Page 1 Original instructions Platform tractors and tow tractors R 07-25, R 08-20 0736 0737 0809 0810 172780 EN - 06/2017...
Page 3 • Information on transport, initial commis- sioning and storage of industrial trucks Internet address and QR code The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 172780 EN - 06/2017...
Page 5: Table Of Contents
Table of contents Foreword Your industrial truck ........... 2 General .
Page 6 Table of contents Safety tests ............26 Periodic safety inspection of the industrial truck .
Page 7 Table of contents Commissioning ........... . . 59 Connecting the battery .
Page 8 STILL SafetyLight (variant) ........
Page 9 Table of contents Special operating situations ..........145 Securing the truck for transportation .
Page 10 Table of contents Removing and installing the front wheels ........186 Removing and installing the drive wheels .
Page 11: Foreword
Foreword...
Page 12: Your Industrial Truck
Foreword Your industrial truck Your industrial truck General The truck described in these operating instruc- tions conforms with the applicable standards and safety regulations. If the truck is to be operated on public roads, it must conform with the existing national regulations for the country in which it is being used.
Page 13: Information About The Documentation
Foreword Information about the documentation Information about the documentation Scope of the documentation • Operating instructions • Operating instructions for attachments (variant) • Spare parts list • VDMA rules for proper use These operating instructions describe all mea- sures necessary for the safe operation and proper maintenance of the truck in all possible variants at the time of printing.
Page 14 Foreword Information about the documentation have found any faults, please contact your service centre. 172780 EN - 06/2017...
Page 15: Information Symbols Used
Foreword Information about the documentation Information symbols used In order to reduce the risk of physical injuries, CAUTION injuries to third parties and potential damage Indicates hazards that may result in damage to, or to the truck, information symbols on warning destruction of the product.
Page 16: Issue Date And Topicality
Issue date and topicality The issue date of these operating instructions can be found on the title page. STILL makes continuous efforts to enhance and improve its trucks. These operating instructions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.
Page 17: Disposing Of Components And Batteries
Foreword Environmental considerations ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck. Disposing of components and batteries The truck consists of different materials. Replaced components or batteries must be • disposed of, • treated or •...
Page 18 Foreword Environmental considerations 172780 EN - 06/2017...
Page 19: Introduction
Introduction...
Page 20: Use Of The Truck
Introduction Use of the truck Use of the truck Intended purpose Your truck is designed for transporting and towing stable loads as stated on the capacity plate within a temperature range of -20°C to +40°C. Please pay particular attention to the VDMA booklet accompanying these operating instructions concerning safe and accident-free operation of industrial trucks, and read the...
Page 21: Inadmissible Use
Introduction Use of the truck Inadmissible use The operating company or driver, and not the manufacturer, is liable for any hazards caused by inadmissible use; see the chapter "Deﬁnition of terms used for responsible persons". Use for purposes other than those described in these operating instructions is prohibited.
Page 22: Residual Risk
Introduction Residual risk speciﬁcations are observed, see. The truck is suitable for indoor and outdoor use in countries ranging from the Tropics to Nordic regions (temperature range: -20°C to +40°C). If the truck is to be used in a cold store, it must be conﬁgured accordingly and, if necessary, approved for such an environment.
Page 23: Danger To Employees
Introduction Residual risk WARNING Risk of accident due to non-observation of safety information! All personnel working in the vicinity of the truck must be instructed regarding the hazards that can arise through use of the truck. – Observe safety regulations in these operating instructions.
Page 24: Overview Of Hazards And Countermeasures
Introduction Residual risk Construction and equipment of the truck correspond with the Machinery Directive 2006/42/EC and are therefore identiﬁed with the CE symbol. They are therefore not included in the hazard assessment, and neither are the attachments on account of their own CE labelling.
Page 25 Introduction Residual risk Hazard Course of action Check note Notes √ done - not applicable Tow tractor equipment Testing If in doubt, consult does not comply with the responsible local regulations factory inspectorate or employers' liability insurance association Driver's lack of skills or Driver training (sit-on BGG 925 (Guidelines qualiﬁcations...
Page 26 Introduction Residual risk Hazard Course of action Check note Notes √ done - not applicable Impermissible usage Provide operating BetrSichVO (improper usage) instructions (Workplace Safety Ordinance) and ArbSchG (Health and Safety at Work Act) Written notice of BetrSichVO instruction to driver (Workplace Safety Ordinance) and ArbSchG (Health and...
Page 27: Special Risks Associated With Using The Truck And Attachments
Introduction Residual risk Hazard Course of action Check note Notes √ done - not applicable Routes intersect Announce right-of-way BetrSichVO rule (Workplace Safety Ordinance) No person detection Employee training BetrSichVO when handling goods (Workplace Safety Ordinance) Special risks associated with using the truck and attachments Approval from the manufacturer and attach- ment manufacturer must be obtained each...
Page 28 Introduction Residual risk 172780 EN - 06/2017...
Page 29: Safety
Safety...
Page 30: Definition Of Responsible Persons
Safety Deﬁnition of responsible persons Deﬁnition of responsible persons Driver This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling trucks to the operating company or an authorised rep- resentative, and have been speciﬁcally in- structed to drive the truck.
Page 31: Operating Company
Safety Deﬁnition of responsible persons DANGER Increased risk of accident if drugs, alcohol or medications are consumed! Drugs, alcohol or medications that affect reactions impair the ability to drive the truck. – Individuals under the inﬂuence of the aforemen- tioned substances are not permitted to perform work of any kind on or with the truck.
Page 32: Basic Principles For Safe Operation
Safety Basic principles for safe operation a vocational qualiﬁcation or a similar document. • Professional experience indicating that the qualiﬁed person has gained practical experience of industrial trucks over a proven period during their career During this time, this person has become familiar with a wide range of symptoms that require checks to be carried out, such as based on the results of a hazard assessment or a...
Page 33: Non-Original Parts
Safety Basic principles for safe operation Non-original parts Original parts, attachments and accessories are specially designed for this truck. Please note that parts, attachments and accessories not supplied by the manufacturer have also not been tested or approved by the manufacturer. CAUTION Danger of damage to truck if non-original parts are used!
Page 34: Drivers With Medical Devices
Safety Basic principles for safe operation WARNING Danger of serious injury from high accumulator pressure! – Depressurise the accumulator before starting work on it. – Contact your service centre. Drivers with medical devices If drivers use medical devices, e.g. pace- makers or hearing aids, their function may be impaired.
Page 35: Insurance Cover On Company Premises
Safety Basic principles for safe operation If the manufacturer goes into liquidation and the company is not taken over by another legal person, the operating company can make modiﬁcations to the truck. To do so, the operating company must fulﬁl the following prerequisites: Design documents, test documents and assembly instructions associated with the...
Page 36: Damage, Defects And Misuse Of Safety Systems
Safety Safety tests Damage, defects and misuse of safety systems Damage or other defects on the truck must be reported to the supervisor or responsible ﬂeet manager immediately so that they can arrange for the defect to be rectiﬁed. Trucks that are not safe for operation or for use on the road must not be used until they have been properly repaired.
Page 37: Insulation Testing
Safety Safety tests – Observe the guidelines regarding inspec- tion work on industrial trucks as speciﬁed by FEM 4.004. The operating company is responsible for ensuring that any defects are remedied without delay. – Contact your service centre. NOTE Observe the national regulations of your country! Insulation testing The insulation of the truck must have sufﬁcient...
Page 38: Safety Regulations For Handling Consumables
Safety Safety regulations for handling consumables Test values for the truck Minimum values over the Nominal voltage Test voltage Test values for new trucks duration of the service life 24 V 50 VDC Min. 50 k > 24 k 48 V 100 VDC Min.
Page 39 Safety Safety regulations for handling consumables WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, always wear a protection suit and eye protection. – When working with battery acid, ne- ver wear a watch or any jewellery. –...
Page 40: Oils
Safety Safety regulations for handling consumables Oils DANGER Oils are ﬂammable! – Follow the statutory regulations. – Do not allow oils to come into contact with hot engine parts. – No smoking, ﬁres or naked ﬂames! DANGER Oils are toxic! –...
