Still RX60-60 User manual

Original instructions
Electric forklift truck
RX60-60
RX60-70
RX60-80
RX60-80/900
6341 6342 6343 6344
56358042501 EN - 10/2018

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.
56358042501 EN - 10/2018 I

Table of contents
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1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformity in accordance with Machinery Directive ............... 6
Accessories ......................................................... 7
Overview ........................................................... 8
Nameplate ......................................................... 11
Production number . . . ............................................... 12
StVZO(RoadTrafficLicensingRegulations)information ....................... 12
Using the truck ...................................................... 12
Commissioning ..................................................... 12
Proper usage ....................................................... 13
Proper use during towing .............................................. 1
3
Impermissibleuse ................................................... 14
Placeofuse ........................................................ 14
Parking in temperatures below-10°C ..................................... 15
Usingworkingplatforms ............................................... 16
Information about the documentation ..................................... 17
Documentationscope ................................................ 17
Supplementarydocumentation .......................................... 18
Issuedateandtopicalityoftheoperatinginstructions .......................... 19
Copyright and trademarkrights .......................................... 19
Explanation of information symbols used . . ................................ 19
Listofabbreviations .................................................. 20
Units ............................................................. 22
Definitionofdirections ................................................ 23
Schematicviews .................................................... 23
Environmental considerations .......................................... 25
Packaging ......................................................... 25
Disposal of components and batteries ..................................... 25
2Safety
Definition of responsible persons ........................................ 28
Operatingcompany .................................................. 28
Specialist .......................................................... 28
Drivers ........................................................... 29
Basic principles for safe operation ....................................... 31
Insurance cover on company premises .................................... 31
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Changes and retrofitting ............................................... 31
Changes to the overhead guard and roof loads . . . ........................... 33
Warning regarding non-originalparts ..................................... 34
Damage, defects and misuse of safety systems . . . ........................... 34
Tyres ............................................................. 35
Medicalequipment ................................................... 36
Exercise caution when handling gas springs and accumulators .................. 37
Lengthoftheforkarms ................................................ 37
Residual risk ....................................................... 39
Residual dangers, residual risks ......................................... 39
Specialrisksassociatedwithusingthetruckandattachments ................... 40
Overview of hazards and countermeasures ................................. 42
Danger to employees ................................................. 45
Safety tests ........................................................ 46
Regular safety inspectionofthetruck ..................................... 46
Insulationtesting .................................................... 46
Safety regulations for handling consumables ............................... 48
Permissible consumables ............................................. 48
Oils .............................................................. 48
Hydraulicfluid ...................................................... 49
Batteryacid ........................................................ 50
Coolantandcoolingfluid .............................................. 51
Disposalofconsumables .............................................. 52
Emissions ......................................................... 53
3Overviews
Overview .......................................................... 58
Driver's compartment ................................................. 60
Operating and display elements ......................................... 61
Display operating unit ................................................. 61
Operatingdevicesforhydraulicanddrivingfunctions .......................... 62
Double mini-lever .................................................... 63
Three-waymini-lever ................................................. 64
Four-waymini-lever .................................................. 65
Joystick4Plus ...................................................... 66
Fingertip .......................................................... 67
Miniconsole ....................................................... 68
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4 Operation
Checks and tasks before daily use ....................................... 70
Visualinspections ................................................... 70
Climbingintoandoutofthetruck ........................................ 73
Shelvesandcupholders .............................................. 76
Adjusting the MSG 65/MSG 75 driver'sseat ................................ 76
Adjustingthearmrest ................................................. 80
Adjustingthesteeringcolumn ........................................... 81
Unlocking the emergency off switch ...................................... 82
Operating the signal horn .............................................. 82
Seatbelt .......................................................... 83
Usingthedriver'scab ................................................. 86
