Still RX60-16 User manual

Original instructions
Electric forklift truck
RX60-16
RX60-18
RX60-20
6311 6313 6315
170525 EN - 10/2016

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
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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 ......................................................... 4
Information about documentation ......................................... 5
Documentationscope ................................................. 5
Issue date and topicality oftheoperatinginstructions ........................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of information symbols used . . ................................. 6
Listofabbreviations ................................................... 7
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 inspections ................................................... 37
Regularsafetyinspectionofthetruck ..................................... 37
Insulationtesting .................................................... 37
Safety regulations for handling consumables ............................... 39
Permissibleconsumables ............................................. 39
Oils .............................................................. 39
Hydraulicfluid ...................................................... 40
Batteryacid ........................................................ 41
Disposalofconsumables .............................................. 42
Emissions ......................................................... 43
4Overviews
General view of truck ................................................. 48
General view of driver’s compartment ..................................... 50
Operating devices and display elements ................................... 52
Display operating unit ................................................. 52
Operatingdevicesforhydraulicandtractionfunctions ......................... 54
Multi-lever ......................................................... 55
Doublemini-lever .................................................... 56
Three-waymini-lever ................................................. 57
Four-way mini-lever .................................................. 58
Joystick4Plus ...................................................... 59
Fingertip .......................................................... 60
Miniconsole ....................................................... 61
Identification points .................................................. 62
Overview .......................................................... 62
Nameplate ......................................................... 67
Productionnumber .................................................. 68
StVZO (Road Traffic Licensing Regulations) information ....................... 68
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5 Operation
Checks and operations prior to commissioning .............................. 70
Visualinspections ................................................... 70
Fillingthewashersystem .............................................. 72
Checking the condition of the wheels and tyres .............................. 73
Adjusting the MSG 65/MSG 75 driver’sseat ................................ 74
Adjustingthearmrest ................................................. 78
Adjustingthesteeringcolumn ........................................... 79
Start-up ........................................................... 79
Climbinginandoutofthetruck .......................................... 79
Connecting the battery male connector .................................... 81
Shelvesandcupholders .............................................. 81
Unlockingtheemergencyoffswitch ...................................... 82
Switchingonthekeyswitch ............................................ 82
Access authorisation withPINcode(variant) ................................ 85
Operating the signal horn .............................................. 95
Seatbelt .......................................................... 96
Driver’scab ........................................................ 99
Checkingthebrakesystemforcorrectfunction .............................. 99
Checkingthesteeringsystemforcorrectfunction ............................100
Checking the emergency offfunction .....................................101
Zeroadjustmentoftheloadmeasurement(variant) ...........................101
Checking the vertical lift mast position (variant) for correct function . ...............103
Driving ............................................................104
Safety regulations when driving .........................................104
Roadways .........................................................106
Setting the drive programme ............................................108
Reducing speed with a raised load (variant) ................................109
Selectingthedrivedirection ............................................110
Actuating the drive directionswitch,multiple-leverversion ......................111
Actuatingthedrivedirectionswitch,mini-leverversion .........................111
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 112
Actuate the drive directionswitch,fingertipversion ...........................112
Actuatingthedrivedirectionswitch,mini-consoleversion ......................113
Startingdrivemode ..................................................113
Starting drive mode, dual-pedal version (variant) .............................115
Operatingtheservicebrake ............................................118
Parkingbrake .................................................... . . 119
Actuating the mechanicalparkingbrake ...................................119
Actuatetheelectricparkingbrake ........................................121
Steering ...........................................................128
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Reducing speed when turning (Curve Speed Control) .........................129
Lifting ............................................................130
Liftingsystemvariants ................................................130
Automaticliftcutout(variant) ...........................................130
Liftmastverticalposition(variant) ........................................131
Typesofliftmast ....................................................135
Malfunctionsduringliftingmode .........................................137
Liftingsystemoperatingdevices .........................................138
Hydraulic blocking function .............................................139
Multi-leverliftingsystem ...............................................141
Controlling the lifting system using a double mini-lever .........................142
Controlling the lifting systemusingatriplemini-lever ..........................143
Controlling the lifting system using a quadruple mini-lever ......................144
Controllingtheliftingsystemusingthejoystick4Plus ..........................145
Controlling the lifting systemwiththefingertipconsole .........................147
Changing the fork arms ...............................................148
Forkextension(variant) ...............................................150
Operation with reversibleforkarms(variant) ................................152
Workingwithloads ...................................................154
Safety regulations when handing loads ....................................154
Beforetakingupload .................................................15
5
Loadmeasurement(variant) ...........................................156
Picking up loads .....................................................159
Danger area .......................................................160
Transportingpallets ..................................................161
Transporting suspended loads ..........................................161
