Still RX70-20/600 User manual

Original instructions
LPG trucks
RX70-20/600
RX70-25
RX70-25/600
RX70-30
RX70-30/600
RX70-35
7385 7386 7387 7388 7391
7392
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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.
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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
Proper usage ....................................................... 12
Proper use during towing .............................................. 13
Impermissibleuse ................................................... 13
Placeofuse ........................................................ 14
Usingworkingplatforms ............................................... 15
Information about the documentation ..................................... 16
Documentationscope ................................................ 16
Supplementarydocumentation .......................................... 17
Issue date and topicalityoftheoperatinginstructions .......................... 18
Copyrightandtrademarkrights .......................................... 18
Explanation of information symbols used . . ................................ 18
List of abbreviations .................................................. 19
Definitionofdirections ................................................ 21
Schematicviews .................................................... 21
Environmental considerations .......................................... 23
Packaging ......................................................... 23
Disposal of components and batteries ..................................... 23
2Safety
Definition of responsible persons ........................................ 26
Operatingcompany .................................................. 26
Specialist .......................................................... 26
Drivers ........................................................... 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
Modifications and retrofitting ............................................ 29
Changes to the overhead guard and roof loads .............................. 31
Warning regarding non-original parts ..................................... 31
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Damage, defects and misuse of safety systems . . . ........................... 32
Tyres ............................................................. 32
Medicalequipment ................................................... 33
Exercise caution when handling gas springs and accumulators .................. 34
Lengthoftheforkarms ................................................ 34
Residual risk ....................................................... 36
Residual dangers, residual risks ......................................... 36
Specialrisksassociatedwithusingthetruckandattachments ................... 37
Overview of hazards and countermeasures ................................. 40
Danger to employees ................................................. 43
Safety tests ........................................................ 44
Regular safety inspection ofthetruck ..................................... 44
Carrying out regular safety inspections on the LPG system ..................... 44
Regularly checking the level of harmful substances in the exhaust gas . . . . ......... 45
Insulationtesting .................................................... 46
Safety regulations for handling consumables ............................... 47
Permissibleconsumables ............................................. 47
Oils .............................................................. 48
Hydraulicfluid ...................................................... 49
Batteryacid ........................................................ 50
LPG .............................................................51
Coolantandcoolingfluid .............................................. 54
Brakefluid ......................................................... 54
Disposal of consumables .............................................. 56
Emissions ......................................................... 57
3Overviews
Overall view ........................................................ 62
Driver's compartment ................................................. 63
Operating devices and display elements ................................... 64
Display and operating unit . . . .......................................... 64
Operating devicesforhydraulicanddrivingfunctions .......................... 65
Doublemini-lever .................................................... 66
Three-waymini-lever ................................................. 67
Four-way mini-lever .................................................. 68
Joystick4Plus ...................................................... 69
Fingertip .......................................................... 70
Miniconsole ....................................................... 71
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4 Operation
Checks and tasks before daily use ....................................... 74
Visualinspections ................................................... 74
Climbinginandoutofthetruck .......................................... 77
Shelvesandcupholders .............................................. 78
Adjusting the MSG 65/MSG 75 driver'sseat ................................ 79
Adjustingthearmrest ................................................. 83
Adjustingthesteeringcolumn ........................................... 84
Unlocking the emergency off switch ...................................... 85
Operating the signal horn .............................................. 85
Seatbelt .......................................................... 86
Driver'scab ........................................................ 89
Checking the condition of the wheels and tyres .............................. 89
Opening the LPG cylinder valve for a double-cylinder holder . . . ................. 90
Checking the brake system forcorrectfunction .............................. 92
Checkingthesteeringsystemforcorrectfunction ............................ 95
Checking the emergency off function ..................................... 95
Zero adjustment of the loadmeasurement(variant) ........................... 96
Checking the vertical lift mast position (variant) for correct function . ............... 97
Switching on and starting .............................................. 98
