Still RX60-35/600 User manual

Original instructions
Electric trucks
RX60-35/600
RX60-40
RX60-40/600
RX60-45
RX60-45/600
RX60-50
RX60-50/600
6327 6328 6329 6330 6367
6368 6369
171533 EN - 02/2019 - 19

Preface
g
Address of manufacturer and
contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.still.de
Rules for the operating
company of industrial trucks
In addition to these operating instructions,
a code of practice containing additional
information for the operating companies of
industrial trucks is also available.
This guide provides information for handling
industrial trucks:
• Information on how to select suitable
industrial trucks for a particular area of
application
• Prerequisites for thesafeoperationof
industrial trucks
• Information on the use of industrial trucks
• Information on transport, initial commis-
sioning and storage of industrial trucks
Internet address and QR code
The information can be accessed at any time
by pasting the address https://m.still.de/vdma
in a web browser or by scanning the QR code.
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Table of contents
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1 Foreword
Your truck .......................................................... 2
Descriptionofthetruck ................................................. 2
General ............................................................ 4
CElabelling ......................................................... 5
EC declaration of conformity in accordance with Machinery Directive ............... 6
Accessories ......................................................... 7
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 .............................. 36
Warning regarding non-original parts ..................................... 36
Damage, defects and misuse of safety systems . . . ........................... 37
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
Climbingintoandoutofthetruck ........................................ 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
Driveways ....................................................... . . 127
Setting the drive programs .............................................130
Sprintmode(variant) .................................................132
Selectingthedrivedirection ............................................133
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Actuatingthedrivedirectionswitch,multiple-leverversion ......................134
Actuatingthedrivedirectionswitch,mini-leverversion .........................134
Actuating the vertical rocker switchforthe"drivedirection",joystick4Plusversion ....135
Actuate the drive direction switch, fingertip version ...........................135
Actuatingthedrivedirectionswitch,mini-consoleversion ......................136
Startingdrivemode ..................................................136
Starting drive mode, dual-pedal version (variant) . . ...........................138
Operatingtheservicebrake ............................................141
Parkingbrake ......................................................142
Actuating the mechanical parking brake ...................................142
Actuatetheelectricparkingbrake ........................................144
Malfunctions in the electricparkingbrake ..................................150
Steering ...........................................................157
Reducing speed when turning (Curve Speed Control) .........................158
Reducing speed with a raisedload(variant) ................................159
Parking ...........................................................160
Parkingthetrucksecurelyandswitchingitoff ...............................160
Wheel chock (variant) ................................................16
1
Lifting ............................................................162
Liftingsystemvariants ................................................162
Typesofliftmast ....................................................162
Liftingsystemoperatingdevices .........................................163
Multi-leverliftingsystem ...............................................164
Controlling the lifting system using a double mini-lever .........................165
Controllingtheliftingsystemusingatriplemini-lever ..........................166
Controlling the lifting system using a quadruple mini-lever ......................167
Controlling the liftingsystemusingthejoystick4Plus ..........................168
Controllingtheliftingsystemwiththefingertipconsole .........................170
Changing the fork arms ...............................................171
Fork extension (variant) ...............................................173
Operationwithreversibleforkarms(variant) ................................175
Malfunctionsduringliftingmode .........................................176
Hydraulic blocking function .............................................177
Automaticliftcutout(variant) ...........................................178
Liftmastverticalposition(variant) ........................................179
Handling loads ......................................................184
Safety regulations when handing loads ....................................184
Beforetakingupload .................................................185
Load measurement (variant) ...........................................186
Picking up loads .....................................................189
Danger area .......................................................190
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Transportingpallets ..................................................191
Transporting suspended loads ..........................................191
Loadpickup ...................................................... . 192
Transportingloads ...................................................196
Settingdownloads ...................................................197
Driving on ascending and descendinggradients .............................199
Drivingonlifts ......................................................200
Driving on loading bridges .............................................201
Attachments .......................................................202
Fittingattachments ..................................................202
Releasingthepressurefromthehydraulicsystem ............................204