Checkingthebrakesystemforcorrectfunction .............................. 86
Checkingthesteeringsystemforcorrectfunction ............................ 89
Checking the emergency offfunction ..................................... 90
Checking the vertical lift mast position (variant) for correct function . ............... 91
Zeroadjustmentoftheloadmeasurement(variant) ........................... 91
Switching on ....................................................... 93
Switchingonthekeyswitch ............................................ 93
AccessauthorisationwithPINcode(variant) ................................ 95
Operating the display and operating unit ...................................105
Indicators .........................................................105
Adjustingthedisplays ................................................107
Symbolsinthedisplay ................................................10
9
Settingthedateortime ................................................114
Resetting the daily kilometres and daily operating hours .......................114
Setting the language . . ...............................................115
Softkeys for operating various equipment variants ............................115
ConfiguringBlue-Qefficiencymode ......................................116
Blue-Q efficiency mode ...............................................118
Functional description . ...............................................118
Switching off additional consumers .......................................119
Switching efficiency mode Blue-Qonandoff ................................119
Traction ...........................................................121
Safety regulations when driving .........................................121
Roadways .........................................................123
Settingthedriveprogramme ............................................125
Sprintmode(variant) .................................................127
Selecting the drive direction ............................................128
Actuatingthedrivedirectionswitch,mini-leverversion .........................129
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 130
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Actuate the drive direction switch, fingertip version ...........................130
Actuatingthedrivedirectionswitch,mini-consoleversion ......................131
Startingdrivemode ..................................................131
Starting drive mode, dual pedal version (variant) . . ...........................134
Operatingtheservicebrake ............................................137
Actuating the mechanical parkingbrake ...................................138
Steering ...........................................................140
Reducing speed when turning (Curve Speed Control) .........................141
Driving on ascending and descending gradients . . ...........................142
Reducing speed with a raised load (variant) ................................143
Parking ...........................................................144
Parking the truck securely andswitchingitoff ...............................144
Wheel chock (variant) ................................................145
Lifting ............................................................146
Liftingsystemvariants ................................................1
46
Automaticliftcutout(variant) ...........................................146
Liftmastverticalposition(variant) ........................................147
Typesofliftmast ....................................................151
Malfunctionsduringliftingmode .........................................152
Hydraulicblockingfunction .............................................153
Lifting system operatingdevices .........................................154
Controlling the lifting system using a double mini-lever .........................155
Controllingtheliftingsystemusingatriplemini-lever ..........................156
Controlling the lifting system using a quadruple mini-lever ......................157
Controllingtheliftingsystemusingthejoystick4Plus ..........................158
Controllingtheliftingsystemwiththefingertipconsole .........................160
Changing the fork arms ...............................................161
Forkextension(variant) ...............................................163
Operationwithreversibleforkarms(variant) ................................165
Handling loads ......................................................167
Safety regulations when handing loads ....................................167
Beforetakingupload .................................................168
Load measurement (variant) ...........................................169
Picking up loads .....................................................172
Danger area .......................................................173
Transportingpallets ..................................................1
74
Transporting suspended loads ..........................................174
Loadpickup ...................................................... . 175
Transporting loads ...................................................179
Setting down loads ...................................................180
Drivingonlifts ......................................................182
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Driving on loading bridges .............................................183
Attachments .......................................................184
Fittingattachments ..................................................184
Releasingthepressurefromthehydraulicsystem ............................186
Generalinstructionsforcontrollingattachments .............................188
Controlling attachments using a double mini-lever ............................190
Controlling attachments using the double mini-lever and the 5th function ...........192
Controllingattachmentsusingatriplemini-lever .............................194
Controlling attachments usingthetriplemini-leverandthe5thfunction .............196
Controlling attachments using a quadruple mini-lever .........................198
Controlling attachments using the quadruple mini-lever and the 5th function .........200
