Still RX20 Series User manual

Original instructions
Electric truck
RX20 14-20 Cat. 2GD/3GD
For use in potentially explosive areas
6219 6220 6221 6222 6223
6224 6225 6226 6227 6228
6229 6230 6231
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Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
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Table of contents
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1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 5
CElabelling ......................................................... 5
Explosion protection notice .............................................. 6
EC declaration of conformity in accordance with Machinery Directive ............... 7
Accessories ......................................................... 8
Labelling points ..................................................... 10
Nameplate ......................................................... 13
Nameplateofthepressure-tighthousing ................................... 14
Production number . . . ............................................... 14
StVZO(RoadTrafficLicensingRegulations)information ....................... 15
Nameplateofthebattery .............................................. 16
Diagnosticinterface .................................................. 18
Using the truck ...................................................... 18
Basicinformationonexplosionprotection .................................. 18
Commissioning ..................................................... 21
Proper use ......................................................... 21
Proper use during towing .............................................. 22
Improperuse ....................................................... 22
Placeofuse ........................................................ 24
Parkingintemperaturesbelow-10°C ..................................... 26
Using working platforms ............................................... 27
Information about the documentation ..................................... 28
Scopeofthedocumentation ............................................ 28
Supplementary documentation .......................................... 29
Issuedateandtopicalityoftheoperatinginstructions .......................... 30
Copyrightandtrademarkrights .......................................... 30
Explanation of signaltermsused ........................................ 30
Listofabbreviations .................................................. 31
Definitionofdirections ................................................ 33
Schematic views .................................................... 33
Environmental considerations .......................................... 35
Packaging ......................................................... 35
Disposal of componentsandbatteries ..................................... 35
2Safety
Definition of responsible persons ........................................ 38
Operatingcompany .................................................. 38
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Competentpersonforexplosionprotectionchecks ........................... 39
Drivers ........................................................... 40
Basic principles for safe operation ....................................... 42
Insurance cover on company premises .................................... 42
Modificationsandretrofitting ............................................ 42
Changes to the overhead guardandroofloads .............................. 44
Warning regarding non-original parts ..................................... 44
Damage, defects and misuse of safety systems . . . ........................... 45
Tyres ............................................................. 46
Medicalequipment ................................................... 48
Exercise caution when handling gas springs and accumulators .................. 48
Lengthoftheforkarms ................................................ 49
Residual risk ....................................................... 50
Residual dangers, residual risks ......................................... 50
Special risks associated withusingthetruckandattachments ................... 52
Overview of hazards and countermeasures ................................. 54
Danger to employees ................................................. 57
Safety tests ........................................................ 58
Carrying out regular inspections on the truck ................................ 58
Explosion-protectionchecks ............................................ 59
Testing the electrical system ............................................ 60
Insulationtesting .................................................... 60
Safety regulations for handling consumables ............................... 62
Permissible consumables ............................................. 62
Oils .............................................................. 62
Hydraulicfluid ...................................................... 63
Batteryacid ........................................................ 64
Disposalofconsumables .............................................. 65
Emissions ......................................................... 66
3Overviews
Overview .......................................................... 70
Driver's compartment ................................................. 72
Shelves ........................................................... 74
Operating devices and display elements ................................... 76
Display/controlunit"STILLEasyControl" .................................. 76
Explosion-protectionwarninglights ...................................... 78
Battery isolatingswitch ................................................ 78
Emergency off switch ................................................. 80
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Resetbutton ....................................................... 80
Multi-lever operation . . ............................................... 81
Double mini-lever .................................................... 82
Triplemini-lever ..................................................... 83
Quadruplemini-lever ................................................. 84
Fingertip .......................................................... 85
Joystick4Plus ...................................................... 86
Mini-console ....................................................... 87
4 Operation
Checks and tasks before daily use ....................................... 90
Visualinspectionsandfunctionchecking .................................. 90
