Still RX70-40 User manual

Original instructions
Diesel truck
RX70-40
RX70-45
RX70-50
7331 7332 7333 7334
57348011825 EN - 12/2015

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
List of abbreviations ................................................... 2
Your truck .......................................................... 4
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformity in accordance with Machinery Directive ............... 6
Information about the documentation ...................................... 7
Documentationscope ................................................. 7
Issue date and topicality oftheoperatinginstructions ........................... 8
Copyrightandtrademarkrights ........................................... 8
Explanation of information symbols used . . ................................. 8
Explanation of the cross-references ....................................... 9
Definitionofdirections ................................................. 9
Schematicviews .................................................... 10
Environmental considerations .......................................... 11
Packaging ......................................................... 11
Disposal of components and batteries ..................................... 11
2 Introduction
Using the truck ...................................................... 14
Proper usage ....................................................... 14
Proper use during towing .............................................. 14
Impermissibleuse ................................................... 14
Placeofuse ........................................................ 15
Usingworkingplatforms ............................................... 16
Residual risk ....................................................... 17
Residual dangers, residual risks ......................................... 17
Specialrisksassociatedwithusingthetruckandattachments ................... 18
Overview of hazards andcountermeasures ................................. 20
Danger to employees . . ............................................... 23
3Safety
Definition of terms used for responsible persons ............................. 26
Operating company .................................................. 26
Specialist .......................................................... 26
Drivers ........................................................... 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
Changes and retrofitting ............................................... 29
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Changes to the overhead guard and roof loads . . . ........................... 31
Warning regarding non-original parts ..................................... 31
Damage, defects and misuse of safetysystems .............................. 32
Lengthoftheforkarms ................................................ 32
Tyres ............................................................. 33
Medicalequipment ................................................... 34
Exercise caution when handling gas springs and accumulators .................. 35
Safety tests ........................................................ 36
Regular safety inspection ofthetruck ..................................... 36
Checkingthedieselengineemissions ..................................... 36
Truckswithparticlefilters .............................................. 37
Insulationtesting .................................................... 38
Safety regulations for handling consumables ............................... 39
Permissibleconsumables ............................................. 39
Oils .............................................................. 39
Hydraulicfluid ...................................................... 40
Batteryacid ........................................................ 41
Dieselfuel ......................................................... 42
Coolantandcoolingfluid .............................................. 44
Disposalofconsumables .............................................. 44
Emissions ......................................................... 46
4Overviews
Truck overview ..................................................... 50
Overview of driver’s compartment ........................................ 51
Operating devices and display elements ................................... 52
Display and operating unit . . . .......................................... 52
Operatingdevicesforhydraulicanddrivingfunctions .......................... 53
Doublemini-lever .................................................... 5
4
Three-waymini-lever ................................................. 55
Four-waymini-lever .................................................. 56
Joystick4Plus ...................................................... 57
Fingertip .......................................................... 58
Identification points .................................................. 59
Overview .......................................................... 59
Nameplate ......................................................... 60
Productionnumber .................................................. 61
StVZO (Road Traffic Licensing Regulations) information ....................... 61
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Equipment ......................................................... 62
Accessories ........................................................ 62
5 Operation
Checks and tasks to be carried out prior to commissioning ...................... 64
Visualinspections ................................................... 64
Checkingthesidecoverislocked ........................................ 66
Fillingthewashersystem .............................................. 6
6
Checking the condition of the wheels and tyres .............................. 67
Topping up the coolant and checking the concentration of the coolant additive ....... 68
Checking the engine oil level ........................................... 69
AdjustingtheMSG65/MSG75driver’sseat ................................ 70
Adjustingthearmrest ................................................. 74
Adjusting the steering column ........................................... 75
Cleaningthedustvalve ............................................... 75
Commissioning ..................................................... 76
Climbing into and out of thetruck ........................................ 76
Climbingintoandoutofatruckwitharaiseddriver’scab ....................... 77
Shelvesandcupholders .............................................. 79
Unlocking the emergencyoffswitch ...................................... 80
Switchingonthekeyswitch ............................................ 80
AccessauthorisationwithPINcode(variant) ................................ 83
Operating the signal horn .............................................. 92
Seatbelt .......................................................... 93
Usingthedriver’scab ................................................. 96
Starting the engine ................................................... 97
Checkingthebrakesystemforcorrectfunction .............................. 99
Checkingthesteeringsystemforcorrectfunction ............................100
Checking the emergencyofffunction .....................................100
Zeroadjustmentoftheloadmeasurement(variant) ...........................101
Checking the vertical lift mast position (variant) for correct function . ...............103
Driving ............................................................104
Safety regulations when driving .........................................104
Roadways .........................................................106
Setting the drive programmes ...........................................108
Actuatingthedrivedirectionswitch,mini-leverversion .........................109
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 109
Actuating the drive direction switch, fingertip version ..........................110
Startingtodrive .....................................................110
