Still R70-40T User manual

Operating Instructions
LPG forklift truck
R70-40T
R70-45T
R70-50T
7081 7082 7083
Ident no. 171673 - EN

Table of contents
g
1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
ECdeclarationofconformity,ECmarkofconformity ........................... 2
Information about documentation ......................................... 3
Documentationscope ................................................. 3
Issuedateandcurrentnessofmanual ...................................... 4
Copyrightandproprietaryrights .......................................... 4
Explanations of the signal terms used: ..................................... 5
Explanation of the cross-references ....................................... 5
Definitionofdirections ................................................. 6
Sample graphics ..................................................... 6
Environmental considerations ........................................... 7
Packaging .......................................................... 7
Disposalofunitsandbatteriesduringrepairwork ............................. 7
2 Introduction
Use of truck ........................................................ 10
Proper use ......................................................... 10
Proper towing usage . . ............................................... 10
Impermissibleuse ................................................... 10
Placeofuse ........................................................ 11
Useofworkingplatforms .............................................. 12
Residual risk ....................................................... 13
Residual dangers, residual risks ......................................... 13
Specialriskswhenusingtheforklifttruckandattachments ...................... 14
Overviewofhazardsandcountermeasures ................................. 16
Riskforemployees ................................................... 18
3Safety
Definition of terms used for responsible persons ............................. 20
Operatingcompany .................................................. 20
Specialist .......................................................... 20
Drivers ........................................................... 20
Essentials for safe operation ........................................... 23
Insurancecoverageoncompanypremises ................................. 23
Changes and retrofitting ............................................... 23
Warning regarding non-original parts ..................................... 24
Damage, defects and misuse of safety devices .............................. 24
171673 [EN] I

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Tyres ............................................................. 25
Medicalequipment ................................................... 25
Safety inspections ................................................... 26
Regularsafetycheckoftheindustrialtrucks ................................ 26
Regularsafetycheckofthefuelgassystem ................................ 27
Regular checking of harmful substances in the exhaust ........................ 27
Insulationtesting .................................................... 28
Safety regulations when handling consumables ............................. 29
Permissibleconsumables ............................................. 29
Oils .............................................................. 29
LPG .............................................................30
Hydraulicfluid ...................................................... 33
Batteryacid ........................................................ 34
Coolant ........................................................... 35
Disposalofconsumables .............................................. 36
Emissions ......................................................... 37
4Overviews
General view ....................................................... 40
Versions of driver’s compartment ........................................ 42
Driver’scompartment,singlepedalversion ................................. 42
Driver’s compartment, dual-pedal version .................................. 44
Operating and display elements ......................................... 46
Display and operating unit . . . .......................................... 46
Directionoftravel/flasher/faultmulti-functiondisplay .......................... 47
Mini-console ....................................................... 47
Identification points .................................................. 48
Overview .......................................................... 48
Nameplate ......................................................... 49
C.U.R.data ....................................................... 50
Vehicle identification number . .......................................... 50
Accessories ........................................................ 51
Special equipment and variants ......................................... 51
Attachments ....................................................... 52
Accessoryoverview .................................................. 52
II 171673 [EN]