Page 41: Lubricants
Safety Safety regulations for handling consumables ENVIRONMENT NOTE Oil is a water-polluting substance! Always store oil in containers that comply • with the applicable regulations. Avoid spilling oils. • Spilt oil should be removed immediately • with oil-binding agents and disposed of according to the regulations.
Page 42: Substances That Are Damaging To Health
Safety Safety regulations for handling consumables WARNING These ﬂuids are pressurised during operation of the truck and are hazar- dous to your health. – Do not allow the ﬂuids to come into contact with the skin. – Avoid inhaling spray. –...
Page 43: Disposal Of Consumables
Safety Emissions Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair, maintenance and cleaning must be collected properly and disposed of in accordance with the national regulations for the country in which the truck is being used. Work must only be carried out in areas designated for that purpose.
Page 44 Safety Emissions Diesel engine emissions (auxiliary If necessary, these values should be deter- mined directly at the workplace in the actual heater) conditions that are present there (additional Check the diesel engine emissions in accor- noise sources, special application conditions, dance with the operating instructions of the sound reﬂections).
Page 45: Overviews
Overviews...
Page 46: Your Truck
Overviews Your truck Your truck Information Your truck offers the best in economy, safety and driving convenience. However, it is primarily down to the operator to maintain these characteristics for a long time and to take advantage of the resulting beneﬁts. These operating instructions contain every- thing you need to know about commissioning, driving, maintaining and repairing the truck.
Page 47 Overviews Your truck For repairs use only genuine spare parts. This is the only way to guarantee that your truck maintains its original technical standard. When ordering spare parts, please specify the part number and the following truck data: Truck type: Serial number/year of manufacture: Delivery date: When taking over the truck, transfer the...
Page 48 Overviews Your truck To avoid subsequent complaints and defects, we ask that you carefully check the functional ability of the truck and the completeness of the equipment at the time of transfer. The following technical documents come with every truck: •...
Page 49: Truck Variants
Overviews Your truck Truck variants Tow tractor version • Tow tractor (short wheelbase); see chapter "Technical data". • Tow tractor (long wheelbase); see chapter "Technical data". 127-59c Platform version • Platform truck 2200 (short loading plat- form); see chapter "Technical data". •...
Page 50: Truck View
Overviews Truck view Truck view Platform version Passenger's seat Drive axle Battery cover Rear wheel Battery Steer cylinder Controller cooling fans Brake calliper Motor cover Front wheel Damper Driver's seat Spring Rear view mirror Rear tow coupling 172780 EN - 06/2017...
Page 51: Tow Tractor Version
Overviews Truck view Tow tractor version Passenger's seat Drive axle Battery cover Rear wheel Battery Steering axle Controller cooling fans Brake calliper Motor cover Front wheel Damper Driver's seat Spring Rear-view mirror Rear tow coupling 172780 EN - 06/2017...
Page 52: Operating And Display Elements
Overviews Operating and display elements Operating and display elements View of the driver's compartment Parking light/dipped beam Keyswitch Display unit Emergency off switch Hazard warning light Heating vents Keypad (variant) Steering wheel Parking brake Accelerator pedal Operating levers: Brake pedal Drive programme selection Operating levers: Direction selection...
Page 53: Display Unit
Overviews Operating and display elements Display unit Reverse travel indicator km or miles, lights up with 15/17 Forward travel indicator Slow travel indicator Overheating indicator km display Error status indicator Interlock malfunction display Brake ﬂuid indicator Miles display Hydraulic ﬂuid indicator Not assigned Display on the display unit Time display...
Page 54: Switch Panel
Overviews Operating and display elements Switch panel NOTE The assignment shown here is an example and may differ on your truck. If you have any questions, please contact your service centre. Heating system toggle switch Rear window wiper/washer toggle switch (variant) Back pedal toggle switch Rotating beacon toggle switch (variant)
Page 55: Labelling Points
Overviews Labelling points Labelling points Data plates and adhesive labels Tyre pressure adhesive label in the driver's Truck serial number on the chassis, above cab on the rear wall the right cab post. Warning label for automatic tow coupling Type/capacity rating plate between the Adhesive label for the pulling force seats Adhesive label for 12-V socket...
Page 56: Identification Plate
Overviews Labelling points Identiﬁcation plate Manufacturer Pulling force Truck type/production number/year of CE mark (this mark certiﬁes that the truck manufacture complies with the relevant EC directives and Tare weight all applicable guidelines) Battery weight Rated drive power Permissible axle loads Battery voltage Address of manufacturer Payload...
Page 57: Equipment
Overviews Equipment Equipment Standard equipment and variants Rear tow coupling • Tow coupling that can be released remotely (Rockinger 244A) • Automatic coupling (Rockinger 244A) • 3-stage coupling Front tow coupling • Automatic coupling • 3-stage coupling Drive unit (2-engine drive) •...
Page 58 Overviews Equipment Driver's seat • MSG 65 synthetic leather cover and lumbar support • Comfort MSG 65 textile cover and lumbar support • Exclusive MSG 65 textile cover, lumbar support and seat heater • Seat belts for driver's seat and passenger seat •...
Page 59: Operation
Operation...
Page 60: Checks And Tasks To Be Carried Out Prior To Commissioning
Operation Checks and tasks to be carried out prior to commissioning Checks and tasks to be carried out prior to commissioning Visual inspections WARNING Risk of accident due to damage or other defects on the truck! Damage to the truck or the attachment (variant) can lead to unpredictable and dangerous situations.
Page 61 Operation Checks and tasks to be carried out prior to commissioning necessary, have the battery male connector replaced by the authorised service centre • The battery cover must be securely closed • The latches on the battery cover must not be damaged or deformed.
Page 62: Before Beginning Your Shift
Operation Checks and tasks to be carried out prior to commissioning Before beginning your shift Carried out   The following checks should be carried out at the beginning of every shift, before taking the tractor into service. Chassis, bodywork and ﬁttings Check the truck for any loose panels or covers.
Page 63: Checking Tyre Pressures
Operation Checks and tasks to be carried out prior to commissioning Checking tyre pressures Tow tractor (short FRONT 7.5 bar wheelbase) REAR 5.0 bar Tow tractor (long FRONT 9.0 bar wheelbase) REAR 5.0 bar Platform trolley (short FRONT 7.5 bar platform) REAR 6.5 bar Platform trolley (long...
Page 64: Checking The Condition Of The Wheels And Tyres
Operation Checks and tasks to be carried out prior to commissioning Checking the condition of the wheels and tyres WARNING Risk of accident! Uneven wear reduces the stability of the truck and increases the braking distance. – Worn or damaged tyres (left or right) must be replaced immediately.
Page 65 Operation Checks and tasks to be carried out prior to commissioning Moving the driver's seat – Lift and hold the lever (1). – Push the driver's seat into the desired position. – Release the lever. – Ensure that the driver's seat is securely engaged.
Page 66 Operation Checks and tasks to be carried out prior to commissioning Adjusting the seat suspension NOTE The driver's seat can be adjusted to suit the weight of the individual driver. To obtain optimal settings for the seat suspension, the driver must perform the adjustment whilst sitting on the seat.
Page 67 Operation Checks and tasks to be carried out prior to commissioning Adjusting the lumbar support (variant) NOTE The lumbar support can be adjusted to suit the contours of the individual driver's spine. Adjusting the lumbar support moves a convex support cushion into the upper or lower part of the backrest.
Page 68: Top Up The Screen Wash Reservoir
Operation Checks and tasks to be carried out prior to commissioning Switching the seat heater (variant) on and off NOTE The seat heater only functions if the seat contact switch is active, i.e. when the driver is sitting on the driver's seat. –...
Page 69: Commissioning
Operation Commissioning Commissioning Connecting the battery Connecting the battery CAUTION Danger of damage to electrical and electronic components from short circuiting! Connecting or disconnecting the battery with the truck switched on may cause damage to electrical and electronic components. – Always turn off the key switch. –...
