WithSCR(SelectiveCatalyticReduction)...Preface g Addressofmanufacturerand contactdetails STILLGmbH Berzeliusstraße10 22113Hamburg,Germany Tel.+49(0)407339-0 Fax:+49(0)407339-1622

Original instructions

Diesel trucksWith SCR (Selective Catalytic Reduction)

RX70-60RX70-70RX70-80

7341 7342 7343 7344

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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

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1 ForewordYour truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Note regarding SCR (Selective Catalytic Reduction) as exhaust gas treatment . . . . . . . . 2CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 4Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Information about the documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Issue date and topicality of the operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7List of abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Definition of directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Schematic views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 IntroductionUsing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Proper usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Proper use during towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Place of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Special risks associated with using the truck and attachments . . . . . . . . . . . . . . . . . . . 20Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3 SafetyDefinition of responsible persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Basic principles for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Insurance cover on company premises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Changes and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Changes to the overhead guard and roof loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Damage, defects andmisuse of safety systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . . 36Length of the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Regular safety inspection of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Checking the diesel engine emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Coolant and cooling fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Disposal of consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4 OverviewsOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Overview of the driver’s compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Operating devices and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Operating devices for hydraulic and driving functions . . . . . . . . . . . . . . . . . . . . . . . . . . 57Double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Three-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Four-way mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Mini console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Labelling points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Production number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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StVZO (Road Traffic Licensing Regulations) information . . . . . . . . . . . . . . . . . . . . . . . 67

5 OperationChecks and tasks to be carried out prior to commissioning . . . . . . . . . . . . . . . . . . . . . . 70Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Filling the washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Checking the condition of the wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Checking the cooling fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Adjusting the MSG 65/MSG 75 driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Adjusting the armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Cleaning the dust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Checking the pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Checking the oil tank on the oil bath air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Climbing into and out of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Unlocking the emergency off switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Switching on the key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Access authorisation with PIN code (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Operating the signal horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Using the driver’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103Checking the brake system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Checking the steering system for correct function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Checking the emergency off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Zero adjustment of the load measurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Checking the vertical lift mast position (variant) for correct function . . . . . . . . . . . . . . . . 109

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Safety regulations when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110Roadways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Setting the drive programme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114Selecting the drive direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115Actuating the drive direction switch, mini-lever version . . . . . . . . . . . . . . . . . . . . . . . . . 116Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 117Actuating the drive direction switch, fingertip version . . . . . . . . . . . . . . . . . . . . . . . . . . 117Actuating the drive direction switch, mini-console version . . . . . . . . . . . . . . . . . . . . . . 118Starting to drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118Starting drive mode, dual-pedal version (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Actuating the mechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126Reducing speed when turning (Curve Speed Control) . . . . . . . . . . . . . . . . . . . . . . . . . 127Reducing speed with a raised load (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128Automatic shut-off of the internal combustion engine (variant) . . . . . . . . . . . . . . . . . . . 128

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Lifting system variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Automatic lift cut out (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129Lift mast vertical position (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130Types of lift mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134Malfunctions during lifting mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135Hydraulic blocking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136Lifting system operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137Controlling the lifting system using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 138Controlling the lifting system using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . 139Controlling the lifting system using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . 140Controlling the lifting system using the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . 141Controlling the lifting system using the fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143Changing the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144Fork extension (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Operation with reversible fork arms (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Safety regulations when handing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Before taking up load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151Loadmeasurement (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Picking up loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155Danger area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156Transporting pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Transport of swinging loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Load pick up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158Transporting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Driving on ascending and descending slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Driving on lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Driving on loading bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Particle filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Particle filter - Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Particle filter - Performing parked regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Particle filter - Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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Working with attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Fitting attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Releasing the pressure from the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177General instructions for controlling attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179Controlling attachments using a double mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Controlling attachments using the double mini-lever and the 5th function . . . . . . . . . . . 183Controlling attachments using a triple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185Controlling attachments using the triple mini-lever and the 5th function . . . . . . . . . . . . . 187Controlling attachments using a quadruple mini-lever . . . . . . . . . . . . . . . . . . . . . . . . . 188Controlling attachments using the quadruple mini-lever and the 5th function . . . . . . . . . 190Controlling attachments via the joystick 4Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Controlling attachments using the joystick 4Plus and the 5th function . . . . . . . . . . . . . . 192Controlling the attachments with the fingertip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Controlling attachments with the fingertip and 5th function . . . . . . . . . . . . . . . . . . . . . . 194Clamp locking mechanism (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196Taking up a load using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Operating auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Switching the lighting on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201Switching the rotating beacon on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202Switching the hazard warning system on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Switching the direction indicators on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203Switching the double working spotlights on and off. . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Operating the windscreen wiper/washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207FleetManager (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207Accident recorder (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Cruise control (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208Driver restraint systems (variants) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Cab operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Opening the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Closing the cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Opening the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Closing the side windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Operating the interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214Operating the rear window heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215Radio (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Heating system (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216Air conditioning (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218Push-up roof window (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219Clipboard (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Trailer operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

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Coupling pin in the counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221Automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223Towing trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Operating the display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232Adjusting the displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Symbols in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233Setting the date or time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238Resetting the daily kilometres and daily operating hours . . . . . . . . . . . . . . . . . . . . . . . 238Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Soft key button for operating various equipment variants . . . . . . . . . . . . . . . . . . . . . . . 239Configuring Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Blue-Q efficiency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242Effects on additional consumers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242Switching efficiency mode Blue-Q on and off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Display messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245Display content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246General messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249Drive-specific messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Operating in special operating situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268Crane loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271Jump-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Procedure in emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276Procedure if truck tips over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Emergency hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278Emergency lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278Releasing the spring-operated brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Disconnecting the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Diesel fuel— Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283Filling up with diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Using the fuel hand pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Topping up AdBlue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Parking the truck securely and switching it off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

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Wheel chock (variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Shutting down and storing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292Recommissioning after shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Cleaning the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297Cleaning load chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Cleaning the windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298After washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

6 MaintenanceGeneral maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Personnel qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Information for carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305Maintenance - 500 hours/half-yearly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305Maintenance - 1000 hours/annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307Maintenance - 3000 hours/every two years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Ordering spare parts and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Quality and quantity of the required operating materials . . . . . . . . . . . . . . . . . . . . . . . . 312Maintenance data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Safety regulations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316Working on the hydraulic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316Working on the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Set values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Lifting and jacking up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318Working at the front of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Providing access to maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320Opening the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320Closing the bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321Removing and attachingthe left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Installing and removing the bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Opening and closing the right-hand service flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Cleaning the radiator and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Topping up the cooling fluid and checking the coolant concentration . . . . . . . . . . . . . . . 327Draining water from the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

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Cleaning the pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Cleaning the oil tank on the oil bath air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331Replacing the air filter cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Lubricating the joints and controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Checking the door latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334Maintaining the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Checking the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Changing the heating system fresh air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337Replacing the recirculated air filter for the heating system . . . . . . . . . . . . . . . . . . . . . . 338Greasing the automatic tow coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338Servicing wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Replacing the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Checking the hydraulic system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345Lubricating the lift mast and roller track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

7 1000-hour maintenance/annual maintenanceOther tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Checking the exhaust gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Checking the lift cylinders and connections for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Checking the fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Checking the reversible fork arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

8 Technical dataDimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

VDI datasheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Ergonomic dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

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1

Foreword

1 ForewordYour truck

Your truckGeneralThe 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 trucks have been fitted with state-of-the-art technology. All that remains is to handlethe truck safely and maintain its functionality.

These operating instructions provide thenecessary information to do this. Read andobserve the information provided beforecommissioning the truck. This will preventaccidents and ensure that the warrantyremains valid.

Note regarding SCR (SelectiveCatalytic Reduction) as exhaust gastreatmentThis truck uses the Selective Catalytic Reduc-tion (SCR) process of exhaust gas treatment.

To enable the SCR process to be performed,the truck uses AdBlue (32.5% urea solution, inaccordance with DIN 70070 / ISO 22241).

It is recommended that the AdBlue tank berefilled with AdBlue every time the diesel fuelis topped up; see the section "Topping upAdBlue".

The applicable European emission require-ments (97/68/EC) state that new enginesmusthave an SCR system.

2 57348011800 EN - 07/2016

Foreword 1Your 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.

57348011800 EN - 07/2016 3

1 ForewordYour truck

EC declaration of conformity in accordance with Machinery Directive

Declaration

STILL GmbH

Berzeliusstraße 10

D-22113 Hamburg Germany

We declare that the

Industrial truck 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

.

4 57348011800 EN - 07/2016

Foreword 1Your truck

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

57348011800 EN - 07/2016 5

1 ForewordInformation about the documentation

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

• Spare parts list• VDMA rules for the proper use of industrialtrucks

These operating instructions describe all mea-sures necessary for the safe operation andproper maintenance of your truck in all pos-sible variants available at the time of printing.Special versions to meet customer require-ments are documented in separate operatinginstructions. If you have any questions, pleasecontact your authorised service centre.

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

Production number...............................................

Year of manufacture...................................................

Please quote the production number during alltechnical enquiries.

Each truck comes with a set of operatinginstructions. These instructions must bestored carefully and must be available to thedriver andoperating companyat any time. Thestorage location is specified in the "Overviews"chapter.

If the operating instructions are lost, theoperator must obtain a replacement from themanufacturer immediately.

The operating instructions are included in thespare parts list and can be reordered there asa spare part.

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.

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Foreword 1Information about the documentation

NOTE

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

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.

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

DANGER

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

WARNING

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

57348011800 EN - 07/2016 7


CAUTION

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

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.

Abbreviation Meaning

°C Degrees Celsius

°F Degrees Fahrenheit

A Amperes

ABE Display operating unit

ArbSchG German labour protection law

BetrSichV German Ordinance on Industrial Safety and Health

BG Employers’ liability insurance association

BGG Employers’ liability insurance association act

BGR Employers’ liability insurance association ruleGerman SocialAccidentInsurance

Employers’ liability insurance association regulation

Approx. Approximately

CE Symbol that confirms conformity with the valid product-specific Europeandirectives

CEE International Commission on the Rules for the Approval of Electrical Equip-ment

cm Centimetres

8 57348011800 EN - 07/2016



cm3 Cubic centimetres

dB Decibels

DFÜ Remote data transmission

DIN German standard

EG European Community

EN European standard

FEM Fédération Européene de la Manutention

Fmax Maximum powerg Grams

GAA Industrial inspectorate

If applicable If applicable

GPRS General Packet Radio Service

h/d Hours per day (time driven each day in hours)

ID no. ID number

ISO International standard

kg Kilogramskg/m3 Kilograms per cubic metre

km/h Kilometres per hour

km/d Kilometres per day (kilometres driven each day)

kN Kilonewtons

kW Kilowatts

kWh/h Energy consumption

l Litres

l/h Litres per hour

l/min Litres per minute

LAN Local area network

LED Light emitting diode

Lp Sound pressure levelLpAZ Continuous sound pressure level in driver’s compartment

LSP Load centre of gravity

o.s. Or similar

m Metres

57348011800 EN - 07/2016 9



m/s Metres per second

m/s2 Metres per second squared

MAK Maximum workplace concentration

Max. Maximum

Min. Minimum

min Minutes

rpm Revolution(s) per minute

mm MillimetresN Newtons

Nm Newton metres

PIN Personal identification number

SE Superelastic

SIT Snap-in tyre for simplified assembly

StVZO German Road Traffic Licensing Regulations

t Tonnes

TRGS Technical Regulations for Hazardous Substances

a.s. And similar

V Volts

VDE Association for Electrical, Electronic & Information Technologies

VDI Association of German Engineers

VDMA German Engineering Federation

W Watts

WLAN Wireless local area networke.g. For example

.

10 57348011800 EN - 07/2016


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.

57348011800 EN - 07/2016 11


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.

12 57348011800 EN - 07/2016

Foreword 1Environmental 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.

57348011800 EN - 07/2016 13

1 ForewordEnvironmental considerations

14 57348011800 EN - 07/2016

2

Introduction

2 IntroductionUsing the truck

Using the 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".

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


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

16 57348011800 EN - 07/2016

Introduction 2Using the truck

DANGER

There is a risk of fatal injury fromfalling off the truck while it is moving!– It is prohibited to carry passengerson 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.

The truck has a closed particle filter systemand therefore fulfils the essential prerequisitesfor use in ventilated halls. The nationalregulations for the country of use must beobserved.

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

If the truck is to be operated on public roads,it must conform to the national regulations forthe country in which it is being used.

The ground must have an adequate loadcapacity (concrete, asphalt) and a roughsurface. Routes, work areas and aisle widthsmust conform to the specifications in theseoperating instructions, see the "Routes"chapter.

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

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 in

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2 IntroductionUsing the truck

the truck’s surroundings. Depending on theapplication, additional fire protection must beprovided on the truck. If in doubt, contact therelevant authorities.

NOTE

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

DANGER

Risk 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

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

– Always ensure sufficient ventilation.

Using working platforms

WARNING

The 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.

18 57348011800 EN - 07/2016

Introduction 2Residual 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.

WARNING

All 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.

The 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

57348011800 EN - 07/2016 19

2 IntroductionResidual 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 transportingswinging 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

20 57348011800 EN - 07/2016


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.

57348011800 EN - 07/2016 21


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 unautho-rised persons

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 nationallaws)

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and employer’sliability insuranceassociations

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 onIndustrial Safety andHealth (BetrSichV)

Contamination ofrespiratory air

Assessment of LPGexhaust gases

O German thresholdlimit values list(MAK-Liste) and theGerman Ordinance onIndustrial Safety andHealth (BetrSichV)

22 57348011800 EN - 07/2016



Notes

Issuing of operatinginstructions

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and German Healthand labour protectionlaw (ArbSchG)

Written notice ofinstruction to driver

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and German Healthand labour protectionlaw (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

57348011800 EN - 07/2016 23



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 valuewithin the permissiblerange

When using batterychargers

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

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and employers’liability insuranceassociation regulation104

When parking LPGtrucks

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

O German Ordinance onIndustrial Safety andHealth (BetrSichV)and employers’liability insuranceassociation regulation104

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


24 57348011800 EN - 07/2016



Notes

Driveways intersect Announce right-of-way rule


No person detectionduring depositing andretrieval

Employee training O German Ordinance onIndustrial Safety andHealth (BetrSichV)

.

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 major

57348011800 EN - 07/2016 25


operational 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.

26 57348011800 EN - 07/2016

3

Safety

3 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

28 57348011800 EN - 07/2016

Safety 3Definition 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

57348011800 EN - 07/2016 29

3 SafetyDefinition of responsible persons

DANGER

The 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.

30 57348011800 EN - 07/2016

Safety 3Basic principles for safe operation

Basic principles 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 is used for work that is not listedin the guidelines or in these instructions andhas to be converted or retrofitted accordingly,you must note that any change to its structuralstate can affect the handling and stability ofthe truck, which in turn can lead to accidents.

You should therefore contact your servicecentre beforehand.

Changes that will adversely affect stability,load capacity and safety systems, amongother things, must not be made without themanufacturer’s approval.

The truck may only be converted with writtenapproval from the manufacturer. Approvalfrom the responsible authority must be ob-tained if necessary.

Changes to the brakes, steering, controlelements, circumferential view, equipmentvariants and attachments must also not bemade without the prior written approval of themanufacturer.

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

57348011800 EN - 07/2016 31

3 SafetyBasic principles for safe operation

DANGER

Risk of injury!Even when using an approved restraint system,there is some residual risk that the driver might beinjured if the truck tips over. This risk of injury can bereduced through the combined use of the restraintsystem and the seat belt. In addition, the seat beltprotects against the consequences of rear-endcollisions and falling off a ramp.– Use the seat belt too.

When carrying out welding work on thetruck, it is essential that the battery and allconnections to the electronic control cards aredisconnected. Contact your service centre.

DANGER

If the truck is not equipped with an overhead guard,there is a risk to the driver’s life, as hemay be struckby a load falling from a lift height of 1800 mm orgreater.Operation of the forklift truck without an overheadguard is prohibited with a lift height greater than1800 mm.– For lift heights of 1800 mm and greater, only use

trucks with on overhead guard

In the event that the manufacturer goes intoliquidation and the company is not takenover by another legal person, the operatingcompany can make changes to the truck.

To do so, the operating company must fulfilthe following prerequisites:

Construction documents, test documentsand assembly instructions associated withthe change must be archived and remainaccessible at all times.

Check that the capacity rating plate, decal in-formation, hazard warnings and the operatinginstructions are consistent with regard to thechanges and modify if necessary.

The change must be designed, checkedand implemented by a design office thatspecialises in industrial trucks in accordancewith the standards and directives valid at thetime the changes are made.

Decal information with the following data mustbe permanently affixed to the truck so it isclearly visible:

32 57348011800 EN - 07/2016


– Type of change

– Date of change

– Name and address of the company imple-menting the change.

Changes to the overhead guard androof loads

DANGER

In 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.

CAUTION

Heavy 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.

57348011800 EN - 07/2016 33


CAUTION

Installation 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

DANGER

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

34 57348011800 EN - 07/2016


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.


57348011800 EN - 07/2016 35


Medical equipment

WARNING

Electromagnetic 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

WARNING

Gas 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.

WARNING

Accumulators 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.

36 57348011800 EN - 07/2016


Length of the fork arms

DANGER

Risk 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.

57348011800 EN - 07/2016 37

3 SafetySafety tests

Safety testsRegular 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 annuallyto TRGS 554.

The exhaust-gas check is to be carried outby a specialist (see ⇒ Chapter "Definition ofresponsible persons", P. 28) and must berecorded in writing.

– Contact your STILL service centre.

38 57348011800 EN - 07/2016

Safety 3Safety tests

NOTE

Observe the national regulations for yourcountry!

Particle filterThe truck has an SCR (Selective CatalyticReduction) exhaust gas treatment system aspart of its standard equipment. The truck maybe operated in entirely or partially enclosedworking areas.

DANGER

Risk to health from exhaust gases! Exhaust gasesfrom internal combustion engines are harmfulto your health. In particular, the soot particlescontained in the diesel exhaust gas can causecancer. Letting the combustion engine idle runsa risk of poisoning from the CO, CH and NOxcomponents 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


– Always ensure that there is sufficient ventilationavailable.

NOTE

Observe the national regulations of thecountry in which the truck is being used!

The operating company must ensure thatthe below requirements are met; see thechapter entitled "Definition of terms used forresponsible persons":• Usage must be reported to the responsibleoccupational health and safety authorities

• Operating instructions must be displayed inthe working areas

• Danger areas must be confined and indi-cated by appropriate warning and safetysigns

57348011800 EN - 07/2016 39

3 SafetySafety tests

• Employeesmust bemadeaware of dangersand protective measures

• The particle filter must be replaced every6000 operating hours. The exhaust-gascheck must be carried out by a competentperson (see the chapter entitled "Definitionof terms used for responsible persons") andthe results must be recorded in writing

NOTE

Observe the TRGS 554 regulations and thenational regulations of the country in which thetruck is being used.

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 /V fornominal battery voltage against ground.

– Contact the authorised service centre.

40 57348011800 EN - 07/2016

Safety 3Safety regulations for handling consumables

Safety regulations for handling consumablesPermissible consumables

DANGER

Failure 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. 6-313).

Oils

DANGER

Oils are flammable!– Follow the statutory regulations.– Do not allow oils to come intocontact with hot engine parts.

– No smoking, fires or naked flames!

DANGER

Oils are toxic!– Avoid contact and consumption.– If vapour or fumes are inhaled,move to fresh air immediately.

– In the event of contact with theeyes, rinse thoroughly (for at least10 minutes) with water and thenconsult an eye specialist.

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

57348011800 EN - 07/2016 41

3 SafetySafety regulations for handling consumables

WARNING

Prolonged intensive contact with theskin can result in dryness and irritatethe skin!– Avoid contact and consumption.– Wear protective gloves.– After any contact, wash the skinwith soap and water, and thenapply a skin care product.

– Immediately change soakedclothing and shoes.

WARNING

There 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

WARNING

These fluids are pressurised duringoperation of the truck and arehazardous to your health.– Do not spill the fluids.– Follow the statutory regulations.– Do not allow the fluids to come intocontact with hot engine parts.

42 57348011800 EN - 07/2016


WARNING

These fluids are pressurised duringoperation of the truck and arehazardous to your health.– Do not allow the fluids to come intocontact with the skin.

– Avoid inhaling spray.– Penetration of pressurisedfluids into the skin is particularlydangerous if these fluids escapeat high pressure due to leaks inthe hydraulic system. In case ofsuch injury, immediate medicalassistance is required.

– 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

WARNING

Battery acid contains dissolvedsulphuric acid. This is toxic.– Avoid touching or swallowing thebattery acid at all costs.

– In case of injury, seek medicaladvice immediately.

57348011800 EN - 07/2016 43


WARNING

Battery acid contains dissolvedsulphuric acid. This is corrosive.– When working with battery acid,always wear a protection suit andeye protection.

– When working with batteryacid, never wear a watch or anyjewellery.

– 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

WARNING

Diesel fuel is combustible.– Observe statutory regulations.– Do not allow diesel fuel to comeinto contact with hot enginecomponents.

Do not smoke!

44 57348011800 EN - 07/2016


WARNING

Diesel fuel is toxic!– Avoid contact and swallowing.– If vapour or fumes are inhaled,administer fresh air immediately.

– After contact with the eyes, rinsethoroughly (for at least 10minutes)with water and then consult an eyespecialist.

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

WARNING

Prolonged 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 skinwith soap and water, and thenapply a skin care product.

– Immediately change soakedclothing and shoes.

WARNING

Risk 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.

57348011800 EN - 07/2016 45


Coolant and cooling fluid

WARNING

Coolant and cooling fluid can behazardous to your health and theenvironment!Coolants are chemical corrosioninhibitors and cooling systemprotecting agents such as Glysantin.Cooling fluid is an appropriatemixture ofwater and coolant. Coolantin both concentrated and dilute formcan be hazardous to your healthif swallowed, or hazardous to theenvironment if spilled.– Store coolant and cooling fluidonly in their original containers anddo not spill them.

– Never store coolant or cooling fluidin empty food containers, bottlesor other 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.

46 57348011800 EN - 07/2016


– Neutralise any spilt battery acid immedi-ately.

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

57348011800 EN - 07/2016 47

3 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

< 75.0 dB(A) 4 dB(A)

The values were determined in the test cycleon an identical machine from the weightedvalues for operating statuses 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


48 57348011800 EN - 07/2016

Safety 3Emissions

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

< 0.31 m/s2 0.093 m/s2

Tests have indicated that the amplitude of thehand and arm vibrations on the steering wheelor the operating devices in trucks is less than2.5 m/s2. There are therefore no measure-ment guidelines for these measurements.

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


57348011800 EN - 07/2016 49

3 SafetyEmissions

Exhaust gases

DANGER

Risk 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.– Always observe the national laws and regulati-

ons of the country of use when using trucks withan internal combustion engine in entirely or par-tially enclosed working areas.


Heat

DANGER

Risk 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 exhaustpipes.

– Keep combustible materials awayfrom the exhaust pipe.

– In the event of burns, seek first aidimmediately.

– If materials are burning, take fireprotection measures immediately.

50 57348011800 EN - 07/2016

Safety 3Emissions

Battery

DANGER

Risk of explosion due to flammablegases!During charging, the battery releasesa mixture of oxygen and hydrogen(detonating gas). This gas mixture isexplosive andmust not be ignited.– Make sure that there is alwayssufficient ventilation in workingareas that are fully or partiallyenclosed

– Keep away from open flames andflying sparks

– Observe the safety regulations forhandling the battery.

57348011800 EN - 07/2016 51

3 SafetyEmissions

52 57348011800 EN - 07/2016

4

Overviews

4 OverviewsOverview

Overview

1 2 3

4

5

6

789

10

11

7341_003-002_V3

1 Lift mast2 Driver’s compartment3 Overhead guard4 Bonnet5 Battery maintenance lid6 Steering axle

7 Drive axle8 Tilt cylinder9 Fork arms10 Fork carriage11 Lift cylinder

54 57348011800 EN - 07/2016

Overviews 4Overview of the driver’s compartment

Overview of the driver’s compartment

9

0

7

8

5

3

1

24

6

100 % +-

5

12890

15:23

F1 F2

1 2 4

6

713

14

7341_003-022810 9

3 5

11

15

12

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

functions7 Compartment8 Bottle holder for max. 1.5 l bottles

9 Driver’s seat10 Compartment and potential storage location

for operating instructions11 Compartment12 Filler cap for windscreen washer reservoir13 Accelerator pedal14 Brake pedal15 Steering column adjustment

NOTE

The truck equipment may differ from theequipment shown.

