Still RX20 14-20 Original Instructions Manual
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Still RX20 14-20 Original Instructions Manual

Electric truck
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Original instructions
Electric truck
RX20 14-20
RX20 14-20/Li-Ion
6219 6220 6221 6222 6223 6224
6225 6226 6227 6228 6229 6230
6231
56368011501 EN - 04/2022  -  13

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Summary of Contents for Still RX20 14-20

  • Page 1 Original instructions Electric truck RX20 14-20 RX20 14-20/Li-Ion 6219 6220 6221 6222 6223 6224 6225 6226 6227 6228 6229 6230 6231 56368011501 EN - 04/2022  -  13...
  • Page 3 ● ing and storage of industrial trucks Internet address and QR code  The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 56368011501 EN - 04/2022  -  13  I...
  • Page 4  You can request to download the spare parts list by copying and pasting the address https:// sparepartlist.still.eu into a web browser or by scanning the QR code shown to the side. On the web page, enter the following pass-...

  • Page 5: Table Of Contents

    Table of contents   Foreword   Your truck ............ 2 Description of the truck .
  • Page 6 Operating devices and display elements ........ 68 Display-operating unit "STILL Easy Control" ........ 68 Lithium-ion battery display.
  • Page 7 Table of contents   Quadruple mini-lever ........... .  76 Fingertip.
  • Page 8 STILL Classic and sprint mode ........
  • Page 9 Table of contents   Actuating the electric parking brake (variant) ....... . .  175 Malfunctions in the electric parking brake .
  • Page 10 Table of contents   Driving onto lifts ............ 244 Driving on loading bridges .
  • Page 11 Table of contents   Depressurising the hydraulic system using the Fingertip ...... 303 Depressurising the hydraulic system using the Fingertip and the 5th function .. 304 Depressurising the hydraulic system using the Joystick 4Plus .
  • Page 12 Table of contents   Turning the interior lighting on or off (variant) ....... . .  371 Radio (variant) .
  • Page 13 Table of contents   Checking the battery condition, acid level and acid density ..... .  441 Checking the battery charge status and calibrating the battery charge indicator .. 442 Charging the lead-acid battery .
  • Page 14 Table of contents   Safety devices ............ 505 Set values .
  • Page 15 Table of contents   VDI datasheet: RX20-14C with steering turntable ...... 543 VDI datasheet: RX20-16 with steering turntable ...... 547 VDI datasheet: RX20-18 and RX20-20 with steering turntable .

  • Page 17: Foreword

    Foreword...

  • Page 18: Your Truck

    It also supports all FleetManager 4.x functions. Assistance systems The STILL RX20 14-20 can be equipped with assistance systems that make it easier to work with loads. Lift height-dependent assistance systems Lift height display ●...
  • Page 19 Foreword Your truck Load-dependent assistance systems Overload detection ● Dynamic Load Control 1 or Dynamic Load ● Control 2 Lift mast tilt angle display ● Automatic mast vertical positioning ● Fork wear protection ● Load measurement, precise load measure- ● ment, total load and tare function Brake system The brake system of the truck is comprised of three different brakes:...
  • Page 20 Your truck of damping pressure peaks in the hydraulic system. Drive The STILL RX20 14-20 is driven via both front wheels by maintenance-free three-phase drives in the front axle with 48-volt technology. Lead-acid batteries and lithium-ion batteries that can be replaced from the side are availa- ble as a power supply source.

  • Page 21: General

    Acceleration and braking behaviour can be in- dividually selected from three different drive programmes. The "STILL Easy Control" display-operating unit simplifies daily use of the truck by pro- viding personally configurable favourites. The display-operating unit also shows the status of the lithium-ion battery.

  • Page 22: Conformity Marking

    Foreword Your truck Conformity marking  The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...

  • Page 23: Declaration That Reflects The Content Of The Declaration Of Conformity

    Your truck Declaration that reflects the content of the declaration of conformity         Declaration     STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany             We declare that the specified machine conforms to the most recent valid version of the directives specified below:  ...

  • 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) ● Two keys for the storage box containing ● the charging cable for the on-board charger (variant) A hexagon socket wrench for emergency ●...
  • Page 25 Foreword Your truck 56368011501 EN - 04/2022  -  13  9...

  • Page 26: Labelling Points

    Foreword Your truck Labelling points 6219_003-010_V3  10 56368011501 EN - 04/2022  -  13...
  • Page 27 Foreword Your truck Decal information: Caution / Read the oper- Warning sign: Danger due to shearing ating instructions / Fasten seat belt / Apply Decal information: Parking brake applied parking brake when leaving the truck / Pas- Decal information: Parking brake released sengers are not allowed / Do not jump off if Decal information: Tyre filling pressure the truck is tipping over / Lean in the oppo-...
  • Page 28 Foreword Your truck VDE-Prüfung geprüft gemäß DIN VDE 0701-0702 6219_003-011_V4  12 56368011501 EN - 04/2022  -  13...

  • Page 29: Nameplate

    Foreword Your truck Decal information: Hydraulic oil tank Decal information: Load capacity: Attach- Decal information: Speed reduction ment Warning sign: Do not stand underneath the Decal information: Load capacity: Basic ta- fork / Do not stand on the fork Warning sign: Danger due to shearing / Decal information: Regular testing Danger due to high fluid pressure Decal information: Battery service...

  • Page 30: Serial Number

    Foreword Your truck Variant 2: Industrial trucks built after  12/2021 Nameplate Manufacturer Model / serial number / year of manufac- ture Industrial truck / Chariot de manutation / Flurförderzeug Tare weight Max. battery weight/min. battery weight (only for electric trucks) Ballast weight (only for electric trucks) Placeholder for "data matrix code"...

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

    Capacity equivalent: Weight: CE labelling P/N: B-P/N: Safety information Custumer order no.: Still order no.: Data/technical data Date: Made in Germany Address of manufacturer Safety Advices for Lithium-Ion Batteries Do not crush. Do not heat or incinerate. Do not short-circuit. Do not dismantle.
  • Page 32 Foreword Your truck Variant 1: Industrial trucks built after  12/2021 Manufacturer Technology Transport information General operating notes CE labelling Data matrix code for the authorised serv- ice centre UKCA labelling Safety information Data/technical data Address of manufacturer  16 56368011501 EN - 04/2022  -  13...

  • Page 33: Using The Truck

    Foreword Using the truck Using the truck Commissioning Commissioning is the initial intended use of the truck. The necessary steps for the commissioning vary depending on the model and equipment of the truck. These steps require preparatory work and adjustment work that cannot be per- formed by the operating company.

  • Page 34: Improper Use

    Foreword Using the truck The regulations regarding trailer operation must be observed; see chapter "Trailer opera- tion". Improper use The operating company or driver, and not the manufacturer, is liable for any hazards caused by improper use. NOTE Please note the definition of the following re- sponsible persons: "operating company"...
  • Page 35 Foreword Using the truck Driving on upward and downward gradients is permitted provided the specified data and specifications are observed, see the "Routes "chapter. The truck is suitable for indoor and outdoor use in countries ranging from the Tropics to Nordic regions (temperature range: -20°C to +40°C).

  • Page 36: Parking In Temperatures Below -10 °C

    Foreword Using the truck Parking in temperatures below -10 °C  CAUTION Batteries may freeze or switch off! If the truck is parked in an ambient temperature of below -10°C for an extended period, the batteries will cool down. For lead-acid batteries, the electrolyte can freeze and damage the batteries.

  • Page 37: 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 Original operating instructions of the lithium- ● ion battery (variant) Operating instructions of other variants that ●...

  • Page 38: Supplementary Documentation

    Foreword Information about the documentation Safely store the complete documentation and pass on to the subsequent operating company when transferring or selling the truck. 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 39: Issue Date And Topicality Of The Operating Instructions

    The issue date and the version of these op- erating 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 40: List Of Abbreviations

    Foreword Information about the documentation ENVIRONMENT NOTE To prevent environmental damage. List of abbreviations This list of abbreviations applies to all types of operating instructions. Not all of the abbre- viations that are listed here will necessarily appear in these operating instructions. Abbrevi- Meaning Explanation...
  • Page 41 Foreword Information about the documentation Abbrevi- Meaning Explanation ation International Organization for Standardi- International standardisation organisation zation Uncertainty of measurement of sound   pressure levels Local Area Network Local area network Light Emitting Diode Light emitting diode Sound pressure level at the workplace  ...

  • Page 42: Definition Of Directions

    Foreword Information about the documentation Definition of directions  The directions "forwards" (1), "backwards" (3), "right" (2) and "left" (4) refer to the installation position of the parts as seen from the driver's compartment; the load is to the front. 6210_001-031 Schematic views View of functions and operating proce-...
  • Page 43 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 44: 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 45: Safety

    Safety...

  • Page 46: Definition Of Responsible Persons

    Safety Definition of responsible persons Definition of responsible persons Operating company The operating company is the natural or legal person or group 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 47: Drivers

    Safety Definition of responsible persons Drivers This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised represen- tative, and have been specifically instructed to drive the truck.
  • Page 48 Safety Definition of responsible persons Prohibition of use by unauthorised per- sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use, e.g.

  • Page 49: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company premises 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 50 Safety Basic principles for safe operation Permissible lithium-ion batteries – Use only lithium-ion batteries that have been approved by STILL for use with this truck. Declaring the use of lithium-ion batter- We recommend that the operating company informs the local fire brigade of the planned use of trucks fitted with lithium-ion batteries.
  • Page 51 Safety Basic principles for safe operation – Ventilate the location of the fire well, as the resulting combustion gases are corrosive if inhaled. – Inform the fire brigade that lithium-ion bat- teries are affected by the fire. – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire.

  • Page 52: Product-Specific Dangers Posed By The Lithium-Ion Battery

    Safety Basic principles for safe operation Product-specific dangers posed  by the lithium-ion battery  WARNING Risk of burns due to hot surfaces! The battery has an integrated brake re- sistor that can heat up to over 100°C during operation. It can take several hours for the brake resistor to cool down to a temperature at which it poses no risk.

  • Page 53: Modifications And Retrofitting

    Safety Basic principles for safe operation occur, depending on the surrounding circum- stances. Touching live components can cause an elec- tric shock, which can have thermal or paralys- ing effects. The latter can cause ventricular fibrillation, cardiac arrest or respiratory paraly- sis, leading to death.
  • Page 54 Safety Basic principles for safe operation  DANGER Risk of explosion from additional bores in the battery hood! Explosive gases can escape and can lead to potentially fatal injuries if they explode. Sealing bores with plugs is not sufficient to prevent gas from escaping. –...

  • Page 55: 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. 56368011501 EN - 04/2022  -  13  39...

  • Page 56: 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 driving safety. We recommend that you obtain approval from the manufacturer and, if necessary, from the relevant regulatory authorities before installing such parts.
  • Page 57 Safety Basic principles for safe operation The following factors can lead to a loss of stability and are therefore prohibited: Different tyres on the same axle, e.g. pneu- ● matic tyres and superelastic tyres Tyres not approved by the manufacturer ●...

  • Page 58: Medical Equipment

    Safety Basic principles for safe operation Medical equipment  WARNING Electromagnetic interference may occur on medical devices! Only use equipment that is sufficiently protected against electromagnetic interference. Medical equipment, such as pacemakers or hearing aids, may not work properly when the truck is in operation.

  • Page 59: Length Of The Fork Arms

    Safety Basic principles for safe operation Length of the fork arms  DANGER Risk of accident due to the incorrect selection of fork arms! – The fork arms must match the depth of the load. If the fork arms are too short, the load may fall off the arms after it has been picked up.

  • Page 60: Residual Risk

    Safety Residual risk Residual risk Residual dangers, residual risks Despite careful working and compliance with standards and regulations, the occurrence of other risks when using the truck cannot be entirely excluded. The truck and all other system components comply with current safety requirements. Nev- ertheless, even when the truck is used for its proper purpose and all instructions are fol- lowed, some residual risk cannot be excluded.

  • Page 61: Special Risks Associated With Using The Truck And Attachments

    Safety Residual risk with these regulations either intentionally or carelessly. Stability The stability of the truck has been tested to the latest technological standards and is guar- anteed provided that the truck is used properly and according to its intended purpose. These standards only take into account the dynamic and static tipping forces that can arise during specified use in accordance with the operat-...
  • Page 62 Safety Residual risk use the truck correctly and without the risk of accidents.  46 56368011501 EN - 04/2022  -  13...
  • Page 63 Safety Residual risk 56368011501 EN - 04/2022  -  13  47...

  • Page 64: 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 65 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 labour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver Industrial Safety and...

  • Page 66: Danger To Employees

    Safety Residual risk Hazard Course of action Check note Notes √ done - Not applicable DGUV rule 113-001 and observe the oper- ating instructions 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-...
  • Page 67 Safety Residual risk The design and equipment of the truck comply with the standards and directives required for CE conformity. The design and equipment al- so comply with the standards and directives necessary for the UKCA compliance that is required in the United Kingdom. The design and equipment are therefore not part of the required scope of the hazard assessment.

  • Page 68: 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 69 Safety Safety tests The exact procedure for this insulation testing is described in the workshop manual for this truck. 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...

  • Page 70: Regularly Testing The Electrical Safety

    Safety Safety tests Regularly testing the electrical  safety The on-board charger and the associated VDE-Prüfung charging cable must be tested at least once a year. This test must be carried out in accordance with the national regulations for the country of use (e.g. DIN VDE 0701/0702 geprüft gemäß...