Page 70: Switching On The Truck With The Driver Code
Operation Commissioning Switching on the truck with the driver code The driver code* is entered using a twelve-key keypad (1) mounted on the dashboard and a rotary on/off switch (2). The driver must enter a ﬁve-digit personal identiﬁcation number (PIN) to start the truck, thereby preventing unauthorised use.
Page 71: Checking The Operating Devices And Their Function
Operation Commissioning Checking the operating devices and their function Before the start of each shift or when taking the truck over from another person, the following operating devices must be checked to ensure they are operating correctly and safely: • Brake system •...
Page 72: Checking The Battery Charge Status
Operation Commissioning Checking the battery charge status CAUTION Risk of battery damage from deep discharge! Deep discharge shortens the battery service life. – Avoid deep discharges. – Do not leave batteries in a discharged or partly discharged state. – Charge a discharged or partly discharged battery.
Page 73: Checking The Foot Brake
Operation Commissioning – Release the parking brake; see chapter "Checking the parking brake". The truck is ready for operation again. Checking the foot brake DANGER Risk of accident! The electrical brake may not be sufﬁcient for emer- gency braking. – Always actuate the brake pedal (1) for emer- gency braking.
Page 74 Operation Commissioning Applying the parking brake – Check the function of the parking brake at walking speed or on a steep gradient by actuating the parking brake button (1). The parking brake engages and the warning light for the active parking brake lights up in the display unit.
Page 75: Checking The Electric Brake
Operation Commissioning Checking the electric brake DANGER Risk of accident! Electric braking may be insufﬁcient for emergency braking. – Always actuate the brake pedal (1) for emer- gency braking. WARNING Risk of accident due to excessive speed! Depending on the charging state of the battery, electric braking may be insufﬁcient when driving downhill and results in the maximum permissible speed of the truck being exceeded.
Page 76: Checking The Interlock Switch
Operation Commissioning Checking the interlock switch DANGER Risk of accident in case of malfunction! Interlock changes impair truck safety. – Never make changes to interlocks. – Always check that the interlock switch is functio- ning correctly before starting your shift or taking over a truck.
Page 77: Fastening And Releasing The Seat Belt (Variant)
Operation Commissioning Fastening and releasing the seat belt (variant) Fastening the seat belt NOTE Sit as far back as possible so that your back is leaning against the seat backrest. The automatic blocking mechanism permits sufﬁcient freedom of movement on the seat. –...
Page 78: Checking The Manual Tow Coupling (Variant)
Operation Commissioning Releasing the seat belt – Push the red button (4) on the buckle (1). – Slowly guide the belt tongue back to the retractor by hand. – Using increased force, pull the seat belt around 10-15 mm out of the retractor to disengage the blocking mechanism.
Page 79: Checking The Automatic Tow Coupling (Variant)
Operation Commissioning Checking the automatic tow coupling (variant) WARNING Risk of being trapped and crushed! – Before carrying out any maintenance work on the coupling, ensure that the coupling is closed. – Do not reach into the open coupling. NOTE If the coupling is engaged and disengaged more than 2-3 times per shift, the coupling must be relubricated on the lubricating nipple.
Page 80: Checking The Remotely Unlockable Tow Coupling (Variant)
Operation Drive mode Checking the remotely unlockable tow coupling (variant) WARNING Risk of trapping or crushing! – Before carrying out any maintenance work on the coupling, ensure that the coupling is closed. – Do not reach into the open coupling. NOTE If the coupling is engaged and disengaged more than 2-3 times per shift, the coupling...
Page 81: Safety Guidelines
– Do not use devices during travel or when hand- ling loads. – Set the volume so that warning signals can still be heard. WARNING Increased risk of accident as a result of impermissi-...
Page 82 Operation Drive mode The speed must be appropriate to the local conditions. For example, the driver must drive slowly around corners, in tight passageways, when driving through swing-doors, at blind spots or on uneven roadways. The driver must always maintain a safe braking distance from vehicles and persons in front and always have the vehicle under control.
Page 83: Switching On The Truck With The Key Switch
Operation Drive mode Extra care should be taken during reverse travel using visual aids. Any glass and mirrors must always be clean and free of ice. Switching on the truck with the key switch WARNING Risk of accident as a result of improper commissi- oning! Before switching on the key switch, all tests prior to commissioning must be performed without any...
Page 84: Stopping The Truck With The Service Brake
Operation Drive mode Stopping the truck with the service brake The electric brake converts the acceleration energy of the truck into electrical energy. This causes the truck to slow. The truck can also be braked with the hydraulic brake by pressing the brake pedal (1).
Page 85: Switching On The Truck With The Driver Code
Operation Drive mode Switching on the truck with the driver code The driver code* is entered using a twelve-key keypad (1) mounted on the dashboard and a rotary on/off switch (2). The driver must enter a ﬁve-digit personal identiﬁcation number (PIN) to start the truck, thereby preventing unauthorised use.
Page 86: Operating The Horn
Operation Drive mode Operating the horn – Press button at the end of the operating lever (1) on the right of the steering column. NOTE As an option, the operating lever can be located on the left-hand side of the steering column.
Page 87: Running The Truck In
Operation Drive mode Running the truck in The truck can be operated at maximum speed immediately after delivery. However, avoid continuous high loads during the ﬁrst 50 operating hours. Checking the wheel nuts WARNING Risk of accident from loose wheel nuts! Within the ﬁrst 50 operating hours of receiving the truck or after changing a wheel, it is IMPERATIVE to check the tightening torques of the wheel nuts...
Page 88: Starting Drive Mode
– Do not use devices during travel or when hand- ling loads. – Set the volume so that warning signals can still be heard. Prepare drive mode Initial driving practice must be carried out in an empty space or on a clear roadway.
Page 89: Accelerating The Truck
Operation Drive mode Accelerating the truck WARNING Risk of accident as a result of excessive speed! The truck may not exceed its permissible maximum speed when travelling on gradients. – Actuate the foot brake to brake the truck. – Gently actuate the accelerator pedal (2). NOTE Depressing the accelerator pedal fully will not increase the rate of acceleration, as maximum...
Page 90: Driving The Truck In Reverse
Operation Drive mode The parking brake is released and the warning light for the applied parking brake goes out on the display unit. NOTE The parking brake engages if the driver leaves the seat. NOTE The parking brake engages if the emergency stop switch is pressed.
Page 91: Parking And Switching Off The Truck
Operation Drive mode Parking and switching off the truck DANGER Increased risk of accident from unauthorised use! Never leave the truck unattended. – Always switch off the truck using the key switch and remove the switch key. – Ensure the truck is parked so as not to cause a hazard or obstruction.
Page 92: Battery
Operation Battery Battery Providing access to maintenance points Opening the battery cover Open the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. NOTE Before opening the battery cover, the engine cover must be closed.
Page 93 Operation Battery Secure the battery cover in the lifted position. – To do this, push the safety stay (1) over the security bolt (2) until the safety stay is hooked in place and secured. – Ensure that the battery cover is secured against falling shut unintentionally.
Page 94 Operation Battery Closing the battery cover Release the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. Release the battery cover. – To do this, push the safety stay (1) over the security bolt (2) until the safety stay is released.
Page 95 Operation Battery Close the battery cover. – To do this, push down the battery cover against the pressure of the gas spring until the locking lever (1) audibly locks (clicks). – Ensure that the battery cover is closed correctly. Opening the engine cover Open the engine cover.
Page 96 Operation Battery Secure the engine cover in the lifted position. – To do this, release the support rod (1) from the holder (in the engine cover). – Latch the support rod in the safety plate (2) such that the support rod is locked in place and secured.
Page 97 Operation Battery Removing the battery cover (platform tractors) Open and lift the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 98 Operation Battery Installing the battery cover (platform tractors) Lift in the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 99 Operation Battery Removing the engine cover (platform tractors) Open and lift the engine cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 100: Battery Cables
Operation Battery Installing the engine cover Lift in the engine cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 101: Charging The Battery
Operation Battery Charging the battery DANGER Danger of death from electric shock! – Never wear watches or jewellery when working on a battery. – Never touch non-insulated cables. – Never place metallic objects on the battery. – Never touch damaged plugs. –...
