Still OPX 20 User manual

Original instructions
Order pickers and tow tractors
OPX 20/25
OPX 20/25 PLUS
OPX-L 12/16/20
OPX-L 20 S
OPX-D 20
LTX 50
LTX-FF 05/10
LTX-T 06
0615 0616 0617 0618 1075
1076 1077 1078 1079 1080
1081 1082 1084 1085 1086
45878043402 EN - 06/2018

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.
45878043402 EN - 06/2018 I

Table of contents
g
1 Introduction
Forklift data ......................................................... 2
General information ................................................... 2
How to Consult the Manual .............................................. 2
Date of edition and latest update of this manual ............................... 4
Copyright and trademark rights ........................................... 4
Delivery of the forklift and documentation ................................... 4
CE labelling ......................................................... 5
EC declaration of conformity in accordance with Machinery Directive ............... 6
Technical service and spare parts ......................................... 7
Type of use ......................................................... 7
Working conditions ................................................... 7
Modifications to Forklift ................................................. 8
Applied equipment .................................................... 8
User obligations ...................................................... 9
Environmental considerations ........................................... 9
Disposal of components and batteries ...................................... 9
Packaging ......................................................... 10
2Safety
Safety guidelines .................................................... 12
GeneralSafetyRules ................................................. 12
Flooring requirements ................................................ 12
Batteryconnectioncables ............................................. 13
External electrical connections .......................................... 13
Requirements for the traction-batterychargingarea .......................... 13
SafetyRegulationsRelativetoForkliftUse ................................. 13
SafetyRegulationsRelativetoOperatingMaterials ........................... 14
Residual risk ....................................................... 15
Residual dangers, residual risks ......................................... 15
45878043402 EN - 06/2018 III

Table of contents
g
Electromagnetic radiation .............................................. 17
Non-ionised radiation ................................................. 17
Noise ............................................................. 17
Electrostatic charge .................................................. 17
Vibrations ......................................................... 18
Safety tests ........................................................ 19
Regularsafetyinspectionofthetruck ..................................... 19
Safety devices ...................................................... 20
Damage, defects and misuse ofsafetydevices .............................. 20
3Overview
Overview of the various models ......................................... 22
OPX range general overview ........................................... 26
LTX50 general overview ............................................... 28
General overview LTX-T .............................................. 30
General overview LTX-FF ............................................. 32
Markings .......................................................... 34
Labelsanddesignationplates .......................................... 34
OPX 20/25 and OPX 20/25 PLUS label location . . . ........................... 35
Location of OPX-L (12/16/20S)labels ..................................... 37
Location of OPX-L20 and OPX-D20 labels ................................. 39
Location of LTX50 labels .............................................. 41
Location of labelsLTX-T ............................................... 43
LocationoflabelsLTX-FF .............................................. 45
Dataplate ......................................................... 47
Serial number ...................................................... 48
Theserialnumberismarkedontheframe .................................. 49
OPX-L (12/16/20S) capacity plate ........................................ 50
OPX-L 20 capacity plate ............................................... 52
OPX-D 20 capacity plate .............................................. 53
CapacityplateLTX-T ................................................. 55
CapacityplateLTX-FF ................................................ 56
Instruments and controls .............................................. 57
Comandi volante - Parte 1 . . . .......................................... 57
Steering wheel controls - Part 2 ......................................... 59
Steering wheel controls - Part 3 ......................................... 61
Backrestcontrols .................................................... 64
Definitionofdirections ................................................66
IV 45878043402 EN - 06/2018

