Still RX60-60 User manual

Original instructions
Electric forklift truck
RX60-60
RX60-70
RX60-80
6341 6342 6343 6344
56358042501 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 the documentation ...................................... 5
Documentationscope ................................................. 5
Issue date and topicality oftheoperatinginstructions ........................... 6
Copyrightandtrademarkrights ........................................... 6
Explanation of information symbols used . . ................................. 6
Listofabbreviations ................................................... 7
Units ............................................................. 10
Definitionofdirections ................................................ 11
Schematicviews .................................................... 11
Environmental considerations .......................................... 13
Packaging ......................................................... 13
Disposal of components andbatteries ..................................... 13
2 Introduction
Using the truck ...................................................... 16
Proper usage ....................................................... 16
Proper use during towing .............................................. 16
Impermissibleuse ................................................... 16
Placeofuse ........................................................ 17
Parking in temperaturesbelow-10°C ..................................... 18
Usingworkingplatforms ............................................... 18
Residual risk ....................................................... 19
Residual dangers, residual risks ......................................... 19
Specialrisksassociatedwithusingthetruckandattachments ................... 20
Overviewofhazardsandcountermeasures ................................. 22
Danger to employees ................................................. 25
3Safety
Definition of responsible persons ........................................ 28
Operatingcompany .................................................. 28
Specialist .......................................................... 28
Drivers ........................................................... 29
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Basic principles for safe operation ....................................... 31
Insurance cover on company premises .................................... 31
Changes and retrofitting ............................................... 31
Changes to the overhead guard and roof loads . . . ........................... 34
Warning regarding non-original parts ..................................... 34
Damage, defects and misuse of safetysystems .............................. 35
Tyres ............................................................. 35
Medicalequipment ................................................... 36
Exercise caution when handlinggasspringsandaccumulators .................. 37
Lengthoftheforkarms ................................................ 37
Safety tests ........................................................ 39
Regular safety inspection ofthetruck ..................................... 39
Insulationtesting .................................................... 39
Safety regulations for handling consumables ............................... 41
Permissible consumables ............................................. 41
Oils .............................................................. 41
Hydraulicfluid ...................................................... 42
Batteryacid ........................................................ 43
Coolantandcoolingfluid .............................................. 44
Disposalofconsumables .............................................. 45
Emissions ......................................................... 46
4Overviews
Overview .......................................................... 50
Overview of the driver’s compartment ..................................... 51
Operating and display elements ......................................... 52
Display operating unit ................................................. 52
Operatingdevicesforhydraulicanddrivingfunctions .......................... 53
Doublemini-lever .................................................... 5
4
Three-waymini-lever ................................................. 55
Four-waymini-lever .................................................. 56
Joystick4Plus ...................................................... 57
Fingertip .......................................................... 58
Miniconsole ....................................................... 59
Identification points .................................................. 60
Overview .......................................................... 60
Nameplate ......................................................... 62
Production number .................................................. 63
StVZO (Road Traffic Licensing Regulations) information ....................... 63
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5 Operation
Checks and tasks to be carried out prior to commissioning ...................... 66
Visualinspections ................................................... 66
Fillingthewashersystem .............................................. 68
Checking the condition of the wheels and tyres .............................. 69
Checkingthecoolantlevel ............................................. 7
0
AdjustingtheMSG65/MSG75driver’sseat ................................ 72
Adjustingthearmrest ................................................. 76
Adjusting the steering column ........................................... 77
Commissioning ..................................................... 78
Climbingintoandoutofthetruck ........................................ 78
Connecting the battery male connector .................................... 81
Unlockingtheemergencyoffswitch ...................................... 82
Switchingonthekeyswitch ............................................ 82
Access authorisation withPINcode(variant) ................................ 85
Operating the signal horn .............................................. 95
Seatbelt .......................................................... 95
Usingthedriver’scab ................................................. 98
Checkingthebrakesystemforcorrectfunction .............................. 98
Checkingthesteeringsystemforcorrectfunction ............................ 99
Checking the emergency offfunction .....................................100
Zeroadjustmentoftheloadmeasurement(variant) ...........................101
Checking the vertical lift mast position (variant) for correct function . ...............102
Traction ...........................................................103
Safety regulations when driving .........................................103
Roadways .........................................................105
Setting the drive programme ............................................107
Selectingthedrivedirection ............................................109
Actuatingthedrivedirectionswitch,mini-leverversion .........................110
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 110
Actuatethedrivedirectionswitch,fingertipversion ...........................111