Table of contents
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5 Operation
Checks and operations prior to start-up .................................... 54
Visualinspections ................................................... 54
Openingthebonnet .................................................. 55
Checking the engine oil level ........................................... 56
Fillingthewashersystem .............................................. 57
Checking the condition of the wheels and tyres .............................. 57
OpeningLPGcylinders ............................................... 58
OpeningtheLPGtankshut-offvalve ...................................... 59
AdjustingtheMSG65/MSG75driver’sseat ................................ 60
AdjustingtheMSG20driver’sseat ....................................... 63
Adjustingthesteeringcolumn ........................................... 65
Start-up ........................................................... 66
Turningonthekeyswitch .............................................. 66
Starting the engine ................................................... 68
Operating the signal horn .............................................. 69
Restrainingbelt ..................................................... 70
Checkingfunctionofbrakesystem ....................................... 73
Checkingfunctionofsteeringsystem ..................................... 74
Settingthetractionprograms ........................................... 75
Driving ............................................................ 76
Safety regulations when driving ......................................... 76
Driveways ......................................................... 78
Driving (single-pedal operation with multiple lever version) ..................... 80
Driving (single-pedal operation with version including mini-console) . .............. 84
Driving (two-pedal operation) ........................................... 88
Servicebrake ....................................................... 91
Operatingtheparkingbrake ............................................ 93
Steering ........................................................... 94
Lifting ............................................................ 95
Liftingsystemvariants ................................................ 95
Liftmastversions .................................................... 95
Malfunction during a lifting operation ...................................... 96
Controls,liftingsystem ................................................ 98
Liftingsystem,multi-leveroperation ...................................... 99
Forkextension ......................................................100
Operationwithreversibleforks ..........................................100
Working with loads ...................................................102
Safety regulations when handling loads . . . ................................102
Priortotakingupaload ...............................................103
Carryingloadingunits ................................................104
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Hazardarea ........................................................104
Transportingpallets ..................................................105
Transportofswingingloads ............................................106
Takinguploads .....................................................107
Transporting loads ...................................................110
Depositingandretrievingloadingunits ....................................113
Driving on ascending and descending slopes ...............................114
Drivingonlifts ......................................................114
Drivingonloadingbridges .............................................115
Workingwithattachments .............................................116
Assemblingattachments ..............................................116
Depressurising connections for attachments ................................117
General information on control of attachments ...............................118
Controllingattachmentsusingmulti-levercontrols ............................119
Operating attachments using multi-lever controls and the 5th function . . ...........120
Takingupaloadusingattachments ......................................121
Operation of additional equipment .......................................122
Switchinglightingonandoff(specialequipment) .............................122
Switchingflashinglightoffandon ........................................123
Switching hazard warning system off and on (special equipment) .................124
Switchingdirectionindicatorsoffandon ...................................125
Operatingthewindscreenwiper/washer ...................................125
Cab ............................................................. . 126
Heater ............................................................127
Drivingwithcruisecontrol ..............................................127
Trailer operation ....................................................130
Towedload ....................................................... . 130
Couplingthetrailer ...................................................131
Towingtrailers ......................................................133
Operation of indicator and operating unit ...................................134
Displays ..........................................................134
Setting and changing the displays ........................................135
Settingthedateortime ................................................135
Resetting the daily kilometres and daily operating hours .......................136
Setting the language .................................................136
Fleet Manager functions ...............................................137
Additional settings ...................................................137
Error messages .....................................................138
Diagram ......................................................... . 138
Faultcodetable .....................................................139
SAFETYBELTmessage ..............................................142
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Message SITZSCHALTER (SEAT SWITCH) ...............................145
AIRFILTERmessage ................................................ 147
BREMSEANZIEHEN(APPLYHANDBRAKE!)message .......................147
GABELN ABSENKEN (LOWER FORKS) message ...........................148
REFERENCELIFTmessage ...........................................149
FAHRGEBER(ACCEL.SENSOR)message ...............................149
BREMSGEBER (BRAKE SENSOR) message ..............................150
SURVEILLANCEmessage ............................................150
MOT/GEN-TEMP(MOT/GENTEMP)message .............................151
LENKEN(STEERING)message ........................................151
OELDRUCK (OIL PRESSURE) message . . ................................152
KUEHLMITTELSTAND(COOLANTLEVEL)message ........................152
KUEHLMITTELTEMP(COOLANTTEMP.)message .........................153
UEBERTEMPERATUR(OVERHEATING)message ..........................153
Operation in special operating situations ...................................154
Transport ..........................................................154
Towing .......................................................... . 156
Crane loading ......................................................156
Frequent short-term operation ..........................................159
Jumpstarting .......................................................160
Behaviour in emergencies .............................................162
Procedure if truck tips over .............................................162
Emergency lowering . . ...............................................163
Disconnecting the battery ..............................................164
Refuelling .........................................................165
Changing the LPG cylinder .............................................165
FillingtheLPGtank ..................................................168
Shut-down .........................................................171
Parkingthetrucksecurely .............................................171
Measures for prolonged shutdown, storage of truck ...........................173
Returningtoserviceafterstorage ........................................174
6 Maintenance
General maintenance information ........................................178
Qualifications of personnel .............................................178
Information regarding performing maintenance ..............................178
Overview of areas requiring maintenance . . ................................180
Intervalsformaintenanceandinspection ..................................181
Orderingsparepartsandwearingparts ....................................185
Quality and quantity of the required operating materials ........................185
171673 [EN] V

