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Still RX20-20L User Manual

Still RX20-20L
454 pages
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Original instructions
Electric truck
RX20 14-20 Cat. 2GD/3GD
For use in potentially explosive areas
6219 6220 6221 6222 6223
6224 6225 6226 6227 6228
6229 6230 6231
56368011531 EN - 06/2019 - 02

Table of Contents

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Still RX20-20L Specifications

General IconGeneral
ModelRX20-20L
Load Capacity2000 kg
Lift Height3000 mm
DriveElectric
Battery Voltage48 V
Power SourceElectric
Mast TypeTriplex

Summary

Electric truck

For use in potentially explosive areas

Specifies suitability for hazardous environments.

Preface

Address of manufacturer and contact details

Provides manufacturer's contact information and location.

Rules for the operating company of industrial trucks

Outlines responsibilities and information for truck operators.

1 Foreword

Description of the truck

Details the general features and capabilities of the truck model.

Explosion protection notice

Indicates compliance with explosion protection licensing regulations.

Labelling points

Identifies and explains various labels and decals found on the truck.

Nameplate

Describes the information found on the truck's main identification plate.

Using the truck

Outlines operational guidance for using the truck safely.

Place of use

Specifies where the truck is permitted to operate, considering hazardous areas.

Information about the documentation

Provides details on the scope and availability of the manual and related documents.

Environmental considerations

Covers environmental aspects and disposal guidelines for truck components.

2 Safety

Definition of responsible persons

Defines roles and responsibilities like operating company, driver, and competent person.

Competent person for explosion protection checks

Outlines the qualifications and experience required for personnel performing explosion protection checks.

Drivers

Specifies the requirements and duties for individuals operating the truck.

Basic principles for safe operation

Covers fundamental guidelines for operating the truck safely and preventing accidents.

Damage, defects and misuse of safety systems

Addresses procedures for reporting and rectifying damage or defects in safety systems.

Tyres

Covers safety regulations and requirements for wheels and tyres, especially in explosive areas.

Residual risk

Discusses inherent risks that remain even with proper safety measures and adherence to instructions.

Overview of hazards and countermeasures

Presents a table summarizing potential hazards and recommended safety measures for truck operation.

Safety tests

Details essential tests and inspections to ensure truck safety and compliance.

Explosion-protection checks

Outlines critical regular checks for explosion protection components according to FEM 4.004.

Testing the electrical system

Covers safety checks for the truck's electrical system, including insulation testing.

3 Overviews

Overview

Provides a general visual overview of the truck's main external components.

Driver's compartment

Details the layout and components within the operator's cabin.

Operating devices and display elements

Explains the functions and locations of the truck's controls and display units.

Emergency off switch

Details the function and operation of the emergency stop switch for immediate shutdown.

Multi-lever operation

Describes how to control lifting and hydraulic functions using multi-lever operating devices.

4 Operation

Checks and tasks before daily use

Outlines essential pre-operation checks to ensure the truck is safe and ready for use.

Safety information regarding electrostatic charge

Explains measures to prevent static charge buildup, critical for explosive areas.

Adjusting the driver's seat

Guides on how to adjust the seat for optimal ergonomics, safety, and comfort.

Seat belt

Covers the importance, fastening, and maintenance of the seat belt for driver safety.

Checking the brake system for correct function

Outlines essential checks for the service and electric brakes to ensure proper function.

Checking the steering system for correct function

Details the procedure for verifying the steering system's proper operation and safety.

Switching on the battery isolating switch

Details the procedure for activating the truck's electrical system via the battery isolating switch.

Unlock the emergency off switch

Describes the process for resetting the emergency off switch to enable truck operation.

Using the driver's cab

Covers the operational context and safety considerations within the driver's cab.

Display-operating unit

Describes the interface for operating the truck, including access authorization and settings.

Access authorisation for the fleet manager (variant)

Covers how fleet managers can authorize truck usage or configure settings.

Lighting

Details the operation of various lighting functions, including symbols and controls.

Driving lights

Explains how to switch the parking and driving lights on and off using the softkeys.