General instructions for controllingattachments .............................208
Controlling attachments using multi-lever operation ...........................210
Operating attachments using multi-lever controls and the 5th function . . ...........211
Controlling attachments using a double mini-lever ............................213
Controlling attachments using the double mini-lever and the 5th function ...........215
Controllingattachmentsusingatriplemini-lever .............................217
Controlling attachmentsusingthetriplemini-leverandthe5thfunction .............219
Controlling attachments using a quadruple mini-lever .........................221
Controlling attachments using the quadruple mini-lever and the 5th function .........223
Controlling attachmentsusingtheJoystick4Plus .............................225
ControllingattachmentswithJoystick4Plusandthe5thfunction .................227
Controlling the attachments with fingertip . . ................................229
Controlling attachments with fingertip and the 5th function ......................230
Clamp locking mechanism (variant) ......................................232
Takingupaloadusingattachments ......................................236
Auxiliary equipment ..................................................23
7
Switchingthelightingonandoff .........................................237
Switchingtheworkingspotlightforreversetravelonandoff .....................238
Switching the rotating beacon on and off . . . ................................238
Switchingthehazardwarningsystemonandoff .............................239
Switchingtheturnindicatorsonandoff ....................................239
Switching the double workingspotlightsonandoff. ...........................242
STILLSafetyLight(variant) .............................................244
Operatingthewindscreenwiper/washer ...................................245
Filling the washer system ..............................................245
FleetManager (variant) . ...............................................246
Shock recognition (variant) .............................................246
Driver restraint systems(variants) .......................................246
Ceilingsensor(variant) ...............................................247
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Cab ..............................................................253
Opening the cab door .................................................253
Closing the cab door .................................................254
Opening the side windows . . . ..........................................254
Closingthesidewindows ..............................................254
Operating the interior lighting ...........................................255
Operating the rear window heating .......................................256
Radio(variant) ......................................................256
Heatingsystem(variant) ..............................................25
7
Push-up roof window (variant) ..........................................259
Clipboard (variant) ...................................................260
Trailer operation ....................................................261
Towedload ....................................................... . 261
Coupling pin in the counterweight ........................................262
Automatictowcoupling ...............................................26
4
Towingtrailers ......................................................272
Cold store application .................................................274
Display messages ...................................................277
Displaycontent .....................................................277
Errorcodetable .....................................................277
General messages ...................................................282
Drive-specificmessages ..............................................291
Procedure in emergencies .............................................295
Emergency shutdown ................................................295
Procedureiftrucktipsover .............................................296
Emergency hammer ..................................................297
Emergency lowering .................................................297
Emergency operation of the electric parking brake . ...........................299
Towing .......................................................... . 300
Connecting and disconnecting the battery male connector ......................303
Connecting the battery male connector ....................................303
Disconnecting the battery male connector ..................................304
Handling the lead-acid battery ..........................................305
Safety regulations for handling the battery ..................................305
Maintainingthebattery ................................................308
Checking the battery condition,acidlevelandaciddensity ......................310
Checkingthebatterychargestatus .......................................311
Chargingthebattery ..................................................311
Charging the battery with thebatterychargingflap ............................314
Equalising charging to preserve the battery capacity ..........................318
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Handling the lithium-ion battery .........................................321
Safety regulations for handling the lithium-ion battery .........................321
Lithium-ion batteries "GGS Li-Ion 80 V BG 7"36.2 kWh and 118.4 kWh .............324
Display messages on the display-operating unit .............................325
Regulations for storing lithium-ion batteries . ................................325
Checking the battery charge state ........................................328
Chargingthebattery ..................................................331
Replacing and transporting the battery ....................................333
General information on replacingthebattery ................................333
Changing to a different battery type .......................................334
Opening/closingthebatterycover ........................................334
Special notes for installingthelithium-ionbattery .............................337