  • Page 71: 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 72: 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 73: 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 74: 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 75: 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 76 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 77 – Observe the safety regulations for handling the battery. Radiation In accordance with the guide- lines DIN EN 62471:2009-03 (VDE 0837-471:2009-03), the STILL Safety- Light and the warning zone light (variant) are assigned to risk group 2 (medium risk) due to their photobiological hazard potential. The Laser-Smartfork assistance system (var- iant) is assigned to laser class 1M.
  • Page 78 Safety Emissions  62 56368011501 EN - 04/2022  -  13...

  • Page 79: Overviews

    Overviews...

  • Page 80: Overview

    Overviews Overview Overview  64 56368011501 EN - 04/2022  -  13...
  • Page 81 Overviews Overview Lift mast Fork carriage Overhead guard Lift cylinder Driver's compartment Rear lighting Battery (in the battery compartment) Battery door Drive axle Steering axle Front lighting Towing device Fork arms Counterweight NOTE The truck equipment may differ from the equipment shown.

  • Page 82: Driver's Compartment

    Overviews Driver's compartment Driver's compartment  66 56368011501 EN - 04/2022  -  13...

  • Page 83: Shelf And Cup Holder

    Emergency off switch of 1.5 litres Key switch Driver's seat Compartment Accelerator pedal Display/control unit "STILL Easy Control" Brake pedal Operating devices for hydraulic and driving Steering column adjustment lever functions Compartment for storing the operating in- structions and the hexagon socket wrench...

  • Page 84: Operating Devices And Display Elements

    Brightness sensor Right-hand favourites bar "STILL Easy Control" is a third-generation dis- play-operating unit for industrial trucks. It is used as an operating device for the usu- al functions of the truck, such as controlling lighting and windscreen wiper functions and adjusting the driving dynamics.
  • Page 85 – 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 mul- ti-lever operation.

  • Page 86: Lithium-Ion Battery Display

    – Observe the chapter entitled "Display ele- ments" in the STILL "Lithium-ion batteries" operating instructions. 6209_003-002 Service LED (red) Temperature LED (yellow/red)

  • Page 87: 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" (variant) NOTE In the dual-pedal version (variant), the drive direction switch (1) is used exclusively to acti-...

  • Page 88: 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  72 56368011501 EN - 04/2022  -  13...
  • Page 89 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 90: 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  74 56368011501 EN - 04/2022  - ...
  • Page 91 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 92: 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"  76 56368011501 EN - 04/2022  - ...
  • Page 93 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 94: 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 95: 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" ing, lowering and sideshift Shift key "F"...

  • Page 96: Travel Direction Selector And Indicator Module (Variant)

    Overviews Operating devices and display elements Travel direction selector and in-  dicator 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 97: Operating

    Operating...

  • Page 98: Checks And Tasks Before Daily Use

    Operating 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 falling.
  • Page 99 Operating Checks and tasks before daily use Component Course of action Ensure that the attachments are mounted correctly in accordance with the operating instructions from the manufacturer. Attachments (variant) Perform a visual inspection to ensure that the at- tachments are intact and are leak-tight. Perform checks to ensure the attachments are working correctly.
  • Page 100 Lighting, warning units Check the integrity and function. Visually inspect for sound condition. 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)

  • Page 101: Climbing Into And Out Of The Truck

    Operating 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 compo- nents ensure that the truck cannot charge statically. –...

  • Page 102: Adjusting The Driver's Seat And Armrest

    Operating Checks and tasks before daily use  CAUTION Components may become damaged through incor- rect use! Truck components, such as the driver's seat, steer- ing wheel, parking brake lever etc., are not designed to be used for climbing in and out of the truck and may be damaged due to misuse.

  • Page 103: Adjusting The Steering Column

    Operating Checks and tasks before daily use Adjusting the steering column  – Pull up and hold the lever (2) for steering column adjustment. – Position the steering column (1), then push the lever down again and allow the steering column to engage.  DANGER Risk of accident! –...

  • Page 104: Function Checking Of The Assistance Systems

    Operating Checks and tasks before daily use NOTE If the angle of the display-operating unit changes during driving, tighten the socket head screws. This makes the display-operat- ing unit more secure in the support mounting. Function checking of the assis- tance systems Checking the assistance systems is one of the checks and tasks that must be performed...

  • Page 105: Unlock The Emergency Off Switch

    Operating 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  function  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 106: Operating The Signal Horn

    Operating 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.  90 56368011501 EN - 04/2022  - ...

  • Page 107: Driver's Cab

    Operating Checks and tasks before daily use Driver's cab  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 108: Checking The Brake System For Correct Function

    Operating Checks and tasks before daily use Checking the brake system for correct 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. – Do not operate the truck if the brake system is faulty.
  • Page 109 Operating 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 lorry ramp  DANGER Risk to life if the truck rolls away! If the parking brake is not applied, the truck could run people over.

  • Page 110: Warming Up The Hydraulic Oil At Cold Ambient Temperatures

    Operating 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 111: Checking The Steering System For Correct Function

    Operating Checks and tasks before daily use – Actuate all hydraulic lifting functions several times. Limiting the load dynamics to load program 1  during the warm-up phase NOTE During the warm-up phase, the load dynamics are limited to load program 1. The adjacent symbol appears on the display until the warm- up phase is complete.

  • Page 112: Driver's Seat

    Operating Driver's seat Driver's seat Adjusting the MSG 65 and MSG 75 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 113 Operating 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 114 Operating Driver's seat Adjusting the MSG 65/MSG 75 seat  suspension NOTE The MSG 65/MSG 75 driver's seat is de- signed 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 115 Operating Driver's seat The seat automatically adjusts to the driver's weight. Adjusting the longitudinal horizontal  suspension (variant) If the driver's seat is equipped with the "longi- tudinal horizontal suspension" variant, impacts in the drive direction are damped by additional seat suspension.
  • Page 116 Operating Driver's seat Adjusting the backrest extension (var-  iant) – Adjust the backrest extension (7) by pulling it out or pushing it into the desired position. To remove the backrest extension, move it past the end stop by firmly pushing it upwards. 6321_003-040_V3 Switching the seat heater (variant) on ...
  • Page 117 Operating Driver's seat Swivelling the driver's seat to the right  for reverse travel (variant)  WARNING Risk of accident due to the seat swivelling. If the driver's seat swivels while the truck is in mo- tion, the seat position is unstable. –...

  • Page 118: 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 119 Operating Driver's seat NOTE The buckle has a buckle switch. When the belt was not fastened, the following occurred: The message Close seat belt   ● appears on the display-operating unit. The truck will not drive at speeds faster ● than 4 km/h.
  • Page 120 Operating Driver's seat Special feature for trucks with HSR re- straint systems (variant) If the bracket is not closed, the message   appears Close restraint system in the display. Fastening on a steep slope  The automatic blocking mechanism prevents the belt from being extended whenever the truck is on a steep gradient.

  • Page 121: Adjusting The Armrest

    Operating Driver's seat Malfunction due to cold – If the buckle or belt retractor are frozen, thaw the buckle or the belt retractor and dry the parts. This prevents the parts from refreezing.  CAUTION The seat belt may be damaged by heat! Do not subject the buckle or belt retractor to exces- sive heat when thawing.
  • Page 122 Operating Driver's seat – Tighten the hand wheel by turning to the right. – Check that the armrest is firmly attached.  106 56368011501 EN - 04/2022  -  13...

  • Page 123: Switching On

    Operating 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 124: Switching On Via Push Button (Variant)

    Operating 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 (variant)  WARNING All checks and tasks required before daily use must...
  • Page 125 Operating 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 ● instructions for FleetManager". 56368011501 EN - 04/2022  - ...

  • Page 126: Display-Operating Unit

    Operating 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 127: Access Authorisation With Pin Code (Variant)

    Operating 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 128 Operating Display-operating unit When the key switch is switched on, the  input menu ap- Access 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 129: Access Authorisation For The Fleet Manager (Variant)

    Operating 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...
  • Page 130 Operating Display-operating unit date, the authorised service centre must set up a fleet manager password. Standard fleet manager password The standard fleet manager password is "1111". For safety reasons, this standard fleet manager password must be changed af- ter the first use. See also the section en- titled "Changing the fleet manager pass- word".
  • Page 131 Operating Display-operating unit The display changes to the  Access au- menu. thorisation – Enter the fleet manager password using the softkeys. – To confirm, press the button. Enter password 6219_003-208_V3_en The message  Fleet manager access   appears. authorisation granted –...
  • Page 132 Operating Display-operating unit – Press the   softkey.  Service – Press the scroll buttons    until  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...

  • Page 133: Pre-Shift Check

    Operating 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 While the driver is doing this, the truck func-...

  • Page 134: Process

    The main display contains the message To complete Pre-Shift Check,   press This means that the Pre-Shift Check is still active and the truck functions are restricted. – To acknowledge the message, press the 6219_003-265_en  softkey. – Switch on and check the function to be tes- ted, e.g.

  • Page 135: All Questions

    Operating Pre-Shift Check speed. When the parking brake is applied again, the view returns to Pre-Shift Check. At the end of the check, truck functions are restricted if they have been adjusted as a re- action to a negative test result. The message Pre-Shift Check truck restric- shows that truck functions tions active...

  • Page 136: Defining The Question Sequence

    Operating Pre-Shift Check Is the capacity rating plate present, undamaged, and legible? Is the driver restraint system damaged? Does the horn work? Does the truck lighting work? Do the warning lights work? Is the antistatic belt present and does it have sufficient con- tact with the floor? Is the corona electrode present and clean? Does the parking brake work properly?
  • Page 137 Operating 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 56368011501 EN - 04/2022  - ...

  • Page 138: Displaying The History

    Operating Pre-Shift Check menu appears.  Pre-Shift Check – Press the  softkey. Question sequence 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 139 Operating 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 56368011501 EN - 04/2022  - ...

  • Page 140: Defining The Shift Start

    Operating Pre-Shift Check menu appears.  Pre-Shift Check – Press the softkey. History History Reset restriction Shift start Question sequence Fleet manager 6219_003-269_en The Pre-Shift Check display opens.  results This display shows all checks and questions that have been answered with the date and Pre-Shift Check results time.
  • Page 141 Operating Pre-Shift Check NOTE If the truck is equipped with the "FleetManag- er" variant, the shifts are defined on the Fleet- Manager interface. See the relevant operating instructions. – Activate the "Access authorisation for the fleet manager". – Press the  ...
  • Page 142 Operating Pre-Shift Check menu appears.  Pre-Shift Check – Press the  softkey. Shift start 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 143 Operating 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 144: Resetting The Truck Restrictions

    Operating 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 reverts to the previous menu. There is no activation bar next to this shift.
  • Page 145 Operating 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 menu appears.  Pre-Shift Check –...
  • Page 146 Operating 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 reverts to the previous Reset the truck restrictions? The entry remains in the history menu.

  • Page 147: Driver Profiles

    Operating 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  softkey is pressed, the main display appears. Hello, 0,0°...
  • Page 148 Operating Driver profiles ped with these variants, drivers must select their profiles manually. NOTE Access to the settings menu is only availa- ble if the truck is at a standstill and the park- ing brake is applied. If the parking brake is released prematurely, the settings menu will close.

  • Page 149: Creating Driver Profiles

    Operating 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 150 Operating Driver profiles – Press the soft-  Driver profiles key  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 151: Renaming Driver Profiles

    Operating 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 152 Operating 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 153 Operating Driver profiles – Press the  Manage driver pro-  softkey. files Lift height preselection Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Fleet manager 6219_003-296_en – Press the  Rename driver pro-  softkey. files Rename driver profiles Delete driver profiles Fleet manager 6219_003-297_en...

  • Page 154: Deleting Driver Profiles

    Operating 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 155 Operating 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 156: Lighting

    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 157: Driving Lights

    Operating 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 158: Working Spotlights

    Operating 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 159: Working Spotlight For Reverse Travel (Variant)

    Operating 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 160 Operating 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 – To switch off the turn indicators, push the lever (1) back to the centre position.

  • Page 161: Hazard Warning System

    Operating 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 162: Stvzo Equipment

    This softkey is used to switch off all light- ing devices that are not permitted on roads subject to German traffic regulations (StVO). This relates to the following variants of lighting equipment: STILL SafetyLight and STILL Safety- ● Light 4Plus Warning zone light and warning zone light ●...

  • Page 163: Rotating Beacon

     WARNING Danger of damage to eyes from look- ing into the STILL SafetyLight® and STILL SafetyLight 4Plus®. Do not look into the STILL SafetyLight® or STILL SafetyLight 4Plus®. STILL SafetyLight® and STILL SafetyLight 4Plus® are visual warning units designed to enable early detection of trucks in driving areas with low visibility (such as drive lanes, high racks), as well as at blind junctions.

  • Page 164: Warning Zone Light And Warning Zone Light Plus (Variants)

    STILL SafetyLight 4Plus® is mounted on a support on the overhead guard such that it is not affected by jolts and vibrations. Depending on the version, the STILL Safety- Light® projects one or more light-blue light spots in front of or behind the truck and thus warns others about the approaching truck.
  • Page 165 Operating Lighting The warning zone light projects a light bar  next to the truck on both the left-hand side and right-hand side of the truck or even behind the truck. This light bar indicates the danger areas to the sides or rear of the truck while in operation.

  • Page 166: Efficiency And Drive Modes

    Therefore, on distances of up to approx. 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. Blue-Q has no influence on: Maximum speed ●...
  • Page 167 Operating 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) 56368011501 EN - 04/2022  -  13  151...

  • Page 168: Switching Blue-Q On And Off

    Operating 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 display/operating unit and Blue-Q efficiency mode is switched on. – To switch off Blue-Q efficiency mode, push the associated softkey again.