Controlling attachments viathejoystick4Plus ...............................202
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........203
Controlling the attachments with fingertip . . ................................204
Controlling attachments with fingertip and the 5th function ......................205
Clamp locking mechanism (variant) ......................................207
Takingupaloadusingattachments ......................................210
Auxiliary equipment ..................................................211
Switchingthelightingonandoff .........................................211
Switchingtheworkingspotlightforreversetravelonandoff .....................212
Switching the rotating beacon on and off . . . ................................213
Switchingthehazardwarningsystemonandoff .............................213
Switchingtheturnindicatorsonandoff ....................................214
Switching the double workingspotlightsonandoff. ...........................216
STILLSafetyLight(variant) .............................................218
Operatingthewindscreenwiper/washer ...................................219
Filling the washer system ..............................................219
FleetManager (variant) . ...............................................220
Shock recognition (variant) .............................................220
12-Vsocket ...................................................... . . 221
Driverrestraintsystems(variants) .......................................221
Ceilingsensor(variant) ...............................................222
Cab ..............................................................228
Opening the cab door . . ...............................................228
Closingthecabdoor ............................................... . . 229
Opening the side windows .............................................229
Closing the side windows ..............................................229
Operatingtheinteriorlighting ...........................................230
Operating the rear window heating .......................................231
Radio(variant) ......................................................231
Heatingsystem(variant) ..............................................232
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Push-up roof window (variant) ..........................................234
Clipboard (variant) ...................................................234
Trailer operation ....................................................235
Towedload ....................................................... . 235
Coupling pin in the counterweight ........................................236
Automatictowcoupling ...............................................238
Towingtrailers ......................................................246
Display messages ...................................................247
Displaycontent .....................................................247
Errorcodetable .....................................................247
General messages ...................................................250
Drive-specificmessages ..............................................25
9
Connecting and disconnecting the battery male connector ......................262
Connecting the battery male connector ....................................262
Disconnecting the battery male connector ..................................263
Handling the battery ..................................................265
Safety regulations when handling the battery ...............................265
Checking the battery chargestatus .......................................268
Chargingthebattery ..................................................268
Equalising charging to preserve the battery capacity ..........................271
Replacing and transporting the battery ....................................273
General information on replacing the battery ................................273
Changing to a different battery type .......................................273
Opening and closing thebatterycover ....................................274
Replacingthebattery .................................................276
PowerPlusLife battery ................................................282
PowerPlusLife®battery ...............................................282
PowerPlusLife®temperaturemonitoring ...................................284
PowerPlusLife®error messages . ........................................284
Cleaning ..........................................................286
Cleaning the truck ...................................................286
Cleaning the electrical system ..........................................288
Cleaning load chains .................................................288
Cleaning the windows ................................................289
After cleaning .......................................................289
Procedure in emergencies .............................................291
Emergency shutdown ................................................291
Procedureiftrucktipsover .............................................293
Emergency hammer ..................................................294
Emergency lowering .................................................294
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Releasingthespring-operatedbrake .....................................296
Towing .......................................................... . 299
Transporting the truck ................................................302
Transportation ......................................................302
Crane loading ......................................................304
Shutdown .........................................................308
Shuttingdownandstoringthetruck ......................................308
Re-commissioningaftershutdown .......................................310
5 Maintenance
Safety regulations for maintenance .......................................312
Generalinformation ..................................................312
Workingonthehydraulicequipment ......................................312
Working on the electrical equipment ......................................312
Safetydevices ......................................................313
