Still 6219 Original Instructions Manual
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Still 6219 Original Instructions Manual

Electric truck
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Table of Contents

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Original instructions
Electric truck
RX20 14-20 Cat. 2GD/3GD
For use in potentially explosive areas
6219 6220 6221 6222 6223 6224
6225 6226 6227 6228 6229 6230
6231
56368011531 EN - 01/2021 - 05

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  • Page 1 Original instructions Electric truck RX20 14-20 Cat. 2GD/3GD For use in potentially explosive areas 6219 6220 6221 6222 6223 6224 6225 6226 6227 6228 6229 6230 6231 56368011531 EN - 01/2021 - 05...
  • Page 3 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. 56368011531 EN - 01/2021 - 05...

  • Page 5: Table Of Contents

    Table of contents Foreword Your truck ............Description of the truck .
  • Page 6 Table of contents Safety Definition of responsible persons......... Operating company .
  • Page 7 Operating devices and display elements ........Display-operating unit "STILL Easy Control" ........
  • Page 8 STILL SafetyLight (variant) ........
  • Page 9 STILL Classic and sprint mode ........
  • Page 10 Table of contents Lifting ............. . Lifting system variants .
  • Page 11 Table of contents Depressurising the hydraulic system using the double mini-lever and the 5th function . Depressurising the hydraulic system using a triple mini-lever..... Depressurising the hydraulic system using the triple mini-lever and the 5th function .
  • Page 12 Table of contents Cab ............. . . Opening and closing the cab door.
  • Page 13 Table of contents Charging the lead-acid battery ..........Equalising charging to preserve the battery capacity .
  • Page 14 Table of contents Maintenance by the authorised service centre: Explosion-protection components - 1000 hours/yearly ............Maintenance - 1000 hours/annually .
  • Page 15 Table of contents VDI datasheet: RX20-16 with swing axle........VDI datasheet: RX20-18 with swing axle.

  • Page 17: Foreword

    Foreword...

  • Page 18: Your Truck

    Your truck Description of the truck General The STILL RX20 14-20 is an electrically driven counterbalanced truck with a steering turnta- ble or a rear swing axle. It has a load capacity of up to 2 tonnes with a load centre of gravity of 500 mm.
  • Page 19 Drive Both front wheels of the STILL RX20 14-20 are driven by a maintenance-free three-phase drive in the front axle with 48-volt technology. Power is supplied by a lead-acid battery that can be replaced from the side.

  • Page 20: General

    The "STILL Easy Control" display-operating unit simplifies daily use of the truck by provid- ing personally configurable favourites. The display-operating unit also monitors the truck functions.

  • Page 21: Ce Labelling

    Foreword Your truck If the truck is to be operated on public roads, it must conform to the existing national regula- tions for the country in which it is being used. The driving permit must be obtained from the appropriate office. The truck has been fitted with state-of-the-art technology.

  • Page 22: Explosion Protection Notice

    Foreword Your truck Explosion protection notice  The explosion protection notice indicates that the manufacturer complies with the explosion protection licensing regulations. 6036_001-001 56368011531 EN - 01/2021 - 05...

  • Page 23: Ec Declaration Of Conformity In Accordance With Machinery Directive

    Foreword Your truck EC declaration of conformity in accordance with Machinery Directive Declaration STILL GmbH Berzeliusstraße 10 D-22113 Hamburg Germany We declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006/42/EC.

  • Page 24: Accessories

    Foreword Your truck Accessories Two keys for the key switch (not for trucks ● with the "Switch on via push button" variant) Two keys for the cab (variant) ● A hexagon socket wrench for emergency ● lowering (in the compartment) A battery change frame ●...
  • Page 25 Foreword Your truck 56368011531 EN - 01/2021 - 05...

  • Page 26: Labelling Points

    Foreword Your truck Labelling points 19 20 8 15 CAT. 2G 6219_901-011_V2 56368011531 EN - 01/2021 - 05...
  • Page 27 Foreword Your truck Decal information: Caution / Read the oper- Warning sign: Dangerous electrical voltage ating instructions / Fasten seat belt / Apply Decal information: Load measurement parking brake when leaving the truck / Pas- Decal information: ANTISTATIC CHECKED sengers are not allowed / Do not jump off if (on the backrest of the driver's seat) the truck is tipping over / Lean in the oppo- Decal information: ELECTRICALLY CON-...
  • Page 28 Foreword Your truck 0044 S.r.l. 20812 LIMBIATE (MB) ‒ Via Marconi, CBH ‒ 5 II 573714 3 Year 20 Ex d IIC T II 2 (1) GD Ex tb IIIC T °C Db IP66 ATEX 043X T.amb. = ‒20°C to + 60°C CABLE ENTRIES : SEE INSTRUCTIONS T cable °C...
  • Page 29 Foreword Your truck Decal information: Hydraulic oil tank Decal information: Regular testing Decal information: Speed reduction Decal information: Battery service Warning sign: Do not stand underneath the Decal information: Caution / Read the oper- fork / Do not stand on the fork ating instructions Warning sign: Danger due to shearing / Decal information: Lifting point...

  • Page 30: Nameplate

    Foreword Your truck Nameplate  The truck can be identified from the informa- tion on the nameplate. Model Production number Address of manufacturer Year of manufacture Empty weight in kg Maximum permissible battery weight [kg] Minimum permissible battery weight [kg] Ballast weight [kg] ATEX number Miretti job number...

  • Page 31: Stvzo (Road Traffic Licensing Regulations) Information

    Foreword Your truck StVZO (Road Traffic Licensing Reg-  ulations) information This label includes information on the weight and load distribution of the truck in kg. Tare weight Total permissible weight Permitted front axle load Permitted rear axle load Payload 56368011531 EN - 01/2021 - 05...

  • Page 32: Nameplate Of The Pressure-Tight Housing

    Foreword Your truck Nameplate of the pressure-tight  housing The flame proof enclosures are marked with a nameplate. The data on the plate corresponds to the approved area of application for the flame proof enclosure. The plate must be posi- 0044 S.r.l.

  • Page 33: Nameplate Of The Battery

    Foreword Your truck Nameplate of the battery The nameplate of the battery is mounted on the battery tray. The information on this name- plate describes the permitted area of use of the battery. Only use explosion-protected batteries – that are approved for the area in which the truck is to be used.
  • Page 34 Foreword Your truck NOTE In this example, the company HAWKER ® quoted as the battery supplier. If the truck is equipped with an explosion-protected battery from another manufacturer, the authorised service centre will provide assistance in de- coding the nameplate of the battery. 56368011531 EN - 01/2021 - 05...

  • Page 35: Diagnostic Interface

    Foreword Your truck Diagnostic interface  The truck is equipped with a diagnostic inter- face for monitoring and reading out the truck control unit. Only the authorised service centre may operate the diagnostic interface. The di- agnostic interface is identified by the decal in- formation (see illustration).

  • Page 36: Using The Truck

    Foreword Using the truck Using the truck Basic information on explosion protection DANGER Risk of explosion! The truck may only be operated in the potentially explosive areas for which it is approved! – Check the area of application by com- paring it with the nameplate informa- tion.
  • Page 37 Foreword Using the truck temperature. This enables ignition caused by overheated equipment surfaces to be preven- ted. Potentially explosive areas for flammable gases, vapours and fumes are divided into zones 0, 1 and 2. Division of potentially explosive areas for gases, vapours and fumes Zone Description Permanent, long-term or frequent dangerous explosive atmosphere...

  • Page 38: Commissioning

    Foreword Using the truck Equipment in group II (gas) is divided in ac- cordance with the characteristics of the explo- sive atmosphere for which it is intended. Equipment in group II (gas) Group Description Propane Ethylene Hydrogen Equipment in group III (dust) is divided in ac- cordance with the characteristics of the explo- sive atmosphere for which it is intended.

  • Page 39: Proper Use

    Foreword Using the truck work and adjustment work that cannot be per- formed by the operating company. See also the chapter entitled "Definition of responsible persons". – To commission the truck, contact the au- thorised service centre. Proper use The truck described in these operating instruc- tions is suitable for lifting, transporting and stacking loads.

  • Page 40: Proper Use During Towing

    Foreword Using the truck Proper use during towing DANGER Risk of explosion! Trailers and tow couplings that do not fulfil explosion-protection regulations can lead to explosions in the surrounding at- mosphere within potentially explosive areas! Do not use the truck for towing. Improper use The operating company or driver, and not the manufacturer, is liable for any hazards caused...
  • Page 41 Foreword Using the truck DANGER Risk of explosion! The truck must not be operated in fire hazard areas or potentially explosive areas that do not conform to the truck's classification. The truck must not be operated in areas where there is a risk of corrosion or in areas with high levels of dust that do not conform to the truck's classification.

  • Page 42: Place Of Use

    Foreword Using the truck Place of use  DANGER There is a risk of explosion during use in potentially explosive areas. The truck may only be operated in the potentially explosive areas for which it is approved! – Check the area of application by com- paring it with the nameplate informa- tion.
  • Page 43 Foreword Using the truck arise during normal operation due to gases, vapours or mists. Zone 21 – category 2D ● Use is permitted in areas where hazardous, potentially explosive atmospheres may arise during normal operation due to dusts. Zone 1 and zone 21 – category 2GD ●...

  • Page 44: Parking In Temperatures Below -10°C

    Foreword Using the truck Driving on upward and downward gradients is permitted, provided the stipulated data and specifications are observed. The truck is suitable for indoor and outdoor use in countries ranging from the Tropics to Nordic regions (temperature range: −10°C to +40°C).
  • Page 45 Foreword Using the truck DANGER Risk of explosion! Working with working platforms that do not meet explosion-protection regula- tions can lead to explosions in the sur- rounding atmosphere within potentially explosive areas! – Only use working platforms that com- ply with the explosion-protection regu- lations.

  • Page 46: Information About The Documentation

    Foreword Information about the documentation Information about the documentation Scope of the documentation Original operating instructions of the truck ● Original operating instructions of the dis- ● play-operating unit Operating instructions of the installed var- ● iants that are not mentioned in the afore- mentioned original operating instructions "UPA"...

  • Page 47: Supplementary Documentation

    Foreword Information about the documentation Store all documentation safely. Hand over the documentation to the next operating company if the truck is transferred or sold. NOTE Please note the definition of the following re- sponsible persons: "operating company" and "driver". Thank you for reading and complying with these operating instructions.

  • Page 48: Issue Date And Topicality Of The Operating Instructions

    The issue date and the version of these oper- ating instructions can be found on the title page. STILL is constantly engaged in the further de- velopment of trucks. These operating instruc- tions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.

  • Page 49: List Of Abbreviations

    Foreword Information about the documentation CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruc- tion. NOTE For technical requirements that require special attention. ENVIRONMENT NOTE To prevent environmental damage -protection information For components, points and procedures rele- vant to explosion protection List of abbreviations This list of abbreviations applies to all types of...
  • Page 50 Foreword Information about the documentation Abbrevi- Meaning Explanation ation European standard European Federation of Materials Han- Fédération Européene de la Manutention dling and Storage Equipment maximum Force Maximum power German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless net- GPRS...

  • Page 51: Definition Of Directions

    Foreword Information about the documentation Abbrevi- Meaning Explanation ation Verband Deutscher Maschinen- und Anla- German Mechanical Engineering Industry VDMA genbau e. V. Association WLAN Wireless LAN Wireless local area network Definition of directions  The directions "forwards" (1), "backwards" (3), "right"...
  • Page 52 Foreword Information about the documentation View of the display-operating unit  NOTE 12,6 10:35 Views of operating statuses and values in the display of the display and operating unit are examples and partly dependent on the truck equipment. As a result, the displays shown of the actual operating statuses and values may vary.

  • Page 53: Environmental Considerations

    Foreword Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.
  • Page 54 Foreword Environmental considerations 56368011531 EN - 01/2021 - 05...

  • Page 55: Safety

    Safety...

  • Page 56: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal person who operates the truck or on whose authority the truck is used. The operating company must ensure that the truck is only used for its proper purpose and in compliance with the safety regulations set out in these operating instructions.

  • Page 57: Competent Person For Explosion Protection Checks

    Safety Definition of responsible persons Competent person for explosion protection checks Competent persons for explosion protection checks (hereinafter referred to as "competent person") are service technicians or persons who fulfil the following requirements: A completed vocational qualification that ● demonstrably proves their professional ex- pertise This proof must consist of a vocational qual- ification or a similar document.

  • Page 58: Drivers

    Safety Definition of responsible persons The competent person is permitted to work on industrial trucks manufactured by STILL that have been converted by Miretti. Drivers This truck must only be driven by persons who fulfil the following points: The driver must: Be physically and mentally able to drive the ●...
  • Page 59 Safety Definition of responsible persons The driver must: Have read and understood the operating in- ● structions; Have familiarised themselves with safe op- ● eration of the truck Adhere to the rules of behaviour in areas at ● risk of explosions Clothing The driver must wear protective equipment (protection suit, safety shoes, safety helmet,...

  • Page 60: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company prem- ises In many cases, company premises are restric- ted public traffic areas. NOTE The business liability insurance should be re- viewed to ensure that, in the event of any damage caused in restricted public traffic areas, there is insurance cover for the truck in respect of third parties.
  • Page 61 Safety Basic principles for safe operation We warn against installing and using restraint systems that have not been approved by the manufacturer. DANGER Risk of explosion from additional bores in the battery hood! Explosive gases can escape and can lead to potentially fatal injuries if they ex- plode.

  • Page 62: Changes To The Overhead Guard And Roof Loads

    Original parts, attachments and accessories are specially designed for this truck. We spe- cifically draw your attention to the fact that parts, attachments and accessories supplied by other companies have not been tested and approved by STILL. 56368011531 EN - 01/2021 - 05...

  • Page 63: Damage, Defects And Misuse Of Safety Systems

    Safety Basic principles for safe operation CAUTION Installation and/or use of such products may there- fore have a negative impact on the design features of the truck and thus impair active and/or passive driv- ing safety. We recommend that you obtain approval from the manufacturer and, if necessary, from the relevant regulatory authorities before installing such parts.

  • Page 64: Tyres

    Safety Basic principles for safe operation Tyres  DANGER Risk of explosion! In potentially explosive areas, wheels and tyres that do not meet explosion- protection regulations may lead to explo- sions in the surrounding atmosphere. – Only use approved, electrically con- ductive tyre types.

  • Page 65: Medical Equipment

    Safety Basic principles for safe operation Changing rim wheel parts ● Combining rim wheel parts from different ● manufacturers Therefore, the above-mentioned factors are prohibited. The following rules must be observed to en- sure stability: – Only use tyres with equal and permitted lev- els of wear on the same axle.

  • Page 66: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Basic principles for safe operation Medical equipment, such as pacemakers or hearing aids, may not work properly when the truck is in operation. – Ask your doctor or the manufacturer of the medical equipment to confirm that the medi- cal equipment is sufficiently protected against electromagnetic interference.
  • Page 67 Safety Basic principles for safe operation addition, be aware that the load centre of gravity may shift as a result of dynamic forces, such as braking. A load that is otherwise rest- ing safely on the fork arms may move for- wards and fall.

  • Page 68: Residual Risk

    Safety Residual risk Residual risk Residual dangers, residual risks DANGER Risk of explosion in the event of fire or smouldering! In the worst case scenario, polluted, damaged or defective components can result in fire or smouldering. If you smell fire: –...
  • Page 69 Safety Residual risk Risks can include: Escape of consumables due to leakages, ● rupture of lines and containers etc. Risk of accident when driving over difficult ● ground such as gradients, very smooth or uneven surfaces, or with poor visibility etc. Falling, tripping etc.

  • Page 70: Special Risks Associated With Using The Truck And Attachments

    Safety Residual risk – Drive with the load lowered. – Even with sideshifts, align the load as cen- trally as possible with the truck and trans- port in this position. – Avoid turning and driving diagonally across slopes or gradients. –...
  • Page 71 Safety Residual risk 56368011531 EN - 01/2021 - 05...

  • Page 72: Overview Of Hazards And Countermeasures

    Safety Residual risk Overview of hazards and countermeasures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.
  • Page 73 Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable Impermissible usage Provide operating in- German Ordinance on (improper usage) structions Industrial Safety and Health (BetrSichV) and German Health and la- bour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver...

  • Page 74: Danger To Employees

    Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable When operating driverless transport systems Roadway quality inad- Clean/clear roadways German Ordinance on equate Industrial Safety and Health (BetrSichV) Loading equipment in- Reposition load on pal- German Ordinance on correct/slipped Industrial Safety and...
  • Page 75 Safety Residual risk included in the hazard assessment. Attach- ments possess their own CE labelling and likewise are not included for that reason. The operating company must, however, select the type and equipment of the trucks so as to comply with the local provisions for deploy- ment.

  • Page 76: Safety Tests

    Safety Safety tests Safety tests Carrying out regular inspections on  the truck The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, the technical condi- tion of the truck must be completely tested with regard to accident safety.

  • Page 77: Explosion-Protection Checks

    Safety and Health once every three years by a competent person; see also "Definition of re- sponsible persons - Competent person". How- ever, as a manufacturer, STILL recommends Nächste Prüfung that this test is carried out annually. If the truck is subject to harsh application conditions, the interval between tests must be shortened.