  • Page 169: 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: STILL Classic...
  • Page 170 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 171: Driving

    Operating 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 172 There is a risk of accident! – 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 173: Roadways

    Operating Driving Roadways Dimensions of roadways and aisle widths The following dimensions and aisle width re- quirements apply under the specified condi- tions to ensure safe manoeuvring. In each case, a check must be performed to determine whether a larger aisle width is necessary, e.g. in the case of deviating load dimensions, at- tachments, lift masts and tow couplings.
  • Page 174 Operating Driving Driving on ascending and descending gradients  WARNING Risk of accident due to the drive unit switching off! Driving up and down longer gradients can cause the drive unit to overheat and switch off. The truck will then no longer decelerate when the accelerator ped- al is released and will coast.
  • Page 175 Operating Driving 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 RX20-16L 6222 27.4 28.7 RX20-18 6223 25.1 26.0 RX20-18L 6224 25.3 28.3 RX20-20L 6225...
  • Page 176 Operating Driving Condition of the roadways Roadways must be sufficiently firm and even. The surface must be free from contamination and fallen objects. Drainage channels, level crossings and similar obstacles must be evened out and, if necessa- ry, ramps must be provided so that trucks can drive over these obstacles with as few bumps as possible.

  • Page 177: Selecting Drive Programmes 1 To 3

    Operating Driving Selecting drive programmes 1 to  The truck has three drive programmes with different preset driving and braking character- istics. The basic principle is that the higher the number of the drive programme selected, the greater the driving dynamics. The drive programme is selected using the display-operating unit under the  ...

  • Page 178: Configuring Drive Programmes A And B

    Operating Driving Selecting drive programme A or  The truck has two driving programmes for personalised handling and braking character- istics. Unlike the fixed drive programmes "1 to 3", the programs "A" and "B" can be configured. The procedure for this is described in the following section.
  • Page 179 Operating Driving – Press the associated softkey for drive programme A drive programme Configuration of the drive programmes using is explained here. drive programme A menu ap-  Setdrive programme A pears. The following parameters can be set: ● Max. speed Determines the maximum speed (varies de- pending on the truck model).

  • Page 180: Selecting The Drive Direction

    Operating Driving Selecting the drive direction  The drive direction of the truck must be selec- ted using the drive direction switch/drive direc- tion selection lever before attempting to drive. The method of actuating the drive direction switch/drive direction selection lever depends on the operating devices that are fitted in the truck.

  • Page 181: Actuating The Drive Direction Switch With The Multiple-Lever Version

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

  • Page 182: Joystick 4Plus Version

    Operating 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 direction selection lever on the travel direction selector and indicator module (variant) can be...

  • Page 183: Indicator Module Version

    Operating Driving Actuating the drive direction se-  lection lever with the travel direc- tion selector and indicator mod- ule version – 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 184 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 185: 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 186 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 187: Operating The Service Brake

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

  • Page 188: Parking Brake

    Operating Driving Electrical braking recovers energy for the bat- tery. This results in a longer operating time be- tween the charging processes and less wear to the brakes.  DANGER If the service brake fails, the truck cannot brake sufficiently. 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...

  • Page 189: Applying The Mechanical Parking Brake

    Operating 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 190 Operating 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 191: Actuating The Electric Parking Brake (Variant)

    Operating 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 192 Operating 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 193 Operating 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 194 Operating 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 195: Malfunctions In The Electric Parking Brake

    Operating 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 196 A possible cause of the malfunction is that the parking brake cannot determine whether 6219_003-006_V2 the truck is stationary or still in motion. The following section describes how to actuate the parking brake when it is faulty: Actuating a faulty parking brake when the...
  • Page 197 Operating Driving The parking brake is applied. NOTE The truck brakes more strongly if the push button (1) is pressed and held down for longer or pressed several times. "Safe parking" function This function monitors the braking effect after the truck is parked. If a sensor is fitted on the lift mast (variant), it also checks whether the fork carriage is lowered.
  • Page 198 Operating Driving  DANGER Risk of fatal injury from being run over if the truck rolls away! Park the truck securely if the parking brake is faulty. Secure the industrial truck to prevent it from rolling away. – To do this, strictly adhere to the following instruc- tions: –...
  • Page 199 Operating Driving NOTE If the parking brake is released via the emer- gency actuation mechanism, it is possible to drive the truck at a low speed. The truck can be moved out of the hazard- ● ous situation or to the repair location. Driving with a faulty parking brake requires ●...

  • Page 200: Steering

    Operating 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 201: 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 202: Speed Reduction When The Cab Door Is Open

    Operating Driving Speed reduction when the cab door is open  WARNING Risk of accident from sudden deceleration of the truck If the cab door is opened while the truck is in motion, the truck brakes automatically. – Keep the cab door closed when driving. With the "cab"...

  • Page 203: Speed Restriction (Variant)

    Operating Driving Speed restriction (variant)  The speed restriction (variant) is a function that can be configured by the fleet manager. It sets a maximum speed that can either be permanent or be called up by the driver. This function helps the driver to comply with speed restrictions, e.g.
  • Page 204 Operating Driving The menu that opens offers the following func- tions: ● Permanent Enabling this function limits the speed until the fleet manager disables this function. ● By pressing a button If this function is activated, the driver may switch the speed restriction on and off by pressing the ...

  • Page 205: Cruise Control (Variant)

    Operating 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 206 Operating Driving – Press the  softkey.  The orange-coloured activation bar next to the 08:20  softkey lights up. The cruise control func- tion is ready. The greyed-out  symbol (1) appears on the display. Taking the cruise control function off standby Pressing the  softkey again takes the func- tion off standby.
  • Page 207 Operating 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). 56368011501 EN - 04/2022  -  13  191...
  • Page 208 Operating 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 209 Operating 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 restriction set to less than 4.5 km/h. ● The truck control unit detects abnormalities, ●...

  • Page 210: Parking

    Operating 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 gradients. – In emergencies, secure the truck us- ing wedges on the side facing down- hill.
  • Page 211 Operating 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 212: Wheel Chock (Variant)

    Operating Parking – In the "push button ignition" variant, press  the button. (1) 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 unless explicit instructions to this effect have been given by the responsible fleet manager.

  • Page 213: Lifting

    Operating 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 214 Operating 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 215: Operating Devices For The Lifting System

    Operating 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 216 Operating 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 217: Controlling The Lifting System Using Multi-Lever Operation

    Operating Lifting Controlling the lifting system us-  ing 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 218 Operating 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). Movements of the lifting system and meanings of the pictograms  Lowering...

  • Page 219: Controlling The Lifting System Using A Double Mini-Lever

    Operating Lifting Controlling the lifting system us-  ing 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 220 Operating Lifting Lifting/lowering the fork carriage To lift the fork carriage: – Move the "lift mast" 360° lever (3) in the direction of the arrow (B). To lower the fork carriage: – Move the "lift mast" 360° lever (3) in the direction of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: –...

  • Page 221: Controlling The Lifting System Using A Triple Mini-Lever

    Operating Lifting Controlling the lifting system us-  ing 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 222 Operating Lifting – Move the "lift mast" 360° lever (3) in the direction of the arrow (A). Tilting the lift mast To tilt the lift mast forwards: – Move the "lift mast" 360° lever (4) in the direction of the arrow (C). To tilt the lift mast backwards: –...

  • Page 223: Controlling The Lifting System Using A Quadruple Mini-Lever

    Operating Lifting Controlling the lifting system us-  ing 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 224 Operating 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 225 Operating Lifting Controlling the lifting system us-  ing 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 226: Controlling The Lifting System Using The Joystick 4Plus

    Operating 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). Movements of the lifting system and meanings of the pictograms  Lowering...
  • Page 227 Operating Lifting 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  To lift the fork carriage: – Pull the Joystick 4Plus (1) backwards (B). To lower the fork carriage: –...

  • Page 228: Dynamics Of The Hydraulic Movements

    Operating 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  Lifting...

  • Page 229: Selecting Load Programs 1 To 3

    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 230: Fork Wear Protection (Variant)

    Operating Lifting – If the load programs are saved as a favour-  ite on a softkey, press the  softkey until the number of the desired load program is shown on the display. The number of dynamic bar segments shows the load dynamics of the selected load pro- gram.

  • Page 231: Changing The Fork Arms

    Operating Lifting protection (variant)" in the chapter entitled "Lift height-dependent assistance systems". The lift cylinders have in-built fixed stops to prevent the fork arms from hitting the ground. The lower stop makes inserting the forks into a pallet more comfortable. The driver cannot adjust the fork wear protec- tion manually.
  • Page 232 Operating Lifting NOTE It is recommended that a transport pallet is ● used to supporting the fork arms when they are being installed or removed. The pallet size depends on the size of fork arms in use. It should be large enough that the fork arms do not protrude after being placed on the pallet.

  • Page 233: Fork Extension (Variant)

    Operating Lifting  DANGER There is a risk of fatal injury from a falling load or fork! – Tighten the locking screw (2) each time a fork is changed. – It is not permitted to drive or to transport loads without the locking screw in place. NOTE If the truck is equipped with the "load meas- urement"...
  • Page 234 Operating Lifting NOTE If the truck is equipped with the "load meas- urement" assistance system (variant), the "tare" function must always be run after the fork arms have been changed. Otherwise, cor- rect load measurement cannot be guaranteed. Attaching   DANGER Risk of fatal injury from falling load! At least 60% of the length of the fork extension must...

  • Page 235: Operation With Reversible Fork Arms (Variant)

    Operating Lifting – Insert the securing bolt fully into the fork extension. – Insert the linch pin into the securing bolt and secure. Operation with reversible fork  arms (variant)  DANGER Risk of fatal injury from falling load! Normal fork arms are not structurally designed for reverse operation.

  • Page 236: Malfunctions During Lifting Mode

    Operating 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 237: Hydraulic Blocking Function

    Operating Lifting 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 238 Operating Lifting NOTE Only the emergency steering function remains available.  222 56368011501 EN - 04/2022  -  13...

  • Page 239: Handling Loads

    Operating 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 240 Operating Handling loads  DANGER Risk of fatal injury from the truck losing stability! Never exceed the load capacity indicated on the capacity rating plate. This applies to compact and homogeneous loads. If these values are exceeded, the stability and rigidity of the fork arms and lift mast cannot be guaranteed.
  • Page 241 Operating Handling loads Basic capacity rating plate 6219_003-337 Basic capacity rating plate Permissible lift height Weight of load to be lifted Distance between the load centre of gravity and the fork back There is always at least one capacity rating plate on the truck: the basic capacity rating plate.
  • Page 242 Operating Handling loads Example of reading the capacity rating plate:  The position numbers in the adjacent graphic correspond to the position numbers on the ba- sic capacity rating plate. Distance between the load centre of 5880 mm gravity and the fork back: 600 mm Permissible lift height: 5880 mm Weight of load to be lifted: 1000 kg The distance between the load centre of grav-...

  • Page 243: Picking Up Loads

    Operating Handling loads A large sideshift enables a strongly off-centre  load position. A large centre offset of the load results in a large reduction in the load capacity of the truck. XZP150 100x40x1200 Since non-integrated attachments can be re- h(mm) placed, multiple residual load capacity rating 6580...

  • Page 244: Danger Area

    Operating Handling loads sufficiently far apart and are positioned as far as possible under the load. If possible, the load should rest on the back of the fork. The load must not protrude too far over the fork tips, nor should the fork tips protrude too far out from the load.

  • Page 245: Transporting Pallets

    Operating Handling loads  DANGER Risk of injury! – Do not step on the fork.  DANGER Risk of injury! – Do not step under the raised forks.  DANGER People may be injured in the danger area of the truck! The danger area of the truck must be completely clear of all personnel, except the driver in his normal operating position.

  • Page 246: Transporting Suspended Loads

    Operating 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, e.g. in Italy. – Contact the relevant authorities. –...

  • Page 247: Picking Up A Load

    Operating Handling loads shift or release unintentionally and cannot be damaged. When transporting suspended loads, suita- ● ble aids (e.g. guy wires or supporting poles) must be available so that accompanying persons can guide suspended loads and prevent the loads from swinging. Take particular care to ensure that there is ●...
  • Page 248 Operating 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 249 Operating 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 250 Operating Handling loads – Lower the load while maintaining ground  clearance. – Tilt the lift mast backwards.  The load can be transported.  234 56368011501 EN - 04/2022  -  13...

  • Page 251: Determining Visibility Conditions When Driving With A Load

    Operating Handling loads Determining visibility conditions when driving with a load 6219_003-336 Area that is not visible (max. 1085 mm) Load Load height (in driving position) Driver's eye level 4000 mm (distance to the front from the rear corner of the load when it is positioned on the fork carriage in the driving position) The driver's field of vision can be severely limited when driving with a larger load (Y) or...

  • Page 252: Transporting Loads

    Operating 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 253: Shake Function (Variant)

    Operating 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 254 Operating 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 255 Operating Handling loads  WARNING Risk of accident due to unintentional switch-off of the intermediate lift cut-out. If the truck is also equipped with the "intermediate lift cut-out" variant and the shake function is performed close to an intermediate lift cut-out lift limit, this may inadvertently cancel the lift limit.
  • Page 256 Operating Handling loads Double mini-lever:  – Move the 360° lever (2) back and forth between positions (A) and (B) four times. Then continue to move the component in the same way. Triple mini-lever:  – Move the 360° lever (3) back and forth between positions (A) and (B) four times.

  • Page 257: Setting Down A Load

    Operating Handling loads Fingertip:  – Move the operating lever (5) back and forth four times. Then continue to move the com- ponent in the same way. 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.
  • Page 258 Operating Handling loads – Drive up to the stack with the load lowered  in accordance with regulations. – Set the lift mast to vertical. – Lift the load to the stacking height. – Drive the truck towards the rack carefully. –...

  • Page 259: Driving On Ascending And Descending Gradients

    Operating Handling loads Driving on ascending and de-  scending gradients  DANGER Risk of fatal injury! Driving on ascending and descending gradients car- ries special dangers! – Always follow the instructions below. – On ascending and descending gradients, the load must be carried facing uphill. –...