Engine preheating ................................................... 98
OpeningtheLPGcylindervalve ......................................... 99
Openingtheshut-offvalveofanLPGtank(variant) ...........................101
Switchingonthekeyswi
tch ............................................102
AccessauthorisationwithPINcode(variant) ................................105
Starting the engine ...................................................115
Operating the display-operating unit ......................................116
Indicators .........................................................116
Adjustingthedisplays ................................................117
Symbolsinthedisplay ................................................1
19
Settingthedateortime ................................................124
Resetting the daily kilometres and daily operating hours .......................124
Setting the language . . ...............................................12
5
Softkeys for operating various equipment variants ............................125
ConfiguringBlue-Qefficiencymode ......................................126
Blue-Q efficiency mode ...............................................1
28
Functional description . ...............................................128
Switching off additional consumers .......................................129
Switching efficiency modeBlue-Qonandoff ................................129
Driving ............................................................131
Safety regulations when driving .........................................131
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Roadways ........................................................ . 133
Settingthedriveprogrammes ...........................................136
Selecting the drive direction ............................................137
Actuatingthedrivedirectionswitch,mini-leverversion .........................138
Actuating the vertical rocker switch for the "drive direction", joystick 4Plusversion ....138
Actuating the drive direction switch, fingertip version ..........................139
Actuatingthedrivedirectionswitch,mini-consoleversion ......................139
Startingtodrive .....................................................139
Starting drive mode, dual pedalversion(variant) .............................142
Operatingtheservicebrake ............................................144
Parkingbrake ......................................................145
Actuating the mechanical parkingbrake ...................................145
Steering ...........................................................147
Driving on ascending and descending gradients . . ...........................148
Reducing speed with a raisedload(variant) ................................149
Automatic shut-off of the internal combustion engine (variant) ...................149
Engine stalls because the evaporator has iced over ...........................150
Parking ...........................................................152
Parkingthetrucksecurelyandswitchingitoff ...............................152
Wheel chock (variant) ................................................155
Lifting ............................................................156
Liftingsystemvariants ................................................156
Automaticliftcutout(variant) ...........................................156
Lift mast vertical position(variant) ........................................157
Typesofliftmast ....................................................161
Malfunctionsduringliftingmode .........................................163
Hydraulic blocking function .............................................164
Liftingsystemoperatingdevices .........................................165
Controlling the lifting system using a double mini-lever .........................166
Controlling the liftingsystemusingatriplemini-lever ..........................167
Controlling the lifting system using a quadruple mini-lever ......................168
Controllingtheliftingsystemusingthejoystick4Plus ..........................169
Controlling the lifting system using the fingertip . . . ...........................171
Changing the fork arms ...............................................172
Forkextension(variant) ...............................................174
Operation with reversibleforkarms(variant) ................................176
Handling loads ......................................................178
Safety regulations when handing loads ....................................178
Before taking up load .................................................179
Loadmeasurement(variant) ...........................................180
Picking up loads .....................................................183
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Danger area .......................................................184
Transportingpallets ..................................................185
Transporting suspended loads ..........................................185
Pickingupaload .................................................. . . 186
Transportingloads ...................................................190
Settingdownaload ................................................ . . 191
Shakefunction(variant) ...............................................192
Drivingonlifts ......................................................196
Driving on loading bridges .............................................1
97
Attachments .......................................................199
Fittingattachments ..................................................199
Releasing the pressure fromthehydraulicsystem ............................201
Generalinstructionsforcontrollingattachments .............................203
Controlling attachments using a double mini-lever ............................205
Controlling attachments using the double mini-lever and the 5th function ...........207
Controllingattachmentsusingatriplemini-lever .............................209
Controlling attachments using the triple mini-lever and the 5th function .............211
Controlling attachments using a quadruple mini-lever .........................213
Controlling attachments using the quadruple mini-lever and the 5th function .........215
Controllingattachmentsviathejoystick4Plus ...............................217
Controlling attachmentsusingthejoystick4Plusandthe5thfunction ..............218