Setvalues ....................................................... . . 313
Liftingandjackingup .................................................3
13
Workingatthefrontofthetruck ..........................................314
General maintenance information ........................................316
Personnel qualifications ...............................................316
Informationforcarryingoutmaintenance ..................................316
Maintenance - 1000 hours/annually ......................................319
Maintenance - 3000 hours/everytwoyears .................................322
Orderingsparepartsandwearingparts ....................................322
Quality and quantity of the required operating materials ........................322
Lubricationplan .....................................................324
Maintenance data table ...............................................325
Providing access to maintenance points ...................................328
Removing and attachingtheleftsidecover .................................328
Installingandremovingthebottomplate ...................................328
Opening/closingthefrontrightcover ......................................330
Removing and attachingtherearcover ....................................331
Preserving operational readiness ........................................332
Checkingthecoolantlevel .............................................332
Topping up cooling fluid andcheckingcoolantcontent .........................333
Cleaningtheradiatorandcheckingtheradiatorforleaktightness .................336
Checking the battery condition, acid level and acid density ......................338
Changing the heating systemfreshairfilter .................................339
Lubricatingthejointsandcontrols ........................................340
Maintainingtheseatbelt ...............................................341
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Checkingthedriver'sseat .............................................342
Checking the door latch ...............................................343
Replacing the recirculated air filter for the heating system ......................343
Servicingwheelsandtyres .............................................344
Replacingthefuses ..................................................346
Checking the hydraulic oil level ..........................................348
Checkingthehydraulicsystemforleaktightness .............................350
Lubricatingtheliftmastandrollertrack ....................................351
Greasing the automatic tow coupling ......................................351
6 1000-hour maintenance/annual maintenance
Other tasks ........................................................356
Checking the lift cylinders and the hydraulic connections for leak tightness ..........356
Checking the fork arms ................................................3
56
Checking the reversible fork arms ........................................357
7 Technical data
Dimensions ........................................................360
VDI datasheet ......................................................362
Ergonomic dimensions ................................................366
Battery specifications .................................................367
Fuse assignment ....................................................369
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358042501 EN - 10/2018

1
Foreword

1Foreword
Your truck
Your truck
Description of the truck
General
The electrically driven counterbalanced
trucks from series RX60–60/70/80 have a
load capacity of up to eight tonnes with a load
centre of gravity of 900 mm. This means that
the truck can reach a top speed of 17 km/h,
which can be increased to 20 km/h thanks to
sprint mode and PowerPlusLife battery.
The bend-resistant and warp-resistant lift
mast enables safe load handling during indoor
and outdoor use, even with heavy loads. In
addition, the driver's compartment features
the most up-to-date ergonomic design in order
to support safety. The steering column and
the driver's compartment are both offset to
one side, enabling comfortable working and
preventing fatigue.
The low centre of gravity of the truck provides
stability, which is guaranteed if the truck is
used according to its intended use.
The truck is equipped with a particularly
long-life air-cooled battery. Thanks to the
high battery capacity of 1240 Ah and battery
replacement from the side, the truck is suitable
for multi-shift use. In addition, the series
supports all the functions of FleetManager4.x.
Brake system
The brake system of the truck comprises three
different brakes:
• Service brake
• Regenerative brake
• Parking brake
The service brake is based on a wear-free,
oil-immersed multi-disc brake. This multi-disc
brake is used as the service brake for heavy
braking or emergency braking with the brake
pedal. In the normal working mode, the
regenerative brake of the electric traction
motor takes effect. The regenerative brake
converts the acceleration energy of the truck
into electrical energy. This causes the truck to
decelerate as soon as the accelerator pedal
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Foreword 1
Your truck
is released. Completely removing your foot
from the accelerator pedal causes the truck to
brake until it comes to a standstill. A parking
brake ensures that the truck remains securely
in place when parked.
Steering
The truck is equipped with a swing axle and
has kickback-free, hydraulic rear-wheel steer-
ing. Stability is guaranteed when cornering
thanks to speed limitation based on the steer-
ing angle. The simple handling of the truck is
assisted by the agile steering axle.
Hydraulic system
The steering, the lift cylinders and the tilt
cylinders of the lift mast are all supplied by
the electrically driven hydraulic pump.
The directional control valve block with electri-
cal proportional technology ensures extremely
sensitive movements and safe handling of the
load. The hydraulic functions can be parame-
terised individually by the authorised service
centre.
Uptothreehydrauliccircuitscanbeusedto
activate attachments (variant). Depending on
the equipment, a hydraulic accumulator is also
available in the lifting circuit for the purpose of
dampening pressure peaks in the hydraulic
system.