Starting drive mode, dual-pedal version (variant) .............................112
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Operatingtheservicebrake ............................................115
Actuating the mechanical parking brake ...................................116
Steering ...........................................................118
Reducing speed with a raised load (variant) ................................119
Automatic shut-off of the internal combustion engine (variant) ...................119
Lifting ............................................................120
Liftingsystemvariants ................................................120
Automaticliftcutout(variant) ...........................................120
Lift mast vertical position (variant) ........................................121
Typesofliftmast ....................................................125
Malfunctionsduringliftingmode .........................................126
Hydraulic blocking function .............................................128
Liftingsystemoperatingdevices .........................................128
Controlling the lifting system using a double mini-lever .........................130
Controlling the lifting systemusingatriplemini-lever ..........................131
Controlling the lifting system using a quadruple mini-lever ......................132
Controllingtheliftingsystemusingthejoystick4Plus ..........................133
Controlling the lifting system using the fingertip . . . ...........................135
Changing the fork arms ...............................................136
Forkextension(variant) ...............................................138
Operation with reversibleforkarms(variant) ................................140
Handling loads ......................................................142
Safety regulations when handing loads ....................................142
Beforetakingupload .................................................14
3
Loadmeasurement(variant) ...........................................144
Picking up loads .....................................................147
Danger area .......................................................148
Transportingpallets ..................................................149
Transporting suspended loads ..........................................149
Loadpickup ...................................................... . 150
Transporting loads ...................................................154
Setting down loads ...................................................155
Shake function (variant) ...............................................156
Driving on ascending and descending slopes ...............................160
Drivingonlifts ......................................................161
Drivingonloadingb
ridges .............................................162
Particle filter system ..................................................163
Particlefilter-Function ................................................163
Particlefilter-Pe
rforming parked regeneration . . . ...........................165
Particlefilter-Displays ................................................168
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Working with attachments .............................................170
Fittingattachments ..................................................170
Releasing the pressure from thehydraulicsystem ............................172
Generalinstructionsforcontrollingattachments .............................174
Controlling attachments using a double mini-lever ............................176
Controlling attachments using the double mini-lever and the 5th function ...........178
Controllingattachmentsusingatriplemini-lever .............................180
Controlling attachments using the triple mini-lever and the 5th function .............182
Controlling attachments using a quadruple mini-lever .........................183
Controlling attachments using the quadruple mini-lever and the 5th function .........185
Controllingattachmentsviathejoystick4Plus ...............................186
Controlling attachments usingthejoystick4Plusandthe5thfunction ..............187
Controlling the attachments with the fingertip ...............................188
Controlling attachments with the fingertip and 5th function ......................189
Clamp locking mechanism (variant) ......................................191
Takingupaloadusingattachments ......................................195
Operating auxiliary equipment ..........................................196
Switching the lighting onandoff .........................................196
Switching the rotating beacon on and off . . . ................................197
Switchingthehazardwarningsystemonandoff .............................198
Switching direction indicatorsonandoff ...................................198
Switching the double working spotlights on and off. ...........................201
Operatingthewindscreenwiper/washer ...................................203
FleetManager (variant) ................................................203
Accidentrecorder(variant) .............................................204
Driverrestraintsystems(variants) .......................................204
Cab operation ......................................................204
Opening the cab door . . ...............................................204
Closingthecabdoor ............................................... . . 205
Opening the side windows .............................................205
Closing the side windows ..............................................206
Operating the rear window heating .......................................207
Radio(variant) ......................................................207
Heatingsystem(variant) ..............................................208
Air conditioning (variant) ...............................................209
Trailer operation ....................................................2
10
Towedload ....................................................... . 210
Coupling pin in the counterweight ........................................211
Automatic tow coupling ...............................................213
Towingtrailers ......................................................221
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Operating the display and operating unit ...................................223
Displays ..........................................................223
Adjustingthedisplays ................................................224
Symbolsinthedisplay ................................................224
Settingthedateortime ................................................229
Resetting the daily kilometres and daily operating hours .......................229
Setting the language .................................................230
Soft key button for operating various equipment variants .......................230
Configuring Blue-Q efficiencymode ......................................231
Additional settings ...................................................232
Blue-Q efficiency mode ...............................................233
Functionaldescription ................................................23
3
Effects on additional consumers .........................................233
SwitchingefficiencymodeBlue-Qonandoff ................................234
Display messages ...................................................236
Displaycontent .....................................................236
Errorcodetable .....................................................237
General messages ...................................................239
Drive-specificmessages ..............................................248
Operation in special operating situations ...................................256
Transport ..........................................................256
Towing .......................................................... . 258
Craneloading ......................................................260
Jump-starting ......................................................263