57348011800 EN - 07/2016 55

4 OverviewsOperating devices and display elements

Operating devices and display elementsDisplay and operating unit

8

9

6

72

0

1

3

5

%75

2

234,7 h

12:15

7314_003-043

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 Lighting button6 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 Interior lighting/rotating beacon button22 Rear window heating/particle filter regener-

ation button23 Menu change button24 Lighting button25 Blue-Q button26 Rear window wiper button

NOTE

Buttons (5, 21, 22) and the accompanyingdisplay elements (6, 7, 17, 18, 19, 20) areassigned according to the equipment variantsin use.

The assignment shown here is an exampleand may differ from the assignment actuallyprogrammed on the truck. Buttons may beassigned multiple functions that are called upaccording to the menu navigation. For furtherinformation, see the "Operating the displayand operating unit" chapter.

56 57348011800 EN - 07/2016

Overviews 4Operating devices and display elements

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

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

57348011800 EN - 07/2016 57


Double mini-lever

F1 F2

7325_003-025

1

23 4

5

6

7

1 "Lift mast" 360° lever2 Function key F13 Function key F24 "Drive direction/turn indicator" cross lever

5 Function key "5th function"6 "Attachments" cross lever7 Signal horn button

NOTE

Depending on the equipment, various electricattachment parts canbe controlled via functionkeys (2) and (3). Changes must only be madeby the STILL service centre.

58 57348011800 EN - 07/2016


Three-way mini-lever

1

2

3 45

6

7

87325_003-026

1 "Lift mast" 360° lever2 Function key F13 Function key F24 "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

Depending on the equipment, various electricattachment parts canbecontrolled via functionkeys (2) and (3). Changes must only be madeby the STILL service centre.

57348011800 EN - 07/2016 59


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 F14 Function key F25 "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


60 57348011800 EN - 07/2016


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

57348011800 EN - 07/2016 61


Fingertip

F1F1 F2F2

7325_003-028

1 2 3 4 5 6

7891011

1 Function key F12 Function key F23 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


62 57348011800 EN - 07/2016


7311_003-0561

2

1 Travel direction switch2 Direction indicator switch

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

57348011800 EN - 07/2016 63

4 OverviewsLabelling points

Labelling pointsOverview

7

8

DANGER

DANGER

1

9

11

12

7341_003-016_V5

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

*

DANGER

54305430 10101010 10801080 10801080 10801080

10501050 11501150 13101310

44304430 11101110 12301230 12501250 15001500

40304030 11501150 12601260 12001200 15001500

37303730 11801180 12901290 14301430 15001500

34303430 12101210 13301330 14701470 15001500

800800 700700 500500600

5030 1270

2

1

3

20xx

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 Prüfung56

3443

9101

9

Mitglied der:FédérationEuropéenede la Manutention

STILL GmbH Hamburg

5

43

2

6

13

15

16

14

10 bar 19

613 18 12 10

21

3

14 5

15

15

417

16117

8

13

9

20

WAL

19

DANGER

DANGER

DANGER

17

20

17

20

1

2

21

64 57348011800 EN - 07/2016

Overviews 4Labelling points

1 Decal information: Caution/read the operat-ing instructions

2 Decal information: Diesel fuel3 Decal information: Sound power level4 Warning sign: Do not stand underneath the

fork/Do not stand on the fork/Danger due toshearing/Danger due to high fluid pressure

5 Decal information: Hydraulic oil tank6 Decal information: Attachment capacity

rating plate7 Decal information: Inspection sticker8 Decal information: FEM test9 Decal information: Caution/Read the op-

erating instructions/Fasten seat belt/Applyparking brake when leaving the truck/Pas-sengers are not allowed/Do not jump off ifthe truck is tipping over/Lean in the oppositedirection to which the truck is tilting

10 Manufacturer’s label text11 Decal information: Nameplate

12 Decal information: Capacity rating plate13 Decal information: Lifting gear attachment

point14 Warning sign: Actuate accumulator/brake

pedal 30x /read operating instructions15 Decal information: Tyre filling pressure16 Decal information: StVZO (German Road

Traffic Licensing Regulations) information(variant)

17 Warning sign: Danger due to shearing/Dan-ger due to high fluid pressure

18 Manufacturer’s label text19 Decal information: Before opening the

bonnet, slide the seat forwards, lower thearmrest and fold the seat backrest down.Then open the bonnet.

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

21 Decal information: To unlock, turn 90° to theright/to lock, turn 90° to the left

57348011800 EN - 07/2016 65







max

min.*

* see Operating instructions voir Mode d'emploi siehe Betriebsanleitung

kg kg

kg

kg

kgkW

V

*

1 2 3

4

5

6

7

89

10

11

12

6210_921-003_V2

1 Type2 Production number3 Year of manufacture4 Tare weight in kg5 Max. permissible battery weight in kg (for

electric forklift trucks only)6 Min. permissible battery weight in kg (for

electric forklift trucks only)7 Ballast weight in kg (for electric forklift trucks

only)8 Refer to the technical data listed in these

operating instructions for more detailedinformation

9 CE labelling10 Nominal drive power in kW11 Battery voltage in V12 Rated capacity in kg

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

66 57348011800 EN - 07/2016

Overviews 4Labelling points

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

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.

57348011800 EN - 07/2016 67


68 57348011800 EN - 07/2016

5

Operation

5 OperationChecks and tasks to be carried out prior to commissioning

Checks and tasks to be carried out prior to commissioningVisual inspections

WARNING

Risk of accident due to damage or other defects onthe truck or on the attachment (variant)!Damage to the truck or the attachment (variant)can lead to unpredictably dangerous situations.If damage or other defects are identified on thetruck or attachment (variant) during the followinginspections, the truck may not be used until it hasbeen properly repaired.– Do not remove or deactivate safety systems or

switches.– Do not change any predefined set values.– Do not use the truck until it has been properly

repaired.

WARNING

There is a risk of falling when working on high partsof the truck.– Use only the steps provided on the truck.– Do not stand on truck components or use them

to help you mount the truck.– Use suitable equipment.

1

2

6210_000-002

Prior to start-up, ensure that the truck is safeto be operated:

• The fork arms must be secured againstlifting and shifting.

• The locking devices (1) of the fork armsmust not be damaged or deformed.

• Fork arms and other lifting accessoriesmust not show any noticeable damage (e.g.bends, cracks, significant wear).

• The roller tracks (2) must be lubricated witha visible grease film.

• The chains must not be damaged and theymust be evenly and adequately tensioned.

• Check the area under the forklift truck forleaking consumables.

• The guard grille (variant) and overheadguard must be undamaged and securelymounted.

70 57348011800 EN - 07/2016

Operation 5Checks and tasks to be carried out prior to commissioning

• Attachments (variant) must be properlymounted and function according to theoperating instructions.

• All decal information signs must be inplace and legible. Replace damaged ormissing adhesive labels in accordance withthe overview in the "Identification points"chapter.

• Anywarning units (e.g. signal horn)must bein perfect condition and function correctly

• Check the visible areas of the hydraulicsystem and hydraulic oil tank for damageand leaks. Damaged hoses must bereplaced by the authorised service centre

• Check the visible areas of the fuel systemand fuel tank for damage and leaks. Dam-aged hoses must be replaced by the autho-rised service centre

• The bonnet and side flap must be lockedsecurely.

• Steps must be clean and free of ice.• Any panes of glass (variant, e.g. wind-screen) must be clean and free of ice.

• Depending on the tyres, the truck may befitted with an antistatic belt. The antistaticbelt must not be damaged. It must also beclean and long enough to touch the ground

• The coupling pin in the counterweight mustshow no noticeable damage (e.g. bends,cracks or breaks). The securing bush in thecounterweight must be present.

• A tow coupling (variant) must show nonoticeable damage (e.g. coupling pinbent, cracks or breaks). Every removablecoupling pin must be secured against losswith a securing device (e.g. a chain, a splitpin or a rope).

• Damage or other defects on the truck orattachment (variant) must be reported tothe supervisor or responsible fleet managerimmediately so that they can arrange for thedefect to be rectified.

57348011800 EN - 07/2016 71


Filling the washer system

CAUTION

Components may become damaged due to theeffects of frost!Water expands when it freezes. If there is noanti-freeze in the washer system, the system maybe damaged due to the build up of ice in freezingconditions.– Always use washer fluid containing anti-freeze.

The windscreen washer reservoir is under thecompartment behind the driver’s seat. Thesight glass (1) displays the fill level.

7331_341-001

2

1

– Open filler cap (2) for the windscreenwasher reservoir.

– Fill the windscreen washer reservoir withwasher fluid and anti-freeze in accor-dance with the maintenance data table;see ⇒ Chapter "Maintenance data ta-ble", P. 6-313.

– Close lid.

– Operate washer system until washer fluid isdischarged from the spray nozzles.

Checking the condition of the wheelsand tyres

WARNING

Risk of accidents! With unevenwear or incorrect airpressure, the stability of the forklift truck decreasesand the braking distance increases.– Change worn or damaged tyres without delay.

72 57348011800 EN - 07/2016


WARNING

Risk of tipping!Tyre quality affects the stability of the truck.If you wish to use a different type of tyre on the truckfrom the tyres approved by the truck manufacturer,or tyres fromadifferentmanufacturer, youmust firstobtain approval from the truck manufacturer.

WARNING

Risk to stability!When using pneumatic tyres or solid rubber tyres,rim wheel parts must never be changed and rimwheel parts from different manufacturers must notbe mixed.

NOTE

Only approved types of tyre may be used; seechapter entitled "Tyres".

12

7321_003-003

– Check tyres (1) for wear or damage.

Tyres must not be damaged or excessivelyworn. They must be worn evenly on bothsides.

– In the case of pneumatic tyres, check the airpressure. The air pressure indicated on theadhesive labels (2) must be observed.

NOTE

Observe the safety principles outlined in thechapter entitled "Tyres".

57348011800 EN - 07/2016 73


7341_003-017

1Checking the cooling fluid levelThe coolant level is monitored by a sensor.

As soon as the COOLANT LEVELmessageappears on the display, proceed as describedbelow.

WARNING

Risk of scalding due to hot cooling fluid!The cooling system is pressurised! Opening thecooling fluid tank (1) may result in hot cooling fluidleaking out. Only open the cooling fluid tank whenthe cooling system is cool.– Switch off the engine and allow it to cool down.– Do not open the cooling fluid tank until the truck

has cooled down.

WARNING

Coolant and cooling fluid can pose a hazard tohealth and the environment!– Observe the safety regulations set out in the

section entitled "Coolant and cooling fluid".

– Top up the cooling fluid if necessary; referto the section entitled "Topping up thecooling fluid and checking the coolantconcentration".

CAUTION

Risk of engine damage!If the coolant level is low, this indicates a leakage inthe cooling system.

– Check the cooling system for leaks; seethe section entitled "Cleaning the radiator,checking for leaks".

Checking the engine oil level

NOTE

To determine the oil level exactly, the truckmust be horizontal when checking.

– Ensure that the truck is parked in a horizon-tal position.

– Open the bonnet.

74 57348011800 EN - 07/2016


7341_003-065

– Stand on the bottom plate of the driver’scab and turn your body slightly to the left asshown.

7341_003-066

– Using both hands, pull out the oil dipstick (1)and wipe it using a cloth.

57348011800 EN - 07/2016 75


7341_003-010

1– Insert the oil dipstick (1) as far as it will goand pull it out again.

The oil level must be between the marks(arrows).

– If the oil level reaches only up to the lowermarking, fill oil in accordance with themaintenance data table.

– Insert the oil dipstick to the stop.

– Close the bonnet.

Adjusting the MSG 65/MSG 75driver’s seat

DANGER

There is a risk of accident if the seat or seat backrestshifts suddenly, which could cause the driver tomove in an uncontrolled manner. This can resultin unintentional actuation of the steering or theoperating devices and thus cause uncontrolledmovements of the truck or load.– Do not adjust the seat or seat backrest while

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

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

securely engaged.

WARNING

On some equipment variants, theamount of head clearance on thetruck may be restricted.On these specific equipment va-riants, the distance between the headand the lower edge of the roofingsheet must be at least 40 mm.

NOTE

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

76 57348011800 EN - 07/2016


WARNING

To 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 seat’s swivel area.

7094_003-0061

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

– 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 the lever (2) and hold.

– 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 MSG 75 seat is equipped with electric airsuspension activated with an electric switchinstead of a lever (3).

– Fully extend weight adjusting lever (3).

– Pump it upor 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 correct driver’s weight has been selectedwhen the arrow (4) is in the centre of theinspection window. A noticeable empty lift ontheweight adjusting lever shows that you havereached the minimum or maximum weightsetting.

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.

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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.

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

DANGER

There 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– Press down the steering columnadjustmentlever (2).

– Position the steering column (1) and pull thelever up again.

DANGER

Risk of accidents!– Ensure that the steering column is secure.The steering columnmust click into place.Never adjust the steering column while driving.

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7311_120-0041

Cleaning the dust valve– Press the dust valve (1) on the air filterhousing between your fingers until no moredust is emitted.

Checking the pre-cleanerThe pre-cleaner is part of the "heavy dustguard" equipment variant and is mounted atthe rear right of the truck. In the pre-cleaner,coarse dust and dirt are removed from theintake air.

Checking the pre-cleaner

7341_003-021

1

2

– Check the dirt level in the pre-cleaner (2).

The pre-cleaner must be cleaned if it is filled tothe upper marking (1), see the "Cleaning thepre-cleaner" chapter.

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7341_003-020

1

2

3

2

2

4

Checking the oil tank on the oil bathair filterThe oil bath air filter is a further variant of the"heavy dust guard" equipment variant and ismounted on the rear right of the truck. The oilbath air filter filters finer dust and dirt particlesthat have passed through the pre-cleaner outof the intake air.

WARNING

There is a risk of slipping on spilled oil, particularlywhen combined with water!The oil tank (4) is filled with oil to the level marker(3).– Carefully remove the oil tank.– Collect any spilt oil immediately using an oil

binding agent and dispose of it in accordancewith regulations.

– Observe the safety information for handling oils,see the "Oils" chapter.

– Fold up the four oil tank locking brackets (2).

– Remove the oil tank from the housing (1).

– Check the dirt level in the oil tank.

The oil tank must be cleaned if the depositeddirt reaches approximately halfway up to theoil level; see the "Cleaning the oil bath filter"chapter.

– Secure the oil tank with the four lockingbrackets on the housing.

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Operation 5Commissioning

CommissioningClimbing into and out of the truck

WARNING

Risk 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 overhead guard post or of yourclothes becoming stuck when climbing out of thetruck.– Ensure that the footwell cover is non-slip.– Do not jump into or out of the truck.– Ensure that you have a secure grip on the truck.

WARNING

Risk of injury when jumping out of the truck!If your clothing or jewellery (e.g. watch, ring etc.)becomes stuck on a component while you 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.

CAUTION

Components 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 may be damaged due to misuse.– Only use the fittings specifically designed for the

purpose of climbing into and out of the truck.

NOTE

The foot that the driver starts with whenclimbing into and out of the truck is crucial inensuring this action is carried out safely. Thiswill depend on the number of steps. Truckswith a single wheel on the front axle featuretwo steps. Trucks with two wheels on the frontaxle feature three steps.

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5 OperationCommissioning

Climbing in and out of trucks featuring asingle wheel and two steps

7341_003-001_V2

21 3

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7

5

4

When climbing into and out of the truck, usethe handles (2) and (4) for support. Theoverhead guard post (1) can also be usedfor support.

Always climb into the truck facing forwards:

– Grip handle (2) with your left hand and holdon.

– Grip handle (4) with your right hand andhold on.

– Place your right foot on the bottom step (5).

– Place your left foot on the top step (6).

– Place your right foot into the footwell (7).

– Enter the truck and sit down on the driver’sseat (3).

Always climb out of the truck backwards:


– Stand up from the driver’s seat and placeyour left foot on the top step (6).

– Grip the handle (4) with your right hand andhold on.

– Place your right foot on the bottom step (5).

– Place your left foot on the ground and climbdown from the truck.

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Climbing in and out of trucks featuringtwo wheels and three steps

7341_003-061

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4

56

When climbing into and out of the truck, usethe handles (2) and (4) for support. Theoverhead guard post (1) can also be usedfor support.

Always climb into the truck facing forwards:


– Grip handle (4) with your right hand andhold on.

– Place your left foot on the bottom step (5).

– Place your right foot on the middle step (6).

– Place your left foot on the top step (7).

– Place your right foot into the footwell (8).

– Enter the truck and sit down on the driver’sseat (3).

Always climb out of the truck backwards:


– Stand up from the driver’s seat and placeyour left foot on the top step (7).

– Grip the handle (4) with your right hand andhold on.

– Place your right foot on the middle step (6).

– Place your left foot on the bottom step (5).

– Place your right foot on the ground andclimb down from the truck.

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6321_003-142

1

Unlocking the emergency off switch

NOTE

Only trucks with a joystick 4Plus (variant) havean emergency off switch.

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

Switching on the key switch

WARNING

Before switching on the key switch, all tests priorto commissioning must be performed without anydefects being detected.– Perform the tests prior to commissioning.– Do not operate the truck if defects have been

detected.– Notify the authorised service centre.

NOTE

If the steering is turned when switching on thetruck, the truck will travel more slowly. Thisdriving speed limitation is disabled as soon asthe truck is steered out of cornering to drive ina straight line. To do this, rotate the steeringwheel by approximately half a turn.

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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 the setlanguage until the truck controllers have fullystarted up.

%75

2

234,7 h

12:15

1 2

347312_003-057_V2

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".

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CAUTION

Lack 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.When the fuel tank is replaced during repair workor because it has been run empty, diesel fuel mustbe pre-pumped with the fuel hand pump after filling,see the "Using the fuel hand pump" chapter.– Never run the fuel tank empty.– If necessary, refuel the truck and pre-pump

diesel fuel.

NOTE

Additional information may appear on thedisplay. If faults occur, refer to the informationin the chapter entitled "Faults".

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, the

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standard 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" buthaveno function as the highest valid driverPINis "99999". Persons with the correspondingaccessauthorisation, 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.

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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 (1).The digits entered for the driver PIN (2) are notvisible, instead being represented by circles.If the driver PIN entered is correct, the familiardisplay appears with the standard display, andall truck functions are available.

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3

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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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8

9

6

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4

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0

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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.

Blue-Q_029_V2

1

2

Defining the driver PIN

NOTE

The driver PIN can only be defined by personswith the corresponding access authorisation,e.g. fleet managers. In order for the fleetmanager to define the driver PIN, the confi-guration menu must be accessed. The confi-guration menu is password-protected. Afterentering the password, the fleet manager canconfigure general settings for the truck. Tochange the password, see the chapter entitled"Changing the password".

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

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7

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2

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2

BQ_030_en_V2

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ESC

PASSWORD appears in the display.

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

– Confirm the entry by pressing the ENTER

button (2).

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2

0

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3

5

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 by pressing theENTER button (2).

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0

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BQ_025_en_V3

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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).


NEW CODE appears in the display.

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

The digits entered donot 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 buttons(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.

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 entry by pressing the ENTER

button (2).

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5

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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

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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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3

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1

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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).

CAUTION

Do 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.

– To correct the newpassword, push the ESC

button (2).

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

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

– To exit the configuration menu, push theESC button repeatedly until the standarddisplays appear.

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F1F1 F2F2

7341_003-060

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 announceyour intentionto overtake.

Seat belt

DANGER

Even when using an approvedrestraint system, there is someresidual risk that the driver mightbe injured 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-end collisions and falling off a ramp.– We therefore recommend that youalso use the seat belt.

DANGER

Only 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).

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7311_003-048

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23

Fastening the seat belt

DANGER

Risk 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 "Faults".

– 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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CAUTION

The 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.

7331_341-002

Using the driver’s cab

DANGER

Risk 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. This will prevent the driver from falling outof the truck if it tips over. The driver’s cab constitu-tes a driver restraint system only if the cab door issturdy and closed. Fabric-covered cabs (variant)with doors made of plastic or canvas do not consti-tute a driver restraint system and offer no protectionfrom the consequences of the 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.

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Starting the engine

DANGER

Risk 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



– Apply the parking brake.

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0 I

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

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7312_003-087_en_V3

The message GLOW flashes, indicating thatthe engine is being preheated.

NOTE

Preheating can take up to 22 seconds. If theengine is already at operating temperature,preheating is not performed.

– If the START message lights up on thedisplay, turn the switch key to position "II"and hold it in this position until the enginestarts

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

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

CAUTION

Risk of engine damage!If the OIL PRESSUREmessage appears on thedisplay after starting the engine, there may be in-sufficient engine lubrication. Insufficient lubricationmay cause engine damage.– Stop the engine immediately.– Check the engine oil level and top up if necessary– If the message continues to appear, notify the

authorised service centre.

– Please note the information in the chapterentitled "Faults".

NOTE

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

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1

5060_003-015

Checking the brake system forcorrect function

DANGER

If the brake system fails, the truck is insufficientlybraked or not braked at all, so there is a risk ofaccident!– Do not commission trucks with a defective brake

system.

Checking the foot brake– Check pedal clearance:

There must be a distance of at least 60 mmbetween the pressure point and the pedalstop.

– Accelerate the truck without a load in a cleararea; see "Driving" chapter.

– Press the brake pedal (1) firmly.

The truck must decelerate noticeably.

6210_342-005

Checking the parking brake

DANGER

If the truck rolls away, there is a risk of being runover 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.

– Check the function of the parking brake atwalking speed or on a steep gradient byapplying the parking brake.

The truck must remain stationary on thegradient with the parking brake applied. Ifthe truck rolls in spite of an actuated parkingbrake, contact your service centre.

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5060_003-031

1Checking the steering system forcorrect function

DANGER

If 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


WARNING

No 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.– Only use the emergency off switch in the event

of a fire risk, to carry out function checking or inorder to park the truck safely.

– Brake the truck by depressing the brake pedal.

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CAUTION

There 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– Only use the emergency off switch in the event


– Steer with a higher level of force.

– Slowly drive the truck forwards.

6321_003-142

1

– Press the emergency off switch (1).

The truck will coast

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

– 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• as part of daily commissioning• after changing the fork arms• after fitting or changing attachments.

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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 notraise the fork more than 800 mm above theground.

NOTE

Operation of the lifting system depends onwhich operating devices the truck is fittedwith; see ⇒ Chapter "Lifting system operatingdevices", P. 5-137.

– Set lift mast to vertical.

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

6210_003-071_V2

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– Keep button (1) for the "zero adjustment"pressed for at least four seconds; the "zeroadjustment"(2)symbol will appear in 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 in theoperating unit display.

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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.

– Actuate function key (1) to switch on thecomfort feature "lift mast vertical position".

Function display (2) must appear in thedisplay.

– 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.

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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 5Driving

WARNING

The 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.

WARNING

In 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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Roadways

Dimensions of roadways andaislewidthsThe following dimensions and aisle widthrequirements apply under the specifiedconditions to ensure safe manoeuvring. Ineach case, it must be checked whether alarger aisle width is necessary, e.g. in thecase of different load dimensions.

Within the EU, the 89/654/EEC directive(minimum health and safety requirementsfor the workplace) must be observed. Therespective national guidelines apply for areasoutside of the EU.

The required aisle widths depend on thedimensions of the load.

For pallets, these are:

Aisle width [mm]

Model Type with pallet1000 x 1200crosswise

with pallet800 x 1200lengthwise

RX70-60(LSP 600) 7341 4907 5107

RX70-70(LSP 600) 7342 4987 5187

RX70-80(LSP 600) 7343 5056 5256

RX70–80(LSP 900) 7344 5185 5385

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

Driving on gradients

WARNING

Driving up and down longer gradients may causethe drive unit to overheat and switch off.Driving up and down longer gradients is not permit-ted due to the minimum specified braking values.The climbing capability values given below only ap-ply to overcoming obstacles on the roadway and toshort differences in level, e.g. ramps.

