lubricating nipples on each side of the steering axle for the axle stub bearing andtrack rod bearings

(B) Sliding surfaces on the lift mast

(C) Load chains

(D) One lubricating nipple on each of the two lift mast bearings1See the following chapter, "Maintenance data table", under this Code.for the respective lubricant specificationThis lubrication plan describes the series-productiontruck with standard equipment. For maintenance points on variant trucks, see the relevant chap-ter and/or instructions provided by the manufacturer.

.

174749 EN - 11/2018 321


Maintenance data table

General lubrication points

Code Unit Operating material Specification QuantityLubrication High-pressure

greaseID no. 0147873 As required

Controls/joints

Code Unit Operating material Specification QuantityHigh-pressuregrease

ID no. 0147873 As requiredLubrication

Oil SAE 80MIL-L2105API GL-4

As required

Dual-pedaloperation

High-pressuregrease

ID no. 0147873 As required

Battery

Code Unit Operating material Specification QuantitySystem contents Distilled water As required

Insulation resistance For further information, refer to the work-shop manual for the truck in question.

Electrical system

Code Unit Operating material Specification QuantityInsulation resistance For further information, refer to the work-

shop manual for the truck in question.

Hydraulic system

Code Unit Operating material Specification QuantityHydraulic oil HVLP 68

DIN 51524, part 3System contents

Hydraulic oil forthe food industry(variant)

USDA H1DIN 51524

Max. 30 l

322 174749 EN - 11/2018


Tyres

Code Unit Operating material Specification QuantitySuperelastic tyres Wear limit To wear mark

Solid rubber tyres Wear limit To wear mark

Minimum tread depth 1.6 mmPneumatic tyres

Air pressure See informationon truck

Steering axle

Code Unit Operating material Specification QuantityWheel nuts/screws Torque wrench For further

information, referto the workshopmanual for the truckin question.

Axle stub nuts Torque wrench For furtherinformation, referto the workshopmanual for the truckin question.

(A) Axle stub bearings,track rod bearings

Grease Aralub 4320DIN 51825-KPF2N20ID no. 0148659

Fill with grease until asmall amount of fresh

grease escapes

Drive axleCode Unit Operating material Specification Quantity

Wheel nuts/screws Torque wrench For furtherinformation, referto the workshopmanual for the truckin question.

Wheel gear Mineral oil FUCHS TITANGEAR HYP LDSAE 80W-90API GL-5

Brake Mineral oil ARAL HGS FLUID127830

Lift mastCode Unit Operating material Specification Quantity(B) Lubrication High-pressure

greaseID no. 0147873 As required

Stop Play Min. 2 mm

174749 EN - 11/2018 323


Code Unit Operating material Specification QuantityScrews for the liftmast bearing

Torque wrench For furtherinformation, referto the workshopmanual for the truckin question.

(D) Lift mast bearing Grease Aralub 4320DIN 51825-KPF2N20ID no. 0148659

Fill with grease until asmall amount of fresh

grease escapes

Load chainsCode Unit Operating material Specification Quantity(C) Lubrication High-load chain

sprayFully syntheticTemperature range:-35°C to +250°CID no. 0156428

As required

Cooling system

Code Unit Operating material Specification QuantitySystem contents Corrosion inhibitor

and coolingsystem protectingagent/water

G12 plusTL-VW 774 F

Approx. 9 l

Fuel tankCode Unit Operating material Specification Quantity

System contents Diesel fuel EN 590, DIN 51628,ASTM D975,NATO F-54 non-roadfuels (light fuel oils,EN 590 quality)

Approx. 58 l

Engine

Code Unit Operating material Specification QuantitySystem contents Engine oil VW 507.00 4.5 l, with filter

changeAir filter Filter insert

Washer system

Code Unit Operating material Specification QuantitySystem contents Washer fluid Winter, ID

no. 172566As required

.

324 174749 EN - 11/2018

Maintenance 5Providing access to maintenance points

Providing access to maintenance points

7311_120-001

1

2

Opening the bonnet

WARNINGRisk of injury!– Switch off the engine before opening the bonnet!

CAUTIONWhen opening the bonnet, the driver's seat maybe damaged if it is not moved as far forwards aspossible.– Slide the driver's seat all the way forwards.

– Move the steering column (1) as far for-wards as possible and secure; see ⇒ Chap-ter "Adjusting the steering column", P. 4-78.

– Slide the driver's seat (2) all the way for-wards; see ⇒ Chapter "Adjusting theMSG 65/MSG 75 driver's seat", P. 4-73.

– For trucks with a rear window (variant), foldthe seat backrest forwards; see ⇒ Chap-ter "Adjusting the MSG 65/MSG 75 driver'sseat", P. 4-73. Remove all protruding ob-jects from the shelf.

7300_003-007_V2

4

– Firmly insert a narrow screwdriver intothe slot (4) of the bonnet release until theinterlock opens. In an emergency, theignition and stop key can also be used forthis purpose.

– Use the handle to open the bonnet.

174749 EN - 11/2018 325

5 MaintenanceProviding access to maintenance points

7300_003-008

2

1

Closing the bonnet

WARNINGWhen closing the bonnet, there is a risk of crushing!When closing the bonnet, nothing must comebetween the bonnet and the edge of the chassis.– Do not grasp any edges. Always close the

bonnet by placing both hands on the handles.

CAUTIONRisk of damage!The bonnet can be equipped with a gas spring (2)with a position lock (variant). This prevents thegas spring from being compressed. Exerting forcewhen closing the bonnet will damage the gas springor bonnet suspension.– Before closing the bonnet, check whether the

gas spring is equipped with a position lock(variant).

– If the gas spring is equipped with a position lock(variant), release the latch (1) before closing thebonnet.

7300_003-008

2

1

Releasing the position lock (variant)

– Press the latch (1) at the PRESS mark andlower the bonnet slightly.

– Release the latch.

Closing the bonnet

– Holding it by the handle, pull down thebonnet until the lock audibly engages.

326 174749 EN - 11/2018

Maintenance 5Providing access to maintenance points

7311_120-001

1

2

– Adjust the seat (2); see the section on"Adjusting the MSG 65/MSG 75 driver'sseat".

– Adjust the steering column (1); see thesection on "Adjusting the steering column".

Installing and removing the bottomplate

Removing the bottom plate

CAUTIONRisk of short circuit if cables are damaged!– Check the connection cables for damage.– When removing and reinstalling the bottom

plate, make sure that the connecting cablesare not damaged.

NOTE

The bottom plate has a recess into which theoperator can insert their fingers in order to liftit. The recess is beneath the rubber mat.

NOTE

The accelerator pedal is attached to thebottom plate and is removed with the bottomplate. The connecting plug for the acceleratoris located underneath the bottom plate.

– Open the bonnet.

– Remove the rubber mat.

– Grasp the recess in the bottom plate (1).

– Raise the bottom plate slightly.

174749 EN - 11/2018 327

5 MaintenanceProviding access to maintenance points

7311_003-013

1– Pull out the bottom plate under the brakepedal and set it down upright.

7311_003-014

2

– Disconnect the plug connection from theaccelerator pedal (2).

– Remove the floor plate and place it in asecure location.

Installing the bottom plate

WARNINGRisk of crushing between the bottom plate and theframe edge!If limbs or objects are between the bottom plate andframe edge when the bottom plate is closed, theycan be crushed.– Make sure that, when you close the bottomplate,

there is nothing between the bottom plate andthe frame edge.

– Set down the bottom plate upright in thefootwell.

– Connect the connection assembly to theaccelerator pedal.

– Position the bottom plate at the front.

– Carefully guide the bottom plate down andclose.

– Insert the rubber mat.

– Close the bonnet.

328 174749 EN - 11/2018

Maintenance 5Maintenance after first 50 operating hours

Maintenance after first 50 operating hoursMaintenance during the break-inperiod

7311_003-026

1

– Check the condition and tension of theV-ribbed belt (1).

NOTE

If the V-ribbed belt is damaged, have it repla-ced by the authorised service centre.

Remaining ready for operationChecking the engine oil level

NOTE

The truck should be parked on as level groundas is possible while this check is carried out.

– Make sure that the truck is level, or park itsecurely on level ground as necessary.

– After switching off the engine, wait for a fewminutes to allow the engine oil distributed inthe engine to run back to the lowest area ofthe engine.


174749 EN - 11/2018 329

5 MaintenanceRemaining ready for operation

7094_121-001

1 2

2

– Pull out the oil dipstick (1) and wipe thedipstick off with a cloth.

– Insert the oil dipstick so that the insertionmarkings are aligned (2).

– Insert the oil dipstick as far as it will go andpull it out again.

The oil level must be between the marks(arrows).

CAUTIONRisk of engine damage!Insufficient engine lubrication can cause enginedamage. An insufficient oil level or theuseof engineoil with different specifications can lead to the failureof engine lubrication, i.e. not all parts of the enginewill be lubricated.– Only use engine oil in line with the maintenance

data table.