Loadpickup ...................................................... . 162
Transporting loads ...................................................166
Setting down loads ...................................................167
Driving on ascending and descending slopes ...............................169
Drivingonlifts ......................................................169
Drivingonloadingbridges .............................................171
Workingwithattach
ments .............................................172
Fittingattachments ..................................................172
Releasingthepressurefromthehydraulicsystem ............................174
General instructionsforcontrollingattachments .............................176
Controlling attachments using multi-lever operation ...........................178
Controlling attachments using multi-lever operation and the 5th function ...........179
Controlling attachments using a double mini-lever . ...........................181
Controlling attachments using the double mini-lever and the 5th function ...........183
Controllingattachmentsusingatriplemini-lever .............................185
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Controlling attachments using the three-way mini-lever and the 5th function .........187
Controlling attachments using a quadruple mini-lever .........................189
Controlling attachments usingthefour-waymini-leverandthe5thfunction ..........191
Controllingattachmentsviathejoystick4Plus ...............................193
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........194
Controlling the attachments with fingertip . . ................................195
Controlling attachments with fingertip and the 5th function ......................196
Clamp locking mechanism (variant) ......................................198
Taking up a load using attachments ......................................201
Operation of additional equipment .......................................202
Switchingthelightingonandoff .........................................202
Switching the rotating beacononandoff ...................................203
Switchingthehazardwarningsystemonandoff .............................203
Switchingdirectionindicatorsonandoff ...................................204
Switching the double workingspotlightsonandoff. ...........................206
Operatingthewindscreenwiper/washer ...................................208
FleetManager (variant) . ...............................................208
Accident recorder (variant) .............................................209
Driverrestraintsystems(variants) .......................................209
Cab operation ......................................................210
Opening the cab door . . ...............................................210
Closingthecabdoor ............................................... . . 211
Openingthesidewindows ........................................... . . 211
Closing the side windows ..............................................211
Operatingtheinteriorlighting ...........................................212
Operating the rear window heating .......................................213
Radio(variant) ......................................................213
Heatingsystem(variant) ..............................................214
Push-up roof window (variant) ..........................................217
Clipboard (variant) ...................................................217
Trailer operation ....................................................218
Towedload ....................................................... . 218
Coupling pin in the counterweight ........................................219
Automatic tow coupling ...............................................221
Towingtrailers ......................................................229
Useincoldstores ....................................................23
1
Operation of the display operating unit ....................................234
Indicators .........................................................234
Adjusting the displays ................................................237
Symbolsinthedisplay ................................................237
Settingthedateortime ................................................242
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Resetting the daily kilometres and daily operating hours .......................242
Setting the language .................................................243
Soft key button for operating various equipment variants .......................243
Blue-Q efficiency mode ...............................................245
Functionaldescription ................................................245
Effects on additional consumers .........................................245
SwitchingefficiencymodeBlue-Qonandoff ................................246
ConfiguringBlue-Qefficiencymode ......................................247
Display messages ...................................................249
Displaycontent .....................................................249
Errorcodetable .....................................................249
General messages ...................................................252
Drive-specificmessages ..............................................261
Operation in special operating situations ...................................264
Transport ..........................................................264
Towing .......................................................... . 267
Craneloading ......................................................269
Procedure in emergencies.............................................272
Emergency shutdown ................................................273
Procedureiftrucktipsover .............................................274
Emergency hammer ..................................................275
Emergency lowering .................................................275
Emergency operation of the electric parking brake . ...........................277
Handling the battery ..................................................2
79
Safety regulations when handling the battery ...............................279
Opening/closing the battery door ........................................283
Disconnecting the battery male connector ..................................285
Maintainingthebattery ................................................286
Checkingthebatterycondition,acidlevelandaciddensity ......................288
Checking the battery chargestatus .......................................289
Chargingthebattery ..................................................289
Equalisingchargetopreventadeepdischargeofthebattery ....................292
Changing to a differentbatterytype .......................................295
General information on battery replacement ................................295
Replacingthebatteryusingaforklifttruck ..................................296
Battery transport withcrane ............................................301
Changing the battery using lift trucks ......................................302
Battery replacement using the mechanical battery carrier ......................307
Replacing the batterywiththehydraulicbatterycarrier .........................312
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Decommissioning ...................................................321
Parkingthetrucksecurelyandswitchingitoff ...............................321
Wheelchock(variant) ................................................323
Shuttingdownandstoringthetruck ......................................323
Recommissioningafterstorage .........................................325
Cleaning ..........................................................327
Cleaningthetruck ...................................................327