  • Page 78: Testing The Electrical System

    Safety Safety tests Testing the electrical system DANGER Risk of explosion! Trucks to be used in potentially explo- sive areas are designed for certain ex- plosion groups, categories and tempera- ture ranges. In potentially explosive areas, trucks that do not meet explosion- protection regulations may lead to explo- sions in the surrounding atmosphere.
  • Page 79 Safety Safety tests NOTE The truck's electrical system and drive batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt- Component Measurements Test values test voltage age U Batt 50 VDC 24 volts > 1200 Ω Batt+ Battery 100 VDC...

  • Page 80: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables WARNING Consumables can be dangerous! – Observe general information and safety informa- tion regarding the use of consumables. – Refer to the chapter entitled "Safety regula- tions for handling consumables". –...

  • Page 81: Hydraulic Fluid

    Safety Safety regulations for handling consumables WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin! – Avoid contact and consumption. – Wear protective gloves. – After any contact, wash the skin with soap and water, and then apply a skin care product.

  • Page 82: Battery Acid

    Safety Safety regulations for handling consumables WARNING These fluids are pressurised during op- eration of the truck and are hazardous to your health. – Do not allow the fluids to come into contact with the skin. – Avoid inhaling spray. –...

  • Page 83: Disposal Of Consumables

    Safety Safety regulations for handling consumables WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, use appropriate PSA (rubber gloves, apron, protection goggles). – When working with battery acid, nev- er wear a watch or jewellery. –...

  • Page 84: Emissions

    Safety Emissions Emissions The values specified apply to a standard truck (compare the specifications in the "Technical data" chapter). Different tyres, lift masts, addi- tional units etc. may produce different values. Noise emissions The values were determined based on meas- uring procedures from the standard EN 12053 "Safety of industrial trucks - Test methods for measuring noise emissions", based on...
  • Page 85 Safety Emissions Vibrations The vibrations of the machine have been de- termined on an identical machine in accord- ance with the standards DIN EN 13059 "Safe- ty of industrial trucks - Test methods for meas- uring vibration" and DIN EN 12096 "Mechani- cal vibration - Declaration and verification of vibration emission values".
  • Page 86 Radiation In accordance with the guidelines DIN EN 62471:2009-03 (VDE 0837-471:2009-03), the STILL Safety- Light and the warning zone light (variants) are assigned to risk group 2 (medium risk) due to their photobiological hazard potential. 56368011531 EN - 01/2021 - 05...

  • Page 87: Overviews

    Overviews...

  • Page 88: Overview

    Overviews Overview Overview 56368011531 EN - 01/2021 - 05...
  • Page 89 Overviews Overview Lift mast Fork carriage Overhead guard Lift cylinder Driver's compartment Rear lighting Battery (in the battery compartment) Battery door Drive axle with traction motors Steering axle Front lighting Towing device Fork arms Counterweight NOTE The truck equipment may differ from the equipment shown.

  • Page 90: Driver's Compartment

    Overviews Driver's compartment Driver's compartment 6219_901-002_V3 56368011531 EN - 01/2021 - 05...
  • Page 91 Emergency off switch Brake pedal Key switch or pushbutton Bottom plate Compartment Pneumatic signal horn Display/control unit "STILL Easy Control" Steering column adjustment lever Operating devices for hydraulic and driving Reset button functions Explosion-protection warning lights Compartment for storing the operating in-...

  • Page 92: Shelves

    Overviews Shelves Shelves 6219_901-015_V3 56368011531 EN - 01/2021 - 05...
  • Page 93 Overviews Shelves WARNING Risk of accident caused by blocked pedals! Objects may fall into the footwell during travel as a result of steering or braking. They can slip between and under the pedals (3, 4). They then block the ped- als.

  • Page 94: Operating Devices And Display Elements

    Display for direction of movement of the Selected load programme with load dynam- truck ics display Brightness sensor Right-hand favourites bar "STILL Easy Control" is a third-generation dis- play-operating unit for industrial trucks. 56368011531 EN - 01/2021 - 05...
  • Page 95 – For information about the other display op- tions, see the original operating instructions entitled "STILL Easy Control display-operat- ing unit". The display-operating unit is attached to the armrest, except in trucks equipped with multi- lever operation.

  • Page 96: Explosion-Protection Warning Lights

    Overviews Operating devices and display elements Explosion-protection warning lights  DANGER Risk of explosion! During operation, the surface tempera- tures and insulation values of various components are monitored by sensors. – Do not operate the truck when a warning light is illuminated. The explosion-protection warning lights are lo- cated on the left-hand post, in the driver's field of view.
  • Page 97 Overviews Operating devices and display elements Push-and-turn version  6219_901-018 Turn version  NOTE This battery isolating switch can be secured in the "OFF" position by using a lead seal or a padlock to prevent the switch from being actu- ated without authorisation.

  • Page 98: Emergency Off Switch

    Overviews Operating devices and display elements Emergency off switch  The emergency off switch (1) is situated on the right-hand side of the steering column. It disconnects the drives from the power supply. Do not use this switch to park the truck safely. Reset button ...

  • Page 99: Multi-Lever Operation

    Overviews Operating devices and display elements Multi-lever operation 6219_003-004_V3 Drive direction switch Operating lever for attachments (variant) "Lift/lower" operating lever Function key for the "5th or 6th function" "Tilt" operating lever (variants) Operating lever for attachments (variant) Signal horn button Function key for the "5th function"...

  • Page 100: Double Mini-Lever

    Overviews Operating devices and display elements Double mini-lever Drive direction switch "F1" function key Cross lever "Attachments" "Lift mast" 360° lever Function key for the "5th function" Display field for the hydraulic functions Signal horn button 56368011531 EN - 01/2021 - 05...
  • Page 101 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 102: Triple Mini-Lever

    Overviews Operating devices and display elements Triple mini-lever Drive direction switch Signal horn button "Auxiliary hydraulics 1" operating lever "F1" function key "Auxiliary hydraulics 2" operating lever "Lift mast" 360° lever Function key for the "5th function" Display field for the hydraulic functions 56368011531 EN - 01/2021 - 05...
  • Page 103 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 104: Quadruple Mini-Lever

    Overviews Operating devices and display elements Quadruple mini-lever Drive direction switch Signal horn button "Tilt" operating lever "F1" function key "Auxiliary hydraulics 1" operating lever "Lift/lower" operating lever "Auxiliary hydraulics 2" operating lever Display field for the hydraulic functions Function key for the "5th function" 56368011531 EN - 01/2021 - 05...
  • Page 105 Overviews Operating devices and display elements NOTE In the dual-pedal version (variant), the drive ● direction switch (1) is used exclusively to activate the cruise control function (variant). The drive direction is selected exclusively via the pedals in the dual-pedal version. The authorised service centre can assign ●...

  • Page 106: Fingertip

    Overviews Operating devices and display elements Fingertip Signal horn button Drive direction switch LED for the "5th function" "Lift/lower" operating lever Function key for the "5th function" "Tilt" operating lever LED for the "Clamp release" "F1" function key Operating lever for "Auxiliary hydraulics 1" LED for "F1"...

  • Page 107: Joystick 4Plus

    Overviews Operating devices and display elements Joystick 4Plus 6219_003-210_V2 Horizontal rocker button for the "3rd and LED for the "clamp release" (variant) 4th hydraulic function": tilting the lift mast Slider for the "4th hydraulic function" Pictograms for the hydraulic functions: lift- Vertical rocker button for the "drive direction"...

  • Page 108: Travel Direction Selector And Indicator Module (Variant)

    Overviews Operating devices and display elements Travel direction selector and indica-  tor module (variant) The travel direction selector and indicator module is located on the steering column be- low the steering wheel. NOTE If the drive direction switch on the operating device is defective and the truck stops in a danger area, the drive direction selection lever on the travel direction selector and indicator...

  • Page 109: Operation

    Operation...

  • Page 110: Checks And Tasks Before Daily Use

    Operation Checks and tasks before daily use Checks and tasks before daily use Visual inspections and function checking WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and fall- ing.
  • Page 111 Operation Checks and tasks before daily use Component Course of action Perform a visual inspection to ensure that the Load chains chains are intact and have adequate and even ten- sion. Ensure that the attachments are mounted correctly in accordance with the operating instructions from the manufacturer.
  • Page 112 Check the setting of the warning zone light. Perform a visual inspection for integrity. Ensure cleanliness. Make sure that the antistatic belt(3) is still long Antistatic belt (3), corona electrode (4) enough to touch the ground in all situations. (See the following illustration.) The discharge wires of the corona electrode (4) must not touch the ground.

  • Page 113: Climbing Into And Out Of The Truck

    Operation Checks and tasks before daily use Depending on the tyres used, the truck is  fitted with one or more antistatic belts (3) and/or with a corona electrode (4). These components ensure that the truck cannot charge statically. – Do not use the truck if there is any damage or defects.
  • Page 114 Operation Checks and tasks before daily use WARNING Risk of injury when jumping out of the truck! If your clothing or jewellery (e.g. watch, ring etc.) be- comes stuck on a component while you are jumping onto or out of the truck, this can lead to serious inju- ries (from falling, loss of fingers etc.).

  • Page 115: Safety Information Regarding Electrostatic Charge

    Operation Checks and tasks before daily use Safety information regarding elec- trostatic charge DANGER Risk of explosion due to static charge! – Always wear an antistatic protection suit when working in a potentially ex- plosive area. This seat is covered in electrically con- ductive material.

  • Page 116: Adjusting The Swivelling Display-Operating Unit

    Operation Checks and tasks before daily use Adjusting the swivelling display-op- erating unit If the truck is equipped with multi-lever opera- tion, the display-operating unit is swivel-moun- ted on the right A-pillar. The display-operating unit can be swivelled from the neutral position to 15° to the left, right, up and down.

  • Page 117: Switching On The Battery Isolating Switch

    Operation Checks and tasks before daily use Switching on the battery isolating switch Push-and-turn version  – Turn the battery isolating switch (1) clock- wise until it unlocks. 6219_901-018 Turn version  – Turn the battery isolating switch (1) in a clockwise direction to the "ON"...

  • Page 118: Unlock The Emergency Off Switch

    Operation Checks and tasks before daily use Unlock the emergency off switch  – Turn the emergency off switch (1) clockwise until it pops out. Checking the emergency off func-  tion WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch disconnects the drives from the power supply.

  • Page 119: Operating The Signal Horn

    Operation Checks and tasks before daily use Operating the signal horn  The signal horn is used to warn people against imminent danger or to announce your intention to overtake. – Press the signal horn button (1). The signal horn sounds. 56368011531 EN - 01/2021 - 05...

  • Page 120: Using The Driver's Cab

    Operation Checks and tasks before daily use Operating the pneumatic signal  horn The signal horn is used to warn people against imminent danger or to announce your intention to overtake. Depending on the application and configura- tion, the truck is equipped with a pneumatic signal horn.
  • Page 121 Operation Checks and tasks before daily use DANGER Risk of fatal injury in the event of falling from the truck if it tips over! In order to prevent the driver from sliding underneath the truck and being crushed if the truck tips over, a restraint system must be in place and must be used.

  • Page 122: Checking The Brake System For Correct Function

    Operation Checks and tasks before daily use Checking the brake system for cor- rect function DANGER Risk of accident in the event of failure of the brake system! If the brake system fails, the truck will be insufficient- ly braked. –...
  • Page 123 Operation Checks and tasks before daily use – Accelerate the unladen truck in a clear area. – Press the brake pedal (1) firmly. The truck must decelerate noticeably. Checking the parking brake on a gradi- ent or a HGV ramp DANGER Risk to life if the truck rolls away! If the parking brake is not applied, the...

  • Page 124: Warming Up The Hydraulic Oil At Cold Ambient Temperatures

    Operation Checks and tasks before daily use NOTE When the emergency off switch is actuated, note the following: The electric brake is disabled. The truck no ● longer responds to the command issued by the accelerator pedal. The power steering is no longer available. ●...

  • Page 125: Checking The Steering System For Correct Function

    Operation Checks and tasks before daily use – Actuate all hydraulic lifting functions several times. NOTE During the warm-up phase, the load dynamics are limited to load program 1. Checking the steering system for  correct function DANGER If the hydraulics fail, there is a risk of accident as the steering characteristics have changed.

  • Page 126: Driver's Seat

    Operation Driver's seat Driver's seat Adjusting the driver's seat WARNING Risk of accident from sudden adjustment of the seat or of the seat backrest! The inadvertent adjustment of the seat or of the seat backrest can lead to uncontrolled movements by the driver.
  • Page 127 Operation Driver's seat Moving the driver's seat  – Raise the lever (1) and hold it in position. – Push the driver's seat into the required po- sition. – Release the lever. – Ensure that the driver's seat is securely en- gaged.
  • Page 128 Operation Driver's seat Adjusting the MSG 65/MSG 75 seat  suspension NOTE The MSG 65/MSG 75 driver's seat is designed for people weighing between 45 kg and 170 kg. The driver's seat can be adjusted to suit the weight of the individual driver. To ob- tain optimal settings for the seat suspension, the driver must perform the adjustment whilst sitting on the seat.
  • Page 129 Operation Driver's seat Adjusting the lumbar support (variant)  NOTE The lumbar support can be adjusted to suit the contours of the individual driver's spine. Ad- justing the lumbar support moves a convex support cushion into the upper or lower part of the backrest.

  • Page 130: Seat Belt

    DANGER Risk of injury if the truck tips over! Even if an approved restraint system is in use, there is still a residual risk that the driver could be injured if the truck tips over. This risk of injury can be reduced through the combined use of the re- straint system and the seat belt.
  • Page 131 Operation Driver's seat Fastening the seat belt  DANGER Mortal danger when driving without wearing a seat belt! If the seat belt is not fastened and the truck tips over or crashes into an obstacle, the driver can be thrown out of the truck.
  • Page 132 Operation Driver's seat Special feature for trucks with a cab (variant) If the truck is equipped with a cab (variant), it will have a cab door sensor. If the seat belt is not fastened and the cab door is not closed, the driving speed is limited to 4 km/h.
  • Page 133 Operation Driver's seat Releasing the seat belt – Push the red button (4) on the buckle (1).  – Slowly guide the belt tongue back to the re- tractor by hand. NOTE Slowly allow the seat belt to retract. The auto- matic blocking mechanism may be triggered if the belt tongue strikes the housing.

  • Page 134: Adjusting The Armrest

    Operation Driver's seat Adjusting the armrest DANGER There is a risk of accident if the armrest lowers suddenly, causing the driver to move in an uncon- trolled manner. This may result in unintentional actuation of the steering or operating devices and thus cause the truck or load to move in an uncontrolled fashion.

  • Page 135: Switching On

    Operation Switching on Switching on Switching on using the key switch WARNING All checks and tasks required before daily use must have been performed without any defects being iden- tified before switching on the truck. – Perform the "visual inspections and functional checks".

  • Page 136: Switching On Via Push Button (Variant)

    Operation Switching on – Refer to the chapter entitled "Display mes- sages". NOTE After connecting the battery, the correct charge state may not be displayed until the battery is placed under load by driving or lifting operations. Switching on via push button (var- iant) WARNING All checks and tasks required before daily use must...
  • Page 137 Operation Switching on – To switch off the truck, press the push but- ton (1) and hold for 1 second. NOTE For the variant with "Access authorisation with PIN code", see ● the relevant section. "FleetManager", see the "original operating ●...

  • Page 138: Display-Operating Unit

    Operation Display-operating unit Display-operating unit Operating the display-operating unit 08:20 7° 2,71 km/h 6219_003-310 The display-operating unit is operated using the control and enter keys (5...8) and the soft- keys (4, 10). The display (2) shows informa- tion about the current driving programme, load programme and the configuration of the fa- vourites bars (1, 3).

  • Page 139: Access Authorisation With Pin Code (Variant)

    Operation Display-operating unit Functions of the control and enter keys Designation Position Functions The softkeys correspond to the adjacent functions or input options. If functions have been stored in the favourites bars (1, 3), these functions can be switched on and off by pressing the Softkeys 4, 10 adjacent softkey.
  • Page 140 Operation Display-operating unit When the key switch is switched on, the  input menu ap- cess authorisation pears. All hydraulic functions and drive functions of the truck are blocked. In the StVZO (German Road Traffic Licensing Regulations) variant, the function of the hazard warning system (variant) is guaranteed.

  • Page 141: Access Authorisation For The Fleet Manager (Variant)

    Operation Display-operating unit – Press the softkey.  Service – Press the scroll keys until the  menu appears. Change PIN codes – Press the softkey. Change PIN codes Calibration – Follow the instructions on the display. Relieve hydraulics Shock sensor Change password (access auth.) Change PIN codes Fleet manager...
  • Page 142 Operation Display-operating unit NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is re- leased prematurely, the settings menu will close. – Stop the truck. –...
  • Page 143 Operation Display-operating unit The message  Fleet manager access appears. authorisation granted – To confirm, press the softkey. "Access authorisation for the fleet manager" is activated. The display returns to the settings Fleet manager menu. access authorisation If the password entered was incorrect, the granted message is dis-...
  • Page 144 Operation Display-operating unit – Press the scroll buttons until the  Change password (access menu appears. auth.) – Press the Version list Change password (ac- softkey. cess auth.) – Follow the instructions on the display. Calibration Relieve hydraulics Shock sensor Change password (access auth.) Fleet manager 6219_003-275_en...