– If the oil level is at or below the lowermark, top up the engine oil via the oil fillingopening.

– If the oil level is above the mark, pleasecontact your authorised service centre.


ENVIRONMENT NOTE

Carefully collect any spilled oil and dispose ofit in an environmentally friendly manner.

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Maintenance 5Remaining ready for operation

7312_003-080

1

Checking the cooling fluid levelThe cooling fluid level is monitored by asensor.

As soon as the message COOLANT LE-VEL appears on the display, proceed as fol-lows.

WARNINGRisk of scalding due to hot cooling fluid!The cooling system is pressurised! Opening thecooling fluid tank may result in hot cooling fluidleaking out. Only open the cooling fluid tank whenthe cooling system is cool.– Switch off the engine and let it cool down.– Do not open the cooling fluid tank until the truck

has cooled down.

WARNINGCoolant and cooling fluid can pose a hazard tohealth and the environment!– Observe the safety regulations set out in the

chapter entitled "Coolant and cooling fluid".

– Check coolant level.

The level must be visible in the middle of thecoolant reservoir (1).

– Topup the cooling fluid if necessary; see thesection entitled "Topping up the cooling fluidand checking the coolant concentration".

CAUTIONRisk of engine damage!If the coolant level is low, this indicates a leak in thecooling system.

– Check the cooling system for leaks; seethe section entitled "Cleaning the radiator,checking for leaks".

174749 EN - 11/2018 331


1

7314_003-005

Cleaning the radiator, checking forleaks– Park the truck securely.


– Clean the radiator (1).

– Clean the radiator fins using a suitablebrush and blow them out using compressedair (max. 2 bar).

– Check the radiator and coolant hoses forleaks and tighten the clips if necessary.

CAUTIONRisk of engine damage!If the cooling fluid level is low, this indicates a leakin the cooling system.– Checkwhether the leakage has been eliminated.– If not, notify the authorised service centre.


Topping up the cooling fluid andchecking the coolant concentration

CAUTIONRisk of engine damage!If the cooling fluid level is low, this indicates a leakin the cooling system.– Check the cooling system for leaks; see the

chapter entitled "Cleaning the radiator".

WARNINGRisk of scalding!Cooling fluid is very hot. There is a risk of scalding.– Open the filler cap (1) on the cooling fluid

reservoir only when the engine is cool.

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7312_003-080

1

– Slowly open the filler cap (1) and releaseover pressure.

– Remove the filler cap.

WARNINGCooling fluids and coolants are hazardous to yourhealth.– Observe the safety regulations for handling the

cooling fluid; see the section entitled "Coolingfluid".

– Check the concentration of the coolant.

Concentration of the coolant

CAUTIONRisk of corrosion!The percentage of coolant must always be atleast 40%, even if frost protection is not neededin warmer climates.If greater frost protection is required for climatic rea-sons, the percentage of coolant can be increasedto up to 60%.The percentage of coolant must not exceed 60%,otherwise the frost protection is reduced. In addi-tion, the cooling effect is also reduced.Only use clean, softened water for the water per-centage.

Frost protectionup to °C

Water percentage%

Coolant percentage%

-25 60 40

-30 55 45

-35 50 50

-40 40 60

For details of the filling quantity in the coolingsystem, see the section entitled "Maintenancedata table".

CAUTIONCoolant with a different specification must not bemixed in!– When topping up, use the coolant listed in the

maintenance data table.Only use coolant additive according to the manu-facturer's guidelines.

174749 EN - 11/2018 333


– Screw the filler cap (1) back on tightly.

8

9

0

6

7

4

3

5

7312_003-070_en_V2

Changing the air filter insert

NOTE

The air filter insert must be changed if the AIRFILTERmessage appears on the display andoperating unit, or at least every 3000 hours orevery two years.

– Open the bonnet; see the chapter entitled"Opening the bonnet".

7312_003-146

1

– Loosen the clamps (1) on the air filterhousing.

334 174749 EN - 11/2018


7312_003-155

2

– Fold up the air filter cover (2).

7312_003-1483

– Lift the air filter cover out of the truck sothat the intake hose (3) is tilted downwardsslightly.

CAUTIONRisk of damage from contamination!– When taking out the filter insert, block the intake

opening (6) using a lint-free cloth.

NOTE

It is recommended that you change the filterinsert instead of cleaning it. Frequent cleaningcan result in damage to the filter insert. Suchdamage poses the risk of dust getting into theengine.

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7312_003-149_V2

5

4

6

– Remove the filter insert (4). Ensure that nodirt can enter the intake opening (6).

– Wipe out the air filter housing using a dampcloth.

– Check the filter insert (4) for contaminationor damage, and change it if necessary.

CAUTIONRisk of damage to components fromcontamination!Damaged filter inserts must be changed to avoidengine damage.

– Remove the cloth (6) from the intakeopening.

– Fit the air filter cover (2) from above at anangle and install in the truck using a swivelmovement. Ensure that the sealing lip (5)of the filter insert is seated correctly in thehousing.

– Allow the clamps (1) on the air filter housingto engage.


7094_121-002

1

Draining water from the fuel filter

WARNINGConsumables are toxic.Observe safety regulations whenhandling Diesel fuel, see ⇒ Chap-ter "Diesel fuel", P. 2-48.

– Open the bonnet, see ⇒ Chapter "Openingthe bonnet", P. 5-325.

– Hold a suitable collection vessel under thedrainage screw (1).

– Open the drainage screw (1) on the filterand drain the fuel (approx. 100 cm3) untilclean fuel is discharged.

– Manually retighten the drainage screw (1).


336 174749 EN - 11/2018


NOTE

Draining this water is particularly importantwhen operating in the tropics and dependingon the quality of fuel used.

NOTE

A second fuel filter (variant) can be installed.Both filters must be drained.

7312_003-131_en_V4

1

Eberspächer particle filters - Regen-erationWhen the engine has been operating forapprox. 7.5 hours, the EXH. GAS PURI-FIERmessage appears on the display-oper-ating unit. Regeneration of the particle filtermust be carried out. The operating device isintegrated into the display-operating unit.

NOTE

The Softkey (1) and the corresponding sym-bols are assigned according to the auxiliaryequipment installed. The assignment shownhere is an example. The assignment pro-grammed for the truck may deviate from thisexample.

NOTE

If particle filter regeneration is not carriedout within 30 minutes, an acoustic signal isemitted (variant). The acoustic signal stopswhen regeneration begins.

174749 EN - 11/2018 337


7312_003-183

F1F1 F2F2

1

1

1

Regeneration emergency off switch

DANGERThere is a risk of fire if smoke isemitted!If smoke is emitted during regenera-tion, this may be caused by a fire. Ac-tuating the emergency off switch (1)cuts off the diesel supply and stops theregeneration process.– If smoke is emitted, press the

emergency off switch immediately.

Regenerating the particle filter– Park in a suitable parking space.

DANGERRisk of fire!The parking space must not be in anarea containing hazardous materialsor in a hall, because hot combustiongases are produced from the exhaustpipe during regeneration.

NOTE

If the engine uses fuel that contains sulphur,an unpleasant combustion odour may benoticeable.

NOTE

It is not possible to start the engine duringregeneration.

The regeneration must be started manuallywith the engine switched off and the ignitionswitched on.

To prevent the particle filter system from beingdestroyed as a result of regeneration takingplace while the engine is running, there isa safety circuit to prevent the regenerationprocess from being started while the engine isrunning.

– Switch off the engine.

– Turn the key switch to the "I" position.

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7312_003-131_en_V4

1


The particulate filter regeneration process isstarted and runs automatically.

7312_003-132_en_V2

4

EXH. GAS PURIFIER PLEASE WAITappears on the display. The status bar (4)below the message indicates the progress ofthe regeneration process.

– Once the regeneration process has started,switch the key switch to position "0".

It is possible to leave the truck unattended dur-ing the regeneration process. Regenerationwill continue even if the switch key is removed.

– Remove the switch key before leaving thetruck unattended.

NOTE

If the ignition is not switched off and the truckis not put into operation again immediatelyafter regeneration, it is possible that the starterbattery could discharge.

After approx. 25 minutes the regenera-tion is complete. The EXH. GAS PURI-FIER PLEASE WAITmessage disappears.The filter is free of soot again.

If the burner flame goes out during the regen-eration process, the control unit will automati-cally initiate another start attempt.

– To cancel regeneration, press the Soft-key again.

The particle filter regeneration process is ter-minated. The message EXH. GAS PURI-FIER goes out.

174749 EN - 11/2018 339


NOTE

The process can be restarted at any time.

8

9

0

6

7

4

3

5

7312_003-133_en_V3

A 57 95

The EXH. GAS PURIFIER message in-dicates malfunctions with the regenerationprocess using the relevant error code.