  • Page 260: Driving Onto Lifts

    Operating Handling loads Driving onto lifts  The driver may only use this truck on lifts with a sufficient load capacity and for which the operating company has been granted authori- sation (refer to the section entitled "Definition of responsible persons").  DANGER There is a risk of fatal injury from being crushed or run over by the truck.

  • Page 261: Driving On Loading Bridges

    Operating 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 262: Lift Height-Dependent Assistance Systems

    Operating Lift height-dependent assistance systems Lift height-dependent assistance systems Optical lift height measuring sys- tem (variant) Design and function  This truck can be fitted with an optical lift height measuring system as a variant. This system is a prerequisite for the assistance systems described in this chapter.
  • Page 263 Operating Lift height-dependent assistance systems Cleaning  It is recommended that the LED sensor glass (2) and the reflector (1) are checked before starting work and, if required, cleaned. The cleaning frequency depends on the appli- cation conditions of the truck. The quality of the light signal may also be reduced as a re- sult of heavy rain or fogging up of the sensor.
  • Page 264 Operating Lift height-dependent assistance systems  CAUTION Risk of damage to the LED lift height sensor through high-pressure cleaning! A high-pressure cleaner can damage the LED lift height sensor due to the penetration of water. This can result in incorrect measurements. –...
  • Page 265 Operating Lift height-dependent assistance systems Emergency operation in the event of malfunctions In the event of a malfunction in the height measurement system, the truck switches to emergency operation. In emergency operation, the assistance sys- tems listed below that are dependent on the lift height are not available: Lift height display ●...

  • Page 266: Lift Height Display (Variant)

    Operating Lift height-dependent assistance systems Lift height display (variant)  If the truck is equipped with the optical lift height measuring system, the current lift height (1) appears permanently in the display- operating unit. The lift height displayed corresponds to the 7,0°...

  • Page 267: Intermediate Lift Cut-Out (Variant)

    Operating Lift height-dependent assistance systems Intermediate lift cut-out (variant)  This function interrupts the lifting process at a set lift height. The intermediate lift cut-out function is useful if the fork carriage is fre- quently lifted to a particular lift height. There are two options when buying the truck: When buying the truck, the lift heights at which the intermediate lift cut-out takes...
  • Page 268 Operating Lift height-dependent assistance systems NOTE The display always displays the next lift limit that is in the path of the current lifting move- ment. The next lift limit at which the function will intervene is highlighted in grey in the display.
  • Page 269 Operating Lift height-dependent assistance systems Option: Lifting beyond the intermediate lift cut-out using the "F button" Optionally, the authorised service centre can configure the function so that the intermedi- ate lift cut-out is suspended by pressing the "F" button on the operating devices for the hydraulic functions.
  • Page 270 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  softkey.  Lift cut-out Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en  254 56368011501 EN - 04/2022  - ...
  • Page 271 Operating Lift height-dependent assistance systems This menu offers three storage locations.  – To configure storage location 1, press Intermediate lift cut-out  softkey. Intermediate lift cut-out 1 Intermediate lift cut-out 2 Intermediate lift cut-out 3 End lift cut-out Fleet manager 6219_003-315_en In this menu, you can define the desired lift ...

  • Page 272: Lift Transition Damping (Variant)

    Operating Lift height-dependent assistance systems – To deactivate the  intermediate lift , press the cut-out 1 Intermediate  softkey. lift cut-out 1 Intermediate – Press the scroll button  lift cut-out 1 intermediate lift cut-out 1 is deactivated. The orange activation bar goes out.

  • Page 273: End Lift Cut-Out (Variant)

    Operating Lift height-dependent assistance systems End lift cut-out (variant)  This assistance system limits the lift height of the fork carriage. This assistance system does not release the driver from the obligation to observe the "Safety regulations for handling loads". The end lift cut-out is active by default when the truck is switched on.
  • Page 274 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  softkey.  Lift cut-out Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en  258 56368011501 EN - 04/2022  - ...
  • Page 275 Operating Lift height-dependent assistance systems – Press the  softkey.  End lift cut-out Intermediate lift cut-out 1 Intermediate lift cut-out 2 Intermediate lift cut-out 3 End lift cut-out Fleet manager 6219_003-315_en In this menu, you can define the desired lift ...

  • Page 276: Speed Reduction When The Fork Carriage Is Raised (Variant)

    Operating Lift height-dependent assistance systems – To deactivate the  End lift cut-out press the  softkey. End lift cut-out – Press the scroll button  Intermediate is deactivated. lift cut-out 1 End lift cut-out The orange activation bar goes out. Enter desired height 6,892 = Clear = Deactivate...
  • Page 277 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  Speed restriction for softkey. lift Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 56368011501 EN - 04/2022  - ...
  • Page 278 Operating Lift height-dependent assistance systems – Press the  softkey.  Lift height Lift height Speed restriction Fleet manager 6219_003-321_en In this menu you can define the desired  height. Speed reduction when NOTE the fork carriage is raised » Lift height The assistance system intervenes automati- cally from 500 mm.
  • Page 279 Operating Lift height-dependent assistance systems – Press the   softkey.  Truck settings – Press the  Speed restriction for softkey. lift Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 56368011501 EN - 04/2022  - ...
  • Page 280 Operating Lift height-dependent assistance systems – Press the softkey.  Speed restriction Lift height Speed restriction Fleet manager 6219_003-321_en In this menu you can define the maximum  speed. – Enter the speed using softkeys  0 to 9 Speed restriction –...

  • Page 281: Electrical Fork Wear Protection (Variant)

    Operating Lift height-dependent assistance systems Electrical fork wear protection  (variant) This assistance system, in conjunction with the optical height measuring system, ensures that the fork arms do not touch the ground. The correct height for inserting the forks in a pallet can also be configured.
  • Page 282 Operating Lift height-dependent assistance systems NOTE Alternatively, the authorised service centre can parametrise the "F" button to cancel the fork wear protection for the complete lowering of the fork. NOTE When you change fork arms, the fork wear protection must be zeroed. –...
  • Page 283 Operating Lift height-dependent assistance systems – Press the  Fork wear protection softkey. Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en In this menu you can define the desired ...

  • Page 284: Tilt Angle-Dependent Assistance Systems

    Operating Tilt angle-dependent assistance systems Tilt angle-dependent assistance systems Mast tilt angle display (variant)  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"...
  • Page 285 Operating Tilt angle-dependent assistance systems positioning reduces wear on various compo- nents, 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- ● tioning" feature Automatic startup of the "Automatic mast ●...

  • Page 286: Function Checking Of The Automatic Mast Vertical Positioning Function (Variant)

    Operating Tilt angle-dependent assistance systems Function checking of the auto- matic mast vertical positioning function (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"...
  • Page 287 Operating Tilt angle-dependent assistance systems – Drive the truck into an area that is to be used for placing loads into stock and re- moving loads from stock. 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.
  • Page 288 Operating Tilt angle-dependent assistance systems – Press the scroll keys    until the  Cal- menu appears. ibration – Press the  softkey. Calibration Maintenance interval Calibration Shock sensor Change password (access auth.) Relieve hydraulics Fleet manager 6219_003-277_en – Press the  softkey.

  • Page 289: Load-Dependant Assistance Systems

    Operating 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 290 Operating Load-dependant assistance systems Configuration by the fleet manager – Activate the "Access authorisation for the fleet manager". – Press the  button. – Press the  softkey. – Press the   softkey.  Truck settings – Press the soft-  Overload detection key.
  • Page 291 Operating Load-dependant assistance systems In this menu you can define the desired  weight. – Enter the weight using softkeys 0 to 9 Overload detection NOTE Only a lower value than the permissible load Enter desired weight capacity of the truck can be entered as an overload.
  • Page 292 Operating Load-dependant assistance systems Dynamic Load Control 1 regulates the lifting and tilting dynamics and the driving dynamics according to the following criteria: Lift height ● Load weight ● Load movements which could lead to critical conditions are slowed down if necessary. Dynamic Load Control 1 intervenes in the fol- lowing operating situations: With a telescopic lift mast:...
  • Page 293 Operating Load-dependant assistance systems  WARNING Risk of accident due to the slow response of the lifting system! If the lifting movements are configured to use low dynamics, the lifting system responds after a delay when the operating device is released, even in an emergency.
  • Page 294 Operating 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 restriction again. Re- lease the accelerator pedal for a short period to do this. The bar display on the display of the display- ...

  • Page 295: Load Measurement (Variant)

    Operating Load-dependant assistance systems If a sensor belonging to Dynamic Load Con-  trol 2 fails, the level of intervention from the function is increased to a maximum. A cross appears instead of the bar. – If this display appears permanently, contact the authorised service centre.

  • Page 296: Calibrating The Load Measurement

    Operating Load-dependant assistance systems NOTE The load measurement must be calibrated in order to ensure accuracy at all times. The "access authorisation for the fleet manager" is required for the calibration. This access is required: After changing the fork arms, ●...
  • Page 297 Operating Load-dependant assistance systems – Activate the "Access authorisation for the fleet manager". – 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...

  • Page 298: Precision Load Measurement (Variant)

    Operating 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 299 Operating Load-dependant assistance systems – Press the  softkey (1).  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 0,0° fork slightly the measurement accuracy in trucks with mul- ti-lever operation.

  • Page 300: Tare Function (Variant)

    Operating 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 301 Operating Load-dependant assistance systems – Press the  softkey (1).  The activation bar next to the  symbol lights 0,70 --,-- 0,0° 6219_003-225   prompt is  Lower fork slightly displayed. – Lower the fork carriage. The value is calculated. The message Zero-  ...

  • Page 302: Total Load (Variant)

    Operating Load-dependant assistance systems Total load (variant)  Use the "total load" variant to calculate the total weight of multiple loads. The "total load" is an additional function of the "load meas- urement". It records the individual loads and stores up to three total loads. This allows, for example, three different con- tainers to be laden and their loading weight to be determined.
  • Page 303 Operating Load-dependant assistance systems The first menu level appears. – Press the  softkey. – Press the  softkey. A menu appears with three storage locations  for the total load. The total load is explained here using  0,00 – Press the  softkey.
  • Page 304 Operating Load-dependant assistance systems The message with the prompt  Lower fork   appears. slightly – 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°...

  • Page 305: Zeroing The Assistance Systems

    Operating Zeroing the assistance systems Zeroing the assistance systems Zeroing process The following assistance systems sometimes require zeroing. Load measurement ● When changing fork arms or attachments Lift height display ● When replacing worn tyres For increasingly worn tyres / for new tyres Mast tilt angle display ●...
  • Page 306 Operating Zeroing the assistance systems – Press the softkey.  Zeroing Auxiliary hydraulics Change PIN codes Manage driver profiles On-board charger Zeroing Fleet manager 6219_003-323_en – Press the softkey for the assistance func-  tion for which the zeroing is to be per- formed, e.g.
  • Page 307 Operating Zeroing the assistance systems The instructions are shown in the display.  Here: Lower forks After the instructions have been followed, Load weight the messages Zeroing successful are displayed. Zeroing failed – If zeroing failed, try again. Lower forks –...

  • Page 308: Depressurising The Hydraulic System

    Operating Depressurising the hydraulic system Depressurising the hydraulic system Need to depressurise the hy- draulic 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 309: Wizard For Depressurising The Hydraulic System

    Operating Depressurising the hydraulic system Wizard for depressurising the hydraulic 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 310 Operating 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, press the softkey.

  • Page 311: Depressurising The Hydraulic System Using Multi-Lever Operation

    Operating Depressurising the hydraulic system The following message appears:  Disen- gage all hydraulic axles, then   switch off the truck – Depressurise the hydraulics, see the rele- vant section for the respective operating de- vices.  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 312: Depressurising The Hydraulic System Using Multi-Lever Operation And The 5Th And 6Th Function

    Operating Depressurising the hydraulic system The hydraulic circuits of the basic functions are now depressurised. 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.

  • Page 313: Depressurising The Hydraulic System Using A Double Mini-Lever

    Operating Depressurising the hydraulic system – Start the "wizard for depressurising the hy- draulic 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.

  • Page 314: Depressurising The Hydraulic System Using The Double Mini-Lever And The 5Th Function

    Operating 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 315: Depressurising The Hydraulic System Using A Triple Mini-Lever

    Operating 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 316: Depressurising The Hydraulic System Using The Triple Mini-Lever And The 5Th Function

    Operating 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 317: Depressurising The Hydraulic System Using A Quadruple Mini-Lever

    Operating 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 318: Depressurising The Hydraulic System Using The Quadruple Mini-Lever And The 5Th Function

    Operating 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 319: Depressurising The Hydraulic System Using The Fingertip

    Operating 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 320: Depressurising The Hydraulic System Using The Fingertip And The 5Th Function

    Operating 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 321: Depressurising The Hydraulic System Using The Joystick 4Plus

    Operating 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 322: Depressurising The Hydraulic System Using The Joystick 4Plus And The 5Th Function

    Operating 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 323: Special Feature For Clamping Attachments

    Operating 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 al- so be depressurised. The procedure is simi- lar to the depressurisation of the hydraulic cir- cuits for the basic functions and the additional functions.

  • Page 324: Exiting The Wizard

    Operating 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 325: Attachments

    Fitting attachments If the truck is equipped with an integrated at- tachment (variant) at the factory, the specifica- tions in the STILL operating instructions for integrated attachments must be observed. If attachments are fitted at the place of use, the specifications in the operating instructions from the attachment manufacturer must be ob- served.
  • Page 326 Operating Attachments  WARNING Risk of accident due to incorrect labelling! The use of attachments can cause accidents if the labelling is incorrect or missing. If the truck is not fitted with an attachment-specific residual load capacity rating plate, and the operating devices are not marked with the relevant pictograms, the truck must not be used.
  • Page 327 Operating Attachments Plug connectors on the lift mast  – Before fitting the attachment, depressurise the hydraulic system; see the chapter enti- tled "Depressurising the hydraulic system".  CAUTION Risk of damage to components! Open connections on the plug connectors (1) can become dirty.

