Still RX70-40 User manual

Original instructions
LPG trucks
RX70-40
RX70-45
RX70-50
7335 7336 7337 7338
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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
List of abbreviations ................................................... 2
Your truck .......................................................... 3
General ............................................................ 3
CElabelling ......................................................... 4
EC declaration of conformity in accordance with Machinery Directive ............... 5
Accessoriesoverview ................................................. 6
Labelling points overview ............................................... 7
Nameplate .......................................................... 8
Production number . . . ................................................ 8
StVZO(RoadTrafficLicensingRegulations)information ........................ 9
Using the truck ....................................................... 9
Proper usage ........................................................ 9
Proper use during towing .............................................. 10
Impermissibleuse ................................................... 10
Placeofuse ........................................................ 10
Usingworkingplatforms ............................................... 12
Information about the documentation ..................................... 13
Documentationscope ................................................ 13
Supplementarydocumentation .......................................... 14
Issue date and topicalityoftheoperatinginstructions .......................... 15
Copyrightandtrademarkrights .......................................... 15
Explanation of information symbols used . . ................................ 15
List of abbreviations .................................................. 16
Definitionofdirections ................................................ 18
Schematicviews .................................................... 18
Environmental considerations .......................................... 20
Packaging ......................................................... 20
Disposal of components and batteries ..................................... 20
2Safety
Definition of terms used for responsible persons ............................. 22
Operatingcompany .................................................. 22
Specialist .......................................................... 22
Drivers ........................................................... 23
Basic principles for safe operation ....................................... 25
Insurance cover on company premises .................................... 25
Changes and retrofitting ............................................... 25
Changes to the overhead guard and roof loads .............................. 27
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Table of contents
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Warning regarding non-original parts ..................................... 27
Damage, defects and misuse of safety systems . . . ........................... 28
Lengthoftheforkarms ................................................ 28
Tyres ............................................................. 29
Medicalequipment ................................................... 30
Exercise caution when handlinggasspringsandaccumulators .................. 31
Lengthoftheforkarms ................................................ 31
Residual risk ....................................................... 33
Residual dangers, residual risks ......................................... 33
Specialrisksassociatedwithusingthetruckandattachments ................... 34
Overview of hazards and countermeasures ................................. 36
Danger to employees ................................................. 39
Safety tests ........................................................ 40
Regularsafetyinspectionofthetruck ..................................... 40
Carrying out regular safetyinspectionsontheLPGsystem ..................... 40
Regularly checking the level of harmful substances in the exhaust gas . . . . ......... 41
Insulationtesting .................................................... 42
Safety regulations for handling consumables ............................... 43
Permissibleconsumables ............................................. 43
Oils .............................................................. 44
Hydraulicfluid ...................................................... 45
Batteryacid ........................................................ 46
LPG .............................................................47
Coolant and cooling fluid .............................................. 50
Disposalofconsumables .............................................. 50
Emissions ......................................................... 52
3Overviews
Truck overview ..................................................... 56
Overview of driver's compartment ........................................ 57
Operating devices and display elements ................................... 58
Display operatingunit ................................................. 58
Operatingdevicesforhydraulicanddrivingfunctions .......................... 58
Doublemini-lever .................................................... 60
Three-way mini-lever ................................................. 61
Four-waymini-lever .................................................. 62
Joystick4Plus ...................................................... 63
Fingertip .......................................................... 64
Miniconsole ....................................................... 65
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4 Operation
Checks and tasks before daily use ....................................... 68
Visualinspections ................................................... 68
Checkingthesidecoverislocked ........................................ 70
Climbingintoandoutofthetruck ........................................ 71
Climbing into and out of a truckwitharaiseddriver'scab ....................... 72
Shelvesandcupholders .............................................. 74
AdjustingtheMSG65/MSG75driver'sseat ................................ 75
Adjustingthearmrest ................................................. 79
Adjustingthesteeringcolumn ........................................... 80
Unlockingtheemergencyoffswitch ...................................... 81
Switchingonthekeyswitch ............................................ 81
AccessauthorisationwithPINcode(variant) ................................ 84
Operating the signal horn .............................................. 94
Seatbelt .......................................................... 94
Usingthedriver'scab ................................................. 97
OpeningtheLPGcylindervalve ......................................... 97
Opening the LPG cylinder valve for a double-cylinder holder . . . ................. 99
OpeningtheLPGtankshut-offvalve ......................................101
Starting the engine ...................................................103
Checking the brake systemforcorrectfunction ..............................104
Checkingthesteeringsystemforcorrectfunction ............................105
Checking the emergency off function .....................................105
Zero adjustment of the loadmeasurement(variant) ...........................106
Checking the vertical lift mast position (variant) for correct function . ...............107
Fillingthewashersystem ..............................................108
Cleaning the dust valve ...............................................109
Operating the display-operating unit ......................................110