Actuatingthedrivedirectionswitch,mini-consoleversion ......................111
Starting drive mode ..................................................111
Starting drive mode, dual pedal version (variant) .............................114
Operatingtheservicebrake ............................................117
Actuating the mechanicalparkingbrake ...................................118
Steering ...........................................................120
Reducing speed when turning (Curve Speed Control) .........................121
Reducing speed witharaisedload(variant) ................................122
Lifting ............................................................123
Liftingsystemvariants ................................................123
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Automaticliftcutout(variant) ...........................................123
Liftmastverticalposition(variant) ........................................124
Typesofliftmast ....................................................128
Malfunctionsduringliftingmode .........................................129
Hydraulicblockingfunction .............................................130
Lifting system operating devices .........................................131
Controlling the lifting system using a double mini-lever .........................132
Controllingtheliftingsystemusingatriplemini-lever ..........................133
Controlling the lifting system using a quadruple mini-lever ......................134
Controllingtheliftingsystemusingthejoystick4Plus ..........................135
Controllingtheliftingsystemwiththefingertipconsole .........................137
Changing the fork arms ...............................................138
Forkextension(variant) ...............................................140
Operationwithreversibleforkarms(variant) ................................142
Handling loads ......................................................144
Safety regulations when handing loads ....................................144
Beforetakingupload .................................................145
Load measurement (variant) ...........................................146
Picking up loads .....................................................149
Danger area .......................................................150
Transportingpallets ..................................................1
51
Transporting suspended loads ..........................................151
Loadpickup ...................................................... . 152
Transporting loads ...................................................156
Setting down loads ...................................................157
Driving on ascending and descending slopes ...............................159
Drivingonlifts ......................................................159
Drivingonloadingbridges .............................................161
Workingwithattachments .............................................162
Fitting attachments ..................................................162
Releasingthepressurefromthehydraulicsystem ............................164
General instructions for controlling attachments . . ...........................166
Controlling attachments using a double mini-lever . ...........................168
Controlling attachments using the double mini-lever and the 5th function ...........170
Controllingattachmentsusingatriplemini-lever .............................172
Controlling attachmentsusingthethree-waymini-leverandthe5thfunction .........174
Controlling attachments using a quadruple mini-lever .........................176
Controlling attachments using the four-way mini-lever and the 5th function ..........178
Controlling attachmentsviathejoystick4Plus ...............................180
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........181
Controllingtheattachmentswithfingertip ..................................182
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Controlling attachments with fingertip and the 5th function ......................183
Clamp locking mechanism (variant) ......................................185
Taking up a load using attachments ......................................189
Operating auxiliary equipment ..........................................190
Switchingthelightingonandoff .........................................190
Switching the rotating beacononandoff ...................................191
Switchingthehazardwarningsystemonandoff .............................192
Switchingthedirectionindicatorsonandoff ................................192
Switching the double workingspotlightsonandoff. ...........................194
Operatingthewindscreenwiper/washer ...................................196
FleetManager (variant) . ...............................................196
Accident recorder (variant) .............................................197
Driverrestraintsystems(variants) .......................................197
Cab operation ......................................................197
Opening the cab door . . ...............................................197
Closingthecabdoor ............................................... . . 198
Openingthesidewindows ........................................... . . 198
Closing the side windows ..............................................199
Operatingtheinteriorlighting ...........................................200
Operating the rear window heating .......................................201
Radio(variant) ......................................................201
Heatingsystem(variant) ..............................................202
Push-up roof window (variant) ..........................................204
Clipboard (variant) ...................................................20
4
Trailer operation ....................................................205
Towedload ....................................................... . 205
Coupling pin in the counterweight ........................................206
Automatic tow coupling ...............................................208
Towingtrailers ......................................................216
Operating the display and operating unit ...................................217
Indicators .........................................................217
Adjustingthedisplays ................................................220
Symbols in the display ................................................220
Settingthedateortime ................................................225
Resetting the daily kilometres and daily operating hours .......................225
Setting the language .................................................226
Soft key button for operating various equipment variants .......................226
Blue-Q efficiency mode ...............................................228
Functional description ................................................228
Effects on additional consumers .........................................228
SwitchingefficiencymodeBlue-Qonandoff ................................229
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ConfiguringBlue-Qefficiencymode ......................................230
Display messages ...................................................232
Displaycontent .....................................................232