  • Page 328: General Instructions For Controlling Attachments

    Operating Attachments General instructions for control- ling 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 329: Attachment Example For The Connection Of The Auxiliary Hydraulics

    Operating Attachments NOTE If several hydraulic functions are used at the same time, these functions can influence each other. For example, if the fork carriage is raised and an attachment is operated at the same time, this may change the lifting speed or the operating speed of the attachment.
  • Page 330 Operating Attachments Attachment example for an attachment for ad-  justment of the fork arms Auxiliary hydraulics 1 Auxiliary hydraulics 2 Electrical connection for switch valve 1 (two switch valves are possible) If an attachment is connected to the auxiliary hydraulics 1 (1) and this attachment requires another function, this is referred to as the function of the auxiliary hydraulics 3.
  • Page 331 Operating 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 applied. If the parking brake is released pre- maturely, the settings menu will close.
  • Page 332 Operating 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 333: Clamp Locking Mechanism (Variant)

    Operating Attachments The return flow is displayed in addition to the  supply flow at full brightness. To adjust the revolution speed, press the  softkey. Auxiliary hydraulics 2 – To save the setting, press the  softkey. Forwards 3 900 1/min The settings are saved.
  • Page 334 Operating Attachments – See the section concerning the relevant op- erating device.  318 56368011501 EN - 04/2022  -  13...

  • Page 335: Controlling Attachments Using Multi-Lever Operation

    Operating 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 336 Operating 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 337: Controlling Attachments Using Multi-Lever Operation And The 5Th And 6Th Function

    Operating 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". The central and bottom parts of the picto- grams on each operating lever show the func- tion that is activated by that lever.
  • Page 338 Operating 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 339: Controlling Attachments Using A Double Mini-Lever

    Operating 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 340 Operating 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 341: Controlling Attachments Using The Double Mini-Lever And The 5Th Function

    Operating Attachments Controlling attachments using  the double 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" (3) and the cross lever (1) are used to control the "5th function".
  • Page 342 Operating 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 extended. If the function key for the "5th function" (3) is actuated and the "attachments" cross lever (1) is moved in the direction of the arrow (A), the fork arms open.

  • Page 343: Controlling Attachments Using A Triple Mini-Lever

    Operating Attachments Controlling attachments using a  triple 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 344 Operating 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 345: Controlling Attachments Using The Triple Mini-Lever And The 5Th Function

    Operating 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 346 Operating 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 347: Controlling Attachments Using A Quadruple Mini-Lever

    Operating 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 348 Operating 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 349: Controlling Attachments Using The Quadruple Mini-Lever And The 5Th Function

    Operating 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 350: Controlling Attachments Using The Fingertip

    Operating 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 351 Operating 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 352: Controlling Attachments Using The Fingertip And The 5Th Function

    Operating 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 1 2 3  the Fingertip and the 5th func- tion NOTE For technical reasons, clamping attachments...
  • Page 353 Operating Attachments Picto- Attachment function gram Move sideshift to the right 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...

  • Page 354: Controlling Attachments Using The Joystick 4Plus

    Operating 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 355 Operating 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 356: Controlling Attachments Using The Joystick 4Plus And The 5Th Function

    Operating 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". The adhesive label bearing the pictograms for the hydraulic functions (3) for the Joy- stick 4Plus (2) and for the horizontal rocker 6219_003-166_V2...

  • Page 357: Picking Up A Load Using Attachments

    Operating 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 358: Auxiliary Equipment

    Operating Auxiliary equipment Auxiliary equipment 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. Shock recognition (variant) The shock recognition is an equipment var- iant of the FleetManager (variant) in which an...
  • Page 359 Operating Auxiliary equipment 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 – To activate the "Intermittent mode" operat- ing stage, press the softkey again. The symbol (2) is shown with an orange back- ground.

  • Page 360: Filling The Washer System

    Operating Auxiliary equipment – To switch this operating stage off, press the softkey repeatedly until the symbol (1) ap- pears again on the display. Roof panel wiper and washer  – To activate the "On" operating stage, press the corresponding softkey  (9).

  • Page 361: Operating The Rear Window Heating

    Operating Auxiliary equipment – Operate the screen washer system until washer fluid is discharged from the spray nozzles. Operating the rear window heat-  – To switch on the rear window heating, push the associated Softkey on the display-oper- ating unit. The rear window heating is switched on.
  • Page 362 Before the truck is able to ac- celerate to the maximum speed permitted for outdoor areas, the speed limitation must still be unlocked. To do this, release the accelerator briefly and then operate the ac- celerator again.
  • Page 363 Operating 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 364 Operating 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 365 Operating 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 366: Run-On Time For Additional Devices

    Operating Auxiliary equipment Sensitivity Range Beam angle 2 m 42° 4 m 33° High (3) 8 m 22.5° 16 m 20° 24 m 15° 2 m 45° 4 m 43° Very high (4) 8 m 30° 16 m 22.5° 24 m 18° – After the adjustment, refit the cover. – Refit the ceiling sensor and connect it. –...
  • Page 367 Operating Auxiliary equipment – Press the softkey   Truck settings – Press the  softkey.  Run-on time Lift cut-out Run-on time Overload detection Fork wear protection Speed reduction when the fork carriage is raised Fleet manager 6219_003-314_en 56368011501 EN - 04/2022  -  13  351...
  • Page 368 Operating Auxiliary equipment In this menu you can define the desired run-on  time. – Enter the run-on time using softkeys  0 to Run-on time – To , press the  button. save NOTE Enter run-on time If a run-on time has been activated, the truck Min.

  • Page 369: Optical Assistance Systems

    Operating Optical assistance systems Optical assistance systems Circumferential view camera system (variant) Design Front camera Left-hand camera Right-hand camera Monitor Rear camera The camera system consists of four cameras and a monitor for the camera images. It pro- vides a 360° circumferential view and supports the driver in handling the truck.
  • Page 370 Operating Optical assistance systems system makes it easier to detect other vehi- cles, people and objects in the vicinity of the truck. For safe operation of the camera system, it must be sufficiently bright. The camera sys- tem is not suitable for poorly lit or dark envi- ronments.
  • Page 371 Operating Optical assistance systems  CAUTION Distorted display of the surroundings. Distances and geometric dimensions of obstacles may differ in reali- ty from the representation on the screen. – Regardless of the cameras, always look in the direction you are driving. –...
  • Page 372 Operating Optical assistance systems Rear field of vision The four cameras cover a 360° detection area around the truck. In the hatched areas of the representation above, the fields of vision of the respective adjacent cameras overlap. Monitor The cameras transmit their images to a moni- tor mounted on the top of the right-hand A col- umn via a double joint.
  • Page 373 Operating Optical assistance systems Operation Before attempting to drive, the driver must en- sure that all four cameras are operational and set correctly. – For the right-hand and left-hand cameras, hold one hand out of the right-hand cab window and one hand out of the left-hand cab window.

  • Page 374: Modular Camera System (Variant)

    Operating Optical assistance systems Modular camera system (var- iant) Design The modular camera system consists of the following components: Camera on the right-hand fork arm Front view camera in the lift mast Monitor Rear view camera on the overhead guard These cameras can only be ordered individu- ally or in the following combinations: Front view camera in the lift mast + rear...
  • Page 375 Operating Optical assistance systems The camera system makes it easier to detect other vehicles, people and objects in the vicin- ity of the truck. For safe operation of the camera system, it must be sufficiently bright. The camera sys- tem is not suitable for poorly lit or dark envi- ronments.
  • Page 376 Operating Optical assistance systems  CAUTION Distorted display of the surroundings. Distances and geometric dimensions of obstacles may differ in reali- ty from the representation on the screen. – Regardless of the cameras, always look in the direction you are driving. –...
  • Page 377 The camera angle is chosen in such a ● way that the counterweight is always visible and thus the immediate surroundings of the truck. STILL recommends not changing this setting. The image is displayed the correct way ● round, just like the interior mirror on a car.
  • Page 378 Operating Optical assistance systems  CAUTION When transporting tall loads, the front view camera cannot detect people or obstacles directly in front of the truck. Do not drive for long distances. If necessary, use a guide. Camera on the right-hand fork arm Camera may only be used to place loads ●...

  • Page 379: Laser-Smartfork Assistance System (Variant)

    Operating Optical assistance systems Cleaning – Clean the camera lenses with compressed air or use a small amount of glass cleaner to moisten the lenses. Do not use an ag- gressive cleaning agent or solvents. – Then carefully wipe away with a lint-free cloth.
  • Page 380 Operating Optical assistance systems  DANGER Risk of injury! Looking into the laser beam can damage the eyes, laser radiation (laser class 1M). – If there is a possibility that people are at risk, switch off the laser immediately. – Never look directly into the laser beam. –...
  • Page 381 Operating Optical assistance systems Precautionary measures – There must be no persons stood on the racking levels onto which the laser beam is projected. – If it is possible to see through the rack on- to racks situated behind the relevant rack, people must not stand on the racking lev- els opposite the rack on which the laser is working.
  • Page 382 See the chapter entitled "Config- uring favourites" in the separate operating instructions for the "STILL Easy Control dis- play-operating unit". – Automatic: Switch on the automatic func- tion using the softkey.
  • Page 383 Operating Optical assistance systems – Fully lower the fork carriage before driving any further. – Depending on the variant, switch off the la- ser. Manual: Press the softkey again to switch off the laser. Automatic: The laser switches off automatically if: The "lift/lower"...
  • Page 384 Operating Optical assistance systems  WARNING Possible damage to the laser due to improper clean- ing! – Do not use aggressive cleaning materials or sol- vents. – Do not use high-pressure cleaning equipment. – Never immerse the laser in water or other liquids. –...

  • Page 385: Cab

    Operating Opening and closing the cab  door  CAUTION Risk of component damage. If the cab door opens while driving, there is risk of damage from a collision. – The cab door must be latched securely in the en- gaged position. The truck has a cab door sensor that is used to monitor the closing of the cab door.

  • Page 386: Opening And Closing The Side Window

    Operating Closing the cab door from the inside: – Take hold of the handle (2). – Pull the cab door inwards and close it. Opening and closing the side  window  WARNING There is a risk of crushing between the window frame and side window due to the side windows slip- ping inadvertently during travel.

  • Page 387: 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. 56368011501 EN - 04/2022  -  13  371...

  • Page 388: Heating System (Variant)

    Operating 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 389 Operating 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 390 Operating 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. The blower is shut off.
  • Page 391 Operating Air conditioning (variant)  The air conditioning dries the air in the cab to prevent the glass panes misting up. The temperature of the air that is blown out is based on the heating level that has been set. The defrost function can be used to de-ice the windscreen quickly.

  • Page 392: Clipboard (Variant)

    Operating Clipboard (variant)  The clipboard (1) with reading lamp (2) is an equipment variant. 6210_003-107 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. –...
  • Page 393 Operating 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. – Use your left hand to take hold of the han- dle (5) on the roof window (1) and pull down until the locking bolt (4) engages.

  • Page 394: Sun Visor And Sun Blind

    Operating 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 395: Trailer Operation

    Operating Trailer 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 396: Coupling Pin In The Counterweight

    Operating Trailer operation  CAUTION Risk of damage to components! A support load is not permitted. – Do not use trailers with tillers supported by the tow coupling. This truck is suitable for the occasional towing of trailers. If the truck is equipped with a tow- ing device, this occasional towing must not exceed 2% of the daily operating time.
  • Page 397 Operating 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 398: Automatic Tow Coupling

    Operating 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. – Insert the coupling pin into the counter- weight, press downwards against the spring pressure and turn it by 90°.
  • Page 399 Operating Trailer operation  DANGER Risk of injury when coupling! People can become trapped between the truck and the trailer. – When coupling, ensure that there are no persons present between the truck and the trailer.  WARNING Risk of crushing when reaching into the coupling. When the coupling pin slams shut, there is a risk of crushing limbs in the coupling.
  • Page 400 Operating Trailer operation  WARNING Risk of component damage if the tiller in the tow coupling 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 service centre can adjust the assembly height for the tow coupling to the tiller height if necessary.
  • Page 401 Operating Trailer operation NOTE The coupling pin is correctly engaged if the control pin (3) does not protrude out of its guide.  DANGER Risk of accident due to open coupling pin! If the coupling pin drops out during towing, the trailer will work loose.
  • Page 402 Operating Trailer operation The tow coupling is opened. – Slowly drive the truck forwards until the tow- ing eye and towing jaws are disconnected. – 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.

  • Page 403: Towing Trailers

    Operating Trailer operation – Tow the trailer. Uncoupling model RO*245  – Take measures to prevent the trailer from rolling away, e.g. using wheel chocks. – Push the hand lever (5) upwards. – Slowly drive the truck forwards until the tow- ing eye and towing jaws are disconnected.

  • Page 404: Cold Store Application

    Operating 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 405 Operating 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 406 Operating Cold store application Limiting the load dynamics to load program 1  during the warm-up phase NOTE During the warm-up phase, the load dynamics are limited to load program 1. The adjacent symbol appears on the display until the warm- up phase is complete.
  • Page 407 Operating Cold store application – Charge the battery fully before each shift. – During the gassing phase, always top up with distilled water. The distilled water will mix with the battery acid so that it does not freeze. Water top-up systems must not be used at temperatures below 0°C, as this could cause the systems and the water present in the hose lines to freeze.