Replacingthebatteryusingforklifttruckorpallettruck .........................338
Replacing the battery using a change frame (variant) ..........................341
Replacing the battery withthehydraulicbatterycarrier .........................345
Transportingthelead-acidbatterybycrane .................................353
Transportingthelithium-ionbatterybycrane ................................354
Cleaning the truck ...................................................355
Cleaningthetruck ...................................................355
Cleaningtheelectricalsystem ..........................................357
Cleanloadchains ................................................. . . 357
Cleaningthewindows .............................................. . . 358
After cleaning .......................................................358
Transporting the truck................................................360
Transport ..........................................................360
Crane loading ......................................................362
Decommissioning ...................................................366
Decommissioningandstoringthetruck ....................................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
Workingatthefrontofthetruck ..........................................374
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General maintenance information ........................................376
Personnelqualifications ...............................................376
Information for carrying out maintenance ..................................376
Maintenance — 1000 hours/annually .....................................379
Maintenance-3000hours/everytwoyears .................................383
Ordering spare parts and wearingparts ....................................383
Quality and quantity of the required operating materials ........................383
Lubricationplan .....................................................385
Maintenancedatatable ...............................................387
Providing access to maintenance points ...................................390
Removingandinstallingthevalvecover ...................................390
Opening the fuse box .................................................390
Preserving operational readiness ........................................392
Lubricatingthejointsandcontrols ........................................392
Checking the battery interlockandbatterycover .............................392
Maintainingtheseatbelt ...............................................394
Checkingthedriver'sseat .............................................395
Maintaining wheels and tyres ...........................................396
Servicingthesteeringaxle .............................................398
Checkingthebattery .................................................400
Checkingthefuses ...................................................400
Replacingfuses .....................................................402
Checkingthehydraulicoillevel ..........................................404
Checking the hydraulic systemforleaktightness .............................405
Lubricatingtheliftmastandrollertrack ....................................406
Greasingtheautomatictowcoupling ......................................406
Preserving operational readiness for cold store application .....................409
Maintaining the heater ................................................409
1000-hour maintenance/yearly maintenance ...............................411
Othertasks ........................................................411
Checking the cable connections .........................................411
Checkingthehydraulicoillevelofthehydraulicbatterycarrier ...................411
Lubricating the slide elements ..........................................413
Oilingthecatchrails ..................................................413
Checking the lift cylinders and connections for leaks ..........................415
Checkingforkarms ..................................................41
6
Checkingthereversibleforkarms ........................................416
Checking the double pedal . . . ..........................................417
Checking the battery changeover frame ...................................417
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6 Technical data
Dimensions ........................................................420
VDI datasheet RX60-35/600 ............................................422
VDI datasheet RX60-40 and RX60-40/600 .................................426
VDI datasheet RX60-45 and RX60-45/600 .................................430
VDI datasheet RX60-50 and RX60-50/600 .................................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

1Foreword
Your truck
Your truck
Description of the truck
General
The STILL RX60 35-50 is an electrically driven
counterbalanced truck with a rear swing axle.
The truck has a load capacity of up to 5.0
tonnes. Alternatively, a load capacity of up
to 3.0 tonnes, 4.0 tonnes, 4.5 tonnes or 5.0
tonnes with a load centre of gravity of 600
mm is available. The truck can reach driving
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 is comprised of
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
motors 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
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Foreword 1
Your truck
brake until it comes to a standstill. A parking
brake ensures that the truck remains securely
in place when parked.
Hydraulic system
The steering system, the lift cylinders and the
tilt cylinders in the lift mast are supplied with
power via 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 damping pressure peaks in the hydraulic
system.
Drive
The STILL RX60 35-50 is driven via both front
wheels by maintenance-free three-phase
drives in the front axle with 80 volt technology.
Power is supplied by lead-acid batteries
or lithium-ion batteries. The batteries are
located at the side of the truck to enable easy
replacement. In both cases, the trucks can be
supplied as a cold store variant.
The driver can help to influence 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.
171533 EN - 02/2019 - 19 3

1Foreword
Your truck
Operation
A multi-lever, Fingertip, 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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