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Operation 5Driving

The truck may be driven on the followingupwards or downwards gradients:

Maximum gradient [%]Model Type

with load Without loadRX70-60(LSP 600) 7341 33 32

RX70-70(LSP 600) 7342 27 30

RX70-80(LSP 600) 7343 24 30

RX70–80(LSP 900) 7344 21 29

LSP = load centre of gravity

The upwards and downwards slopes may notexceed the gradient listed above and shouldhave a rough surface.

Smooth and gradual transitions at the top andbottom of the gradient should prevent the loadfrom falling to the ground or the truck beingdamaged.

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 objects must be compensated for, andif necessary, ramps must be provided so thattrucks can drive over these with as few bumpsas possible.

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Ensure sufficient load capacity of manholes,drain covers and the like.

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


Hazard areasHazardous areas on the roadways mustbe marked by standard traffic signs or, ifnecessary, by additional warning signs.

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

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6311_003-028_V2

1

1 2

– Push the drive programme button (1)repeatedly until the number of the requireddrive programme appears on the display(2).

Drive programmes 1–5 are available.

Essentially, the higher the number of the driveprogramme, the greater the driving dynamics.

The following drive programmes are available:

Drive programme 1 2 3 4 5

Speed (km/h) 20 20 20 20 20

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) 80 90 100 100 100.

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 is

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5 OperationDriving

then 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.

5060_003-096

F1 F2

1

Actuating the drive direction switch,mini-lever version– For the "forwards" drive direction, push thecross lever (1) forwards

– For the "backwards" drive direction, pushthe cross lever backwards

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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).

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

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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

DANGER

Being trapped under a rolling or tipping truck couldcause fatal injuries.– Sit down 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 is equipped with a seatswitch. This checks whether the driver’s seatis occupied. If it is not occupied or in the caseof malfunction of the seat switch, the truckcannot be moved and all lifting functions arelocked. In this situation, the message SEATSWITCH appears in the operating unit display.

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


– Release the parking brake.

– Select the desired drive direction.

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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.

3

5060_003-084

– Press the accelerator pedal (3).

The truck will travel in the selected drive direc-tion. The speed is controlled by the accelera-tor pedal position. When the accelerator pedalis released, the truck decelerates.

NOTE

The truck can briefly be stopped on upwardor downward gradients without actuatingthe parking brake (electric brake). The truckbegins to creep downhill slowly.

DANGER

Risk 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– Do not leave the truck without actuating the

parking brake!

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.

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NOTE

Thedrivedirection canalso be changedduringtravel. Your foot can remain on the acceleratorpedal. The truck decelerates and is thenaccelerated again in the opposite direction(reversing).

NOTE

In the event of an electrical fault with theaccelerator the drive unit is shut down. Theelectrical brake (service brake) causes thetruck to decelerate. The truck cannot be drivenagain until the accelerator pedal has beenreleased and then actuated again, providedthe electrical fault has been corrected. If thetruck still won’t operate, park it securely andcontact your service centre.

Starting drive mode, dual-pedalversion (variant)

DANGER

Being trapped under a rolling or tipping truck couldcause fatal injuries.– Sit down 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 is equipped with a seatswitch. This checks whether the driver’s seatis occupied. If it is not occupied or in the caseof malfunction of the seat switch, the truckcannot be moved and all lifting functions arelocked. In this situation, the message SEATSWITCH appears in the operating unit display.

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



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5060_003-085

2 1

– Press the right accelerator pedal (1) to drive"forwards" and press the left acceleratorpedal (2) to drive "backwards".

NOTE

In the dual pedal version, any drive directionswitches on the operating devices have noeffect.

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 speed is controlled by the accelera-tor pedal position. When the accelerator pedalis released, the truck decelerates.

NOTE

The truck can briefly be stopped on upwardor downward gradients without actuatingthe parking brake (electric brake). The truckbegins to creep downhill slowly.

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DANGER

Risk of accident!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.– Do not leave the truck without actuating the

parking brake!

Changing the drive direction– Remove foot from actuated acceleratorpedal.

– Actuate the accelerator pedal for the otherdirection.

The truck will travel in the selected drivedirection.

NOTE

In the event of an electrical fault with theaccelerator the drive unit is shut down. Theelectrical brake (service brake) causes thetruck to decelerate. The truck cannot be drivenagain until the accelerator pedal has beenreleased and then actuated again, providedthe electrical fault has been corrected. If thetruck still won’t operate, park it securely andcontact your service centre.

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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.

DANGER

Risk 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.

DANGER

Risk 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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Zero braking (variant)

DANGER

Risk 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 brakeThe truck is equipped with a mechanicalparking brake.

Actuating the mechanical parkingbrake

DANGER

There 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.

NOTE

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

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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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A

A B

A B

B

5060_003-007

1

Steering

DANGER

If 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 steering wheel(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 "Technical data", P. 351.

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6327_003-006

Reducing speed when turning(Curve Speed Control)This function reduces the speed of the truck asthe steering angle increases, regardless of theamount to which the accelerator has been ac-tuated. If the steering angle is reduced againupon exiting the curve, the truck accelerates inline with how far the accelerator is depressed.

However, the function does not release thedriver from the duty to approach a curve at aspeed according to the following factors:• The carried load• The roadway conditions• The radius of the curve

DANGER

The Curve Speed Control function cannot overridethe physical limits of stability. Despite this function,there still is a risk of tipping!– Before using this function, familiarise yourself

with the change to the driving and steeringcharacteristics of the truck.

DANGER

Increased risk of tipping if the Curve Speed Controlfunction is disabled! If the controller fails while thetruck is in motion or if the controller is disabled,the truck will no longer automatically brake whensteering.– Do not turn off the key switch while driving.– Actuate the emergency stop switch only in

emergencies.– Always adapt your driving style to the conditions.

Despite the Curve Speed Control function, thetruckmay overturn in extreme cases within thefollowing situations:• Cornering too fast on uneven or inclinedroadways.

• Turning the steering wheel sharply whiledriving.

• Cornering with an inadequately securedload.

• Cornering too fast on a smooth or wetroadway.

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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 and after a presetwaiting time 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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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. 5-134

• The operating device with which thehydraulic functions are controlled, see⇒ Chapter "Lifting system operating de-vices", P. 5-137

Regardless of the equipment variants of thetruck, the basic specifications and proceduresmust be complied with, see ⇒ Chapter "Safetyregulations when handing loads", P. 5-150.

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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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 the "F1"(1) button on the displayoperating unit. The automatic lift cut out isnow overridden and a load can be lifted tothe truck’s maximum lift height.

To switch the automatic lift cut out back on:

– Press the "F1"(1) button again.

Lift mast vertical position (variant)

DescriptionIf the truck is equipped with the "lift mastvertical position" comfort feature (variant),the driver can put goods, such as paper rolls,down vertically with precision and thus avoiddamage when unloading. The tilt cylindersrun into the end stops gently to prevent hardvibrations and impacts. Oscillating motions ofthe truck are minimised, thus increasing worksafety. The lift mast vertical position reduceswear on various components and thereforereduces maintenance costs.

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Operation 5Lifting

CAUTION

Risk 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 approach towards the "lift mastvertical position"

• Gentle running-in to the end stops

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.

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Automatic approach towards the "liftmast vertical position"

6210_003-067_V2

21

– Switch on the "lift mast vertical position"comfort feature via the button (1) on thedisplay and operating unit.

– Tilt the lift mast forwards using the corre-sponding operating device. The lift maststops automatically as soon as the prese-lected setting is reached for the "lift mastvertical position".

If the comfort feature is switched off, the liftmast tilts forwards past the "lift mast verticalposition" 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 stops

The 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.

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

6210_003-067_V2

21

– Actuate the button (1) to switch on the "liftmast vertical position" comfort feature; thefunction display (2) in the display shows theactivated status.

– 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".

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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".

Tilt the lift mast forwards beyond the verticalposition:

– Release the operating device for tilting 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 deactivate the "lift mast vertical position",actuate the button (1) again.

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.

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.

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6210_003-070_en_V2

12

3

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

– Press and hold the button (1) for the "liftmast vertical position" for at least fiveseconds.

The message "? VERTICAL POSITION"will appear on the display.

Storing the mast position:

– Press the drive program button (3).

The current mast position is stored.

Cancelling calibration:

– Press the menu change button (2).

The calibration is cancelled.

Types of lift mastOne of the following lift masts may be installedin the truck:

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.

DANGER

Risk 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.

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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).

DANGER

Risk 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.

Malfunctions during lifting mode

Incorrect extension sequence

DANGER

Risk of accidents!With triple masts (variant), an incorrect extensionsequence may occur, i.e. the inner lift mast mayextend before the free lift has finished. As a result,the overall height is exceeded and damage mayoccur in passageways or from low ceilings.

An incorrect extension sequence may, forinstance, result from:• The hydraulic oil temperature being too low.• The fork carriage becoming blocked in theinner lift mast.

• Blocking of the free lift cylinder.• The chain roller becoming blocked at thefree lift cylinder.

– 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

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Load chains not under tension

DANGER

Danger 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 becoming blocked inthe lift mast due 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.

WARNING

Risk of injury!– Observe the safety regulations for working on lift

masts; see ⇒Chapter "Working at the front of thetruck", P. 6-318.

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 5Lifting

– Sit down on the driver’s seat.

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:

DANGER

Reaching 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.

57348011800 EN - 07/2016 137

5 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

DANGER


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.

138 57348011800 EN - 07/2016

Operation 5Lifting

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

DANGER



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.

57348011800 EN - 07/2016 139

5 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

DANGER



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 5Lifting

Controlling the lifting system usingthe joystick 4Plus

DANGER


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).

2

DC

6210_003-090


– Tilt the horizontal rocker button (2) to the left(D).


– Tilt the horizontal rocker button (2) to theright (C).

57348011800 EN - 07/2016 141

5 OperationLifting

1

6210_003-091

E

F

7312_003-022_V2

DC

B

A

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.

142 57348011800 EN - 07/2016

Operation 5Lifting

F1F1 F2F2

7325_003-038

1

2

1 2

6210_003-043

6210_713-002_V2

2

1

Controlling the lifting system usingthe fingertip

DANGER



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.

57348011800 EN - 07/2016 143

5 OperationLifting

Changing the fork arms

DANGER

There is a risk of being run over if the truck rollsaway, and therefore a danger to life.– 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.

WARNING

There is a risk of injury when changing the forkarms; the fork arms’ weight could cause them to fallon your legs, feet or knees. The space to the leftand 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 onto oneside.

144 57348011800 EN - 07/2016

Operation 5Lifting

1

2

6210_003-027

Removal– Select a pallet corresponding to the fork armsize.

– Position the pallet to the left or right of thefork carriage.

– Raise the fork carriage until the lower edgesof the fork arms are approx.3 cmhigher thanthe height of the pallet.

– Actuate the parking brake and make sure itis applied securely.

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

– Undo the locking screw (2) on the right orleft.

– Pull the locking lever (1) upwards and pushthe fork arms outwards onto the pallet.

Installation– Position the fork arms to the left or right ofthe fork carriage on a pallet.

– Push the fork arms onto the fork carriagefrom the outside towards the centre.

– Pull the locking lever (1) upwards and pushthe fork arms into the required position.Ensure that the locking lever snaps intoplace.

– Fit and tighten the locking screw (2).

DANGER

There is a risk to life caused by a falling load or fork!– Tighten the locking screw after every fork

replacement.– It is not permitted to drive or transport loads

without the locking screw.

NOTE

If the truck is equipped with the "load measu-rement" comfort feature, then a "zero adjust-ment of the load measurement" is imperativeafter the fork arms have been changed; see⇒ Chapter "Zero adjustment of the load mea-surement (variant)", P. 5-107. Otherwisecorrect measurement of the load cannot beguaranteed.

57348011800 EN - 07/2016 145

5 OperationLifting

Fork extension (variant)

DANGER

There 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.

WARNING

There 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.

WARNING

There 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.– 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 adjustmentof the load measurement" is imperative afterthe fork extension has been changed; see the"Zero adjustment of the load measurement"chapter. Otherwise, correct load measure-ment cannot be guaranteed.

146 57348011800 EN - 07/2016

Operation 5Lifting

7071_003-104_V2

1

2

3

Attachment

DANGER

Risk 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.

57348011800 EN - 07/2016 147

5 OperationLifting

Operation with reversible fork arms(variant)

6210_862-013

Normal operationThe reversible fork arms (variant) can be liftedand tilted with the lift mast in the samemanneras a normal fork.

6210_862-014

Max. 600 mm

2

1

Reverse operation

DANGER

Risk to life from falling load!Standard fork arms are not structurally designed forreverse operation. If this is not observed, this canlead to material failure and the load falling.– Do not carry out reverse operation with the

standard fork arms.

WARNING

Risk of accident from slipping load!Loads may slip on the fork arms (1) if there is noload support. A fork extension (variant) cannot besecured against slipping.– Load pick-up on the fork arms is not permitted.– The fork extension (variant) must not be used.

WARNING

Risk 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 the load centre of gravity up to a

max. of 600 mm above the ground.

148 57348011800 EN - 07/2016

Operation 5Lifting

NOTE

If the truck is equippedwith the "loadmeasure-ment" comfort feature, thena "zero adjustmentof the load measurement" is obligatory afterthe reversible fork arms have been changed;see ⇒ Chapter "Zero adjustment of the loadmeasurement (variant)", P. 5-107. Otherwise,correct load measurement cannot be guaran-teed.

57348011800 EN - 07/2016 149

5 OperationHandling loads

Handling loads

6210_003-030

Safety regulations when handingloadsThe safety regulations for handling loads areshown in the following sections.

DANGER

There 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!

DANGER

Risk 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.

DANGER

Risk 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.

150 57348011800 EN - 07/2016

Operation 5Handling 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".

WARNING

The figures show examples.Only the capacity rating plateson the truckare valid!

The attachment of additional weights toincrease load capacity is prohibited.

DANGER

Risk 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.

57348011800 EN - 07/2016 151


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)

WARNING

Risk 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.

152 57348011800 EN - 07/2016


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

DANGER

Risk 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".

CAUTION

If 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

57348011800 EN - 07/2016 153


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

– Press button (1) for "load measurement";the "load measurement" symbol (2) ap-pears on the display highlighted in black.

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.

154 57348011800 EN - 07/2016


6210_003-073_en

3

When the loadmeasurement has been carriedout correctly, the determined load weight isdisplayed in the operating unit.

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.

DANGER

Risk 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.

57348011800 EN - 07/2016 155


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.

DANGER

Risk of injury!– Do not step on the fork.

DANGER

Risk of injury!– Do not step under the raised forks.

DANGER

People 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.

156 57348011800 EN - 07/2016


DANGER

Danger of death from falling loads!– Never walk or stand underneathsuspended 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

Transport of swinging loadsContact your national regulatory authorities(employer’s liability insurance associations inGermany) prior to transporting swinging loads.

National regulations may place restrictionson these operations. Contact the relevantauthorities.

DANGER

Swinging loads can result in the 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.

57348011800 EN - 07/2016 157


DANGER

Loss of stability due to slipped, unstable or, inparticular, hanging loads!The following information should be noted whentransporting hanging loads:

• Swinging of the load is to be prevented byusing the proper driving speed and drivingmanner (careful steering, braking).

• Hanging loads must be coupled to the truckin such a way that the harness cannot shiftor release unintentionally, and cannot bedamaged.

• Take particular care to ensure that there areno persons in the direction of travel in thedriving lane.

• Ensure that swinging loads do not putpersons at risk.

• When transporting hanging loads, suitabledevices (e.g. guy wires or hand rails) areto be made available and used by guidepersons.

DANGER

Risk of accidents!When transporting hanging loads, never abruptlyperform or end driving and load movements duringtransport.Never drive on slopes with a hanging load!Containers with fluids cannot be transported ashanging loads.

Load pick up

DANGER

There 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 loadingequipment and incorrectly formed loadsmust not be stored.

158 57348011800 EN - 07/2016


– 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.

CAUTION

Component damage possible!When inserting the fork into the racking, ensure thatthe racking and load are not damaged.

57348011800 EN - 07/2016 159


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.

DANGER

Risk of accidents!– Beware of any people in the danger area.

CAUTION

Component damage possible!– Ensure that the roadway behind you is clear.

– Move backwards carefully and slowly untilthe load is clear of the racking. Brake gently.

DANGER

Never tilt the lift mast with a raised load due to therisk of tipping!– Lower the load before tilting the lift mast.

160 57348011800 EN - 07/2016


5060_003-102

– Lower the load while maintaining groundclearance.

5060_003-101


The load can be transported.

57348011800 EN - 07/2016 161


6210_800-011

Transporting loads

NOTE

Observe the information in the chapter entitled"Safety regulations when driving".

DANGER

The 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".

162 57348011800 EN - 07/2016


6210_800-014

– Never drive with a load protruding to theside (e.g. with the sideshift)!

Setting down loads

DANGER

Risk of accident due to changed moment of tilt!Pleasenote that the liftmast canbe tilted far enoughforward with a raised load to cause the truck to tipover.The load centre of gravity and the moment of tiltboth change when the load slips. The truck may tipforwards.– Only tilt the lift mast forwards with a raised lifting

accessory when it is directly above the stack.– When the lift mast is tilted forward, take particular

care to ensure that the truck does not tip forwardsand that the load does not slip.

WARNING

Risk 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.

NOTE

If the truck is to be used to store a raised loadwith the lift mast tilted forwards, e.g. in a rackwith sloping racking channels, an additional

57348011800 EN - 07/2016 163


load capacity diagrammust be created as thestability will be affected.• Contact the authorised service centre onthis matter.

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.

DANGER

Risk 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.

164 57348011800 EN - 07/2016


6210_001-008

Driving on ascending and descend-ing slopes

DANGER

Danger to life!Onascending and descending slopes the loadmustbe carried facing uphill.It is only permitted to drive on ascending anddescending slopes if they are marked as trafficroutes and can be used safely.The driver must check that the ground is clean witha good grip.It is not permitted to perform turns on ascendingslopes, to approach them diagonally or to park thetruck on them.Drive at a reduced speed on descending slopes.It is not permitted to put items into stock or toremove them from stock while on an ascendingor descending slope.The forklift truck should not be parked on a slope.– In case of emergency, secure the truck with

chocks.

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.

DANGER

There 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.

57348011800 EN - 07/2016 165







max

min.*


kg kg

kg

kg

kgkW

V

*

1

2

7321_003-011_V2

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.

6210_001-010

Driving on loading bridges

DANGER

Risk 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.

166 57348011800 EN - 07/2016

Operation 5Particle filter system






max

min.*


kg kg

kg

kg

kgkW

V

*

1

2

7321_003-011_V2

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


= Actual total weight.

Particle filter systemParticle filter - Function

DANGER

Risk to health from exhaust gases! Exhaust gasesfrom internal combustion engines are harmfulto your health. In particular, the soot particlescontained in the diesel exhaust gas can causecancer. Allowing the internal combustion engine toidle represents a risk of poisoning from the CO, CHandNOx 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


– Always ensure that there is sufficient ventilationavailable.

This truck is equipped with a closed particlefilter system that filters carcinogenic sootparticles out of the exhaust gas and collectsthem in the particle filter.

57348011800 EN - 07/2016 167

5 OperationParticle filter system

The use of a particle filter is recommended forapplications in closed halls with a low degreeof ventilation.

Operating principle during normaloperationThe soot particles that are filtered out ofthe exhaust gas and collected in the filterare removed by means of a continuousregeneration process.

This process requires a sufficiently highexhaust gas temperature, which is alsoreached during normal operation. The truckis then used to such a degree that it burnsoff the soot during operation. The drivermust not interfere with this process. No otherconsumables (e.g. additives) are required.

Operating principle during low-loadoperationIf the truck is used little, a sufficiently highexhaust gas temperature may not be reached.In addition, very low ambient temperaturesmay prevent a sufficiently high exhaust gastemperature being reached. This causesthe regeneration process to be disrupted.The soot filtered out of the exhaust gasthen collects in the particle filter, as it is notburned off during the continuous regenerationprocess. In this case, a parked regenerationof the particle filter must be performed. Thisregeneration process, which takes approx. 30minutes, canonly be performedwhen the truckis stationary, meaning the truck cannot beused during this time. The driver is informed ofthe need for a parked regeneration in advanceby means of corresponding messages on thedisplay and operating unit. Details of thesemessages are provided in the chapter entitled"Messages regarding parked regeneration onthe display and operating unit".

Interrupting parked regenerationReleasing the parking brake during parked re-generation interrupts the parked regenerationprocess.

168 57348011800 EN - 07/2016


In the display and operating unit, the followingmessage appears: PARK. REG. ERROR.

NOTE

If regeneration is interrupted too frequently,additional engine maintenance may berequired from the authorised service centre.


– Restart parked regeneration.

The restarted parked regeneration requiresanother 30 minutes to complete, no matterhow complete the interrupted parked regener-ation was.

If the display message PARK. REG. ERRORappears more than twice in successionwithout the parking brake being releasedduring parked regeneration, there may be amalfunction in the internal combustion engine.

– Notify the authorised service centre.

Particle filter - Performing parkedregeneration

CAUTION

Risk of damage to components! If parked regene-ration is not performed when required, the particlefilter may become damaged.A full parked regeneration must be performed inorder to completely empty the particle filter.

CAUTION

During the parked regeneration process, very hotcombustion gases escape from the exhaust pipe!The parked regeneration must not be performedin areas containing hazardous materials or highlyflammable materials, or in a hall. In addition, thefollowing instructions must be observed exactly.

During parked regeneration, the surfacetemperature of the exhaust gas system ishigher than the usual operating temperature.This can causeadhering dust andoils to ignite.If the truck is operated with an exhaust gasextraction unit, parked regeneration is notpermitted. The operating company must

57348011800 EN - 07/2016 169


determine whether parked regeneration ispermitted where the truck is being used orwhether the truckmust bemoved to a separatearea for this purpose.

The parked regeneration must be carriedout while the internal combustion engine isrunning. During the regeneration process,the truck automatically changes the speed ofthe internal combustion engine. The drivercannot influence this change. If the parkedregeneration requested by the truck is notperformed and this remains the case for anextended period of time, the particle filter maybecome damaged. If this happens, it wouldneed to be repaired by your authorised servicecentre.

Before performing parked regeneration, thefollowing points must be observed:• Observe the operating instructions from theoperating company

• Always thoroughly clean dust, oils and othersettling substances from the exhaust gassystem

• Remove any connected exhaust gasextraction units

• Perform parked regeneration in a suitableplace

NOTE

Parked regeneration can only be performedif the parking brake is engaged. If the parkingbrake is not engaged, APPLY HANDBRAKE!appears on the display.

As soon as the message EXH.GAS PURI-FIER appears in the display and operatingunit, parked regeneration can be performed.To do this, proceed as follows:

– Park the truck in a place that is suitable forparked regeneration.

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7071_003-101

0 I

1

II– Switch the key switch (1) to position "0" andwait until the display has turned off.

– Turn the key switch back to the "I" position.

8

9

0

6

7

4

3

5

ESC

1

2

Themessage START PARK. REG.? as wellas the soft keys OK (1) and ESC (2) appear onthe display.

– To start the parked regeneration process,press the OK button (1).

The message START IC ENGINE appearson the display.

– To interrupt the parked regenerationprocess, press the ESC button (2).

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7071_003-101

0 I

1

II– Start the engine. To do this, turn the switchkey (1) to position "II" and hold it there untilthe engine has started. Then release theswitch key.

7312_003-132_en_V2

4

The particle filter regeneration process isstarted. EXH.GAS PURIFIER PLEASEWAIT appears on the display. The statusbar (4) below the message indicates theregeneration progress.

NOTE

During parked regeneration, the engine speedfluctuates and the power of the radiator fanis reduced. The drive unit and the hydrauliccontroller are switched off and do not respondwhen the corresponding operating devicesare actuated.

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7341_003-039_en_V2

The parked regeneration process is completewhen the status bar disappears and REGE-NERATION COMPLETED appears on thedisplay. The truck is ready for operation again.

NOTE

The system requests parked regenerationevery 500 operating hours at the latest ifit has not already been performed due tosoot accumulation in the particle filter. Themessage EXH.GAS PURIFIER appears onthe display and parked regeneration must beperformed.

