Still RX70 Series User manual

Original instructions
Diesel trucks
With SCR (Selective Catalytic Reduction)
RX70-60
RX70-70
RX70-80
RX70-80/900
7341 7342 7343 7344
57348011800 EN - 11/2018

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
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Table of contents
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1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 5
Note regarding SCR (Selective Catalytic Reduction) as exhaust gas treatment ........ 5
Useintheeventoffrost ................................................ 6
CElabelling ......................................................... 6
EC declaration of conformity in accordance with Machinery Directive ............... 7
Accessories ......................................................... 8
Labelling points ..................................................... 10
Nameplate ......................................................... 13
Production number . . . ............................................... 14
StVZO(RoadTrafficLicensingRegulations)information ....................... 14
Using the truck ...................................................... 14
Proper usage ....................................................... 14
Proper use during towing .............................................. 15
Impermissibleuse ................................................... 15
Placeofuse ........................................................ 16
Usingworkingplatforms ............................................... 17
Information about the documentation ..................................... 18
Documentationscope ................................................ 18
Supplementarydocumentation .......................................... 19
Issuedateandtopicalityoftheoperatinginstructions .......................... 20
Copyright and trademarkrights .......................................... 20
Explanation of information symbols used . . ................................ 20
Listofabbreviations .................................................. 21
Definition of directions ................................................ 23
Schematicviews .................................................... 23
Environmental considerations .......................................... 25
Packaging ......................................................... 25
Disposal of components and batteries ..................................... 25
2Safety
Definition of responsible persons ........................................ 28
Operatingcompany .................................................. 2
8
Specialist .......................................................... 28
Drivers ........................................................... 29
Basic principles for safe operation ....................................... 31
Insurance cover on company premises .................................... 31
Changes and retrofitting ............................................... 31
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Changes to the overhead guard and roof loads . . . ........................... 33
Warning regarding non-original parts ..................................... 33
Damage, defects and misuse of safetysystems .............................. 34
Tyres ............................................................. 34
Medicalequipment ................................................... 36
Exercise caution when handlinggasspringsandaccumulators .................. 36
Lengthoftheforkarms ................................................ 37
Residual risk ....................................................... 38
Residual dangers, residual risks ......................................... 38
Specialrisksassociatedwithusingthetruckandattachments ................... 39
Overview of hazards and countermeasures ................................. 42
Danger to employees ................................................. 45
Safety tests ........................................................ 46
Regularsafetyinspectionofthetruck ..................................... 46
Checking the diesel engineemissions ..................................... 46
Particlefilter ........................................................ 47
Insulationtesting .................................................... 48
Safety regulations for handling consumables ............................... 49
Permissibleconsumables ............................................. 49
Oils .............................................................. 49
Hydraulicfluid ...................................................... 50
Batteryacid ........................................................ 51
Dieselfuel ......................................................... 52
Coolant and cooling fluid .............................................. 54
Disposalofconsumables .............................................. 54
Emissions ......................................................... 56
3Overviews
Overview .......................................................... 60
Driver's compartment ................................................. 62
Operating devices and display elements ................................... 63
Display and operatingunit ............................................. 63
Operatingdevicesforhydraulicanddrivingfunctions .......................... 64
Doublemini-lever .................................................... 65
Three-way mini-lever ................................................. 66
Four-waymini-lever .................................................. 67
Joystick4Plus ...................................................... 68
Fingertip .......................................................... 69
Miniconsole ....................................................... 70
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4 Operation
Testing and activities before daily use ..................................... 72
Visualinspections ................................................... 72
Climbingintoandoutofthetruck ........................................ 75
Shelvesandcupholders .............................................. 78
Adjusting the MSG 65/MSG 75 driver'sseat ................................ 78
Adjustingthearmrest ................................................. 82
Adjustingthesteeringcolumn ........................................... 83
Unlocking the emergency off switch ...................................... 84
Operating the signal horn .............................................. 84
Seatbelt .......................................................... 85
Usingthedriver'scab ................................................. 88
Checkingthebrakesystemforcorrectfunction .............................. 88
Checkingthesteeringsystemforcorrectfunction ............................ 91
Checking the emergency offfunction ..................................... 91
Zeroadjustmentoftheloadmeasurement(variant) ........................... 92
Checking the vertical lift mast position (variant) for correct function . ............... 94
Switching on and starting.............................................. 94
Switchingonthekeyswitch ............................................ 94
AccessauthorisationwithPINcode(variant) ................................ 97
Starting the engine ...................................................107
Operating the display and operating unit ...................................109
Displays ........................................................ . . 109
Adjustingthedisplays ................................................110