Table of contents
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Maintenancedatatable ...............................................186
Safety instructions for maintenance ......................................188
General information ..................................................188
Carrying out work on the hydraulic equipment ...............................188
Workingonelectricalequipment .........................................188
Workingontheignitionsystem ..........................................189
Workingongasfuel(LPG)system .......................................189
Safetydevices ......................................................190
Setvalues .........................................................190
Raisingandjackingup ................................................191
Workingatthefrontoftheforklifttruck .....................................192
Preparation for maintenance ...........................................194
Installingandremovingthefloorplate .....................................194
Removingandinstallingtherearcovering ..................................195
Cleaning ..........................................................196
Cleaning the truck ...................................................196
Cleaning the electrical system ..........................................197
Cleanloadchains ...................................................197
Cleaning the windscreens . . . ..........................................198
Afterwashing .......................................................198
Maintenance after first 50 operating hours ..................................199
Maintenanceduringthebreak-inperiod ...................................199
Maintenance as required ..............................................200
Cleaning the radiator, checking for leaks ...................................200
Topping up coolant and checking coolant concentration .......................200
Changing the air filter insert . . ..........................................202
Servicingthebattery .................................................204
Maintaining hydraulic equipment ........................................207
Servicingwheelsandtyres .............................................208
Checkingadjustmentofthefootbrake .....................................209
Checkingtheparkingbrakesetting .......................................210
Lubricatingjointsandcontrols ..........................................211
Checking the door latch ...............................................211
Maintainingthesteeringaxle ...........................................211
Servicing the mast bearing . . . ..........................................214
Load chain maintenance ..............................................214
Lubricatingtheliftmastandrollertrack ....................................217
Maintainingtherestrainingbelt ..........................................217
Maintainingtherestraintsystem .........................................219
Checkdriver’sseat ...................................................219
Replacingfuses .....................................................219
VI 171673 [EN]

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Attachment maintenance ..............................................221
500-hour maintenance/semi-annual maintenance ............................222
Checking the evaporator and pressure regulator .............................222
1000-hour maintenance/annual maintenance ...............................223
Workthatmustalsobecarriedout .......................................223
Maintainanceofdriveaxle .............................................223
Adjustingtheparkingbrake ............................................224
Lubricating the parking brake lever bearing and ratchet ........................224
Checking the counterweight attachment . . . ................................224
Changing the engine oil and filter ........................................224
Checking the ribbed V-belt .............................................226
Replacingthesparkplugs .............................................227
Checking the exhaust gas system ........................................227
Changing the LPG filter ...............................................227
OverhaulingtheLPGsystem ......................................... . . 229
Checkingthelambdacontrolsystem ......................................230
Checking the heating system for leaks ....................................230
Check lift cylinders and connections for leaks. ...............................230
Maintainliftingsystem ................................................231
Checkingtheclearancebetweenforkcarriagestopandrun-outstop ..............233
Checkingtheforkarms ................................................233
Checkingreversibleforkarms ..........................................234
3000-hour maintenance/two-year maintenance .............................235
Workthatmustalsobecarriedout .......................................235
Changing the gear lubricant oil ..........................................235
Checking the wheel bearing ............................................236
Checking the engine mountings .........................................236
ReplacinghosesintheLPGsystem .................................... . . 237
6000-hour maintenance ...............................................239
Workthatmustalsobecarriedout .......................................239
Changing the hydraulic oil and filter .......................................239
9000-hour maintenance/five-year maintenance .............................243
Workthatmustalsobecarriedout .......................................243
Changing the coolant . . ...............................................243
10-year maintenance .................................................246
CheckingtheLPGtank .............................................. . . 246
171673 [EN] VII