Particle filter - Displays

NOTE

To guarantee economic use of the truck, itis important to follow the specifications inthese operating instructions exactly. If notesabout particle filter regeneration shown onthe screen of the display and operating unitare not observed, this can lead to longer truckdowntimes.

The following table describes the messagesthat appear on the display and operating unitrelating to parked regeneration and if parkedregeneration is not performed:

Messages Meaning Comment

EXH.GAS PURIFIERCarry out parked regenerationof the particle filter.

See the section entitled "Per-forming parked regeneration"

STARTPARK. REG.?

Prompt asking whether parkedregeneration of the particlefilter should now be performed.

START IC ENGINE Request to start the engine.

EXH.GAS PURIFIERPLEASE WAIT

The particle filter is beingregenerated.

A status bar shows theregeneration progress.

REGENERATIONCOMPLETED

The parked regenerationprocess is complete.

The truck is ready for operationagain.

57348011800 EN - 07/2016 173


PARK. REG.URGENT! ! !

Parked regeneration of theparticle filter is urgentlyrequired.

Until parked regeneration hasbeen carried out, themaximumspeed of the truck is reducedto 2 km/h. The lifting speed isrestricted.

PARK. REG.ERROR

Regeneration was interrupteddue to an error.

The parking brake wasreleased during parkedregeneration.Apply the parking brake andrestart regeneration.If the message appears morethan twice in successionwithout the parking brakebeing released during parkedregeneration, there may bea malfunction in the internalcombustion engine. In thiscase, notify your authorisedservice centre.

ASH LOAD

The particle filter has becomeclogged with ash. Repairmust be performed by theauthorised service centre.

EXH.GAS PURIFIERSERVICE! ! !

Because regeneration has notbeen performed, the particlefilter systemmust be repairedby the authorised servicecentre. To avoid furtherdamage, take the truck outof operation until the repair hasbeen performed.

Until the particle filter systemhas been repaired, themaximum speed of the truckis reduced to 2 km/h. Thelifting speed is significantlyrestricted.

.

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Operation 5Working with attachments

Working with 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.

NOTE

Please note the definition of "competentperson" in the sense of responsible persons!

CAUTION

Attachments must be CE-certified. If the truck isnot fitted with an attachment-specific residual loadcapacity rating plate, and the operating devices arenot marked with the relevant pictograms, the truckmust 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).

57348011800 EN - 07/2016 175

5 OperationWorking with attachments

DANGER

There is risk to life caused by a falling load!Attachments that hold the load by exerting pressureon it (e.g. clamps)must beadditionally controlled 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.

DANGER

There 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.

7341_003-019

Hydraulic connection– Before fitting the attachment, release thepressure from the hydraulic system.

CAUTION

Risk 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 attachments have been disassembled,

attach theprotective caps to theplug connectors.

Mounting attachmentsMounting the attachment and connecting theenergy supply for power-driven attachmentsmust only be performed by authorised per-sonnel in accordance with the informationprovided by the manufacturer and supplier ofthe attachment. After each assembly, the at-tachmentmust be checked for correct functionprior to initial commissioning.

NOTE

Please note the definition of "competentperson" in the sense of responsible persons!

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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 in 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 "Picking up aload using attachments".

7341_003-019

Releasing the pressure from thehydraulic systemPrior to assembling attachments, the pressuremust be released from the plug connectors(see image).

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 chapter 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.

57348011800 EN - 07/2016 177


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.

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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.

WARNING

Use 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.

57348011800 EN - 07/2016 179


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.

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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).

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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.

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7312_003-112

12E

F

7312_003-113_V2

E F

Controlling attachments usingthe double mini-lever and the 5thfunction

NOTE

The "lift mast" 360° lever and the "attach-ments" cross lever control four hydraulic func-tions. The "5th function" designation refersto the fact that switching functions using the"5th function" function key (1) control the 5thhydraulic function via the cross lever.

The pictograms on the "attachments" crosslever show the respective functions that areactivated by this lever.


– Actuate the "5th function"(1) function keyand move the "attachments"(2)cross leverin 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"(2) cross leverin the direction of the arrow (F).

The attachment moves in accordance with thepictogram in position (F).

57348011800 EN - 07/2016 183


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

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.


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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

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.


57348011800 EN - 07/2016 185


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.

7325_003-040

E

F

2

1

3

Controlling attachments using thetriple mini-lever and the 5th function

NOTE

Four hydraulic functions are controlled usingthe "lift mast" 360° lever and operating levers(1) and (2). 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 (3).



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5060_003-120_V2

E

F

– Actuate the "5th function" function key (3)and move operating lever (1) towards (E)


– Actuate the "5th function" function key (3)and move operating lever (1) towards (F)


NOTE



5060_003-122

3

4

1

2





4 Rotate to the right.

57348011800 EN - 07/2016 187


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



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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.

7325_003-042

4

1

25

3

E

F

Controlling attachments using thequadruple mini-lever and the 5thfunction

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"(5) key.



57348011800 EN - 07/2016 189


5060_003-120_V2

E

F

– 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



5060_003-122

3

4

1

2





4 Rotate to the right.

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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


Operatingdevice

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.


57348011800 EN - 07/2016 191


Controlling attachments using thejoystick 4Plus and the 5th function

6210_003-096

1– Note the following attachment functions andpictograms.

Operatingdevice

Function of theattachment

1Horizontalrocker button+ shift button "F"

Release/open clamp

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 switch (2) in the direction shown inthe pictogram so that the attachmentmovesaccordingly.

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.


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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.

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F1F1 F2F2

7325_003-044

13

2Controlling attachments with thefingertip and 5th function

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.

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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



57348011800 EN - 07/2016 195


6210_003-035

10 11

14

12

15

17 18

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 Open/close clamps

17 Turn to the left/right

18 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.

DANGER

There 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.

It is not necessary to release the clamp lockingmechanism in order to close the clamp.

– To close the clamp, pull the cross lever (1)back.

– To operate clamping attachments, see thesection entitled "Controlling attachmentsusing the double mini-lever and the 5thfunction".

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) back.

57348011800 EN - 07/2016 197


– To operate clamping attachments, see thesection entitled "Controlling attachmentsusing the triple mini-lever and the 5thfunction".

7325_003-049

1

2

Quadruple mini-lever– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





– To operate clamping attachments, see thesection entitled "Controlling attachmentsusing the quadruple mini-lever and the 5thfunction".

198 57348011800 EN - 07/2016


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 shiftkey "F"(3) and move the horizontal rockerbutton (1) to the right.

NOTE



– To close the clamp, press and hold shift keyF (3) and move the horizontal rocker button(1) to the left.

– To operate the clamping attachments, seethe section entitled "Controlling attach-ments using the joystick 4Plus and the 5thfunction".

57348011800 EN - 07/2016 199


7325_003-050

F1F1 F2F2

1

2Fingertip switch– To release the clamp locking mechanism,push the operating lever (1) forwards.


NOTE





– To operate the clamping attachments; seethe section entitled "Controlling attach-ments using the fingertip and the 5th func-tion".

1

2

3

7090_860-002

Taking up a load using attachments

WARNING

Risk 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.

WARNING

Risk 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.

200 57348011800 EN - 07/2016

Operation 5Operating auxiliary equipment

– The rating plates show the permissiblevalues for:

• Load capacity Q (kg) (1)• Lift height h (mm) (2)• Load distance C (mm) (3)

Operating 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.

NOTE

On the version with StVZO (German RoadTraffic Licensing Regulations) equipment, theparking light and the licence plate lamp canbe switched on without the key switch beingswitched on.

57348011800 EN - 07/2016 201

5 OperationOperating auxiliary 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

On the version with StVZO (German RoadTraffic Licensing Regulations) equipment,the parking light and the licence plate lampare switched on by switching on the workingspotlights.

Switching the rotating beacon on andoff

5060_003-045_V2

21

– Push the button (1) for switching on therotating beacon.

The rotating beacon symbol (2) appears onthe display. The rotating beacon is switchedon.

NOTE

Pushing the button again switches the rotatingbeacon off again.

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5060_003-011_V2

1

2

Switching the hazard warningsystem on and off– Push the button (1) to switch on the hazardwarning system.

All direction indicators and indicatorlights (2) flash.

NOTE

Pushing the button again switches the hazardwarning system off again.

NOTE

The hazard warning system can also beswitched on without the key switch beingswitched on.

Switching the direction indicators onand off

5060_003-096

F1 F2

1

Mini-lever version– Switch on the direction indicators bymovingthe drive direction/turn indicator cross lever(1) to the left or right.

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2 3

5060_003-012_V2

The direction indicators and the correspon-ding direction indicator lights (2) or (3) flash.

– Switch off the direction indicators bymovingthe cross lever to the centre position

5060_003-046

1

Mini-console version– Switch on the direction indicators bymovingthe turn indicator switch (1) to the left or tothe right.

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2 3

5060_003-012_V2

The direction indicators and the correspon-ding direction indicator lights (2) or (3) flash.

– Switch off the direction indicators bymovingthe turn indicator switch to the centreposition

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 on switchingthe lower working spotlights on, see the"Switching lighting on and off" chapter.

NOTE

This function is not available if the truck isequipped with rear window heating.

57348011800 EN - 07/2016 205


– Turn the key switch to position "I".

6311_003-030_V3

1

– Press button (1).

NOTE

Pressing the button again switches the work-ing spotlights off again.

Switching the upper working spotlightson/off automatically– Turn the key switch to position "I".

– For information on switching on workingspotlights, see the "Switching lighting onand off" chapter.

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

In these two seconds, a maximum of two liftscan take place so that the working spotlightsdo not switch on each time a precise adjust-ment is made. If more lifts are carried outduring this time, the upper working spotlightswill remain switched off.

NOTE

The upper working spotlights are switchedoff automatically when the truck is driven forlonger than one second and faster than 2.1km/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.


– Switch on the working spotlights.

206 57348011800 EN - 07/2016


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.

CAUTION

Possible component damage caused by collision ifthe proximity switch is set incorrectly.– The proximity switch may be adjusted by trained

personnel.– Inform the relevant service centre.

Operating the windscreenwiper/washer

7312_003-171_V3

1

2

– Press the button (1) to activate the frontwiper/washer (variant) and the roof panelwiper (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 shown below.

Button actuation Operating stage

Off

1st time On

2nd time Interval

3rd time + hold Washer

4th time Off.

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.

57348011800 EN - 07/2016 207


Accident recorder (variant)The accident recorder is an equipment variantto the FleetManager (variant), which is in-stalled in the truck’s acceleration sensor. Theacceleration sensor records data in the eventof an accident. This data can be electronicallyread out and evaluated. For further informa-tion, contact your STILL service centre.

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 used forreverse travel or when travelling at speeds of< 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.

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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 via the display andoperating unit.

Switching on cruise control

WARNING

Risk 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)

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7325_003-057

F1F1 F2F2

F1 F2

1

11

– Re-actuate the drive direction switch (1)for forward travel for at least one second,or press the corresponding button on thedisplay and operating unit.

8

9

0

6

7

4

3

5

2

7312_003-150

The current speed is saved. The forwardsdrive direction indicator (2) flashes.

The cruise control symbol on the display andoperating unit is shown in black.

– 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 button (seearrows, previous picture) on the displayand 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 drive direction indicator (2) lights up.

The cruise control symbol on the display andoperating unit is shown in white.

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.

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5 OperationCab operation

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.

Cab operation

7331_341-0034 5

2

1

3

Opening the cab door

DANGER

There is a risk of damage caused by collision if thecab door opens while driving.– The cab door must be latched securely in the

engaged position.

Opening the cab door from the outside:– Insert the key in the door lock (1), unlockand remove the key.

– 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.

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Operation 5Cab operation

Closing the cab door

DANGER

There is a risk of damage caused by collision if thecab door opens while driving.– The cab door must be latched securely in the

engaged position.

7331_341-007

4

2

1

3

Opening the side windows

WARNING

There is a risk of crushing between the windowframe and side window from 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:The front sidewindow (4) can be opened in thesame way as the rear side window.

57348011800 EN - 07/2016 213


7331_341-007

4

2

1

3

Closing the side windows

WARNING

There is a risk of crushing between the windowframe and side window from 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.

– Make sure that the handle engages in thestop slot (3).

Closing the front side window:The front side window (4) can be closed in thesame way as the rear side window.

7300_003-006

3

1

2

Operating the interior lightingAn interior light (1) with swivelling support (3)is fitted in the right-hand roof lining of the cab.

The interior lighting can be operated usingthe switch (2) in the roof lining and via thecorresponding soft key button on the displayand operating unit.

NOTE

The interior lighting cannot be switched onusing the switch in the roof lining if it has beenswitched off on the display and operating unit.The interior lighting cannot be switched on atthe display and operating unit if the switch inthe roof lining is in position "0".

Switching on the interior lighting

– Check whether the switch in the roof liningis in position "I"; if not, move the switch toposition"I".

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6311_003-013_V2

21

– Switch on the interior lighting using thecorresponding soft key button (1) on thedisplay and operating unit.

The "interior lighting" symbol (2) appears inthe display on the display and operating unit.

The interior lighting is switched on.

Adjusting the beam direction

– To change the beam direction, carefullyswivel the support into the required position.

Switching off the interior lighting

– Switch off the interior lighting using thecorresponding soft key button on the displayand operating unit.

The "interior lighting" symbol goes out in thedisplay on the display and operating unit.

The interior lighting is switched off.

NOTE

We do not recommend that you use the switchin the roof lining to turn off the interior lighting.If the interior lighting is switched off using theswitch in the roof lining, both the switch in theroof lining and the button on the display andoperating unit must always be actuated toswitch on the light.

Operating the rear window heating

6311_003-014_V2

21

– Switch the rear window heating on or offwith button (1).

The "rear window heating" symbol (2) appearsin the display.

NOTE

The rear window heating will switch off au-tomatically after approx. 10 minutes or afterpressing the switch again.

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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.

WARNING

The 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.

Heating system (variant)

DANGER

Risk of explosion!There is a risk of explosion if theheater is operated in the vicinity ofstorage areas or similar areas wherefuel vapours or coal dust, wood dustand crop dust can accumulate.– Do not expose spray cans or gascartridges to the flow of hot air.

– Do not operate the heater inhazardous areas.

DANGER

Risk of fire as a result of heat buildingup in the heating element!Heat may build up if the air intakeopening is blocked or the heatingelement collects dust. The heatingelement may overheat or short-circuit.– Do not cover the air intakeopening.

– Do not operate the heating systemwithout a fresh air filter andrecirculated air filter fitted.

216 57348011800 EN - 07/2016


DANGER

Risk of burns!When the heating system is ope-rated, the heating system housingbecomes hot and can burn the skin ifit is touched.– Do not touch the heating systemhousing during operation.

CAUTION

Risk of blower malfunction!The fresh air filter and recirculated air filter collectdust and dirt particles from the intake air. If the filterelements are not fitted, dust and dirt particles mayblock the blower.– Do not operate the blower without a fresh air filter

and recirculated air filter fitted.

Switching on the blower

2

6341_003-021

1

– 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

NOTE

The heating system only heats up when theblower is switched on. If the blower switchis switched off, the heating system will notfunction, regardless of the position of theheater switch.

– To switch the heating system on, firstswitch on the blower switch (1) and thenthe heating switch (2).

The heating system is in operation. The air isheated up to the heat output level set at theheating switch (2).

57348011800 EN - 07/2016 217


Adjusting the air flow

7331_345-002

4

3

– Adjust the air flow at the front outlet vents(3) and at the outlet vent in the footwell (4).

Air conditioning (variant)

Switching on the air conditioning

1

2

7331_346-001

3

– Switch the blower switch (1) on.

– Set the cryostat (2) to the desired level.

– Switch on the air conditioning by pressingthe switch (3).

Switching off the air conditioning– Switch off the air conditioning by pressingthe switch (3).

– Switch off the blower switch (1).

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6210_003-105_V2

1

2

3

3

Push-up roof window (variant)

WARNING

Risk 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

6210_003-107

21

Clipboard (variant)The clipboard (1) with reading lamp (2) is anequipment variant.

57348011800 EN - 07/2016 219

5 OperationTrailer operation

Trailer operation

6210_313-001

Towed load

DANGER

There 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.

CAUTION

Risk 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 towed load present corresponds tothe rated capacity of the truck, it is not permitted totransport a load on the fork at the same time. Theload can be distributed between the fork and thetrailer.– Check the load distribution and adjust to corre-

spond to the rated capacity.– Observe the permissible rigidity value of the tow

coupling.

CAUTION

Risk 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 centreof the application conditions. The service centreprovides the required data.– Inform the authorised service centre.

220 57348011800 EN - 07/2016

Operation 5Trailer operation

CAUTION

Damage to the tow coupling due to overloading!Tow couplings RO*243 and RO*244 must beindividually checked to ensure that they are suitablefor the planned towing operation. The permissiblerigidity value of the tow coupling must always betaken into account. The authorised service centrecan check and/or confirm the maximum towed loadfor the planned towing operation.– Observe the operating instructions for the tow

coupling.– Inform the authorised service centre.

CAUTION

Risk 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. Themanufacturer must be consulted if the truck isto be used for towing on a more regular basis.

Coupling pin in the counterweight

Coupling the trailer

DANGER

If you briefly leave the truck to couple or uncouple,there is a risk to life caused by the truck rolling awayand running you over.– Apply the parking brake.– Lower the fork to the ground.– Turn off the key switch and remove the key.

57348011800 EN - 07/2016 221


1 7090_900-008

– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks (1).

7331_313-001

32

– Push the coupling pin (2) down, turn 90°and pull out.

– Adjust tiller height.

DANGER

Persons may become trapped between the truckand trailer.When hooking up, ensure that no one is betweenthe truck and trailer.

– Slowly move the truck back.

– Bymoving the truck back, introduce the tillerinto the gap (3) of the counterweight.

DANGER

In 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 for good condition.– Ensure that the coupling pin is correctly inserted

and 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.

222 57348011800 EN - 07/2016


Uncoupling the trailer– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.

7331_313-001

32

– 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).

Automatic tow coupling

DANGER


DANGER

Never jack up or crane load the truck on the towcoupling. The tow coupling is not designed for thisand could be deformed or destroyed. The truckcould fall off, with potentially fatal consequences!– Use the tow coupling only for towing.– For jacking up and crane loading, use only the

designated lifting points.

DANGER

The tow coupling is not designed for support loadsand could be deformed or destroyed. This couldcause the supported load to fall, with potentiallyfatal consequences!– The tow coupling should be subjected only to

horizontal loads, i.e. the tiller must be horizontal.

57348011800 EN - 07/2016 223


DANGER

If you briefly leave the truck to couple or uncouple,there is a risk to life caused by the truck rolling awayand running you over.– Apply the parking brake.– Lower the fork to the ground.– Turn off the key switch and remove the key.

WARNING

Never 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.

CAUTION

Risk 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, check 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, check the tow coupling

for damage.– Replace tow coupling if damaged, if necessary

contact the authorised service centre.

CAUTION

Risk 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.

224 57348011800 EN - 07/2016


CAUTION

Risk of component damage if the tiller in the towcoupling is tilted!The tiller should if possible be kept horizontal whentowing. This ensures a sufficient rotation range atthe top and bottom. The authorised service centrecan adjust the assembly height for the tow couplingto the tiller height if necessary.– Make sure that the tiller is level.– To change the coupling height, contact the


1 7090_900-008

Coupling model RO*243

CAUTION



NOTE

TowcouplingRO*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.

57348011800 EN - 07/2016 225


3

7321_003-064

2

– Pull out the safety handle (3).

– Push the hand lever (2) upwards.

DANGER


CAUTION

When 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.


DANGER

If thecoupling 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.


– Tow the trailer.

Closing model RO*243 by hand

DANGER

Risk of injury from hand becoming trapped!Do not reach into the coupling pin area with yourhand. If, for example, a tow rope is to be secured inthe tow coupling, use only a suitable device to closethe tow coupling (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 andthen closes the tow coupling automatically.

226 57348011800 EN - 07/2016


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.

Coupling model RO*244 A

CAUTION



NOTE

Tow coupling RO*244 A is intended for atow-bar eye in accordance with DIN 74054(bore diameter 40 mm) or DIN 8454 (borediameter 35 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.

57348011800 EN - 07/2016 227


DANGER

Persons may become trapped between the truckand trailer!When hooking up, ensure that no one is betweenthe truck and trailer.

CAUTION

When 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.

– 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) doesnot protrude out of itsguide.

DANGER

If 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.



228 57348011800 EN - 07/2016


Closing model RO*244 A by hand

DANGER

Risk of injury from hand becoming trapped!Do not reach into the coupling pin area with yourhand. If, for example, a tow rope is to be secured inthe tow coupling, only actuate the tow coupling viathe closing 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.

– Push the hand lever (2) upwards until itsnaps into place.



– Close the tow coupling by actuating theclosing lever (1).

NOTE

To protect the lower coupling pin bush againstcontamination, always keep the tow couplingclosed.

57348011800 EN - 07/2016 229


7321_003-066_V2

57

6

Coupling model RO*245

NOTE

Tow coupling RO 245 is intended for a tow-bareye 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.




DANGER

Persons may become trapped between the truckand trailer!When hooking up, ensure that no one is betweenthe truck and trailer.


DANGER

If thecoupling 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.



230 57348011800 EN - 07/2016


7321_003-066_V2

57

6

Uncoupling model RO*245– Take measures to prevent the trailer fromrolling away, e.g. use wheel chocks.



– Push the closing lever (7) on the left side ofthe tow coupling down as far as it will go.

The tow coupling is closed.

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.

NOTE


57348011800 EN - 07/2016 231

5 OperationOperating the display and operating unit

Operating the display and operating unitDisplays

%75

2

234,7 h

12:15

1 2

347312_003-057_V2

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".

7312_003-185

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.

232 57348011800 EN - 07/2016

Operation 5Operating the display and operating unit

7312_003-056_en_V3

ESC

1 2 3Adjusting 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.


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

The display changes to thePASSWORDmenu.

– Press the return key (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• Configuring Blue Q

Symbols in the display

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

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Symbols for operating messages

Description Symbol

Empty field No display

Please wait

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

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Description Symbol

Are you sure?

Oil pressure.

Symbols for error messages

Description Symbol

Brake systemmalfunction

Overheating of the engine

Overheating

Malfunction in the electrical system

General malfunction.

Symbols for auxiliary equipment soft keyfunctionsFor the auxiliary equipment, the followingsymbols for the soft key functions are used onthe left in the display:

Description Symbol


General function key OFF

General function key 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

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Description Symbol

Heater blower OFF

Heater blower ON

Rotating beacon OFF

Rotating beacon ON

Seat heater OFF

Seat heater ON

Signal horn OFF

Signal horn ON.

Symbols for the soft key functions formenu navigation and for acknowledgingmessagesFor menu navigation and to acknowledgemessages, the following symbols for thesoft key functions are used on the left of thedisplay:

Description Symbol


ESC button to return to the main menu

ENTER button to confirm

OK button to confirm

RES button to reset

Button to return to the main menu

Button to return to the previous edit field

Scroll button to scroll up

Scroll button to scroll downScroll button to count up

Scroll button to count down.

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.

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Description LED

Function off LED OFF

Function on LED ON.

Symbols for numeric keypadThe available inputs and the positions of thekeys are shown for inputting digits, ESC andENTER .

BQ_037

1

2

6

7

3

4

5

ESC

Keys for the digits 1 to 7 and the ESC andENTER keys for inputting the fleet managerpassword

1

2

6

7

3

4

5

8

9

0

BQ_038

Keys for digits 0 to 9 for inputting the driver PIN(access code)

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8

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0

6

7

4

3

5

7312_003-054_en_V3

1 2 3 4Setting the date or time– Switch to the "CONFIGURATION"menu; see ⇒ Chapter "Adjusting the dis-plays", P. 5-233.

– Press the drive program key (1) or menuselection key (2) until the option TIMEappears.Confirm your selection by pressingthe Return key (4).

The "TIME" menu appears.

– Press the drive program button (1) or themenu change button (2) until the desiredtime appears in the display.

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

– Confirm the time set by pressing the Returnkey (4).

– Use the arrow key (3) to exit the menu andreturn to the next higher level.

NOTE

The date is set in a similar manner.

8

9

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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 "CONFIGURATION"menu; see ⇒ Chapter "Adjusting the dis-plays", P. 5-233.

– Press drive program button (1) or menuselection button (2) until the DAY-KMoption appears. Confirm your selectionby pressing the Return key.

