Still RX60-25 User manual

Original instructions
Electric trucks
RX60-25
RX60-25/600
RX60-25L
RX60-25L/600
RX60-30
RX60-30L
RX60-30L/600
RX60-35
6345 6346 6347 6348 6353
6354 6355 6356
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Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
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Table of contents
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1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformity in accordance with Machinery Directive ............... 6
Accessories ......................................................... 7
Labelling points ...................................................... 8
Nameplate ......................................................... 10
Production number . . . ............................................... 10
StVZO(RoadTrafficLicensingRegulations)information ....................... 11
Nameplate of a lithium-ion battery ........................................ 11
Using the truck ...................................................... 11
Commissioning ..................................................... 11
Proper usage ....................................................... 12
Proper use during towing .............................................. 12
Impermissibleuse ................................................... 13
Placeofuse ........................................................ 13
Parkingintemperaturesbelow-10°C ..................................... 14
Usingworkingplatforms ............................................... 15
Information about the documentation ..................................... 16
Documentationscope ................................................ 16
Supplementarydocumentation .......................................... 17
Issue date and topicalityoftheoperatinginstructions .......................... 18
Copyrightandtrademarkrights .......................................... 18
Explanation of information symbols used . . ................................ 18
List of abbreviations .................................................. 19
Definitionofdirections ................................................ 21
Schematicviews .................................................... 21
Environmental considerations .......................................... 23
Packaging ......................................................... 23
Disposal of components and batteries ..................................... 23
2Safety
Definition of responsible persons ........................................ 26
Operatingcompany .................................................. 26
Specialist .......................................................... 26
Drivers ........................................................... 27
Basic principles for safe operation ....................................... 29
Insurance cover on company premises .................................... 29
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Specialfeatureswhenusinglithium-ionbatteries(variant) ...................... 30
Changes and retrofitting ............................................... 33
Changes to the overhead guard androofloads .............................. 35
Warning regarding non-original parts ..................................... 36
Damage, defects and misuse of safety systems . . . ........................... 36
Tyres ............................................................. 37
Medicalequipment ................................................... 38
Exercise caution when handling gas springs and accumulators .................. 39
Lengthoftheforkarms ................................................ 39
Residual risk ....................................................... 41
Residual dangers, residual risks ......................................... 41
Special risks associated withusingthetruckandattachments ................... 42
Overview of hazards and countermeasures ................................. 44
Danger to employees ................................................. 47
Safety tests ........................................................ 48
Regularsafetyinspectionofthetruck ..................................... 48
Insulationtesting .................................................... 48
Safety regulations for handling consumables ............................... 50
Permissibleconsumables ............................................. 50
Oils .............................................................. 50
Hydraulicfluid ...................................................... 51
Batteryacid ........................................................ 52
Disposalofconsumables .............................................. 53
Emissions ......................................................... 54
3Overviews
General view ....................................................... 58
General view of driver's compartment ..................................... 60
Shelves and cup holders .............................................. 61
Operating devices and display elements ................................... 62
Display operating unit ................................................. 62
Lithium-ion batterydisplay ............................................. 63
Operatingdevicesforhydraulicandtractionfunctions ......................... 64
Multi-lever ......................................................... 65
Doublemini-lever .................................................... 6
6
Three-waymini-lever ................................................. 67
Four-waymini-lever .................................................. 68
Joystick4Plus ...................................................... 69
Fingertip .......................................................... 70
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Miniconsole ....................................................... 71
4 Operation
Checks and tasks before daily use ....................................... 74
Visual inspections and functionchecking .................................. 74
Climbinginandoutofthetruck .......................................... 77
AdjustingtheMSG65/MSG75driver'sseat ................................ 78
Seatbelt .......................................................... 82
Adjustingthearmrest ................................................. 85
Adjustingthesteeringcolumn ........................................... 86
Unlocking the emergency offswitch ...................................... 87
Operating the signal horn .............................................. 88
Driver'scab ........................................................ 89
Checking the brake systemforcorrectfunction .............................. 90
Checkingthesteeringsystemforcorrectfunction ............................ 93
Checking the emergency off function ..................................... 94
Checking the vertical liftmastposition(variant)forcorrectfunction ................ 95
Zeroadjustmentoftheloadmeasurement(variant) ........................... 95
Switching on ....................................................... 97
Switchingonthekeysw
itch ............................................ 97
AccessauthorisationwithPINcode(variant) ................................ 99
Display-operating unit ................................................109