  • Page 145: Description Of The Pre-Shift Check (Variant)

    Operation Pre-shift check Pre-shift check Description of the Pre-Shift Check (variant) The Pre-Shift Check is a guided dialogue in the display-operating unit. It also helps the driver conduct the necessary "visual inspec- tions and function checking" before everyday use. After the truck has been switched on, the driver must answer questions about the condi- tion of the forklift truck with "...

  • Page 146: Process

    The main display contains the message complete Pre-Shift Check, press This means that the Pre-Shift Check is still ac- tive and the truck functions are restricted. – To acknowledge the message, press the 6219_003-265_en softkey.

  • Page 147: All Questions

    Operation Pre-shift check – Switch on and check the function to be tes- ted, e.g. lighting. – Press the back button to go back to the  Pre-Shift Check. – Answer the question based on the result of Pre-S the function check. The next question appears.
  • Page 148 Operation Pre-shift check Is the tyre pressure correct? Is the overhead guard visibly damaged? Is the entry area or footwell dirty or slippery? Are the windows clean and undamaged? Are the maintenance lids securely closed? Is the battery door/hood undamaged and securely closed? Is the battery lock present, undamaged and closed? Is the battery connection assembly dirty or damaged (e.g.

  • Page 149: Defining The Question Sequence

    Operation Pre-shift check Defining the question sequence The questions for the Pre-Shift Check can be defined in a random sequence or in a fixed se- quence. The random sequence is advisable, because the questions are then read more consciously by the driver. This means that there is no rou- tine aspect.

  • Page 150: Displaying The History

    Operation Pre-shift check The Pre-Shift Check menu appears.  – Press the "Question sequence" softkey. History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en Pressing the softkey allows fixed or random  question sequences to be selected. The orange activation bar displays the current selection.
  • Page 151 Operation Pre-shift check – Press the softkey.  Service – Press the scroll keys until the  Pre- menu appears. Shift Check – Press the softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en 56368011531 EN - 01/2021 - 05...

  • Page 152: Defining The Shift Start

    Operation Pre-shift check The Pre-Shift Check menu appears.  – Press the "History" softkey. History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en The Pre-Shift Check results display opens.  This display shows all checks and questions that have been answered with the date and Pre-Shift Check results time.
  • Page 153 Operation Pre-shift check – Activate the "Access authorisation for the fleet manager". – Press the softkey.  Service – Press the scroll keys until the  Pre- menu appears. Shift Check – Press the softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration...
  • Page 154 Operation Pre-shift check The Pre-Shift Check menu appears.  – Press the "Shift start" softkey. History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en In this menu, you can call up the shift to be  defined and its start time. The orange activation bar indicates which shifts are activated.
  • Page 155 Operation Pre-shift check In this menu you can define the shift start.  – Enter the time using softkeys "0 to 9". – To , press the button. save Shift start 1 The shift start is now defined. The Pre-Shift Check is always requested from this shift start time.

  • Page 156: Resetting The Truck Restrictions

    Operation Pre-shift check – Press the scroll button to deactivate the  shift. – To confirm, press the button. Shift start 1 The time is shown in grey. The shift is deactivated. The display returns to the previous menu. There is no activation bar next to this shift.
  • Page 157 Operation Pre-shift check – Press the scroll keys until the  Pre- menu appears. Shift Check – Press the softkey. Pre-Shift Check Message list Maintenance interval Version list Pre-Shift Check Calibration Fleet manager 6219_003-268_en The Pre-Shift Check menu appears.  –...
  • Page 158 Operation Pre-shift check A question pops up asking if you want to reset  the truck restrictions. – To confirm, press the softkey. The full scope of the truck functions is now available. The display returns to the previous Reset the truck restrictions? The entry remains in the history menu.

  • Page 159: Driver Profiles

    Operation Driver profiles Driver profiles Driver profiles (variant)  This variant allows up to ten individual driver profiles to be created. The driver is greeted with the selected name after logging in. Once the softkey is pressed, the main display is shown.
  • Page 160 Operation Driver profiles equipped with these variants, drivers must se- lect their profiles manually. NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is re- leased prematurely, the settings menu will close.

  • Page 161: Creating Driver Profiles

    Operation Driver profiles The orange activation bar displays the current  selection. – Press the softkey for the required driver profile. Guido The driver profile is active. The driver is gree- ted with the selected name the next time that Horst the truck is switched on.
  • Page 162 Operation Driver profiles – Press the soft-  Driver profiles Driver profiles Truck information Display settings Configure favourites Truck settings 6219_003-293_en This menu provides storage space for saving  ten driver profiles. – Press the softkey for the required storage location.

  • Page 163: Renaming Driver Profiles

    Operation Driver profiles menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name The driver profile is active. The driver is gree- ted with the selected name after the next log- Any changes that drivers make to the settings Enter driver name while they are logged in are saved.
  • Page 164 Operation Driver profiles – Press the  Rename driver profiles softkey. Driving programme Rename driver profiles 6219_003-298_en menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name Renaming by the fleet manager –...
  • Page 165 Operation Driver profiles – Press the  Manage driver profiles softkey. Lift height preselection Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Fleet manager 6219_003-296_en – Press the  Rename driver profiles softkey. Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en 56368011531 EN - 01/2021 - 05...

  • Page 166: Deleting Driver Profiles

    Operation Driver profiles menu is displayed.  Driver name – Use the softkeys to enter the desired name. – To confirm, press the button. Driver name Enter driver name Horst = Clear = abc -> ABC = Save = Cancel 6219_003-295_en Deleting driver profiles The fleet manager has access authorisation to...
  • Page 167 Operation Driver profiles – Press the  Delete driver profiles softkey. Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en – Press the softkey for the driver profile to be  deleted. The driver profile is deleted. Guido Horst Lisa Driver 4 Available storage position 5 6219_003-294_en...

  • Page 168: Lighting

    – To access this sub-menu, push the but- Symbols for the lighting and their meanings Parking light Headlights Hazard warning system Rotating beacon STILL SafetyLight Warning zone light Front working spotlights Rear working spotlights Roof working spotlights Only the symbols of the lighting devices that are installed in the truck can be selected.

  • Page 169: Driving Lights

    Operation Lighting Driving lights  – To switch on the parking light (1), push the associated Softkey on the display-operating unit. The front side lights and the tail lights light up. – To switch on the driving light (2), press the associated Softkey on the display-operating unit.

  • Page 170: Working Spotlights

    Operation Lighting Working spotlights Front and rear working spotlights  – To switch on the front working spot- lights (3), push the associated Softkey on the display-operating unit. The front working spotlights light up. – To switch off the front working spot- lights (3), push the Softkey again.

  • Page 171: Working Spotlight For Reverse Travel (Variant)

    Operation Lighting Working spotlight for reverse travel (variant) In this equipment variant, a working spotlight for reverse travel is fitted on the rear of the overhead guard and provides optimum illumi- nation of the roadway during reverse travel. – Press the softkey.
  • Page 172 Operation Lighting – To switch on the left or right turn indicator,  move the lever (1) to the desired direction. 6219_003-098 The turn indicators and the turn indicator dis-  play (2) or (3) on the display-operating unit flash. 08:20 –...

  • Page 173: Hazard Warning System

    Operation Lighting Hazard warning system  Switching the hazard warning system on and off is different for trucks with and without the StVZO (German Road Traffic Licensing Regu- lations) variant. – To switch on the hazard warning system, push the associated Softkey on the display- operating unit.

  • Page 174: Stvzo Equipment

    This softkey is used to switch off all light- ing devices that are not permitted on roads subject to the StVZO. This relates to the following variants of lighting equipment: STILL SafetyLight ● Warning zone light ● Working spotlight ●...

  • Page 175: Rotating Beacon

    Operation Lighting NOTE This function is configured for the German StVZO ex works. Outside of Germany, observe the national ● regulations for the country of use. The authorised service centre can amend ● the function so that fewer lighting devices or more lighting devices are switched off.

  • Page 176: Still Safetylight (Variant)

    Danger of damage to eyes from looking into the STILL SafetyLight. Do not look into the STILL SafetyLight. The STILL SafetyLight is a visual warning unit designed to enable early detection of trucks in driving areas with low visibility (such as drive lanes, high racks), as well as at blind junc- tions.

  • Page 177: Warning Zone Light (Variant)

    Operation Lighting Warning zone light (variant)  WARNING Danger of damage to eyes from looking into the warning zone light. Do not look into the warning zone light. Adjust the warning zone light so as not to dazzle bystanders or the driver when climbing in and out of the truck.

  • Page 178: Tilt-Angle-Dependent Assistance Systems

    Operation Tilt-angle-dependent assistance systems Tilt-angle-dependent assistance systems Mast tilt angle display  Knowing the actual tilt angle of the lift mast makes it easier to place loads into stock and remove loads from stock. If the truck is equip- ped with the "mast tilt angle display" assis- tance system, the lift mast tilt angle (1) is shown on the display.
  • Page 179 Operation Tilt-angle-dependent assistance systems increasing work safety. Automatic mast verti- cal positioning reduces wear on various com- ponents, thereby reducing repair costs. The "automatic mast vertical positioning" as- sistance system consists of the following indi- vidual functions: Display of the "Automatic mast vertical posi- ●...

  • Page 180: Function Checking Of The Automatic Mast Vertical Positioning Function (Variant)

    Operation Tilt-angle-dependent assistance systems – See the section entitled "Calibrating the au- tomatic mast vertical positioning". Function checking of the automatic mast vertical positioning function (variant) CAUTION Risk of damage to property due to the lift mast collid- ing with racks or other objects! –...
  • Page 181 Operation Tilt-angle-dependent assistance systems NOTE The wizard requires access authorisation for the fleet manager. Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is released prematurely, the settings menu will close.
  • Page 182 Operation Tilt-angle-dependent assistance systems – Press the softkey.  Service – Press the scroll keys until the  Cal- menu appears. ibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en 56368011531 EN - 01/2021 - 05...
  • Page 183 Operation Tilt-angle-dependent assistance systems – Press the softkey.  Lift mast tilting The wizard for calibrating the load measure- ment is started. Lift mast tilting – Follow the instructions on the display. – If the message Calibration Load measurement appears, press the softkey.

  • Page 184: Load-Dependant Assistance Systems

    Operation Load-dependant assistance systems Load-dependant assistance systems Overload detection (variant) WARNING Risk of accident as a result of exceeding the permis- sible load capacity! This assistance system does not replace the driver's duty to observe the load capacity specified on the nameplate.

  • Page 185: Dynamic Load Control 1

    Operation Load-dependant assistance systems Dynamic Load Control 1 WARNING Risk of accident as a result of overloading! Dynamic Load Control 1 is not a safety function and does not release the driver from the duty to observe the information specified in the load capacity dia- gram! WARNING Risk of accident due to the slow response of the lift-...

  • Page 186: Dynamic Load Control 2

    Operation Load-dependant assistance systems NOTE When the fork carriage has been lowered be- low the lift heights mentioned above, the driver can deactivate the speed limitation again. Re- lease the accelerator pedal for a short period to do this. If a sensor belonging to Dynamic Load Con- trol 1 fails, the level of intervention from the function is increased to a maximum.
  • Page 187 Operation Load-dependant assistance systems The fork carriage is at least 2.1 m off the ground. With a triple lift mast or NiHo lift mast: ● The fork carriage is in the second lifting stage The truck centre of gravity has shifted to an ●...

  • Page 188: Load Measurement (Variant)

    Operation Load-dependant assistance systems When the combination of load weight and load centre of gravity exceeds the speci- fied value, the display moves into the red area. The dynamics of the lifting movements and tilting movements are significantly re- duced. –...

  • Page 189: Calibrating The Load Measurement

    Operation Load-dependant assistance systems WARNING Risk of accident as a result of exceeding the residual load capacity. If the weight determined by a load measurement ex- ceeds the permissible residual load capacity of the truck, the truck cannot be operated safely. –...
  • Page 190 Operation Load-dependant assistance systems – Apply the parking brake. – Press the button. – Press the "Settings" Softkey – Activate the "Access authorisation for the fleet manager". – Press the softkey.  Service – Press the scroll keys until the ...

  • Page 191: Precision Load Measurement (Variant)

    Operation Load-dependant assistance systems – Press the softkey.  Load measurement The wizard for calibrating the load measure- ment is started. Lift mast tilting – Follow the instructions on the display. – If the message Calibration Load measurement appears, press the softkey.
  • Page 192 Operation Load-dependant assistance systems – Press the "Precision load measure-  ment" (1) softkey. 0,70 --,-- 0,0° 6219_003-222 prompt is  Lower fork slightly displayed. – Lower the fork carriage. NOTE 0,70 Lower Slowly lowering the fork carriage increases the 0,0°...

  • Page 193: Tare Function

    Operation Load-dependant assistance systems If the calculation was successful, the meas-  ured weight of the load (1) is displayed. NOTE If the tare function was not active, the full 0,70 weight of the load being picked up is dis- 1,32 played.
  • Page 194 Operation Load-dependant assistance systems – Press the "Tare" softkey (1).  The activation bar next to the "Tare" sym- lights up. 0,70 --,-- 0,0° 6219_003-225 prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The message Zero- is displayed.

  • Page 195: Total Load (Variant)

    Operation Load-dependant assistance systems Total load (variant)  Use the "total load" variant to calculate the to- tal weight of multiple loads. The "total load" is an additional function of the "load measure- ment". It records the individual loads and stores up to three total loads.
  • Page 196 Operation Load-dependant assistance systems The first menu level appears. – Press the "Load" softkey – Press the "Total load" softkey The "Total load" menu appears. A total of  three load totals can be saved. The total load is explained here using 0,00 –...
  • Page 197 Operation Load-dependant assistance systems prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The Calc. ongo- message appears. 0,70 Lower If the calculation was successful, the load is 0,0° fork slightly displayed. Adding a load –...

  • Page 198: Efficiency And Drive Modes

    Therefore, on distances of up to ap- prox. 40 m, lower speeds are reached than would be the case if the efficiency mode was not activated. As in "STILL Classic" mode, the maximum speed is 20 km/h. has no influence on: Maximum speed ●...
  • Page 199 Operation Efficiency and drive modes Shut-off Seat switch Truck is stationary Drive direction Screen heating *No shut-off for StVZO (German Road Traffic Licensing Regulations) equipment (variant) 56368011531 EN - 01/2021 - 05...

  • Page 200: Switching Blue-Q On And Off

    Operation Efficiency and drive modes Switching Blue-Q on and off – To switch on Blue-Q efficiency mode, push the softkey The Blue-Q symbol appears on the dis- play/operating unit and Blue-Q efficiency mode is switched on. – To switch off Blue-Q efficiency mode, push the associated softkey again.

  • Page 201: Configuring Blue-Q

    The orange activation bar appears next to the pushed softkey. The main display button takes you to the main display. STILL Classic and sprint mode  The drive modes affect the handling of the truck. Two different drive modes are available:...
  • Page 202 The symbol disappears and the mode is switched off. The truck is then back in STILL Classic mode. Automatic switch off for sprint mode If the truck is operated in sprint mode at the maximum performance level, the truck will consume more energy.

  • Page 203: Driving

    Operation Driving Driving Safety regulations when driving Driving conduct The driver must follow the public rules of the road when driving in company traffic. 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 surfaces.
  • Page 204 There is a risk of acci- dent! – Do not use devices during travel or when handling loads. – Set the volume so that warning signals can still be heard. WARNING In areas where use of mobile phones is prohibited, use of a mobile phone or radio telephone is not per- mitted.

  • Page 205: Roadways

    The required aisle widths depend on the di- mensions of the load. Required aisle widths with pallet Aisle width [mm] With pallet With pallet Model Type 1000x1200 800x1200 crosswise lengthwise RX20-14C 6219 3186 3311 RX20-16C 6220 3186 3311 RX20-16 6221 3269 3394 RX20-16L 6222...
  • Page 206 Trucks can theoretically be driven on the as- cending and descending gradients specified in the following table. Maximum climbing capability Maximum climbing capability [%] Model Type With a load Without a load RX20-14C 6219 30.3 27.9 RX20-16C 6220 27.6 26.0 RX20-16 6221 28.0 27.4...
  • Page 207 Operation Driving Legend for model Compact Long Swing axle version The ascending and descending gradients must not exceed the gradients listed above and must have a rough surface. The top and bottom of the gradient must fea- ture smooth and gradual transitions to prevent the load from falling to the ground or the truck being damaged.

  • Page 208: Selecting Drive Programmes 1 To

    Operation Driving Rules for roadways and the working area It is only permitted to drive on routes author- ised for traffic by the operating company or its representatives. Traffic routes must be free from obstacles. The load must only be set down and stored in the designated locations.