– Have any malfunctions rectified by theauthorised service centre.

– To acknowledge the message, push theSoftkey .

Lubricating the joints and controls– Oil or grease other bearing points andjoints according to the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 5-322.

• Driver's seat guide• Lubricate bonnet hinges at the lubricatingnipple

• Control linkage for valves• In the cab, lubricate door hinges at thelubricating nipple (variant)

• Lubricate shafts and joints in dual-pedaloperation (variant)

340 174749 EN - 11/2018


Maintaining the seat belt

DANGERThere is a risk to life if the seat belt fails during anaccident!If the seat belt is faulty, it may tear or open duringan accident and no longer keep the driver in thedriver's seat. The driver may therefore be hurledagainst the truck components or out of the truck.– Ensure operational reliability by continually

testing.– Do not use a truck with a defective seat belt.– Have any defective seat belts replaced by your

authorised service centre.– Only use genuine spare parts.– Do not make any changes to the seat belt.

NOTE

The checks below must be carried out ona regular basis (monthly). In the case ofsignificant strain, a daily check is necessary.

Checking the seat belt

6327_342-009

1

23

– Pull out the seat belt (3) completely andcheck for fraying.

The seat belt must not be frayed or cut. Thestitching must not be loose.

– Check that the seat belt is not dirty.

– Check whether parts are worn or damaged(including the anchor points).

174749 EN - 11/2018 341


7090_342-0051

4

– Check the buckle (1) for proper locking.

When the belt tongue (2) is inserted, the seatbelt must be held securely. The belt tongue(2) must release when the red button (4) ispressed.

– The automatic blocking mechanism mustbe tested at least once a year:

– Park the forklift truck on level ground.

– Pull out the seat belt using a jerking move-ment.

The automatic blocking mechanism mustblock extension of the belt.

– Tilt the seat at least 30°; to do this, tilt thebonnet.

– Slowly pull out the seat belt.

The automatic blocking mechanism mustblock extension of the belt.

Cleaning the seat belt– Clean the seat belt if it is dirty but withoutusing chemical cleaning materials (a brushwill suffice).

Replacement after an accidentThe seat belt must always be replaced by theauthorised service centre after an accident.

342 174749 EN - 11/2018


6327_342-010

Checking the driver's seat

WARNINGRisk of injury!– After an accident, check the driver's seat with

attached restraining belt and fastening.

– Check the controls for correct operation.

– Check the condition of the seat (e.g. wearon the upholstery) and secure fastening tothe hood.

WARNINGRisk of injury!– Have the seat repaired by the service centre if

you identify any damage during the checks.

Checking the door latch– Inspect the condition of the catch bolt andcheck for wear.

– Check the lock mechanism for easy opera-tion.

Servicing wheels and tyres

WARNINGRisk of accident!Uneven wear reduces the stability of the truckand increases the braking distance. The level ofwear exhibited by tyres on the same axle must beapproximately the same.– Worn or damaged tyres (left or right) must be

replaced immediately.– When changing wheels or tyres, ensure that this

does not cause the truck to tilt to one side (e.g.always replace right-hand and left-hand wheelsat the same time).

– Changes must only be made following consulta-tion with the manufacturer.

174749 EN - 11/2018 343


WARNINGRisk to stability!Tyre quality affects the stability of the truck. Thereis a risk of tipping!When using pneumatic tyres or solid rubber tyres,rim wheel parts must never be changed and rimwheel parts from different manufacturers must notbe mixed.– Obtain approval from the truck manufacturer

before using a different type of tyre or a differenttyre manufacturer.

Checking condition and wear of the tyres

60 J

60 J

Superelastic tyres (variant)

– Check the remaining distance between thetyre tread and the (60 J) wear mark.

Super-elastic tyres (variant) can beworn downto the (60 J) wear mark.

– Remove any foreign bodies embedded inthe tyre.

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Pneumatic tyres (variant)

– Check the tread depth on all four tyres.

The tread depth for pneumatic tyres (variant)must be at least 1.6 mm at every point on thetread. If the tread is worn down to the wearmark (2) at any point on the tyre, replace thetyres on one axle.

– Remove any foreign bodies embedded inthe tyre.

1Checking the air pressure

NOTE

The correct air pressure for pneumatic tyres(variant) is determinedby the type of tyre used.The air pressure measured must correspondto the manufacturer's information.

– Observe the air pressure value indicated onthe adhesive label (1) on the truck.

– Check the air pressure of all four tyres andcompare with the air pressure values statedon the adhesive labels.

– Add or release air as required if the airpressure deviates from the values stated.

174749 EN - 11/2018 345


47321_003-112

Checking wheel fastenings– Check that all wheel fastenings (4) are se-curely fastened and retighten as necessary.

– Observe the relevant torques; see sectionentitled "Maintenance data table".

Servicing the battery

NOTE

Battery maintenance is carried out in accor-dance with the battery manufacturer's opera-ting manual!

WARNINGThere is a risk of damage, short circuitand explosion.Do not place anymetal objects or toolson the battery. Keep away from nakedflames and fire. Smoking is forbidden.

Checking the battery charge status– Remove the bottom plate; see ⇒ Chap-ter "Installing and removing the bottomplate", P. 5-327

Mind the accelerator as you do so.

346 174749 EN - 11/2018


7312_003-040

1– With maintenance-free batteries, check thecharge status at the inspection window (1):

• Green: The battery is optimally charged.• Black: The battery charge status is nolonger optimal. The battery should berecharged. After recharging, the indicatorchanges back to green.

• Transparent-(light-coloured): The chargestatus is no longer adequate for reliablestarting. It is necessary to change thebattery.

Charging the battery– With batteries that are not maintenance-free, check the level of the battery acid.

WARNINGThe electrolyte (dilute sulphuric acid)is poisonous and caustic.– Follow the safety regulations for

working with battery acid; see⇒ Chapter "Battery acid", P. 2-47.

– Check battery acid level.

The battery acid must be up to the lower edgeof the insert in the battery housing or up to5 mm above the upper edge of the plates.Observe the manufacturer's specifications!

CAUTIONThe battery can be damaged!– Fill up missing fluid with distilled water only.

174749 EN - 11/2018 347


7090_606-002– Unscrew the battery cell cover and checkthe acid density with an acid siphon.

The acid density must achieve the value in thetable. The listed density of the acid refers to27°C acid temperature.

Acid density Empty Full

Normal 1.13 1.28

Tropics 1.08 1.23

WARNINGRisk of explosion! Charging releasesgases that are explosive.While charging, the surfaces of thebattery cells must be free to ensuresufficient ventilation.The charging area must be properlyventilated.Keep bonnet open during charging;avoid spark formationnear thebattery.

– Charge discharged batteries immediatelyuntil they are fully charged again.

The charging current shall not exceed 1/10 ofcapacity.

The cell covers of the batteries must be keptdry and clean.

Any spillage of battery acid must be neu-tralised immediately.

Terminals and lugs must be clean, lightlycoated with battery grease and tightlyscrewed.

– After charging, screw the cell covers backon.

– Fit the bottom plate, see ⇒ Chap-ter "Installing and removing the bottomplate", P. 5-327.

348 174749 EN - 11/2018


Replacing fuses

DANGERRisk of fire!Using the wrong fuses can result in short circuits.– Use only fuses with the prescribed nominal cur-

rent, see the section entitled "Fuse assignment".

– Remove the cover at the back.

1 1

117311_003-021

– Open the cover fastenings (1) and removethe cover.

– Replace the defective fuse with one that israted for the nominal current according to"Fuse assignment".

– Close the cover to secure the fuse box.

– Install the back covers.

– Perform a function check. If the errorpersists or if the fuse is still defective, notifyyour authorised service centre.

Checking the hydraulic oil level

CAUTIONHydraulic oils are hazardous to your health and areunder pressure during operation.– Note safety regulations for working with hydrau-

lic oils; see ⇒ Chapter "Hydraulic fluid", P. 2-46.

– Park the truck securely; see ⇒ Chap-ter "Parking the truck securely and switch-ing it off", P. 4-142.

– Open the bonnet; see ⇒ Chapter "Openingthe bonnet", P. 5-325.

174749 EN - 11/2018 349


7311_003-019

1– Unscrew breather filter with oil dipstick (1).

7094_700-002

1

2

– Check the oil level. The oil level must be atleast up to the mark (2) on the dipstick.

– If the oil level does not reach the specifiedlevel, pour hydraulic oil of the correspondingspecification (see ⇒ Chapter "Maintenancedata table", P. 5-322) into the filler neck untilit reaches theuppermarking asamaximum.

NOTE

Use a funnel.

– Screw in the breather filter with oil dipstick.

– Close bonnet again.

ENVIRONMENT NOTE

Carefully collect up any spilled oil and disposeof it in an environmentally friendly manner.