Indicators .........................................................109
Adjustingthedisplays ................................................111
Symbolsinthedisplay ................................................113
Settingthedateortime ................................................1
18
Resetting the daily kilometres and daily operating hours .......................118
Setting the language . . ...............................................119
Softkeys for operating various equipment variants ............................119
Blue-Q efficiency mode ...............................................121
Functional description . ...............................................121
Switching off additionalconsumers .......................................122
SwitchingefficiencymodeBlue-Qonandoff ................................122
ConfiguringBlue-Qefficiencymode ......................................123
Driving ............................................................125
Safety regulations when driving .........................................125
Roadways .........................................................127
Setting the drive programme ............................................130
Selectingthedrivedirection ............................................131
Actuatingthedrivedirectionswitch,multiple-leverversion ......................132
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Actuatingthedrivedirectionswitch,mini-leverversion .........................132
Actuating the vertical rocker switch for the "drive direction", joystick 4Plusversion ....133
Actuate the drive direction switch, fingertip version ...........................133
Actuatingthedrivedirectionswitch,mini-consoleversion ......................134
Startingdrivemode ..................................................134
Starting drive mode, dual-pedalversion(variant) .............................136
Operatingtheservicebrake ............................................139
Parkingbrake ......................................................140
Actuating the mechanical parkingbrake ...................................140
Actuatetheelectricparkingbrake ........................................142
Malfunctionsintheelectricparkingbrake ..................................148
Steering ...........................................................155
Reducing speed when turning (Curve Speed Control) .........................156
Reducing speed with a raised load (variant) ................................157
Parking ...........................................................158
Parkingthetrucksecurelyandswitchingitoff ...............................158
Wheel chock (variant) ................................................159
Lifting ............................................................160
Liftingsystemvariants ................................................160
Typesofliftmast ....................................................160
Lifting system operatingdevices .........................................161
Multi-leverliftingsystem ...............................................163
Controlling the lifting system using a double mini-lever .........................164
Controlling the liftingsystemusingatriplemini-lever ..........................165
Controlling the lifting system using a quadruple mini-lever ......................166
Controllingtheliftingsystemusingthejoystick4Plus ..........................167
Controlling the liftingsystemwiththefingertipconsole .........................169
Changing the fork arms ...............................................170
Forkextension(variant) ...............................................172
Operation with reversibleforkarms(variant) ................................174
Malfunctionsduringliftingmode .........................................175
Hydraulicblockingfunction .............................................176
Automatic lift cut out(variant) ...........................................177
Liftmastverticalposition(variant) ........................................178
Handling loads ......................................................183
Safety regulations when handing loads ....................................183
Beforetakingupload .................................................184
Loadmeasurement(variant) ...........................................185
Picking up loads .....................................................188
Danger area .......................................................189
Transportingpallets ..................................................190
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Transporting suspended loads ..........................................190
Loadpickup ...................................................... . 191
Transportingloads ...................................................195
Settingdownloads ...................................................196
Driving on ascending and descending gradients .............................198
Drivingonlifts ......................................................199
Driving on loading bridges .............................................200
Attachments .......................................................201
Fittingattachments ..................................................201
Releasingthepressurefromthehydraulicsystem ............................203
Generalinstructionsforcontrollingattachments .............................207
Controlling attachments using multi-lever operation ...........................209
Operating attachments using multi-lever controls and the 5th function . . ...........210
Controlling attachments using a double mini-lever ............................212
Controlling attachments using the double mini-lever and the 5th function ...........214
Controllingattachmentsusingatriplemini-lever .............................216
Controlling attachments using the triple mini-lever and the 5th function .............218
Controlling attachments using a quadruple mini-lever .........................220
Controlling attachments using the quadruple mini-lever and the 5th function .........222
ControllingattachmentsusingtheJoystick4Plus .............................224
Controlling attachmentswithJoystick4Plusandthe5thfunction .................226
Controlling the attachments with fingertip . . ................................228
Controlling attachments with fingertip and the 5th function ......................229
Clamp locking mechanism(variant) ......................................231
Takingupaloadusingattachments ......................................235
Auxiliary equipment ..................................................236
Switching the lighting on andoff .........................................236
Switchingtheworkingspotlightforreversetravelonandoff .....................237
Switching the rotating beacon on and off . . . ................................237
Switching the hazard warningsystemonandoff .............................238
Switchingtheturnindicatorsonandoff ....................................238
Switching the double working spotlights on and off. ...........................241
STILL SafetyLight (variant) .............................................243
Operatingthewindscreenwiper/washer ...................................244