  • Page 209: Configuring Drive Programmes A And B

    Operation Driving – If the drive programmes are saved as a fa-  vourite on a softkey, press the "Drive pro- gramme" softkey until the number of the desired drive programme is shown on the display. The number of dynamic bar segments indi- cates the driving dynamics of the selected drive programme.
  • Page 210 Operation Driving NOTE Access to the settings menu is only available if the truck is at a standstill and the parking brake is applied. If the parking brake is re- leased prematurely, the settings menu will close. – Stop the truck. –...

  • Page 211: Selecting The Drive Direction

    Operation Driving The settings are saved. – To cancel the setting, press the "Can- cel" softkey. The settings return to the most recently saved value. Press the button once to return to the pre- vious menu level without saving the changes. Selecting the drive direction ...

  • Page 212: Actuating The Drive Direction Switch With The Multiple-Lever Version

    Operation Driving NOTE When the seat is vacated, the selected drive direction is set to the "neutral position". To drive, the drive direction switch/drive direction selection lever must be actuated again. Actuating the drive direction switch  with the multiple-lever version –...

  • Page 213: Joystick 4Plus Version

    Operation Driving Actuating the drive direction switch  with the Fingertip version – For the "forwards" drive direction, push the drive direction switch (1) forwards. – For the "backwards" drive direction, pull the drive direction switch (1) backwards. NOTE If the drive direction switch (1) is defective and the truck stops in a danger area, the drive di- rection selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 214: Indicator Module Version

    Operation Driving Actuating the drive direction selec-  tion lever with the travel direction selector and indicator module ver- sion – For the "forwards" drive direction, push the drive direction selection lever (1) forwards. – For the "backwards" drive direction, push the drive direction selection lever (1) back- wards.
  • Page 215 Depending on the equipment, the following variants of warning units for reverse travel may be present: An acoustic signal will be heard. ● The STILL SafetyLight lights up. ● The hazard warning system flashes. ● – Press the accelerator pedal (3).

  • Page 216: Starting Drive Mode, Dual Pedal Version (Variant)

    If the truck still cannot be operated, park the truck securely and con- tact the authorised service centre.
  • Page 217 Depending on the equipment, the following variants of warning units for reverse travel may be present: An acoustic signal will be heard. ● The STILL SafetyLight lights up. ● The hazard warning system flashes. ● The truck travels in the selected drive direc- tion.

  • Page 218: Operating The Service Brake

    If the truck still cannot be operated, park the truck securely and con- tact the authorised service centre.

  • Page 219: Parking Brake

    Operation Driving DANGER If the service brake fails, the truck cannot brake sufficiently. There is a risk of accident! If the driver notices that the electrical braking effect has reduced by 50% and that the drive torque has decreased to 50% of the normal level, a component failure may have occurred.

  • Page 220: Applying The Mechanical Parking Brake

    Operation Driving Applying the mechanical parking brake DANGER There is a risk of fatal injury from being run over if the truck rolls away. – The truck must not be parked on a slope. – In emergencies, secure the truck us- ing wedges on the side facing down- hill.
  • Page 221 Operation Driving After the parking brake has been released, the previously selected drive direction is retained and is shown on the drive direction indicator. Special features when the parking brake is released Cause Effect The driver's seat is vacated and the parking The message Apply parking brake brake has not been applied.

  • Page 222: Actuating The Electric Parking Brake (Variant)

    Operation Driving DANGER Risk of fatal injury from being run over if the truck rolls away! If the parking brake is faulty, park the truck safely and secure it so that it cannot roll away. – If necessary, use wedges to prevent the truck from rolling away.
  • Page 223 Operation Driving Symbols for the parking brake in the display-operating unit Symbol Description The parking brake was applied automatically. Actuating the accelerator pedal automatically releases the parking brake. The parking brake was applied by pressing the push button. Pressing the push button is the only way to release the parking brake. Releasing the electric parking brake af- ter the truck has been switched on –...
  • Page 224 Operation Driving Automatically triggered actuation when the truck is stationary Cause Effect The electric parking brake will make a noise The driver's seat is vacated. when it is applied. The LED (2) lights up with a steady light. After a specified delay, the electric parking brake is applied with an audible sound.
  • Page 225 Operation Driving Actuation of the electric parking brake  when the truck is in motion Manual actuation when the truck is in motion – Press the push button (1). The truck is braked with the drive unit in ac- cordance with the selected drive programme. Once the truck has come to a standstill, the electric parking brake is applied with an audi- ble sound.

  • Page 226: Malfunctions In The Electric Parking Brake

    Operation Driving Cause Effect The truck will coast to a stop. Once the truck has come to a standstill, the electric parking brake is applied with an audible The emergency off switch is actuated. sound. The LED (2) lights up with a steady light. The symbol appears in the display.
  • Page 227 A possible cause of the malfunction is that the parking brake cannot determine whether the 6219_003-006_V2 truck is stationary or still in motion. The follow- ing section describes how to actuate the park- ing brake when it is faulty: Actuating a faulty parking brake when the...
  • Page 228 Operation Driving The parking brake is applied. NOTE Keeping the push button (1) pressed for an extended time or pressing it multiple times makes the truck brake harder. "Safe parking" function This function monitors the braking effect after the truck is parked. If a sensor is fitted on the lift mast (variant), the function also checks whether the fork carriage is lowered.
  • Page 229 Operation Driving DANGER Risk of fatal injury from being run over if the truck rolls away! If the parking brake is faulty, park the truck safely. Secure the truck to prevent it from rolling away. – To do this, strictly adhere to the following instruc- tions: –...
  • Page 230 Operation Driving NOTE If the parking brake is released via the emer- gency actuation process, it is possible to drive the truck at a low speed. The truck can then be moved out of the ● hazardous situation or to the repair location. Driving with a faulty parking brake requires ●...

  • Page 231: Steering

    Operation Driving Steering  DANGER Risk of accident! If the hydraulics fail, there is a risk of accident as the steering characteristics will have changed. – Do not operate the truck if it has a defective steer- ing system. – Steer the truck by turning the steering wheel (1) accordingly.

  • Page 232: Reducing Speed When Turning (Curve Speed Control)

    DANGER The Curve Speed Control function cannot override the physical limits of stability. Despite this function, there still is a risk of tipping! – Before using this function, familiarise yourself with the change to the driving and steering characteris- tics of the truck.

  • Page 233: Speed Reduction When The Fork Carriage Is Raised (Variant)

    Operation Driving Speed reduction when the fork car- riage is raised (variant) If the truck is equipped with this variant, the driving speed is automatically reduced to 5 km/h (forwards and backwards) from a lift height of more than 500 mm. If the fork carriage is lowered below this lift height again, the driving speed limitation is de- activated.

  • Page 234: Speed Limitation (Variant)

    Operation Driving NOTE There is a variant that prevents the truck from being driven when the cab door is open. The message Close cab door appears in the display. Speed limitation (variant)  The speed limitation (variant) is a function that can be configured by the fleet manager.
  • Page 235 Operation Driving – Activate the "Access authorisation for the fleet manager". The "Settings menu" opens on the display. – Press the softkey Truck settings – Press the softkey. Speed limitation The menu that opens offers the following func- tions: ● Permanent Enabling this function limits the speed until the fleet manager disables this function.

  • Page 236: Cruise Control (Variant)

    Operation Driving Cruise control (variant)  The "cruise control" assistance function allows the driver to maintain a constant truck speed over a reasonable distance. In addition, the cruise control function can be used to comply with any speed restriction that is in force on the company's premises.
  • Page 237 Operation Driving – Press the "cruise control" softkey.  The orange-coloured activation bar next to the 08:20 "cruise control" softkey lights up. The cruise control function is ready. The greyed-out "cruise control" symbol (1) appears on the display. Taking the cruise control function off standby Pressing the "cruise control "...
  • Page 238 Operation Driving – Actuate the drive direction switch (2) for for-  wards travel. NOTE In the dual-pedal version (variant), the drive direction switch (2) is used exclusively to acti- vate and deactivate the cruise control function (variant). 56368011531 EN - 01/2021 - 05...
  • Page 239 Operation Driving The cruise control function is active. The cur-  rent speed is saved. 08:20 Two beeps signal that the cruise control func- tion is active. The symbol (4) appears in black in the display. – Take your foot off the accelerator pedal. The truck continues to drive at the selected speed until the cruise control function is deac- tivated.
  • Page 240 Operation Driving Other conditions that will cause the truck con- trol unit to deactivate the cruise control func- tion are: Vacating the driver's seat ● Truck speed less than 2.5 km/h. ● Speed limit set to less than 4.5 km/h. ●...

  • Page 241: Parking

    Operation Parking Parking Parking the truck securely and switching it off DANGER There is a risk of fatal injury from being run over if the truck rolls away. – Do not park the truck on a gradient. – In emergencies, secure the truck us- ing wedges on the side facing down- hill.
  • Page 242 Operation Parking – Lower the fork carriage to the ground.  – Tilt the lift mast forwards until the tips of the fork arms rest on the ground. – If attachments (variant) are fitted, retract the working cylinders; see the chapter entitled "General instructions for controlling attach- ments".
  • Page 243 Operation Parking – In the "push button ignition" variant, press  the button. (1) Depending on the truck version: – Push the battery isolating switch (1).  6219_901-018 56368011531 EN - 01/2021 - 05...

  • Page 244: Wheel Chock (Variant)

    Operation Parking – Turn the battery isolation switch (1) anti-  clockwise up to the stop and into the "OFF" position. NOTE Switch keys, FleetManager cards (variant), FleetManager transponder chips (variant) and the PIN code for access authorisation (variant) must not be handed over to other persons un- less explicit instructions to this effect have been given by the responsible fleet manager.

  • Page 245: Lifting

    Operation Lifting Lifting Lifting system variants The movement of the fork carriage and the lift mast heavily depends on the following equip- ment: The lift mast with which the truck is equip- ● ped, see C hapter "Lift mast versions", ⇒ ...
  • Page 246 Operation Lifting NiHo lift mast (variant)  During lifting, the inner lift cylinder moves up to free lift (3) and then the outer lift cylinders raise the inner lift mast up to the maximum height (2). NOTE When lifting above the free lift, the fork car- riage always remains at the upper edge of the extending lift mast.

  • Page 247: Operating Devices For The Lifting System

    Operation Lifting Mono lift mast "Easy-View"  When lifting, the inner lift mast rises above the outer lift cylinders. The lift mast takes the fork carriage with it via a chain. In this scenario, the fork carriage rises at twice the speed of the inner lift mast.
  • Page 248 Operation Lifting Fingertip ● Joystick 4Plus ● For clarity, the movements of the lifting system  are referred to by the letters (A, B, C, D) in this subchapter. Lower the fork carriage Lift the fork carriage Tilting the lift mast forwards Tilting the lift mast backwards –...

  • Page 249: Controlling The Lifting System Using Multi-Lever Operation

    Operation Lifting Controlling the lifting system using  multi-lever operation DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 250 Operation Lifting Tilting the lift mast To tilt the lift mast forwards: – Move the "tilting" operating lever (2) in the direction of the arrow (C). To tilt the lift mast backwards: – Move the "tilting" operating lever (2) in the direction of the arrow (D).

  • Page 251: Controlling The Lifting System Using A Double Mini-Lever

    Operation Lifting Controlling the lifting system using a  double mini-lever DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 252 Operation Lifting – Move the "lift mast" 360° lever (3) in the di- rection of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" 360° lever (4) in the di- rection of the arrow (C). To tilt the lift mast backwards: –...

  • Page 253: Controlling The Lifting System Using A Triple Mini-Lever

    Operation Lifting Controlling the lifting system using a  triple mini-lever DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 254 Operation Lifting – Move the "lift mast" 360° lever (3) in the di- rection of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" 360° lever (4) in the di- rection of the arrow (C). To tilt the lift mast backwards: –...

  • Page 255: Controlling The Lifting System Using A Quadruple Mini-Lever

    Operation Lifting Controlling the lifting system using a  quadruple mini-lever DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...
  • Page 256 Operation Lifting – Move the "lifting/lowering" operating lev- er (3) in the direction of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" operating lever (4) in the direction of the arrow (C). To tilt the lift mast backwards: –...
  • Page 257 Operation Lifting Controlling the lifting system using  the Fingertip DANGER Reaching into or climbing between moving parts of the truck (e.g. lift mast, sideshifts, working equip- ment, load carrying devices etc.) can lead to seri- ous injury or death and is therefore prohibited. –...

  • Page 258: Controlling The Lifting System Using The Joystick 4Plus

    Operation Lifting Tilting the lift mast To tilt the lift mast forwards: – Move the "tilting" operating lever (1) in the direction of the arrow (C). To tilt the lift mast backwards: – Move the "tilting" operating lever (1) in the direction of the arrow (D).
  • Page 259 Operation Lifting the pictograms for the hydraulic functions are located in positions (2) and (4). The pictograms are arranged according to the directions of movement of the Joy- stick 4Plus (1) and the horizontal rocker but- ton (3). Lifting/lowering the fork carriage ...

  • Page 260: Dynamics Of The Hydraulic Movements

    Operation Lifting Fork carriage sideshift  To move the fork carriage to the left: – Push the Joystick 4Plus (1) to the left (E). To move the fork carriage to the right: – Push the Joystick 4Plus (1) to the right (F). Movements of the lifting system and meanings of the pictograms Lowering...

  • Page 261: Selecting Load Programs 1 To

    When the operating device is released, the ● hydraulic movement decelerates very quick- The fork carriage quickly comes to a stand- still. Minimum dynamics The hydraulic movement accelerates very ● slowly when actuating the operating device.

  • Page 262: Fork Wear Protection (Variant)

    Operation Lifting – If the load programs are saved as a favour-  ite on a softkey, press the "Load dynam- ics" softkey until the number of the de- sired load program is shown on the display. The number of dynamic bar segments shows the load dynamics of the selected load pro- gram.

  • Page 263: Changing The Fork Arms

    Operation Lifting Changing the fork arms DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! – Do not perform any work on trucks in potentially explosive areas.
  • Page 264 Operation Lifting WARNING If the fork arms fall on your legs, feet or knees during replacement, there is a risk of injury due to their weight. The space to the left and right of the fork is a danger area. –...
  • Page 265 Operation Lifting Removing  – Select the pallet according to the size of the fork arms. – Position the pallet to the left or right of the fork carriage. – Raise the fork carriage until the lower edges of the fork arms are approx. 3 cm higher than the height of the pallet.

  • Page 266: Fork Extension (Variant)

    Operation Lifting Fork extension (variant) DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! – Do not perform any work on trucks in potentially explosive areas.
  • Page 267 Operation Lifting WARNING There is a risk of tipping! The weight and dimensions of the fork extension af- fect the stability of the truck. The permissible weights stated on the capacity rating plate must be reduced in proportion to the actual load distance. If the truck is equipped with a fork extension ex works, then the capacity rating plate will already have been adjusted accordingly.

  • Page 268: Operation With Reversible Fork Arms (Variant)

    Operation Lifting – Insert the securing bolt located behind the fork back fully into the fork extension. – Insert the linch pin into the securing bolt and secure. Detaching – Remove the linch pin (3) from the securing bolt (2). –...
  • Page 269 Operation Lifting DANGER Risk of explosion! Only reversible fork arms that comply with explosion-protection regulations may be used in potentially explosive areas. These fork arms are specially coated to prevent sparks forming when coming in- to contact with the load or floor. –...

  • Page 270: Malfunctions During Lifting Mode

    Operation Lifting Reversible fork arms (1) can be used to reach  an additional lift height. The reversible fork arms are attached to the fork carriage in the same manner as standard fork arms. Loads may be lifted on and beneath the reversible fork arms.

  • Page 271: Hydraulic Blocking Function

    Operation Lifting – Notify your service centre Load chains not under tension DANGER Danger caused by a falling load! – Make sure that the chain(s) does (do) not become slack when lowering the load. Slack chains can, for instance, result from: Resting the fork carriage or the load on the ●...
  • Page 272 Operation Lifting NOTE Only the emergency steering function remains available. 56368011531 EN - 01/2021 - 05...

  • Page 273: Handling Loads

    Operation Handling loads Handling loads Safety regulations when handing  loads The safety regulations for handling loads are shown in the following sections. DANGER There is a risk to life caused by falling loads or if parts of the truck are being lowered. –...

  • Page 274: Before Picking Up A Load

    Operation Handling loads Before picking up a load Load capacity  The load capacity indicated for the truck on the capacity rating plate must not be excee- ded. The load capacity is influenced by the load centre of gravity and the lift height as well as by the tyres, if applicable.

  • Page 275: Picking Up Loads

    Operation Handling loads Example  Weight of load to be lifted: 880 kg (3) Load distance from fork back: 500 mm (1) Permitted lift height: 5230 mm (2) 5230 mm WARNING Risk of accident from the truck losing stability! The permissible loading of the attachments (variant) and the reduced load capacity of the combination of truck and attachment must not be exceeded.

  • Page 276: Danger Area

    Operation Handling loads DANGER Risk of accident from a falling load! When transporting small items, attach a load safety guard (variant) to prevent the load from falling on the driver. A closed roof covering (variant) should also be used. Removable roof panels may not be removed. Adjusting the fork ...