Page 102 Operation Battery Preparation – Switch off the key switch. – Open the battery cover; see chapter entitled "Opening the battery cover and motor cover". – Disconnect the battery male connector (1). – Attach the battery plug (1) to the battery charger connector (2).
Page 103: Changing The Battery Using A Crane
Operation Battery Changing the battery using a crane DANGER Risk of death from suspended loads! – Never walk or stand underneath suspended loads. – The hoist must be designed to carry the weight of the battery (see battery plate or identiﬁcation plate).
Page 104 Operation Battery – Disconnect the battery male connector; see chapter "Charging the battery". – Batteries with open terminals or connectors must be covered with a rubber mat to prevent short circuits. Disconnecting the battery – Attach a suitable hoist to the battery. –...
Page 105: Transporting And Setting Down The Battery
Operation Battery Transporting and setting down the battery DANGER If the battery swings in an uncontrolled manner, it can crush people. There is a risk of fatality!! – Never walk or stand underneath suspended loads. – Do not allow the battery to bump into anything whilst it is being lifted or allow it to move in an uncontrolled manner.
Page 106 Operation Battery DANGER Danger of death from electric shock! – Never wear watches or jewellery when working on a battery. – Do not place metallic objects on the battery. – Never touch non-insulated cables. – Never touch damaged plugs. – ALWAYS use an insulated tool. –...
Page 107 Operation Battery Preparation Switch off the key switch. – Open the lid (1) of the side battery connec- tor. – Insert the charger plug into the battery connector (2). Charging The lower LED (4) in the display of the display unit lights up for up to 5 minutes before the charging process begins.
Page 108: Equalising Charge To Prevent A Deep Discharge Of The Battery
Operation Battery Unplug the battery charger from the battery connector. – Close the cover plate (3) of the battery connector. Equalising charge to prevent a deep discharge of the battery Lead-acid batteries must be charged at least once per week for equalisation purposes. This is to ensure that all battery cells are evenly charged.
Page 109 Operation Battery – Please refer to the operating instruc- tions from the manufacturer of the battery charger. Ending the equalising charge The equalising charge ends automatically. If the battery is required during this process, you can interrupt the equalising charge by pressing the "stop button"...
Page 110: Replacing The Battery Using A Hand Pallet Truck (Variant For Platform Tractors)
Operation Battery Replacing the battery using a hand pallet truck (variant for platform tractors) CAUTION Danger of truck damage if original batteries are not used! – The replacement battery MUST be identical in size and weight to the standard battery. –...
Page 111 Operation Battery CAUTION Risk of battery damage from battery tipping over! – Only store the battery on a suitable beam support or on suitable racking. – Do not store the battery on a wooden beam or similar. – Carefully drive the hand pallet stacker truck under the battery.
Page 112: Lighting
Operation Lighting WARNING Increased risk of accident when transporting with lack of care! – Always transport batteries carefully. – Always drive at low speed. – Always avoid sharp corners. WARNING Risk of accident due to improper means of trans- port! The load capacity of the hand pallet truck in use must at least match the battery weight (see battery identiﬁcation plate).
Page 113: Switching The Direction Indicators On And Off
Operation Lighting – Press the top toggle switch. The parking light, headlights and rear lights are switched off. Main beam – Press forward and engage operating lever (3) on the left of the steering column with the driving light switched on. The blue main beam indicator light illuminates on the display unit - the main beam is switched –...
Page 114: Turning The Hazard Warning System On And Off
Operation Lighting If a trailer equipped with lighting is coupled, the direction indicator light for the trailer (5) also ﬂashes. NOTE The direction indicators are not self-cancel- ling, ensure that the direction indicators are cancelled after manoeuvring. NOTE As an option, the operating lever can be located on the right hand side.
Page 115: Switching The Interior Illumination On And Off
Operation Lighting Switching the interior illumination on and off Cab illumination – Press the toggle switch (1) on the cab ceiling. Cab illumination is switched on. – Actuate the toggle switch on the cab ceiling in the opposite direction. Cab illumination is switched off. Reading light –...
Page 116: Switching The Rotating Beacon (Variant) On And Off
Operation Lighting Switching the rotating beacon (variant) on and off – Push the toggle switch (1) downwards. The rotating beacon is switched on. – Push the toggle switch upwards. The rotating beacon is switched off. NOTE The other switches shown here are only examples and may not correspond to the equipment on your truck.
Page 117: Still Safetylight (Variant)
Operation Display unit STILL SafetyLight (variant) The STILL SafetyLight is a visual warning unit to enable early detection of trucks in driving areas with low visibility (such as drive lanes, high racks), as well as at blind junctions. The STILL SafetyLight is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations.
Page 118: Speedometer Indicator
Operation Display unit Speedometer indicator – Switch on the truck. The speedometer indicator (1) illuminates in the display unit. The mode indicator (2) for miles or km illumi- nates. The display on the display unit (3) indicates the speed as soon as the truck starts moving. The operating hours are displayed there when the truck is at a standstill.
Page 119: Hour Meter
Operation Display unit Hour meter – Switch on the truck. The hourglass mode indicator (2) illuminates. The display on the display unit (1) shows the operating time of the truck in hours. NOTE Once the truck starts moving, the hour meter is replaced by the speed indicator.
Page 120: Distance Indicator
Operation Display unit Distance indicator – Switch on the truck. After ten seconds, the mode indicator for miles (2) or km (1) illuminates. The display on the display unit indicates the distance driven in km or miles. NOTE The odometer can be programmed to display km or miles.
Page 121: Parking Brake Indicator
Operation Display unit Parking brake indicator – Parking brake indicator (1) illuminates in the display unit. Parking brake is activated. Display plain text messages In the event of the driver making an operating error, plain text messages are shown on the display.
Page 122: Hydraulic Oil Warning Indicator
Operation Display unit Hydraulic oil warning indicator – Hydraulic oil warning indicator (2) illumi- nates in the display unit. Low hydraulic oil level in the steering system. – Bring the truck to a standstill. – Ensure the truck is parked so as not to cause a danger or obstruction.
Page 123: Warning Indicator For The Interlock
Operation Display unit Warning indicator for the interlock – Interlock warning indicator (1) illuminates in the display unit. Interlocked or locked function is actuated. – Check that the key switch is working cor- rectly. – Check that the emergency off switch is working correctly.
Page 124: Warning Display For Brake Fluid
Operation Display unit Warning display for brake ﬂuid – The warning display for the brake ﬂuid (1) illuminates on the display unit. Low brake ﬂuid level. – Bring the truck to a standstill. – Ensure the truck is parked so as not to cause a danger or obstruction.
Page 125: Trailer And Load
Operation Trailer and load Trailer and load Towing guidelines DANGER Increased risk of accident if used under difﬁcult operating conditions! When towing trailers under difﬁcult operating con- ditions, e.g. on gradients or icy, slippery surfaces, the maximum safe load is determined by braking performance and not the maximum towing capacity of the tractor.
Page 126: Loading A Platform
Operation Trailer and load Loading a platform DANGER Increased risk of accidents due to unauthorised loads and improper use! – Never exceed the maximum loads shown! These values apply to compact and homoge- neous loads. – Do not transport people on the loading surface. –...
Page 127: Towing Trailers
Operation Trailer and load Towing trailers DANGER Risk of serious injury or death from tipping truck and trailer! Truck and trailer may tip over when driving on steeply sloping terrain. – Never negotiate gradients diagonally or cross- wise. WARNING Increased risk of accident due to trailers rolling away! Using a trailer changes the truck handling charac- teristics.
Page 128: Operating The Manual Coupling
Operation Trailer and load Operating the manual coupling DANGER If the coupling pin drops out or is damaged during towing, the trailer will become loose and uncon- trollable. This causes a risk of accident! – Use only original coupling pins that have been checked for good condition.
Page 129 Operation Trailer and load – Push the coupling pin (2) down, turn the pin by 90° and pull the pin out. – Using reverse inching (at the rear of the truck), drive the truck towards the drawbar until the drawbar is in the coupling jaw of the tow coupling;...