Errorcodetable .....................................................232
General messages ...................................................235
Drive-specificmessages ..............................................244
Operating in special operating situations ...................................247
Transportation ......................................................247
Towing .......................................................... . 250
Craneloading ......................................................252
Procedure in emergencies .............................................257
Emergency shutdown ................................................257
Procedureiftrucktipsover .............................................258
Emergency hammer ..................................................259
Emergency lowering .................................................259
Releasing the spring-operated brake .....................................261
Handling the battery ..................................................265
Safety regulations when handling the battery ...............................265
Changing to a different battery type .......................................267
Opening and closing the battery cover ....................................268
Disconnecting the battery male connector ..................................270
Checkingthebatterychargestatus .......................................272
Chargingthebattery ..................................................272
Equalising charge to preventadeepdischargeofthebattery ....................275
Replacingthebatteryusingatruck .......................................277
PowerPlusLife battery ................................................283
PowerPlusLife®battery ...............................................283
PowerPlusLife®temperaturemonitoring ...................................284
PowerPlusLife®error messages . ........................................285
Decommissioning ...................................................286
Parkingthetrucksecurelyandswitchingitoff ...............................286
Wheel chock (variant) ................................................288
Shutting down and storingthetruck ......................................288
Re-commissioningaftershutdown .......................................290
Cleaning ..........................................................292
Cleaning the truck ...................................................292
Cleaning the electrical system ..........................................294
Cleaning load chains .................................................295
Cleaning the windows ................................................295
Afterwashing .......................................................296
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6 Maintenance
General maintenance information ........................................298
Personnel qualifications ...............................................298
Informationforcarryingoutmaintenance ..................................298
Maintenance - 1000 hours/annually ......................................301
Maintenance - 3000 hours/everytwoyears .................................304
Orderingsparepartsandwearingparts ....................................304
Quality and quantity of the required operating materials ........................304
Lubricationplan .....................................................306
Maintenance data table ...............................................307
Safety regulations for maintenance .......................................310
Generalinformation ..................................................310
Workingonthehydraulicequipment ......................................310
Working on the electrical equipment ......................................310
Safetydevices ......................................................311
Setvalues ....................................................... . . 311
Liftingandjackingup .................................................311
Workingatthefrontofth
etruck ..........................................312
Providing access to maintenance points ...................................314
Removingandattachingtheleftsidecover .................................314
Installing and removingthebottomplate ...................................314
Opening/closingthefrontrightcover ......................................316
Removingandattachingtherearcover ....................................317
Servicing ..........................................................318
Cleaningtheradiatorandcheckingforleaks ................................318
Topping up cooling fluid and checking coolant content .........................319
Servicing wheels and tyres .............................................321
Replacingthefuses ..................................................323
Checking the battery condition, acid level and acid density ......................326
Checking the hydraulicoillevel ..........................................327
Changing the heating system fresh air filter . ................................328
Replacingtherecirculatedairfilterfortheheatingsystem ......................330
1000-hour maintenance/annual maintenance ...............................331
Othertasks ...................................................... . . 331
Checkingthedriver’sseat .............................................331
Maintaining the seatbelt ...............................................331
Checking the door latch ...............................................333
Lubricatingthejointsandcontrols ........................................333
Lubricating the liftmastandrollertrack ....................................333
Checkingtheliftcylindersandconnectionsforleaks ..........................334
Checkingthehydraulicsystemforleaks ...................................334
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Checkingtheforkarms ................................................335
Checkingthereversibleforkarms ........................................335
Greasing the automatic tow coupling ......................................336
7 Technical data
Dimensions ........................................................340
VDI datasheet ......................................................342
Ergonomic dimensions ................................................346
Battery specifications .................................................347
Fuse assignment ....................................................349
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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.
25
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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
.
56358042501 EN - 10/2016 3

1Foreword
Your truck
Accessories
• Key for key switch (two pieces)
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering
45
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Foreword 1
Information about the documentation
Information about the 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.
56358042501 EN - 10/2016 5

1Foreword
Information about the 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 the 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 the 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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