  • Page 277: Transporting Pallets

    Operation Handling loads DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position. If persons fail to leave the danger area despite warnings: –...

  • Page 278: Transporting Suspended Loads

    Operation Handling loads Transporting suspended loads  Before transporting suspended loads, consult the national regulatory authorities (in Germa- ny, the employer's liability insurance associa- tions). National regulations may place restrictions on these operations. Contact the relevant authori- ties. DANGER Suspended loads that begin to swing can result in the following risks: Impaired braking characteristics and steer- ●...

  • Page 279: Transporting Swinging Loads

    Operation Handling loads DANGER Risk of accident! When transporting suspended loads, never perform or end driving and load movements abruptly. Never drive on slopes with a suspended load. Transporting containers holding fluids as hanging loads is not permitted. Transporting swinging loads DANGER Risk of explosion from spark discharge! Suspended loads can swing uncontrolla-...
  • Page 280 Operation Handling loads Once the "automatic mast vertical positioning" assistance system has been calibrated, a pal- let can be stored horizontally in a rack when the truck is standing on a HGV ramp, for ex- ample. – Lift the fork carriage slightly. –...
  • Page 281 Operation Handling loads – Press the scroll keys until the  Cal- menu appears. ibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en – Press the softkey.  Lift mast tilting The wizard for calibrating the load measure- ment is started.
  • Page 282 Operation Handling loads Automatic mast vertical positioning  (variant) CAUTION Risk of damage to property due to the lift mast collid- ing with racks or other objects! – Before using the "automatic mast vertical position- ing" assistance system, position the truck at a suf- ficient distance from racks and other objects.

  • Page 283: Picking Up A Load

    Operation Handling loads – Tilt the lift mast forwards. The lift mast stops in the vertical position. NOTE The lift mast also stops in the vertical position if it is tilted forwards by ≥ 3° from a backward tilt. NOTE The automatic mast vertical positioning must be calibrated in order to ensure accuracy at all times.
  • Page 284 Operation Handling loads – Approach the rack carefully, brake gently  and stop just in front of the rack. – Position the forks.  – Set the lift mast to vertical. – Lift the fork carriage to the stacking height. CAUTION Risk of component damage! When the fork is inserted into the rack, take care not...
  • Page 285 Operation Handling loads – Insert the fork as far under the load as pos-  sible. Stop the truck as soon as the fork back is resting on the load. The load centre of gravity must be midway between the fork arms.
  • Page 286 Operation Handling loads – Lower the load while maintaining ground  clearance. – Tilt the lift mast backwards.  The load can be transported. 56368011531 EN - 01/2021 - 05...

  • Page 287: Transporting Loads

    Operation Handling loads Transporting loads  NOTE Observe the information in the chapter entitled "Safety regulations when driving". DANGER The higher a load is lifted, the less stable it be- comes. The truck can tip over. The load can fall. There is an increased risk of accidents.

  • Page 288: Shake Function (Variant)

    Operation Handling loads – Never drive with a load protruding to the  side (e.g. with the sideshift)! Shake function (variant) NOTE The shake function is intended only for short- term use, as it reduces the service life of the load chains due to the increased loading on them.
  • Page 289 Operation Handling loads Operation To activate the shake function: – Move the corresponding operating device for the "Lifting" function over the zero posi- tion four times in quick succession. The fork carriage moves as normal. The shake function is active after the fourth time the operating device is moved.
  • Page 290 Operation Handling loads Joystick 4Plus:  – Move the Joystick 4Plus (1) back and forth between positions (A) and (B) four times. Then continue to move the component in the same way. 6210_003-089 Double mini-lever:  – Move the 360° lever (2) back and forth be- tween positions (A) and (B) four times.
  • Page 291 Operation Handling loads Triple mini-lever:  – Move the 360° lever (3) back and forth be- tween positions (A) and (B) four times. Then continue to move the component in the same way. Quadruple mini-lever:  – Move the operating lever (4) back and forth between positions (A) and (B) four times.

  • Page 292: Setting Down A Load

    Operation Handling loads Setting down a load DANGER Risk of accident due to changed moment of tilt! The load centre of gravity and the moment of tilt move due to tilting the lift mast forwards with a raised load or due to the load slipping. The truck may tip forwards.

  • Page 293: Driving On Ascending And Descending Gradients

    Operation Handling loads – Lower the load until it rests securely on the  rack. DANGER Risk of accident! – Beware of any people in the danger area. – Ensure that the roadway behind you is clear. – Move the truck back until the fork arms can be lowered without touching the stack.

  • Page 294: Driving Onto Lifts

    Operation Handling loads – Reduce the driving speed on descending gradients. It is not permitted to drive on long ascending and descending gradients greater than 15% due to the specified minimum braking and sta- bility values. – Before driving on ascending and descend- ing gradients greater than 15%, consult the authorised service centre.
  • Page 295 Operation Handling loads Determining the total actual weight  – Park the truck securely and switch it off. – Determine the unit weights by reading the truck nameplate and, if necessary, the nameplate on the attachment (variant) and/or by weighing the load to be lifted. –...

  • Page 296: Driving On Loading Bridges

    Operation Handling loads Driving on loading bridges  DANGER Risk of accident from the truck crashing! Steering movements can cause the rear of the truck to veer off the loading bridge towards the edge. This may cause the truck to crash. For three-wheel trucks, the useable area of the load- ing bridge must be enclosed so that the rear drive wheel does not fall through.

  • Page 297: Depressurising The Hydraulic System

    Operation Depressurising the hydraulic system Depressurising the hydraulic system Need to depressurise the hydraulic system To enable additional hydraulic functions other  than the basic functions to be used, the truck has plug connectors (1) on the lift mast. Clamping and non-clamping attachments can be connected to these plug connectors.

  • Page 298: Wizard For Depressurising The Hydraulic System

    Operation Depressurising the hydraulic system Wizard for depressurising the hy- draulic system The hydraulics are depressurised using a wiz- ard on the display-operating unit. If this function is required for daily operation, contact your authorised service centre. The authorised service centre can enable the func- tion for the driver.
  • Page 299 Operation Depressurising the hydraulic system – Press the scroll keys until the  menu appears. lieve hydraulics – Push the soft- Relieve hydraulics key. The following message appears:  Caution, the lift mast may move! – To confirm, push the softkey.

  • Page 300: Depressurising The Hydraulic System Using Multi-Lever Operation

    Operation Depressurising the hydraulic system The following message appears:  Disengage all hydraulic axles, then switch off the truck – Depressurise the hydraulics; see the corre- sponding section. WARNING The movements of the load lift system present a risk of crushing. During the depressurisation process, the fork car- riage or the lift mast can move slightly.

  • Page 301: 6Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the additional functions The additional features include features such as the sideshift and fork adjustment. Clamping attachments are also connected to these hy- draulic circuits. These functions are controlled via hydraulic circuits three and four.

  • Page 302: Depressurising The Hydraulic System Using A Double Mini-Lever

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th and 6th hydraulic function" If the truck has a "5th and 6th hydraulic func- tion", their hydraulic circuits must also be dep- ressurised. The procedure is similar to the de- pressurisation of the hydraulic circuits for the basic functions and the additional functions.

  • Page 303: Depressurising The Hydraulic System Using The Double Mini-Lever And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 304: Depressurising The Hydraulic System Using A Triple Mini-Lever

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 305: Depressurising The Hydraulic System Using The Triple Mini-Lever And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 306: Depressurising The Hydraulic System Using A Quadruple Mini-Lever

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 307: 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 308: Depressurising The Hydraulic System Using The Fingertip

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 309: Depressurising The Hydraulic System Using The Fingertip And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 310: Depressurising The Hydraulic System Using The Joystick 4Plus

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  1 2 3 the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised. The procedure is similar to the depressurisation of the hydraulic circuits for the basic functions and the additional func- tions.

  • Page 311: Depressurising The Hydraulic System Using The Joystick 4Plus And The 5Th Function

    Operation Depressurising the hydraulic system Depressurising the hydraulic circuits for  the basic functions The basic functions include the first four hy- draulic functions. The basic functions are con- trolled via the first two hydraulic circuits. The basic functions are: Lifting the fork carriage ●...

  • Page 312: Special Feature For Clamping Attachments

    Operation Depressurising the hydraulic system – Start the "wizard for depressurising the hy- draulic system". Depressurising the hydraulic circuits for  the "5th hydraulic function" If the truck has a "5th hydraulic function", the hydraulic circuit of this function must also be depressurised.

  • Page 313: Exiting The Wizard

    Operation Depressurising the hydraulic system Push the operating device once in the ● "Open" direction. Push the operating device once in the ● "Close" direction. – Observe the section entitled "Clamp locking mechanism (variant)" in the chapter entitled "Attachments". Exiting the wizard –...

  • Page 314: Attachments

    If the truck is equipped with an integrated at- tachment (variant) at the factory, the specifica- tions in the STILL operating instructions for in- tegrated attachments must be observed. If attachments are fitted at the place of use,...
  • Page 315 Operation Attachments used, such as mirrors, a camera, a monitor system etc. – Observe the following warning notices. DANGER Risk of fatal injury from falling load! If attachments that hold the load by clamping it or ex- erting pressure on it do not have a second method of operating the function (lock), the load can work loose and fall off.
  • Page 316 Operation Attachments Alternating operation using an electrical switch valve If non-integrated attachments for alternating operation are used in conjunction with an elec- trical switch valve for the 5th and 6th hydraulic function, the electrical switch valve must oper- ate at 12 V. –...
  • Page 317 Operation Attachments specifications of the manufacturer and suppli- er of the attachment. – Observe the residual load capacity rating plate; see the chapter entitled "Picking up a load using attachments". 56368011531 EN - 01/2021 - 05...

  • Page 318: General Instructions For Controlling Attachments

    Operation Attachments General instructions for controlling attachments Attachments can be controlled via the first four hydraulic functions but also as a variant via the 5th or 6th function. The 5th or 6th function is activated via a button on the operating de- vice and by moving the operating device or additional push buttons.

  • Page 319: Attachment Example For The Connection Of The Auxiliary Hydraulics

    Operation Attachments WARNING Use of attachments can give rise to additional haz- ards such as a change in the centre of gravity, addi- tional danger areas etc. Attachments must only be deployed for their inten- ded use as described in the relevant operating in- structions.
  • Page 320 Operation Attachments In the menu for the available hydraulic axles for attachments, the designation Hydraulic specifies the connection of the corre- axle sponding auxiliary hydraulics. See also the section entitled "Adjusting the hydraulic speed for attachments" in this chapter. Attachment example for an attachment for ad- ...
  • Page 321 Operation Attachments NOTE The adjustment procedure requires access authorisation for the fleet manager. Access to the settings menu is only available if the truck is at a standstill and the parking brake is ap- plied. If the parking brake is released prema- turely, the settings menu will close.
  • Page 322 Operation Attachments This menu indicates the supply flow.  The return flow is shown in a lighter colour. The currently set speed of the hydraulic ● Auxiliary hydraulics 2 pump is given in The currently set supply flow rate is given in ●...

  • Page 323: Clamp Locking Mechanism (Variant)

    Operation Attachments The return flow is displayed in addition to the  supply flow at full brightness. To adjust the speed, push the "Plus" "Minus" softkey. Auxiliary hydraulics 2 – To save the setting, press the "Confirm" softkey. Forwards 3 900 1/min The settings are saved.
  • Page 324 Operation Attachments – See the section concerning the relevant op- erating device. 56368011531 EN - 01/2021 - 05...

  • Page 325: Controlling Attachments Using Multi-Lever Operation

    Operation Attachments Controlling attachments using multi-  lever operation In this version, the attachments (variant) are controlled using the operating levers (1, 3). The pictograms for the hydraulic func- tions (2, 4) are affixed to the operating levers. – Observe the pictograms (2) or (4). The pictograms are arranged according to the directions of movement of the operating lev- er (1) or (3).
  • Page 326 Operation Attachments NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary. Clamp locking mechanism NOTE For technical reasons, no clamp locking mech-...

  • Page 327: Controlling Attachments Using Multi-Lever Operation And The 5Th And 6Th Function

    Operation Attachments Controlling attachments using multi-  lever operation and the 5th and 6th function The function keys for the "5th and 6th func- tion" (1, 2) and the operating levers (3, 4) are used to control the "5th function" or the "6th function".
  • Page 328 Operation Attachments – Note the following attachment functions and pictograms. Picto- Attachment function gram Move the side shift frame or fork for- wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Push off the load...

  • Page 329: Controlling Attachments Using A Double Mini-Lever

    Operation Attachments Controlling attachments using a  double mini-lever In this version, the attachments (variant) are controlled using the "attachments" cross lev- er (1). The adhesive label bearing the picto- grams for the hydraulic functions (2) is affixed at the designated point. –...
  • Page 330 Operation Attachments NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary. Clamp locking mechanism ...

  • Page 331: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using the  double mini-lever and the 5th func- tion NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (3) and the cross lever (1) are used to control the "5th function".
  • Page 332 Operation Attachments Example using the pictograms for configura-  tion (1): If the "attachments" cross lever (1) is moved in the direction of the arrow (A), the fork is exten- ded. If the function key for the "5th function" (3) is actuated and the "attachments"...

  • Page 333: Controlling Attachments Using A Triple Mini-Lever

    Operation Attachments Controlling attachments using a tri-  ple mini-lever In this version, the attachments (variant) are controlled using the operating levers (1, 2). The adhesive label bearing the pictograms for the hydraulic functions (3) for the operating lever (2) and the adhesive label (4) for the op- erating lever (1) are affixed at the designated points.
  • Page 334 Operation Attachments Picto- Attachment function gram Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 335: Controlling Attachments Using The Triple Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using the  triple mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (2) and the operating lever (1) are used to control the "5th function".
  • Page 336 Operation Attachments Example using the pictograms for configura-  tion (1): If the operating lever (1) is moved in the direc- tion of the arrow (E), the sideshift moves to the left. If the function key for the "5th function" (2) is actuated and the operating lever (1) is moved in the direction of the arrow (E), the fork arms open.

  • Page 337: Controlling Attachments Using A Quadruple Mini-Lever

    Operation Attachments Controlling attachments using a  quadruple mini-lever In this version, the attachments (variant) are controlled using the operating levers (1, 2). The adhesive label bearing the pictograms for the hydraulic functions (3) for the operating lever (2) and the adhesive label (4) for the op- erating lever (1) are affixed at the designated points.
  • Page 338 Operation Attachments Picto- Attachment function gram Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 339: Controlling Attachments Using The Quadruple Mini-Lever And The 5Th Function

    Operation Attachments Controlling attachments using the  quadruple mini-lever and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the "5th function". The function key for the "5th function" (2) and the operating lever (1) are used to control the "5th function".

  • Page 340: Controlling Attachments Using The Fingertip

    Operation Attachments Picto- Attachment function gram Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.
  • Page 341 Operation Attachments Picto- Attachment function gram Move the side shift frame or fork for- wards Move the side shift frame or fork backwards Move the sideshift to the left Move sideshift to the right Adjust fork arms: open Adjust fork arms: close Release load retainer Clamp load retainer Open clamps...

  • Page 342: Controlling Attachments Using The Fingertip And The 5Th Function

    Operation Attachments It is not necessary to release the clamp lock- ing mechanism in order to close the clamp. – To close the clamp, pull the operating lev- er (2) backwards. Controlling attachments using the  1 2 3 Fingertip and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function.
  • Page 343 Operation Attachments Picto- Attachment function gram Adjust fork arms: open Adjust fork arms: close Rotate to the left Rotate to the right NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 344: Controlling Attachments Using The Joystick 4Plus

    Operation Attachments Controlling attachments using the  Joystick 4Plus In this version, the attachments (variant) are controlled via the Joystick 4Plus (1) and the slider (4). The adhesive label bearing the pic- tograms for the hydraulic functions (2) for the Joystick 4Plus (1) and the adhesive label (3) for the slider (4) are affixed at the designated points.
  • Page 345 Operation Attachments Picto- Attachment function gram Rotate to the left Rotate to the right Tip shovel over Tip shovel back NOTE The pictograms are affixed according to the attachment fitted at the factory. If an attach- ment with different functions is fitted, the au- thorised service centre must check that the pictograms bear the correct representation and must change them if necessary.

  • Page 346: Controlling Attachments Using The Joystick 4Plus And The 5Th Function

    Operation Attachments Controlling attachments using the  Joystick 4Plus and the 5th function NOTE For technical reasons, clamping attachments must not be controlled via the 5th function. Use shift key "F" (4) and the Joystick 4Plus (2) and the horizontal rocker button (1) to control the "5th function".

  • Page 347: Picking Up A Load Using Attachments

    Operation Attachments The attachment moves accordingly in the di- rections (E) or (F) as shown in the pictogram. – Push the horizontal rocker button (1) in the direction (G) or (H). The attachment moves accordingly in the di- rections (G) or (H) as shown in the pictogram. –...