Climbingintoandoutofthetruck ........................................ 94
Safety information regardingelectrostaticcharge ............................ 95
Adjustingthedriver'sseat .............................................. 96
Seatbelt ........................................................ . . 101
Adjustingthearmrest .................................................1
04
Adjustingthesteeringcolumn ...........................................105
Switchingonthebatteryisolatingswitch ...................................105
Unlock the emergency offswitch .........................................107
Checking the emergency off function .....................................107
Operating the signal horn ..............................................108
Operating the pneumatic signal horn ......................................109
Usingthedriver'scab .................................................109
Checkingthebrakesystemforcorrectfunction ..............................112
Checking the steeringsystemforcorrectfunction ............................115
Checking the automatic mast vertical positioning (variant) for correct function ........115
Switching on .......................................................116
Switchingonusingt
hekeyswitch ........................................116
Switchingonviapushbutton(variant) .....................................118
Display-operating unit ................................................119
Access authorisationwithPINcode(variant) ................................119
Access authorisation for the fleet manager (variant) ...........................120
Lighting ...........................................................121
Meaning of the symbols ...............................................121
Drivinglights .......................................................122
Workingspotlights ...................................................123
Working spotlight for reversetravel(variant) ................................124
Turnindicators ......................................................124
Hazardwarningsystem ............................................. . . 125
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Rotatingbeacon ....................................................126
STILLSafetyLight(variant) .............................................127
Warningzonelight(variant) ............................................1
28
Efficiency and drive modes .............................................129
Blue-Q(variant) .....................................................129
SwitchingBlue-Qonandoff ............................................1
31
STILLClassicandsprintmode ..........................................131
Traction ...........................................................133
Safety regulations when driving .........................................133
Roadways ........................................................ . 135
Selectingdriveprogrammes1to3 .......................................139
Selecting drive programme AorB ........................................140
ConfiguringdriveprogrammesAandB ....................................140
Selectingthedrivedirection ............................................142
Actuating the drive directionswitch,multiple-leverversion ......................143
Actuatingthedrivedirectionswitch,mini-leverversion .........................143
Actuating the drive direction switch, Fingertip version .........................144
Actuating the vertical rockerswitchforthe"drivedirection",joystick4Plusversion ....144
Actuatingthedrivedirectionswitch,mini-consoleversion ......................145
Startingdrivemode ..................................................145
Starting drive mode, dual pedal version (variant) . . ...........................147
Operatingtheservicebrake ............................................150
Applying the mechanical parking brake ....................................151
Steering ...........................................................153
Reducing speed when turning (Curve Speed Control) .........................154
Speed reduction when the fork carriage is raised (variant) ......................155
Speed reduction when the cab door is open .................................155
Speed restriction (variant) . . . ..........................................156
Parking ...........................................................158
Parking the truck securelyandswitchingitoff ...............................158
Wheel chock (variant) ................................................161
Lifting ............................................................162
Lifting system variants ................................................162
Liftmastversions ....................................................162
Operatingdevicesfortheliftingsystem ....................................164
Controlling the lifting system using multi-lever operation .......................166
Controlling the lifting system using a double mini-lever .........................168
Controllingtheliftingsystemusingatriplemini-lever ..........................170
Controlling the lifting system using a quadruple mini-lever ......................172
ControllingtheliftingsystemusingtheFingertip .............................174
ControllingtheliftingsystemusingtheJoystick4Plus .........................175
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Dynamicsofthehydraulicmovements ....................................177
Selectingloadprograms1to3 ..........................................178
Changing the fork arms ...............................................179
Forkextension(variant) ...............................................182
Operationwithreversibleforkarms(variant) ................................185
Malfunctions during lifting mode .........................................186
Hydraulicblockingfunction .............................................188
Handling loads ......................................................189
Safety regulations when handing loads ....................................189
Beforepickingupaload ...............................................190
Pickinguploads .....................................................191
Danger area .......................................................192
Transportingpallets ..................................................193
Transporting suspended loads ..........................................194
Pickingupaload .................................................. . . 195
Transportingloads ...................................................198
Shakefunction(variant) ...............................................199
Settingdownaload ................................................ . . 203