The "DAY KM" menu appears.

– Reset the values by pressing the RES (4)button.

– Use the arrow key (3) to exit the menu andreturn to the next higher level.

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NOTE

The daily operating hours are reset in thesame manner.

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 "CONFIGURATION"menu; see ⇒ Chapter "Adjusting the dis-plays", P. 5-233.

– Press drive program button (1) or menuselection button (2) until the LANGUAGEoption appears. Confirm your selection bypressing Return key(4).

The "LANGUAGE" menu appears.

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

– Confirm your selection by pressing theReturn key (4).

– Use arrow key (3) to exit the menu andreturn to the next higher level.

Soft key button for operating variousequipment variantsThere are two soft key columns available onthe display operating unit. With these softkey columns, you can switch the additionalfunctions on and off, e.g. a rotating beacon.The second soft key column is only availableif the truck has more than three additionalfunctions.

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1 2 3

ABE_Softkeytasten_V2

A grey bar (3) highlights the active soft keycolumn, i.e. the soft keys in this column can beoperated. To change the soft key column:

– Briefly press the "Menu change button"(1).The grey bar jumps to the other soft keycolumn. The required soft keys are nowactive and the functions assigned to themcan be switched on and off using thecorresponding soft key buttons (2).

NOTE

In order to shift between the individual menusof the display operating unit, press the "Menuchange button" (1) for approx. 1 second.

NOTE

The functions of the two soft key columnsdepend on the individual equipment of thetruck. Therefore, the soft keys on your displayoperating unit may vary to those shown here.

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

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

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8

9

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6

7

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3

5

7312_003-179_en

1 2 3 4– Switch to the CONFIGURATIONmenu;see ⇒ Chapter "Adjusting the dis-plays", P. 5-233

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

– Confirm your selection by pressing theReturn key (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 with Returnbutton (4).

– Use arrow key (3) to exit the menu andreturn to the next higher level.

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5 OperationBlue-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".

Effects on additional consumersThe following table shows the specific condi-tions that cause certain auxiliary devices toshutdown when Blue Q is activated. The aux-iliary devices available depend on the truckequipment.

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Operation 5Blue-Q efficiency mode

Shut-off Seat switch Truck stopped Drive directionFront workingspotlight* X X Backwards > 3 km/h

Rear workingspotlight* X X Forwards

Top double workingspotlight* X X > 3 km/h

Headlight* X X -

Side light - - -

Front wiper X X Backwards > 3 km/h

Rear wiper X X Forwards

Seat heater X - -

Cab heating X - -

*No shutdown for StVZO (Road Traffic Licensing Regulations) equipment..

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 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. For information onconfiguring the Blue-Q operating modes, seechapter "Configuring Blue Q efficiency mode".

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5 OperationBlue-Q efficiency mode

2

6210_003-065_V3

1 2

– Press the Blue-Q button (1).

The Blue-Q symbol (2) appears next to thedrive programme symbol in the display andoperating unit, which means that the Blue-Qefficiency mode is activated.

Pressing the Blue-Q button once again turnsthe Blue-Q efficiency mode off again.

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Operation 5Display messages

Display messages

8

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7312_003-157

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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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5 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

Control unitA1401Control unitA1431A2551

Oil pressureA3040

No brake oil pressure or sensor fault, truck only moves atemergency mode speed.Notify your authorised service centre.

Oil pressureA3043

Brake oil pressure too high or sensor fault, truck only movesat emergency mode speed.Notify your authorised service centre.

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.

ACCEL. SENSORA3002A3003A3004A3005A3006A3007A3505

Sensor fault, truck cannot be driven.Contact your service centre.

ACCEL. SENSORA3008

Accelerator voltages (for dual pedal) do not match; truckcannot be driven.Contact your service centre.

ACCEL. SENSORA3811

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

Switch defective, truck only moves at emergency modespeed.Notify your authorised service centre.

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Comment

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 programme parameters are outside the permittedrange. The drive programme parameters are limited inter-nally.Notify your authorised service centre.

SEAT SWITCHA3027

Seat switch has not been operated for approx. 8 hours.Truck can possibly still be driven at a reduced speed andwith reduced 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.

DIRECTION SWITCHA3020

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


EXT1A3112A3113


EXT2A3117A3118


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.

POWER SUPPLYA2242A2257

Transmitter power supply short circuit. Truck cannot bedriven.Notify your authorised service centre.

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Comment

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.

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

Replace the filter cartridges.If this does not resolve the problem, contact your authorisedservice centre.

CONTROL UNITA3305

CIO not functioning.Notify your authorised service centre.

EXH. GAS PURIFIERA5791

No regeneration and no intermediate glow.Notify your authorised service centre.

EXH. GAS PURIFIERA5792A5793A5794A5796

Regeneration cannot be started.Notify your authorised service centre.

EXH. GAS PURIFIERA5795A5797A5798

Regeneration has been interrupted.Notify your authorised service centre.

ALTERNATORA5811

Starter battery is not charged.Notify your authorised service centre.

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Comment

V-engine malfunctionA5821

Engine control unit (ECU) reports engine error.Truck can still be operated.Notify your authorised service centre.

Switch off immediately!V-engineA5822

Engine control unit (ECU) reports serious engine error,switch engine off immediately.Truck only moves at emergency mode speed. The liftingspeed is severely reduced.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.

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

DANGER

Risk 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.

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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.


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.

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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.

– 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

DANGER

There 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.

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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 STEERING message 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.

EMERGENCY SWITCHmessage

WARNING

No 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

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? 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

REFERENCECYCLEmessageIf 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 theposition of the fork, themessageREFERENCECYCLE (variant)mayappear 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.

– To drive again, lower the fork to a maximumof 300 mm above the ground.

The truck can now be driven again with nospeed limitation.

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7325_003-056_en_V2

F1 F2

SAFETY BELTmessage

DANGER

Risk of fatal injury in the event offalling from the truck if it tips over!If the truck tips over, the driver is atrisk of injury even if a restraint systemis used. The risk of injury can bereduced by using a combinationof a restraint system and a seatbelt. In addition, the seat beltprotects against the consequencesof rear-end collisions and falling offramps.– We recommend that you alwaysuse 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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DANGER

Risk 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 thedisplay. 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 SURVEILLANCEmessage 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.

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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! mes-sage ! !If 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 fallssharply, theADBLUE FILLING LEVELmes-sage appears on the display and 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, max. 5 litres of AdBluemust be 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 deteriorationin the quality of the exhaust gas cleaned withAdBlue, the message ADBLUE QUALITYURGENT! appears on the display and operat-ing unit.

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. The driving speedis limited to 5 km/h.

– Contact the authorised service centre inorder to rectify the error.

Message: FUEL FILTERThe 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 the

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display, 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 andaddcoolingfluid if necessary.

CAUTION

Risk 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 chargeand it will no longer be possible to operate thetruck.


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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.

The truck can still be operated but yourauthorised service centre must be notifiedof the error immediately. The error message isshown on the display and operating unit untilthe error has been rectified by the authorisedservice centre.

AIR FILTERmessageIf the AIR FILTER message appears onthe display, the air filter cartridges must bechanged; see the chapter entitled "Replacingthe air filter cartridges".

OIL PRESSUREmessage

CAUTION

Risk 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-generation is complete. The truck is ready foroperation again.

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SCR-SYSTEM SERVICEmessageIf the message SCR-SYSTEM SERVICEappears on the display, there is a fault in theSCR exhaust gas treatment system.


SCR-SYSTEM MALFUNCTION mes-sageIf the message SCR-SYSTEM MALFUNC-TION appears on the display, there is a faultin the SCR exhaust gas treatment system.


Message PARK. REG. URGENT! ! !If 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.

Message PARK. REG. ERRORIf 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.

Message START PARK. REG.?If the message START PARK. REG.?appears on the display, the truck is ready forparked regeneration.

– Perform parked regeneration.

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START IC ENGINEmessageIf the message START IC ENGINE appearson the display, the internal combustion engineof the truck can be started.


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5 OperationOperating in special operating situations

Operating in special operating situationsTransport

CAUTION

Risk of material damage from overloading!If the truck is driven onto a means of transport,the load capacity of the means of transport, theramps and loading bridges must be greater thanthe total actual weight of the truck. Componentsmay become permanently deformed or damageddue to overloading.– Determine the total actual weight of the truck.– Only load the truck if the load capacity of the

means of transport, the ramps and loadingbridges is greater than the total actual weightof the truck.






max

min.*


kg kg

kg

kg

kgkW

V

*

1

2

7321_003-011_V2

Determining the total actual weight– Park the truck securely; see ⇒ Chap-ter "Parking the truck securely and switch-ing it off", P. 5-291.

– Determine the unit weights by reading thetruck nameplate and, if necessary, theattachment (variant) nameplate.

– Add the determined unit weights to obtainthe total actual weight of the truck:

Tare weight (1)




= Total actual weight

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Operation 5Operating in special operating situations

DANGER

Risk of accident from the truck crashing!Steering movements can cause the tail end to veeroff the loading bridge towards the edge. This maycause the truck to crash– Before driving over a loading bridge, ensure that

it is installed and secured properly.– Ensure that the transport vehicle onto which the

truck is to be driven has been sufficiently securedagainst moving.

– Maintain a safety distance from the edges,loading bridges, ramps, working platforms etc.

– Drive slowly and carefully onto the transportvehicle.

7331_003-002

Inserting wedges– Use two wedges to secure each of the frontand rear wheels against rolling away.

Lashing down

CAUTION

Abrasive lashing straps can rub against the surfaceof the truck and cause damage.– Position slip-resistant pads beneath the lifting

points (e.g. rubber mats or foam).

7341_003-026_V2

1

– Attach lashing straps (1) to both sides of thetruck and lash the forklift to the rear.

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7341_003-027_V2

2

1

– Attach lashing straps (1) to the coupling pin(2) or loop around the coupling pin and lashthe truck to the side.

DANGER

The truck can slip if the lashing straps slip!The truck must be lashed securely so that it cannotmove during transportation.– Make sure that the lashing straps are tightened

securely and that the pads cannot slip off.

6036Ba-0265060_003-070

Towing

DANGER

The brake system on the towing vehicle may fail.Risk of accident!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 beable to absorb the tractive and braking forces fromthe unbraked towed load (total actual weight of thetruck).– Check the tractive and braking forces of the

towing vehicle.

DANGER

The truck could drive into the towing vehicle whenthe towing vehicle brakes. Risk of accident!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. For safety reasons, only atested tow bar may be used.– Use a tested tow bar.

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CAUTION

If 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.

DANGER

People can be crushed between the truck andtowing vehicle during manoeuvring. There is a riskof fatal injury!The towing vehicle may only be manoeuvred andthe tow bar may only be attached using a secondperson as a guide. This ensures that the driver ofthe towing vehicle and the mechanic attaching thetow bar are aware of possible risks.– Only manoeuvre with a guide.

CAUTION

Steering is stiff! There is no power steering if thehydraulics fail!– The selected towing speed must allow the truck

and towing vehicle to be effectively braked andcontrolled at all times.

CAUTION

If the truck is not steered while it is being towed, itmay 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.

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CAUTION

Component damage as a result of blocked brakes!The truck is equipped with a negative spring-operated brake. As a result, when you switch theengine off, the multi-disc brakes in the drive wheelunits block. For towing, the brake must be releasedat the brake valve. Otherwise, the truck is towedwith the wheels blocked.Once the spring-operated brake is released, pres-sure builds up gradually again in the brake hydrau-lics and the brakes can block again. Note the towingtimewhen the key switch is switchedoff. The towingprocess must be interrupted in each case and thebrake released again.– Releasing the spring-operated brake– Note the towing time and release the spring-

operated brake again as necessary.

– Set down load and lower fork arms close tothe ground.

– Place the drive direction switch in theneutral position.


– Switch off the key switch.

– Check the tractive and braking forces of thetowing vehicle.

– With the help of a guide, move the towingvehicle to the truck.

– Secure the tow bar to the tow coupling of thetowing vehicle and the truck.

– Release the spring-operated brake

– Sit in the driver’s seat in the truck to betowed and fasten the seat belt.

– Where possible, activate the restraintsystems provided.


– Select a towing speed that allows the truckand towing vehicle to be effectively brakedand controlled at all times.

– Tow the truck.

– Note the towing time (refer to the tablein the section entitled "Releasing thespring-operated brake") and release thespring-operated brake again as necessary.

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– After towing, secure the truck against rollingaway (e.g. by applying the parking brake orusing wedges).

– Remove the tow bar.

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 dealt with here, please contactthe manufacturer with regard to specialequipment variants.

Trucks may only be laden by persons with suf-ficient experience with the suitable harnessesand hoists.






max

min.*


kg kg

kg

kg

kgkW

V

*

1

2

7321_003-011_V2

Determining the loading weight– Park the truck securely; see chapter "Park-ing the truck securely".

– 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.

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Hooking on the lifting straps

CAUTION

Harnesses may damage the truck’s paintwork!Harnesses may damage paintwork by rubbing andpressing on the surface of the truck. Particularlyhard or sharp-edged harnesses, such as wires orchains, can quickly damage the surface.– Use textile harnesses, e.g. lifting straps, with

edge protectors or similar protective devices ifnecessary.

DANGER

If the hoists and harnesses fail and cause the truckto fall, the consequences are potentially fatal!– Use only hoists and harnesses with sufficient

load capacity for the determined loading weight.– Use only the truck’s designated lifting points.– Make sure that harnesses, such as hooks,

shackles, belts etc., are only used in the indi-cated load direction.

– The harnesses must not be damaged by truckparts.

NOTE

The lifting points are indicated by a hooksymbol.

7341_003-028

3

– Loop the lifting straps around the maintraverse (3) on the outer mast of the liftmast as shown.

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7341_003-029_V2

4

– Loop the lifting straps around the counter-weight (4) as shown.

– Determine the truck’s centre of gravity, see"Dimensions" chapter.

7321_003-013

5 6– Adjust the length of the harnesses so thatthe lifting eye (6) is vertically above thetruck’s centre of gravity.

This ensures that the truck hangs level whenlifted.

– Attach the lifting straps to the lifting eye andinsert the safety device (5).

CAUTION

Incorrectly fitted harnesses may damage attach-ment parts!Pressure from the harnesses can damage ordestroy attachment parts when the truck is lifted.If attachment parts are in the way (e.g. lighting, rearwindow, trademark emblem etc.), these must beremoved before loading.– Secure harnesses in such a way that they do not

touch any attachment parts.

– Check that harnesses cannot collide withattachment parts.

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Loading the truck

DANGER

If the raised truck swings in anuncontrolled fashion, it may crushpeople. There is a risk to life!– Never walk or stand underneathsuspended loads.

– Do not allow the truck to bump intoanything 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.

7341_003-012

+ -12

-

+

Jump-starting

NOTE

A12-V power source (e.g. second forklift truckof the same type) must be available.

WARNING

Risk 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 connection conti-nues, a short circuit can occur.– Ensure that the correct order is followed when

connecting and disconnecting the jump leads.

– Remove the side cover; refer to the sectionentitled "Attaching and removing the leftside cover".

– Leave 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.

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– Connect the negative cable (1) to thenegative terminal on the current-givingbattery.

– Connect the negative cable to the negativeterminal on the discharged battery.

CAUTION

The 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.


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.

– Disconnect the positive cable from thepositive terminal on the current-givingbattery.

NOTE

Leave the engine to run because the battery isnot yet sufficiently charged.

– Reattach the side cover.

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5 OperationProcedure in emergencies

Procedure in emergencies

6321_003-142

1

Emergency shutdownThe emergency off switch (1) is used for theemergency shutdown. The emergency offswitch may be used to carry out functionchecking and to shut down the truck safely.

NOTE


WARNING

No 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.– Only use the emergency off switch in the event of

danger, to carry out function checking or to parkthe truck safely.

– To brake, actuate the service brake.

WARNING

There 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.– Only use the emergency off switch in the event


– Steer with a higher level of force.

NOTE

Actuating the emergency off switch alsoswitches off the electric brake, the hydraulicsystem and the drive unit.

In drive mode, this has the following effect:• No reduction in truck speed when theaccelerator pedal is released, accordingto the drive programme selected. The truckwill coast

• The electric brake does not function duringthe first part of brake pedal travel. To brake

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Operation 5Procedure in emergencies

the truck using the mechanical brake, thebrake pedal must be pushed down further

• 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

• The "Curve Speed Control" system (auto-matic reduction of truck speedwhen corner-ing) does not function. The truck must bedecelerated with the mechanical brake bypressing the brake pedal

• No hydraulic functions are available

– 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.

7090_001-005

Procedure if truck tips over

DANGER

If 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

WARNING

When 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 controller fails whilst a loadis raised, emergency lowering can be per-formed. An emergency lowering screw for thispurpose is located on the control block.

DANGER

There is a risk to life from fallingloads or if parts of the truck are beinglowered.– Do not walk beneath the raisedload.

– Follow the steps described below.

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WARNING

The 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

A hexagon socket wrench is located beneaththe bottomplate on the brake valve for carryingout the steps detailed below. This hexagonsocket wrench must remain in the truck at alltimes.

– Remove the bottom plate

17341_003-014

– Take the Allen key (1) out of the supportmounting.

– Open the front right cover.

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7341_003-015

2

3

– Loosen the emergency lowering screw (3)on the control block (2) a maximum of1.5 revolutions using the Allen key.

– Screw the emergency lowering screw backin after the load is lowered.

– Return the Allen key to the support mount-ing provided.

– Install the bottom plate.

– Close the front right cover.

DANGER

If 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.

Releasing the spring-operated brake

CAUTION

Component damage as a result of blocked brakes!In order to tow the truck, the multi-disc brakes mustnot be blocked in the wheel drive units.– Repeatedly release the spring-operated brake

during the towing process, in accordance withthe table below.

The truck is equipped with a negative spring-operated brake. Switching off the enginewill block the multi-disc brakes in the wheeldrive units after a few minutes. However, thetruck can still be moved until the drive wheelunits are blocked. In order to tow the truck,the spring-operated brake must be releasedby actuating the brake valve. Otherwise, thetruck is towed with the wheels blocked.

NOTE

The brake valve is installed in front of thedriver’s seat beneath the bottom plate.

The coupling pin from the counterweightcan be used as an aid to actuate the brakevalve. If there is no removable coupling pinavailable on the truck, for example, if the

280 57348011800 EN - 07/2016


truck is equipped with automatic tow coupling(variant), the bottom plate must be raisedcompletely in order to access the brake valve.

Once the spring-operated brake is released,the pressure gradually drops again in thebrake hydraulics and the brakes can blockagain. The towing process must be inter-rupted at certain times and the spring-oper-ated brake released again, in accordance withthe table below.

Hydraulic oiltemperature

Period after releasing thespring-operated brake untilit is blocked once again

°C Minutes Seconds

-20 190 0

20 7 40

50 2 50

95 1 50

Actuate the brake valve by means of a cou-pling pin:

– Take the coupling pin out of the counter-weight.

6341_003-034

– Grip the rubber tab in the rubber mat usingthe finger opening and pull up the tab.

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6341_003-036

1

2

– Insert the coupling pin (1) into the bore (2)on the bottom plate until the pin noticeablyrests on the brake valve plate beneath.

– Repeatedly press the coupling pin downvertically.

The spring-operated brake is released.

NOTE

To fully release the spring-operated brake,press down on the brake valve plate at least30 times. The pressure that builds up in thebrake hydraulics as a result releases thespring-operated brake.

– Once the spring-operated brake is re-leased, fold the rubber tab in the rubbermat back down.

– Insert the coupling pin in the counterweight.

Actuate the brake valve without a coupling pin:

– Remove the rubber mat.

– Remove the bottom plate.

7341_003-030

3

– Press the brake valve plate (3) downrepeatedly.

The spring-operated brake is released.

NOTE

To fully release the spring-operated brake,press down on the brake valve plate at least30 times. The pressure that builds up in thebrake hydraulics as a result releases thespring-operated brake.

– After releasing the spring-operated brake,re-install the bottom plate and the rubbermat.

WARNING

Risk of injury through falling or slipping!

If the bottom plate is not inserted, there is a dangerof shoes getting stuck, causing you to fall. Evenwhen the bottom plate is installed, there is still adanger of slipping and injury if the rubber mat is notused.– Install the bottom plate and rubber mat.

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Operation 5Refuelling

7341_003-011

-

+

2

1

3

Disconnecting the batteryProceed as follows to disconnect the battery:

– Remove the side cover, see ⇒ Chap-ter "Removing and attachingthe left sidecover", P. 6-322.

– Loosen the screw joint (2) of the battery-terminal clip (1) on the negative terminal (3).

– Lift the battery-terminal clip off the batterynegative terminal and place it to the side.

RefuellingDiesel fuel — Specifications

CAUTION

Risk of component damage if non-approved fuelsare used!Use only approved fuels with the following specifi-cations.

If non-approved fuels are used, compliancewith specified emission values and the servicelife of the engine cannot be guaranteed! Thistruck is equipped with an engine that fulfils therequirements of the EU level IIIB and US EPAinterim Tier 4 standards, and also with anexhaust gas follow-up treatment concept inthe form of a particle filter (DPF).

The truck may be operated only with sulphur-free diesel fuels as defined by the followingstandards:• EN 590• ASTMD 975 Grade 2-D S15• ASTM D 975 Grade 1-D S15• or non-road fuels (light fuel oils) in line withthe EN 590 standard

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5 OperationRefuelling

If these fuel types are not used, compliancewith specified emission values and the servicelife 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 is 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.

The following limits in accordancewith EN 590must be complied with (amongst other things):

Parameter Unit ValueCetanenumber1) - Min. 51

Density at15 C

kg/m3 820–845

Sulphurcontent

mg/kg Max. 101) The use of diesel fuels with a lowercetane number can lead to white smokedevelopment and misfiring. In winter, theuse of diesel fuels with a higher cetanenumber is recommended.

Sulphur content in the diesel fuel

CAUTION

Insufficient lubrication can lead to engine damage!– Use only sulphur-free diesel fuels in accordance

with manufacturer specifications.

Insufficient lubrication capacity in diesel fuelswith a sulphur content > 500 mg/kg can lead

284 57348011800 EN - 07/2016


to serious problems through wear, above all incommon rail injection systems. In sulphur-freediesel fuels in accordance with EN 590 andASTM D 975, sufficient lubrication capacity isguaranteed with corresponding fuel additivesduring refining.

Fuels with a sulphur content > 0.5% (m/m)require a shortened lubricating oil changeinterval and must not be used in engines witha particle filter system. Fuels with a sulphurcontent > 1.0% (m/m) are also not permissibledue to high corrosion and significant lifetimereduction of the engine.

Winter operation with diesel fuel

CAUTION

Adding 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.

In winter operation, special demands areplaced on the low-temperature performanceof fuels. Generally, diesel fuels that can beused at temperatures down to -44 C areavailable on the open market. Therefore, itis not necessary to add additives to improvethe fluidity. Adding petrol can lead to theformation of vapour pockets (cavitation) inthe fuel system. This disrupts the function ofthe fuel injection system and, if done over along period, can lead to component damage.

Non-road fuels

NOTE

In some European countries, non-road-fuelsare defined with the same characteristics aslight fuel oil. The permissibility as a fuel ishandled differently in the individual countries.Light fuel oils and non-road-fuels are suitable

57348011800 EN - 07/2016 285


for the engine if all limits of EN 590 arecomplied with.• 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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Filling up with diesel fuel

CAUTION

Lack 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. Whenthe fuel tank is replaced during repair work orbecause it has been run empty, diesel fuel mustbe pre-pumped with the fuel hand pump after filling,see the "Using the fuel hand pump" chapter.– Never run the fuel tank empty.– Refuel truck and pre-pump diesel fuel.

The fuel reserve is shown by the fuel levelindicator (1) flashing on the display screen ofthe display and operating unit.

DANGER

There is a risk of fire when filling upwith diesel fuel.– Turn off the engine before fillingup.

– When refuelling, smoking or theuse of an open flame is strictlyforbidden!

– Comply with the legal provisionsfor handling diesel fuel.

– Observe safety regulations forhandling diesel fuel, see the"Diesel fuel" chapter.

CAUTION

Use of non-permissible fuels can lead to enginedamage!– Use of fuel additives supporting soot burn-off is

not permitted.– Starting aids (such as "Startpilot" or similar) must

not be used.– In low temperatures use winter diesel.– The truck may only be operated with diesel fuel

in accordance with manufacturer specifications,see the "Diesel fuel — Specifications" chapter.