Controlling the attachments with the fingertip ...............................219
Controlling attachments with the fingertip and 5th function ......................220
Clamp locking mechanism(variant) ......................................222
Takingupaloadusingattachments ......................................225
Auxiliary equipment ..................................................226
Switching the lighting on andoff .........................................226
Switchingtheworkingspotlightforreversetravelonandoff .....................227
Switching the rotating beacon on and off . . . ................................228
Switching the hazard warningsystemonandoff .............................228
Switchingtheturnindicatoronandoff .....................................229
Switching the double working spotlights on and off. ...........................232
STILL SafetyLight (variant) .............................................234
Operatingthewindscreenwiper/washer ...................................235
Fillingthewashersystem ..............................................235
FleetManager (variant) . ...............................................2
36
Shock recognition (variant) .............................................236
Cruisecontrol(variant) ................................................236
Driver restraint systems(variants) .......................................240
Ceilingsensor(variant) ...............................................240
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Cab ..............................................................246
Opening the cab door .................................................246
Closing the cab door .................................................247
Opening the side windows . . . ..........................................248
Closingthesidewindows ..............................................248
Operating the interior lighting ...........................................249
Operating the rear window heating .......................................250
Radio(variant) ......................................................251
Radio with Bluetooth interface(variant) ....................................252
Heatingsystem .....................................................254
Push-up roof window (variant) ..........................................255
Clipboard (variant) ...................................................256
12Vsocket ....................................................... . 256
Trailer operation ....................................................257
Towedload ....................................................... . 257
Coupling pin in the counterweight ........................................258
Automatictowcoupling ...............................................260
Towingtrailers ......................................................268
Display messages ...................................................270
Displaycontent .....................................................270
Errorcodetable .....................................................270
General messages ...................................................273
Drive-specificmessages ..............................................282
Refuelling .........................................................290
Changing the LPG cylinder . . . ..........................................290
Changing the LPG cylinder in a double-cylinder holder ........................293
Filling the LPG tank (variant) ............................................295
Cleaning ..........................................................299
Cleaning the truck ...................................................299
Cleaning the electricalsystem ..........................................301
Cleaning load chains .................................................301
Cleaning the windows ................................................302
Afterwashing .......................................................302
Procedure in emergencies .............................................303
Emergency shutdown ................................................303
Procedure if truck tipsover .............................................304
Emergency hammer ..................................................305
Emergency lowering .................................................305
Disconnecting the battery ..............................................307
Jump-starting ......................................................308
Towing .......................................................... . 310
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Transporting the truck ................................................313
Transporting .......................................................313
Crane loading ......................................................315
Short-term operation . . ...............................................318
Decommissioning ...................................................319
Shutting down and storing thetruck ......................................319
Returningtoserviceafterdecommissioning ................................321
5 Maintenance
Safety regulations for maintenance .......................................324
Generalinformation ..................................................324
Workingonthehydraulicequipment ......................................324
Working on the electrical equipment ......................................325
Working on the ignition system ..........................................325
WorkingontheLPGsystem ........................................... . 326
Safetydevices ......................................................327
Setvalues ....................................................... . . 327
Liftingandjackingup .................................................327
Workingatthefrontofthetruck ..........................................328
General maintenance information ........................................330
Personnel qualifications ...............................................330
Informationforcarryingoutmaintenance ..................................330
Maintenance - 1000 hours/annually ......................................333
Maintenance - 3000 hours/every two years . ................................337
Orderingsparepartsandwearingparts ....................................337
Quality and quantity of the required operating materials ........................338
Lubricationplan .....................................................339
