Still RX50-13 User manual

Original instructions
Electric forklift truck
RX50-10
RX50-13
RX50-15
RX50-16
5060 5061 5063 5065 5066
55048011501 EN - 12/2015

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
55048011501 EN - 12/2015 I

Table of contents
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1 Foreword
Your truck .......................................................... 2
General ............................................................ 2
CElabelling ......................................................... 2
EC declaration of conformity in accordance with Machinery Directive ............... 3
Accessories ......................................................... 3
Information about documentation ......................................... 4
Documentationscope ................................................. 4
Issue date and topicality oftheoperatinginstructions ........................... 5
Copyrightandtrademarkrights ........................................... 5
Explanation of information symbols used . . ................................. 5
Listofabbreviations ................................................... 6
Definitionofdirections ................................................. 9
Schematicviews ..................................................... 9
Environmental considerations .......................................... 11
Packaging ......................................................... 11
Disposal of components and batteries ..................................... 11
2 Introduction
Use of truck ........................................................ 14
Proper usage ....................................................... 14
Proper use during towing .............................................. 14
Impermissibleuse ................................................... 14
Placeofuse ........................................................ 15
Parkingintemperaturesbelow-10°C ..................................... 16
Using working platforms ............................................... 16
Residual risk ....................................................... 17
Residual dangers, residual risks ......................................... 17
Special risks associatedwithusingthetruckandattachments ................... 18
Overviewofhazardsandcountermeasures ................................. 20
Danger to employees . . ............................................... 23
3Safety
Definition of responsible persons ........................................ 26
Operatingcompany .................................................. 26
Specialist .......................................................... 26
Drivers ........................................................... 27
Essentials for safe operation ........................................... 29
Insurance cover on company premises .................................... 29
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Changes and retrofitting ............................................... 29
Changes to the overhead guard and roof loads . . . ........................... 32
Warning regarding non-originalparts ..................................... 32
Damage, defects and misuse of safety systems . . . ........................... 33
Tyres ............................................................. 33
Medicalequipment ................................................... 34
Exercise caution when handling gas springs and accumulators .................. 35
Lengthoftheforkarms ................................................ 35
Safety tests ........................................................ 37
Regularsafetyinspectionofthetruck ..................................... 37
Insulationtesting .................................................... 37
Safety regulations for handling consumables ............................... 39
Permissibleconsumables ............................................. 39
Oils .............................................................. 39
Hydraulicfluid ...................................................... 40
Batteryacid ........................................................ 41
Brakefluid ......................................................... 42
Disposal of consumables .............................................. 44
Emissions ......................................................... 45
4Overviews
General view of truck ................................................. 50
General view of driver’s compartment ..................................... 52
Operating devices and display elements ................................... 53
Display and operating unit . . . .......................................... 53
Operating devices forhydraulicandtractionfunctions ......................... 55
Multi-lever ......................................................... 56
Doublemini-lever .................................................... 57
Three-way mini-lever ................................................. 58
Four-waymini-lever .................................................. 59
Joystick4Plus ...................................................... 60
Fingertip .......................................................... 61
Miniconsole ....................................................... 62
Identification points .................................................. 64
Overview .......................................................... 64
Nameplate ......................................................... 65
Productionnumber .................................................. 66
StVZO (Road Traffic Licensing Regulations) information ....................... 66
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5 Operation
Checks and operations prior to commissioning .............................. 68
Visualinspections ................................................... 68
Fillingthewashersystem .............................................. 70
Checking the condition of the wheels and tyres .............................. 71
Adjusting the GS15 driver’s seat ......................................... 72
AdjustingtheMSG65/MSG75driver’sseat ................................ 74
Adjustingthearmrest ................................................. 77
Commissioning ..................................................... 79
Climbingon/off ...................................................... 79
Connecting the battery male connector .................................... 81
Shelfandcupholder ................................................. 81
Unlockingtheemergencyoffswitch ...................................... 82
Switchingonthekeyswitch ............................................ 83
Access authorisation withPINcode(variant) ................................ 86
Operating the signal horn .............................................. 96
Seatbelt .......................................................... 97
Checking the brake systemforcorrectfunction .............................. 99
Checkingthesteeringsystemforcorrectfunction ............................100
Checking the emergency stop function ....................................101
Zero adjustment of the loadmeasurement(variant) ...........................101
Checking the vertical lift mast position (variant) for correct function . ...............103