Symbolsinthedisplay ................................................111
Settingthedateortime ................................................116
Resetting the daily kilometres and daily operating hours .......................117
Setting the language . . ...............................................117
Softkeys for operating various equipment variants ............................118
Configuring Blue-Q efficiencymode ......................................118
Blue-Q efficiency mode ...............................................120
Functional description . ...............................................120
Switching off additional consumers .......................................121
SwitchingefficiencymodeBlue-Qonandoff ................................121
Driving ............................................................123
Safety regulations when driving .........................................123
Roadways .........................................................125
Settingthedriveprogramme ............................................127
Selecting the drive direction ............................................128
Actuatingthedrivedirectionswitch,mini-leverversion .........................129
Actuating the vertical rocker switch for the "drive direction", joystick 4Plus version . . . . 130
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Actuating the drive direction switch, fingertip version ..........................130
Actuatingthedrivedirectionswitch,mini-consoleversion ......................131
Startingtodrive .....................................................131
Starting drive mode, dual pedal version (variant) . . ...........................133
Operatingtheservicebrake ............................................136
Parkingbrake ......................................................137
Actuating the mechanical parking brake ...................................137
Steering ...........................................................139
Reducing speed when turning (Curve Speed Control) .........................140
Driving on ascending and descending gradients . . ...........................141
Reducing speed with a raised load (variant) ................................142
Automatic shut-off of the internal combustion engine (variant) ...................142
Parking ...........................................................143
Parkingthetrucksecurelyandswitchingitoff ...............................143
Wheel chock (variant) ................................................144
Lifting ............................................................145
Liftingsystemvariants ................................................145
Automatic lift cut out (variant) ...........................................145
Liftmastverticalposition(variant) ........................................146
Typesofliftmast ....................................................150
Malfunctions during liftingmode .........................................151
Hydraulicblockingfunction .............................................152
Liftingsystemoperatingdevices .........................................153
Controlling the lifting system using a double mini-lever .........................154
Controllingtheliftingsystemusingatriplemini-lever ..........................155
Controlling the lifting system using a quadruple mini-lever ......................156
Controlling the liftingsystemusingthejoystick4Plus ..........................157
Controlling the lifting system using the fingertip . . . ...........................159
Changing the fork arms ...............................................160
Fork extension (variant) ...............................................162
Operationwithreversibleforkarms(variant) ................................164
Handling loads ......................................................166
Safety regulations when handing loads ....................................166
Beforetakingupload .................................................167
Loadmeasurement(variant) ...........................................168
Picking up loads .....................................................171
Danger area .......................................................172
Transportingpallets ..................................................173
Transporting suspended loads ..........................................173
Loadpickup ...................................................... . 174
Transporting loads ...................................................178
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Settingdownloads ...................................................179
Drivingonlifts ......................................................181
Driving on loading bridges .............................................182
Particle filter system ..................................................183
Particlefilter-Function ................................................183
Particle filter - Performing parked regeneration ..............................185
Particlefilter-Displays ................................................188
Attachments .......................................................190
Fittingattachments ..................................................190
Releasingthepressurefromthehydraulicsystem ............................192
Generalinstructionsforcontrollingattachments .............................194
Controlling attachments using a double mini-lever ............................196
Controlling attachments using the double mini-lever and the 5th function ...........198
Controllingattachmentsusingatriplemini-lever .............................200
Controlling attachments usingthetriplemini-leverandthe5thfunction .............202
Controlling attachments using a quadruple mini-lever .........................204
Controlling attachments using the quadruple mini-lever and the 5th function .........206
Controlling attachmentsviathejoystick4Plus ...............................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
Takingupaloadusingattachments ......................................216
Auxiliary equipment ..................................................2
17
Switchingthelightingonandoff .........................................217
Switchingtheworkingspotlightforreversetravelonandoff .....................218
Switching the rotating beacon on and off . . . ................................219
Switchingthehazardwarningsystemonandoff .............................219
Switchingtheturnindicatorsonandoff ....................................220
Switching the double workingspotlightsonandoff. ...........................222
STILLSafetyLight(variant) .............................................224
Operatingthewindscreenwiper/washer ...................................225
Filling the washer system ..............................................225
FleetManager (variant) . ...............................................226
Shock recognition (variant) .............................................226
Cruise control (variant) ................................................226
12-Vsocket ...................................................... . . 230
Driverrestraintsystems(variants) .......................................231
Ceiling sensor (variant) ...............................................231
Cab ..............................................................237
Opening the cab door . . ...............................................237
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Closing the cab door .................................................238