  • Page 408: Display Messages

    Operating Display messages Display messages Messages Certain truck conditions may cause event-rela- ted messages to be shown on the display of the display-operating unit. There are messages about operation and messages about the truck. If a message about operation appears, the display-operating unit will prompt you to perform an action.
  • Page 409 Operating Display messages Code Shown on display Cause/action This message about the on-board charger is triggered by different causes: A possible fault in the electrical connection be- tween the battery and the on-board charger. The fuse for the on-board charger on the truck  ...
  • Page 410 Operating Display messages Code Shown on display Cause/action If the temperature at the drive units is too high, this message appears. Sprint mode is no longer Acceleration restricted.     available. The truck switches to Classic mode. Temperature Acceleration is restricted. Curve Speed Control reduces the curve speed.
  • Page 411 Operating Display messages Code Shown on display Cause/action The load on the driver's seat is released but the parking brake cannot engage due to a defect. Secure the truck against     - Secure the truck with wedges so that the truck rolling away does not roll away.
  • Page 412 Operating Display messages Code Shown on display Cause/action The truck control unit detects that the braking force of the electric parking brake is reducing.     - Secure the truck with wedges so that the truck Check parking brake does not roll away. - Contact your authorised service centre.
  • Page 413 Operating Display messages Code Shown on display Cause/action This message is not displayed during normal Configuration: Please   operation.   wait - Contact the authorised service centre. If the truck is equipped with an integrated charg- er (variant) and charging is complete, this mes-  ...
  • Page 414 Operating Display messages Code Shown on display Cause/action There is a fault with the charging program. The On-board charger power V7001 charging process is performed with reduced reduction, service re- V7062 power.   quired - Contact the authorised service centre. This message is not displayed during normal  ...
  • Page 415 Operating Display messages Code Shown on display Cause/action If the battery is charged after locking sprint mode or a normal temperature is reached, this     Enable sprint mode message appears. Sprint mode can be used again once the truck has been restarted. If the battery experiences under-voltage or too high a temperature, this message appears.

  • Page 416: Messages About The Truck

    – 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 417: Procedure In Emergencies

    Operating Procedure in emergencies Procedure in emergencies Emergency shutdown   WARNING No electric braking assistance is available when the emergency off switch is actuated! Actuating the emergency off switch (1) disconnects the drives from the power supply. The regenerative brake will not hold the truck on a slope. –...

  • Page 418: Procedure If Truck Tips Over

    Operating Procedure in emergencies To decelerate the truck using the mechani- cal brake, the brake pedal has to be press- ed down further. The truck can only be held on a slope using ● the mechanical brake, not the regenerative brake.

  • Page 419: Emergency Hammer

    Operating Procedure in emergencies Emergency hammer  The emergency hammer is used to rescue the driver if he is shut inside the cab in a hazard- ous situation, for example if the truck has top- pled over and the cab door cannot be opened. Single-pane safety glass can be struck rela- tively safely using the emergency hammer in order for the driver to escape or be rescued...

  • Page 420: Emergency Lowering

    Operating Procedure in emergencies The message Emerg. direct. via   drive direction switch pears. The temperature of the display-operating ● unit is too low. This status is shown in the display as fol- lows:   The display-operating unit has failed. ●...
  • Page 421 Operating Procedure in emergencies – Remove the lid (1) on the right-hand side of  the footwell panelling near the accelerator pedal. – Remove the hexagon socket wrench (2)  from the compartment on the right next to the driver's seat. 6219_003-260 –...

  • Page 422: Emergency Actuation Of The Electric Parking Brake (Variant)

    Operating Procedure in emergencies – Re-tighten the emergency lowering screw. – Return the hexagon socket wrench to the support mounting in the compartment. – Refit the lid.  DANGER If the truck is operated while the hydraulic controller is blocked, there is an increased risk of accidents. –...
  • Page 423 Operating 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  attach it. Releasing the parking brake  – To release the parking brake, push down the hand wheel (1) and gently turn it an- ti-clockwise until the lower limit stop is reached.

  • Page 424: Towing

    Operating Procedure in emergencies Towing  Safety information  DANGER The brake system on the towing vehicle may fail. Risk of accident! If the brake system of the towing vehicle is not ade- quately sized, the vehicle may not brake safely or the brakes may fail.
  • Page 425 Operating Procedure in emergencies  DANGER Risk to life when manoeuvring! People can be crushed between the truck and the towing vehicle during manoeuvring. To ensure that the driver of the towing vehicle and the fitter attaching the tow bar are made aware of possible risks, the towing vehicle may only be man- oeuvred and the tow bar may only be attached when a second person is acting as a guide.
  • Page 426 Operating Procedure in emergencies – Sit on the driver's seat in the truck to be towed. Fasten the seat belt. – Use the available restraint systems. – Release the parking brake. – Select a towing speed that allows the truck and the towing vehicle to be braked and controlled effectively at all times.

  • Page 427: Connecting And Disconnecting The Battery Male Connector

    Operating Connecting and disconnecting the battery male connector Connecting and disconnecting the battery male connector Connecting the battery male  connector – Open the battery door.  CAUTION Potential for damage to the battery male connector! If the battery male connector is connected while the key switch is on (under load), a jump spark will be produced.

  • Page 428: Disconnect The Battery Male Connector

    Operating Connecting and disconnecting the battery male connector Disconnect the battery male  connector – Open the battery door.  CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the key switch is on (under load), an arc will be produced.

  • Page 429: Charging Quick-Access

    Operating Charging quick-access Charging quick-access Charging quick-access above the battery door (variant) The charging quick-access (variant) is an ad- ditional charger socket behind a lid on the left- hand side panel. This charger socket enables charging of lead-acid batteries and lithium-ion batteries without having to open the battery door.
  • Page 430 Operating Charging quick-access – 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.  DANGER Risk of fire due to overheated connec- tion assemblies! Plugs that are not fully plugged in can produce excessive heat.
  • Page 431 Operating Charging quick-access General NOTE To ensure maximum battery life, always charge lead-acid batteries fully. For intermedi- ate charging during work breaks, use an elec- trolyte circulation pump (variant). Lithium-ion batteries may be charged intermediately as often as required with no restriction to the bat- tery life.
  • Page 432 Operating Charging quick-access – When the charging process is complete, disconnect the charging cable from the charging quick-access (2). 2. Lead-acid battery with truck switched The parking brake is applied automatically or a message appears in the display of the dis- play-operating unit prompting the driver to ap- ply the parking brake.
  • Page 433 Operating Charging quick-access Charging state display in the display-op- erating unit for lithium-ion batteries When charging lithium-ion batteries, the  charging state display (3) appears in the dis- play-operating unit. If the charging state display (3) does not ap- 10:48 pear, there is an error. The charging quick-ac- cess (2) may not recognise the charging ca- ble.

  • Page 434: On-Board Charger

    Operating On-board charger On-board charger General information about the on-board charger (variant) With an on-board charger (variant), there is no need to keep space for a battery charger on company premises. This battery charger is suitable for operation using the public 400-V three-phase supply system with a CEE-16-A socket.

  • Page 435: Changing The Battery Type Used

    Reconfiguration not required: Changing from a lead-acid battery to a ● STILL lithium-ion battery Changing from one STILL lithium-ion bat- ● tery to another STILL lithium-ion battery The battery charger receives all necessary data directly from the lithium-ion battery.

  • Page 436: Configuring The On-Board Charger

    Operating On-board charger Reconfiguration required: Changing from a STILL lithium-ion battery ● to a lead-acid battery Changing from a large lead-acid battery to ● a smaller lead-acid battery with a lower bat- tery capacity or vice versa – Refer to the section entitled "Changing to a different battery type"...
  • Page 437 Operating On-board charger menu  On-board charger The following functions can be configured or switched on: Charging characteristic curve ● Charging characteristic curve ● Charging start time Charging start time ● Charging current limitation ● Maintenance charge Charging current limitation Maintenance charge Fleet manager 6219_003-285_en...
  • Page 438 Operating On-board charger menu  Charging start time – Enter the charging start time using soft- keys  Charging start time – To , press the  button. save – To activate the charging start time, press the scroll button  Enter time to The display reverts to the On-board start charging...
  • Page 439 Operating On-board charger The symbol changes to  (3). The orange  activation bar lights up next to the softkey. The charging state indicator (2) is animated in 10,0 green. Battery charging takes place. The remaining charging time (1) is displayed in the top-left. 75 % 6219_003-289 Charging current limitation...

  • Page 440: Charging The Battery

    Operating On-board charger active, the on-board charger checks the charging state of the battery from time to time and charges it if necessary. – Press the soft- Maintenance charge key. If the maintenance charge is active, the or- ange activation bar lights up next to the soft- key.
  • Page 441 Operating On-board charger  DANGER Risk of explosion due to static charge! If the driver is electrostatically charg- ed, touching the battery may produce sparks. These sparks can ignite oxyhy- drogen gas that has formed. – To dissipate a possible electrostatic charge, touch an earthed component that is situated a long way from the battery.
  • Page 442 Operating On-board charger  DANGER Risk of fire due to arcs! If the charging plug is disconnected dur- ing the charging process (under load), an arc will be produced. This can lead to erosion at the contacts, which consider- ably shortens the service life of the con- tacts and poses a fire hazard.
  • Page 443 Operating On-board charger NOTE To ensure maximum battery life, always charge lead-acid batteries fully. For intermedi- ate charging during work breaks, use an elec- trolyte circulation pump (variant). Lithium-ion batteries may be charged intermediately as often as required with no restriction to the bat- tery life.
  • Page 444 Operating On-board charger – Plug the truck plug (4) of the charging cable  into the charger socket (3) on the truck. – Make sure that the interlock (5) has closed correctly. After a self-test, the battery charger auto- matically begins the charging process. The LED (6) pulses in yellow.
  • Page 445 Operating On-board charger Charging state display on the charger  socket The LED (6) on the charger socket uses dif- ferently coloured flash codes to indicate the current status of the charging process. Only the authorised service centre may rectify mal- functions.
  • Page 446 Operating On-board charger Status Flash code Charging process was aborted or no system voltage present. Overtemperature of the connected battery   Yellow/red Wait for restart after power failure Legend: → LED off → LED on → LED flashing → LED pulsing →...
  • Page 447 Operating On-board charger End of the charging process  When the battery is fully charged, the bat- tery charger automatically stops the charging process. The charging state display (7) on 10:48 the display-operating unit of the truck shows 100% 100 % 6219_003-263 –...
  • Page 448 Operating On-board charger Stopping the charging process manually – Briefly press the charging button (8) on the  truck plug. The charging status display on the display-op- erating unit goes out. The mains plug can now be disconnected. – If the charging process needs to be started again, pull out the truck plug and plug it back in after approx.
  • Page 449 Operating On-board charger Cleaning Check the on-board charger on a regular ba- sis for contamination, particularly in the area of the fans. If significant contamination has accumulated on the battery charger, cooling may be im- paired. The isolation to the truck chassis may also be compromised.

  • Page 450: Compatible Batteries

    – Use only the batteries listed here. In addition to proprietary STILL lithium-ion batteries, only the following batteries may be used: Manufacturer Designation Capacity PzS, TCSM wet battery < 1700 Ah (48 V)

  • Page 451: Performance Data

    Operating On-board charger for gel batteries) is maintained. This produces the maximum battery capacity. If larger batter- ies than specified are charged, over the long term, the batteries can be damaged or may not fully charge. The values shown are for the maximum charging current of 170 A.

  • Page 452: Handling The Lead-Acid Battery

    Operating Handling the lead-acid battery Handling the lead-acid battery Safety regulations for handling the battery – National statutory provisions for the country of use must be followed when setting up and operating battery charging stations.  CAUTION Possible 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-...
  • Page 453 Operating Handling the lead-acid battery  WARNING Risk of crushing/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 454 Operating Handling the lead-acid battery  DANGER Risk of explosion due to flammable gases! During charging, the battery releases a mixture of oxygen and hydrogen (oxyhy- drogen gas). This gas mixture is explo- sive and must not be ignited. There must be no flammable materi- als or spark-forming operating materials within 2 m of the battery charger and the industrial truck when it is parked for...
  • Page 455 Operating Handling the lead-acid battery Performing battery maintenance The cell covers of the battery must be kept dry and clean. Terminals and cable shoes must be clean, lightly coated with battery grease and screwed on tightly. – Neutralise any spilt battery acid immediate- –...

  • Page 456: Maintaining The Battery

    Operating Handling the lead-acid battery – Do not block the ventilation gaps. – If the battery cover is deformed, contact the authorised service centre. Maintaining the battery  DANGER Danger to life and limb! – Observe the instructions in the chapter entitled "Safety regulations when handling the battery".

  • Page 457: Checking The Battery Condition, Acid Level And Acid Density

    Operating Handling the lead-acid battery Checking the battery condition, acid level and acid density  WARNING The electrolyte (dilute sulphuric acid) is poisonous and caustic! – Observe safety regulations for han- dling battery acid; see chapter "Bat- tery acid". – Wear personal protective equipment (rubber gloves, apron and protection goggles).

  • Page 458: Checking The Battery Charge Status And Calibrating The Battery Charge Indicator

    Operating Handling the lead-acid battery For a discharged battery, the acid density must be no lower than 1.14 kg/l. Checking the battery charge sta-  tus and calibrating the battery charge indicator  CAUTION Deep discharges shorten the service life of the bat- tery.
  • Page 459 Operating Handling the lead-acid battery calibrated to the newly inserted battery. The stored battery charge history is then deleted in the display-operating unit. – Activate the "Access authorisation for the fleet manager". – Press the  button. – Press the  softkey. –...