Driving ............................................................104
Safety regulations whendriving .........................................104
Driveways ....................................................... . . 106
Settingthedriveprograms .............................................108
Reducing speed with a raisedload(variant) ................................109
Special overhead guard for drive-in racks (variant) ...........................109
Selectingthedrivedirection ............................................111
Actuating the drive directionswitch,multiple-leverversion ......................112
Actuatingthedrivedirectionswitch,mini-leverversion .........................112
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 113
Actuate the drive directionswitch,fingertipversion ...........................113
Actuatingthedrivedirectionswitch,mini-consoleversion ......................114
Startingdrivemode ..................................................114
Starting drive mode, dual-pedal version (variant) .............................116
Operatingtheservicebrake ............................................119
Actuating the mechanical parking brake . . . ................................120
Steering ...........................................................121
Reducing speed when turning (Curve Speed Control) .........................122
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Lifting ............................................................123
Liftingsystemvariants ................................................123
Automatic lift cut out (variant) ...........................................123
Liftmastverticalposition(variant) ........................................124
Typesofliftmast ....................................................128
Malfunctions during lifting mode .........................................130
Liftingsystemoperatingdevices .........................................131
Hydraulicblockingfunction .............................................132
Multi-lever lifting system ...............................................134
Controlling the lifting system using a double mini-lever .........................135
Controllingtheliftingsystemusingatriplemini-lever ..........................136
Controlling the lifting system using a quadruple mini-lever ......................137
Controllingtheliftingsystemusingthejoystick4Plus ..........................138
Controllingtheliftingsystemwiththefingertipconsole .........................140
Changing the fork arms ...............................................141
Forkextension(variant) ...............................................143
Operationwithreversibleforkarms(variant) ................................145
Workingwithloads ...................................................147
Safety regulations when handing loads ....................................147
Beforetakingupload .................................................148
Load measurement (variant) ...........................................149
Picking up loads .....................................................152
Danger area .......................................................153
Transportingpallets ..................................................1
54
Transportofswingingloads ............................................154
Pickingupaload ....................................................155
Transporting loads ...................................................1
59
Setting down loads ...................................................160
Driving on ascending and descending slopes ...............................162
Drivingonlifts ......................................................162
Drivingonloadingbridges .............................................164
Workingwithattachments .............................................165
Fitting attachments ..................................................165
Releasingthepressurefromthehydraulicsystem ............................167
General instructions for controlling attachments . . ...........................169
Controlling attachments using multi-lever operation ...........................171
Controlling attachments using multi-lever operation and the 5th function ...........172
Controlling attachments using a double mini-lever . ...........................174
Controlling attachmentsusingthedoublemini-leverandthe5thfunction ...........176
Controllingattachmentsusingatriplemini-lever .............................178
Controlling attachments using the three-way mini-lever and the 5th function .........180
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Controlling attachments using a quadruple mini-lever .........................182
Controlling attachments using the four-way mini-lever and the 5th function ..........184
Controlling attachments via thejoystick4Plus ...............................186
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........187
Controlling the attachments with fingertip . . ................................188
Controlling attachments with fingertip and the 5th function ......................189
Clamp locking mechanism (variant) ......................................191
Takingupaloadusingattachments ......................................195
Operation of additional equipment .......................................196
Switchinglightingonandoff ............................................197
Switching the rotating beacon on and off . . . ................................197
Switching the hazard warningsystemonandoff .............................198
Switchingdirectionindicatorsonandoff ...................................198
Switching the double working spotlights on and off. ...........................201
Operating the windscreen wiper/washer ...................................203
FleetManager (variant) . ...............................................203
Accidentrecorder(variant) .............................................204
Driver restraint systems(variants) .......................................204
Clipboard (variant) ...................................................204
Trailer operation ....................................................205
Towedload ....................................................... . 205
Tow coupling RO*230 . ...............................................206
Tow coupling RO*244 . ...............................................208
Towingtrailers ......................................................210
Cold store application .................................................211
Operating the display and operating unit ...................................214
Indicators .........................................................214
Adjustingthedisplays ................................................217
Symbolsinthedisplay ................................................217
Setting the date or time ................................................222
Resetting the daily kilometres and daily operating hours .......................222
Setting the language . . ...............................................223
Soft key button for operating various equipment variants .......................223
ConfiguringBlue-Qefficiencymode ......................................224
