Still R 07-25 User manual

Original instructions
Platform tractors and tow tractors
R 07-25, R 08-20
0736 0737 0809 0810
172780 EN - 06/2017

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• 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.
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Table of contents
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1 Foreword
Your industrial truck ................................................... 2
General ............................................................ 2
CElabelling ......................................................... 2
Information about the documentation ...................................... 3
Scopeofthedocumentation ............................................. 3
Informationsymbolsused ............................................... 5
Issuedateandtopicality ................................................ 6
Copyright and trademark rights ........................................... 6
Explanation of the cross-references ....................................... 6
Environmental considerations ........................................... 6
Packaging .......................................................... 6
Disposingofcomponentsandbatteries ..................................... 7
2 Introduction
Use of the truck ..................................................... 10
Intended purpose .................................................... 10
Inadmissible use .................................................... 11
Parkingintemperaturesbelow-10°C ..................................... 11
Placeofuse ........................................................ 11
Residual risk ....................................................... 12
Residual dangers, residual risks ......................................... 12
Danger to employees . . ............................................... 13
Overviewofhazardsandcountermeasures ................................. 14
Specialrisksassociatedwithusingthetruckandattachments ................... 17
3Safety
Definition of responsible persons ........................................ 20
Driver ............................................................ 20
Operatingcompany .................................................. 21
Specialist .......................................................... 21
Basic principles for safe operation ....................................... 22
Tyres ............................................................. 22
Non-originalparts ................................................... 2
3
Gasspringandaccumulator ............................................ 23
Driverswithmedicaldevices ............................................ 24
Modifications and retrofitting ............................................ 24
Insurance cover on company premises .................................... 25
Damage, defects and misuse of safety systems .............................. 26
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Safety tests ........................................................ 26
Periodicsafetyinspectionoftheindustrialtruck .............................. 26
Insulationtesting .................................................... 27
Safety regulations for handling consumables ............................... 28
Permissibleconsumables ............................................. 28
Battery ........................................................... 28
Oils .............................................................. 30
Lubricants ......................................................... 31
Hydraulicfluid ...................................................... 31
Substances that are damaging to health ................................... 32
Disposalofconsumables .............................................. 33
Emissions ......................................................... 33
4Overviews
Your truck ......................................................... 36
Information ........................................................ 36
Truckvariants ...................................................... 39
Truck view ......................................................... 40
Platformversion ..................................................... 40
Towtractorversion ................................................... 41
Operating and display elements ......................................... 42
Viewofthedriver'scompartment ........................................ 42
Displayunit ........................................................ 43
Switch panel ....................................................... 44
Labelling points ..................................................... 45
Data plates and adhesive labels ......................................... 45
Identificationplate ................................................... 46
Equipment ......................................................... 47
Standard equipment andvariants ........................................ 47
5 Operation
Checks and tasks to be carried out prior to commissioning ...................... 50
Visualinspections ................................................... 50
Before beginning yourshift ............................................. 52
Checkingtyrepressures ............................................... 53
Adjustingthesteeringcolumn ........................................... 53
Checking the condition of the wheels and tyres . . . ........................... 54
AdjustingtheMSG65/MSG75driver'sseat ................................ 54
Topupthescreenwashreservoir ........................................ 58
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Commissioning ..................................................... 59
Connecting the battery . ............................................... 59
Switchingonthetruckwiththekeyswitch .................................. 59
Switchingonthetruckwiththedrivercode ................................. 60
Checking the operating devices and their function ............................ 61
Checking the battery charge status ....................................... 62
Checking the emergency off switch ....................................... 62
Checkingthefootbrake ............................................... 63
Checkingtheparkingbrake ............................................ 6
3
Checkingtheelectricbrake ............................................ 65
Checkingtheinterlockswitch ........................................... 66
Fastening and releasing theseatbelt(variant) ............................... 67
Checking the manual tow coupling (variant) ................................ 68
Checkingtheautomatictowcoupling(variant) ............................... 69
Checking the remotely unlockable tow coupling (variant) ....................... 70
Drive mode ........................................................ 70
Roadways ......................................................... 70
Safetyguidelines .................................................... 71
Switchingonthetruckwiththekeyswitch .................................. 73
Stoppingthetruckwiththeservicebrake ................................... 74
Switchingonthetruckw
iththedrivercode ................................. 75
Operatingthehorn ................................................... 76
Running the truck in . . . ............................................... 77
Selecting the drive programme .......................................... 77
Startingdrivemode .................................................. 78
Acceleratingthetruck ................................................. 79
Applying the parking brake ............................................. 79
Drivingthetruckinreverse ............................................. 80
Parkingandswitchingoffthetruck ....................................... 81
Battery ........................................................... 82
Providingaccesstomaintenancepoints ................................... 82
Batterycables ...................................................... 90
Chargingthebattery .................................................. 91
Changing the battery using a crane ....................................... 93
Transportingandsettingdownthebattery .................................. 95
Charging the battery with the sidebatteryconnector .......................... 95
Equalisingchargetopreventadeepdischargeofthebattery .................... 98