Opening the side windows . . . ..........................................238
Closingthesidewindows ..............................................238
Operatingtheinteriorlighting ...........................................239
Operating the rear window heating .......................................240
Radio(variant) ......................................................241
Heatingsystem(variant) ..............................................241
Airconditioning(variant) ...............................................243
Push-up roof window (variant) ..........................................244
Clipboard (variant) ...................................................244
Trailer operation ....................................................245
Towedload ....................................................... . 245
Coupling pin in the counterweight ........................................246
Automatictowcoupling ...............................................248
Towingtrailers ......................................................256
Display messages ...................................................257
Displaycontent .....................................................257
Errorcodetable .....................................................258
General messages ...................................................261
Drive-specificmessages ..............................................270
Refuelling .........................................................277
Dieselfuel—Specifications ............................................277
Fillingupwithdieselfuel ...............................................280
Using the fuel hand pump ..............................................281
Topping up AdBlue ..................................................283
Cleaning ..........................................................284
Cleaning the truck ...................................................284
Cleaning the electrical system ..........................................286
Cleaning load chains .................................................286
Cleaning the windows ................................................28
7
Afterwashing .......................................................287
Procedure in emergencies .............................................288
Emergency shutdown ................................................288
Procedureiftrucktipsover .............................................289
Emergency hammer ..................................................290
Emergency lowering .................................................290
Releasing the spring-operated brake .....................................293
Disconnecting and connecting the battery ..................................295
Jump-starting ......................................................296
Towing .......................................................... . 297
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Transporting the truck ................................................300
Transport ..........................................................300
Crane loading ......................................................302
Shutdown .........................................................306
Shuttingdownandstoringthetruck ......................................306
Recommissioning after decommissioning ..................................307
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 - 500 hours ..............................................317
Maintenance - 1000 hours/annually ......................................319
Maintenance - 3000 hours/everytwoyears .................................323
Orderingsparepartsandwearingparts ....................................323
Quality and quantity of the required operating materials ........................324
Lubricationplan .....................................................325
Maintenance data table ...............................................326
Providing access to maintenance points ...................................329
Openingthebonnet ................................................ . . 329
Closing the bonnet ...................................................331
Removingandattachingtheleftsidecover .................................333
Installing and removingthebottomplate ...................................333
Opening and closing the right-hand service flap ..............................335
Remaining ready for operation ..........................................336
Checking the engine oillevel ...........................................336
Cleaningthedustvalve ...............................................339
Fillingthewashersystem ..............................................339
Checking the pre-cleaner ..............................................340
Checkingtheoiltankontheoilbathairfilter .................................340
Checkingthecoolingfluidlevel ..........................................341
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Topping up the cooling fluid and checking the coolant concentration . . . . . . .........343
Cleaning the radiator and checking for leaks ................................346
Draining water from the fuel filter .........................................347
Cleaning the pre-cleaner ..............................................349
Cleaning the oil tank on the oil bath air filter .................................349
Replacing the air filter cartridges .........................................350
Changing the heating system fresh air filter .................................352
Lubricatingthejointsandcontrols ........................................353
Maintainingtheseatbelt ...............................................35
4
Checkingthedriver'sseat .............................................356
Checking the door latch ...............................................356
Replacing the recirculated air filter for the heating system ......................356
Servicingwheelsandtyres .............................................357
Replacingthefuses ..................................................359
Checking the hydraulic oillevel ..........................................360
Checkingthehydraulicsystemforleaktightness .............................362
Lubricatingtheliftmastandrollertrack ....................................363
Greasing the automatic towcoupling ......................................363
6 1000-hour maintenance/annual maintenance
Other tasks ........................................................368
Checking the exhaust gas system .......................................368
Checking the lift cylinders and the hydraulic connections for leak tightness ..........368
Checking the fork arms ................................................369
Checking the reversible fork arms ........................................369
7 Technical data
Dimensions ........................................................372
VDI datasheet ......................................................374
Ergonomic dimensions ................................................378
Fuse assignment ....................................................380
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1
Foreword

1Foreword
Your truck
Your truck
Description of the truck
General
Counterbalanced trucks in the RX70-60/70/80
series with a load capacity of up to 8.0 t are
equipped with an internal combustion/electric
drive. The internal combustion/electric drive
combines the advantages of an internal
combustion engine with the precise control
of an electric drive.