Driving on ascending and descending gradients .............................204
Drivingonlifts ......................................................205
Driving on loading bridges .............................................207
Dynamic Load Control ................................................208
Description ........................................................208
Reduction of dynamics accordingtotheloadweight ..........................209
"SilentLift"forkwearprotection(variant) ...................................209
Liftmastverticalposition(variant) ........................................210
Lift mast tilt angle display(variant) .......................................211
Overloaddetection(variant) ............................................211
Speed reduction when the fork carriage is raised (variant) ......................212
Load measurement (variant) ...........................................212
Tarefunction(variant) ................................................213
Precisionloadmeasurement(variant) .....................................215
Totalload(variant) ...................................................2
17
Attachments .......................................................220
Fittingattachments ..................................................220
Depressurising the hydraulicsystem ......................................223
Generalinstructionsforcontrollingattachments .............................229
Controlling attachments using multi-lever operation ...........................231
Controlling attachments using multi-lever operation and the 5th and 6th function . . . . . 233
Controlling attachments using a double mini-lever ............................235
Controlling attachments using the double mini-lever and the 5th function ...........237
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Controllingattachmentsusingatriplemini-lever .............................239
Controlling attachments using the triple mini-lever and the 5th function .............240
Controlling attachments using a quadruple mini-lever .........................242
Controlling attachments using the quadruple mini-lever and the 5th function .........244
ControllingattachmentsusingtheFingertip .................................245
Controlling attachments with Fingertip and the 5th function .....................247
ControllingattachmentsusingtheJoystick4Plus .............................249
ControllingattachmentswithJoystick4Plusandthe5thfunction .................251
Clamp locking mechanism (variant) ......................................252
Pickingupaloadusingattachments ......................................255
Auxiliary equipment ..................................................256
General note .......................................................256
FleetManager (variant) ................................................256
Shock recognition (variant) . . . ..........................................256
Driver restraint systems (variants) .......................................256
Actuating the windscreen wipers and windscreen washers (variant) . . . . . . .........257
Fillingthewashersystem ..............................................259
Ceiling sensor (variant) ...............................................259
Cab ..............................................................265
Opening and closing the cab door ........................................265
Opening and closing the side window .....................................266
Turningtheinteriorlightingonoroff(variant) ................................267
Heatingsystem(variant) ..............................................267
Air conditioning (variant) ...............................................270
Operating the rear window heating .......................................271
Clipboard (variant) ...................................................272
Sun visor and sun blind ................................................273
Trailer operation ....................................................273
Safetyinformationfortraileroperation .....................................273
Towedload ....................................................... . 274
Coupling pin in the counterweight ........................................275
TowcouplingRO*244 ............................................... . 277
Towingtrailers ......................................................281
Cold store application .................................................282
Display messages ...................................................286
Behaviour when the explosion-protectionwarninglightsareilluminated ............286
Messages .........................................................288
Messages about operation . . . ..........................................288
Messages about the truck . . . ..........................................293
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Procedure in emergencies .............................................296
Emergency shutdown . ...............................................296
Automatic emergency shutdown .........................................297
Procedure if truck tips over .............................................299
Emergency hammer . . . ...............................................300
Emergency lowering . . ...............................................301
Towing .......................................................... . 302
Connecting and disconnecting the battery male connector ......................305
Connecting the battery male connector ....................................305
Disconnect the battery male connector ....................................307
Handling the battery ..................................................310
Safety regulations for handlingthebattery ..................................310
Maintainingthebattery ................................................315
Checking the battery condition, acid level and acid density ......................316
Checking the battery chargestatus .......................................318
Charging the lead-acid battery ..........................................318
Equalisingchargingtopreservethebatterycapacity ..........................322
Replacing and transporting the battery ....................................324
Generalinformationonreplacingthebattery ................................324
Changing to a different battery type .......................................325
Opening/closing the batterydoor ........................................326
Replacingthebatteryusingatruck .......................................329
Replacingthebatteryusingalifttruckandabatterychangeframe ................334