Page 130 Operation Trailer and load – Using reverse inching, drive the truck slowly forwards and guide the drawbar completely out of the coupling. – Carefully set down the drawbar. – Insert the coupling pin. Push down against the pressure of the retaining spring, turn by 90°...
Page 131: Actuating Reverse Inching (Variant)
Operation Trailer and load Actuating reverse inching (variant) DANGER Risk of serious or fatal injury from being hit by tiller! – Never stand between the truck and trailer while the back keying is being operated. – Stand to the side and stand clear of the truck wheels.
Page 132: Opening And Closing The Side Panel
Operation Trailer and load Opening and closing the side panel WARNING Risk of crushing! – Do not reach between the side panel and the chassis. WARNING Risk of crushing! – Do not attempt to open the side panel when a load is resting against the side panel.
Page 133 Operation Trailer and load Pull the lever (2) until the lock (3) is unlocked. Opening the side panel at the left-hand side Push the safety button (1) towards the centre of the side panel until the lever is released. Pull the lever (2) until the lock (3) is unlocked. Hold the side panel in place while doing this.
Page 134 Operation Trailer and load Fold down the side panel (4) using both hands. 172780 EN - 06/2017...
Page 135 Operation Trailer and load Closing the side panel Fold up the side panel (4) using both hands and hold it in place. 172780 EN - 06/2017...
Page 136 Operation Trailer and load Closing the side panel at the left-hand side Push down the lever (1) until the lock (2) is locked and the safety button (3) is secured. 172780 EN - 06/2017...
Page 137 Operation Trailer and load Closing the side panel at the right-hand side Push down the lever (1) until the lock (2) is locked and the safety button (3) is secured. Before attempting to drive Make sure that the side panel is closed and securely locked.
Page 138: Operating The Automatic Coupling
Operation Trailer and load Operating the automatic coupling Coupling the trailer DANGER Increased risk of accident due to improper opera- tion of the coupling! The safety of the coupling can only be veriﬁed by noting the position of the coupling pin (3). The coupling pin must not project beyond its guide after a trailer has been coupled (see decal informa- tion).
Page 139 Operation Trailer and load – Using reverse inching, carefully drive the truck towards the drawbar until the drawbar is in the coupling jaw of the tow coupling; see the chapter "Actuating reverse inching". The coupling closes on contact and the lever (2) on the coupling snaps down.
Page 140: Operating The Remotely Unlockable Coupling
Operation Trailer and load – Using reverse inching, drive the truck slowly forwards and guide the drawbar completely out of the coupling. Operating the remotely unlockable coupling DANGER Increased risk of accident due to improper opera- tion of the coupling! If the tow coupling pin (8) is not fully engaged, the trailer can become separated from the truck inadvertently.
Page 141 Operation Trailer and load – Connect the trailer lighting (variant) to the truck via the trailer socket. – Check that the trailer lights are operating correctly. – Remove the equipment used to prevent the coupled load from rolling away. – Release the trailer brake (if present). NOTE If the coupling pin is not completely lowered, the red indicator light (4) lights up.
Page 142: Auxiliary Equipment
Operation Auxiliary equipment When the coupling pin is fully raised, the yellow indicator light (5) lights up. – Carefully drive the truck forwards until the drawbar and coupling are disconnected. NOTE If the coupling pin is not completely raised, the red indicator light (4) lights up. The drive mode is then deactivated and the truck does not drive.
Page 143: Switching The Heating System On And Off
Operation Auxiliary equipment Switching the heating system on and – Push toggle switch (1) down. The heating system is switched on. – Push the toggle switch up. The heating system is turned off. – Push toggle switch to middle position. Only the fan is running.
Page 144: Logging The Driver Code In And Out
Operation Auxiliary equipment Logging the driver code in and out The driver code* is entered using a twelve-key keypad (1) mounted on the dashboard and a rotary on/off switch (2). The unit requires the driver to enter a ﬁve digit personal identiﬁcation number (PIN) in order to operate the tractor, thus preventing unauthorised use.
Page 145 Operation Auxiliary equipment Accessing ﬂeet manager menus – Switch on the device at the rotary switch (2). The screen on the display unit prompts you to enter the PIN. – Enter the ﬁve-digit ﬂeet manager PIN followed by via the keypad. NOTE The pre-set ﬂeet manager PIN is 9 8 7 6 5...
Page 146 Operation Auxiliary equipment Fleet manager truck deactivation – Log in as the ﬂeet manager and open the ﬂeet manager command menu. – Enter via the keypad. 0 0 2 – Press the button. – Enter to deactivate the truck. All driver PINs become invalid and the truck can no longer be started.
Page 147 Operation Auxiliary equipment Add/delete driver PINs – Log in as the ﬂeet manager and open the ﬂeet manager command menu. – Enter via the keypad. 0 0 4 – Press the button. To delete an existing driver PIN: – Enter driver PIN. –...
Page 148: Fleetmanager - Logging In And Logging Off
Operation Auxiliary equipment Set/reset learner operation (reduced power) – Log in as the ﬂeet manager and open the ﬂeet manager command menu. – Enter via the keypad. 0 0 6 – Press the button. To set/reset learner operation: – Enter driver PIN. NOTE The display will show "1"...
Page 149: Switching The Seat Heater (Variant) On And Off
Operation Auxiliary equipment Switching the seat heater (variant) on and off – Push the toggle switch (1) downwards. The seat heater is switched on. – Push the toggle switch upwards. Seat heater is switched off. NOTE The switch in the seat backrest switches the seat heater for the driver seat or for the passenger seat on and off.
Page 150 Operation Auxiliary equipment Preparation – Open or remove the engine cover; see the chapter entitled "Opening the battery cover and engine cover". – Ensure that the fuel tank is ﬁlled. To ﬁll the fuel tank, see the chapter entitled "Filling the tank for the auxiliary heating system".
Page 151 Operation Auxiliary equipment Operating unit for the auxiliary heating system Button for heating ON Temperature control dial Button for blower ON Indicator light for blower OFF button Indicator light for heating Switching on the auxiliary heating system – Press the button (1). The heating system is switched on and the indicator light (6) illuminates.
Page 152 Operation Auxiliary equipment Switching on the blower – Press the button (3). The blower is switched on and the indicator light (4) illuminates. Switching off the auxiliary heating system and blower – Press the button (5). The heating system and blower switch off and the indicator lights (4/6) go out.
Page 153: Switching The Rear Window Wiper/Washer On And Off
Operation Auxiliary equipment Switching the rear window wiper/washer on and off Operating stage Position of the toggle switch (2) Rear window wiper ON Centre position Rear window wiper OFF Washer and wiper function ON Down NOTE The other switches shown here are only examples and may not correspond to the equipment on your truck.
Page 154 Operation Auxiliary equipment Operating stage Operating lever (2) Slow Position "I" Fast Position "II" Interval Position "J" Position "O" Wiper and washer function (automati- Press the knob on the end of the operating lever cally wipes 4x) NOTE As an option, the operating lever can be ﬁtted on the right-hand side of the steering column (optional).
Page 155: Special Operating Situations
Operation Special operating situations Special operating situations Securing the truck for transportation Trucks with a front tow coupling CAUTION Risk of truck damage if the truck breaks free! – Only use the lashing points provided. – Only use harnesses with a sufﬁcient load capa- city.
Page 156 Operation Special operating situations Trucks without front tow coupling CAUTION Risk of truck damage if the truck breaks free! – Only use the lashing points provided. – Only use harnesses with a sufﬁcient load capa- city. – Only use harnesses with sufﬁcient tensile strength.
Page 157: Towing The Truck
Operation Special operating situations Towing the truck DANGER The brake system on the towing vehicle may fail. There is a risk of accident! If the brake system of the towing vehicle is not adequately sized, the truck may not brake securely or the brakes may fail.
Page 158 Operation Special operating situations CAUTION If the truck being towed is not steered, it may veer out in an uncontrolled manner! – The truck to be towed must also be steered by a driver. – Where possible, activate the restraint systems provided.
Page 159 Operation Special operating situations Towing Someone must sit in the truck to be towed in order to steer it and brake it. Agree clear communication signs with the driver of the tow tractor before towing. – Always use a tow bar for towing. –...