Displays ........................................................ . . 110
Adjustingthedisplays ................................................11
1
Symbolsinthedisplay ................................................112
Settingthedateortime ................................................117
Resetting the daily kilometres and daily operating hours .......................118
Setting the language . . ...............................................118
Softkeys for operating various equipment variants ............................119
Configuring Blue-Q efficiencymode ......................................119
Shock recognition (variant) .............................................120
Additional settings ...................................................121
Blue-Q efficiency mode ...............................................122
Functional description . ...............................................122
Switching off additional consumers .......................................123
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SwitchingefficiencymodeBlue-Qonandoff ................................123
Driving ............................................................125
Safety regulations when driving .........................................125
Roadways ........................................................ . 127
Settingthedriveprogrammes ...........................................129
Actuating the vertical rockerswitchforthe"drivedirection",joystick4Plusversion ....130
Actuatingthedrivedirectionswitch,mini-leverversion .........................130
Actuating the drive direction switch, fingertip version ..........................131
Actuating the vertical rockerswitchforthe"drivedirection",joystick4Plusversion ....131
Actuatingthedrivedirectionswitch,mini-consoleversion ......................132
Startingtodrive .....................................................132
Starting drive mode, dual pedal version (variant) . . ...........................134
Operatingtheservicebrake ............................................137
Actuating the mechanical parking brake ...................................138
Steering ...........................................................140
Driving on ascending and descending gradients . . ...........................141
Driving on ascending and descending gradients . . ...........................142
Reducing speed with a raisedload(variant) ................................143
Automatic shut-off of the internal combustion engine (variant) ...................143
Parking ...........................................................144
Parking the truck securelyandswitchingitoff ...............................144
Wheel chock (variant) ................................................146
Lifting ............................................................147
Lifting system variants ................................................147
Automaticliftcutout(variant) ...........................................147
Liftmastverticalposition(variant) ........................................148
Typesofliftmast ....................................................152
Malfunctionsduringliftingmode .........................................153
Hydraulicblockingfunction .............................................155
Lifting system operatingdevices .........................................155
Controlling the lifting system using a double mini-lever .........................157
Controllingtheliftingsystemusingatriplemini-lever ..........................158
Controlling the lifting system using a quadruple mini-lever ......................159
Controllingtheliftingsystemusingthejoystick4Plus ..........................160
Controlling the lifting system using the fingertip . . . ...........................162
Changing the fork arms ...............................................163
Forkextension(variant) ...............................................165
Operationwithreversibleforkarms(variant) ................................167
Handling loads ......................................................169
Safety regulations when handing loads ....................................169
Beforetakingupload .................................................170
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Loadmeasurement(variant) ...........................................171
Pickinguploads .....................................................174
Danger area .......................................................175
Transportingpallets ..................................................176
Transporting suspended loads ..........................................176
Loadpickup ...................................................... . 177
Transportingloads ...................................................181
Settingdownloads ...................................................182
Shakefunction(variant) ...............................................18
3
Drivingonlifts ......................................................187
Driving on loading bridges .............................................188
Attachments .......................................................190
Fittingattachments ..................................................190
Releasingthepressurefromthehydraulicsystem ............................192
General instructions for controllingattachments .............................194
Controlling attachments using a double mini-lever ............................196
Controlling attachments using the double mini-lever and the 5th function ...........198
Controlling attachmentsusingatriplemini-lever .............................200
Controlling attachments using the triple mini-lever and the 5th function .............202
Controlling attachments using a quadruple mini-lever .........................204
Controlling attachments using the quadruple mini-lever and the 5th function .........206
Controllingattachmentsviathejoystick4Plus ...............................208
Controlling attachments using the joystick 4Plus and the 5th function . . . ...........209
Controlling the attachments with the fingertip ...............................210
Controlling attachments with the fingertip and 5th function ......................211
Clamp locking mechanism (variant) ......................................213
Taking up a load using attachments ......................................216
Auxiliary equipment ..................................................217
Switchingthelightingonandoff .........................................217
Switching the working spotlightforreversetravelonandoff .....................218
Switching the rotating beacon on and off . . . ................................219
Switchingthehazardwarningsystemonandoff .............................219
Switching the turn indicatoronandoff .....................................220
Switching the double working spotlights on and off. ...........................223
STILLSafetyLight(variant) .............................................225
Operating the windscreenwiper/washer ...................................226
Fillingthewashersystem ..............................................226
FleetManager (variant) . ...............................................227
Shock recognition (variant) .............................................227
Cruisecontrol(variant) ................................................227
Driverrestraintsystems(variants) .......................................231
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Ceilingsensor(variant) ...............................................231
Cab ..............................................................237
Opening the cab door .................................................237
Opening the side windows . . . ..........................................237
Closing the cab door .................................................238
Opening the side windows . . . ..........................................238