Checking the hydraulic system forleak tightness

WARNINGHydraulic oil is hazardous to health!Hydraulic oil under pressure canescape from leaking pipes and lines,and cause injuries.– Wear suitable protective gloves,

protection goggles etc.

350 174749 EN - 11/2018


CAUTIONHydraulic hoses become brittle!– Do not store hydraulic hoses for more than two

years.– Do not use hydraulic hoses for more than six

years if they are subject to normal wear.– Do not use hydraulic hoses for more than two

years if they are subject to a high level of wear.– Complywith the specifications ofDGUV113-020

in Germany.– Outside of Germany, observe the national

regulations for the country of use.

– Check pipe and hose connection screwjoints for leaks (traces of oil).

Replace hose lines if they display the followingabnormalities:• Outer layer has been damaged, or is brittleor cracked

• Leaking• Deformation (e.g. with blisters or kinks)• A fitting has come loose• A fitting is badly damaged or corroded

Replace pipes if they display the followingabnormalities:• Abrasion• Deformation and bending• Leaking

16210_800-020

Lubricating the lift mast and rollertrack– Remove dirt and lubricant residue from theroller track.

– Lubricate the roller tracks (1) of the outside,middle, and inside mast with a super-pressure adhesion lubricant to reducewear. See ⇒ Chapter "Maintenance datatable", P. 5-322.

NOTE

Spray the roller track evenly from a distance ofapprox. 15-20 cm. Wait approx. 15 minutesuntil the equipment is ready to use again.

174749 EN - 11/2018 351


Greasing the automatic tow coupling

NOTE

Wear to moving parts can be significantlyreduced by appropriate servicing and regularlubrication of the coupling.

– Avoid over-greasing!

NOTE

Close the coupling before cleaning witha high-pressure cleaner. After cleaning,lubricate the coupling pin, tow bar eye andits supporting surface again.

3

7321_003-091

21

Model RO*243– Pull out the safety handle (3).


– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 5-322.

– Close the coupling by raising the couplingpin with a suitable tool.

– For journeys with a rigid drawbar trailer,lubricate the underside of the tow bar eyeand the supporting surface on the coupling.

7321_003-092

– Determine the wear on the coupling pin.

The diameter of the spherical part must not beless than 36.5 mm.

Model RO*244 A– Open coupling.

352 174749 EN - 11/2018


Wartung_Rockinger 244 A

1– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 5-322.

– Grease coupling pin, tow bar eye and itssupporting surface.

7321_003-094

Model RO*245– Lubricate via the points provided for thispurpose (lubricating nipple, opened cou-pling) in accordance with the maintenancedata table; see ⇒ Chapter "Maintenancedata table", P. 5-322.

– Grease the supporting surface for thetow-bar eye.

174749 EN - 11/2018 353


7321_003-095

Model RO*841– Lubricate via the points provided for thispurpose (lubricating nipple, opened cou-pling) in accordance with the maintenancedata table; see ⇒ Chapter "Maintenancedata table", P. 5-322.

– Grease the supporting surface for thetow-bar eye.

7314_003-036

11

1

2

3

Changing the heating system freshair filter– Open the cab door to the right.

– Loosen the mounting screws (1) andremove the cover (2) .

– Check the filter mat (3) for contamination.

– If the filter mat is grey in colour, replace it.

NOTE

Change the filter mat at least every 2 months.

– Clean the fresh-air inlet by removing dustand dirt.

354 174749 EN - 11/2018

Maintenance 51000-hour maintenance / Annual maintenance

1000-hour maintenance / Annual maintenanceOther tasks– Perform all tasks required to maintainfull operability; see the chapter entitled"Remaining ready for operation".

Checking the exhaust gas system– Inspect the exhaust gas system for externaldamage, secure fit, and leaks.

7094_810-004

Checking the lift cylinders andconnections for leaks

WARNINGRisk of injuryObserve safety regulations for working on the liftmast, see the "Working at the front of the truck"chapter.

– Check hydraulic connections and lift cylin-ders for leaks (visual inspection).

– Have leaking screw joints or leaking hy-draulic cylinders repaired by the authorisedservice centre.

1

2

2

3

d3911398

Checking the fork arms

CAUTIONFork arms must not be uneven!– Always replace both fork arms.

– Check the fork arms (1) for visible deforma-tion and excessive wear.

No cracks or deformations must be visible onthe fork arms in the area around the fork bend.Wear must not amount to more than 10% ofthe original thickness.

– Check that the locking screws (2) arepresent and securely attached.

– Replace any worn or deformed fork arms.

174749 EN - 11/2018 355

5 Maintenance1000-hour maintenance / Annual maintenance

Check the condition and correct operation ofthe fork latch:

– Move the locking lever (3) into a verticalposition.

It must be possible to move the fork arm.

– Move the locking lever into a horizontalposition.

The latch must engage in a recess on the forkcarriage. It must not be possible to move thefork arm.

– Replace faulty fork latches.

Checking the reversible fork arms

NOTE

This check is only required for reversible forkarms (variant).

– Check the outside of the fork bend (1) forcracks. Contact your service centre.

356 174749 EN - 11/2018

6

Technical data

6 Technical dataDimensions

Dimensions

1 Seat is adjustable ± 90 mm 2 Fork spacing is adjustable

358 174749 EN - 11/2018

Technical data 6Dimensions

NOTE

Measurements h1, h3, h4, h6 and b1 arespecified by the customer and can be takenfrom the order confirmation.

Centre of gravity "S" (distance measuredfrom the front axle)

RX70-16 791 mm

RX70-18 828 mm

RX70-20 837 mm

NOTE

The specified centre of gravity "S" relatesto trucks with standard equipment. If, forexample, the truck is equipped with a differentlift mast, attachment or driver protectionstructure, this value is only a guide value. Ifnecessary, the centre of gravity "S" must bedetermined on an individual basis for eachtruck.

174749 EN - 11/2018 359

6 Technical dataVDI datasheet for RX70-16, RX70-18 and RX70-20

VDI datasheet for RX70-16,RX70-18 and RX70-20

NOTE

This VDI datasheet specifies only the techni-cal values of the truck version with standardequipment. Different tyres, lift masts, additio-nal units etc. may produce different values.

Characteristics

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Manufacturer STILL GmbH STILL GmbH STILL GmbH

DriveDiesel en-gine/electric

Dieselengine/electric

Dieselengine/electric

Operation Seated Seated Seated

Load capacity/load Q (kg) 1600 1800 2000

Load centre of gravity distance c(mm) 500 500 500

Load distance X (mm) 395 395 405

Wheelbase Y (mm) 1450 1487 1526.

Weights

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Net weight kg 2706 2856 3059

Axle load with front load kg 3817 4149 4568

Axle load with rear load kg 489 507 491

Axle load without front load kg 1230 1266 1382

Axle load without rear load kg 1476 1590 1677.

Wheels, chassis frame

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Tyres SE SE SE

Front tyre size 18x7–8 18x7–8 200/50–10

360 174749 EN - 11/2018

Technical data 6VDI datasheet for RX70-16, RX70-18 and RX70-20

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Rear tyre size 18x7–8 18x7–8 18x7–8

Number of front wheels (x = driven) 2x 2x 2x

Number of rear wheels (x = driven) 2 2 2

Front track width b10 (mm) 932 932 942

Rear track width b11 (mm) 895 895 895.

Basic dimensions

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313Tilt of lift mast/fork carriage,forwards

Degree 3 3 3

Tilt of lift mast/fork carriage,backwards

Degree 8 8 8

Height with lift mast retracted h1 (mm) 2160 2160 2160

Free lift h2 (mm) 150 150 150

Lift1 h3 (mm) 3230 3230 3150

Height with lift mast extended h4 (mm) 3873 3873 3725

Height to top of overhead guard h6(mm) 2117 2117 2117

Seat height h7(mm) 1015 1015 1015

Coupling height h10 (mm) 474 474 474

Total length l1 (mm) 2975 3012 3061

Length including fork back l2 (mm) 2175 2212 2261

Total width b1 (mm) 1099 1099 1138

Fork arm thickness s (mm) 40 40 40

Fork arm width e (mm) 80 80 80

Fork arm length l (mm) 800 800 800Fork carriage ISO 2328class/form II/A II/A II/A

Fork carriage width b3 (mm) 980 980 980Ground clearance with load underlift mast

m1 (mm) 90 90 90

1 The lift specified in the table takes into account the tyre deflection and the tolerances of the tyre diameter.

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6 Technical dataVDI datasheet for RX70-16, RX70-18 and RX70-20

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313Ground clearance at centre ofwheelbase

m2 (mm) 133 133 133

Aisle width for pallet 1000 x 1200crosswise

Ast (mm) 3523 3557 3603

Aisle width for pallet 800 x 1200lengthwise Ast (mm) 3727 3762 3810

Turning radius Wa(mm) 1926 1961 1998

Smallest pivot point distance b13 (mm) 538 544 550.