The fuel-tank filler neck is located on theright-hand side in the drive direction, on themudguard of the front wheel.

57348011800 EN - 07/2016 287


7341_003-009

2

1– Turn the locking cap (2) at the filler neck tothe left and remove.

– Fill up with clean diesel fuel, for the maxi-mum filling quantity see the "Maintenancedata table" chapter.

– Place the locking cap onto the filler neckand turn completely to the right.

Using the fuel hand pump

CAUTION

Lack 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.– Refuel truck and pre-pump diesel fuel.

1

2

7341_003-049

The fuel hand pump (2) is located on the fuelfilter (1) beneath the right service flap.

If the fuel tank was complete empty, it ispossible that the fuel cannot be supplied by thefuel pump alone after refuelling. Use the fuelhand pump to pre-pump fuel into the systemuntil the fuel pump reaches sufficient supplypower. The fuel hand pump must used, forexample, after the tank has been run empty,after initial filling or after draining for repairwork.

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7341_003-024_V2

1

– Open the service flap (1) on the right.

1

2

7341_003-049

– To pump, pull the fuel hand pump (2) outand push it in again ten times.

NOTE

A light hissing sound you may hear indicatesthat the fuel is flowing and is not a fault on thetruck.

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7341_003-009

2

1Topping up AdBlueThe AdBlue filler neck is located on the frontright-hand side of the truck, above the dieselfiller neck (2).

It is recommended that the AdBlue tank berefilled with AdBlue every time the diesel fuelis topped up.

– Turn the locking cap (1) of the AdBlue fillerneck to the left and remove.

– Add AdBlue.

The AdBlue tank holds a maximum of 10 l.

– Place the locking cap onto the AdBlue fillerneck and turn completely to the right.

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Operation 5Decommissioning

Decommissioning

5060_003-130

Parking the truck securely andswitching it off

DANGER

Risk of fatal injury frombeing run overif the truck rolls away!– The truck must not be parked on aslope.

– In emergencies, secure the truckusing wedges on the side facingdownhill.

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

DANGER

There 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.

– If fitted, press the emergency off switch;see the chapter entitled "Emergencyshutdown".

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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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.

Shutting down and storing the truck

CAUTION

Component 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.

CAUTION

Danger 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.

CAUTION

Danger 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.

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Operation 5Decommissioning

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 timesand, 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 awarmanddry location.

– 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.

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5 OperationDecommissioning

Recommissioning after shutdownIf the truck has been shut down for longer thansixmonths, itmust be carefully checkedbeforebeing recommissioned. As in the annualinspection, this check should also includeall safety items for the truck.

– Clean the truck thoroughly; see chapter"Cleaning".

– Oil joints and controls.

– Check battery condition and acid density,and recharge if necessary.

– Restore engine to normal condition accord-ing to regulations of engine manufacturer.

– Check the engine oil for condensationwaterand replace if necessary.

– Check the hydraulic oil for condensationwater and replace if necessary.

– Perform the same maintenance tasks asbefore initial commissioning.

– Put the truck into operation.

During commissioning, the following must bechecked in particular:• Drive, controller, steering• Brakes (service brake, parking brake)• Lifting system (lifting accessories, loadchains, mounting)

NOTE

For further information, see the truck work-shopmanual or contact the authorised servicecentre.

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Operation 5Cleaning

CleaningCleaning the truck– Park the truck securely.

WARNING

There is a risk of injury due to fallingwhen climbing onto the truck!When climbing onto the truck, youcan get stuck or slip on componentsand fall. Higher points on the truckmay only be made accessible withcorresponding devices.– Adhere strictly to the followingsteps.

– For climbing onto the truck, use only thesteps provided for this purpose.

– For reaching inaccessible places, usedevices such as stepladders or platforms.

CAUTION

If water penetrates the electrical system, there is arisk of short circuit!– Adhere strictly to the following steps.

– Before cleaning, switch the electricalsystem off so that there is no voltage.

– Do not spray drive units and electricalcomponents or their covers directly withwater.

CAUTION

Failure to follow these instructions could result indamaged components!The engine must be switched off during washing.Water should not be used for cleaning the areaaround the central electrical system; instead, onlyclean with a dry cloth or clean compressed air.

CAUTION

Excessive water pressure or water and steam thatare too hot can damage truck components.– Adhere strictly to the following steps.

– Only use high-pressure cleaners with amaximum output power of 50 bar and at amaximum temperature of 85°C.

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5 OperationCleaning

– When using high-pressure cleaners, makesure there is a distance of at least 20 cmbetween the nozzle and the object beingcleaned.

– Do not aim the cleaning jet directly atadhesive labels or decal information.

DANGER

Risk of fire!Deposits/accumulations of combusti-ble materials may ignite in the vicinityof hot components (e.g. exhaustpipes).– Adhere strictly to the followingsteps.

– Regularly remove all deposits/accumula-tions of foreign materials in the vicinity ofhot components.

– Do not place combustible materials in theengine compartment.

DANGER

Flammable fluids can be ignited byhot components on the truck, causinga risk of fire!– Adhere strictly to the followingsteps.

– Do not use flammable fluids for cleaning.

– Observe the manufacturer’s guidelines forworking with cleaning materials.

CAUTION

Abrasive cleaning materials can damage compo-nent surfaces!Using abrasive cleaning materials that are unsuita-ble for plastics may dissolve plastic parts or makethem brittle. The display and operating unit screenmay become cloudy.– Adhere strictly to the following steps.

– Clean plastic parts with plastic cleaningmaterials only.

– Observe the manufacturer’s guidelines forworking with cleaning materials.

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Operation 5Cleaning

Washing the truck exterior– Clean the truck exterior with water-solublecleaning materials and water (water jet,sponge, cloth).

– Clean all walk-in areas, the oil filling open-ings and their surroundings, and the lubri-cating nipples before lubricating.

NOTE

Please note: The more often the truck iscleaned, the more frequently it must belubricated.

7071_003-091

Cleaning the electrical system

CAUTION

Cleaning electrical system partswith water can damage the electricalsystem.– Cleaning electrical system partswith 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.

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5 OperationCleaning

6210_810-004

Cleaning load chains

WARNING

Risk 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.

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.

CAUTION

Do not damage the rear window heater (inside)!– Take great care when cleaning the rear window

and do not use any objects with sharp edges.

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Operation 5Cleaning

– 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.

CAUTION

Risk 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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5 OperationCleaning

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6

Maintenance

6 MaintenanceGeneral maintenance information

General maintenance informationPersonnel qualificationsOnly qualified and authorised personnelare allowed to perform maintenance work.The annual testing must be carried out bya qualified person. The examination andassessment of the qualified person mustbe unaffected by operational and economicconditions and must be conducted solelyfrom a safety perspective. They must havesufficient knowledge and experience tobe able to assess the condition of a forklifttruck and the effectiveness of the protectiveequipment in accordance with technicalconventions and the principles for testingforklift trucks.

Maintenance work without specialqualificationsSimple maintenance work, e.g. checkingthe hydraulic oil level, may be carried out byuntrained personnel. A qualification, like thatof a specialist, is not required to carry out thiswork. The required operations are describedin sufficient detail in the corresponding placesin these operating instructions.

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.

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Maintenance 6General 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

CAUTION

Risk 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


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Maintenance instructionsMaintenance work must be carried out inaccordance with the following maintenanceintervals. The intervals are designed forstandard use. Depending on the applicationconditions of the truck, shorter maintenanceintervals can be set, on agreement with theoperating company.

These factors may call for shorter mainten-ance intervals:• Contaminated, poor quality roads• Dusty or salty air• High 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

For maintenance tasks, only use originalspare parts, and only use consumablesthat have been prescribed in the overviewof consumables.

Maintenance - 500 hours/half-yearly

At operating hours Carriedout

500 1000 1500 2000 2500

Exhaust system

Replace the filter in the AdBlue dosing module.

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Maintenance - 1000 hours/annuallyAt operating hours

1000 2000 4000 5000 7000Carriedout

8000 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 dual pedal variant for damage and correct function, and lubricate

Tyres and wheels

Check tyres for wear and check the air pressure if necessary

Check wheels for damage and check the tightening torques

Power unit

Check the mounting of the drive axle and check the drive axle for leaks.

Check cooling system for leaks and check water pumps for correct function

Check gearbox oil level

Change gearbox oil (once after 1000 hours)

Internal combustion engine

Check condition of the internal combustion engine (visual inspection)

Check valve clearance and adjust if necessary (every 2000 hours)

Change engine oil and oil filter

Check the air filter and the microfilter, and replace if necessary

Check cooling system for leaks and correct function

Check coolant and top up if necessary

Check exhaust system

Fuel system

Check fuel system for leaks and correct function

Check fuel pre-filter (water trap) and drain water if necessary

Replace fuel pre-filter (once a year)

Replace fuel filter (main filter)

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At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Steering

Check steering system for correct function and for leaksCheck that the steering wheel is firmly attached and check the turning handle fordamageSteering axle: Check that it is firmly attached, check for leaks, and apply grease

Check steering stop

Brake

Check all mechanical brake parts for condition and correct function

Check brake valve for correct function and leaks

Service brake function check

Parking brake function check

Electrical system

Check all power cable connections

Check switches, transmitters and sensors for correct function

Check lighting and indicator lights

Starter battery

Measure the cold-start current; recharge or replace the battery if necessary.

Hydraulics

Check hydraulic system for condition, correct function and leaks

Check the hydraulics blocking function (ISO valve)

Check the oil level

Lift mast

Check mast bearings for damage and lubricate. Check the tightening torque

Check mast profiles for damage and wear, and lubricate

Check load chains for damage and wear. Adjust and lubricate

Check lift cylinders and connections for damage and leaks

Check guide pulleys for damage and wear

Check support rollers and chain rollers for damage and wear

Check the play between the fork carriage stop and run-out barrier

Check tilt cylinders and connections for damage and leaks

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At operating hours

1000 2000 4000 5000 7000Carriedout

8000 10000 11000 13000 14000

Check fork carriage for damage and wear

Check fork arm interlock for damage and correct function

Check fork arms for wear and deformation

Check that there is a safety screw on the fork carriage or on the attachment

Check the auxiliary hydraulics hoses for damage

Special equipment

Heating system: Check fresh air filters and beat outHeating system: Check for damage; observe manufacturer’s maintenance instruc-tionsAir conditioning: Check fresh air filter and recirculated air filter, and beat out

Air conditioning: function checkCheck attachments for wear and damage; observe manufacturer’s maintenanceinstructionsCheck trailer coupling for wear and damage; observe manufacturer’s maintenanceinstructionsGeneral

Read out error numbers and delete list

Reset maintenance interval

Check labelling for completeness

Test drive the truck

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310 57348011800 EN - 07/2016


Maintenance - 3000 hours/every two years

At operating hours Carriedout

3000 6000 9000 12000 15000

Note

Perform all 1000-hour maintenance work.

Power unit

Change the gearbox oil

Internal combustion engine

Internal combustion engine, general overhaul (every 12,000 hours)

Replace the poly-v belt and tensioning pulleys (every two years)

Change the air filter and fine filter

Change coolant (every two years)

Change the spark plugs at the burner

Diesel particle filter: Change filter element (every 6000 to 12,000 hours)

Hydraulics

Change the hydraulic oil

Change the return line filter, breather filter and high-pressure filter

Special equipment

Air conditioning: Replace the fresh air filter and the recirculated air filter

Air conditioning: Replace the accumulator dryer and refill with refrigerant

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.

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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!

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Maintenance data table

General lubrication points

Unit Operating material Specifications DimensionsLubrication High-pressure grease ID no. 0147873 As required

Controls/joints

Unit Operating material Specifications DimensionsHigh-pressure grease ID no. 0147873 As requiredLubrication

Oil SAE 80MIL-L2105API-GL4

As required

Dual-pedal operation High-pressure grease ID no. 0147873 As required

Battery

Unit Operating material Specifications DimensionsSystem contents Distilled water As required

Insulation resistance DIN 43539VDE 0510

Min. 500 /V againstearth

Electrical system

Unit Operating material Specifications DimensionsInsulation resistance DIN EN 1175

VDE 0117Min. 1000 /V against

earth

Hydraulic system

Unit Operating material Specifications DimensionsHydraulic oil HVLP68 or ISOVG68

DIN 51524, part 2System contents

Hydraulic oil for thefood industry (variant)

USDA H1DIN 51524

Max. 125 l

Tyres

Unit Operating material Specifications DimensionsSuperelastic tyres Wear limit To wear mark

Minimum tread depth 1.6 mm

Air pressure See information ontruck

Pneumatic tyres

Minimum tread depth 1.6 mm

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AL80-01 steering axle

Unit Operating material Specifications DimensionsWheel nuts/screws Torque wrench DIN 74361-A 20-10

A2C640 Nm

Axle stub bearing,spherical bearing

Grease Aralub 4320DIN 51825-KPF2N20ID no. 0148659

Fill with grease until asmall amount of fresh

grease escapesWheel bearing, wheelbearing rotary shaftseal

Grease DIN 51825-KP2 K-30,lithium-saponifiedID no. 0163488

Fill with grease

AE80-01 drive axleUnit Operating material Specifications Dimensions

Wheel nuts/screws Torque wrench DIN 74361-A 20-10A2C

640 Nm

SAE 80W-90API-GL4

Filling incl. servicebrake

Gearbox oil

ARAL EP Plus80W-90BP Energear HT80W-90Castrol SyntraxUniversal 80W-90

For furtherinformation, referto the workshop

manual for the truckin question.

Lift mastUnit Operating material Specifications Dimensions

Lubrication High-pressure grease ID no. 0147873 As required

Stop Play Min. 2 mm

Mast bearing screws Torque wrench Cylinder headbolt M24x90-12.9ISO 4762

1100 Nm

Load chainsUnit Operating material Specifications Dimensions

Lubrication High-load chain spray Fully syntheticTemperature range:-35°C to +250°CID no. 0156428

As required

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Cooling system

Unit Operating material Specifications DimensionsSystem contents Corrosion inhibitor

and cooling systemprotecting agent/water

40% coolant/60%water, for frostprotection down to-25 CVWG12 plus (violet)TL-VW 774 F

Approx. 42 l

Air conditioning

Unit Operating material Specifications DimensionsSystem contents Refrigerant ID no. 7449600005 1350 g

Fuel tankUnit Operating material Specifications Dimensions

System contents Diesel fuel EN 590, DIN 51628,ASTM D975,NATO F-54 non-roadfuels (light fuel oils,EN 590 quality)

Approx. 110 l

Engine

Unit Operating material Specifications DimensionsSystem contents Engine oil DQC III-10 LA,

DQC IV-10 LA13 l, with filter change

Air filter system

Unit Operating material Specifications DimensionsAir filter Filter cartridge and

safety cartridgeOil-bath air filter Engine oil DQC III-10 LA,

DQC IV-10 LALevel mark on the

oil tank

Washer system

Unit Operating material Specifications DimensionsSystem contents Washer fluid Winter, ID no. 172566 As required

Exhaust gas treatment (SCR)

Unit Operating material Specifications DimensionsSystem contents AdBlue 32.5% urea solution,

in accordancewith DIN 70070 /ISO 22241

Approx. 10 l

.

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6 MaintenanceSafety regulations for maintenance

Safety regulations for maintenanceGeneral information

DANGER

Risk 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 6Safety regulations 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.

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6 MaintenanceSafety regulations 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

DANGER

There 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

DANGER

Risk 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.

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Maintenance 6Safety regulations for maintenance

CAUTION

Possibility 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

DANGER

Risk 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

DANGER

Risk of accident!This work must only be performed by an authorisedservice technician.– Arrange for an authorised service technician to

secure the lift mast.

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6 MaintenanceProviding access to maintenance points

Providing access to maintenance points

7311_120-001

1

2

Opening the bonnet

WARNING

Risk of injury!– Switch off the engine before opening the bonnet!

CAUTION

When 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. 5-80.

– Slide the driver’s seat (2) all the way for-wards; see ⇒ Chapter "Adjusting the MSG65/MSG 75 driver’s seat", P. 5-76.

– For trucks with a rear window (variant), foldthe seat backrest forwards; see ⇒ Chap-ter "Adjusting the MSG 65/MSG 75 driver’sseat", P. 5-76. 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.

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Maintenance 6Providing access to maintenance points

Closing the bonnet– Holding it by the handle, pull down thebonnet until the lock audibly engages.

7311_120-001

1

2

– Adjust the seat (2); refer to ⇒ Chapter "Ad-justing the MSG 65/MSG 75 driver’sseat", P. 5-76.

– Adjust the steering column (1).

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Removing and attachingthe left side cover

1

2

7341_003-006_V2

Removing the cover– Release the quick release clamps (1) with a1/4 revolution.

– Remove the cover (2) and put carefullyaside.

Attaching the cover– Carefully position the cover (2).

– Lock the quick release clamps (1) with a1/4 turn.

Installing and removing the bottomplate

Removing the bottom plate.

CAUTION

Risk of short circuit if cables are damaged!– Check the connecting 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 that the ope-rator can insert his fingers into to lift it. Therecess is beneath the rubber mat.

NOTE

The accelerator pedal is attached to thebottom plate and is removed with this also.The connecting plug for the accelerator islocated underneath the bottom plate.

– Remove the rubber mat.

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1 2

3

7341_003-013

– Grasp the recess (3) in the bottom plate (2).

– Lift up the bottom plate.

7341_003-018

1

– Disconnect the plug connector (1) on theaccelerator pedal.

– Lift bottomplate and place in a safe location.

Installing the bottom plate

WARNING

Risk of crushing between bottom plate and frameedge!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 bottom plate,

there is nothing between the cover and the frameedge.

– Position the bottom plate at the front.

– Connect the connection assembly to theaccelerator pedal.

– Carefully guide the bottom plate down andclose.

– Insert the rubber mat.

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Opening and closing the right-handservice flap

7341_003-024_V2

1

Opening the service flap

WARNING

Risk of injury from the service flap dropping!The service flap (1) is equipped with gas springsthat hold the service flap in opened position. In thecase of additional load, for example, through heavyobjects, strong wind or other persons, the serviceflap can drop suddenly. Through cold weather andageing, the performance of the gas springs can alsoreduce and lead to the flap dropping.– Make sure that the service flap is not being

pushed down by strong winds or other persons.– If the gas springs no longer hold the service flap

independently, notify the authorised servicecentre.

6341_003-033

1 2

3

4

– Unlock the quick release clamp (1) with a1/4 turn in a clockwise direction.

– Open the service flap lock (3) with the key.

– To unlock, pull the handle (4) and at thesame time use the other handle (2) to swivelthe service flap upwards.

NOTE

Beneath the service flap there is a latch thatengages in the upper position of the serviceflap and prevents accidental closing.

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7341_003-056_V2

1

2

– Make sure that the safety hook (1) engagesin the gap of the holder (2).

Closing the service flap

CAUTION

Limbs can become trapped when closing theservice flap— risk of crushing!When you close the service flap, there must benothing between the service flap and the edge ofthe frame.– Do not grasp any edges. Always close the

battery cover by grasping one of the handlesin each hand.

– Carefully close the service flap.– Only close the service flap if there are no parts of

the body in the way.

6341_003-033

1 2

3

4

– To close the service flap, take hold of thehandles (2) and (4) at the same time andpull down firmly.

– Make sure that the service flap lock en-gages when you close it.

– Lock (3) the service flap using the key.

– Lock the quick release clamp (1) with a 1/4turn in an anti-clockwise direction.

NOTE

The service flap is only correctly locked if thetop section of the handle (4) closes flush withthe cover.

57348011800 EN - 07/2016 325

6 MaintenanceService work

Service workCleaning the radiator and checkingfor leaks

WARNING

Risk of burns due to hot components!Components on the engine (e.g. engine block,radiator, etc.) can be so hot that direct contact canburn the skin and can burn or singe materials.– Make sure that the engine and cooling system

have cooled down.– Do not grasp or touch hot components.– In the event of burns, seek first aid immediately.– If materials are burning, take fire-fightingmeasu-

res immediately.

– Park the truck securely.


7341_003-052

1– Clean the radiator fins (1) on the radiatorwith a suitable brush and blow them outusing compressed air (max. 2 bar).

– Check the radiator and coolant hoses forleaks and tighten the clips if necessary.

CAUTION

In the event of a leak, there is a risk of enginedamage due to overheating!A loss of cooling fluid from leaking coolant hoses orfrom the radiator reduces the cooling capacity. Theengine may become excessively hot and severelydamaged.– Tighten clips at leaking hose connections.– Checkwhether the leakage has been eliminated.

If not, notify the authorised service centre.


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Maintenance 6Service work

7341_003-057

1

2

– Perform a visual inspection of the radiatorfrom the rear of the truck.

– If necessary, unscrew the screw joints (2)for the radiator grille and dismantle it toclean the radiator behind.

– Clean the radiator grille (1).

– If necessary, re-attach the radiator grilleand screw tight.

NOTE

Make sure that the radiator grille is tightlyscrewed on.

7341_003-050

1 2Topping up the cooling fluid andchecking the coolant concentration

WARNING

Risk of scalding due to hot cooling fluid!The cooling system is pressurised! When openingthe cooling fluid expansion reservoir (2), coolantcan escape if the engine is hot. Always switch theengine off and let it cool down before opening thecoolant reservoir.– Switch off engine and let it cool down.– Do not open the radiator filler cap (1) until the

engine has cooled down.

WARNING

Cooling fluid and coolant are hazardous to health!

– Observe the safety regulations for handlingcoolant.

CAUTION

Risk of engine damage!If the cooling fluid level is low, this indicates a leakin the cooling system.– Check the cooling system for leaks; refer to

the section entitled "Cleaning the radiator andchecking for leaks".


57348011800 EN - 07/2016 327


– Open the radiator cap (1) slowly and releaseexcess pressure.

– Turn further and remove the radiator fillercap.

– Check the concentration of the coolant.

Concentration of the coolant

CAUTION

Risk of corrosion!The percentage of coolant must always be atleast 40%, even if frost protection is not neededin warmer climates.If an increased level of frost protection is requiredfor climatic reasons, the percentage of coolant canbe increased to 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

percentage.

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".

CAUTION

Coolant with a different specification must not bemixed in!– Only use the coolant specified in the mainten-

ance data table to top up the cooling system.– Only use coolant according to the manufactu-

rer’s instructions.

328 57348011800 EN - 07/2016


7341_003-050

1 2– Screw the radiator filler cap (1) back ontightly.


Draining water from the fuel filter

WARNING

Diesel fuel is flammable, toxic anddamages the environment! Contactwith diesel fuel can cause skinirritation and spilled diesel fuel cancause slipping.– Observe safety regulationsregarding handling diesel fuel,see the "Safety regulations forhandling consumables" chapter.

7341_003-024_V2

1

– Open the service flap (1) on the right.

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7341_003-023

1

2

3

5

4

– Cover the area beneath the fuel filter (1)carefully with a cleaning cloth.

CAUTION

Risk of fire!The heat protection sleeve (5) of the exhaust gassystem must not be polluted with diesel fuel. Ifdiesel fuel penetrates the material of the heatprotection sleeve, this can lead to the sleeve andsurrounding components catching fire.– Make sure that diesel fuel does not pollute the

heat protection sleeve.

– Keep a suitable collection container be-neath the outlet pipe (3).

CAUTION

Component damage possible!

The fuel filter is equipped with a level indicator thatreports water aggregation in the fuel filter on thedisplay and operating unit. The sensor cable (4) isembedded with the screw plug (2). Do not loosenthe screw plug more than one revolution; otherwisethe sensor cable may be damaged.– Carefully undo the screw plug.

– Undo the screw plug (2) on the fuel filter anddrain fluid until clean diesel fuel emerges.

– Tighten the screw plug again by hand.

– Remove the cleaning cloth from the heatprotection sleeve.

– Close the service flap on the right.

NOTE

Draining is particularly necessary in tropicalclimates and dependent on the fuel qualityused.

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7341_003-058

3

2

1

4

Cleaning the pre-cleaner– Loosen clamp (1) on pre-cleaner.

– Remove housing cover (2).

– Remove and empty dust container (3).

– Clean coarse contamination from lower partof container (4).

– Re-attach dust container and secure withclamp.

NOTE

Do not fill pre-cleaner with oil. Replacedamaged container parts.