Working spotlights

Describes the operation of front, rear, and roof-mounted working spotlights for illumination.

Hazard warning system

Explains how to activate and deactivate the hazard warning system for increased visibility.

Efficiency and drive modes

Covers different drive modes that affect truck performance and energy consumption.

Traction

Details aspects related to the truck's movement, including driving safety and regulations.

Selecting drive programmes 1 to 3

Explains how to choose between three preset drive and braking characteristic programmes.

Selecting the drive direction

Details how to select the forward or reverse drive direction using the appropriate switch.

Starting drive mode

Outlines the critical safety steps and procedures required to safely start the truck's drive mode.

Operating the service brake

Explains the function of the service brake and how it interacts with electric and mechanical braking systems.

Checking the parking brake on a gradient or a ramp

Describes the procedure for verifying the parking brake's effectiveness on inclines to prevent rolling.

Speed restriction (variant)

Covers the function for limiting the truck's maximum speed, configurable by fleet managers.

Parking

Details procedures for safely parking the truck and switching it off.

Lifting

Covers the operation and systems related to the truck's lifting mast and fork carriage.

Controlling the lifting system using multi-lever operation

Explains how to operate the lifting system using multi-lever controls, including pictograms.

Controlling the lifting system using a double mini-lever

Describes the operation of the lifting system via the double mini-lever control.

Controlling the lifting system using a triple mini-lever

Explains how to operate the lifting system using the triple mini-lever controls.

Controlling the lifting system using a quadruple mini-lever

Details the operation of the lifting system via the quadruple mini-lever controls.

Controlling the lifting system using the Fingertip

Describes how to control the lifting system using the Fingertip control interface.

Controlling the lifting system using the Joystick 4Plus

Explains the operation of the lifting system via the Joystick 4Plus control.

Dynamics of the hydraulic movements

Discusses how hydraulic movement dynamics affect truck response and suitability for different tasks.

Selecting load programs 1 to 3

Explains how to choose load programs to adjust lifting behaviors based on load dynamics.

Changing the fork arms

Details the procedure and safety precautions for changing fork arms, including for explosive areas.

Malfunctions during lifting mode

Addresses potential issues and malfunctions that can occur during lifting operations.

Hydraulic blocking function

Explains the safety function that disables hydraulics when the driver's seat is unoccupied.

Handling loads

Covers essential safety rules and procedures for safely handling loads with the truck.

Before picking up a load

Outlines procedures and considerations before lifting any load to ensure safety and stability.

Picking up loads

Details the correct method for securely picking up loads to ensure stability and prevent accidents.

Setting down a load

Explains the procedure for safely lowering and placing a load, considering tilt and stability.

Driving on ascending and descending gradients

Provides safety instructions and limitations for operating the truck on inclines.

Determining the total actual weight

Explains how to calculate the truck's total weight for safe transport and operation on bridges.

Driving on loading bridges

Covers safety precautions and requirements for driving the truck onto loading bridges.

Dynamic Load Control

Describes an assistance function that improves load handling and safety by regulating movements.

Reduction of dynamics according to the load weight

Explains how load weight influences dynamic movements and assistance function activation.

Lift mast vertical position (variant)

Details the automatic feature for maintaining the lift mast's vertical position for precise load placement.

Overload detection (variant)

Covers the system that warns the driver and limits hydraulic functions when an excessive load is detected.

Load measurement (variant)

Explains the function that measures and displays the weight of the lifted load for driver security.

Tare function (variant)

Describes how to zero the load measurement to record only the load's weight, excluding forks/attachments.

Precision load measurement (variant)

Explains the function for accurate load weight measurement, within 1% of rated capacity.

Attachments

Covers the installation, control, and safety aspects of various truck attachments.

Fitting attachments

Provides essential safety instructions and procedures for installing attachments onto the truck.

Controlling attachments using multi-lever operation

Details how to control attachments using multi-lever operating devices and their pictograms.

Controlling attachments using a double mini-lever

Explains the control of attachments using the double mini-lever system.

Controlling attachments using a triple mini-lever

Describes how to control attachments using the triple mini-lever controls.