  • Page 348: Auxiliary Equipment

    Operation Auxiliary equipment Auxiliary equipment General note Depending on which zone the truck has been modified for, the number of pieces and the ap- pearance of auxiliary equipment will vary. FleetManager (variant) FleetManager is an equipment variant and can be fitted to the truck in different versions. The description and operation information can be found in the separate operating instructions for the corresponding FleetManager versions.
  • Page 349 Operation Auxiliary equipment Press softkey Operating stage 3rd time Hold (possible in all Washer operating stages) Front windscreen wiper and washer  – To activate the "On" operating stage, press the softkey (1). The "On" operating stage is activated. The symbol (3) appears –...
  • Page 350 Operation Auxiliary equipment Rear window wiper and washer  – To activate the "On" operating stage, press the corresponding softkey (5). The "On" operating stage is activated. The symbol (7) appears – To activate the "Intermittent mode" operat- ing stage, press the softkey again. The symbol (6) is shown with an orange back- ground.

  • Page 351: Filling The Washer System

    Operation Auxiliary equipment Filling the washer system  – Open the filler cap (1) of the washer sys- tem. – Fill the washer reservoir (2) with washer flu- id as described in the "Maintenance data ta- ble". CAUTION Damage due to the effects of frost! When water freezes, it expands.

  • Page 352: Ceiling Sensor (Variant)

    Operation Auxiliary equipment – To switch on the rear window heating, push  the associated softkey on the display-oper- ating unit. The rear window heating is switched on. – To switch off the rear window heating, push the softkey again. The rear window heating is switched off.
  • Page 353 Before the truck is able to acceler- ate to the maximum speed permitted for outdoor areas, the speed limitation must still be unlocked. To do this, release the accel- erator briefly and then operate the accelera- tor again.
  • Page 354 Operation Auxiliary equipment Changing the sensor settings NOTE The ceiling sensor system is supplied by STILL with the following factory settings: Sensitivity: High ● Ceiling height: 24 m ● – Park the truck securely and switch it off. – Turn the union nut (4) anti-clockwise to ...
  • Page 355 Operation Auxiliary equipment The sensor is adjusted using DIP switches (6).  – To access the DIP switches, open the cover on the underside of the sensor housing with the key (5). During this process, the two tabs of the key (5) fit into the recesses of the cover.
  • Page 356 Operation Auxiliary equipment Representation of the beam angle depending  on the sensitivity of the sensor that has been set, from (1) "low" to (4) "very high". The sensor has different beam angles de- 2 3 4 pending on the combination of range and sen- sitivity that has been set.
  • Page 357 Operation Auxiliary equipment Sensitivity Range Beam angle 42° 33° High (3) 22.5° 16 m 20° 24 m 15° 45° 43° Very high (4) 30° 16 m 22.5° 24 m 18° – After the adjustment, refit the cover. – Refit the ceiling sensor and connect it. –...

  • Page 358: Cab

    Operation Opening and closing the cab door  DANGER Risk of explosion due to static charge! The plastic parts on category 2 trucks are coated with a special antistatic paint. This paint prevents the build-up of an electrostatic charge in plastic compo- nents.

  • Page 359: Opening And Closing The Side Window

    Operation – Pull the handle (4). Unlock the door lock. – Open the cab door (3) by pulling it out- wards. Opening the cab door from the inside: – Take hold of the handle (2) and the latch (1). – Push in the latch. Push the cab door out- wards.

  • Page 360: Turning The Interior Lighting On Or Off (Variant)

    Risk of accident! – Do not operate the radio when driving or when handling loads. – Adjust the radio volume so that you can still hear warning signals. 56368011531 EN - 01/2021 - 05...

  • Page 361: Heating System (Variant)

    Operation Heating system (variant) DANGER There is a risk of poisoning if heavily polluted surrounding air is aspirated in- to the closed cab! – Do not operate the heating system in the vicinity of storage areas or similar areas in which fuel vapours or fine dust (e.g.
  • Page 362 Operation Operating devices of the heating sys-  The operating devices of the heating system include: Heating level control knob Fan control knob Air vent control knob Switching on the blower and heating system – Turn the fan control knob (2) to the desired blower position.
  • Page 363 Operation Switching off the heating system and blower – Turn the heating level control knob (1) in an anticlockwise direction until it reaches the stop. The heating system is shut off. – Turn the fan control knob (2) in an anti- clockwise direction until it reaches the stop.
  • Page 364 Operation Air conditioning (variant)  The air conditioning dries the air in the cab to prevent the glass panes misting up. The tem- perature of the air that is blown out is based on the heating level that has been set. The de- frost function can be used to de-ice the wind- screen quickly.

  • Page 365: Clipboard (Variant)

    Operation Clipboard (variant)  The removable clipboard (1) is an equipment variant. Push-up roof window (variant)  WARNING Risk of crushing! – When closing the roof window, do not reach be- tween the roof window and the overhead guard. – Do not reach in to touch the components as they are being closed.
  • Page 366 Operation – Use your left hand to take hold of the han- dle (5) on the roof window (1) and push upwards until the locking bolt (4) engages. The roof window (1) is held in the pushed-up position – To close the roof window, pull out the lock- ing bolt (4) with your right hand and keep hold of the locking bolt.

  • Page 367: Sun Visor And Sun Blind

    Operation Sun visor and sun blind  The truck can be equipped with a sun vi- sor (2), a sun blind for the roof (1) and a sun blind for the driver's view to the front (4). – To adjust the sun visor (2), grasp it and move it to the desired position.

  • Page 368: Trailer Operation

    Operation Trailer operation Trailer operation Safety information for trailer opera- tion DANGER Risk of explosion! Trailers, tow couplings and coupling pins that do not meet explosion-protection regulations can cause explosions in the surrounding atmosphere within potential- ly explosive areas! – Only use trailers, tow couplings and coupling pins that meet explosion- protection regulations.

  • Page 369: Towed Load

    Operation Trailer operation Towed load  DANGER There is an increased risk of accident when using a trailer. Using a trailer changes the truck handling character- istics. When towing, operate the truck such that the trailer train can be safely driven and braked at all times.

  • Page 370: Coupling Pin In The Counterweight

    Operation Trailer operation This truck is suitable for the occasional towing of trailers. If the truck is equipped with a tow- ing device, this occasional towing must not ex- ceed 2% of the daily operating time. The man- ufacturer must be consulted if the truck is to be used for towing on a more regular basis.
  • Page 371 Operation Trailer operation – Push the coupling pin (1) down, turn the pin  by 90° and pull it out. NOTE Exceptions for the RX20-14C and RX20-16C: Turn the coupling pin (1) by 90° and pull it out. – Adjust the height of the tiller. DANGER People can become trapped between the truck and the trailer.

  • Page 372: Tow Coupling Ro*244

    Operation Trailer operation – Push the coupling pin (2) down, turn the pin  by 90° and pull it out. – Slowly move the truck forwards and guide the tow-bar eye completely out of the re- cess (2) in the counterweight. –...
  • Page 373 Operation Trailer operation DANGER If you briefly leave the truck to couple or uncouple the trailer, there is a risk to life caused by the truck rolling away and running you over. – Apply the parking brake. – Lower the forks to the ground. –...
  • Page 374 Operation Trailer operation WARNING Risk of component damage if the tiller in the tow cou- pling is tilted! The tiller should be kept as horizontal as possible when towing. This ensures that the rotation range is sufficient at the top and bottom. The authorised serv- ice centre can adjust the assembly height for the tow coupling to the tiller height if necessary.
  • Page 375 Operation Trailer operation NOTE The coupling pin is correctly engaged if the control pin (3) does not protrude out of its guide. DANGER If the coupling pin drops out during towing, the trail- er will work loose and can no longer be controlled. Risk of accident! The control pin (3) must not protrude out of its guide.

  • Page 376: Towing Trailers

    Operation Trailer operation – Close the tow coupling by actuating the closing lever (1). NOTE To protect the lower coupling pin bush against contamination, always keep the tow coupling closed. Towing trailers  7090_900-011 – Drivers who are towing a trailer for the first time must practise driving with a trailer in a suitable area.

  • Page 377: Cold Store Application

    Operation Cold store application Cold store application  The truck is suitable for use in cold stores. Cold store equipment with low-temperature hydraulic oil may be required. The truck is equipped for two different types of application. The cold store symbol indicates the variant with cold store equipment that uses low-tem- perature hydraulic oil.
  • Page 378 Operation Cold store application WARNING Risk of accident due to restricted operational readi- ness! At very low temperatures, the display-operating unit requires a longer period of time to reach operational readiness. The truck is not ready for operation during this time. This status is shown in the display as follows: –...
  • Page 379 Operation Cold store application CAUTION Risk of component damage! The lead-acid batteries must not be left in the cold store overnight without power uptake or charging. – Charge the battery outside the cold store and operate the truck using a replacement battery.

  • Page 380: Display Messages

    Operation Display messages Display messages Behaviour when the explosion-pro-  tection warning lights are illumina- DANGER Risk of explosion! During operation, the temperatures and insulation values of various components are monitored by sensors. The explo- sion-protection warning lights indicate when limit values have been reached. If dangerous limit values are detected, the truck control unit automatically shuts down the drive unit.
  • Page 381 Operation Display messages NOTE Observe the "Actuating the reset button after automatic emergency shutdown" section in the chapter entitled "Procedure in emergen- cies". Traction motor and pump motor monitoring Surface temperature of the right- hand traction motor The maximum surface temperature of the right-hand traction motor has been reached.

  • Page 382: Messages

    Operation Display messages – Tow the truck out of the potentially explo- sive area. – See the section entitled "Towing" in the chapter entitled "Operating in special oper- ating situations". Actuating the reset button is prohibited in the event of an insulation fault. –...
  • Page 383 Operation Display messages Code Shown on display Cause/action The access authorisation (variant) is preventing the use of the truck. Log in - Enable the access authorisation. The battery charge state is too low for truck use. Battery empty - Charge the battery. V6905 V6985 The battery charge state is low.
  • Page 384 Operation Display messages Code Shown on display Cause/action The battery door is open. The truck will only move at a reduced speed. Close the battery door - Close the battery door. The lithium-ion battery is too cold. Battery too cold - Move the truck to a warmer environment.
  • Page 385 Operation Display messages Code Shown on display Cause/action If the truck is switched off without having first applied the parking brake, this message ap- Switch off truck? pears. - Apply the parking brake. If the truck is to be switched off although the parking brake is not applied, this message ap- Switch off truck any- pears.
  • Page 386 Operation Display messages Code Shown on display Cause/action The parking brake cannot be applied due to a technical fault. - Apply the parking brake according to the sec- Parking brake cannot be tion entitled "Malfunctions in the electric parking applied brake".
  • Page 387 Operation Display messages Code Shown on display Cause/action If the truck is equipped with an integrated charg- er (variant) and charging is complete, this mes- sage appears. Remove charging cable - Disconnect the charger plug from the plug connection on the truck. The charging button on the truck plug of the charging cable has been held down too long.
  • Page 388 Operation Display messages Code Shown on display Cause/action This message is not displayed during normal operation. Parameter calibration - Contact the authorised service centre. If the configured sequence for applying the re- straint systems is not observed, this message Seatbelt sequence appears.

  • Page 389: Messages About The Truck

    Operation Display messages Code Shown on display Cause/action If the battery experiences under-voltage or too high a temperature, this message appears. Sprint mode blocked — Sprint mode is no longer available. battery - Observe the previous message. If the temperature at the drive units is too high, this message appears.
  • Page 390 – Switch the truck off and on again. – If the message still appears, please contact the authorised service centre. The messages are sorted in ascending order according to their code:...

  • Page 391: Procedure In Emergencies

    Operation Procedure in emergencies Procedure in emergencies Emergency shutdown  WARNING No electric braking assistance is available if the emergency off switch or the battery isolating switch has been actuated. Actuating the emergency off switch (1) disconnects the drives from the power supply. Actuating the bat- tery isolating switch (2) disconnects the entire truck from the power supply.

  • Page 392: Actuating The Reset Button After Automatic Emergency Shutdown

    Operation Procedure in emergencies No power steering effect; the steering ● forces are increased by the remaining emergency steering function The "Curve Speed Control" system (auto- ● matic reduction in truck speed when corner- ing) does not function. Brake the truck using the service brake.
  • Page 393 Operation Procedure in emergencies DANGER Risk of explosion! Only the safety officer is authorised to order the reset button to be pressed. They must use a suitable measuring de- vice to determine that there is not a po- tentially explosive mixture of air in the area around the truck.

  • Page 394: Procedure If Truck Tips Over

    Operation Procedure in emergencies Procedure if truck tips over  DANGER If the truck tips over, the driver could fall out and slide under the truck with potentially fatal conse- quences. There is a risk to life. Failure to comply with the limits specified in these operating instructions, e.g.

  • Page 395: Emergency Driving Via The Drive Direction Switch/Drive Direction Selection Lever

    Operation Procedure in emergencies WARNING When glass is smashed there is a risk of injury caused by glass splinters! When the cab glass is smashed, splinters of glass can shoot into the face and cause damage to skin and eyes through cuts. When a pane of glass is smashed, the face should be turned away and cov- ered with the crook of the free arm.

  • Page 396: Emergency Lowering

    Operation Procedure in emergencies – Fasten the seat belt. – Release the parking brake. – Push the drive direction switch/drive direc- tion selection lever in the desired drive di- rection. – Press the accelerator pedal. – Drive the truck to a safe area and park the truck safely.
  • Page 397 Operation Procedure in emergencies – Remove the hexagon socket wrench (2)  from the compartment on the right next to the driver's seat. 6219_003-260 – Using the hexagon socket wrench, turn the  emergency lowering screw (3) a maximum of 1.5 revolutions to loosen it. WARNING The load is lowered! Unscrewing the emergency lowering screw regulates...

  • Page 398: Emergency Actuation Of The Electric Parking Brake (Variant)

    Operation Procedure in emergencies Emergency actuation of the electric parking brake (variant) DANGER There is a risk of fatal injury from being run over if the truck rolls away. The truck can roll away when the park- ing brake is released. –...
  • Page 399 Operation Procedure in emergencies – Lift the cover (2) and fold it up.  – Pull out the hand wheel (1). 6219_003-228 – Turn the hand wheel (1) round and then at-  tach it. Releasing the parking brake – To release the parking brake, push down the hand wheel (1) and gently turn it anti- clockwise until the lower limit stop is reached.

  • Page 400: Towing

    Operation Procedure in emergencies Towing  Safety information DANGER Risk of explosion through spark forma- tion! If the truck has to be towed out of a po- tentially explosive area, the towing vehi- cle and tow bar used must comply with explosion-protection regulations.
  • Page 401 Operation Procedure in emergencies DANGER There is a risk of fatal injury during manoeuvring! People can be crushed between the truck and towing vehicle during manoeuvring. The towing vehicle may only be manoeuvred and the tow bar may only be attached using a second person as a guide.
  • Page 402 Operation Procedure in emergencies CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the truck is switched on (under load), an arc will be produced. This can lead to erosion at the contacts, which considerably shortens the service life of the contacts.
  • Page 403 Operation Procedure in emergencies – After towing, secure the truck so that it can- not roll away, e.g. by applying the parking brake or by using wheel chocks. – Remove the tow bar. 56368011531 EN - 01/2021 - 05...

  • Page 404: Connecting And Disconnecting The Battery Male Connector

    Operation Connecting and disconnecting the battery male connector Connecting and disconnecting the battery male connector Connecting the battery male con- nector DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...
  • Page 405 Operation Connecting and disconnecting the battery male connector Category 2 version  NOTE The category 2 and category 3 versions of the trucks have different battery male connectors. The specific features of the category 2 version are described here. The battery male connec- tors on the category 2 version are non-inter- changeable.

  • Page 406: Disconnect The Battery Male Connector

    Operation Connecting and disconnecting the battery male connector – Ensure that the battery male connector (2)  and the plug connection (3) on the truck are dry, clean and free of foreign objects. – Take hold of the battery male connector by its handle (1).
  • Page 407 Operation Connecting and disconnecting the battery male connector Category 2 version  NOTE The category 2 and category 3 versions of the trucks have different battery male connectors. The specific features of the category 2 version are described here. The battery male connec- tors on the category 2 version are non-inter- changeable.
  • Page 408 Operation Connecting and disconnecting the battery male connector – Take hold of the battery male connector by  its handle (1). – Lift the joining plate (4). – Pull out the battery male connector (2) from the plug connection (3) on the truck and set it down safely.

  • Page 409: Handling The Lead-Acid Battery

    Operation Handling the lead-acid battery Handling the lead-acid battery Safety regulations for handling the battery DANGER There is a risk of explosion if non-ex- plosion-protected batteries are used! Batteries intended for use in potentially explosive areas are designed for certain explosion groups, categories and tem- perature ranges.
  • Page 410 Operation Handling the lead-acid battery CAUTION Potential for damage to the battery charger! Incorrect connection or incorrect opera- tion of the charging station or the battery charger may result in damage to compo- nents. – Follow the operating instructions for the charging station or battery charg- er and for the battery.
  • Page 411 Operation Handling the lead-acid battery WARNING Risk of crushing and shearing! The battery is very heavy. There is a risk of serious injury if any parts of the body are caught under the battery. There is a risk of injury if any parts of the body are wedged between the battery door and the edge of the chassis when the battery door is closed.
  • Page 412 Operation Handling the lead-acid battery – Keep the battery door open during charg- ing. – Do not place any metal objects on the bat- tery. – Fully open any protective structures (e.g. fabric-covered cab). – Have fire extinguishing equipment ready. Lifting accessories DANGER Risk of accident!
  • Page 413 Operation Handling the lead-acid battery – For information on handling battery acid, see the "Battery acid" section in the chapter entitled "Safety regulations for handling consumables". Damage to cables and battery male  connectors CAUTION There is a risk of short circuit if the ca- bles are damaged.