Maintenance data table ...............................................340
Providing access to maintenance points ...................................342
Openingthebonnet ................................................ . . 342
Closing the bonnet ...................................................345
Removing and attaching the rearcover ....................................347
Installingandremovingthebottomplate ...................................348
Maintenance after the first 50 operating hours ...............................350
Maintenance during the break-inperiod ...................................350
Preserving operational readiness ........................................350
Checking the engine oil level ...........................................350
Cleaningthedustvalve ...............................................351
Fillingthewashersystem ..............................................351
Checkingthelevelofthecoolingfluid .....................................352
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Cleaning the radiator, checking for leaks ...................................354
Topping up the cooling fluid and checking the coolant concentration . . . . . . .........354
Replacing the air filter cartridges .........................................356
Lubricatingthejointsandcontrols ........................................358
Maintainingtheseatbelt ...............................................359
Checkingthedriver'sseat .............................................361
Checking the door latch ...............................................361
Maintaining wheels and tyres . ..........................................361
Maintainingthebattery ................................................364
Replacingfuses .....................................................367
Checkingthehydraulicoillevel ..........................................367
Checking the hydraulic systemforleaktightness .............................369
Lubricatingtheliftmastandrollertrack ....................................370
Greasingtheautomatictowcoupling ......................................370
1000-hour maintenance/yearly maintenance ...............................373
Othertasks ........................................................373
Checkingtheexhaustgassystem .......................................373
Changing the LPG filter ...............................................37
3
Checking the lift cylinders and connections for leaks ..........................375
Checkingtheforkarms ................................................375
Checking the reversibleforkarms ........................................376
10-year maintenance .................................................377
CheckingtheLPGtank(variant) .........................................377
6 Technical data
Dimensions ........................................................380
VDI datasheet for RX70-20/600 and RX70-25 ...............................382
VDI datasheet for RX70-25/600 and RX70-30 ...............................386
VDI datasheet for RX70-30/600 and RX70-35 ...............................390
Ergonomic dimensions ................................................394
Fuse assignment ....................................................395
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1
Foreword

1Foreword
Your truck
Your truck
Description of the truck
General
The trucks in the RX70-20/25/30/35 series
with a load capacity of up to 3.5 t are equipped
with an internal combustion engine/electric
drive. This drive combines the advantages
of the internal combustion engine with the
precise control of an electric drive. The
maximum speed is 21 km/h (without load).
The bend-resistant and warp-resistant lift
mast enables safe load handling, even with
heavy loads. The comfortable driver's com-
partment features the most up-to-date er-
gonomic design to prevent signs of fatigue
and increase safety.
The truck supports all functions of FleetMan-
ager 4.0.
Brake system
The brake system of the truck is comprised of
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
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-
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Foreword 1
Your truck
ing. Stability is guaranteed when cornering
thanks to speed limitation based on the steer-
ing angle. Simple handling of the truck is as-
sisted by the manoeuvrable steering axle.
Hydraulic system
All lift cylinders are hydraulically actuated. The
oil volume flow required for the steering and
the lift mast is provided by a gear pump con-
nected to the internal combustion engine. The
directional control valve block with electrical
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.
Up to three hydraulic circuitscanbeusedto
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 internal combustion engine drives an
electric three-phase generator. The gener-
ated current is routed to a maintenance-free,
electrical 22-kW three-phase AC traction mo-
tor, which drives the truck using the two front
wheels. An electronic speed controller gently
provides high torque for both forwards and
backwards travel.
The components for the drive unit and the
lift drive are enclosed in order to prevent the
ingress of dust or moisture. This means that
the truck is suitable for indoor and outdoor
use. In addition, all drives for traction, steering
and lifting are maintenance-free.
The driving characteristics and lifting be-
haviour can be adapted to the application
or driving habits. Five drive programmes are
available for this purpose. The maximum driv-
ing speed is 21 km/h. The Blue-Q energy-sav-
ing mode reduces energy consumption by up
to 10% without impairing performance.
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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:
• 2-way mini-lever
• 3-way mini-lever
• 4-way 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 in 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 (electric 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
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1Foreword
Your truck
Overview
Labelling points on the left of the truck
1
10
7
7
6
5
11
12
DANGER
DANGER
76
DANGER
DANGER
D
A
N
G
E
R
DANGER
11
12
34
10 bar
2
10
1
2
2
3
4
8
13 14 15
9
14
WA
L
5430 1010 1080 1080 1080
1050 1150 1310
4430 1110 1230 1250 1500
4030 1150 1260 1200 1500
3730 1180 1290 1430 1500
3430 1210 1330 1470 1500
800 700 500 600
5030 1270
2
1
3
15 16
16
8
9
13
857
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