Fillingthewashersystem ..............................................244
FleetManager (variant) . ...............................................2
45
Shock recognition (variant) .............................................245
Driverrestraintsystems(variants) .......................................245
Ceiling sensor (variant) ...............................................246
Cab ..............................................................252
Opening the cab door . . ...............................................252
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Closing the cab door .................................................253
Opening the side windows . . . ..........................................253
Closingthesidewindows ..............................................253
Operatingtheinteriorlighting ...........................................254
Operating the rear window heating .......................................255
Radio(variant) ......................................................255
Heatingsystem(variant) ..............................................256
Push-up roof window (variant) ..........................................258
Clipboard (variant) ...................................................259
Trailer operation ....................................................260
Towedload ....................................................... . 260
Coupling pin in the counterweight ........................................261
Automatictowcoupling ...............................................263
Towingtrailers ......................................................271
Cold store application .................................................27
3
Display messages ...................................................276
Displaycontent .....................................................276
Errorcodetable .....................................................276
General messages ...................................................281
Drive-specificmessages ..............................................290
Procedure in emergencies .............................................294
Emergency shutdown ................................................294
Procedureiftrucktipsover .............................................295
Emergency hammer ..................................................296
Emergency lowering .................................................296
Emergency operation of the electric parking brake . ...........................298
Towing .......................................................... . 299
Connecting and disconnecting the battery male connector ......................302
Connecting the battery male connector ....................................302
Disconnecting the battery male connector ..................................303
Handling the lead-acid battery ..........................................304
Safety regulations for handling the battery ..................................304
Maintainingthebattery ................................................3
07
Checkingthebatterycondition,acidlevelandaciddensity ......................309
Checkingthebatterychargestatus .......................................310
Chargingthebattery ..................................................310
Chargingthebatterywiththebatterychargingflap ............................313
Equalising charging to preserve the battery capacity ..........................317
Handling the lithium-ion battery .........................................320
Safety regulations for handling the lithium-ion battery .........................320
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Lithium-ionbatteries"GGSLi-ion80V"24.1kWhand60kWh ...................323
Display messages on the display-operating unit .............................324
Regulations for storing lithium-ionbatteries .................................324
Checkingthebatterychargestatus .......................................327
Chargingthebattery ..................................................330
Replacing and transporting the battery ....................................332
Generalinformationonreplacingthebattery ................................332
Changing to a different battery type .......................................333
Converting to lithium-ion batteries ........................................333
Opening/closingthebatterycover ........................................335
Specialnotesforinstallingthelithium-ionbattery .............................338
Replacing the battery usingforklifttruckorpallettruck .........................338
Replacing the battery using a change frame (variant) ..........................341
Replacingthebatterywiththehydraulicbatterycarrier .........................345
Transporting the lead-acidbatterybycrane .................................353
Transportingthelithium-ionbatterybycrane ................................354
Cleaning the truck ...................................................355
Cleaningthetruck ...................................................355
Cleaningtheelectricalsystem ..........................................357
Cleaningloadchains .................................................357
Cleaningthewindows ................................................35
8
After cleaning .......................................................358
Transporting the truck ................................................360
Transport ..........................................................360
Crane loading ......................................................362
Decommissioning ...................................................366
Decommissioning and storingthetruck ....................................366
Returningtoserviceafterdecommissioning ................................368
5 Maintenance
Safety regulations for maintenance .......................................372
Generalinformation ..................................................372
Workingonthehydraulicequipment ......................................372
Working on the electrical equipment ......................................372
Safetydevices ......................................................373
Setvalues ....................................................... . . 373
Liftingandjackingup .................................................373
Workingatthefrontofthetru
ck ..........................................374
General maintenance information ........................................376
Personnel qualifications ...............................................376
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Information for carrying out maintenance ..................................376
Maintenance — 1000 hours/annually .....................................379
Maintenance - 3000 hours/everytwoyears .................................383
Orderingsparepartsandwearingparts ....................................383
Quality and quantity of the required operating materials ........................383
Lubricationplan .....................................................384
Maintenancedatatable ...............................................386
Providing access to maintenance points ...................................389
Removing and installing the valvecover ...................................389