Blue-Q efficiency mode ...............................................226
Functional description ................................................226
Effects on additional consumers .........................................226
SwitchingefficiencymodeBlue-Qonandoff ................................227
Malfunctions .......................................................229
Screencontent ................................................... . . 229
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EMERGENCYSWITCHmessage .......................................230
SEATSWITCHmessage ..............................................230
SAFETYBELTmessage ..............................................233
APPLYHANDBRAKEmessage .........................................234
LOWERFORKSmessage .............................................235
REFERENCECYCLEmessage .........................................235
SERVICEBRAKEmessage ............................................236
Operation in special operating situations ...................................237
Transporting .......................................................237
Towing .......................................................... . 240
Craneloading ......................................................243
Behaviour in emergencies .............................................2
47
Emergency shutdown ................................................247
Procedureiftrucktipsover .............................................248
Emergency lowering .................................................248
Handling the battery ..................................................251
Safety regulations when handling the battery ...............................251
Opening and closing the battery hood .....................................254
Opening/closing the battery door ........................................259
Disconnecting the battery male connector ..................................261
Battery replacement usingabridge .......................................262
Batterytransportwithcrane ............................................269
Changing the battery using the internal roller channel .........................270
Battery replacement using an external roller channel ..........................273
Battery installation or battery replacement without onboard devices . . . ............277
Maintainingthebattery ................................................278
Decommissioning ...................................................282
Parkingthetrucksecurelyandswitchingitoff ...............................282
Wheel chock (variant) ................................................284
Shutting down and storingthetruck ......................................284
Recommissioningafterstorage .........................................286
Cleaning ..........................................................288
Cleaning the truck ...................................................2
88
Cleaning the electrical system ..........................................290
Cleaning load chains .................................................291
Afterwashing .......................................................292
6 Maintenance
General maintenance information ........................................294
Personnelqualifications ...............................................294
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Informationforcarryingoutmaintenance ..................................294
Maintenance — 1000 hours/annually .....................................297
Maintenance - 3000 hours/everytwoyears .................................301
Orderingsparepartsandwearingparts ....................................301
Quality and quantity of the required operating materials ........................301
Maintenance data table ...............................................303
Safety regulations for maintenance .......................................306
Generalinformation ..................................................306
Working on the hydraulic equipment ......................................306
Working on the electrical equipment ......................................306
Safetydevices ......................................................307
Setvalues ....................................................... . . 307
Liftingandjackingup .................................................307
Workingatthefrontofthetruck ..........................................308
Providing access to maintenance points ...................................310
Removing/installingthevalvecover ......................................310
Removing/installingthebottomplate .....................................311
Removing/installing the bottom plate for dual pedal operation (variant) .............313
Maintenance .......................................................315
Lubricatingthejointsandcontrols ........................................315
Checking the battery hoodlock ..........................................315
Maintainingtheseatbelt ...............................................316
Checkingthedriver’sseat .............................................318
Servicing wheels and tyres .............................................318
Checking the drive axle for oil level, leaks and general condition . .................320
Checkingthebrakefluidlevel ...........................................321
Checking the brake fluidlevelsensor .....................................322
Checking the battery condition, acid level and acid density ......................324
Checkingthefuses ...................................................325
Changing fuses .....................................................327
Checkingthehydraulicoillevel ..........................................329
Checkingthehydraulicsystemforleaks ...................................330
Lubricating the liftmastandrollertrack ....................................331
Maintenance for trucks used in cold stores . ................................331
Maintaining the tow coupling ............................................331
1000-hour maintenance / Annual maintenance ..............................333
Othertasks ...................................................... . . 333
Checking the cable connections .........................................333
Checking accelerator pedal and brake pedal ................................333
Checkingthebrakesystemforcorrectoperationandleaks .....................333
Checking the dual pedal ...............................................334
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Checking the lift cylinders and connections for leaks ..........................334
Checkingforkarms ..................................................335
Checking the reversible fork arms ........................................335
7 Technical data
Dimensions ........................................................338
VDI datasheet: RX50-10 and RX50-13 ....................................339
VDI datasheet: RX50-15 andRX50-16 ....................................343
Ergonomic dimensions ................................................347
Battery specifications .................................................348
Fuse assignment ....................................................351
X5
5048011501 EN - 12/2015