Table of contents
g
Lift mast ........................................................... 67
Typesofliftmasts(wherepresent) ....................................... 67
Options and variants ................................................. 68
Listofoptionsandvariants ............................................. 68
Electrical socket for the cigarette lighter located on the dashboard (optional) ........ 69
Accessory mounting bar with data socket (optional) ........................... 70
Rearstoragecompartment(optional) ..................................... 72
Electrical socket for trailer lighting (optional) ................................ 73
Sistemidiilluminazione ............................................... 74
Lithium-ionbattery(Li-Ion) ............................................. 78
FleetManager (Option) . ............................................... 79
Foldawaystep(option) ................................................ 80
Locking fork or straddle lowering during travel (option) ......................... 80
BatteryelectrolytelevelindicatorLED(optional) ............................. 81
Cab (optional) ...................................................... 82
Batterylocklever(optional) ............................................ 84
4Use
Authorised and safe use ............................................... 86
Intended use of the trucks .............................................. 86
Safetyinstructionsforusingthetruck ..................................... 86
ForkliftUseinCold-StorageRooms. ...................................... 90
Truck transport and lifting .............................................. 90
Transportingthetruck ................................................ 90
ClimaticConditionsforTransportandStorage ............................... 90
Loading and unloadingthetruck ......................................... 91
Breaking-In ........................................................ 92
Sequence to follow for using the truck ..................................... 93
Checks and actions prior to commissioning ................................. 94
Listofchecksbeforeuse .............................................. 94
Checking and refilling the windscreen washer tank (only present on version with
cab) ............................................................96
Optional driver's seat adjustments ....................................... 97
Safety guidelines for adjustment work (described in the following paragraphs) ....... 97
Height-adjustable steering wheel (option) . . ................................ 98
Height-adjustable STANDARDseatbackrest(option) ......................... 99
Height-adjustableSLIMseatbackrest(option) ..............................100
Foldawayseat(option) ................................................101
Adjusting the platform(optional) .........................................103
45878043402 EN - 06/2018 V

Table of contents
g
Climbing on and off the truck ............................................104
Drive modes and positions .............................................105
Drive modes and positions . . . ..........................................105
Driving position with the operator on board the truck ..........................106
Operator position and driving mode with operator on the ground next to the truck: using
seatbackrestcontrols(optionalfeature) .................................108
Operator position and driving mode with operator on the ground next to the truck: using
steering wheel controls (optionalfeature) ................................110
Stopping the truck in EMERGENCIES ....................................113
On/off systems ......................................................114
On/offkey .........................................................114
Numerickeypad—Start-upusingaPIN(Digicodeoption) .....................115
Driving ............................................................117
Truckoperation .....................................................117
Steering ...........................................................118
Truckbrakesystems .................................................120
Reversedrive ......................................................121
Parking and stopping the truck ..........................................122
Mobile platform .....................................................123
Using the mobile platform(wherepresent) .................................123
Moving the load .....................................................125
Safety guidelines for handling loads ......................................125
Checks to be carried outbeforeliftingaload ................................126
Usingthebackrestforkcontrols(wherepresent) .............................127
Using additional fork controls (only for model LTX FF) .........................130
Takingupload ......................................................133
Palletisingaload ....................................................133
Transporting loads on the forks ..........................................134
Depositing a load on the ground .........................................135
Using the truck on inclines, loading bridges and lifts. ..........................136
Load back rest with vertical pallet hook (optional) . ...........................137
Handling trailers .....................................................139
Towingtrailers ......................................................139
Towingthetrailer ....................................................141
Couplingthetrailer ...................................................142
Single-positionormulti-positiontowinghook ................................143
Automatic-closure towing hook ..........................................145
Lifting and lowering trailers – LiftRunner (if present) ...........................148
Loadingtrailers .....................................................150
UsingtheversionwithrearloadbedLTX-T .................................151
VI 45878043402 EN - 06/2018

Table of contents
g
Charging the battery ..................................................154
AccessingthebatteryfortrucksWITHOUTamobileplatform ....................154
Accessing the battery for trucks with a mobile platform (optional) .................155
BatteryRecharging ..................................................157
Recharging the battery using the on-board battery charger (optional) . . . ...........158
5 Maintenance
General Information ..................................................162
Operations Preliminary to Maintenance ...................................162
Maintenance — 1000 hours ............................................163
Maintenance — 3000 hours ............................................1
66
Maintenance — 10,000 hours ...........................................167
Regular Service .....................................................168
CleaningtheForklift ..................................................1
68
Lubricating and cleaning the lifting chains . . ................................168
Maintenance as required ..............................................169
Preparation ........................................................169
Batterytype ........................................................169
Unlockingthebattery(beforereplacingthebattery) ...........................171
Battery replacement withremovalfromthetop ..............................173
Replacingthebatterywithsideremoval ...................................174
Fuses ........................................................... . 177
Decommissioning ...................................................178
GeneralInformation ..................................................178
ForkliftTowing ......................................................179
Temporary Putting OutofCommission ....................................179
Checks and Inspections After a Long Period of Inactivity .......................179
Permanent Putting Out of Commission (Demolition) ..........................179
6 Technical data
Datasheet (VDI) .....................................................182
Datasheet (VDI) .....................................................214
Supply table ........................................................221
45878043402 EN - 06/2018 VII