Performance data

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Driving speed with load km/h 22 22 22

Driving speed without load km/h 22 22 22

Lifting speed with load m/s 0.52 0.52 0.52

Lifting speed without load m/s 0.54 0.54 0.54

Lowering speed with load m/s 0.59 0.59 0.59

Lowering speed without load m/s 0.59 0.59 0.59

Pulling force with load N 13,000 13,000 13,000

Pulling force without load N 6700 6700 6700

Climbing capability2 with load % 27 26 26

Climbing capability without load % 28 28 28

Acceleration time with load s 4.9 5.0 5.1

Acceleration time without load s 4.6 4.7 4.7

Service brake electr./hydr. electr./hydr. electr./hydr.

CAUTIONTo use the truck safely—with or without a load—themaximum ascending or descending gradient per-mitted for travel is 15%.– If you have any questions, please contact the


2 The stated values are used only to compare performance of trucks in the same category.The gradient values in no way represent the normal daily operating conditions.

362 174749 EN - 11/2018

Technical data 6VDI datasheet for RX70-16, RX70-18 and RX70-20

Engine

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Engine manufacturer/model VW/BXT VW/BXT VW/BXTEngine power rating in accordancewith ISO 1585 kW 28 28 28

Nominal speed rpm 2350 2350 2350

Number of cylinders/displacement cm3 4/1900 4/1900 4/1900Fuel consumption3 in accordancewith the VDI cycle l/h 1.9 2.0 2.2

.

Other

Model RX70-16 RX70-18 RX70-20

Type number 7311 7312 7313

Working pressure for attachments bar 230 230 230

Oil volume for attachments l/min 30 30 30

Capacity of fuel tank l 58 58 58Noise level LpAZ (driver's compart-ment)4 dB (A) < 74 < 74 < 74

Sound power level LwAZ (workingcycle) dB (A) < 99 < 99 < 99

Human vibration: acceleration5according to EN 13059 m/s2 0.71 0.71 0.71

Tow coupling, DIN type/model Bolt Bolt Bolt.

3 With Blue-Q energy-saving program4 Without cab. Values differ with a cab.5 With a standard driver's seat.

174749 EN - 11/2018 363

6 Technical dataErgonomic dimensions

0000_003-002

40 mm

Ergonomic dimensions

WARNINGDanger of impact injuries to the head!If the head of the operator is located too close to theunderside of the roof, the suspension of the driver'sseat or an accidentmay cause the head to strike theoverhead guard.To avoid head injuries, a minimum distance of40 mmmust be ensured between the underside ofthe roof and the head of the tallest operator.To determine the actual head clearance, the opera-tor must sit in the driver's seat and the seat suspen-sion must be set to this driver's requirements.Due to the individual nature of height and bodyweight aswell as thewide variety of types of driver'sseat and overhead guard, the minimum headclearance must be ensured in every truck.

The driver's compartment has been designedtaking ergonomics in the workplace intoaccount and in accordance with EN ISO 3411.In general, from the seat position, the operatorhas sufficient space to reach the operatingdevices safely, to operate the truck and to viewthe outline of the truck. Operators whose bodysize deviates from the specified dimensionson which EN ISO 3411 is based must beindividually considered by the operatingcompany.

364 174749 EN - 11/2018

Technical data 6Ergonomic dimensions

174749 EN - 11/2018 365

6 Technical dataFuse assignment

Fuse assignment

1F08 12-V battery (constant positive terminal),variants, 10 A

1F09 Switch lock, 5 A1F10 Cooling fluid pump, 10 A1F11 Converter, 5 A1F12 Pump, variant, 10 A1F15 12 V for TCU, display and operating unit, 5 A1F16 12-V options, servo hydraulics, 10 A1F17 Time-delay relay, terminal 15, 10 A

1F18 12-V options, servo hydraulics, 10 A1F19 12-V engine control unit ECU, 10 A1F21 Engine control unit components, 15 A1F22 Engine control unit components, 15 A4F01 Signal horn, 10 A9F03 12-V Option Board, 15 A9F04 Starter, terminal 50, 30 A9F6 Engine glow plug relay (diesel trucks only),

50 A

NOTE

Depending on the specification, not all fuseswill be present in the truck.

366 174749 EN - 11/2018

Indexg

AAccess authorisation

Changing the password . . . . . . . . . . . 99Defining the driver PIN . . . . . . . . . . . . 95Entering the access code . . . . . . . . . 93Selecting the driver PIN . . . . . . . . . . . 96

Access authorisation with PIN code . . . . 92Accessories

Overview . . . . . . . . . . . . . . . . . . . . . . 7Actuating the drive direction switch

Fingertip version . . . . . . . . . . . . . . . 126Joystick 4Plus version . . . . . . . . . . 125Mini-console version . . . . . . . . . . . . 126Mini-lever version . . . . . . . . . . . . . . 125

Actuating the parking brakeWhen the truck is moving . . . . . . . . . 138

Address of manufacturer . . . . . . . . . . . . . IAdjusting the armrest . . . . . . . . . . . . . . . 77Adjusting the fork . . . . . . . . . . . . . . . . . 172Adjusting the steering column . . . . . . . . . 78After washing . . . . . . . . . . . . . . . . . . . . 285Aisle widths . . . . . . . . . . . . . . . . . . . . . 120

AttachmentsAssembly . . . . . . . . . . . . . . . . . . . . 183Controlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 189Controlling using the double

mini-lever and the 5th function . . 191Controlling using the joystick 4Plus

and the 5th function . . . . . . . . . . 202Controlling using the quadruple

mini-lever and the 5th function . . 199Controlling using the triple

mini-lever and the 5th function . . 195Controlling via the joystick 4Plus . . . 201Controlling with a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 197Controlling with a triple mini-lever . . . 193Controlling with the fingertip . . . . . . . 203Controlling with the fingertip and 5th

function . . . . . . . . . . . . . . . . . . . 204General controlling . . . . . . . . . . . . . 187Mounting . . . . . . . . . . . . . . . . . . . . 184Releasing the pressure from the

connections . . . . . . . . . . . . . . . . 185Special risks . . . . . . . . . . . . . . . . . . . 35Taking up a load . . . . . . . . . . . . . . . 209

Automatic lift cut out . . . . . . . . . . . . . . . 144Automatic tow coupling . . . . . . . . . . . . 241

Coupling RO*243 . . . . . . . . . . . . . . 243Coupling RO*244 A . . . . . . . . . . . . . 245Coupling RO*245 . . . . . . . . . . . . . . 247Coupling RO*841 . . . . . . . . . . . . . . 248Uncoupling RO*243 . . . . . . . . . . . . 244Uncoupling RO*244 A . . . . . . . . . . . 246Uncoupling RO*245 . . . . . . . . . . . . 248Uncoupling RO*841 . . . . . . . . . . . . 249

BBattery

Charging . . . . . . . . . . . . . . . . . . . . . 347Checking the charge status . . . . . . . 346Disposal . . . . . . . . . . . . . . . . . . . . . . 22Servicing . . . . . . . . . . . . . . . . . . . . 346

Battery acid . . . . . . . . . . . . . . . . . . . . . . 47

174749 EN - 11/2018 367

Indexg

Before taking up load . . . . . . . . . . . . . . 167Blue-Q

Configure . . . . . . . . . . . . . . . . . . . . 113Functional description . . . . . . . . . . . 115Switching off . . . . . . . . . . . . . . . . . . 116Switching off additional consumers . 116Switching on . . . . . . . . . . . . . . . . . . 116

Bottom plateInstalling . . . . . . . . . . . . . . . . . . . . . 328Removing . . . . . . . . . . . . . . . . . . . . 327

CCab

Operating the interior lighting . . . . . . 233Operating the rear window heating . . 234

CE labelling . . . . . . . . . . . . . . . . . . . . . . . 5Ceiling sensor . . . . . . . . . . . . . . . . . . . 224Changes to the forklift truck . . . . . . . . . . 27Changing the air filter insert . . . . . . . . . 334Changing the drive direction . . . . . . . . . 128

Dual pedal version . . . . . . . . . . . . . 130Changing the fork arms . . . . . . . . . . . . 160Changing the heating system fresh air

filter . . . . . . . . . . . . . . . . . . . . . . 354Changing the password . . . . . . . . . . . . . 99Check the coolant concentration . . . . . . 332Checking the cooling fluid level . . . . . . . 331Checking the door latch . . . . . . . . . . . . 343Checking the driver's seat . . . . . . . . . . . 343Checking the emergency off function . . . 86Checking the engine oil level . . . . . . . . 329Checking the exhaust gas system . . . . . 355Checking the fork arms . . . . . . . . . . . . . 355Checking the lift cylinders and

connections for leaks . . . . . . . . . 355Checking wheel fastenings . . . . . . . . . . 346Clamp locking mechanism