Opening the fuse box .................................................389
Preserving operational readiness ........................................391
Lubricating the joints and controls ........................................391
Checkingthebatteryinterlockandbatterycover .............................391
Maintainingtheseatbelt ...............................................393
Checking the driver's seat .............................................394
Maintaining wheels and tyres . ..........................................395
Servicingthesteeringaxle .............................................397
Checkingthebattery .................................................399
Checkingthefuses ...................................................399
Replacingfuses .....................................................401
Checking the hydraulic oillevel ..........................................403
Checkingthehydraulicsystemforleaktightness .............................404
Lubricatingtheliftmastandrollertrack ....................................405
Greasing the automatic towcoupling ......................................405
Preserving operational readiness for cold store application .....................408
Replacing the heater filter mat ..........................................408
1000-hour maintenance/yearly maintenance ...............................411
Othertasks ........................................................411
Checking the cable connections .........................................411
Checking the hydraulicoillevelofthehydraulicbatterycarrier ...................411
Lubricatingtheslideelements ..........................................413
Oilingthecatchrails ..................................................413
Checking the lift cylinders and connections for leaks ..........................415
Checkingforkarms ..................................................416
Checkingthereversibleforkarms ........................................416
Checking the double pedal . . . ..........................................417
Checking the battery changeover frame ...................................417
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6 Technical data
Dimensions ........................................................420
VDI datasheet for RX60-25 and RX60-25/600 ...............................422
VDI datasheet for RX60-25L and RX60-25L/600 .............................426
VDI datasheet for RX60-30 and RX60-35 ..................................430
VDI datasheet for RX60-30L and RX60-30L/600 .............................434
Ergonomic dimensions ................................................438
Information about the lead-acid battery ....................................439
Information about the lithium-ion battery ...................................441
Fuse assignment ....................................................442
Fuse assignment standard equipment ....................................442
Fuse assignment equipmentvariants .....................................443
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1
Foreword
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1Foreword
Your truck
Your truck
Description of the truck
General
The STILL RX60 25-35 is an electrically driven
counterbalanced truck with a rear swing axle.
The truck has a load capacity of 2.5 to 3.5
tonnes. Alternatively, a load capacity of up to
3.0 tonnes with a load centre of gravity of 600
mm is available. The truck can reach speeds
of up to 20 km/h without a load.
It is suitable for interior use and for outdoor
use.
The display-operating unit manages all func-
tions that are not called up by the operating
devices for drive functions and hydraulic func-
tions. All messages and driving condition
information are issued via the display. The
display-operating unit uses the current battery
charge state and the selected drive program
to calculate the remaining available time until
the battery has to be recharged and displays
this information.
The truck supports all functions of FleetMan-
ager 4.0 (variant).
Brake system
The brake system of the truck comprises three
different brakes:
• Service brake
• Regenerative brake
• Mechanically actuated parking brake
• Electrically actuated parking brake (variant)
The service brake is based on a wear-free,
oil-immersed multi-disc brake. This multi-disc
brake is used as the service brake for heavy
braking or emergency braking with the brake
pedal. In the normal working mode, the
regenerative brake of the electric traction
motor takes effect. The regenerative brake
converts the acceleration energy of the truck
into electrical energy. This causes the truck to
decelerate as soon as the accelerator pedal
is released. Completely removing your foot
from the accelerator pedal causes the truck to
brake until it comes to a standstill. A parking
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Your truck
brake ensures that the truck remains securely
in place when parked.
Hydraulic system
The steering system and the lift and tilt cylin-
ders in the lift mast are supplied with power
by a hydraulic pump operated by an electric
motor.
The proportional valve technology provides
particularly 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
Both front wheels of the STILL RX60 25-35
are driven by a maintenance-free three-phase
drive in the front axle with 80-volt technology.
Lead-acid batteries and lithium-ion batteries
that can be replaced from the side are avail-
able as a power supply source. In both cases,
the trucks can be supplied as a cold store vari-
ant.
The driver can help to determine the energy
consumption and performance of the truck
using the "Blue-Q" efficiency mode, which
allows the required setting for each current
application to be called up via the display-
operating unit.
Steering
The kickback-free, hydraulic rear-wheel
steering with "Curve Speed Control" (CSC)
ensures driving stability when cornering,
allowing the truck to achieve a small turning
circle and negotiate narrow aisle widths.
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1Foreword
Your truck
Operation
A multi-lever, fingertip switch, mini-lever and
the Joystick 4Plus are available as operating
devices for the hydraulic functions. These
operating devices enable precise operation
and smooth control of the lifting speed thanks
to directly controlled valves and proportional
valve technology.
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.
The display-operating unit monitors the truck
functions, including each individual cell in the
lithium-ion battery.
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.
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Foreword 1
Your truck
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.
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1Foreword
Your truck
EC declaration of conformity in accordance with Machinery Directive
Declaration
STILL GmbH
Berzeliusstraße 10
D-22113 Hamburg Germany
We declare that the
Industrial truck according to these operating instructions
Model according to these operating instructions
conforms to the latest version of the Machinery Directive 2006/42/EC.
Personnel authorised to compile the technical documents:
See EC compliance declaration
STILL GmbH
.
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