Drive concept
The RX60 60–80 is driven by a maintenance-
free 80-volt three-phase drive.
Power is supplied by a battery that is located
at the side for ease of access. The optional
cold store variant is available for operating the
truck in temperatures down to —30°C.
The driver can help to influence the energy
consumption and performance of the truck
using the Blue-Q efficiency mode, which
allows the required setting for each current
application to be called up via the display-
operating unit.
56358042501 EN - 10/2018 3

1Foreword
Your truck
Operating devices
The truck is characterised by an accessible
operating concept. When purchasing the
truck, a variety of operating devices and
equipment variants are available:
• Double mini-lever
• Triple mini-lever
• Quadruple mini-lever
• Joystick 4Plus
• Fingertip switch
• Single pedal
• Dual pedal
Hands are always kept free for steering and
for controlling the operational movements to
allow efficient working. The forces that need
to be applied for this purpose are reduced to
a minimum thanks to the compact steering
wheel.
Operational information, such as the fuel level
or an indication that the Blue-Q energy-saving
mode is enabled, is shown on the display-
operating unit.
For drive mode, the truck features either
single-pedal or dual-pedal operation. The
accelerator pedal is used to accelerate and
brake (regenerative brake) the truck. In
emergency situations or when carrying heavy
loads, the driver can also brake the truck using
the service brake by pressing the brake pedal.
In dual-pedal operation, the truck has one
pedal for the "Forwards" drive direction and
one pedal for the "Reverse" drive direction.
Acceleration and braking behaviour can be
individually selected from five different drive
programmes.
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.
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Foreword 1
Your truck
The driving permit must be obtained from the
appropriate office.
The truck has been fitted with state-of-the-
art technology. Following these operating
instructions will allow the truck to be handled
safely. By complying with the specifications in
these operating instructions, the functionality
and the approved features of the truck will be
retained.
Get to know the technology, understand it
and use it safely - these operating instructions
provide the necessary information and help to
avoid accidents and to keep the truck ready for
operation beyond the warranty period.
Therefore:
– Before commissioning the truck, read
the operating instructions and follow the
instructions.
– Always follow all of the safety information
contained in the operating instructions and
on the truck.
CE-Symbol
CE labelling
The manufacturer uses CElabellingtoindi-
cate that the truck complies with the standards
and regulations valid at the time of marketing.
This is confirmed by the issued EC declaration
of conformity. The CE labelling is attached to
the nameplate.
An independent structural change or addition
to the truck can compromise safety, thus
invalidating the EC declaration of conformity.
The EC declaration of conformity must be
carefully stored and made available to the
responsible authorities.
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1Foreword
Your truck
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
.
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Foreword 1
Your truck
Accessories
• Key for key switch (two pieces)
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering
56358042501 EN - 10/2018 7

1Foreword
Your truck
Overview
Labelling points, left
DANGER
DANGER
DANGER
3
DANGER
DANGER
Regelmäßige Prüfung
(FEM 4.004)
nach nationalen Vorschriften
basierend auf den EG-Richtlinien:
2009/104/EG, 99/92/EG
Die Prüfplakette ersetzt nicht das Prüfprotokoll
Nächste Prüfung
56344391019
Mitglied der:
Fédération
Européene
de la Manutention
STILL GmbH Hamburg
20xx
46
15
10 bar DANGER
7
13
16
8
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1
14
5430
5430
1010
1010
1080
1080
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1080
1050
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1150
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1310
1310
4430
4430
1110
1110
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1250
1250
1500
1500
4030
4030
1150
1150
1260
1260
1200
1200
1500
1500
3730
3730
1180
1180
1290
1290
1430
1430
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1500
3430
3430
1210
1210
1330
1330
1470
1470
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5030 1270
2
1
3
910
STILL Hamburg
Berzeliusstr. 10
22113 Hamburg
Tel.: 01804 / 784 55 24
Ihr STILL Service
Nächste Prüfung
733906
BATTERIESERVICE
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