Releasing . . . . . . . . . . . . . . . . . . . . 206Cleaning the electrical system . . . . . . . 284Cleaning the truck . . . . . . . . . . . . . . . . 282Cleaning the windows . . . . . . . . . . . . . 285

Climbing into the truck . . . . . . . . . . . . . . 71Climbing out of the truck . . . . . . . . . . . . . 71Clipboard . . . . . . . . . . . . . . . . . . . . . . . 237Closing the bonnet . . . . . . . . . . . . . . . . 326Closing the cab door . . . . . . . . . . . . . . . 231Closing the side windows . . . . . . . . . . . 232Condition of the roadways . . . . . . . . . . 122Consumables . . . . . . . . . . . . . . . . . . . . 45

Coolant and cooling fluid safetyinformation . . . . . . . . . . . . . . . . . . 50

Disposal . . . . . . . . . . . . . . . . . . . . . . 50Safety information for diesel fuel . . . . 48Safety information for handling

battery acid . . . . . . . . . . . . . . . . . 47Safety information for handling oils . . . 45Safety information for hydraulic fluid . . 46

Contact details . . . . . . . . . . . . . . . . . . . . . ICoolant and cooling fluid . . . . . . . . . . . . 50Cooling fluid . . . . . . . . . . . . . . . . . . . . . 332

Topping up . . . . . . . . . . . . . . . 331 – 332Copyright and trademark rights . . . . . . . . 17Coupling pin in the counterweight . . . . . 239

Uncoupling . . . . . . . . . . . . . . . . . . . 240Crane loading . . . . . . . . . . . . . . . . . . . 300

Determining the loading weight . . . . 301Hooking on the lifting straps . . . . . . . 301

Cruise control . . . . . . . . . . . . . . . . . . . 220

DDamage . . . . . . . . . . . . . . . . . . . . . . . . 30Danger area . . . . . . . . . . . . . . . . . . . . 172Danger to employees . . . . . . . . . . . . . . . 41Declaration of conformity . . . . . . . . . . . . . 6Decommissioning

Recommissioning . . . . . . . . . . . . . . 305Defects . . . . . . . . . . . . . . . . . . . . . . . . . 30Defining the driver PIN . . . . . . . . . . . . . . 95Definition of directions . . . . . . . . . . . . . . 20Description of the truck . . . . . . . . . . . . . . . 2Diesel engine emissions

Checking . . . . . . . . . . . . . . . . . . . . . 42

368 174749 EN - 11/2018

Indexg

Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . 48Non-road fuels . . . . . . . . . . . . . . . . 279Specifications . . . . . . . . . . . . . . . . . 276Sulphur content . . . . . . . . . . . . . . . . 278Topping up . . . . . . . . . . . . . . . . . . . 280Winter operation . . . . . . . . . . . . . . . 278

Dimensions . . . . . . . . . . . . . . . . . . . . . 358Display and operating unit . . . . . . . . . . . 58

Additional indicators . . . . . . . . . . . . 104Adjusting the displays . . . . . . . . . . . 105Configure Blue Q . . . . . . . . . . . . . . . 113Standard display elements . . . . 91, 104

Display messagesDisplay content . . . . . . . . . . . . . . . . 251Drive-specific . . . . . . . . . . . . . . . . . 263General . . . . . . . . . . . . . . . . . . . . . 254

Display operating unitResetting the daily kilometres . . . . . 112Setting the date . . . . . . . . . . . . . . . . 111Setting the language . . . . . . . . . . . . 112Setting the time . . . . . . . . . . . . . . . . 111

Display symbols . . . . . . . . . . . . . . . . . . 106Auxiliary equipment softkey

functions . . . . . . . . . . . . . . . . . . 108Error messages . . . . . . . . . . . . . . . 108Menu navigation softkey functions . . 109Numeric keypad . . . . . . . . . . . . . . . 110Operating messages . . . . . . . . . . . . 106Status LEDs . . . . . . . . . . . . . . . . . . 110Warning messages . . . . . . . . . . . . . 107

DisposalBattery . . . . . . . . . . . . . . . . . . . . . . . 22Components . . . . . . . . . . . . . . . . . . . 22

Documentation scope . . . . . . . . . . . . . . 15Double mini-lever . . . . . . . . . . . . . . . . . . 60

Lifting/lowering the fork carriage . . . 154Tilting the lift mast . . . . . . . . . . . . . . 154

Driver rights, duties and rules ofbehaviour . . . . . . . . . . . . . . . . . . 25

Driver's cabUse . . . . . . . . . . . . . . . . . . . . . . . . . 83

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Driveways . . . . . . . . . . . . . . . . . . . . . . 120Driving

Ascending gradients . . . . . . . . . . . . 140Descending gradients . . . . . . . . . . . 140

Driving lightsSwitching on and off . . . . . . . . . . . . 210

Driving on lifts . . . . . . . . . . . . . . . . . . . 181Driving on loading bridges . . . . . . . . . . 182

EEberspächer particle filters

Regeneration . . . . . . . . . . . . . . . . . 337EC declaration of conformity in

accordance with MachineryDirective . . . . . . . . . . . . . . . . . . . . 6

Electric parking brakeEmergency operation . . . . . . . . . . . 291Malfunctions . . . . . . . . . . . . . . . . . . 270

EmergenciesDisconnecting the battery . . . . . . . . 292Emergency operation of the electric

parking brake . . . . . . . . . . . . . . . 291Truck tipping over . . . . . . . . . . . . . . 288Using the emergency hammer . . . . . 289

Emergency hammer . . . . . . . . . . . . . . . 289Emergency lowering . . . . . . . . . . . . . . 289Emergency shutdown . . . . . . . . . . . . . 286Emissions . . . . . . . . . . . . . . . . . . . . . . . 52

Exhaust gases . . . . . . . . . . . . . . . . . 54Heat . . . . . . . . . . . . . . . . . . . . . . . . . 54Noise emissions . . . . . . . . . . . . . . . . 52Vibrations . . . . . . . . . . . . . . . . . . . . . 53

Entering the access code . . . . . . . . . . . . 93Ergonomic dimensions . . . . . . . . . . . . . 364Error code table . . . . . . . . . . . . . . . . . . 252Example . . . . . . . . . . . . . . . . . . . . . . . 168

FFilling the washer system . . . . . . . . . . . 219Fingertip . . . . . . . . . . . . . . . . . . . . . . . . 64


174749 EN - 11/2018 369

Indexg

Fitting attachments . . . . . . . . . . . . . . . 183FleetManager . . . . . . . . . . . . . . . . . . . 220

Shock recognition . . . . . . . . . . . . . . 220Fork arms

Length . . . . . . . . . . . . . . . . . . . . . . . 33Fork extension . . . . . . . . . . . . . . . . . . . 162Four-way mini-lever . . . . . . . . . . . . . . . . 62Fuel filter

Draining water . . . . . . . . . . . . . . . . . 336Fuse assignment . . . . . . . . . . . . . . . . . 366Fuse box

Fuses . . . . . . . . . . . . . . . . . . . . . . . 366Relays . . . . . . . . . . . . . . . . . . . . . . 366

GGas spring with position lock (variant)

Releasing the latch . . . . . . . . . . . . . 326General . . . . . . . . . . . . . . . . . . . . . . . . . . 4

HHandling gas springs and accumulators . 32Hazard areas . . . . . . . . . . . . . . . . . . . . 123Hazard warning system . . . . . . . . . . . . 212Hazards and countermeasures . . . . . . . . 38Heating system . . . . . . . . . . . . . . . . . . 235

Air circulation . . . . . . . . . . . . . . . . . 236Defrost . . . . . . . . . . . . . . . . . . . . . . 236Switching on . . . . . . . . . . . . . . . . . . 235Switching on the blower . . . . . . . . . . 235

Hydraulic blocking function . . . . . . . . . . 152Releasing . . . . . . . . . . . . . . . . . . . . 152

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 46Hydraulic system

Checking for leak tightness . . . . . . . 350Checking the oil level . . . . . . . . . . . . 349

IImpermissible use . . . . . . . . . . . . . . . . . 12

Information for carrying out mainte-nance . . . . . . . . . . . . . . . . . . . . 312

Maintenance timeframe . . . . . . . . . . 313Information symbols . . . . . . . . . . . . . . . . 17Insulation testing . . . . . . . . . . . . . . . . . . 44Insurance cover on company premises . . 27Interior lighting . . . . . . . . . . . . . . . . . . . 233Issue date of the operating instructions . . 17

JJacking up . . . . . . . . . . . . . . . . . . . . . . 310Joystick 4Plus . . . . . . . . . . . . . . . . . . . . 63

Fork-carriage sideshift . . . . . . . . . . . 158Lifting/lowering the fork carriage . . . 157Tilting the lift mast . . . . . . . . . . . . . . 158