1
Introduction

1Introduction
Forklift data
Forklift data
We recommend that you record the principal
forklift data in the following table so that they
are available if required by the sales network
or authorised service centre.
Type
Serial number
Date of delivery
.
General information
• This manual contains "Original Instructions"
provided by the manufacturer.
• The "operator" is defined as the person
driving the forklift.
• The "user" is the physical or legal person
who has the forklift truck used by the
operators.
• For correct use of the truck and in order to
avoid accidents, the operator is obliged to
read, understand and apply the contents
of this manual and the plates and stickers
applied to the truck.
• This manual must be stored carefully
and remain on board the truck for quick
consultation.
• The manufacturer assumes no responsibil-
ity for any accidents to persons or damage
to things due to failure to observe the con-
tents of this manual and the plates and
stickers applied to the truck.
• The forklift may not be put to any use other
that than indicated in this manual.
• The forklift must be used by appropriately
trained operators only. For the necessary
operator training, contact the authorised
sales network.
• Persons working near the forklift must also
be instructed in the risks associated with
use of the forklift.
• In the interests of clear information, some
illustrations in this manual show the forklift
without the safety equipment (guards,
panels, etc.). The forklift may not be used
without safety equipment.
How to Consult the Manual
There is a table of contents at the beginning
of the manual for ease of use. The manual is
divided into chapters with specific topics. The
name and title of the chapter are given at the
top of each page The following is found at the
bottom of each page: the type of manual, the
identifying code, the language and the manual
version.
Some general information is provided in this
manual. Please only consider the information
relevant for your specific forklift.
The following symbols have been used to
highlight some parts of this manual.
DANGER
Failure to observe the instructions highlighted with
this symbol may jeopardise safety.
245
878043402 EN - 06/2018

Introduction 1
HowtoConsulttheManual
CAUTION
Failure to observe the instructions highlighted with
this symbol may cause damage to the forklift and,
in some cases, result in warranty invalidity.
ENVIRONMENT NOTE
Failure to observe the instructions highlighted
with this symbol may cause environmental
damage.
NOTE
This symbol is used to provide additional
information.
45878043402 EN - 06/2018 3

1Introduction
Date of edition and latest update of this manual
Date of edition and latest
update of this manual
The publication date of these operating
instructions is printed on the cover sheet.
The manufacturer makes continuous efforts
to improve its industrial trucks, and therefore
reserves the right to implement changes and
to accept no claims concerning the information
provided in this manual.
To receive technical assistance, please
contact the service centre authorised by your
closest manufacturer.
Copyright and trademark
rights
These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Delivery of the forklift and documentation
Ensure that the truck has all of the options
requested and that it has been delivered with
the following documentation:
• Original instructions
• EC Declaration of Compliance;
If the forklift has been delivered with a traction
battery and/or battery charger, ensure that
such products conform to the order and that
the relative user and maintenance manual are
included, as well as the EC declaration for the
battery charger.
If applied equipment, other equipment or
devices are present, ensure that they conform
to the order and that the relative use and
maintenance manual and of the relative EC
declaration (if provided by regulations in
effect) are included.
All of the above documentation must be kept
for the entire operative life of the forklift. In the
event that the documentation is lost or dam-
aged, contact the authorised sales network for
copies of the original documentation.
445
878043402 EN - 06/2018

Introduction 1
CE labelling
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.
45878043402 EN - 06/2018 5

1Introduction
EC declaration of conformity in accordance with Machinery Directive
EC declaration of conformity in accordance with Machinery Di-
rective
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
645
878043402 EN - 06/2018