Page 160: Crane Loading The Truck
Operation Special operating situations Crane loading the truck Crane loading is only intended for transporting the complete truck for its initial commission- ing. For application conditions that require frequent loading or that are not presented here, please contact the service centre with regard to particular variants.
Page 161 Operation Special operating situations CAUTION Harnesses may damage the truck's paintwork! Harnesses may damage paintwork by chaﬁng and pressing on the surface of the truck. Hard or sharp-edged harnesses, such as wires or chains, damage the surface. – Use textile harnesses, e.g. lifting straps, with edge protectors or similar protective devices if necessary.
Page 162: Decommissioning
Operation Decommissioning Decommissioning Taking the truck out of operation If the tractor is taken out of operation for NOTE over two months, it must be parked in a well Do not use a polythene sheet to cover the ventilated, frost free, clean and dry room and tractor as this encourages the formation of the following measures must be carried out.
Page 163: Maintenance
Maintenance...
Page 164: Safety Regulations For Maintenance
Maintenance Safety regulations for maintenance Safety regulations for maintenance Personnel qualiﬁcations Only qualiﬁed and authorised personnel are allowed to perform maintenance work. The annual testing must be carried out by a qualiﬁed person. The examination and assessment of the qualiﬁed person must be unaffected by operational and economic conditions and must be conducted solely from a safety perspective.
Page 165: Safety Guidelines
Maintenance Safety regulations for maintenance Safety guidelines No changes, modiﬁcations or additions may – Always handle, charge and maintain be made to the tractor without approval from batteries according to the manufacturer's the manufacturer. instructions supplied with the battery. – Always ensure that the lifting equipment DANGER used has the required load capacity and Incorrect inspection and maintenance procedures...
Page 166: Set Values
Maintenance Safety regulations for maintenance – Label all controls to indicate a service or Only use clean containers when replenishing repair operation is being carried out. fuels and lubricants. – Protective equipment, i.e. safety footwear, ENVIRONMENT NOTE industrial goggles, protective masks, protective gloves etc.
Page 167: Working On The Hydraulic Equipment
Work on the electrical system (e.g. connecting a radio, additional headlights etc.) is only permitted with written approval from the STILL service centre. Working on the hydraulic equipment Hydraulic equipment must be depressurised prior to all work.
Page 168: General Maintenance Information
Maintenance General maintenance information – Disconnect the battery General maintenance information Ordering spare parts and wearing parts Spare parts are provided by our spare parts service department. The information required for ordering parts can be found in the spare parts list. Only use spare parts as per the manufac- turer's instructions.
Page 169: Inspection And Maintenance Data
Maintenance General maintenance information Inspection and maintenance data Unit Material/Lubricant Capacity/Adjustment value Hydraulic ﬂuid 10 litres Steering ﬂuid tank 2 x 450 cc Front 195 Nm Wheel bolts Rear 195 Nm Tyres Front 7.5 bar Short wheel base tow Rear 5.0 bar tractor Tyres...
Page 170: Recommended Lubricants
Maintenance Cleaning Recommended lubricants Power steering hydraulic oil STANDARD Anti wear hydraulic oil Grade ISO VG 22-32 Viscosity index ≥ 300 e.g Shell Tellus Arctic 32 NOTE The above speciﬁcation is an oil with a high viscosity index that allows the use of hydrau- lics in ambient temperatures of between -20°C and +40°C (oil temperatures between -20°C and +80°C).
Page 171: Cleaning The Truck
Maintenance Cleaning – Turn the switch key to the left and remove it. – Open the battery cover; see the chapter entitled "Opening the battery cover". – Disconnect the battery male connector (3). Cleaning the truck WARNING There is a risk of injury due to falling when climbing onto the truck! When climbing onto the truck, it is possible to get stuck or slip on...
Page 172 Maintenance Cleaning – Switch off the electrical system before cleaning. – Do not spray electrical components and the covers on these components directly with water. WARNING Failure to follow these instructions could result in damaged components! The engine must be switched off during washing. Do not use water to clean the area around the central electrical system;...
Page 173 Maintenance Cleaning DANGER Risk of ﬁre! Flammable ﬂuids can be ignited by hot components on the truck. – Strictly adhere to the following steps. – Do not use ﬂammable ﬂuids for cleaning. – Observe the manufacturer's guidelines for working with cleaning materials. CAUTION Abrasive cleaning materials can damage compo- nent surfaces!
Page 174 Maintenance Cleaning This is the only means of guaranteeing good visibility. CAUTION Do not damage the rear window heating (inside)! Take great care when cleaning the rear window and do not use any objects with sharp edges. – Clean the windows. NOTE Cleaning can be done using a commercially available glass cleaner.
Page 175: Providing Access To Maintenance Points
Maintenance Providing access to maintenance points Providing access to maintenance points Providing access to maintenance points Opening the battery cover Open the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. NOTE Before opening the battery cover, the engine cover must be closed.
Page 176 Maintenance Providing access to maintenance points Secure the battery cover in the lifted position. – To do this, push the safety stay (1) over the security bolt (2) until the safety stay is hooked in place and secured. – Ensure that the battery cover is secured against falling shut unintentionally.
Page 177 Maintenance Providing access to maintenance points Closing the battery cover Release the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. Release the battery cover. – To do this, push the safety stay (1) over the security bolt (2) until the safety stay is released.
Page 178 Maintenance Providing access to maintenance points Close the battery cover. – To do this, push down the battery cover against the pressure of the gas spring until the locking lever (1) audibly locks (clicks). – Ensure that the battery cover is closed correctly.
Page 179 Maintenance Providing access to maintenance points Secure the engine cover in the lifted position. – To do this, release the support rod (1) from the holder (in the engine cover). – Latch the support rod in the safety plate (2) such that the support rod is locked in place and secured.
Page 180 Maintenance Providing access to maintenance points Removing the battery cover (platform tractors) Open and lift the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 181 Maintenance Providing access to maintenance points Installing the battery cover (platform tractors) Lift in the battery cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 182 Maintenance Providing access to maintenance points Removing the engine cover (platform tractors) Open and lift the engine cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 183 Maintenance Providing access to maintenance points Installing the engine cover Lift in the engine cover. WARNING Risk of crushing! When lifting and closing, limbs could become trapped. – Do not reach between covers and chassis. – Only lift up and position the covers using two people.
Page 184: Servicing
Maintenance Servicing Servicing Fuses Fuses (generation 1) Located under the bottom plate below the driver, accessible through a cutout. Signal horn 10 A Switch relay for the 10 A sidelights/headlights Left-hand sidelights 10 A Right-hand sidelights 10 A Main beam headlights 10 A Dipped beam headlights 10 A...
Page 185 Maintenance Servicing Fuses (generation 2) Located under the bottom plate below the driver, accessible through a cutout. Signal horn 10 A Switch relay for the 10 A sidelights/headlights Left-hand sidelights 10 A Right-hand sidelights 10 A Main beam headlights 10 A Dipped beam headlights 10 A Brake lights...
Page 186: Check The Braking System
Maintenance Servicing Check the braking system DANGER Increased risk of accident as a result of defective brake system! – Never drive a truck with a defective brake system. – If the brake system is defective, park the truck securely and immediately inform a superior or responsible ﬂeet manager so that they can have the defect rectiﬁed.
Page 187: Checking The Suspension Shock Absorbers
Maintenance Servicing Checking the suspension shock absorbers – Check the front and rear shock absorbers for corrosion and leakage. – Check the rubber mounting bushes of the shock absorbers for wear or cracks. Changing the brake ﬂuid CAUTION It is recommended the brake ﬂuid be changed every 5000 hours or 5 years, whichever is earlier.
Page 188: Checking The Steering Fluid Level
Maintenance Servicing Checking the steering ﬂuid level DANGER Hydraulic oil is toxic! This ﬂuid is hazardous to your health. – Do not swallow the ﬂuid. – Do not allow the ﬂuid to come into contact with the skin. – Always use appropriate personal protective equipment (e.g.