Replacing the battery using a hand pallet truck (variant for platform tractors) .........100
Lighting ...........................................................102
Switchingtheroadlightsonandoff .......................................102
Switchingthedirectionindicatorsonandoff ................................103
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Turningthehazardwarningsystemonandoff ...............................104
Switchingtheinteriorilluminationonandoff ................................105
Switchingthefoglamp(varian
t)onandoff .................................105
Switching the rotating beacon (variant) on and off . ...........................106
Switchingtheworkingspotlights(variant)onandoff ..........................106
STILLSafetyLight(variant) .............................................1
07
Display unit ........................................................107
Warningindicator ....................................................107
Speedometer indicator ................................................108
Overheating indicator .................................................108
Hourmeter ....................................................... . 109
Slowspeedindicator .................................................109
Distanceindicator ...................................................110
Drivedirectionindicator ...............................................110
Parkingbrakeindicator ................................................1
11
Displayplaintextmessages ............................................111
Hydraulicoilwarningindicator ..........................................112
Battery discharge indicator .............................................112
Warningindicatorfortheinterlock ........................................113
Displayunitscreen ...................................................113
Warning display for brakefluid ..........................................114
Maximumspeedwarningindicator .......................................114
Trailer and load .....................................................115
Towingguidelines ...................................................115
Loadingaplatform ...................................................116
Loadingtrailers .....................................................116
Towingtrailers ......................................................117
Operating the manual coupling ..........................................118
Actuatingreverseinching(variant) .......................................121
Opening and closing the side panel .......................................122
Operating the automatic coupling ........................................128
Operating the remotely unlockable coupling ................................130
Auxiliary equipment ..................................................1
32
Drivercodekeypad ..................................................132
Switchingtheheatingsystemonandoff ...................................133
Logging the driver code inandout ........................................134
FleetManager — logging in and logging off .................................138
Switching the seat heater (variant) on and off ...............................139
Switching the diesel auxiliary-heating system (variant) on and off .................139
Switching the rear window wiper/washer on and off ...........................143
Switchingthefrontwindscreenwiper/washeronandoff ........................143
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Special operating situations ............................................145
Securingthetruckfortransportation ......................................145
Towingthetruck .....................................................147
Crane loading the truck ...............................................150
Decommissioning ...................................................152
Taking the truck out of operation .........................................152
Decommissioningthetruck ............................................152
6 Maintenance
Safety regulations for maintenance .......................................154
Personnel qualifications ...............................................154
Safetyguidelines ....................................................155
Setvalues ....................................................... . . 156
Safetydevices ......................................................156
Working on the electrical equipment ......................................156
Workingonthehydraulicequipment ......................................157
Working in potentially explosiveareas .....................................157
General maintenance information ........................................158
Orderingsparepartsandwearingparts ....................................158
Inspection and maintenance data ........................................159
Recommended lubricants .............................................160
Cleaning ..........................................................160
Preparing the truck forcleaning .........................................160
Cleaningthetruck ...................................................161
Providing access to maintenance points ...................................165
Providing access to maintenancepoints ...................................165
Servicing ..........................................................174
Fuses ........................................................... . 174
Check the braking system .............................................176
Checkingthesuspensionshockabsorbers .................................177
Changing the brake fluid ...............................................177
Checking the steering fluidlevel .........................................178
Checkingthebrakefluidlevel ...........................................179
Checkingtheauxiliaryheatingsystem(variant) ..............................180
Checking the diesel auxiliaryheaterfilter ...................................181
Changing the steering fluid and filter ......................................182
Lubricatingthesteeringlinkagebearings ..................................183
Checking operating devicesandfunctions .................................184
Checkingthesteeringlinkageforwear ....................................184
Specialremovaltool ..................................................185
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Removing and installing the front wheels ...................................186
Removingandinstallingthedrivewheels ..................................189
Replacing the gearbox breatherfilter ......................................191
Check security of the wheel bolts ........................................191
Checkingbatteryandbatterycablestatus ..................................192
Filling the tank for the diesel auxiliaryheater ................................193
Lubricating the axle stub bearing of the steering system ........................194
Checking and lubricating latches and hinges ................................194
Checking steering fluid hosesfordamage ..................................195
Replacingthebreatherfilterforthesteeringfluidtank .........................195
Checkingthebatteryacidlevelandspecificgravity ...........................196
Checking the condition and safety of the electrical connections and cables ..........197
Maintenance intervals ................................................198
Routineinspectionandmaintenance .....................................198
Maintenance instructions ..............................................199
Maintenance-50hours ...............................................200
Maintenance-1
000hours/year .........................................201
Maintenance - 2000 hours/every2years ...................................203
Maintenance-5000hours/every3years ...................................205
7 Technical data
Battery data ........................................................208
Wheel rim and tyre data ...............................................2
09
Technical data - platform truck (2200) .....................................210
Technical data - platform truck (2600) .....................................215
Technical data - long wheelbase tow tractor ................................220
Technical data - tow tractor with short wheelbase ............................225
Towed load for the front coupling (tow tractors with short and long wheelbases) ......229
VIII 172780 EN - 06/2017