1
Foreword

1Foreword
Your truck
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.
Thetruckshavebeenfittedw
ith state-of-the-
art technology. All that remains is to handle
the truck safely and maintain its functionality.
These operating instructions provide the
necessary information to do this. Read and
observe the information provided before
commissioning the truck. This will prevent
accidents and ensure that the warranty
remains valid.
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 andmadeavailabletothe
responsible authorities.
25
5048011501 EN - 12/2015

Foreword 1
Your truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
Accessories
• Key for key switch (two pieces)
• Hexagon socket wrench for emergency
lowering (not in multi-lever operation)
55048011501 EN - 12/2015 3

1Foreword
Information about documentation
Information about documentation
Documentation scope
• Original operating instructions
• Original operating instructions for attach-
ments (variant)
• Spare parts list
• VDMA rules for the proper use of industrial
trucks
These operating instructions describe all mea-
sures necessary for the safe operation and
proper maintenance of your truck in all pos-
sible variants available at the time of printing.
Special versions to meet customer require-
ments are documented in separate operating
instructions. If you have any questions, please
contact your authorised service centre.
Enter the production number and year of
manufacturer from the nameplate in the space
provided:
Production number
...............................................
Year of manufacture
...................................................
Please quote the production number during all
technical enquiries.
Each truck comes with a set of operating
instructions. These instructions must be
stored carefully and must be available to the
driver and operating company at any time. The
storage location is specified in the "Overviews"
chapter.
If the operating instructions are lost, the
operator must obtain a replacement from the
manufacturer immediately.
The operating instructions are included in the
spare parts list and can be reordered there as
a spare part.
The personnel responsible for operating and
maintaining the equipment must be familiar
with these operating instructions.
The operating company must ensure that all
users have received, read and understood
these operating instructions.
45
5048011501 EN - 12/2015

Foreword 1
Information about documentation
NOTE
Please observe the definition of the following
responsible persons: "operating company"
and "driver".
Thank you for reading and complying with
these operating instructions. If you have any
questions or suggestions for improvements,
or if you have found any errors, please contact
the authorised service centre.
Issue date and topicality of the
operating instructions
The issue date of these operating instructions
can be found on the title page.
STILL is constantly engaged in the further
development of trucks. These operating
instructions are subject to change, and any
claims based on the information and/or
illustrations contained in them cannot be
asserted.
Please contact your authorised service centre
for technical support relating to your truck.
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.
Explanation of information symbols
used
DANGER
Indicates procedures that must be strictly adhered
to in order to prevent the risk of fatalities.
WARNING
Indicates procedures that must be strictly adhered
to in order to prevent the risk of injuries.
55048011501 EN - 12/2015 5

1Foreword
Information about documentation
CAUTION
Indicates procedures that must be strictly adhered
to in order to prevent material damage and/or
destruction.
NOTE
For technical requirements that require
special attention.
ENVIRONMENT NOTE
To prevent environmental damage.
List of abbreviations
NOTE
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.
Abbreviation Meaning
°C Degrees Celsius
°F Degrees Fahrenheit
AAmperes
ABE Display operating unit
ArbSchG German labour protection law
BetrSichV German Ordinance on Industrial Safety and Health
BG Employers’ liability insurance association
BGG Employers’ liability insurance association act
BGR Employers’ liability insurance association rule
German Social
Accident
Insurance
Employers’ liability insurance association regulation
Approx. Approximately
CE Symbol that confirms conformity with the valid product-specific European
directives
CEE International Commission on the Rules for the Approval of Electrical Equip-
ment
cm Centimetres
65
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Foreword 1
Information about documentation
Abbreviation Meaning
cm3Cubic centimetres
dB Decibels
DFÜ Remote data transmission
DIN German standard
EG European Community
EN European standard
FEM Fédération Européene de la Manutention
Fmax Maximum power
gGrams
GAA Industrial inspectorate
If applicable If applicable
GPRS General Packet Radio Service
h/d Hours per day (time driven each day in hours)
ID no. ID number
ISO International standard
kg Kilograms
kg/m3Kilograms per cubic metre
km/h Kilometres per hour
km/d Kilometres per day (kilometres driven each day)
kN Kilonewtons
kW Kilowatts
kWh/h Energy consumption
lLitres
l/h Litres per hour
l/min Litres per minute
LAN Local area network
LED Light emitting diode
LpSound pressure level
LpAZ Continuous sound pressure level in driver’s compartment
LSP Load centre of gravity
o.s. Or similar
mMetres
55048011501 EN - 12/2015 7

1Foreword
Information about documentation
Abbreviation Meaning
m/s Metres per second
m/s2Metres per second squared
MAK Maximum workplace concentration
Max. Maximum
Min. Minimum
min Minutes
rpm Revolution(s) per minute
mm Millimetres
N Newtons
Nm Newton metres
PIN Personal identification number
SE Superelastic
SIT Snap-in tyre for simplified assembly
StVZO German Road Traffic Licensing Regulations
tTonnes
TRGS Technical Regulations for Hazardous Substances
a.s. And similar
VVolts
VDE Association for Electrical, Electronic & Information Technologies
VDI Association of German Engineers
VDMA German Engineering Federation
W Watts
WLAN Wireless local area network
e.g. For example
.
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5048011501 EN - 12/2015