Transporting the lead-acidbatterybycrane .................................341
Cleaning the truck ...................................................342
Noteonflameproofenclosures ....................................... . . 342
Cleaningthetruck ...................................................34
2
Cleaningtheelectricalsystem ..........................................344
Cleaningloadchains .................................................345
Cleaning the windows ................................................346
After cleaning .......................................................346
Transporting the truck ................................................347
Transport ..........................................................347
Crane loading ......................................................349
Decommissioning ...................................................350
Safety information forshuttingdownandrestarting ...........................350
Decommissioningandstoringthetruck ....................................351
Useafterstorageordecommissioning ....................................353
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5 Maintenance
Safety regulations for maintenance .......................................356
General information ..................................................356
Working on the hydraulic equipment ......................................357
Workingontheelectricalequipment ......................................357
Safetydevices ......................................................357
Setvalues .........................................................357
Liftingandjackingup .................................................358
Working at the front of the truck ..........................................358
General maintenance information ........................................360
Personnelqualifications ...............................................360
Maintenance of the explosion protection components .........................361
Information for carrying out maintenance ..................................362
Maintenance - explosion-protection components 150 hours/month . . . ............364
Maintenance - explosion-protection components 450 hours/every three months ......364
Maintenance - explosion-protection components 1000 hours/year ................365
Maintenance - 1000 hours/annually ......................................366
Maintenance - 3000 hours/everytwoyears .................................369
Orderingsparepartsandwearingparts ....................................369
Quality and quantity of the required operating materials ........................370
Lubricationplan .....................................................371
Maintenancedatatable ...............................................372
Preserving operational readiness ........................................374
Changing the light bulb ................................................3
74
Lubricatingthejointsandcontrols ........................................375
Checkingthebatteryinterlockandthebatterydoorinterlock ....................376
Maintaining the seat belt ...............................................377
Checkingthedriver'sseat .............................................379
Checkingtheantistaticpaintlayer ........................................380
Maintaining the heater or air conditioning system . . ...........................382
Servicingwheelsandtyres .............................................384
Checkingtheforkarms ................................................386
Checking the reversibleforkarms ........................................388
Servicingthesteeringaxle .............................................388
Checkingthebattery .................................................389
Adjusting the warning zonelight .........................................389
Replacingthefuses ..................................................390
Checkingthehydraulicsystemforleaktightness .............................390
Checking the hydraulicoillevel ..........................................392
Lubricatingtheliftmastandrollertrack ....................................394
Preserving operational readiness for cold store application .....................394
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1000-hour maintenance/yearly maintenance ...............................395
Othertasks ...................................................... . . 395
Checking the lift cylinders andconnectionsforleaks ..........................395
Checking the double pedal .............................................395
Checking the battery changeover frame . . . ................................396
6 Technical data
Ergonomic dimensions ................................................398
Dimensions ........................................................399
VDI datasheet: RX20-14C with steering turntable ............................401
VDI datasheet: RX20-16 with steering turntable .............................405
VDI datasheet: RX20-18 and RX20-20 with steering turntable ...................409
VDI datasheet: RX20-16 with swing axle ...................................414
VDI datasheet: RX20-18 with swing axle ...................................418
RX20-20 swing axle VDI datasheet .......................................422
Battery specifications .................................................426
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1
Foreword

1Foreword
Your truck
Your truck
Description of the truck
General
The STILL RX20 14-20 is an electrically
driven counterbalanced truck with a steering
turntable or a rear swing axle. It has a load
capacity of up to 2 tonnes with a load centre of
gravity of 500 mm. The truck can reach driving
speeds of up to 20 km/h without a load.
The truck is suitable for indoor and outdoor
use and for use in potentially explosive areas.
The driver's compartment has an ergonomic
design with the steering column and driver's
seat offset to one side.
The "STILL Easy Control" display-operating
unit manages all functions that are not called
up by the operating devices for drive functions
and hydraulic functions. The driving condition
information and all messages are issued via
a large colour display. The display/operating
unit uses the current battery charge state and
the selected drive programme to calculate the
remaining available time until the battery has
to be recharged and displays this information.
It also supports all FleetManager 4.x functions.
Assistance functions "Dynamic Load
Control"
The STILL RX20 14-20 can be equipped with
assistance functions that make it easier to
work with loads.