Page 189: Checking The Brake Fluid Level
Maintenance Servicing Checking the brake ﬂuid level DANGER Increased risk of accident as a result of a failure of the brake system! – Never operate the truck when the brake ﬂuid level is low. – Immediately ﬁll the brake ﬂuid reservoir and check the brake system for leaks.
Page 190: Checking The Auxiliary Heating System (Variant)
Maintenance Servicing Checking the auxiliary heating system (variant) DANGER Danger of death from carbon monoxide! Danger of death from carbon monoxide poisoning in enclosed areas. – Never operate the auxiliary heater in enclosed areas such as a garage. The auxiliary heating system should be operated at least once a month when not in regular use.
Page 191: Checking The Diesel Auxiliary Heater Filter
Maintenance Servicing Checking the diesel auxiliary heater ﬁlter ENVIRONMENT NOTE Diesel fuel is harmful to the environment! Improper handling of fuels poses a risk to people and the environment. – Do not spill fuel. – Make sure that no fuel gets into the sewage system, surface water, groundwater or onto the soil.
Page 192: Changing The Steering Fluid And Filter
Maintenance Servicing Changing the steering ﬂuid and ﬁlter DANGER Risk of very serious injury due to steering failure! – Never operate truck with a low hydraulic oil level. – Immediately ﬁll the steering ﬂuid tank and check the steering system for leaks. WARNING These ﬂuids are pressurised during operation of the truck and are hazardous to your health!
Page 193: Lubricating The Steering Linkage Bearings
Maintenance Servicing Spilt hydraulic ﬂuid should be removed • immediately with oil-binding agents and disposed of according to the regulations. Dispose of old hydraulic ﬂuid according to • the regulations. Lubricating the steering linkage bearings – Using a grease gun, lubricate the steering linkage bearings until grease emerges from the bearings.
Page 194: Checking Operating Devices And Functions
Maintenance Servicing Checking operating devices and functions – Check the function of the brake pedal. – Check the function of the steering. – Check the function of the accelerator pedal. – Check the function of the switch for the parking brake. –...
Page 195: Special Removal Tool
Maintenance Servicing Special removal tool With large wheels, tyres should be changed using a trolley jack (1) or a tool (2) and a crane and/or a lifting device. CAUTION Risk of truck damage when working without aids! The wheels are heavy. –...
Page 196: Removing And Installing The Front Wheels
Maintenance Servicing Removing and installing the front wheels The special lifting block The special lifting block for installation and removal is located: • underneath the bonnet • next to the battery connector (3) on the tow tractor • on the inside of the battery door (2) on the platform truck Removal DANGER...
Page 197 Maintenance Servicing WARNING Risk of serious crush injuries from falling wheels! The wheels are heavy. – Work carefully when removing the wheels. – Never place hands or feet underneath the raised wheel. – Use moveable trolleys, lifting devices or cranes for assistance.
Page 198 Maintenance Servicing – Raise the truck from the ﬂoor until the wheels are no longer in contact with the ground. – Remove the square timbers. – Remove the hydraulic jack and the special lifting block. – Lower the truck onto the ground. –...
Page 199: Removing And Installing The Drive Wheels
Maintenance Servicing Removing and installing the drive wheels DANGER Danger of serious injury or even death from falling truck! – Only use hydraulic jacks with a sufﬁcient load capacity (see Identiﬁcation plate). – The hydraulic jack must only be used to raise the truck for short periods of time, e.g.
Page 200 Maintenance Servicing Removal – Park the truck securely. – Switch off the key switch. – Disconnect the battery. – Block the front wheels. – Loosen the wheel bolts - DO NOT remove the wheel bolts. – Place the hydraulic jack underneath the rear undercarriage plate at the locations shown.
Page 201: Replacing The Gearbox Breather Filter
Maintenance Servicing Replacing the gearbox breather ﬁlter – Switch off the key switch. – Open and secure the bonnet. – Remove and dispose of both breather ﬁlters. – Install new breather ﬁlters. 127-127 Check security of the wheel bolts – After removing a wheel, the security of the bolts MUST be checked within 50 hours of operation.
Page 202: Checking Battery And Battery Cable Status
Maintenance Servicing Checking battery and battery cable status DANGER Risk of fatal electrical shock! – Never wear watches or jewellery when working on a battery. – Never place metallic objects on the battery. – Never touch uninsulated cables. – Never touch damaged plugs. –...
Page 203: Filling The Tank For The Diesel Auxiliary Heater
Maintenance Servicing Filling the tank for the diesel auxiliary heater DANGER Risk of ﬁre as a result of ﬂammable fuel! – Before refuelling, switch off the auxiliary heater. – When refuelling, smoking or the use of an open ﬂame is strictly forbidden. –...
Page 204: Lubricating The Axle Stub Bearing Of The Steering System
Maintenance Servicing * Variant Lubricating the axle stub bearing of the steering system – Lubricate the upper and lower axle stub bearings using a grease gun until grease emerges from the bearings. 127-72 Checking and lubricating latches and hinges – Inspect and lubricate: •...
Page 205: Checking Steering Fluid Hoses For Damage
Maintenance Servicing Checking steering ﬂuid hoses for damage – Examine the outer cover of the hoses for signs of brittleness, tears, blisters, ballooning or cracks. – Ensure that hoses are not twisted, kinked, bent, trapped or under tension. – Replace all defective hoses. –...
Page 206: Checking The Battery Acid Level And Specific Gravity
Maintenance Servicing Checking the battery acid level and speciﬁc gravity WARNING The electrolyte (diluted sulphuric acid) is poisonous and caustic! – Observe safety regulations for handling battery acid; see the chapter entitled "Battery acid". – Wear personal protective equip- ment (rubber gloves, apron and protection goggles).
Page 207: Checking The Condition And Safety Of The Electrical Connections And Cables
Maintenance Servicing Checking the condition and safety of the electrical connections and cables DANGER Danger of death from electric shock! – Never wear watches or jewellery when working on a battery. – Never touch non-insulated cables. – Never touch damaged plugs. –...
Page 208: Maintenance Intervals
Maintenance Maintenance intervals Maintenance intervals Routine inspection and maintenance Your truck will remain operational only if the DANGER maintenance and checks are carried out The majority of accidents and injuries that occur regularly and according to the information and in workshops are caused by the failure to observe instructions in these operating instructions.
Page 209: Maintenance Instructions
Maintenance Maintenance intervals Maintenance instructions Maintenance work must be carried out in accordance with the following maintenance intervals. The intervals are designed for standard use. Depending on the application conditions of the truck, shorter maintenance intervals can be set, on agreement with the operating company.
Page 210: Maintenance - 50 Hours
Maintenance Maintenance intervals Maintenance - 50 hours At operating hours Carried out   The following procedures should be carried out after the ﬁrst 50 hours of operation. Before carrying out the procedures Check for error codes using diagnostic software Reset the service interval using diagnostic software Undercarriage Check that the wheel bolts are securely ﬁtted.
Page 211: Maintenance - 1000 Hours/Year
Maintenance Maintenance intervals Maintenance — 1000 hours/year At operating hours 1000 3000 7000 9000 11000 Carried out 13000 17000 19000   Depending on the application, environmental conditions and driving style, the follo- wing steps must be carried out at the intervals speciﬁed above, or more frequently if required.
Page 212 Maintenance Maintenance intervals 172780 EN - 06/2017...
Page 213: Maintenance - 2000 Hours/Every 2 Years
Maintenance Maintenance intervals Maintenance - 2000 hours/every 2 years At operating hours 2000 4000 6000 8000 12000 Carried out 14000 16000 18000   Depending on the application, environmental conditions and driving style, the follo- wing procedures must be carried out at the intervals speciﬁed above, or if necessary more frequently.
Page 214 Maintenance Maintenance intervals At operating hours 2000 4000 6000 8000 12000 Carried out 14000 16000 18000   Check the steering ﬂuid level. Top up if necessary Check the steering ﬂuid hoses for damage and leaks. Replace if necessary Special equipment and accessories Check diesel heater ﬁlter (if applicable) General Check labelling for completeness...