  • Page 414: Maintaining The Battery

    Operation Handling the lead-acid battery Maintaining the battery DANGER Danger to life and limb! – Observe the instructions in the chapter entitled "Safety regulations when handling the battery". WARNING Battery acid is toxic and corrosive! – Observe the safety regulations in the chapter enti- tled "Battery acid".

  • Page 415: Checking The Battery Condition, Acid Level And Acid Density

    Operation Handling the lead-acid battery Checking the battery condition, acid level and acid density WARNING The electrolyte (diluted sulphuric acid) is poisonous and corrosive! – Observe the safety regulations for handling battery acid; see the chapter entitled "Battery acid". – Wear personal protective equipment (rubber gloves, apron and protection goggles).
  • Page 416 Operation Handling the lead-acid battery – A defective battery must only be repaired by the authorised service centre. – Open the filler cap (1) and check the acid  level. For batteries with "caged cell plugs", the liquid must reach the bottom of the cage. For batteries without "caged cell plugs", the liquid must reach a height of approx.

  • Page 417: Checking The Battery Charge Status

    Operation Handling the lead-acid battery Checking the battery charge status  CAUTION Deep discharges shorten the service life of the bat- tery. Deep discharge begins when the battery charge dis- play is red (3) (0% of the available battery capacity, i.e.
  • Page 418 Operation Handling the lead-acid battery DANGER Risk of explosion due to old batteries! Old and inadequately maintained batteries can cause excessive gas emissions and excessive heating dur- ing charging. The increased production of explosive gas can lead to an explosion. –...
  • Page 419 Operation Handling the lead-acid battery CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the truck is switched on (under load), an arc will be produced. This can lead to erosion at the contacts, which considerably shortens the service life of the contacts.
  • Page 420 Operation Handling the lead-acid battery DANGER Risk of explosion! The battery door must be kept slightly open during the charging process to en- sure sufficient ventilation. The battery door can be locked in the open  position using a support bracket. –...

  • Page 421: Equalising Charging To Preserve The Battery Capacity

    Operation Handling the lead-acid battery CAUTION There is a risk of short circuit if the ca- bles are damaged. Do not crush the battery cable when closing the battery cover. – Ensure that the battery cable does not come into contact with the battery door.
  • Page 422 Operation Handling the lead-acid battery – Observe the information in the operating in- structions of the battery charger regarding how to perform an equalising charge. Starting the equalising charge – Charge the battery. – After charging, leave the battery in the charger.

  • Page 423: Replacing And Transporting The Battery

    Operation Replacing and transporting the battery Replacing and transporting the battery General information on replacing the battery DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...

  • Page 424: Changing To A Different Battery Type

    Operation Replacing and transporting the battery Changing to a different battery type The truck can be converted to a different bat- tery type and capacity. The new battery capacity and new battery type must be set in the display-operating unit. If this is not done, the actual battery dis- ●...

  • Page 425: Opening/Closing The Battery Door

    Operation Replacing and transporting the battery – Press the Back button – Press the softkey. Capacity – Press the corresponding softkey for the bat- tery capacity according to the nameplate of the battery. The activation bar next to the selection lights The main display button takes you to the main display.
  • Page 426 Operation Replacing and transporting the battery Locking the battery door into a slightly  open position The battery door can be locked in the open position using a support bracket. – Pull the support bracket (1) up and out of its support eyelet (2) on the battery door.
  • Page 427 Operation Replacing and transporting the battery WARNING Risk of accident due to the battery door opening! An unlocked battery door may open if the truck de- celerates sharply. If the battery door opens while driving, there is risk of damage from a collision. –...

  • Page 428: Replacing The Battery Using A Truck

    Operation Replacing and transporting the battery Replacing the battery using a truck  Preparing WARNING Risk of accident! The load capacity of the truck in use must at least match the battery weight (see the battery name- plate). – Observe the nameplates of the battery and of the change frame.
  • Page 429 Operation Replacing and transporting the battery – Disconnect the battery male connector.  – Disconnect the potential equalisation con- nection if necessary. WARNING Risk of crushing or shearing! No one must stand directly next to the battery or between the battery and the truck when removing and inserting the battery.
  • Page 430 Operation Replacing and transporting the battery Transporting and setting down the bat- tery WARNING Risk of crushing or shearing! The battery must be transported very carefully, i.e. at a low speed, using a slow steering movement and careful braking. – Do not use the methods described here to trans- port the battery over long distances.
  • Page 431 Operation Replacing and transporting the battery CAUTION Risk of damage! – Position the battery cables on the bat- tery in such a way that the cables cannot be crushed either when re- moving or inserting the battery or when closing the battery door. Once the battery is correctly positioned in the battery compartment: –...
  • Page 432 Operation Replacing and transporting the battery – Insert the battery male connector fully into  the plug connection on the truck. – Close the battery door. 6219_901-010 56368011531 EN - 01/2021 - 05...

  • Page 433: Replacing The Battery Using A Lift Truck And A Battery Change Frame

    Operation Replacing and transporting the battery Replacing the battery using a lift truck and a battery change frame WARNING Risk of accident due to overloading the lift truck! The load capacity of the lift truck used must at least match the weight of the battery and the weight of the change frame.
  • Page 434 Operation Replacing and transporting the battery – Adjust the stop (1) so that the battery will later be centred on the change frame. NOTE To pick up batteries with large trays, fasten the side stop in the outer bores, e.g. tray 366. The battery must lie against the side stop (1) and against the stops (3).
  • Page 435 Operation Replacing and transporting the battery NOTE Battery replacement using a hand pallet truck is allowed only if using the change frame per- mitted for this purpose. – For permitted combinations, observe and comply with the following table. Tray Battery type Battery change frame Lead-acid battery, circuit B 56364206701...
  • Page 436 Operation Replacing and transporting the battery – Disconnect the battery male connector.  – Disconnect the potential equalisation con- nection if necessary. WARNING Risk of crushing or shearing! No one must stand directly beside the battery or between the battery and the lift truck when removing or inserting the battery.
  • Page 437 Operation Replacing and transporting the battery – Carefully drive the lift truck under the bat-  tery until the battery touches the stops (1) and (2). – Carefully lift the battery until it maintains a sufficient distance from the seating and from the chassis above.
  • Page 438 Operation Replacing and transporting the battery Installing the battery  – Pick up the battery and transport it to the truck. – Position the battery cable on the battery so that it will not become trapped when the battery is inserted. –...
  • Page 439 Operation Replacing and transporting the battery – Close the battery lock.  – Insert the battery male connector fully into  the plug connection on the truck. CAUTION Potential for damage to the battery male connector! If the battery male connector is connected while the truck is switched on or the battery charger is under load, a transition spark will be produced.

  • Page 440: Transporting The Lead-Acid Battery By Crane

    Operation Replacing and transporting the battery Transporting the lead-acid battery  by crane DANGER There is risk of fatal injury from being struck by falling loads! – Never walk or stand underneath sus- pended loads. The tray for the lead-acid battery (1) is equip- ped with four lifting eyes.

  • Page 441: Cleaning The Truck

    Operation Cleaning the truck Cleaning the truck Note on flame proof enclosures Depending on the category of the truck, it can be equipped with one or more flame proof en- closures. These flame proof enclosures con- tain components of the truck control unit and other electrical and electronic components.
  • Page 442 Operation Cleaning the truck DANGER Risk of fire due to flammable cleaning materials! Flammable cleaning materials can be ig- nited by hot components. – Do not use any flammable cleaning materials. DANGER Risk of fire due to flammable materials! Deposits and solids can be ignited by hot components, e.g.
  • Page 443 Operation Cleaning the truck CAUTION Abrasive cleaning materials can damage the surfa- ces of components! Using abrasive cleaning materials that are unsuitable for plastics can cause plastic parts to dissolve or be- come brittle. The screen on the display-operating unit could become cloudy.

  • Page 444: Cleaning The Electrical System

    Operation Cleaning the truck Cleaning the electrical system WARNING Danger of electric shocks due to residual capacity! – Never reach into the electrical system with your bare hands. CAUTION Cleaning electrical system parts with wa- ter can damage the electrical system. Cleaning electrical system parts with wa- ter is forbidden! –...

  • Page 445: Cleaning The Windows

    Operation Cleaning the truck – Immediately after drying the chain, spray it with chain spray. Move the chain several times during this procedure. For chain spray specifications, refer to the "Maintenance data table". ENVIRONMENT NOTE Dispose of any fluid that has been spilled or collected in the collection vessel in an environ- mentally friendly manner.

  • Page 446: After Cleaning

    Operation Cleaning the truck After cleaning  CAUTION Risk of short circuit! Ingress of moisture or dirt into the battery male con- nector and plug connection can lead to an electrical short circuit. – Use compressed air to dry the battery male con- nector and the plug connection before connecting them.

  • Page 447: Transporting The Truck

    Operation Transporting the truck Transporting the truck Transport DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...
  • Page 448 Operation Transporting the truck DANGER Risk of accident from the truck crashing! Steering movements can cause the rear of the truck to veer off the loading bridge towards the edge. This may cause the truck to crash. – Before driving across a loading bridge, ensure that the loading bridge is properly attached and secured.
  • Page 449 Operation Transporting the truck Lashing down DANGER The load may slip if the lashing straps/tension belts slip! The truck must be lashed securely so that it cannot move during transportation. – Make sure that the lashing straps/tension belts are tightened securely and that the pads cannot slip off.

  • Page 450: Crane Loading

    Operation Transporting the truck – Position the lashing straps/tension belts for  the coupling pin around the coupling pin as shown and lash the truck at an angle to- wards the front. Crane loading Crane loading is only intended for transporting the complete truck, including the lift mast, for its initial commissioning.

  • Page 451: Decommissioning

    Operation Decommissioning Decommissioning Safety information for shutting down and restarting DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work may be performed on the truck in potentially explosive areas. –...
  • Page 452 Operation Decommissioning Measures to be implemented before de- commissioning – Clean the truck thoroughly; see the chapter entitled "Cleaning the truck". – Lift the fork carriage to the stop several times. – Tilt the lift mast forwards and backwards several times and, if fitted, move the attach- ment repeatedly.

  • Page 453: Use After Storage Or Decommissioning

    Operation Decommissioning CAUTION Tyre deformation as a result of continuous loading on one side! Have the truck raised and jacked up by the author- ised service centre so that all wheels are off the ground. This prevents permanent deformation of the tyres.
  • Page 454 Operation Decommissioning that were carried out before initial commis- sioning. – The explosion protection inspection must be performed by the authorised service centre. – Perform the "visual inspections and func- tional checks". The following points in particular must be checked: Drive ●...

  • Page 455: Maintenance

    Maintenance...

  • Page 456: Safety Regulations For Maintenance

    Maintenance Safety regulations for maintenance Safety regulations for maintenance General information DANGER Risk of explosion! Working on a truck within potentially ex- plosive areas can lead to explosions in the surrounding atmosphere. No work must be performed on the truck in potentially explosive areas! –...

  • Page 457: Working On The Hydraulic Equipment

    Maintenance Safety regulations for maintenance – Avoid collisions with the ceiling of the hall and the resultant damage. Working on the hydraulic equipment The hydraulic system must be depressurised prior to all work on the system. Working on the electrical equipment DANGER Risk of explosion! Work on the electrical equipment must...

  • Page 458: Lifting And Jacking Up

    Maintenance Safety regulations for maintenance Lifting and jacking up DANGER There is a risk to life if the truck tips over! If not raised and jacked up properly, the truck may tip over and fall off. Only the hoists specified in the workshop manual for this truck are allowed and are tested for the necessary safety and load capacity.
  • Page 459 Maintenance Safety regulations for maintenance Removing the lift mast DANGER Risk of accident! This work must only be performed by an authorised service technician. – Commission the authorised service centre to re- move the lift mast. Securing the lift mast against falling off DANGER Risk of accident! This work must only be performed by an authorised...

  • Page 460: General Maintenance Information

    Maintenance General maintenance information General maintenance infor- mation Personnel qualifications DANGER Risk of explosion! The operating company is responsible for its work equipment in accordance with the German Ordinance on Industrial Safety and Health (BetrSichV). It is the operating company's responsibility to en- sure that testing and repairs are carried out properly.

  • Page 461: Maintenance Of The Explosion Protection Components

    Maintenance General maintenance information Maintenance personnel for batteries Batteries must only be charged, serviced, and replaced by personnel who have received ap- propriate training in accordance with the in- structions from the manufacturers of the bat- tery, battery charger and truck. –...

  • Page 462: Information For Carrying Out Maintenance

    Maintenance General maintenance information According to the standard "DIN EN 1755:2015-02" they include: checking the flame proof enclosure of the ● truck control unit and the restricted breath- ing housing for damage and integrity compliance with the minimum intervals for ●...
  • Page 463 Maintenance General maintenance information Maintenance timeframe If maintenance is needed, the message appears on the Service required display. – Arrange for the authorised service centre to perform the maintenance work on the truck. – The maintenance check lists indicate the maintenance work that is due.

  • Page 464: Monthly

    Maintenance General maintenance information The "Settings menu" opens on the display. – Press the softkey. Service The "Service menu" opens on the display. – Press the Maintenance interval softkey. This menu shows the operating hours remain- ing until the next scheduled maintenance in- terval or the latest date of the next scheduled maintenance interval.

  • Page 465: Maintenance By The Authorised Service Centre: Explosion-Protection Components - 1000 Hours/Yearly

    Maintenance General maintenance information At operating hours 1050 1200 1350 1500 1650 1800 1950 2100 2250 2400 2550 2700 2850 3000 3150 3300 3450 3600 3750 3900 4050 4200 4350 4500 4650 4800 4950 5100 5250 5400 5550 5700 5850 6000 6150 6300...

  • Page 466: Maintenance - 1000 Hours/Annually

    Maintenance General maintenance information Maintenance - 1000 hours/annually At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Chassis, bodywork and fittings Check the chassis for cracks. Check the overhead guard/cab and panes of glass for damage. Check that the cab door sensor is working correctly and check for damage.
  • Page 467 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check that the steering axle is securely mounted, check for leaks and apply grease. Check the steering stop. Brake system Check the condition of all mechanical brake parts and check that they are working correctly.
  • Page 468 Maintenance General maintenance information At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check the hydraulics blocking function (ISO valve). Check the oil level. Lift mast Check the mast bearings for damage. Lubricate the mast bearings and check the tightening torque.

  • Page 469: Maintenance - 3000 Hours/Every Two Years

    Maintenance General maintenance information Maintenance - 3000 hours/every two years Carried At operating hours 3000 6000 9000 12000 15000   Note Perform all 1000-hour maintenance work. Power unit Change the gearbox oil in the drive wheel unit. Replace the bleeder screws on the drive wheel units. Hydraulics Change the hydraulic oil.

  • Page 470: Quality And Quantity Of The Required Operating Materials

    Maintenance General maintenance information Quality and quantity of the required operating materials Only the operating materials specified in the maintenance data table may be used. – The required consumables and lubricants can be found in the maintenance data table. Oil and grease types of a different quality must not be mixed.

  • Page 471: Lubrication Plan

    Maintenance General maintenance information Lubrication plan Code Lubrication point Swing axle: two lubricating nipples on each side of the steering axle on the steering arm Steering turntable: not present Sliding surfaces on the lift mast Load chains 56368011531 EN - 01/2021 - 05...
  • Page 472 Maintenance General maintenance information Code Lubrication point One lubricating nipple on each of the two lift mast bearings The respective lubricant specification can be found in the "Maintenance data table" section be- low, under this Code. This lubrication plan describes the series-production truck with standard equipment. For mainte- nance points on variant trucks, see the relevant chapter and/or instructions provided by the man- ufacturer.

  • Page 473: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table DANGER Risk of explosion due to static charge! If bio-hydraulic oils are used, hydraulic systems become prone to the build-up of static charges. This can lead to static discharge; in potentially explosive areas, this can subsequently lead to explosions in the surrounding atmosphere.
  • Page 474 Maintenance General maintenance information Hydraulic system Code Unit Operating materials Specifications Dimension System filling Hydraulic oil HVLP 68 23 to 30 l DIN 51524, Part 3 Dependent on the lift mast and overall Hydraulic oil for cold HVLP 32 height store application DIN 51524, Part 3 NOTE...
  • Page 475 Maintenance General maintenance information Lift mast Code Unit Operating materials Specifications Dimension Lubrication High-pressure ID no. 0147873 As required grease Stop Play Min. 2 mm Lift mast bearing Grease Aralub 4320 Fill with grease until DIN 51825-KPF2N20 a small amount of ID no.

  • Page 476: Preserving Operational Readiness

    Maintenance Preserving operational readiness Preserving operational readiness Changing the light bulb DANGER Risk of explosion if incorrect light bulbs are used! The lighting of the truck is designed to enable it to enter approved zones. Other light bulbs increase sur- face temperatures.

