2018 STILL RX60-25 RX60-30 RX60-35 Electric Forklift Workshop Manual – PDF Download

Description

2018 STILL RX60-25, RX60-30 and RX60-35 Electric Forklift Workshop Manual

This is the full STILL workshop literature for the RX60-25, RX60-30 and RX60-35 series electric forklift trucks, published as document 56338012001 EN in June 2018 under Edition 2018/06, Version 2. Across 416 pages it covers the complete truck, from the traction motor and Carraro EC35 drive axle to the hydraulic system, MaLiS lift masts, electrical and electronic controls, brake systems, lithium-ion battery technology and the DiaMon / STEDS-Navigator diagnostic environment. This is the same reference material a STILL service engineer works from — not a generic overview.

File Details

• Manual type: Workshop literature / service and repair manual
• Brand: STILL
• Model series: RX60-25, RX60-30, RX60-35 electric forklift trucks
• Type carriers covered: 6345, 6346, 6347, 6348, 6353, 6354, 6355, 6356
• Document number: 56338012001 EN
• Edition: 2018/06 — Version 2
• Language: English
• Pages: 416
• Format: PDF

Chapters Covered

• 00 Product information — Foreword, product overview for the RX60 25-35, safety information, parking the truck secured for service work, working on the electrical system, jacking up the front and rear, securing the fork carriage, restrictions and obligations, penalties, speed limitation with a Tensor battery and for legal use on public roads
• 01 Service — Maintenance 1000 hours/annually, maintenance 3000 hours/every two years, operating materials, measuring instruments and testing equipment, harnesses and hoists 1.0 t – 3.5 t, standardised tightening torques for standard-pitch, fine-pitch threads and hose fittings
• 02 Diagnostics — Introduction to DiaMon, STEDS-Navigator, diagnostics service box, diagnostic set-up, starting DiaMon, working with DiaMon, reading out and clearing the error list, reading out access codes, working using ABE, clearing error lists
• 11 Electric motor — Traction motor general technical data, electrical connections, traction drive, sensors, pin sensor, temperature sensor KTY84
• 22 Mechanical drive axle — Drive axle EC35 general technical data Carraro EC 35, drive axle without pump motor removal and installation, drive axle with pump motor removal and installation, wheel drive, service brake, differential gearbox and brake, basic setting of the brake system, testing the brake system
• 30 Chassis, bodywork and fittings — Frame, working with gas springs, battery door, battery lock, battery door sensor, counterweight
• 42 Steering system — Hydraulic steering general technical data, steering unit, steering wheel and steering column, steering angle sensor 3B01, steering angle-dependent handling performance CSC, CSC functional test, steering axle, swing axle, wheel hub, steering angle, tie rod, axle stub
• 50 Operating devices — Drive and brake actuation, changing the brake cable for the service brake, brake cable change for handbrake, actuating force of the handbrake, brake sensor, parking brake switch 1S3, accelerator pedal generation 2, accelerator single-pedal, electric parking brake
• 56 Operating console — Turn indicator module for the drive direction generation 2, direction indicator module FABLI, display and operating unit ABE 2
• 60 Electrics/electronics — General technical data, overview of controllers, electrical system, switch-on process, software compatibility, PAN process, parameter management, error ring buffer, temperature monitoring, electrical checks, intermediate circuit, insulation testing, CAN bus system, power cables, fuses, contactor, sensor system, vertical lift mast position, tilt angle sensor 7B46, load measurement, additional electrical installation, 7A21 converter PCB, Option Board, CAN-Power-Port (CPP), Relay-Power-Port (RPP)
• 64 Electronic controls — Truck control unit, Main Control Unit (MCU 2), MCU removal and installation, Supply Unit (SU 2), SU removal and installation, converters, inverters
• 69 Batteries and accessories — Lead-acid battery, 2014 discharge indicator, battery plug, maintenance guidelines for appliance plugs, repair of battery male connector contacts, working with reducer sleeves, lithium-ion technology, working on lithium-ion batteries, general technical data, battery management system (BMS), diagnostics, battery display, battery discharge indicator, battery charge, battery male connector, battery discharge, deeply discharged battery, removing/installing the battery cable, converting from lead-acid to lithium-ion
• 70 Hydraulics — General — General technical data, hydraulic oil, depressurising the hydraulics, lifting, lowering and tilting operating speeds, safety check, basic hydraulics, hydraulic tank, return line filter, breather filter, intake filter, high-pressure filter, conical nipple fittings, bolted joint
• 71 Working hydraulics — Pump-motor unit, tilt cylinder, mast tilt, auxiliary hydraulics, attachments, second operating function for attachments, clamp locking mechanism with servo hydraulics, clamp locking mechanism for hand levers, accumulator
• 76 Valves — Hand lever general technical data, hand lever valve block, emergency lowering, hydraulic transmitter, valve block removal/installation, directional control valve block, check valve for hydraulics blocking function, servo hydraulics valve block, manual lowering, directional control valve block (servo)
• 80 Load lift system — Mast bearings, Carraro MaLiS mast bearing
• 81 MaLiS lift mast — Lift mast general technical data, hose safety valve of triplex mast, support roller play (108/117/130), load chains checking and cleaning, run-out barrier, working on lift masts, lift mast removal and installation, telescopic lift mast, NiHo lift mast, triplex lift mast, lift cylinder, outer cylinders, middle cylinder, end position damping
• 84 Load support — Fork carriage removal and installation, fork wear protection
• X Circuit diagrams — Hydraulic circuit diagram multi-levers, hydraulic circuit diagram servo hydraulics

Together these chapters give a technician the full picture of the RX60-25 / RX60-30 / RX60-35 truck: how each assembly is built, how it comes apart, what the correct torque, clearance and adjustment values are, and how the truck’s controllers and CAN bus networks interact. The mix of mechanical procedures (drive axle, wheel hubs, lift cylinders, mast rollers) with electrical and diagnostic content (insulation testing, converter replacement, parameter copying, error ring buffer) means this is a single reference for the whole machine rather than a parts-only or electrical-only book.

What This Manual Helps You Do

Whether you are servicing a single RX60-25 or maintaining a fleet of RX60-30 and RX60-35 trucks, this STILL RX60-25/30/35 electric forklift workshop manual covers the tasks you would otherwise have to guess at: removing and refitting the Carraro EC35 drive axle with or without the pump motor, setting the multi-disc brake on the differential gearbox, adjusting the load chains and support roller play on MaLiS telescopic, NiHo and triplex lift masts, changing the electric parking brake cable and running its calibration, diagnosing the truck with DiaMon and STEDS-Navigator, reading and clearing the error list, and interpreting the intermediate circuit, insulation and CAN bus tests.

Getting the torque, clearance and adjustment values right on a forklift matters — an incorrectly set brake, a mis-tensioned load chain or a mis-calibrated steering angle sensor can lead to a truck that fails its FEM 4.004 inspection or, worse, causes an accident on site. Having the STILL procedure in front of you, with the exact figures the manufacturer specifies, is what this RX60-25 / RX60-30 / RX60-35 workshop manual delivers.

It also covers the lithium-ion technology variant of the RX60 range, which has been available since December 2017. The lithium-ion chapters explain the battery management system, the battery display, how to handle a deeply discharged battery, how to check that the battery male connector is de-energised, and how to convert a truck from lead-acid to lithium-ion using the changeover kit.

Delivery

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Instant PDF download after payment — no shipping, no waiting. Read it on a laptop, tablet or phone in the workshop or print the pages you need for the job at hand. The file is the same 416-page STILL workshop literature, Edition 2018/06, Version 2, and is yours to keep and return to whenever a new task comes up.