Page 215: Maintenance - 5000 Hours/Every 3 Years
Maintenance Maintenance intervals Maintenance - 5000 hours/every 3 years At operating hours Carried out 5000 10000 15000 20000   Depending on the application, environmental conditions and driving style, the fol- lowing procedures must be carried out at the intervals speciﬁed above, or more frequently if required.
Page 216 Maintenance Maintenance intervals At operating hours Carried out 5000 10000 15000 20000   Special equipment and accessories Renew the diesel heater fuel ﬁlter (if applicable) General Check labelling for completeness Test drive the truck 172780 EN - 06/2017...
Page 217: Technical Data
Technical data...
Page 218: Battery Data
Technical data Battery data Battery data R 07-25 (short wheelbase) Voltage Capacity Weight Tray Cell type a [mm] b [mm] [mm] (Ah) [kg] 203* 3PzS 1026 4PzS 1026 1210 4PzS 1026 1210 4PzS 1028 1558 4PzS 1028 1558 *Special design for truck chassis necessary.
Page 219: Wheel Rim And Tyre Data
Technical data Wheel rim and tyre data 5PzS 1028 1863 6PzS 1028 2178 6PzS 1028 2178 R 08-20 (platform truck) Capacity Tray Voltage (V) Cell type a [mm] b [mm] [mm] Weight [kg] (Ah) 3PzS 1026 4PzS 1026 4PzS 1026 1210 4PzS 1026...
Page 220: Technical Data - Platform Truck (2200)
Technical data Technical data - platform truck (2200) Technical data - platform truck (2200) 172780 EN - 06/2017...
Page 221 Technical data Technical data - platform truck (2200) Characteristics – platform tractor (2 200) Power unit: battery, diesel, petrol, LP gas, mains Battery power Operation: Manual, pedestrian, stand-on, seated, Seated order picker Load capacity (t) 2 Rated drawbar pull, with/without load on platform (Based on level, dry surface with rolling resistance of 200 N/t) 5kW = 500/900...
Page 222 Technical data Technical data - platform truck (2200) Dimensions – platform tractor (2 200) 4.16 Loading platform, length (mm) 2 200 4.17 Rear overhang (mm) 730 4.18 Loading platform, width (mm) 1 300 4.19 Overall length (mm) 3 530 (mm) 1 300 4.21 Overall width (mm) 150 4.32 Ground clearance, centre of wheelbase...
Page 223 Technical data Technical data - platform truck (2200) Other – platform tractor (2 200) Type of drive control AC - microprocessor Noise level at operator's ear dB (A) 69 Towing coupling, design/type, DIN/no Rockinger 244 Towing diagram Speed (km/h) Combined weight trailed plus carried (t) Permissible haul per hour (m) Gradient (%) Drawbar pull (N)
Page 224 Technical data Technical data - platform truck (2200) NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill gradients. NOTE The tow tractor must only be used with braked trailers. 172780 EN - 06/2017...
Page 225: Technical Data - Platform Truck (2600)
Technical data Technical data — platform truck (2600) Technical data — platform truck (2600) 172780 EN - 06/2017...
Page 226 Technical data Technical data — platform truck (2600) Characteristics – platform tractor (2 600) Power unit: battery, diesel, petrol, LP gas, mains Battery power Operation: Manual, pedestrian, stand-on, seated, Seated order picker Load capacity (t) 2 Rated drawbar pull, with/without load on platform (Based on level, dry surface with rolling resistance of 200 N/t) 5kW = 500/900...
Page 227 Technical data Technical data — platform truck (2600) Dimensions – platform tractor (2 600) 4.16 Loading platform, length (mm) 2 600 4.17 Rear overhang (mm) 1 130 4.18 Loading platform, width (mm) 1 300 4.19 Overall length (mm) 3 930 (mm) 1 300 4.21 Overall width (mm) 150...
Page 228 Technical data Technical data — platform truck (2600) Other – platform tractor (2 600) Type of drive control AC - microprocessor Noise level at operator's ear dB (A) 69 Towing coupling, design/type, DIN/no Rockinger 244 Towing diagram Speed (km/h) Combined weight trailed plus carried (t) Permissible haul per hour (m) Gradient (%) Drawbar pull (N)
Page 229 Technical data Technical data — platform truck (2600) NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill gradients. NOTE The tow tractor must only be used with braked trailers. 172780 EN - 06/2017...
Page 230: Technical Data - Long Wheelbase Tow Tractor
Technical data Technical data - long wheelbase tow tractor Technical data - long wheelbase tow tractor 172780 EN - 06/2017...
Page 231 Technical data Technical data - long wheelbase tow tractor Characteristics – long wheelbase tow tractor Power unit: battery, diesel, petrol, LP gas, mains Battery power Operation: Manual, pedestrian, stand-on, seated, Seated order picker Nominal towed load (Based on level, dry surface with rolling resistance of (t) 25 200 N/t) Rated drawbar pull...
Page 232 Technical data Technical data - long wheelbase tow tractor Dimensions – long wheelbase tow tractor 4.13 Platform height, without load (mm) 1 000 4.16 Loading platform, length (mm) 1 955 4.17 Rear overhang (mm) 615 4.18 Loading platform, width (mm) 1 170 (1 120 at rear) 4.19 Overall length (mm) 3 480 (mm) 1 300...
Page 233 Technical data Technical data - long wheelbase tow tractor Towing diagram Speed (km/h) Trailer weight (t) Permissible haul per hour (m) Gradient (%) Drawbar pull (N) NOTE The speed / drawbar pull performance of the tractor can be programmed between the two limits shown to suit the application.
Page 234 Technical data Technical data - long wheelbase tow tractor NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill gradients. NOTE Only braked trailers are permitted for loads ex- ceeding 9 t and when travelling on downward slopes.
Page 235: Technical Data - Tow Tractor With Short Wheelbase
Technical data Technical data - tow tractor with short wheelbase Technical data - tow tractor with short wheelbase 172780 EN - 06/2017...
Page 236 Technical data Technical data - tow tractor with short wheelbase Characteristics – short wheelbase tow tractor Power unit: battery, diesel, petrol, LP gas, mains Battery power Operation: Manual, pedestrian, stand-on, seated, Seated order picker Nominal towed load (Based on level, dry surface with rolling resistance of (t) 25 200 N/t) Rated drawbar pull...
Page 237 Technical data Technical data - tow tractor with short wheelbase Dimensions – short wheelbase tow tractor 4.13 Platform height, without load (mm) 1 000 4.16 Loading platform, length (mm) 1 520 4.17 Rear overhang (mm) 615 4.18 Loading platform, width (mm) 1 170 (1 120 at rear) 4.19 Overall length (mm) 3 045...
Page 238 Technical data Technical data - tow tractor with short wheelbase Towing diagram Speed (km/h) Trailer weight (t) Permissible haul per hour (m) Gradient (%) Drawbar pull (N) NOTE The speed / drawbar pull performance of the tractor can be programmed between the two limits shown to suit the application.
Page 239: Towed Load For The Front Coupling (Tow Tractors With Short And Long Wheelbases)
Technical data Towed load for the front coupling (tow tractors with short and long wheelbases) NOTE The permissible haul per hour is the total distance travelled, including the return journey and any downhill gradients. NOTE Only braked trailers are permitted for loads ex- ceeding 9 t and when travelling on downward slopes.
Page 240 Technical data Towed load for the front coupling (tow tractors with short and long wheelbases) 172780 EN - 06/2017...
Page 241 Index Decommissioning the truck ..152 Defects ......26 Actuating reverse inching .
Page 242 Packaging ......6 STILL SafetyLight ....107 Personnel qualiﬁcations .
Page 243 Index Towing diagram Warning indicator for the interlock ..113 Platform truck (2200) ... . 213 Wheel rim and tyre Platform truck (2600) ... . 218 Technical data .
Page 246 STILL GmbH 172780 EN – 06/2017...

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R 08-20

Still R 07-25 Original Instructions Manual

1 Foreword

2 Introduction

3 Safety

4 Overviews

5 Operation

6 Maintenance

7 Technical Data

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