Controlling attachments using the Fingertip

Explains the operation of attachments using the Fingertip control interface.

Controlling attachments using the Joystick 4Plus

Details how to control attachments using the Joystick 4Plus control system.

Clamp locking mechanism (variant)

Describes the mechanism that prevents clamps from accidentally opening, enhancing safety.

Auxiliary equipment

Lists and describes various optional auxiliary equipment fitted to the truck.

Driver restraint systems (variants)

Refers to separate instructions for different driver restraint systems available for the truck.

Actuating the windscreen wipers and windscreen washers (variant)

Explains how to operate the windscreen wipers and washers through button sequences.

Ceiling sensor (variant)

Details the ceiling sensor system, an assistance feature for reducing speed in halls.

Cab

Covers the operation and features related to the truck's cabin.

Opening and closing the cab door

Provides instructions for safely opening and closing the cab door.

Heating system (variant)

Details the operation of the truck's heating system and its safety precautions.

Trailer operation

Covers procedures and safety information related to operating the truck with trailers.

Safety information for trailer operation

Provides critical safety guidelines for towing trailers, especially in potentially explosive areas.

Towed load

Discusses the handling characteristics and risks when towing a load.

Coupling the trailer

Explains the step-by-step process for safely connecting a trailer to the truck.

Uncoupling the trailer

Provides instructions for safely disconnecting a trailer from the truck.

Cold store application

Covers operational considerations and requirements for using the truck in cold storage environments.

Operation

Provides instructions and warnings for operating the truck in cold storage conditions.

Display messages

Explains various messages displayed by the truck's system and the required actions.

Behaviour when the explosion-protection warning lights are illuminated

Details immediate safety actions required when explosion-protection warning lights activate.

Messages about operation

Lists messages indicating required actions or operational status changes.

Procedure in emergencies

Outlines critical procedures to follow in various emergency situations.

Emergency shutdown

Describes how to perform an immediate shutdown of the truck's systems in an emergency.

Automatic emergency shutdown

Explains the truck's automatic shutdown feature triggered by dangerous limit values for safety.

Procedure if truck tips over

Provides crucial safety instructions and rules of behavior if the truck begins to tip over.

Emergency hammer

Details the use of the emergency hammer for escaping the cab if doors are inaccessible.

Emergency lowering

Explains how to perform emergency lowering of the load if the hydraulic controller fails.

Towing

Covers safety information and procedures related to towing the truck, especially in explosive areas.

Connecting and disconnecting the battery male connector

Provides instructions and safety precautions for connecting and disconnecting the battery.

Handling the battery

Covers essential safety regulations and procedures for handling the truck's battery.

Safety regulations for handling the battery

Outlines critical safety rules for working with batteries, especially in potentially explosive areas.

Parking the truck securely

Details how to park the truck safely, particularly when battery work is performed.

Fire protection measures

Lists safety measures to prevent fire and explosion risks associated with batteries, especially during charging.

Battery weight and dimensions

Emphasizes the importance of battery weight and dimensions for truck stability during replacement.

Replacing and transporting the battery

Covers the procedures and safety considerations for replacing and transporting the truck's battery.

Changing to a different battery type

Explains the process of setting new battery parameters in the display unit when changing battery types.

Opening/closing the battery door

Details the procedure for opening and closing the truck's battery access door.

Replacing the battery using a lift truck and a battery change frame

Describes the specialized procedure for replacing the battery using lifting equipment.

Transporting and setting down the battery

Provides instructions for safely transporting and setting down the battery, including storage precautions.

Cleaning the truck

Outlines procedures for cleaning the truck, emphasizing safety in potentially explosive areas and avoiding water damage.

Cleaning the electrical system

Details how to clean electrical system components safely, avoiding water and abrasive materials.

Cleaning load chains

Explains the safe procedure for cleaning load chains using specific materials and methods.

Transporting the truck

Covers the procedures and safety measures for transporting the truck on other vehicles or equipment.

Determining the total actual weight

Explains how to calculate the truck's total weight, essential for safe transport planning.