Jump starting . . . . . . . . . . . . . . . . . . . . 293

LLabelling points . . . . . . . . . . . . . . . . . . . . 8Lashing . . . . . . . . . . . . . . . . . . . . . . . . 299Lift cut out

Automatic . . . . . . . . . . . . . . . . . . . . 144Lift mast

Lubricating the roller track . . . . . . . . 351Removing . . . . . . . . . . . . . . . . . . . . 311Securing against falling off . . . . . . . . 311Securing against tilting backwards . . 311

Lift mast versionsHi-Lo lift mast . . . . . . . . . . . . . . . . . 150Triplex lift mast . . . . . . . . . . . . . . . . 151

Lift mast vertical position . . . . . . . . . . . 145Automatic approach . . . . . . . . . . . . 147Calibrating . . . . . . . . . . . . . . . . . . . 149Description . . . . . . . . . . . . . . . . . . . 145Display . . . . . . . . . . . . . . . . . . . . . . 147Possible restrictions . . . . . . . . . . . . 149Run-in to end stops . . . . . . . . . . . . . 147Tilting the lift mast backwards . . . . . 148Tilting the lift mast forwards . . . . . . . 148

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . 310

370 174749 EN - 11/2018

Indexg

Lifting systemControlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 154Controlling using a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 156Controlling using a triple mini-lever . . 155Controlling using the fingertip . . . . . . 159Controlling using the joystick 4Plus . 157Operating devices . . . . . . . . . . . . . . 153

LightingSTILL SafetyLight . . . . . . . . . . . . . . 218Switching on and off . . . . . . . . . . . . 210

List of abbreviations . . . . . . . . . . . . . . . . 18Load

Picking up . . . . . . . . . . . . . . . . . . . . 174Setting down . . . . . . . . . . . . . . . . . . 179transporting . . . . . . . . . . . . . . . . . . 178

Load capacity . . . . . . . . . . . . . . . . . . . 167Load chains

Cleaning . . . . . . . . . . . . . . . . . . . . . 284Load measurement . . . . . . . . . . . . . . . 168

Description . . . . . . . . . . . . . . . . . . . 168Execution . . . . . . . . . . . . . . . . . . . . 169Zero adjustment . . . . . . . . . . . . . . . . 87

Lubricating the joints and controls . . . . . 340

MMaintenance data table . . . . . . . . . . . . 322

Battery . . . . . . . . . . . . . . . . . . . . . . 322Controls/joints . . . . . . . . . . . . . . . . . 322Cooling system . . . . . . . . . . . . . . . . 324Drive axle . . . . . . . . . . . . . . . . . . . . 323Electrical system . . . . . . . . . . . . . . . 322Engine . . . . . . . . . . . . . . . . . . . . . . 324Fuel tank . . . . . . . . . . . . . . . . . . . . . 324General lubrication points . . . . . . . . 322Hydraulic system . . . . . . . . . . . . . . 322Lift mast . . . . . . . . . . . . . . . . . . . . . 323Load chains . . . . . . . . . . . . . . . . . . 324Steering axle . . . . . . . . . . . . . . . . . . 323Tyres . . . . . . . . . . . . . . . . . . . . . . . 323Washer system . . . . . . . . . . . . . . . . 324

Maintenance during the break-inperiod . . . . . . . . . . . . . . . . . . . . 329

Maintenance work without specialqualifications . . . . . . . . . . . . . . . 312

Malfunctions during lifting mode . . . . . . 151Malfunctions in the electric parking

brake . . . . . . . . . . . . . . . . . . . . . 270Measuring the insulation resistance of

the electrical system . . . . . . . . . . . 44Medical equipment . . . . . . . . . . . . . . . . . 32Message

? VERTICAL POSITION . . . . . . . . . 258ACCELERATOR . . . . . . . . . . . . . . . 256ADBLUE FILLING LEVEL . . . . . . . . 265ADBLUEQUALITY . . . . . . . . . . . . . 265ADBLUEQUALITY URGENT! . . . . . 265ADBLUE REFILL 5l . . . . . . . . . . . . . 265ADBLUE URGENT! . . . . . . . . . . . . 264AIR FILTER . . . . . . . . . . . . . . . . . . 268ALTERNATOR . . . . . . . . . . . . . . . . 267APPLY HANDBRAKE . . . . . . . . . . . 255ARE YOU SURE ? . . . . . . . . . . . . . 260ASH LOAD . . . . . . . . . . . . . . . . . . . 266BRAKE SENSOR . . . . . . . . . . . . . . 256CODEDENIED . . . . . . . . . . . . . . . . 256COOLANT LEVEL . . . . . . . . . . . . . 267CUTOUTMODE . . . . . . . . . . . . . . . 264EMERGENCY SWITCH . . . . . . . . . 258EMPTY . . . . . . . . . . . . . . . . . . . . . . 267EXH.GAS PURIFIER . . . . . . . . . . . 263EXH.GAS PURIFIER PLEASE

WAIT . . . . . . . . . . . . . . . . . . . . . 264EXH.GAS PURIFIER SERVICE! ! ! . 264FUEL FILTER . . . . . . . . . . . . . . . . . 267GLOW . . . . . . . . . . . . . . . . . . . . . . 266HYBRID SYSTEM . . . . . . . . . . . . . . 266HYDRAULIC PUMP . . . . . . . . . . . . 266LOWER FORKS . . . . . . . . . . . . . . . 257LPG AUTO. VALVE . . . . . . . . . . . . . 268NOT VALID . . . . . . . . . . . . . . . . . . . 263OIL PRESSURE . . . . . . . . . . . . . . . 268OVERHEATING . . . . . . . . . . . . . . . 262PARK. REG. ERROR . . . . . . . . . . . 269

174749 EN - 11/2018 371

Indexg

PARK. REG. URGENT! ! ! . . . . . . . . 269PARKING BRAKE ACTIVE . . . . . . . 256PARKING BRAKE: APPLY

HANDBRAKE! . . . . . . . . . . . . . . 257REFERENCECYCLE . . . . . . . . . . . 258REGENERATION COMPLETED . . . 268RELEASE PARKING BRAKE . . . . . 256SAFETY BELT . . . . . . . . . . . . . . . . 259SCR-SYSTEMMALFUNCTION . . . 269SCR-SYSTEM SERVICE . . . . . . . . 269SEAT SWITCH . . . . . . . . . . . . . . . . 260SERVICE BRAKE . . . . . . . . . . . . . . 255START IC ENGINE . . . . . . . . . . . . . 270START PARK. REG.? . . . . . . . . . . . 269STEERING . . . . . . . . . . . . . . . . . . . 257SURVEILLANCE . . . . . . . . . . . . . . 263SWITCHOFF TRUCK? . . . . . . . . . . 256TILTING SPEED . . . . . . . . . . . . . . . 257

MessagesDrive-specific . . . . . . . . . . . . . . . . . 263General . . . . . . . . . . . . . . . . . . . . . 254

Mini console . . . . . . . . . . . . . . . . . . . . . . 65Misuse of safety systems . . . . . . . . . . . . 30MSG 65/MSG 75 driver's seat

Adjusting . . . . . . . . . . . . . . . . . . . . . 73Adjusting the backrest extension . . . . 76Adjusting the lumbar support . . . . . . . 76Adjusting the seat backrest . . . . . . . . 74Adjusting the seat suspension . . . . . . 75Moving . . . . . . . . . . . . . . . . . . . . . . . 74Switching the seat heater on and off . . 77

NNameplate . . . . . . . . . . . . . . . . . . . . . . . 10Neutral position . . . . . . . . . . . . . . . . . . 124

OOils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Opening the bonnet . . . . . . . . . . . . . . . 325Opening the cab door . . . . . . . . . . . . . . 230

Opening the side windows . . . . . . . . . . 231Operating company . . . . . . . . . . . . . . . . 24Operating devices for hydraulic and

driving functions . . . . . . . . . . . . . . 59Operating materials

Quality and quantity . . . . . . . . . . . . 320Operating procedures . . . . . . . . . . . . . . 20Operating the service brake . . . . . . . . . 131Operating the signal horn . . . . . . . . . . . . 80Ordering spare parts andwearing parts . 319Overall view

Driver's compartment . . . . . . . . . . . . 57Overhead guard

Drilling . . . . . . . . . . . . . . . . . . . . . . . 29Roof loads . . . . . . . . . . . . . . . . . . . . 29Welding . . . . . . . . . . . . . . . . . . . . . . 29

PPackaging . . . . . . . . . . . . . . . . . . . . . . . 22Parking brake . . . . . . . . . . . . . . . . . . . 132

Electric parking brake . . . . . . . . . . . 134Mechanical parking brake . . . . . . . . 132