  • Page 460: Charging The Lead-Acid Battery

    Operating Handling the lead-acid battery – Press the  Calibrate discharge softkey. indicator After the instruction has been executed, the message Calibrate discharge indicator Calibration successful is dis- Calibration unsuccessful played. – If the calibration failed, try again. – If the calibration fails repeatedly, contact your authorised service centre.
  • Page 461 Operating Handling the lead-acid battery  DANGER There is a risk of damage, short circuiting and ex- plosions! – Do not place any metal objects or tools on the battery. – Keep away from naked flames. – Do not smoke.  WARNING Battery acid is toxic and corrosive! –...
  • Page 462 Operating Handling the lead-acid battery – Do not place any metal objects or tools on the battery. – Keep away from naked flames. Do not smoke. – Check the battery cables for damage. If necessary, have the battery cables re- placed by the authorised service centre.
  • Page 463 Operating Handling the lead-acid battery 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. – Swing the support bracket (1) outwards in an anticlockwise direction.

  • Page 464: Equalising Charging To Preserve The Battery Capacity

    Operating Handling the lead-acid battery – Close the battery door. When doing so, en-  sure that no cables are crushed between the chassis and the battery door. The battery door must be locked in place. The truck is equipped with a door contact switch for the battery door.
  • Page 465 Operating Handling the lead-acid battery the equalising charge begins between 6 and 24 hours after the end of the actual charging process. The equalising charge takes up to 2 hours. – Please refer to the operating instructions from the manufacturer of the battery charg- Ending the equalising charge The equalising charge ends automatically.

  • Page 466: Handling The Lithium-Ion Battery

    Operating Handling the lithium-ion battery Handling the lithium-ion battery Safety regulations for handling the lithium-ion battery First-aid measures  WARNING Risk of injury! Escaping gases can lead to breathing difficulties. Course of action required if gases or liquids escape – Immediately ventilate the area or go out into the fresh air;...
  • Page 467 Operating Handling the lithium-ion battery  WARNING Risk of crushing/shearing! The battery is very heavy. There is a risk of serious injury if any parts of the body are caught under the battery. If parts of the body are wedged between the battery door and the edge of the chassis when the battery door is closed, this could lead to injuries.
  • Page 468 Operating Handling the lithium-ion battery – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire. Battery weight and dimensions  DANGER Risk of tipping due to change in battery weight! The battery weight and dimensions affect the stability of the truck.

  • Page 469: Illustration Of A Lithium-Ion Battery

    Operating Handling the lithium-ion battery Illustration of a lithium-ion battery Example image Technology compartment Safety valve Battery male connector Diagnostic connector Lifting eyes Display  WARNING Risk of accident due to weakened lifting eyes. If bent lifting eyes are straightened, they lose their rigidity.

  • Page 470: Special Instructions And Course Of Action For C-Line Lithium-Ion Batteries

    The truck will then not be decelerated by the regenerative brake. – To brake, actuate the service brake. The STILL C-Line lithium-ion batteries are de- signed and built for indoor use. The ambient temperature range must be between +5°C...
  • Page 471 Operating Handling the lithium-ion battery Driving  DANGER Risk of accident due to the battery switching off when driving downhill! If the truck is driven downhill on a gradient of ≥ 8% at a speed of at least 16 km/h for longer than 85 m and the battery has a charge state of ≥ 95%, the battery may switch off.

  • Page 472: Regulations For Storing Lithium-Ion Batteries

    Operating Handling the lithium-ion battery Regulations for storing lithium- ion batteries NOTE Lithium-ion batteries are classified as danger- ous goods according to class 9. The following recommendations apply: Wherever possible, store batteries at ● ground level so that they cannot be dam- aged by falling Store the batteries in a segregated area ●...
  • Page 473 Operating Handling the lithium-ion battery – Store in a way that protects the batteries against short circuits – Store batteries at a safe distance from flam- mable materials – Do not store batteries together with metallic objects – Store lithium-ion batteries separately from other types of batteries (no mixed storage) –...

  • Page 474: Checking The Battery Charge State

    Operating Handling the lithium-ion battery Checking the battery charge state The charge state of the lithium-ion battery can be read on the display-operating unit of the truck and on the lithium-ion battery display. Reading on the display-operating unit  – Apply the parking brake. –...
  • Page 475 Operating Handling the lithium-ion battery The truck can no longer be moved. A charge state of > 20% to 30% is indicated ● by yellow bars. A charge state of > 30% to 100% is indica- ● ted by green bars When charging, the charge state LEDs (3) light up green as a chase light.

  • Page 476: Charging The Lithium-Ion Battery

    Operating Handling the lithium-ion battery – If the charge state drops below 15%, drive to the charging station and charge the bat- tery.  WARNING There is no electric brake assistance when the bat- tery is switched off! The drives are de-energised when the battery is au- tomatically switched off.
  • Page 477 Operating Handling the lithium-ion battery To read the battery charge status, see the section entitled "Checking the battery charge status". – Park the truck securely. – Open the battery door completely. – Disconnect the battery male connector. – Keep away from naked flames. Do not smoke.
  • Page 478 Operating Handling the lithium-ion battery – Observe the information in the operating in- structions for the battery and for the battery charger. NOTE 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 479 Operating Handling the lithium-ion battery – Close the battery door. When doing so, en-  sure that no cables are crushed between the chassis and the battery door. The truck is equipped with a door contact switch for the battery door. If the battery door is not fully closed, the message Close appears on the display of...

  • Page 480: Replacing And Transporting The Battery

    Using his/her access authorisation, the fleet manager can set the new battery capacity and the new battery type in the display-operating unit. – Use only lithium-ion batteries that have been approved by STILL for use with this truck.  464 56368011501 EN - 04/2022  -  13...

  • Page 481: Converting To Lithium-Ion Batteries

    Operating Replacing and transporting the battery Setting the new battery capacity and the new battery type – Stop the truck. – Apply the parking brake. – Press the  button. – Press the  softkey. The first menu level appears. – Activate the "Access authorisation for the fleet manager".

  • Page 482: Opening And Closing The Battery Door

    Operating Replacing and transporting the battery – Use only lithium-ion batteries that have been approved by STILL for use with this truck. Opening and closing the battery door Opening the battery door on standard  trucks – Grasp the door handle (1) on the battery door.
  • Page 483 Operating Replacing and transporting the battery Locking the battery door in 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 484 Operating 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 485: Special Notes For Installing The Lithium-Ion Battery

    Operating Replacing and transporting the battery Special notes for installing the  lithium-ion battery With the exception of the following special notes, lithium-ion batteries are replaced in the same way as lead-acid batteries. – Push down the lifting eyes before inserting the battery into the battery compartment.
  • Page 486 Operating Replacing and transporting the battery Removing the battery – Park the truck safely and switch it off. – Open the battery door.  CAUTION Potential for damage to the battery male connector! If the battery male connector is disconnected while the key switch is on (under load), an arc will be produced.
  • Page 487 Operating Replacing and transporting the battery – Open the battery locks (1).  NOTE If the battery locks cannot be opened by hand, the coupling pin (2) from the counterweight can be used as a lever extension. – Carefully drive the truck under the battery. –...
  • Page 488 Operating Replacing and transporting the battery Installing the battery  – Pick up the battery and transport it to the truck.  CAUTION Risk of component damage! If the lifting eyes protrude from the lithium-ion battery (variant), they will strike the truck chassis and bend. –...
  • Page 489 Operating Replacing and transporting the battery – Carefully lower the battery. – Carefully move the lifting accessories out from under the battery.  CAUTION Potential for damage to the battery male connector! If the battery male connector is connected while the key switch is on (under load), a jump spark will be produced.
  • Page 490 Operating Replacing and transporting the battery – Insert the battery male connector fully into  the plug connection on the truck. – Close the battery door.  474 56368011501 EN - 04/2022  -  13...

  • Page 491: Replacing The Battery Using A Lift Truck And A Battery Change Frame

    Operating 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 be at least equal to the weight of the battery and the weight of the change frame.
  • Page 492 Operating 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. Lithium-ion battery, e.g. tray 511 ●...
  • Page 493 Operating 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 Lead-acid battery, circuit A...
  • Page 494 Operating Replacing and transporting the battery – Disconnect the battery male connector.   WARNING Risk of crushing/shearing! No one must stand directly beside the battery or between the battery and the lift truck when removing or inserting the battery.  CAUTION Potential for damage to the battery ca- ble! –...
  • Page 495 Operating 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 is a suffi- cient distance from the surface and from the chassis at the top.
  • Page 496 Operating 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 497 Operating Replacing and transporting the battery – Carefully move the lifting accessory out from under 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 key switch is switched on or while the battery charger is under load, a transition spark will be produced at...

  • Page 498: Replacing The Battery Using A Hydraulic Battery Carrier (Variant)

    Operating Replacing and transporting the battery Replacing the battery using a hydraulic battery carrier (variant)  DANGER The battery weight and dimensions affect the stabil- ity of the truck. The weight ratios must not be changed when replac- ing the battery. The battery weight must remain with- in the weight range specified on the nameplate.
  • Page 499 Operating Replacing and transporting the battery Emergency off function when moving  the battery The emergency off switch (2) is located on the carriage next to the connection for the battery male connector (1). – In the event of an emergency, actuate the emergency off switch (2) or disconnect the battery male connector (1).
  • Page 500 Operating Replacing and transporting the battery – (B) Disconnect the battery male connector  from the plug connection of the truck. – (C) Insert the battery male connector into the plug connection of the battery carrier. The condition display on the carrier lights up green.
  • Page 501 Operating Replacing and transporting the battery The rollers of the carrier lower and lift the car-  rier. The condition display on the carrier now lights up red. – (G) Extend the carrier until the carriage has  reached its end position (F).  WARNING Risk of crushing! Never reach under the battery to remove obstacles.
  • Page 502 Operating Replacing and transporting the battery – (H) Remove the battery from the carrier us-  ing suitable lifting gear. For more informa- tion see the section entitled "Transporting the battery by crane". – To prevent damage to the truck when the crane is used, ensure that the truck is parked at a sufficient distance from any ob- stacles.
  • Page 503 Operating Replacing and transporting the battery – (L) After inserting, return the remote control  to its holder. The condition display on the carrier lights up green. – (M) Disconnect the battery male connector from the plug connection of the carrier. –...

  • Page 504: Transporting The Lead-Acid Battery By Crane

    Operating Replacing and transporting the battery Transporting the lead-acid bat-  tery 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 505: Transporting The Lithium-Ion Battery By Crane

    Operating Replacing and transporting the battery Transporting the lithium-ion bat-  tery by crane  DANGER There is risk of fatal injury from being struck by falling loads! – Never walk or stand underneath sus- pended loads.  WARNING Risk of accident due to weakened lifting eyes. If bent lifting eyes are straightened, they lose their rigidity.

  • Page 506: Cleaning The Truck

    Operating Cleaning the truck Cleaning the truck Cleaning the truck  WARNING Risk of injury from falling off the truck! When climbing onto the truck, there is a risk of getting stuck or slipping and falling. Use suitable equipment to reach higher points on the truck.
  • Page 507 Operating Cleaning the truck  CAUTION Excessive water pressure or water and steam that are too hot can damage truck components. – Strictly adhere to the following steps.  CAUTION Possible component damage due to compressed air. – If components are cleaned with compressed air, the air must have a maximum pressure of 0.15 bar.

  • Page 508: Cleaning The Electrical System

    Operating Cleaning the truck – Clean plastics only with cleaning materials intended for plastics. – Clean the truck exterior using water-soluble cleaning materials and water. Cleaning with a water jet, a sponge or a cloth is recom- mended. – Clean all accessible areas. –...

  • Page 509: Cleaning Load Chains

    Operating Cleaning the truck Cleaning load chains   WARNING Risk of accident! Load chains are safety elements. The use of cold/chemical cleaners or fluids that are corrosive or contain acid or chlorine can damage the chains and is forbidden! – Observe the manufacturer's guidelines for working with cleaning materials.

  • Page 510: Cleaning The Windows

    Operating Cleaning the truck Cleaning the windows  Any glass, for example cab windows (variant), must always be kept clean and free of ice. This is the only means of guaranteeing good visibility.  CAUTION Do not damage the rear window heater (inside). –...

  • Page 511: Transporting The Truck

    Operating Transporting the truck Transporting the truck Transport  CAUTION Risk of material damage from overloading! If the truck is driven onto a means of transport, the load capacity of the means of transport, lorry ramps and loading bridges must be greater than the total actual weight of the truck.
  • Page 512 Operating 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 513: Crane Loading

    Operating Transporting the truck Lashing down  CAUTION Abrasive lashing straps/tension belts can rub against the surface of the truck and cause damage. – Position slip-resistant pads (e.g. rubber mats or foam) underneath the lifting points. – Hook the lashing straps/tension belts onto ...
  • Page 514 Operating Transporting the truck with the harnesses expressly provided and ap- proved for this purpose. – Do not load the truck by crane!  498 56368011501 EN - 04/2022  -  13...

  • Page 515: Decommissioning

    Operating Decommissioning Decommissioning Decommissioning and storing the truck  CAUTION Damage to components due to incorrect storage! Improper storage or decommissioning for a period of more than two months can result in corrosion damage to the truck. If the truck is parked in an ambient temperature of below -10°C for an extended period, the batteries will cool down.
  • Page 516 Operating Decommissioning  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 electric arc will be produced. This can lead to erosion of the contacts, which considerably shortens the service life of the contacts.

  • Page 517: Use After Storage Or Decommissioning

    Operating Decommissioning service centre to find out about additional courses of action. Use after storage or decommis- sioning If the truck has been decommissioned for lon- ger than six months it must be checked care- fully before being used again. As with the annual safety inspection, this inspection must also include all safety-related aspects of the truck.
  • Page 518 Operating Decommissioning  502 56368011501 EN - 04/2022  -  13...

  • Page 519: Maintenance

    Maintenance...