Cleaningtheelectricalsystem ..........................................329
Cleaningloadchains .................................................330
Cleaningthewindows .............................................. . . 331
Afterwashing .......................................................331
6 Maintenance
General maintenance information ........................................334
Personnel qualifications ...............................................334
Informationforcarryingoutmaintenance ..................................334
Maintenance — 1000 hours/annually .....................................337
Maintenance - 3000 hours/every two years . ................................341
Orderingsparepartsandwearingparts ....................................341
Quality and quantity of the required operating materials ........................341
Lubricationplan .....................................................343
Maintenance data table ...............................................344
Safety regulations for maintenance .......................................347
Generalinformation ..................................................347
Workingonthehydraulicequipment ......................................347
Working on the electrical equipment ......................................347
Safetydevices ......................................................348
Setvalues ....................................................... . . 348
Lifting and jacking up .................................................348
Workingatthefrontofthetruck ..........................................349
Providing access to maintenance points ...................................351
Removing/installingthevalvecover ......................................351
Maintenance .......................................................352
Lubricatingthejointsandcontrols ........................................352
Checking the battery interlock and battery door ..............................353
Maintainingtheseatbelt ...............................................353
Checkingthedriver’sseat .............................................355
Maintaining wheelsandtyres ...........................................356
Servicingthesteeringaxle .............................................358
Checkingthebattery .................................................360
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Checkingthefuses ...................................................360
Replacingfuses .....................................................362
Checking the hydraulic oil level ..........................................364
Checkingthehydraulicsystemforleaks ...................................365
Lubricatingtheliftmastandrollertrack ....................................366
Maintenance for trucks used in coldstores .................................366
Greasingtheautomatictowcoupling ......................................366
Maintaining the heater ................................................369
1000-hour maintenance / Annual maintenance ..............................371
Othertasks ........................................................371
Checkingthecableterminals ...........................................371
Checking the hydraulic oil levelofthehydraulicbatterycarrier ...................371
Lubricatingtheslideelements ..........................................372
Oilingthecatchrails ..................................................372
Checking the lift cylinders and connections for leaks ..........................374
Checkingforkarms ..................................................375
Checkingthereversibleforkarms ........................................375
Checking the double pedal .............................................376
Checking the battery changeover frame ...................................376
7 Technical data
Dimensions ........................................................378
VDI datasheet ......................................................379
Ergonomic dimensions ................................................384
Battery specifications .................................................385
Fuse assignment ....................................................387
Fuse assignment standard equipment ....................................387
Fuse assignment equipment variants .....................................388
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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.
21
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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
.
170525 EN - 10/2016 3

1Foreword
Your truck
Accessories
• Key for key switch (2 pieces)
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering
• Battery replacement frame
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Foreword 1
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.
170525 EN - 10/2016 5

1Foreword
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.
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Foreword 1
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.
Abbrevi-
ation Meaning Explanation
ABE Display operating unit
Arb-
SchG Arbeitsschutzgesetz German implementation of EU occupa-
tional health and safety directives
Betr-
SichV Betriebssicherheitsverordnung German implementation of the EU work-
ing equipment directive
BG Berufsgenossenschaft German insurance company for the
company and employees
BGG Berufsgenossenschaftlicher Grundsatz German principles and test specifications
for occupational health and safety
BGR Berufsgenossenschaftliche Regel German rules and recommendations for
occupational health and safety
DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations
CE Communauté Européenne Confirms conformity with product-specific
European directives (CE mark)
CEE Commission on the Rules for the Approval
of the Electrical Equipment
International commission on the rules for
the approval of electrical equipment
DC Direct Current Direct current
DFÜ Datenfernübertragung Remote data transmission
DIN Deutsches Institut für Normung German standardisation organisation
EG European Community
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1Foreword
Information about documentation
Abbrevi-
ation Meaning Explanation
EN European standard
FEM Fédération Européene de la Manutention European Federation of Materials Han-
dling and Storage Equipment
Fmax maximum Force Maximum power
GAA Gewerbeaufsichtsamt
German authority for monitoring/issuing
regulations for worker protection, environ-
mental protection, and consumer protec-
tion
GPRS General Packet Radio Service Transfer of data packets in wireless
networks
ID no. ID number
ISO International Organization for Standard-
ization International standardisation organisation
LAN Local Area Network Local area network
KpA Uncertainty of measurement of sound
pressure levels
LED Light Emitting Diode Light emitting diode
LpSound pressure level at the workplace
LpAZ Average continuous sound pressure level
in the driver’s compartment
LSP Load centre of gravity Distance of the centre of gravity of the load
from the front face of the fork backs
MAK Maximum workplace concentration Maximum permissible air concentrations
of a substance at the workplace
Max.Maximum Highest value of an amount
Min.Minimum Lowest value of an amount
PIN Personal Identification Number Personal identification number
PPEPersonal protective equipment
SE Super-Elastic Superelastic tyres (solid rubber tyres)
SIT Snap-In Tyre Tyres for simplified assembly, without
loose rim parts
StVZO Straßenverkehrs-Zulassungs-Ordnung German regulations for approval of
vehicles on public roads
TRGS Technische Regel für Gefahrstoffe Ordinance on hazardous materials appli-
cable in the Federal Republic of Germany
VDE Verband der Elektrotechnik Elektronik
Informationstechnik German technical/scientific association
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