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 low centre of gravity of the truck provides
stability, which is guaranteed if the truck is
used according to its intended use.
The truck is equipped with a particle filter and
an SCR system. This means that it is suitable
for indoor and outdoor use, and complies with
the currently applicable emission directives.
The series is suitable for multi-shift operation
and supports all FleetManager 4.x functions.
Brake system
The brake system of the truck is comprised of
three different brakes:
• Service brake
• Regenerative brake
• Parking brake
The service brake is basedonawear-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
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Foreword 1
Your truck
brake ensures that the truck remains securely
in place when parked.
Steering
The truck is equipped with a swing axle and
has kickback-free hydraulic rear-wheel steer-
ing. Stability is guaranteed when cornering
thanks to speed limitation based on the steer-
ing angle. The simple handling of the truck is
assisted by the agile steering axle.
Hydraulic system
All lift cylinders are hydraulically actuated. The
oil volume required for the steering and the lift
mast is supplied by an electrically controlled
hydraulic pump. The directional control valve
block with electrical proportional technology
ensures extremely sensitive movements
and safe handling of the load. The hydraulic
functions can be parameterised individually
by the authorised service centre.
Uptothreehydrauliccircuitscanbeusedto
activate attachments (variant). Depending on
the equipment, a hydraulic accumulator is also
available in the lifting circuit for the purpose of
dampening pressure peaks in the hydraulic
system.
Drive concept
The truck is equipped with an internal combus-
tion engine with an engine power rating of 80
kW. This uses an AC motor to generate current
for an electrical traction motor. The electronic
revolution control provides high torque on the
front wheel axle for forward and reverse travel.
This allows sensitive acceleration or deceler-
ation, and enables driving speeds of up to 20
km/h
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.
Five drive programmes can be used to adapt
the driving characteristics and lifting behaviour
to the application or driving habits. The Blue-Q
energy-saving mode reduces energy con-
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1Foreword
Your truck
sumption by up to 10% without impairing per-
formance. The truck's cutting-edge exhaust
regeneration system also keeps it well within
the thresholds of the currently applicable IIIB
EU standard. This is achieved using selective
catalytic reduction combined with a diesel par-
ticulate filter.
Operating devices
The truck is characterised by an accessible
operating concept. When purchasing the
truck, a variety of operating devices and
equipment variants are available:
• Double mini-lever
• Triple mini-lever
• Quadruple mini-lever
• Joystick 4Plus
• Fingertip switch
• Single pedal
• Dual pedal
Hands are always kept free for steering and
for controlling the operational movements to
allow efficient working. The forces that need
to be applied for this purpose are reduced to
a minimum thanks to the compact steering
wheel.
Operational information, such as the fuel level
or an indication that the Blue-Q energy-saving
mode is enabled, is shown 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.
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Foreword 1
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 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.
Note regarding SCR (Selective
Catalytic Reduction) as exhaust gas
treatment
This truck uses the Selective Catalytic Reduc-
tion (SCR) process of exhaust gas treatment.
To enable the SCR process to be performed,
the truck uses AdBlue (32.5% urea solution, in
accordance with DIN 70070 / ISO 22241).
It is recommended that the AdBlue tank be
refilled with AdBlue every time the diesel fuel
is topped up; see the section "Topping up
AdBlue".
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1Foreword
Your truck
The applicable European emission require-
ments (97/68/EC) state that new engines must
have an SCR system.
Useintheeventoffrost
AdBlue freezes at temperatures of -11°C
and below. If the AdBlue tank and the lines
freeze, they will be heated automatically
during startup and operation. The system will
thaw out again in under 30 minutes. During
this time, the truck can be operated without
restrictions.
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.
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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
• Key for key switch (two pieces)
• Key for cab (variant)
• Hexagon socket wrench for emergency
lowering
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