  • Page 520: Safety Regulations For Maintenance

    Maintenance Safety regulations for maintenance Safety regulations for maintenance General information To prevent accidents during maintenance and repair work, all necessary safety measures must be taken, e.g.: – Apply the parking brake. – Turn off the key switch and remove the key. –...

  • Page 521: Safety Devices

    Maintenance Safety regulations for maintenance Rings, metal bracelets etc. must be removed before working on electric components. To prevent damage to electronic systems with electronic components, such as an electronic driving regulator or lift control, these compo- nents must be removed from the truck prior to the start of electric welding.

  • Page 522: Working At The Front Of The Truck

    Maintenance Safety regulations for maintenance Working at the front of the truck  DANGER Risk of accident due to an unsecured lift mast. If the lift mast or fork carriage is raised, no work may be performed on the lift mast or at the front of the truck unless the appropriate safety measures are put in place.

  • Page 523: General Maintenance Information

    Maintenance General maintenance information General maintenance infor- mation Personnel qualifications Only qualified and authorised personnel are allowed to perform maintenance work. Regu- lar safety checks and checks after unusual incidents must be performed by a competent person. The competent person must conduct their evaluation and assessment from a safety standpoint, unaffected by operational and eco- nomic conditions.
  • Page 524 Maintenance General maintenance information below. This ensures that the truck remains ready for operation and provides optimal per- formance and service life. It is also a precondi- tion for any warranty claims. Maintenance timeframe If maintenance is needed, the message  ...

  • Page 525: Setting Up And Adjusting The Due Date Counter For Maintenance And Safety Checks

    Maintenance General maintenance information The first menu level appears. – Activate the "Access authorisation for the fleet manager". – 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 526 Maintenance General maintenance information Setup and adjustment by the fleet man- ager For the fleet manager, due date counters are also defined for the following checks: Regular testing of the truck for electric ● trucks and IC trucks Battery testing for electric trucks ●...
  • Page 527 Maintenance General maintenance information menu  Safety check – Press the scroll button to activate the input. Safety check – Enter the desired date using softkeys 0 to – To , press the  button. save Enter date Due date counter for individual mainte- 30 .

  • Page 528: 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  ...
  • Page 529 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.    ...
  • Page 530 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).  ...

  • Page 531: 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  ...
  • Page 532 Maintenance General maintenance information Before carrying out lubricating work, filter changes or any work on the hydraulic system, carefully clean the area around the part in- volved. When topping up working materials, use only clean containers!  516 56368011501 EN - 04/2022  -  13...

  • Page 533: 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 One lubricating nipple on each of the two lift mast bearings The respective lubricant specification can be found in the "Maintenance data table"...

  • Page 534: Maintenance Data Table

    Maintenance General maintenance information Maintenance data table General lubrication points Code Unit Operating materials Specifications Dimension   Lubrication High-pressure ID no. 0147873 As required grease Battery Code Unit Operating materials Specifications Dimension   System filling Distilled water   As required Insulation resistance   DIN 43539 For further informa- VDE 0510...
  • Page 535 Maintenance General maintenance information Hydraulic battery carrier Code Unit Operating materials Specifications Dimension   Catch rail Multi-purpose oil, Rivolta TRS Plus As required acid-free, resin-free ID no. 0149847 Slide elements and High-pressure ID no. 0147873 As required guide rails grease System filling Hydraulic oil HVLP 68 Have the battery car-...
  • Page 536 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. 0148659 fresh grease escapes  ...

  • Page 537: Preserving Operational Readiness

    Maintenance Preserving operational readiness Preserving operational readiness Lubricating the joints and con-  trols – 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 ●...

  • Page 538: Checking The Battery Interlock And The Battery Door Interlock

    Maintenance Preserving operational readiness Checking the battery interlock  and the battery door interlock  DANGER A malfunction of the battery interlock and the bat- tery door interlock can cause the battery door to open and the battery could possibly fall out when the truck is tilted or during sharp deceleration.

  • Page 539: Maintaining The Seat Belt

    Maintenance Preserving operational readiness Maintaining the seat belt  DANGER There is a risk to life if the seat belt fails during an accident! If the seat belt is faulty, it may tear or open during an accident and no longer keep the driver in the driver's seat.

  • Page 540: Checking The Driver's Seat

    Maintenance Preserving operational readiness – The belt tongue (2) must release when the  red button (4) is pressed. – The automatic blocking mechanism must be tested at least once a year: – Park the forklift truck on level ground. –...

  • Page 541: Servicing The Heating System Or Air Conditioning

    Maintenance Preserving operational readiness Servicing the heating system or air conditioning Replacing the filter mat – Loosen the screw (1).  – Remove the cover (2). – 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.
  • Page 542 Maintenance Preserving operational readiness – Loosen the screws (1) on the filter  frame (2). – Remove the filter frame (2). – Remove any dust and dirt from the fresh-air  inlet (1) beneath the filter mat carrier.  526 56368011501 EN - 04/2022  -  13...

  • Page 543: 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 544: Servicing The Steering Axle

    Maintenance Preserving operational readiness Checking wheel fastenings – Check that the wheel-fastening screws (3) of the drive axle and the wheel-fastening nuts of the steering axle are securely in place and re-tighten as necessary. – Observe the torques specified in the "main- tenance data table".

  • Page 545: Checking The Battery

    Maintenance Preserving operational readiness Checking the battery – For information on checking the battery, see the chapter entitled "Checking the battery condition, acid level and acid density". Adjusting the warning zone light  – Switch on the truck. – Make sure that the parking brake is applied. –...

  • Page 546: Checking The Hydraulic System For Leak Tightness

    Maintenance Preserving operational readiness Checking the hydraulic system for leak tightness  WARNING Hydraulic oil is hazardous to health! Hydraulic oil under pressure can escape from leaking pipes and lines, and cause injuries. – Wear suitable protective gloves, pro- tection goggles etc.  CAUTION Hydraulic hoses become brittle! –...
  • Page 547 Maintenance Preserving operational readiness 56368011501 EN - 04/2022  -  13  531...

  • Page 548: Check The Hydraulic Oil Level

    Maintenance Preserving operational readiness Check the hydraulic oil level  90°  WARNING Hydraulic oils are hazardous to your health. – Observe the safety regulations in the chapter enti- tled "Hydraulic fluid". NOTE 90° When changing to a different type of hydraulic oil, the authorised service centre must adjust the parameters of the truck control unit.
  • Page 549 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 re-  quired filling levels for the different lift mast versions.

  • Page 550: Lubricating The Lift Mast And Roller Track

    Maintenance Preserving operational readiness Lubricating the lift mast and roll-  er 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 551: 1000-Hour Maintenance/Annual Maintenance

    Maintenance 1000-hour maintenance/annual maintenance 1000-hour maintenance/annual maintenance Other work that must be carried – Perform all tasks required to maintain full operability; see the chapter entitled "Re- maining ready for operation". Checking the lift cylinders and  connections for leaks  WARNING Risk of injury Observe safety regulations for working on the lift...

  • Page 552: Checking The Fork Arms

    Maintenance 1000-hour maintenance/annual maintenance Checking the fork arms  – 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 553: Checking The Double Pedal

    Maintenance 1000-hour maintenance/annual maintenance Checking the double pedal  – Remove the floorplate. – Check that the support and springs of the double pedal mechanism are securely posi- tioned. – Check that all screws are sealed with lock- ing varnish. 6327_003-026 Checking the battery change- over frame...
  • Page 554 Maintenance 1000-hour maintenance/annual maintenance  538 56368011501 EN - 04/2022  -  13...

  • Page 555: Technical Data

    Technical data...

  • Page 556: 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 557: Dimensions

    Technical data Dimensions Dimensions α β Seat is adjustable ± 90 mm Fork spacing is adjustable 56368011501 EN - 04/2022  -  13  541...
  • Page 558 Technical data Dimensions NOTE Measurements h and b are cus- tomised and can be taken from the order con- firmation.  542 56368011501 EN - 04/2022  -  13...

  • Page 559: 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 Q (kg) 1400...
  • Page 560 Technical data VDI datasheet: RX20-14C with steering turntable Model RX20-14C Type number 6219 Number of rear wheels   (x = driven) Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-14C Type number 6219 Forwards tilt of lift mast/fork car- α...
  • Page 561 VDI datasheet: RX20-14C with steering turntable 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 562 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) Battery capacity (Ah) Battery weight Energy consumption in accordance...

  • Page 563: 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...
  • Page 564 Technical data VDI datasheet: RX20-16 with steering turntable Model RX20-16C RX20-16 RX20-16L Type number 6220 6221 6222 Number of rear wheels   (x = driven) Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-16C RX20-16 RX20-16L Type number 6220 6221 6222...
  • Page 565 RX20-16C 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 566 Technical data VDI datasheet: RX20-16 with steering turntable Electric motor Model RX20-16C RX20-16 RX20-16L Type number 6220 6221 6222 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 B DIN 43531 B DIN 43531 B circuit Battery voltage...

  • Page 567: 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...
  • Page 568 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...
  • Page 569 RX20-18 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 570 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 43531 A (B)

  • Page 571: 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...
  • Page 572 Technical data VDI datasheet: RX20-16 with swing axle Model RX20-16P RX20-16PL Type number 6226 6227 Number of rear wheels   (x = driven) Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-16P RX20-16PL Type number 6226 6227 Forwards tilt of lift mast/fork car- α...
  • Page 573 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 574 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 DIN 43531 A circuit Battery voltage U (V)

  • Page 575: 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...
  • Page 576 Technical data VDI datasheet: RX20-18 with swing axle Model RX20-18P RX20-18PL Type number 6228 6229 Number of rear wheels   (x = driven) Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-18P RX20-18PL Type number 6228 6229 Forwards tilt of lift mast/fork car- α...
  • Page 577 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 578 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 U (V) Battery capacity...

  • Page 579: 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...
  • Page 580 Technical data RX20-20 swing axle VDI datasheet Model RX20-20P RX20-20PL Type number 6230 6231 Number of rear wheels   (x = driven) Track width, front (mm) Track width, rear (mm) Basic dimensions Model RX20-20P RX20-20PL Type number 6230 6231 Forwards tilt of lift mast/fork car- α...
  • Page 581 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 582: 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 Battery voltage...
  • Page 583 Technical data Eco-design requirements for electric motors and variable speed drives All variable speed drives in this industrial truck are exempt from Regulation (EU) 2019/1781 because these variable speed drives do not meet the description given in Article 2 "Scope", Item (1) (b). 56368011501 EN - 04/2022  -  13  567...

  • Page 584: Battery Specifications For Lead-Acid Batteries

    Technical data Battery specifications for lead-acid batteries Battery specifications for lead-acid batteries  CAUTION The battery weight and the battery dimensions affect the stability of the truck. When replacing the battery, the weight ratios must not be changed. The battery weight must remain within the weight range specified on the nameplate.
  • Page 585 Technical data Battery specifications for lead-acid batteries Battery designa- Capacity Circuit Weight/ Battery compartment di- Tray tion [Ah] ballast mensions [mm] weight [kg] Length Width Height 5PzV 550 5PzS 575 5PzS 625 56368011501 EN - 04/2022  -  13  569...

  • Page 586: Battery Specifications For X-Line Lithium-Ion Batteries

    Technical data Battery specifications for X-Line lithium-ion batteries Battery specifications for X-Line lithium-ion batteries – For more information, please refer to the nameplate and the operating instructions for the lithium-ion battery. X-Line Li-Ion 48 V (BG 1) 17.2 kWh, 28.6 kWh and 51.5 kWh   Battery group 1.4 Battery group 1.5 Battery group 1.6...
  • Page 587 Technical data Battery specifications for X-Line lithium-ion batteries X-Line Li-Ion 48 V (BG 9) 17.2 kWh, 28.6 kWh and 51.5 kWh   Battery group 9.4 Battery group 9.5 Battery group 9.6 Nominal voltage [V] 47.71 47.71 47.71 Nominal capacity [Ah] 1080 Nominal energy [kWh] 17.2 28.6 51.5 Length [mm]...

  • Page 588: Battery Specifications For C-Line Lithium-Ion Batteries

    Technical data Battery specifications for C-Line lithium-ion batteries Battery specifications for C-Line lithium-ion batteries – For more information, please refer to the nameplate and the operating instructions for the lithium-ion battery. X-Line Li-Ion 48 V (BG 2, BG 3) 17.2 kWh, 28.6 kWh and 51.5 kWh  ...
  • Page 589 Index   General controlling....312 Information on the auxiliary hydraulics. 572 Access authorisation for the fleet manag- Load capacity....311 er.
  • Page 590 Index   Before picking up a load Clean the truck Capacity rating plate....223 After cleaning....Blue-Q Climbing into the truck.
  • Page 591 Battery......STILL Classic....153 Noise emissions.
  • Page 592 Index   Hazardous areas....160 Insulation testing....Hazards and countermeasures.
  • Page 593 Dynamic Load Control 1... 275 STILL SafetyLight®....Dynamic Load Control 2... 276 Still Safety Light® 4Plus.
  • Page 594 Index   Manual tow coupling Performance data....435 Coupling..... . . 380 Regularly testing the electrical safety.
  • Page 595 Index   Functions available while the truck is in Residual dangers....44 motion..... . . Residual risk.
  • Page 596 Index   Schematic views....Storing the truck....499 Scope of the documentation.
  • Page 597 Speed restriction....187 Ceiling sensor....345 STILL SafetyLight® and STILL Safety- Variants Light 4Plus®.
  • Page 598 Index   Wheels and tyres Working on the hydraulic equipment..504 Checking the condition and wear of the Working spotlight for reverse travel tyres......527 Switching on and off.
  • Page 600 STILL GmbH 56368011501 EN - 04/2022  -  13...

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Rx20 14-20/li-ion

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