Closingthesidewindows ..............................................239
Operatingtheinteriorlighting ...........................................240
Operating the rear window heating .......................................241
Radio(variant) ......................................................241
Heatingsystem(variant) ..............................................242
Air conditioning (variant) ...............................................243
Trailer operation ....................................................244
Towedload ....................................................... . 244
Coupling pin in the counterweight ........................................245
Automatictowcoupling ...............................................247
Towingtrailers ......................................................255
Display messages ...................................................257
Displaycontent .....................................................257
Errorcodetable .....................................................257
General messages ...................................................260
Drive-specificmessages ..............................................269
Refuelling .........................................................277
Changing the LPG cylinder .............................................277
Changing the LPG cylinder in a double-cylinder holder ........................280
FillingtheLPGtank ..................................................282
Procedure in emergencies .............................................285
Emergency shutdown ................................................285
Procedureiftrucktipsover .............................................286
Emergency hammer ..................................................287
Emergency lowering .................................................288
Towing .......................................................... . 291
Jump-starting ......................................................293
Disconnectingthebattery ..............................................294
Transporting the truck ................................................296
Transport ..........................................................296
Craneloading ......................................................298
Cleaning ..........................................................302
Cleaning the truck ...................................................302
Cleaning the electrical system ..........................................304
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Cleaningloadchains .................................................304
Cleaningthewindows .............................................. . . 305
Afterwashing .......................................................305
Decommissioning ...................................................306
Shuttingdownandstoringthetruck ......................................306
Recommissioning after shutdown ........................................306
5 Maintenance
Safety regulations for maintenance .......................................310
Generalinformation ..................................................310
Working on the hydraulic equipment ......................................310
Working on the electrical equipment ......................................311
Workingontheignitionsystem ..........................................311
Safetydevices ......................................................312
Setvalues ....................................................... . . 312
Liftingandjackingup .................................................312
Workingatthefrontoft
hetruck ..........................................312
General maintenance information ........................................314
Personnel qualifications ...............................................314
Information for carryingoutmaintenance ..................................314
Maintenance — 1000 hours/annually .....................................317
Maintenance - 3000 hours/every two years . ................................321
Maintenance instructions ..............................................323
Orderingsparepartsandwearingparts ....................................323
Quality and quantity of the required operating materials ........................323
Lubricationplan .....................................................324
Maintenance data table ...............................................325
Providing access to maintenance points ...................................328
Opening the side service flap ...........................................328
Closingthesideserviceflap ............................................329
Openingthebonnet ................................................ . . 329
Closing the bonnet ...................................................331
Installingandremovingthebottomplate ...................................332
Preserving operational readiness ........................................335
De-icing the evaporator ...............................................335
Checking the engine oil level ...........................................336
Topping up the coolant and checking the coolant concentration . .................337
Replacing the air filter cartridges .........................................339
Lubricatingthejointsandcontrols ........................................341
Checking the door latch ...............................................341
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Table of contents
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Maintainingtheseatbelt ...............................................342
Checkingthedriver'sseat .............................................343
Greasing the automatic tow coupling ......................................344
Servicingwheelsandtyres .............................................346
Servicingthebattery .................................................348
Replacingfuses .....................................................351
Lubricatingtheliftmastandrollertrack ....................................351
Othertasks ........................................................353
1000-hour maintenance/yearly maintenance ...............................354
Cleaning the radiator, checking for leaks ...................................354
Checkingthereversibleforkarms ........................................354
Checkingtheforkarms ................................................355
Checkingthehydraulicoillevel ..........................................355
Checking the lift cylinders and connections for leaks ..........................357
Checking the hydraulic systemforleaktightness .............................357
6 Technical data
Dimensions ........................................................360
VDI datasheet ......................................................362
Wheels and tyres ....................................................365
Fuse assignment ....................................................368
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1
Foreword

1Foreword
List of abbreviations
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
ArbSchG Arbeitsschutzgesetz German implementation of EU occupa-
tional health and safety directives
Betr-
SichV Betriebssicherheitsverordnung German implementation of the EU working
equipment directive
BG Berufsgenossenschaft German insurance company for the com-
pany 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
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
257
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Foreword 1
Your truck
Abbrevi-
ation Meaning Explanation
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
PPE Personal 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 vehi-
cles 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
VDI Verein Deutscher Ingenieure German technical/scientific association
VDMA Verband Deutscher Maschinen- und
Anlagenbau e.V.