7341_003-020

1

2

3

2

2

4

Cleaning the oil tank on the oil bathair filter

WARNING

There is a risk of slipping on spilled oil, particularlywhen combined with water!The oil tank (4) is filled with oil.– Carefully remove the oil tank.– Collect spilt oil immediately using an oil binding

agent and dispose of in an environmentallyfriendly way.

– Observe the safety information for handling oils,see the "Oils" chapter.

– Release the four clamps (2) on the oil tankand carefully remove the oil tank (1).

– Empty the oil tank and clean using degreas-ing cleaning material.

ENVIRONMENT NOTE

Oils are water pollutants!• Dispose of contaminated oil, oil sludge andused cleaning material in an environmen-tally friendly way.

– Fill the oil tank (4) to the level mark (3) withengine oil.

For engine oil specifications, see the chapterentitled "Maintenance data table".

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– Carefully install the oil tank and engage thefour clamps (2) on the housing (1).

8

9

0

6

7

4

3

5

7312_003-070_en_V2

Replacing the air filter cartridges

NOTE

The air filter cartridges must be changed ifthe AIR FILTERmessage appears on thedisplay and operating unit, or at least every3000 hours or every two years.

– Open the bonnet; see the chapter entitled"Opening the bonnet".

7321_003-075

1

112

– Release the three clamps (1) on the air filterand remove the air filter cover (2).

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3

7321_003-076

– Remove the filter cartridge (3).

CAUTION

Risk of engine damage!The safety cartridge must remain in the air filterhousing until all residual dirt has been removedfrom the housing so that no dirt enters the intakesystem!

– Wipe out the air filter housing using a dampcloth.

4

7321_003-077

– Remove the safety cartridge (4), check forcontamination, and change it if necessary.

– Refit the safety cartridge.

– Insert a new filter cartridge (3).

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7321_003-078

7

77

6

5

– Refit the air filter cover (5) with the mark (6)facing upwards

– Engage the clamps (7) on the air filter.


Lubricating the joints and controls– Oil or grease other bearing points andjoints according to the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-313.

• 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)

Checking the door latch– Inspect the condition of the catch bolt andcheck for wear.

– Check the lock mechanism for easy opera-tion.

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Maintaining the seat belt

DANGER

There 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.– Only have a defective belt replaced by your

service centre.– Only use genuine spare parts.– Do not make any changes to the belt.

NOTE

Carry out the following checks on a regularbasis (monthly). In the case of significantstrain, a daily check is necessary.

Checking the seat belt

6327_342-009

1

23

– Pull out the belt (3) completely and checkfor wear.

The belt must not be frayed or cut. Thestitching must not be loose.

– Check whether the belt is dirty.

– Check whether parts are worn or damaged,including the attachment points.

– Check the buckle (1) to ensure that it locksin properly.

When the belt tongue (2) is inserted, the beltmust be held securely.

57348011800 EN - 07/2016 335


7090_342-0051

4

– The belt tongue (2) must release when thered button (4) is pressed.

– The automatic blocking mechanism mustbe tested at least once a year:

– Park the forklift truck on level ground.

– Pull out the belt with a jerk.

The automatic blocking mechanism mustblock extension of the belt.

– Tilt the seat at least 30 ° (if necessary,remove the seat).

– Slowly extend the belt.

The automatic blocking mechanism mustblock extension of the belt.

Cleaning the seat belt

– Clean the seat belt as necessary, butwithout using chemical cleaning materials(a brush will suffice).

Replacement after an accidentAs a rule, the seat belt must be changed afteran accident.

6327_342-010

Checking the driver’s seat

WARNING

Risk 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.

WARNING

Risk of injury!– Have the seat repaired by the service centre if

you identify any damage during the checks.

336 57348011800 EN - 07/2016


Changing the heating system freshair filterThe fresh air filter for the heating system is onthe right on the exterior of the cab.

7341_003-0471

2

– Loosen the quick-release clamp (1) byturning it and remove the cover (2).

7341_003-048

3 4– Grasp the filter insert (3) at the fingeropening (4) and remove it completely fromthe filter housing.

– Check the filter insert for contamination andbeat out.

NOTE

Replace the filter insert when it is clearly grey,but at least every two months.

– Remove pollution present in the filterhousing and fresh-air inlet.

– Insert the filter insert back into the filterhousing.

– Ensure that the filter insert sits correctly andprecisely in the filter housing.

– Attach the cover and lock the quick-releaseclamp.

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6341_003-037

2

1

2

3

Replacing the recirculated air filterfor the heating systemThe recirculated air filter for the heatingsystem is located on the right-hand side of thecab, underneath the heating system panelling(1).

– Unscrew the screws (2) and remove theheating system panelling.

– Completely remove the filter mat (3) fromthe filter housing.

– Check the filter mat for contamination andbeat out.

NOTE

Replace the filter mat when it is clearly grey,but at least every two months.

– Remove any dirt that has collected in thefilter housing and recirculated-air inlet.

– Re-insert the filtermat into the filter housing.

– Make sure that the filter mat sits correctlyand accurately in the filter housing.

– Attach the heating system panelling andsecure tightly in place using the screws.

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.

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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. 6-313.

– 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.

Wartung_Rockinger 244 A

1– Grease using the lubricating nipple(1) inaccordance with the maintenance datatable; see ⇒ Chapter "Maintenance datatable", P. 6-313.

– Grease coupling pin, tow bar eye and itssupporting surface.

57348011800 EN - 07/2016 339


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. 6-313.

– Grease the supporting surface for thetow-bar eye.

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. 6-313.

– Grease the supporting surface for thetow-bar eye.

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12

7321_003-003

Servicing wheels and tyres

WARNING

Risk of accident!Uneven wear reduces the stability of the truck andincreases the braking distance.– Worn or damaged tyres (left or right) must be

replaced immediately.

WARNING

Risk of tipping!Tyre quality affects the stability of the truck.If you wish to use a different type of tyre on the truckfrom the tyres approved by the truck manufacturer,or tyres fromadifferentmanufacturer, youmust firstobtain approval from the truck manufacturer.

WARNING

Risk to stability!When using pneumatic tyres or solid rubber tyres,rim wheel parts must never be changed and rimwheel parts from different manufacturers must notbe mixed.

Checking air pressure– Check the air pressure of all four tyres;adjust if necessary.

NOTE

The correct air pressure for pneumatic tyres(variant) is determined by the type of tyresused. Observe the information on the adhe-sive labels (2) on the truck.

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7081_003-059

3Checking condition and wear of the tyres

WARNING

Tyre quality affects the stability and handling of thetruck.Changes can only be made in consultation with themanufacturer.When changingwheels or tyres, always ensure thatthis does not cause the truck to tilt to one side (e.g.always change right and left wheels at the sametime).

NOTE

The wear of the tyres on an axle must beapproximately the same.• The tread depth (1) for pneumatic tyresmust be at least 1.6 mm at every point onthe tread.

• Super-elastic tyres (variant) can be worndown to the wear mark (3).

– Check the tread depth on all four tyres.

– Check distance between the tyre tread andthe wear mark.

– Remove any foreign bodies imbedded inthe tyre tread.

Checking wheel fastenings– Check that the wheel fastening (4) is se-curely fastened and retighten as necessary.

47321_003-112

– Observe the torques; see the "maintenancedata table".

342 57348011800 EN - 07/2016


Replacing the fuses– Open the bonnet.

DANGER

Risk of fire! Using the wrong fuses can result inshort circuits.– Use only fuses with the prescribed nominal

current, see the "Fuse assignment" chapter.

1 1

117311_003-021

– Open the cover fastenings (1) and removethe cover.

– Change the defective fuse.


Checking the hydraulic oil level

CAUTION

Hydraulic oils are hazardous to your health and areunder pressure during operation.– Note the safety regulations in the "Hydraulic

fluid" chapter.

– Park the truck securely.

– Remove the left side cover.

57348011800 EN - 07/2016 343


7341_003-051_V2

1

– Unscrew breather filter (1).

7094_700-002

1

2

– Check the oil level on the oil dipstick. The oillevel must be at least up to the mark (2) onthe dipstick.

– If the oil level is too low, pour hydraulic oil ofthe corresponding specification accordingto the maintenance data table into the fillerneck.

– Pour hydraulic oil up to the upper end of themarking (2) on the oil dipstick (maximum).

NOTE

Use a funnel.

ENVIRONMENT NOTE

Carefully collect any spilled oil and dispose ofit in an environmentally friendly manner.

– Screw in the breather filter with oil dipstick.

– Attach the left side cover.

344 57348011800 EN - 07/2016


Checking the hydraulic system forleaks

WARNING

Hydraulic oil under pressure canescape from leaking lines and causeinjuries to the skin.Wear suitable protective gloves,industrial goggles etc.

WARNING

Hydraulic hoses become brittle!Hydraulic hoses should not be used longer than 6years.The specifications of BGR 237 should be compliedwith. Deviating national laws are to be taken intoaccount.

– Check pipe and hose connection screwjoints for leaks (traces of oil).

Hose lines must be changed if:• The outer layer has been breached orbecomes brittle with tears

• They are leaking• There are unnatural deformations (e.g.bubble formation or buckling)

• A fitting is detached from the hose• A fitting is badly damaged or corroded

Pipes must be changed if:• There is abrasion with the loss of material• There are unnatural deformations anddetectable bending stress

• They are leaking

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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. 6-313.

NOTE

Spray the roller track evenly from a distance ofapprox. 15-20 cm. Wait approx. 15 minutesuntil the equipment is ready to use again.

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7

1000-hour maintenance/annual mainte-nance

7 1000-hour maintenance/annual maintenanceOther tasks

Other tasks– Perform all maintenance work; see the"Maintenance" chapter.

Checking the exhaust gassystem– Inspect the exhaust gas system for externaldamage, secure fit, and leaks.

7341_003-053

Checking the lift cylinders andconnections for leaks

WARNING

Risk of injury!Observe 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 3

7094_842-001

Checking the fork arms– Check the fork arms (1) for visible deforma-tion and excessive wear.

Wear must not amount to more than 10% ofthe original thickness.

– Check the fork latch (3) for correct opera-tion.

– Check that the locking screw (2) is securedand cannot fall out of the fork arms.

– Replace any worn or deformed fork arms.

CAUTION

Fork arms must not be uneven!– Always replace both fork arms.

348 57348011800 EN - 07/2016

1000-hour maintenance/annual maintenance 7Checking the reversible fork arms

6210_842-003

1

Checking the reversible forkarms

NOTE

This check is only required for reversible forkarms (variant).

– Check the outside of the fork bend (1) forcracks. Contact your service centre.

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7 1000-hour maintenance/annual maintenanceChecking the reversible fork arms

350 57348011800 EN - 07/2016

8

Technical data

8 Technical dataDimensions

Dimensions

1 Seat is adjustable ± 90 mm 2 Fork spacing is adjustable

352 57348011800 EN - 07/2016

Technical data 8VDI datasheet

NOTE

Measurements h1, h3, h4, h6 and b1 arecustomer-specific and can be taken from theorder confirmation.

Centre of gravity "S" (distance measuredfrom the front axle)

RX70-60 1036 mm

RX70-70 1036 mm

RX70-80 1036 mm

RX70-80 (LSP 900) 1036 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 individually for each truck.

VDI datasheetNOTE

These values apply to the standard device.Values for variantsmay deviate from this data.

Key data

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Manufacturer STILLGmbH

STILLGmbH

STILLGmbH

STILLGmbH

Drive: electric, diesel,petrol, LPG, mains electric Diesel Diesel Diesel Diesel

Operation: manual,accompanied, standing,seated, order picker

Seated Seated Seated Seated

Rated capacity/load Q (kg) 6000 7000 8000 8000Load centre of gravitydistance

c (mm) 600 600 600 900

57348011800 EN - 07/2016 353

8 Technical dataVDI datasheet

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Load distance x (mm) 710 720 720 750

Wheelbase y (mm) 2285 2285 2405 2480.

Weights

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Net weight kg 10477 11370 12274 14690

Axle load with front load kg 14854 16599 18396 20535

Axle load with rear load kg 1623 1771 1878 2155

Axle load without front load kg 5415 5555 6006 7213

Axle load without rear load kg 5062 5815 6268 7477.

Wheels, chassis frame

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Tyres: superelastic (SE),solid rubber (V), pneu-matic (L)

SE SE SE SE

Front wheel size 355/65-15 8.25-15 8.25-15 315/70-15

Rear wheel size 28x9-15 250-15 250-15 28x12.5–15Number of front wheels(x = driven) 2x 4x 4x 4x

Number of rear wheels(x = driven) 2 2 2 2

Front track width, singletyre

b 10(mm) 1306 1510 1510 1561

Rear track widthb 11(mm) 1358 1358 1358 1432

.

Basic dimensions

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Tilt of lift mast/fork carriage,forwards

De-grees 5 5 5 5

Tilt of lift mast/fork carriage,backwards

De-grees 8 8 8 8

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RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Height with lift mastretracted

h1(mm) 2710 2710 2710 2710

Free lifth2(mm) 150 150 150 150

Lift height h3(mm) 3500 3150 3150 2750

Height with lift mastextended

h4(mm) 4440 4240 4240 4140

Height above overheadguard

h6(mm) 2697 2697 2697 2697

Seat height in relation toSIP/standing height

h7(mm) 1719 1719 1719 1719

Coupling height h10(mm) 510/660 510/660 510/660 510/660

Overall length l1 (mm) 4640 4732 4800 5520

Length including fork back l2 (mm) 3440 3532 3600 3720

Overall width b1 1597 1998 1998 2140

Fork arm thickness s (mm) 70 70 70 70

Fork arm width e (mm) 150 150 150 150

Fork arm length l (mm) 1200 1200 1200 1800Fork carriage DIN 15173,class/form A, B

Class IV,form A

Class IV,form A

Class IV,form A

Class IV,form A

Fork carriage width b3(mm) 1600 1800 1800 2180

Ground clearance with loadunder lift mast

m1(mm) 220 220 220 220

Ground clearance at thecentre of the wheelbase

m2(mm) 210 210 210 210

Aisle width for pallets 1000x 1200 crosswise

Ast(mm) 4907 4987 5056 5185

Aisle width for pallets 800 x1200 lengthwise

Ast(mm) 5107 5187 5256 5385

Turning radius Wa(mm) 3007 3067 3136 3235

Smallest pivot pointdistance

b13(mm) 877 877 894 900

.

57348011800 EN - 07/2016 355

8 Technical dataVDI datasheet

Performance data

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Driving speed with load km/h 20 20 20 20

Driving speed without load km/h 20 20 20 20

Lifting speed with load m/s 0.51 0.42 0.42 0.41

Lifting speed without load m/s 0.51 0.42 0.42 0.43

Lowering speed with load m/s 0.56 0.50 0.50 0.50Lowering speed withoutload m/s 0.52 0.42 0.42 0.42

Pulling force with load N 51090 46370 46300 43400

Pulling force without load N 31680 32540 35460 36750Climbing capability withload % 33 27 24 21

Climbing capability withoutload % 32 30 30 29

Acceleration time with load s 5.4 5.5 5.6 5.7Acceleration time withoutload

s 4.9 5.0 5.1 5.1

Service brake Mech./hydr. Mech./hydr. Mech./hydr. Mech./hydr..

Engine

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Engine manufac-turer/model

Deutz/TCD 4.1 l

Deutz/TCD 4.1 l

Deutz/TCD 4.1 l

Deutz/TCD 4.1 l

Engine power rating inaccordance with ISO 1585 kW 80 80 80 80

Nominal speed rpm 2400 2400 2400 2400

Number of cylinders 4 4 4 4

Displacement cm3 4038 4038 4038 4038Fuel consumption inaccordance with the VDIcycle

l/h 7.0 7.8 8.6 9.2

On-board power supply V 12 12 12 12.

356 57348011800 EN - 07/2016


Other

RX70–60 RX70–70 RX70–80 RX70–80LSP 900

Version of drive unit Diesel-electric

Diesel-electric

Diesel-electric

Diesel-electric

Working pressure forattachments bar 260 260 260 260

Oil flow for attachments l/min 60 60 60 60

Capacity of fuel tank l 110 110 110 110

AdBlue tank capacity l 10 10 10 10Sound pressure levelLpAZ 1) dB (A) 75 75 75 75

Sound power level LwAZ dB (A) 97 97 97 97Human vibration accel-eration 2) according toEN 13059

m/s2 0.31 0.31 0.31 0.31

Tow coupling, type/model Bolt Bolt Bolt Bolt

1) With cab. Without a cab, the sound pressure level is increased2) With standard driver’s seat

.

57348011800 EN - 07/2016 357

8 Technical dataErgonomic dimensions

0000_003-002

40 mm

Ergonomic dimensions

WARNING

Danger 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.

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Technical data 8Ergonomic dimensions

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8 Technical dataFuse assignment

Fuse assignment

1F08 12 V battery (permanent positive), variants,10 A

1F09 Switch lock, terminal 30, 10 A1F10 Cooling fluid pump, 10 A1F11 Converter, 10 A1F12 Reserve, 15 A1F15 12 V for TCU, display and operating unit, 10

A1F16 12 V for servo hydraulics, 10 A1F17 Time-delay relay, terminal 15, 10 A

1F18 Converter for cooling fluid pump, axle/con-verter, 15 A

1F19 12 V engine control unit (ECU), 10 A1F21 Burner air pump, preheating control unit,

exhaust gas recirculation, 10 A1F22 Spark-ignition control unit, 15 A4F01 Signal horn, 10 A9F03 12 V for Option Board, 10 A9F04 Starter motor, terminal 50, 30 A

360 57348011800 EN - 07/2016

Technical data 8Fuse assignment

7341_003-062

9F189F06 9F10/9F11

9F06 Sheathed-element heater plug, 25 A9F10 Air conditioning (variant), 20 A9F11 Air conditioning (variant), 20 A9F18 Burner pump, 60 A

Additional fuses

In this truck, additional fuses are located on afuse holder to the right of the fuse box.

NOTE

Depending on the equipment, not all fuses willbe present in the truck.

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8 Technical dataFuse assignment

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Indexg

AAccess authorisation

Changing the password . . . . . . . . . . . 96Defining the driver PIN . . . . . . . . . . . . 92Entering the access code . . . . . . . . . 91Selecting the driver PIN . . . . . . . . . . . 94

Access authorisation with PIN code . . . . 89Accessories . . . . . . . . . . . . . . . . . . . . . . . 5Accident recorder . . . . . . . . . . . . . . . . . 208Actuating the drive direction switch

Fingertip version . . . . . . . . . . . . . . . 117Joystick 4Plus version . . . . . . . . . . 117Mini-console version . . . . . . . . . . . . 118Mini-lever version . . . . . . . . . . . . . . 116

AdBlueTopping up . . . . . . . . . . . . . . . . . . . 290

Address of manufacturer . . . . . . . . . . . . . IAdjusting the armrest . . . . . . . . . . . . . . . 79Adjusting the fork . . . . . . . . . . . . . . . . . 156Adjusting the steering column . . . . . . . . . 80After washing . . . . . . . . . . . . . . . . . . . . 299

AttachmentsControlling using a double

mini-lever . . . . . . . . . . . . . . . . . . 181Controlling using the double

mini-lever and the 5th function . . 183Controlling via the joystick 4Plus . . . 191Controlling with a quadruple

mini-lever . . . . . . . . . . . . . . . . . . 188Controlling with a triple mini-lever . . . 185Controlling with the fingertip . . . . . . . 193Controlling with the fingertip and 5th

function . . . . . . . . . . . . . . . . . . . 194Controlling with the quadruple

mini-lever and the 5th function . . 190Controlling with the triple mini-lever

and the 5th function . . . . . . . . . . 187Fitting . . . . . . . . . . . . . . . . . . . . . . . 175General controlling . . . . . . . . . . . . . 179Mounting . . . . . . . . . . . . . . . . . . . . 176Releasing the pressure from the

connections . . . . . . . . . . . . . . . . 177Special risks . . . . . . . . . . . . . . . . . . . 20Taking up a load . . . . . . . . . . . . . . . 200

Automatic lift cut out . . . . . . . . . . . . . . . 129Automatic tow coupling . . . . . . . . . . . . 223

Coupling RO*243 . . . . . . . . . . . . . . 225Coupling RO*244 A . . . . . . . . . . . . . 227Coupling RO*245 . . . . . . . . . . . . . . 230Uncoupling RO*243 . . . . . . . . . . . . 227Uncoupling RO*244 A . . . . . . . . . . . 229Uncoupling RO*245 . . . . . . . . . . . . 231

BBattery

Disposal . . . . . . . . . . . . . . . . . . . . . . 13Battery acid . . . . . . . . . . . . . . . . . . . . . . 43Before taking up load . . . . . . . . . . . . . . 151Blue-Q

Configure . . . . . . . . . . . . . . . . . . . . 240Functional description . . . . . . . . . . . 242Switching off . . . . . . . . . . . . . . . . . . 243Switching on . . . . . . . . . . . . . . . . . . 243

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Bottom plateInstalling . . . . . . . . . . . . . . . . . . . . . 323Removing . . . . . . . . . . . . . . . . . . . . 322

CCab

Operating the interior lighting . . . . . . 214Operating the rear window heating . . 215

CE labelling . . . . . . . . . . . . . . . . . . . . . . . 3Changes to the forklift truck . . . . . . . . . . 31Changing the drive direction . . . . . . . . . 119

Dual pedal version . . . . . . . . . . . . . 122Changing the fork arms . . . . . . . . . . . . 144Changing the heating system fresh air

filter . . . . . . . . . . . . . . . . . . . . . . 337Changing the password . . . . . . . . . . . . . 96Checking for leaks . . . . . . . . . . . . . . . . 326Checking the coolant concentration . . . 327Checking the cooling fluid level . . . . . . . . 74Checking the door latch . . . . . . . . . . . . 334Checking the driver’s seat . . . . . . . . . . 336Checking the engine oil level . . . . . . . . . 74Checking the exhaust gas system . . . . . 348Checking the fork arms . . . . . . . . . . . . . 348Checking the lift cylinders and

connections for leaks . . . . . . . . . 348Checking wheel fastenings . . . . . . . . . . 342Clamp locking mechanism

Releasing . . . . . . . . . . . . . . . . . . . . 196Cleaning the dust valve . . . . . . . . . . . . . 81Cleaning the electrical system . . . . . . . 297Cleaning the radiator . . . . . . . . . . . . . . 326Cleaning the truck . . . . . . . . . . . . . . . . 295Cleaning the windows . . . . . . . . . . . . . 298Climbing into the truck . . . . . . . . . . . . . . 83Climbing out of the truck . . . . . . . . . . . . . 83Clipboard . . . . . . . . . . . . . . . . . . . . . . . 219Closing the bonnet . . . . . . . . . . . . . . . . 321Closing the cab door . . . . . . . . . . . . . . . 213Closing the side windows . . . . . . . . . . . 214Condition of the roadways . . . . . . . . . . 113

Consumables . . . . . . . . . . . . . . . . . . . . 41Coolant and cooling fluid safety

information . . . . . . . . . . . . . . . . . . 46Disposal . . . . . . . . . . . . . . . . . . . . . . 46Safety information for diesel fuel . . . . 44Safety information for handling

battery acid . . . . . . . . . . . . . . . . . 43Safety information for handling oils . . . 41Safety information for hydraulic fluid . . 42

Contact details . . . . . . . . . . . . . . . . . . . . . ICoolant . . . . . . . . . . . . . . . . . . . . . . . . 327Coolant and cooling fluid . . . . . . . . . . . . 46Cooling fluid

Topping up . . . . . . . . . . . . . . . . . . . 327Copyright and trademark rights . . . . . . . . . 7Coupling pin in the counterweight . . . . . 221

Coupling . . . . . . . . . . . . . . . . . . . . . 221Uncoupling . . . . . . . . . . . . . . . . . . . 223

Crane loading . . . . . . . . . . . . . . . . . . . 271Determining the loading weight . . . . 271Hooking on the lifting straps . . . . . . . 272

Cruise control . . . . . . . . . . . . . . . . . . . 208Curve Speed Control . . . . . . . . . . . . . . 127

DDamage . . . . . . . . . . . . . . . . . . . . . . . . 34Danger area . . . . . . . . . . . . . . . . . . . . 156Danger to employees . . . . . . . . . . . . . . . 25Declaration of conformity . . . . . . . . . . . . . 4Defects . . . . . . . . . . . . . . . . . . . . . . . . . 34Defining the driver PIN . . . . . . . . . . . . . . 92Definition of directions . . . . . . . . . . . . . . 11Diesel engine emissions