Wedging the wheels

Details the safety procedure for securing the truck's wheels to prevent rolling during transport.

Lashing down

Provides instructions on how to securely lash the truck to the transport vehicle to prevent movement.

Decommissioning

Covers safety information and procedures for shutting down, decommissioning, and storing the truck.

Safety information for shutting down and restarting

Outlines critical safety measures for safely shutting down and preparing the truck for restart.

Decommissioning and storing the truck

Details the procedures for safely decommissioning and storing the truck, including environmental precautions.

5 Maintenance

Safety regulations for maintenance

Provides essential safety rules that must be followed during all maintenance and repair activities.

Personnel qualifications

Specifies the required qualifications and training for personnel performing maintenance and repairs.

Maintenance of the explosion protection components

Details the testing and maintenance requirements for explosion protection components according to standards.

Information for carrying out maintenance

Provides guidance on determining when maintenance is required and how to perform it.

Service menu

Explains how to access and use the service menu for managing maintenance intervals.

Preserving operational readiness

Covers procedures to maintain the truck in optimal working condition.

Checking the seat belt

Details regular checks for wear, damage, and proper function of the seat belt.

Replacement after an accident

States that seat belts must typically be replaced after any accident.

Checking the driver's seat

Covers checks for the driver's seat, including safety features like antistatic properties and secure fastening.

Checking the antistatic paint layer

Details how to check the integrity of the antistatic paint layer on plastic parts, crucial for explosion protection.

Maintaining the heater or air conditioning system

Explains how to maintain the cabin's climate control systems, including filter replacement.

Servicing wheels and tyres

Covers safety regulations and procedures for servicing truck wheels and tyres.

Checking the condition and wear of the tyres

Details how to check tyre condition, wear, and fastenings for optimal stability and safety.

Checking the fork arms

Outlines inspection procedures for fork arms, including cladding thickness and crack checks, especially for explosive areas.

Checking the condition and correct operation of the latch

Explains how to check the fork arm latch for proper function and security.

Checking the reversible fork arms

Details inspection procedures for reversible fork arms, emphasizing explosion protection compliance.

Checking the battery

Refers to other sections for detailed battery checks.

Replacing the fuses

States that fuse replacement must only be done by authorized service centers due to electrical hazards.

Checking the hydraulic system for leak tightness

Details procedures for checking hydraulic systems for leaks and the condition of hoses.

Checking the hydraulic oil level

Provides instructions on how to check and maintain the hydraulic oil level, including precautions for dual-pedal operation.

1000-hour maintenance/yearly maintenance

Outlines maintenance tasks to be performed at 1000-hour intervals or annually.

Checking the lift cylinders and connections for leaks

Describes visual inspection of lift cylinders and connections for leaks as a maintenance check.

Checking the battery changeover frame

Specifies visual inspection of screw joints and welded seams on the battery changeover frame.

6 Technical data

Ergonomic dimensions

Discusses the ergonomic design of the driver's compartment and minimum head clearance requirements.

Dimensions

Provides key dimensional data for various truck configurations, illustrated with diagrams.

VDI datasheet: RX20-14C with steering turntable

Specifies technical data for the RX20-14C model with steering turntable, for standard equipment.

VDI datasheet: RX20-16 with steering turntable

Provides technical data for RX20-16 models with steering turntable, noting variations due to equipment.

VDI datasheet: RX20-18 and RX20-20 with steering turntable

Lists technical data for RX20-18 and RX20-20 models with steering turntable.

VDI datasheet: RX20-16 with swing axle

Specifies technical data for RX20-16 models with a swing axle.

VDI datasheet: RX20-18 with swing axle

Details technical data for RX20-18 models featuring a swing axle.

VDI datasheet: RX20-20 swing axle VDI datasheet

Provides technical data for RX20-20 models equipped with a swing axle.

Battery specifications

Lists detailed specifications for batteries, including capacity, circuit, and compartment dimensions.

Gradients

Explains the maximum permissible ascending and descending gradients for safe truck operation.

Electric motor

Provides technical data for the truck's electric motor, including power ratings and battery specifications.

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