Parking the truck securely . . . . . . . . . . 142Particle filter

Operational requirements . . . . . . . . . 43Personnel qualifications . . . . . . . . . . . . 312Picking up loads . . . . . . . . . . . . . . . . . . 171Pin in the counterweight

Coupling . . . . . . . . . . . . . . . . . . . . . 239Place of use . . . . . . . . . . . . . . . . . . . . . . 12Procedure if truck tips over . . . . . . . . . . 288Production number . . . . . . . . . . . . . . . . 10Prohibition of use by unauthorised

persons . . . . . . . . . . . . . . . . . . . . 26Proper usage . . . . . . . . . . . . . . . . . . . . . 11Push-up roof window . . . . . . . . . . . . . . 236

QQuadruple mini-lever


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RRadiator

Checking for leaks . . . . . . . . . . . . . . 332Cleaning . . . . . . . . . . . . . . . . . . . . . 332

Radio . . . . . . . . . . . . . . . . . . . . . . . . . 234Rear window heating . . . . . . . . . . . . . . 234Recommissioning after decommis-

sioning . . . . . . . . . . . . . . . . . . . . 305Reducing speed with a raised load . . . . 141Relays . . . . . . . . . . . . . . . . . . . . . . . . . 366Replacing fuses . . . . . . . . . . . . . . . . . . 349Resetting the daily kilometres . . . . . . . . 112Resetting the daily operating hours . . . . 112Residual dangers . . . . . . . . . . . . . . . . . . 34Residual risks . . . . . . . . . . . . . . . . . . . . 34Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 27Reversible fork arm

Checking . . . . . . . . . . . . . . . . . . . . 356Reversible fork arms . . . . . . . . . . . . . . 164Roadways . . . . . . . . . . . . . . . . . . 122 – 123

Ascending gradients . . . . . . . . . . . . 121Descending gradients . . . . . . . . . . . 121Dimensions of aisle widths . . . . . . . . 120Dimensions of roadways . . . . . . . . . 120

Rotating beacon . . . . . . . . . . . . . . . . . . 212Rules for roadways and the working

area . . . . . . . . . . . . . . . . . . . . . . 122

SSafety devices . . . . . . . . . . . . . . . . . . . 310Safety inspection . . . . . . . . . . . . . . . . . . 42Safety regulations for maintenance

General information . . . . . . . . . . . . 308Safety devices . . . . . . . . . . . . . . . . 310Set values . . . . . . . . . . . . . . . . . . . . 310Working on the electrical equip-

ment . . . . . . . . . . . . . . . . . . . . . 309Working on the hydraulic equip-

ment . . . . . . . . . . . . . . . . . . . . . 308Working on the ignition system . . . . . 309

Safety regulations for working on the liftmast . . . . . . . . . . . . . . . . . . . . . 310

Safety regulations when driving . . . . . . 118Safety regulations when handing loads . 166Schematic views . . . . . . . . . . . . . . . . . . 20Scope of the documentation

UPA solutions . . . . . . . . . . . . . . . . . . 16Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 80

Checking . . . . . . . . . . . . . . . . . . . . 341Cleaning . . . . . . . . . . . . . . . . . . . . . 342Fastening . . . . . . . . . . . . . . . . . . . . . 81Fastening on a steep slope . . . . . . . . 82Maintaining . . . . . . . . . . . . . . . . . . . 341Malfunction due to cold . . . . . . . . . . . 82Releasing . . . . . . . . . . . . . . . . . . . . . 82Replacement after an accident . . . . 342

Selecting the drive direction . . . . . . . . . 124Selecting the driver PIN . . . . . . . . . . . . . 96Set values . . . . . . . . . . . . . . . . . . . . . . 310Setting chocks . . . . . . . . . . . . . . . . . . . 299Setting the date . . . . . . . . . . . . . . . . . . 111Setting the drive programs . . . . . . . . . . 123Setting the language . . . . . . . . . . . . . . 112Setting the time . . . . . . . . . . . . . . . . . . 111Shock recognition . . . . . . . . . . . . . . . . 220Shutting down the truck . . . . . . . . . . . . 303Special risks . . . . . . . . . . . . . . . . . . . . . 35Stability . . . . . . . . . . . . . . . . . . . . . . . . . 35Starting drive mode

Dual pedal version . . . . . . . . . . . . . 129Starting the engine . . . . . . . . . . . . . . . . 102Starting to drive . . . . . . . . . . . . . . . . . . 126Status LEDs . . . . . . . . . . . . . . . . . . . . 110Steering . . . . . . . . . . . . . . . . . . . . . . . . 139Steering system

Checking for correct function . . . . . . . 86Storing the truck . . . . . . . . . . . . . . . . . . 303StVZO (Road Traffic Licensing

Regulations) information . . . . . . . 11Switching off the truck . . . . . . . . . . . . . 142Switching on the key switch . . . . . . . . . . 89

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TTechnical data

Dimensions . . . . . . . . . . . . . . . . . . 358Three-waymini-lever . . . . . . . . . . . . . . . 61Topicality of the operating instructions . . 17Towed load . . . . . . . . . . . . . . . . . . . . . 238Towing . . . . . . . . . . . . . . . . . . . . . . . . 295

Proper use . . . . . . . . . . . . . . . . . . . . 12Trailers

Towing . . . . . . . . . . . . . . . . . . . . . . 249Transport . . . . . . . . . . . . . . . . . . . . . . . 298Transporting pallets . . . . . . . . . . . . . . . 173Transporting suspended loads . . . . . . . 173Triple mini-lever


Turn indicator . . . . . . . . . . . . . . . . . . . . 213Fingertip version . . . . . . . . . . . . . . . 214Mini-console version . . . . . . . . . . . . 215Mini-lever version . . . . . . . . . . . . . . 213

Types of lift mast . . . . . . . . . . . . . . . . . 149Telescopic mast . . . . . . . . . . . . . . . 150

TyresSafety principles . . . . . . . . . . . . . . . . 30

UUnlocking the emergency off switch . . . . 79Using working platforms . . . . . . . . . . . . . 14

VVariant

Ceiling sensor . . . . . . . . . . . . . . . . . 224

VariantsAccess authorisation with PIN code . . 92Automatic lift cut out . . . . . . . . . . . . 144Automatic shut-off of the internal

combustion engine . . . . . . . . . . . 141Clamp locking mechanism . . . . . . . . 206Clipboard . . . . . . . . . . . . . . . . . . . . 237Cruise control . . . . . . . . . . . . . . . . . 220Emergency off switch . . . . . . . . . . . . 79FleetManager . . . . . . . . . . . . . . . . . 220Fork extension . . . . . . . . . . . . . . . . 162Gas spring with position lock . . . . . . 326Hi-Lo lift mast . . . . . . . . . . . . . . . . . 150Lift mast vertical position . . . . . . . . . 145Lifting systems . . . . . . . . . . . . . . . . 144Loadmeasurement . . . . . . . . . . . . . 168Push-up roof window . . . . . . . . . . . . 236Radio . . . . . . . . . . . . . . . . . . . . . . . 234Reducing speed with a raised load . . 141Reversible fork arms . . . . . . . . . . . . 164Shock recognition . . . . . . . . . . . . . . 220Triplex lift mast . . . . . . . . . . . . . . . . 151Wheel chock . . . . . . . . . . . . . . . . . . 143Windscreen wiper/washer . . . . . . . . 219Zero braking . . . . . . . . . . . . . . . . . . 132

VDI datasheetRX70-16 . . . . . . . . . . . . . . . . . . . . . 360RX70-18 . . . . . . . . . . . . . . . . . . . . . 360RX70-20 . . . . . . . . . . . . . . . . . . . . . 360

Vertical lift mast positionChecking for correct function . . . . . . . 89

View of functions and operations . . . . . . . 20View of operating procedures . . . . . . . . . 20Views of the display operating unit . . . . . 21Visual inspections . . . . . . . . . . . . . . . . . 68

WWarning regarding non-original parts . . . 29Wheel chock . . . . . . . . . . . . . . . . . . . . 143

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Wheels and tyresChecking condition and wear of the

tyres . . . . . . . . . . . . . . . . . . . . . 344Checking the air pressure . . . . . . . . 345Checking wheel fastenings . . . . . . . 346Servicing . . . . . . . . . . . . . . . . . . . . 343

Windscreen wiper/washer . . . . . . . . . . 219Working at the front of the truck . . . . . . . 310Working on the electrical equipment . . . 309Working on the hydraulic equipment . . . 308Working on the ignition system . . . . . . . 309

Working spotlight for reverse travelSwitching on and off . . . . . . . . . . . . 211

Working spotlightsAutomatically switching on/off . . . . . 217Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 217Manually switching on/off . . . . . . . . 216Switching on and off . . . . . . . . 211, 216

ZZero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . . 87

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174749 EN – 11/2018

Original instructions Diesel truck - MVC-Empilhadores

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Transcript of Original instructions Diesel truck - MVC-Empilhadores