• Electronic overload protection
• Reduction of the tilt speed of the lift mast
according to the load weight
• Reduction of the dynamics according to the
load weight
• Changes to the driving dynamics according
to the load and lift height
• Load measurement and precision load
measurement
• Lift mast tilt angle display
• Speed reduction when the fork carriage is
raised
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Foreword 1
Your truck
• Lift mast vertical positioning
• Fork wear protection
Brake system
The brake system of the truck is comprised of
three different brakes:
• Service brake
• Regenerative brake
• Mechanically actuated parking brake
• Electrically actuated parking brake (variant)
The service brake is based on a wear-free,
oil-immersed multi-disc brake. This multi-disc
brake is used as the service brake for heavy
braking or emergency braking with the brake
pedal. In the normal working mode, the
regenerative brake of the electric traction
motors takes effect. The regenerative brake
converts the acceleration energy of the truck
into electrical energy. This causes the truck to
decelerate as soon as the accelerator pedal
is released. If the foot is completely removed
from the accelerator pedal, the truck brakes
until it comes to a standstill. A parking brake
ensures that the truck remains securely in
place when parked.
Hydraulic system
The steering system, the lift cylinders and the
tilt cylinders in the lift mast are supplied with
power via a hydraulic pump operated by an
electric motor.
The proportional valve technology provides
particularly sensitive movements and safe
handling of the load. The hydraulic functions
can be parameterised individually by the
authorised service centre.
Uptothreehydrauliccircuitscanbeusedto
activate attachments (variant). Depending on
the equipment, a hydraulic accumulator is also
available in the lifting circuit for the purpose
of damping pressure peaks in the hydraulic
system.
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1Foreword
Your truck
Drive
Both front wheels of the STILL RX20 14-20
are driven by a maintenance-free three-phase
drive in the front axle with 48-volt technology.
Power is supplied by a lead-acid battery that
can be replaced from the side.
The driver can help to influence the energy
consumption and performance of the truck
using the "Blue-Q" efficiency mode. which
allows the required setting for each current
application to be called up via the display-
operating unit.
Steering
The kickback-free, hydraulic rear-wheel
steering with "Curve Speed Control" (CSC)
ensures driving stability when cornering,
allowing the truck to achieve a small turning
circle and negotiate narrow aisle widths.
Operation
The multi-lever, the Fingertip mini-lever and
the Joystick 4Plus are available as operating
devices for the hydraulic functions. These
operating devices enable precise operation
and smooth control of the lifting speed thanks
to directly controlled valves and proportional
valve technology.
The acceleration behaviour and braking
behaviour can be selected individually using
different drive programmes.
For drive mode, the truck features either sin-
gle-pedal or dual-pedal operation. Accel-
eration and braking (electric brake) via the
accelerator pedal or dual-pedal operation.
One pedal for the "forwards" drive direction
and one pedal for the "reverse" drive direction.
Acceleration and braking behaviour can be
individually selected from three different drive
programmes.
The "STILL Easy Control" display-operating
unit simplifies daily use of the truck by provid-
ing personally configurable favourites. The
display-operating unit also monitors the truck
functions.
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Foreword 1
Your truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
If the truck is to be operated on public roads, it
must conform to the existing national regula-
tions for the country in which it is being used.
The driving permit must be obtained from the
appropriate office.
The truck has been fitted with state-of-the-
art technology. Following these operating
instructions will allow the truck to be handled
safely. By complying with the specifications in
these operating instructions, the functionality
and the approved features of the truck will be
retained.
Get to know the technology, understand it
and use it safely - these operating instructions
provide the necessary information and help to
avoid accidents and to keep the truck ready for
operation beyond the warranty period.
Therefore:
– Before commissioning the truck, read
the operating instructions and follow the
instructions.
– Always follow all of the safety information
contained in the operating instructions and
on the truck.
CE-Symbol
CE labelling
The manufacturer uses CE labelling to indi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
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1Foreword
Your truck
6036_001-001
Explosion protection notice
The explosion protection notice indicates that
the manufacturer complies with the explosion
protection licensing regulations.
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