Checking . . . . . . . . . . . . . . . . . . . . . 38Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . 44

Filling up . . . . . . . . . . . . . . . . . . . . . 287Non-road fuels . . . . . . . . . . . . . . . . 285Specifications . . . . . . . . . . . . . . . . . 283Sulphur content . . . . . . . . . . . . . . . . 284Winter operation . . . . . . . . . . . . . . . 285

Dimensions . . . . . . . . . . . . . . . . . . . . . 352Dimensions of roadways . . . . . . . . . . . 112

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Direction indicators . . . . . . . . . . . . . . . 203Mini-console version . . . . . . . . . . . . 204Mini-lever version . . . . . . . . . . . . . . 203

Disconnecting the battery . . . . . . . . . . . 283Display and operating unit . . . . . . . . . . . 56

Additional indicators . . . . . . . . . . . . 232Adjusting the displays . . . . . . . . . . . 233Configure Blue Q . . . . . . . . . . . . . . . 240Standard display elements . . . . 88, 232

Display messagesDisplay content . . . . . . . . . . . . . . . . 245Drive-specific . . . . . . . . . . . . . . . . . 258General . . . . . . . . . . . . . . . . . . . . . 249

Display operating unitResetting the daily kilometres . . . . . 238Setting the date . . . . . . . . . . . . . . . . 238Setting the language . . . . . . . . . . . . 239Setting the time . . . . . . . . . . . . . . . . 238

Display symbols . . . . . . . . . . . . . . . . . . 233Auxiliary equipment soft key

functions . . . . . . . . . . . . . . . . . . 235Error messages . . . . . . . . . . . . . . . 235Menu navigation soft key functions . . 236Numeric keypad . . . . . . . . . . . . . . . 237Operating messages . . . . . . . . . . . . 234Status LEDs . . . . . . . . . . . . . . . . . . 236Warning messages . . . . . . . . . . . . . 234

DisposalBattery . . . . . . . . . . . . . . . . . . . . . . . 13Components . . . . . . . . . . . . . . . . . . . 13

Documentation scope . . . . . . . . . . . . . . . 6Double mini-lever . . . . . . . . . . . . . . . . . . 58

Lifting/lowering the fork carriage . . . 138Tilting the lift mast . . . . . . . . . . . . . . 138

Driver rights, duties and rules ofbehaviour . . . . . . . . . . . . . . . . . . 29

Driver’s cabUse . . . . . . . . . . . . . . . . . . . . . . . . 102

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . 29Driving

on ascending and descendingslopes . . . . . . . . . . . . . . . . . . . . 165

Driving lightsSwitching on and off . . . . . . . . . . . . 201

Driving on gradients . . . . . . . . . . . . . . . 112Driving on lifts . . . . . . . . . . . . . . . . . . . 165Driving on loading bridges . . . . . . . . . . 166

EEC declaration of conformity in

accordance with MachineryDirective . . . . . . . . . . . . . . . . . . . . 4

Effects on additional consumers . . . . . . 242Emergencies

Truck tipping over . . . . . . . . . . . . . . 277Using the emergency hammer . . . . . 278

Emergency hammer . . . . . . . . . . . . . . . 278Emergency lowering . . . . . . . . . . . . . . 278Emergency off

Checking for correct function . . . . . . 106Unlocking the switch . . . . . . . . . . . . . 86

Emergency shutdown . . . . . . . . . . . . . 276Emissions . . . . . . . . . . . . . . . . . . . . . . . 48

Battery . . . . . . . . . . . . . . . . . . . . . . . 51Exhaust gases . . . . . . . . . . . . . . . . . 50Heat . . . . . . . . . . . . . . . . . . . . . . . . . 50Noise emissions . . . . . . . . . . . . . . . . 48Vibrations . . . . . . . . . . . . . . . . . . . . . 49

Entering the access code . . . . . . . . . . . . 91Ergonomic dimensions . . . . . . . . . . . . . 358Error code table . . . . . . . . . . . . . . . . . . 246Example . . . . . . . . . . . . . . . . . . . . . . . 152

FFilling the washer system . . . . . . . . . . . . 72Fingertip . . . . . . . . . . . . . . . . . . . . . . . . 62


Fitting attachments . . . . . . . . . . . . . . . 175FleetManager . . . . . . . . . . . . . . . . . . . 207

Accident recorder . . . . . . . . . . . . . . 208Fork arms

Length . . . . . . . . . . . . . . . . . . . . . . . 37Fork extension . . . . . . . . . . . . . . . . . . . 146

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Four-way mini-lever . . . . . . . . . . . . . . . . 60Fuel filter

Draining water from . . . . . . . . . . . . . 329Fuel hand pump . . . . . . . . . . . . . . . . . . 288Fuse assignment . . . . . . . . . . . . . . . . . 360

GGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . 2

HHandling gas springs and accumulators . 36Hazard areas . . . . . . . . . . . . . . . . . . . . 114Hazard warning system . . . . . . . . . . . . 203Hazards and countermeasures . . . . . . . . 22Heating system . . . . . . . . . . . . . . . . . . 216

Adjusting the air flow . . . . . . . . . . . . 218Switching on . . . . . . . . . . . . . . . . . . 217Switching on the blower . . . . . . . . . . 217

Hydraulic blocking function . . . . . . . . . . 136Releasing . . . . . . . . . . . . . . . . . . . . 136

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . 42Hydraulic system

Checking for leaks . . . . . . . . . . . . . . 345Checking the oil level . . . . . . . . . . . . 343

IIdentification points

Overview . . . . . . . . . . . . . . . . . . . . . 64Impermissible use . . . . . . . . . . . . . . . . . 16Information for carrying out mainte-

nance . . . . . . . . . . . . . . . . . . . . 302Maintenance timeframe . . . . . . . . . . 303

Information symbols . . . . . . . . . . . . . . . . . 7Inserting wedges . . . . . . . . . . . . . . . . . 267Insulation testing . . . . . . . . . . . . . . . . . . 40Insurance cover on company premises . . 31Interior lighting . . . . . . . . . . . . . . . . . . . 214Issue date of the operating instructions . . . 7

JJacking up . . . . . . . . . . . . . . . . . . . . . . 318

Joystick 4Plus . . . . . . . . . . . . . . . . . . . . 61Fork-carriage sideshift . . . . . . . . . . . 142Lifting/lowering the fork carriage . . . 141Tilting the lift mast . . . . . . . . . . . . . . 141

Jump-starting . . . . . . . . . . . . . . . . . . . . 274

LLashing down . . . . . . . . . . . . . . . . . . . 267Left side cover . . . . . . . . . . . . . . . . . . . 322

Attaching . . . . . . . . . . . . . . . . . . . . 322Removing . . . . . . . . . . . . . . . . . . . . 322

Lift cut outAutomatic . . . . . . . . . . . . . . . . . . . . 129

Lift mastLubricating the roller track . . . . . . . . 346Removing . . . . . . . . . . . . . . . . . . . . 319Securing against falling off . . . . . . . . 319Securing against tilting backwards . . 319

Lift mast versionsTriplex lift mast . . . . . . . . . . . . . . . . 135

Lift mast vertical position . . . . . . . . . . . 130Automatic approach . . . . . . . . . . . . 132Calibrating . . . . . . . . . . . . . . . . . . . 134Description . . . . . . . . . . . . . . . . . . . 130Display . . . . . . . . . . . . . . . . . . . . . . 132Possible restrictions . . . . . . . . . . . . 133Run-in to end stops . . . . . . . . . . . . . 132Tilting the lift mast backwards . . . . . 133Tilting the lift mast forwards . . . . . . . 132

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . 318Lifting system

Controlling using a doublemini-lever . . . . . . . . . . . . . . . . . . 138

Controlling using a quadruplemini-lever . . . . . . . . . . . . . . . . . . 140

Controlling using a triple mini-lever . . 139Controlling using the fingertip . . . . . . 143Controlling using the joystick 4Plus . 141Operating devices . . . . . . . . . . . . . . 137

LightingSwitching on and off . . . . . . . . . . . . 201

List of abbreviations . . . . . . . . . . . . . . . . . 8

366 57348011800 EN - 07/2016

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LoadPicking up . . . . . . . . . . . . . . . . . . . . 158Setting down . . . . . . . . . . . . . . . . . . 163transporting . . . . . . . . . . . . . . . . . . 162

Load capacity . . . . . . . . . . . . . . . . . . . 151Load chains

Cleaning . . . . . . . . . . . . . . . . . . . . . 298Load measurement . . . . . . . . . . . . . . . 152

Description . . . . . . . . . . . . . . . . . . . 152Execution . . . . . . . . . . . . . . . . . . . . 153Zero adjustment . . . . . . . . . . . . . . . 107

Lubricating the joints and controls . . . . . 334

MMaintenance data table . . . . . . . . . . . . 313

Air conditioning . . . . . . . . . . . . . . . . 315Air filter system . . . . . . . . . . . . . . . . 315Battery . . . . . . . . . . . . . . . . . . . . . . 313Controls/joints . . . . . . . . . . . . . . . . . 313Cooling system . . . . . . . . . . . . . . . . 315Drive axle . . . . . . . . . . . . . . . . . . . . 314Electrical system . . . . . . . . . . . . . . . 313Engine . . . . . . . . . . . . . . . . . . . . . . 315Exhaust gas treatment (SCR) . . . . . 315Fuel tank . . . . . . . . . . . . . . . . . . . . . 315General lubrication points . . . . . . . . 313Hydraulic system . . . . . . . . . . . . . . 313Lift mast . . . . . . . . . . . . . . . . . . . . . 314Load chains . . . . . . . . . . . . . . . . . . 314Steering axle . . . . . . . . . . . . . . . . . . 314Tyres . . . . . . . . . . . . . . . . . . . . . . . 313Washer system . . . . . . . . . . . . . . . . 315

Maintenance work without specialqualifications . . . . . . . . . . . . . . . 302

Malfunctions during lifting mode . . . . . . 135Measuring the insulation resistance of

the electrical system . . . . . . . . . . . 40Medical equipment . . . . . . . . . . . . . . . . . 36Message

? VERTICAL POSITION . . . . . . . . . 253ACCELERATOR . . . . . . . . . . . . . . . 250ADBLUE FILLING LEVEL . . . . . . . . 260

ADBLUEQUALITY . . . . . . . . . . . . . 260ADBLUEQUALITY URGENT! . . . . . 260ADBLUE REFILL 5l . . . . . . . . . . . . . 260ADBLUE URGENT! . . . . . . . . . . . . 259AIR FILTER . . . . . . . . . . . . . . . . . . 263ALTERNATOR . . . . . . . . . . . . . . . . 262APPLY HANDBRAKE . . . . . . . . . . . 249ARE YOU SURE ? . . . . . . . . . . . . . 255ASH LOAD . . . . . . . . . . . . . . . . . . . 261BRAKE SENSOR . . . . . . . . . . . . . . 250CODEDENIED . . . . . . . . . . . . . . . . 250COOLANT LEVEL . . . . . . . . . . . . . 262CUTOUTMODE . . . . . . . . . . . . . . . 259EMERGENCY SWITCH . . . . . . . . . 252EMPTY . . . . . . . . . . . . . . . . . . . . . . 262EXH.GAS PURIFIER . . . . . . . . . . . 258EXH.GAS PURIFIER PLEASE

WAIT . . . . . . . . . . . . . . . . . . . . . 259EXH.GAS PURIFIER SERVICE! ! ! . 259FUEL FILTER . . . . . . . . . . . . . . . . . 261GLOW . . . . . . . . . . . . . . . . . . . . . . 261HYBRID SYSTEM . . . . . . . . . . . . . . 261HYDRAULIC PUMP . . . . . . . . . . . . 261LOWER FORKS . . . . . . . . . . . . . . . 251LPG AUTO. VALVE . . . . . . . . . . . . . 263NOT VALID . . . . . . . . . . . . . . . . . . . 258OIL PRESSURE . . . . . . . . . . . . . . . 263OVERHEATING . . . . . . . . . . . . . . . 257PARK. REG. ERROR . . . . . . . . . . . 264PARK. REG. URGENT! ! ! . . . . . . . . 264PARKING BRAKE ACTIVE . . . . . . . 251PARKING BRAKE: APPLY

HANDBRAKE! . . . . . . . . . . . . . . 251REFERENCECYCLE . . . . . . . . . . . 253REGENERATION COMPLETED . . . 263RELEASE PARKING BRAKE . . . . . 251SAFETY BELT . . . . . . . . . . . . . . . . 254SCR-SYSTEMMALFUNCTION . . . 264SCR-SYSTEMSERVICE . . . . . . . . 264SEAT SWITCH . . . . . . . . . . . . . . . . 255SERVICE BRAKE . . . . . . . . . . . . . . 249START IC ENGINE . . . . . . . . . . . . . 265

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START PARK. REG.? . . . . . . . . . . . 264STEERING . . . . . . . . . . . . . . . . . . . 252SURVEILLANCE . . . . . . . . . . . . . . 258SWITCHOFF TRUCK? . . . . . . . . . . 251TILTING SPEED . . . . . . . . . . . . . . . 252

MessagesDrive-specific . . . . . . . . . . . . . . . . . 258General . . . . . . . . . . . . . . . . . . . . . 249

Mini console . . . . . . . . . . . . . . . . . . . . . . 63Misuse of safety systems . . . . . . . . . . . . 34MSG 65/MSG 75 driver’s seat

Adjusting . . . . . . . . . . . . . . . . . . . . . 76Adjusting the backrest extension . . . . 79Adjusting the lumbar support . . . . . . . 78Adjusting the seat backrest . . . . . . . . 77Adjusting the seat suspension . . . . . . 78Moving . . . . . . . . . . . . . . . . . . . . . . . 77Switching the seat heater on and off . . 79

NNameplate . . . . . . . . . . . . . . . . . . . . . . . 66Neutral position . . . . . . . . . . . . . . . . . . 116Note regarding exhaust gas treatment . . . 2

OOil bath air filter

Cleaning the oil tank . . . . . . . . . . . . 331Visual inspection . . . . . . . . . . . . . . . . 82

Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Opening the bonnet . . . . . . . . . . . . . . . 320Opening the cab door . . . . . . . . . . . . . . 212Opening the side windows . . . . . . . . . . 213Operating company . . . . . . . . . . . . . . . . 28Operating devices for hydraulic and

driving functions . . . . . . . . . . . . . . 57Operating materials

Quality and quantity . . . . . . . . . . . . 312Operating procedures . . . . . . . . . . . . . . 11Operating the service brake . . . . . . . . . 123Operating the signal horn . . . . . . . . . . . . 99Ordering spare parts andwearing parts . 311

Overhead guardDrilling . . . . . . . . . . . . . . . . . . . . . . . 33Roof loads . . . . . . . . . . . . . . . . . . . . 33Welding . . . . . . . . . . . . . . . . . . . . . . 33

OverviewDriver’s compartment . . . . . . . . . . . . 55

PPackaging . . . . . . . . . . . . . . . . . . . . . . . 13Parked regeneration

Interruption . . . . . . . . . . . . . . . . . . . 168Performing . . . . . . . . . . . . . . . . . . . 169

Parking brake . . . . . . . . . . . . . . . . . . . 124Mechanical parking brake . . . . . . . . 124

Parking the truck securely . . . . . . . . . . 291Particle filter

Displays . . . . . . . . . . . . . . . . . . . . . 173Function . . . . . . . . . . . . . . . . . . . . . 167Low-load operation . . . . . . . . . . . . . 168Normal operation . . . . . . . . . . . . . . 168Parked regeneration . . . . . . . . . . . . 169

Personnel qualifications . . . . . . . . . . . . 302Picking up loads . . . . . . . . . . . . . . . . . . 155Place of use . . . . . . . . . . . . . . . . . . . . . . 17Pre-cleaner

Cleaning . . . . . . . . . . . . . . . . . . . . . 331Visual inspection . . . . . . . . . . . . . . . . 81

Procedure if truck tips over . . . . . . . . . . 277Production number . . . . . . . . . . . . . . . . 67Prohibition of use by unauthorised

persons . . . . . . . . . . . . . . . . . . . . 30Proper usage . . . . . . . . . . . . . . . . . . . . . 16Push-up roof window . . . . . . . . . . . . . . 219

QQuadruple mini-lever


RRadio . . . . . . . . . . . . . . . . . . . . . . . . . 216Rear window heating . . . . . . . . . . . . . . 215

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Recommissioning after shutdown . . . . . 294Reducing speed when turning . . . . . . . 127Reducing speed with a raised load . . . . 128Replacing the air filter cartridges . . . . . . 332Replacing the fuses . . . . . . . . . . . . . . . 343Replacing the recirculated air filter for

the heating system . . . . . . . . . . . 338Resetting the daily kilometres . . . . . . . . 238Resetting the daily operating hours . . . . 238Residual dangers . . . . . . . . . . . . . . . . . . 19Residual risks . . . . . . . . . . . . . . . . . . . . 19Retrofitting . . . . . . . . . . . . . . . . . . . . . . . 31Reversible fork arm

Checking . . . . . . . . . . . . . . . . . . . . 349Reversible fork arms . . . . . . . . . . . . . . 148Right-hand service flap

Closing . . . . . . . . . . . . . . . . . . . . . . 325Opening . . . . . . . . . . . . . . . . . . . . . 324

Roadways . . . . . . . . . . . . . . . . . . 112 – 114Rotating beacon . . . . . . . . . . . . . . . . . . 202Rules for roadways and the working

area . . . . . . . . . . . . . . . . . . . . . . 114

SSafety devices . . . . . . . . . . . . . . . . . . . 318Safety inspection . . . . . . . . . . . . . . . . . . 38Safety regulations for maintenance

General information . . . . . . . . . . . . 316Safety devices . . . . . . . . . . . . . . . . 318Set values . . . . . . . . . . . . . . . . . . . . 318Working on the electrical equip-

ment . . . . . . . . . . . . . . . . . . . . . 317Working on the hydraulic equip-

ment . . . . . . . . . . . . . . . . . . . . . 316Working on the ignition system . . . . . 317

Safety regulations for working on the liftmast . . . . . . . . . . . . . . . . . . . . . 318

Safety regulations when driving . . . . . . 110Safety regulations when handing loads . 150Schematic views . . . . . . . . . . . . . . . . . . 11

Seat belt . . . . . . . . . . . . . . . . . . . . . . . . 99Checking . . . . . . . . . . . . . . . . . . . . 335Cleaning . . . . . . . . . . . . . . . . . . . . . 336Fastening . . . . . . . . . . . . . . . . . . . . 100Fastening on a steep slope . . . . . . . 101Maintaining . . . . . . . . . . . . . . . . . . . 335Malfunction due to cold . . . . . . . . . . 101Releasing . . . . . . . . . . . . . . . . . . . . 101Replacement after an accident . . . . 336

Selecting the drive direction . . . . . . . . . 115Selecting the driver PIN . . . . . . . . . . . . . 94Set values . . . . . . . . . . . . . . . . . . . . . . 318Setting the date . . . . . . . . . . . . . . . . . . 238Setting the drive programme . . . . . . . . . 114Setting the language . . . . . . . . . . . . . . 239Setting the time . . . . . . . . . . . . . . . . . . 238Shutdown

Recommissioning . . . . . . . . . . . . . . 294Shutting down the truck . . . . . . . . . . . . 292Special risks . . . . . . . . . . . . . . . . . . . . . 20Spring-operated brake

Releasing . . . . . . . . . . . . . . . . . . . . 280Stability . . . . . . . . . . . . . . . . . . . . . . . . . 20Starting drive mode

Dual-pedal version . . . . . . . . . . . . . 120Starting the engine . . . . . . . . . . . . . . . . 103Starting to drive . . . . . . . . . . . . . . . . . . 118Status LEDs . . . . . . . . . . . . . . . . . . . . 236Steering . . . . . . . . . . . . . . . . . . . . . . . . 126Steering system

Checking for correct function . . . . . . 106Storing the truck . . . . . . . . . . . . . . . . . . 292StVZO (Road Traffic Licensing

Regulations) information . . . . . . . 67Switching off the

air conditioning . . . . . . . . . . . . . . . . 218Switching off the truck . . . . . . . . . . . . . 291Switching on the

air conditioning . . . . . . . . . . . . . . . . 218Switching on the key switch . . . . . . . . . . 86

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TTechnical data

Dimensions . . . . . . . . . . . . . . . . . . 352VDI datasheet . . . . . . . . . . . . . . . . . 353

Three-waymini-lever . . . . . . . . . . . . . . . 59Topicality of the operating instructions . . . 7Towed load . . . . . . . . . . . . . . . . . . . . . 220Towing . . . . . . . . . . . . . . . . . . . . . . . . 268

Proper use . . . . . . . . . . . . . . . . . . . . 16Trailers

Towing . . . . . . . . . . . . . . . . . . . . . . 231Transport . . . . . . . . . . . . . . . . . . . . . . . 266Transport of swinging loads . . . . . . . . . 157Transporting pallets . . . . . . . . . . . . . . . 157Triple mini-lever


Types of lift mast . . . . . . . . . . . . . . . . . 134Telescopic mast . . . . . . . . . . . . . . . 134

TyresSafety principles . . . . . . . . . . . . . . . . 34

UUsing working platforms . . . . . . . . . . . . . 18

VVariants

Access authorisation with PIN code . . 89Accident recorder . . . . . . . . . . . . . . 208Automatic lift cut out . . . . . . . . . . . . 129Automatic shut-off of the internal

combustion engine . . . . . . . . . . . 128Clamp locking mechanism . . . . . . . . 196Clipboard . . . . . . . . . . . . . . . . . . . . 219Cruise control . . . . . . . . . . . . . . . . . 208Emergency off switch . . . . . . . . . . . . 86FleetManager . . . . . . . . . . . . . . . . . 207Fork extension . . . . . . . . . . . . . . . . 146Heating system . . . . . . . . . . . . . . . . 216Lift mast vertical position . . . . . . . . . 130Lifting systems . . . . . . . . . . . . . . . . 129Loadmeasurement . . . . . . . . . . . . . 152Push-up roof window . . . . . . . . . . . . 219Radio . . . . . . . . . . . . . . . . . . . . . . . 216Reducing speed with a raised load . . 128Reversible fork arms . . . . . . . . . . . . 148Triplex lift mast . . . . . . . . . . . . . . . . 135Wheel chock . . . . . . . . . . . . . . . . . . 292Windscreen wiper/washer . . . . . . . . 207Zero braking . . . . . . . . . . . . . . . . . . 124

VDI datasheet . . . . . . . . . . . . . . . . . . . 353Vertical lift mast position

Checking for correct function . . . . . . 109View of functions and operations . . . . . . . 11View of operating procedures . . . . . . . . . 11Views of the display operating unit . . . . . 12Visual inspection

Oil bath air filter . . . . . . . . . . . . . . . . . 82Pre-cleaner . . . . . . . . . . . . . . . . . . . . 81

Visual inspections . . . . . . . . . . . . . . . . . 70

WWarning regarding non-original parts . . . 33Wheel chock . . . . . . . . . . . . . . . . . . . . 292

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Wheels and tyresChecking air pressure . . . . . . . . . . . 341Checking condition and wear of the

tyres . . . . . . . . . . . . . . . . . . . . . 342Checking wheel fastenings . . . . . . . 342Servicing . . . . . . . . . . . . . . . . . . . . 341

Windscreen wiper/washer . . . . . . . . . . 207Working at the front of the truck . . . . . . . 318Working on the electrical equipment . . . 317Working on the hydraulic equipment . . . 316

Working on the ignition system . . . . . . . 317Working spotlights

Automatically switching on/off . . . . . 206Lift-height-controlled switching

on/off . . . . . . . . . . . . . . . . . . . . . 206Manually switching on/off . . . . . . . . 205Switching on and off . . . . . . . . 202, 205

ZZero adjustment of the load measure-

ment . . . . . . . . . . . . . . . . . . . . . 107

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STILL GmbH

57348011800 EN – 07/2016

Documents

WithSCR(SelectiveCatalyticReduction)...Preface g Addressofmanufacturerand contactdetails STILLGmbH Berzeliusstraße10 22113Hamburg,Germany Tel.+49(0)407339-0 Fax:+49(0)407339-1622