  • Page 477: Lubricating The Joints And Controls

    Maintenance Preserving operational readiness Lubricating the joints and controls  – Oil or grease bearings and joints according to the "maintenance data table". Driver's seat guide ● Cab door hinges (variant) ● Battery-door hinges or battery-cover hinges ● Actuating rod (1) for valves (with multi-lever ●...

  • Page 478: Maintaining The Seat Belt

    Maintenance Preserving operational readiness – Check that the door lock (2) and the battery lock (4) move easily and that they are not deformed or damaged. – Check that the indexing bolt (3) on the door lock is seated correctly and that it is not de- formed or damaged.
  • Page 479 Maintenance Preserving operational readiness Checking the seat belt – Pull out the belt (3) completely and check  for wear. The belt must not be frayed or cut. The stitch- ing must not be loose. – Check whether the belt is dirty. –...

  • Page 480: Checking The Driver's Seat

    6327_342-010 – After an accident, check the driver's seat and its attached restraining belt and check that the seat is still securely fastened. – Have the seat repaired by the authorised service centre if you identify any damage during the checks.

  • Page 481: Checking The Antistatic Paint Layer

    Maintenance Preserving operational readiness Maximum permissi- Category of the truck ble damaged area IIB + H IIB + C 20 cm IIB + H – Please contact your authorised service cen- tre for replacement or advice if you have any questions. Checking the antistatic paint layer DANGER Risk of explosion due to static charge!

  • Page 482: Servicing The Heating System Or Air Conditioning

    Maintenance Preserving operational readiness Refer to the table below! For repairs, it is absolutely essential to use ● antistatic paint made by the same manufac- turer and with the same specifications. Maximum permissible damage to the surfa- Maximum permissi- Category of the truck ble damaged area 100 cm IIB + H...
  • Page 483 Maintenance Preserving operational readiness – Check the filter mat (1) for contamination.  – If the filter mat is grey in colour, replace it. NOTE Change the filter mat at least every two months. Cleaning the fresh-air inlet The fresh-air inlet must be cleaned if the filter mat: Is damaged, ●...
  • Page 484 Maintenance Preserving operational readiness – Remove any dust and dirt from the fresh-air  inlet (1) beneath the filter mat carrier. 56368011531 EN - 01/2021 - 05...

  • Page 485: Servicing Wheels And Tyres

    – If you wish to use a type of tyre or tyre manufac- turer that has not been approved by STILL, obtain approval from STILL prior to use. – Do not change rim parts and do not mix rim parts from different manufacturers.

  • Page 486: Servicing The Steering Axle

    Maintenance Preserving operational readiness Checking the condition and wear of the  tyres – Remove any foreign bodies embedded in the tyres (1). The level of wear exhibited by tyres on the same axle must be approximately the same. Superelastic tyres and solid rubber tyres can be worn down to the "60J wear limit"...

  • Page 487: Checking The Battery

    Maintenance Preserving operational readiness WARNING Risk of crushing! Do not actuate the steering during lubrication. – Switch on the truck. – Actuate the steering. – Park the truck safely again. – Repeat the lubrication procedure. NOTE Please note: the more often the truck is cleaned, the more frequently it must be lubri- cated.

  • Page 488: Replacing The Fuses

    Maintenance Preserving operational readiness Replacing the fuses DANGER Danger from electrical current! High voltages are present in the fuse box. There is a risk of electric shock. – Do not open the fuse box. – The fuses must be replaced only by the authorised service centre.
  • Page 489 Maintenance Preserving operational readiness Replace pipes if they display the following ab- normalities: Abrasion ● Deformation and bending ● Leaking ● 56368011531 EN - 01/2021 - 05...

  • Page 490: Check The Hydraulic Oil Level

    Maintenance Preserving operational readiness Check the hydraulic oil level  6219_901-016_V2 90° WARNING Hydraulic oils are hazardous to your health. – Observe the safety regulations set out in the chapter entitled "Hydraulic fluid". 90° NOTE When changing to a different type of hydraulic oil, the authorised service centre must adjust the parameters of the truck control unit.
  • Page 491 Maintenance Preserving operational readiness ENVIRONMENT NOTE Carefully collect any spilt hydraulic oil. Dis- pose of this hydraulic oil in accordance with environmental regulations. The marks (1), (2) and (3) indicate the mini-  mum filling levels for the different lift mast ver- sions.

  • Page 492: Lubricating The Lift Mast And Roller Track

    Maintenance Preserving operational readiness Lubricating the lift mast and roller  track – Remove dirt and lubricant residue from the roller track. – Lubricate the roller tracks (1) of the outside, middle, and inside mast with a super-pres- sure adhesion lubricant to reduce wear. C hapter "Maintenance data table", ⇒ ...

  • Page 493: 1000-Hour Maintenance/Annual Maintenance

    Maintenance 1000-hour maintenance/annual maintenance 1000-hour maintenance/annual maintenance Other work that must be carried out – Perform all tasks required to maintain full operability; see the chapter entitled "Re- maining ready for operation". Checking the lift cylinders and con-  nections for leaks WARNING Risk of injury Observe safety regulations for working on the lift...
  • Page 494 Maintenance 1000-hour maintenance/annual maintenance holes allow the remaining cladding thickness to be determined. The surface of the back of the fork (4) is also clad with the same material. There must be no cracks or deformations visi- ble on the fork arms in the area around the fork bend (3).

  • Page 495: Checking The Reversible Fork Arms

    Maintenance 1000-hour maintenance/annual maintenance Checking the condition and correct op-  eration of the latch – Check the fork arms (1) for any visible de- formation. Wear must not amount to more than 10% of the original thickness. CAUTION Risk of component damage! Always replace worn fork arms in pairs.

  • Page 496: Checking The Double Pedal

    Maintenance 1000-hour maintenance/annual maintenance – Check the cladding of the fork arms for wear; see the section entitled "Checking the fork arms". – If the fork bends or the cladding show signs of damage, notify the authorised service centre. Checking the double pedal ...

  • Page 497: Technical Data

    Technical data...

  • Page 498: Ergonomic Dimensions

    Technical data Ergonomic dimensions Ergonomic dimensions  40 mm WARNING Danger of impact injuries to the head! If the head of the operator is located too close to the underside of the roof, the suspension of the driver's seat or an accident may cause the head to strike the overhead guard.

  • Page 499: Dimensions

    Technical data Dimensions Dimensions α β Seat is adjustable ± 90 mm Fork spacing is adjustable 56368011531 EN - 01/2021 - 05...
  • Page 500 Technical data Dimensions NOTE Measurements h and b are cus- tomised and can be taken from the order con- firmation. 56368011531 EN - 01/2021 - 05...

  • Page 501: Vdi Datasheet: Rx20-14C With Steering Turntable

    This VDI datasheet specifies only the techni- cal values for trucks with standard equipment. Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX20-14C Type number 6219 Manufacturer STILL GmbH Drive Electric Operation Seat Rated capacity/load...
  • Page 502 Technical data VDI datasheet: RX20-14C with steering turntable Model RX20-14C Type number 6219 Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-14C Type number 6219 Forward tilt of lift mast/fork carriage α (degrees) Backwards tilt of lift mast/fork car- β...
  • Page 503 Performance data Model RX20-14C Type number 6219 Driving speed with load (Blue-Q/ km/h 16/16/20 STILL Classic/sprint mode) Driving speed without load (Blue-Q/ km/h 16/16/20 STILL Classic/sprint mode) Lifting speed with load (Blue-Q/ 0.54 STILL Classic/sprint mode) Lifting speed without load (Blue-Q/ 0.75...
  • Page 504 Technical data VDI datasheet: RX20-14C with steering turntable Electric motor Model RX20-14C Type number 6219 Traction motor, power rating at S2: 2x6.5 60 min Lift motor, power rating at 20% ED Standard; Battery DIN 43531 B circuit Battery voltage U (V)

  • Page 505: Vdi Datasheet: Rx20-16 With Steering Turntable

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX20-16C RX20-16 RX20-16L Type number 6220 6221 6222 Manufacturer STILL GmbH STILL GmbH STILL GmbH Drive Electric Electric Electric Operation Seat Seat Seat Rated capacity/load Q (kg) 1600...
  • Page 506 Technical data VDI datasheet: RX20-16 with steering turntable Model RX20-16C RX20-16 RX20-16L Type number 6220 6221 6222 Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-16C RX20-16 RX20-16L Type number 6220 6221 6222 Forward tilt of lift mast/fork carriage α...
  • Page 507 RX20-16 RX20-16L Type number 6220 6221 6222 Driving speed with load (Blue-Q/ km/h 16/16/20 16/16/20 16/16/20 STILL Classic/sprint mode) Driving speed without load (Blue-Q/ km/h 16/16/20 16/16/20 16/16/20 STILL Classic/sprint mode) Lifting speed with load (Blue-Q/ 0.53 0.53 0.53 STILL Classic/sprint mode) Lifting speed without load (Blue-Q/ 0.75...
  • Page 508 Technical data VDI datasheet: RX20-16 with steering turntable WARNING To use the truck safely – with or without a load – the maximum ascending or descending gradient permit- ted for travel is 15%. – If you have any questions, contact your authorised service centre.

  • Page 509: Vdi Datasheet: Rx20-18 And Rx20-20 With Steering Turntable

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX20-18 RX20-18L RX20-20L Type number 6223 6224 6225 Manufacturer STILL GmbH STILL GmbH STILL GmbH Drive Electric Electric Electric Operation Seat Seat Seat Rated capacity/load Q (kg)
  • Page 510 Technical data VDI datasheet: RX20-18 and RX20-20 with steering turntable Model RX20-18 RX20-18L RX20-20L Type number 6223 6224 6225 Number of rear wheels (x = driven) Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-18 RX20-18L RX20-20L Type number 6223 6224...
  • Page 511 RX20-18L RX20-20L Type number 6223 6224 6225 Driving speed with load (Blue-Q/ km/h 16/16/20 16/16/20 16/16/20 STILL Classic/sprint mode) Driving speed without load (Blue-Q/ km/h 16/16/20 16/16/20 16/16/20 STILL Classic/sprint mode) Lifting speed with load (Blue-Q/ 0.52 0.52 0.45 STILL Classic/sprint mode) Lifting speed without load (Blue-Q/ 0.75...
  • Page 512 Technical data VDI datasheet: RX20-18 and RX20-20 with steering turntable Electric motor Model RX20-18 RX20-18L RX20-20L Type number 6223 6224 6225 Traction motor, power rating at S2: 2x6.5 2x6.5 2x6.5 60 min Lift motor, power rating at S3: 15% Standard; Battery DIN 43531 A circuit...

  • Page 513: Vdi Datasheet: Rx20-16 With Swing Axle

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX20-16P RX20-16PL Type number 6226 6227 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seat Seat Rated capacity/load Q (kg) 1600...
  • Page 514 Technical data VDI datasheet: RX20-16 with swing axle Model RX20-16P RX20-16PL Type number 6226 6227 Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-16P RX20-16PL Type number 6226 6227 Forward tilt of lift mast/fork carriage α (degrees) Backwards tilt of lift mast/fork car- β...
  • Page 515 Model RX20-16P RX20-16PL Type number 6226 6227 Driving speed with load (Blue-Q/ km/h 16/16/20 16/16/20 STILL Classic/sprint mode) Driving speed without load (Blue-Q/ km/h 16/16/20 16/16/20 STILL Classic/sprint mode) Lifting speed with load (Blue-Q/ 0.53 0.53 STILL Classic/sprint mode) Lifting speed without load (Blue-Q/ 0.75...
  • Page 516 Technical data VDI datasheet: RX20-16 with swing axle Electric motor Model RX20-16P RX20-16PL Type number 6226 6227 Traction motor, power rating at S2: 2x6.5 2x6.5 60 min Lift motor, power rating at S3: 15% kW Standard; Battery DIN 43531 A (B) DIN 43531 A circuit Battery voltage...

  • Page 517: Vdi Datasheet: Rx20-18 With Swing Axle

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX20-18P RX20-18PL Type number 6228 6229 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seat Seat Rated capacity/load Q (kg) 1800...
  • Page 518 Technical data VDI datasheet: RX20-18 with swing axle Model RX20-18P RX20-18PL Type number 6228 6229 Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-18P RX20-18PL Type number 6228 6229 Forward tilt of lift mast/fork carriage α (degrees) Backwards tilt of lift mast/fork car- β...
  • Page 519 Model RX20-18P RX20-18PL Type number 6228 6229 Driving speed with load (Blue-Q/ km/h 16/16/20 16/16/20 STILL Classic/sprint mode) Driving speed without load (Blue-Q/ km/h 16/16/20 16/16/20 STILL Classic/sprint mode) Lifting speed with load (Blue-Q/ 0.52 0.52 STILL Classic/sprint mode) Lifting speed without load (Blue-Q/ 0.75...
  • Page 520 Technical data VDI datasheet: RX20-18 with swing axle Electric motor Model RX20-18P RX20-18PL Type number 6228 6229 Traction motor, power rating at S2: 2x6.5 2x6.5 60 min Lift motor, power rating at S3: 15% kW Standard; Battery DIN 43531 A (B) DIN 43531 A circuit Battery voltage...

  • Page 521: Rx20-20 Swing Axle Vdi Datasheet

    Different tyres, lift masts, additional units etc. can produce different values. Key data Model RX20-20P RX20-20PL Type number 6230 6231 Manufacturer STILL GmbH STILL GmbH Drive Electric Electric Operation Seat Seat Rated capacity/load Q (kg) 2000...
  • Page 522 Technical data RX20-20 swing axle VDI datasheet Model RX20-20P RX20-20PL Type number 6230 6231 Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-20P RX20-20PL Type number 6230 6231 Forward tilt of lift mast/fork carriage α (degrees) Backwards tilt of lift mast/fork car- β...
  • Page 523 Model RX20-20P RX20-20PL Type number 6230 6231 Driving speed with load (Blue-Q/ km/h 16/16/20 16/16/20 STILL Classic/sprint mode) Driving speed without load (Blue-Q/ km/h 16/16/20 16/16/20 STILL Classic/sprint mode) Lifting speed with load (Blue-Q/ 0.45 0.45 STILL Classic/sprint mode) Lifting speed without load (Blue-Q/ 0.63...

  • Page 524: Eco-Design Requirements For Electric Motors And Variable Speed Drives

    Technical data Eco-design requirements for electric motors and variable speed drives Electric motor Model RX20-20P RX20-20PL Type number 6230 6231 Traction motor, power rating at S2: 2x6.5 2x6.5 60 min Lift motor, power rating at S3: 15% kW Standard; Battery DIN 43531 A (B) DIN 43531 A circuit...

  • Page 525: Battery Specifications

    Technical data Battery specifications Battery specifications DANGER There is a risk of explosion from using a battery with the incorrect specifica- tion! Using batteries that do not correspond to explosion-protection regulations may lead to explosions in the surrounding at- mosphere in potentially explosive areas! –...
  • Page 526 Technical data Battery specifications Battery designa- Capacity Circuit Weight/ Battery compartment di- Tray tion [Ah] ballast mensions [mm] weight [kg] Length Width Height 5PzV 500 5PzV 550 5PzS 575 5PzS 625 6PzV 600 6PzV 660 1064 6PzS 690 6PzS 750 5TCSM 660 5PzV 500 5PzV 550...

  • Page 527: Information On The Auxiliary Hydraulics

    Technical data Information on the auxiliary hydraulics – If you have any questions, contact your au- thorised service centre. Information on the auxiliary hydraulics The information on the auxiliary hydraulics dif- fers depending on the truck. Take this into consideration when selecting the attachment. Maximum system pressure "P "...
  • Page 528 Technical data Information on the auxiliary hydraulics 56368011531 EN - 01/2021 - 05...
  • Page 529 Index Controlling with the fingertip and the UMBERS AND YMBOLS 5th function....1000-hour maintenance/annual mainte- General controlling....302 nance.
  • Page 530 Index Blue-Q Cold store application....Configuring..... 185 Batteries.
  • Page 531 Actuating the reset button..376 STILL Classic....185 Emergency actuation of the electric Drive programme parking brake.
  • Page 532 Index Fork arms Depressurising using the triple mini-lev- er and the 5th function... 289 Latch......479 Exiting the wizard.
  • Page 533 Meaning of the symbols... Malfunctions during lifting mode..STILL SafetyLight....160 Malfunctions in the electric parking brake. 210 StVZO equipment.
  • Page 534 Index Operating devices for hydraulic and driving Picking up loads....259 functions Place of use......26 Double mini-lever.
  • Page 535 Index Rotating beacon Shake function..... 272 Switching on and off....159 Double mini-lever.
  • Page 536 Index Tilt-angle-dependent assistance systems Variants Automatic mast vertical positioning. . Access authorisation for the fleet man- 162, ager......Mast tilt angle display.
  • Page 537 Index VDI datasheet Wedging the wheels....RX20-14C steering turntable..Wheel chock..... . RX20-16 steering turntable.
  • Page 540 STILL GmbH 56368011531 EN - 01/2021 - 05...

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