German Mechanical Engineering Industry
Association
WLAN Wireless LAN Wireless local area network
.
Your truck
General
The truck described in these operating instruc-
tions corresponds to the applicable standards
and safety regulations.
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1Foreword
Your truck
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.
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 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 and made available to the
responsible authorities.
457
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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
.
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1Foreword
Your truck
Accessories overview
• Key for key switch (2 pieces)
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering
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Foreword 1
Your truck
Labelling points overview
1 Decal information: Fixing point for lifting
gear
2 Manufacturer's label text
3 Warning sign: Danger due to shearing/Dan-
ger due to high fluid pressure
4 Warning sign: Do not stand underneath the
fork/Do not stand on the fork
5 Nameplate
6 Warning sign: Danger due to shearing/Dan-
ger due to high fluid pressure/and warning
sign: Do not stand underneath the fork/Do
not stand on the fork
7 Decal information: Joystick functions
(variant)
8 Decal information: Top up hydraulic oil
9 Decal information: Tyre filling pressure
(variant), on both sides of the truck
10 Decal information: Armrest adjustment
11 Decal information: Lifting gear attachment
points
12 Decal information: Caution / Read the
operating instructions / Fasten seat belt
/ Apply parking brake when leaving the
truck / Passengers are not allowed / Do
not jump off if the truck is tipping over / Lean
in the opposite direction to which the truck is
tipping
13 Decal information: Capacity rating plate/Ca-
pacity rating plate: Attachment (variant)
14 Decal information: Head clearance
15 Decal information: Sound power level
16 Capacity rating plate
17 Decal information: FEM test with inspection
sticker
18 Decal information: Ceiling sensor
19 Decal information: StVZO (German Road
Traffic Licensing Regulations) information
(variant)
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1Foreword
Your truck
Type-Modèle-Typ / Serial no.-No. de série-Serien-Nr. / year-année-Baujahr
Rated capacity
Capacité nominale
Nenn-Tragfähigkeit
Battery voltage
Tension batterie
Batteriespannung
Rated drive power
Puissance motr.nom.
Nenn-Antriebsleist.
Unladen mass
Masse à vide
Leergewicht
max
min.*
* see Operating instructions
voir Mode d'emploi
siehe Betriebsanleitung
kg kg
kg
kg
kg
kW
V
*
D-22113 Hamburg
Berzeliusstr. 10
123
4
4
5
6
7
9
10
11
12
13
6210_921-003_V3
8
1 Type
2 Production number
3 Year of manufacture
4 Tare weight in kg
5 Max. permissible battery weight in kg
6 Min. permissible battery weight in kg
7 Ballast weight in kg
8 Address of manufacturer
9 Refer to the technical data listed in these
operating instructions for more detailed
information
10 CE labelling
11 Nominal drive power in kW
12 Battery voltage in V
13 Rated capacity in kg
Nameplate
The truck can be identified from the informa-
tion on the nameplate.
The information for the battery weights (5,
6) and the ballast weight (7) only applies to
electric forklift trucks.
7090_921-004
xx xxxx x xxxxx
1
2
3
4
Production number
NOTE
The production number is used to identify the
truck. It can be found on the nameplate and
must be referred to in all technical questions.
The production number contains the following
coded information:
(1) Production location
(2) Model
(3) Year of manufacture
(4) Sequential number
857
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