1
Foreword

1Foreword
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. The driving permit must be obtained
from the appropriate office.
Thetruckshavebeenfittedw
ith state-of-the-
art technology. Now all that remains is to
handle the trucks safely and maintain their
functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
CE-Symbol
CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored andmadeavailabletothe
relevant authorities.
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Foreword 1
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. Special ver-
sions to meet customer requirements are doc-
umented in separate operating instructions. If
you have any questions, please contact your
service centre.
The production number and year of manufac-
ture can be found on the nameplate; see the
chapter "Truck description".
Production number .......................................
........
Year of manufacture.......................................
............
Please quote the production number during all
technical enquiries.
Operating instructions are provided with every
truck. These instructions must be stored
carefully and must be available to the driver
and operating company at any time.
If the operating instructions are lost, the op-
erating company must obtain a replacement
from the manufacturer immediately.
The operating instructions are included in the
spare parts list and can be reordered as a
spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company must ensure that all
users have received, read and understood
these instructions.
Thank you for reading and complying with
these instructions. If you have any questions
or suggestions for improvements, or if you
172780 EN - 06/2017 3

1Foreword
Information about the documentation
have found any faults, please contact your
service centre.
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Foreword 1
Information about the documentation
Information symbols used
In order to reduce the risk of physical injuries,
injuries to third parties and potential damage
to the truck, information symbols on warning
signs indicate specific dangers, special
information or procedures.
DANGER
Indicates hazards that may result in bodily injury or
death and/or severe product damage.
WARNING
Indicates hazards that may result in bodily injury
and/or severe product damage.
CAUTION
Indicates hazards that may result in damage to, or
destruction of the product.
ENVIRONMENT NOTE
Indicates hazards that may be harmful to the
environment.
NOTE
Identifies technical information requiring
special attention because the connection may
not be obvious even to skilled personnel.
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1Foreword
Environmental considerations
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.
If you require technical support for the vehicle,
please contact the authorised service centre.
Have a good trip, your partner
STILL GmbH
Berzeliusstr. 10
22113 Hamburg, Germany
Copyright and trademark rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Explanation of the cross-references
Cross-references refer to the respective
chapter.
Example:
• Refer to a chapter: See chapter entitled
"Definition of terms used for responsible
persons"
Environmental considerations
Packaging
When the truck is delivered, certain parts
are packaged to provide protection during
transport. This packaging must be completely
removed prior to commissioning.
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Foreword 1
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
• recycled in accordance with the regional or
national regulations of the country of use.
NOTE
Observe the battery manufacturer documen-
tation when disposing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.
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1Foreword
Environmental considerations
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2
Introduction

2Introduction
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
safety regulations for gas vehicles and the
regulations for use of the tow tractor when
driving on public roads.
It is imperative that operating and service staff
follow the VDMA booklet for users of industrial
trucks.
The user, and not the manufacturer, is re-
sponsible for any injury or damage arising as
a result of misuse, neglect, abuse, alterations,
incorrect maintenance or repairs and applica-
tions not authorised by the manufacturer.
Should you want to use the truck for applica-
tions not covered in these operating instruc-
tions, please contact your local distributor. No
modifications or conversions may be made,
or additional equipment fitted to your tractor,
without prior permission of the manufacturer.
For attachments, the operating instructions
supplied by the attachment manufacturer
apply.
DANGER
Risk of serious injury or death from use in potentially
explosive areas!
Never use standard trucks in areas in which there
is a risk of explosion due to gases, vapours or
combustible and explosive powders.
Trucks that are required for operation in such envi-
ronments must be specially protected. They must
also be accompanied by a specific EC declaration
of conformity and the appropriate operating instruc-
tions.
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