Introduction 1
Technical service and spare parts
Technical service and spare parts
For scheduled maintenance and any repairs to
the forklift, contact only the authorised service
network.
The authorised service network has personnel
trained by the manufacturer, original spare
parts and the tools necessary to carry out
maintenance and repairs.
Servicing by the authorised service network
and the use of original spare parts maintain
the technical characteristics of the forklift over
time.
Only original spare parts provided by the man-
ufacturer may be used for forklift maintenance
and repairs. The use of non-original spare
parts invalidates the warranty and renders the
user responsible for any accidents due to the
inappropriateness of the non-original parts.
Type of use
"Normal use conditions"oftheforkliftare
understood as:
• lifting and/or transport of loads using forks
with weight and load centre within the
values provided (see Chapter 6 - Technical
Data).
• transport and/or lifting on smooth, flat and
compact surfaces;
• transport and/or lifting of stable loads
uniformly distributedontheforks;
• transport and/or lifting with the load centre
approximately on the forklift's median
longitudinal plane.
DANGER
The forklift must not be used for other purposes.
Any other use renders the user solely responsible
for injury/damage to persons and/or objects and
voids the warranty.
The following scenarios are examples of
incorrect use of the forklift truck:
• Transport on uneven (irregular or non-
compact) surfaces
• loads that exceed the weight and/or load
centre limits;
• transporting non-stable loads;
• transporting loads not equally distributed on
the forks;
• transporting swinging loads;
• transporting loads whose load centre is
considerably displaced with respect to the
forklift's longitudinal median plane;
• transporting loads of dimensions such as to
block the view of the operator when driving;
• transporting loads piled so high that they
could fall onto the operator;
• travelling with a load over 300 mm off the
ground;
• transporting and/or lifting people;
• Pushing loads
• moving upwards or downwards on a slope
with the load facing downwards;
• turning at high speed;
• turning and/or moving sideways on slopes
(upwards or downwards);
• colliding with stationary and/or mobile
structures;
DANGER
Improper use of the forklift could cause it and/or at
the load to overturn.
Working conditions
The truck has been designed and built for
internal transport.
The truck with cab option has been designed
and built for internal and external transport.
45878043402 EN - 06/2018 7

1Introduction
Modifications to Forklift
Do not use beyond the limits of the climatic
conditions indicated below:
• Maximum ambient temperature: +40°C
• Minimum ambient temperature: +5°C
• Altitude up to 2000 m
• Relative humidity between 30% and 95%
(without condensation).
CAUTION
Do not use the truck in dusty environments.
Using the truck in environments with high concen-
trations of salty air or water could cause problems
with the truck and cause corrosion of metallic parts.
If the truck must be used in conditions outside
of the limits indicated or, in any case, under
extreme conditions (extreme weather, cold-
storage rooms, presence of strong magnetic
fields etc.), appropriate equipment and/or
usage precautions are necessary. Contact
the authorised sales network for information.
DANGER
The truck must not be used in environments where
there is a risk of explosion and the truck must not be
used to handle explosive loads.
For trucks that must operate in environments
where there is a risk of explosion or where they
must handle explosive loads, the appropriate
equipment is necessary and this must be
accompanied by a specific EC Declaration
of Compliance, which replaces that of the
standard truck, and by the relevant use and
maintenance manual.
Contact the authorised sales network for
information.
Modifications to Forklift
No modifications may be made to the forklift,
otherwise the EC certificate and the warranty
will become invalid, with the exception of:
• Assembly of the options, only if provided by
the manufacturer
• Assembly of applied equipment, only if
provided by the manufacturer
WARNING
Before installing optional or additional equipment,
please exclusively contact the sales network autho-
rised by the manufacturer.
DANGER
If the forklift is equipped at the factory or later with
devices that emit non-ionising radiation (such as
radio transmitters, RFID players, data terminals,
scanners, etc), the compatibility of such devices
must be verified with the presence of operators
using medical devices (such as heart pacemakers).
Applied equipment
To apply additional equipment after purcha-
sing, you must contact the sales network au-
thorised by the truck manufacturer, which will:
• verify feasibility
• install the equipment
• add a label with the new residual capacity is
• provide documentation on the equipment
(user and maintenance manual and EC
certificate).
CAUTION
The truck user must be trained in the operation and
correct use of the equipment
The user must check that the equipment is working
correctly before use.
845
878043402 EN - 06/2018

Introduction 1
User obligations
User obligations
Users must comply with applicable local legis-
lation governing forklift use and maintenance.
Environmental considerations
Disposal of components and
batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
• disposed of,
• treated or
• recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when dispo-
sing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste mana-
gement company for disposal purposes.
45878043402 EN - 06/2018 9

1Introduction
Environmental considerations
Packaging
During delivery of the truck, certain parts
are packaged to provide protection during
transport. This packaging must be removed
completely prior to initial start-up.
ENVIRONMENT NOTE
The packaging material must be disposed of
properly after delivery of the truck.
10 45878043402 EN - 06/2018