Table of contents
g
7 Technical data
Dimensions ........................................................248
VDI datasheet ......................................................249
Wheels and tyres ....................................................252
Fuse assignment ....................................................253
Fuseassignmentinmainfuseholder .....................................253
Fuseassignmentspecialequipment ......................................254
8 Circuit diagrams
Hydraulics .........................................................256
Hydrauliccircuitdiagram ..............................................256
Electrical equipment .................................................258
Legendforcircuitdiagrams ............................................258
VIII 171673 [EN]

1
Foreword

1Foreword
Your industrial truck
Your industrial truck
General
The industrial trucks described in this user
manual are built to the applicable standards
and safety regulations. If your industrial truck
is to be driven on public roads it must satisfy
the applicable Road Traffic Act provisions for
the country concerned. The vehicle excise
licence must be obtained from the appropriate
office.
The industrial trucks are fitted with the most
up-to-date technology Now it’s up to you to
operate your industrial truck safely and obtain
the benefits of its functional capabilities.
This user manual gives you the necessary
information for this. Read it and follow these
instructions before bringing your industrial
trucks into use! This way you will avoid acci-
dents, spare yourself worry and maintain the
warranty.
CE-Symbol
EC declaration of conformity, EC
mark of conformity
With the EC declaration of conformity, the
manufacturer confirms the compliance of the
industrial truck with the standards and reg-
ulations valid at the time of marketing. The
EC conformity mark is shown on the factory
nameplate and indicates compliance with the
above regulations.
A structural change or addition to the industrial
truck on one’s own authority can affect the
safety in an unreliable way thus invalidating
the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
2 171673 [EN]

Foreword 1
Information about documentation
Information about documentation
Documentation scope
• Operating and maintenance manual
• Operating and maintenance manual for
attachments (special equipment)
• Maintenance data table
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
• Inspection and test log book for power-
driven industrial trucks (Germany only)
This operating and maintenance manual de-
scribes all necessary measures for safe oper-
ation and correct maintenance of your indus-
trial truck. It includes all variants available up
to the time of going to press. Special designs
to meet customer requirements are docu-
mented in a separate operating and mainte-
nance manual. For further information, please
contact your service centre.
Please enter the factory no. and year of
manufacture from the factory nameplate
in the space provided ⇒ Chapter "Name-
plate", P. 4-49 below:
Factory no. ...............................................
Year of manufacture
...................................................
Please provide these numbers for all technical
questions.
An operating and maintenance manual is pro-
vided with every industrial truck. This manual
must be stored carefully and must be available
to the driver and operator at any time. The
storage location is specified in the Overviews
chapter ⇒ Chapter "Overviews", P. 39.
If the operating instructions are lost, the op-
erator must obtain a replacement from the
manufacturer immediately.
The operating and maintenance manual is
included in the spare parts list and can be
reordered as a spare part.
171673 [EN] 3