Procedure in emergencies .............................................264
Emergency shutdown ................................................264
Procedure if truck tipsover .............................................265
Emergency hammer ..................................................266
Emergency lowering .................................................267
Disconnecting the battery ..............................................269
Refuelling .........................................................270
Dieselfuel-Specifications .............................................270
Filling up with dieselfuel ...............................................274
Cleaning ..........................................................276
Cleaning the truck ...................................................276
Cleaning the electricalsystem ..........................................278
Cleaning load chains .................................................279
Cleaning the windows ................................................279
Afterwashing .......................................................280
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Decommissioning ...................................................281
Parkingthetrucksecurely .............................................281
Wheelchock(variant) ................................................282
Shuttingdownandstoringthetruck ......................................282
Recommissioningaftershutdown ........................................284
6 Maintenance
General maintenance information ........................................286
Personnel qualifications ...............................................286
Informationforcarryingoutmaintenance ..................................286
Maintenance instructions ..............................................289
Orderingsparepartsandwearingparts ....................................289
Quality and quantity of the required operating materials ........................289
Lubricationplan .....................................................290
Maintenance data table ...............................................291
Intervals for maintenance and inspection ..................................295
Maintenance — 1000 hours/annually .....................................295
Maintenance - 3000 hours/every two years . ................................299
Safety regulations for maintenance .......................................300
Generalinformation ..................................................3
00
Workingonthehydraulicequipment ......................................300
Working on the electrical equipment ......................................301
Working on the ignitionsystem ..........................................301
Safetydevices ......................................................302
Setvalues ....................................................... . . 302
Lifting and jacking up .................................................302
Workingatthefrontofthetruck ..........................................302
Providing access to maintenance points ...................................304
Opening the side serviceflap ...........................................304
Closingthesideserviceflap ............................................305
Openingthebonnet ................................................ . . 306
Closing the bonnet ...................................................307
Installingandremovingthebottomplate ...................................307
Maintenance .......................................................309
Cleaning the radiator,checkingforleaks ...................................309
Replacing the air filter cartridges .........................................309
Drainingwaterfromthefuelfilter .........................................311
Lubricating the jointsandcontrols ........................................312
Checking the door latch ...............................................313
Maintainingtheseatbelt ...............................................313
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Checkingthedriver’sseat .............................................315
Greasingtheautomatictowcoupling ......................................315
Servicingwheelsandtyres .............................................318
Servicingthebattery .................................................320
Replacingfuses .....................................................322
Lubricating the lift mast and rollertrack ....................................322
7 1000 hour maintenance/annual maintenance
Other tasks ........................................................324
Checking the hydraulic system for leaks ...................................324
Checking the hydraulic oil level ..........................................325
Checking the lift cylinders and connections for leaks ..........................326
Checking the fork arms ................................................326
Checking the reversible fork arms ........................................327
8 Technical data
Dimensions ........................................................330
VDI datasheet ......................................................332
Fuse assignment ....................................................335
X5
7348011825 EN - 12/2015

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.
Abbreviation Meaning
°C Degrees Celsius
°F Degrees Fahrenheit
AAmperes
ABE Display operating unit
ArbSchG German labour protection law
BetrSichV German Ordinance on Industrial Safety and Health
BG Employers’ liability insurance association
BGG Employers’ liability insurance association act
BGR Employers’ liability insurance association rule
German Social
Accident
Insurance
Employers’ liability insurance association regulation
Approx. Approximately
CE Symbol that confirms conformity with the valid product-specific European
directives
CEE International Commission on the Rules for the Approval of Electrical Equip-
ment
cm Centimetres
cm3Cubic centimetres
dB Decibels
DFÜ Remote data transmission
DIN German standard
EG European Community
EN European standard
FEM Fédération Européene de la Manutention
Fmax Maximum power
gGrams
GAA Industrial inspectorate
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Foreword 1
List of abbreviations
Abbreviation Meaning
If applicable If applicable
GPRS General Packet Radio Service
h/d Hours per day (time driven each day in hours)
ID no. ID number
ISO International standard
kg Kilograms
kg/m3Kilograms per cubic metre
km/h Kilometres per hour
km/d Kilometres per day (kilometres driven each day)
kN Kilonewtons
kW Kilowatts
kWh/h Energy consumption
lLitres
l/h Litres per hour
l/min Litres per minute
LAN Local area network
LED Light emitting diode
LpSound pressure level
LpAZ Continuous sound pressure level in driver’s compartment
LSP Load centre of gravity
o.s. Or similar
mMetres
m/s Metres per second
m/s2Metres per second squared
MAK Maximum workplace concentration
Max. Maximum
Min. Minimum
min Minutes
rpm Revolution(s) per minute
mm Millimetres
N Newtons
Nm Newton metres
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1Foreword
Your truck
Abbreviation Meaning
PIN Personal identification number
SE Superelastic
SIT Snap-in tyre for simplified assembly
StVZO German Road Traffic Licensing Regulations
tTonnes
TRGS Technical Regulations for Hazardous Substances
a.s. And similar
VVolts
VDE Association for Electrical, Electronic & Information Technologies
VDI Association of German Engineers
VDMA German Engineering Federation
W Watts
WLAN Wireless local area network
e.g. For example
.
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.
The trucks have been fitted with 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.
45
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Foreword 1
Your 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.
57348011825 EN - 12/2015 5

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
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.
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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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