1Foreword
Information about documentation
This operating and maintenance manual must
be drawn to the attention of staff responsi-
ble for the operation and maintenance of the
trucks.
The operator (see ⇒ Chapter "Definition of
terms used for responsible persons", P. 20)
must ensure that all users have received, read
and understood this manual.
Thank you for reading and complying with this
manual. For further information or improve-
ment suggestions, or if you have identified
errors, please contact our service centre.
Issue date and currentness of man-
ual
May 2007
STILL is constantly engaged in the further de-
velopment of industrial trucks. Please note
that these operating instructions are subject to
change and any claims based on the informa-
tion and figures contained in these operating
instructions cannot be asserted.
If you require technical support for your in-
dustrial truck, please contact the responsible
service centre.
We hope you enjoy your driving
STILL GmbH
Berzeliusstr. 4
22113 Hamburg, Germany
Copyright and proprietary rights
This manual - and any excerpts thereof - may
not be reproduced, translated or tansmitted in
any form to third parties without the express
written permission of the manufacturer.
4 171673 [EN]

Foreword 1
Information about documentation
Explanations of the signal terms
used:
DANGER
In the case of work procedures that must be strictly
adhered to in order to prevent a danger to the life or
physical condition of persons.
WARNING
In the case of procedures that must be strictly adhe-
red to in order to prevent injury to persons.
CAUTION
In the case of procedures that must be strictly ad-
hered to in order to prevent material damage and/or
destruction.
NOTE
For technical requirements that require spe-
cial attention.
ENVIRONMENT NOTE
To prevent environmental damage.
Explanation of the cross-references
Cross references are used to direct the reader
to the appropriate section or chapter.
Examples:
• Cross reference to a section: ⇒ Chap-
ter "Explanation of the cross-refer-
ences",P.1-5
• Cross reference to a chapter: ⇒ Chap-
ter "Definition of terms used for responsible
persons", P. 20
171673 [EN] 5

1Foreword
Information about documentation
6210_001-031
42
3
1
Definition of directions
The directions forwards (1), backwards (3),
right (2), left (4) give the installation locations
of parts as seen from the driving position; the
load is at the front.
6210_001-009
Sample graphics
This documentation explains the (usually se-
quential) sequence of certain functions or
operations. Schematic diagrams of a coun-
terbalance truck are used to illustrate these
sequences.
NOTE
These schematic diagrams are not represen-
tative of the constructed state of the docu-
mented industrial truck. They serve only to
illustrate the sequences.
6 171673 [EN]

Foreword 1
Environmental considerations
Environmental considerations
Packaging
During delivery of the industrial truck, cer-
tain parts are packaged to provide protection
during transport. This packaging must be re-
moved completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be properly dis-
posed of after delivery of the industrial truck.
Disposal of units and batteries during
repair work
It may be necessary to replace units as part of
maintenance work. Replaced units must then
be disposed of.
Your vehicle is comprised of different materi-
als. Each of these materials must be
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
When disposing of batteries, please refer to
the battery manufacturer’s documentation.
ENVIRONMENT NOTE
We recommend working with a waste ma-
nagement company for disposal purposes.
171673 [EN] 7

1Foreword
Environmental considerations
8 171673 [EN]

2
Introduction

2Introduction
Use of truck
Use of truck
Proper use
The forklift truck described in this operating
manual is suitable for lifting, transporting and
stacking loads.
The truck may only be used for its proper pur-
pose, as set out and described in this operat-
ing manual.
If the truck is to be used for other purposes
than those specified in the operating manual,
the approval of the manufacturer and, if nec-
essary, the responsible regulator authorities,
must be obtained beforehand to prevent haz-
ards.
The maximum load to be lifted is specified on
the capacity plate (load diagram) and may not
be exceeded.
Proper towing usage
This forklift truck is suitable for the occasional
towing of trailers and is equipped with a towing
device for this purpose. This occasional tow-
ing may not exceed 2% of the daily operating
time. If you want to use the forklift truck for
more frequent towing, the manufacturer must
be consulted.
The trailer operation provisions must be
followed. See ⇒ Chapter "Trailer opera-
tion", P. 130.
Impermissible use
Every hazard caused by impermissible use
is the responsibility of the operator or driver
and not of the manufacturer (also see in this
matter ⇒ Chapter "Definition of terms used for
responsible persons", P. 20).
Use for purposes other than those described
in these operating instructions is prohibited.
10 171673 [EN]