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Still STED Electric forklift truck RX60-25-35, RX60-40-50 Workshop manual – PDF DOWNLOAD
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Still STED Electric forklift truck RX60-25-35, RX60-40-50 Workshop manual – PDF DOWNLOAD
Electric forklift truck RX60-25-35, RX60-40-50
RX60-25 RX60-30
RX60-35
RX60-40
RX60-45
RX60-50
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Description
Still STED Electric forklift truck RX60-25-35, RX60-40-50 Workshop manual – PDF DOWNLOAD
FILE DETAILS:
Still STED Electric forklift truck RX60-25-35, RX60-40-50 Workshop manual – PDF DOWNLOAD
Language : English
Pages : 460
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Still STED Electric forklift truck RX60-25-35, RX60-40-50 Workshop manual – PDF DOWNLOAD
Electric forklift truck RX60-25-35, RX60-40-50
RX60-25 RX60-30
RX60-35
RX60-40
RX60-45
RX60-50
Special features of this series
The series described belongs to the RX family. A few units with a high proportion of common parts make up many different trucks of different versions.
• Ergonomic driver’s workplace Generation 2 mini-lever Generation 2 display operating unit Electric parking brake
• Blue-Q Characteristic curve optimisation of the drive The following can be parameterised: switching off auxiliary consumers and enabling the consumption display Load measurement
• Mast vertical position Hydraulics blocking function in accordance with EN ISO 3691-1
• Container overhead guard The container roof with its reduced overall height can be added as a variant to all truck types. However, the truck’s actual container compatibility depends on the height of the chassis and must be checked separately. See operating instructions, chapter 7 “Technical data”.
TABLE OF CONTENTS:
Still STED Electric forklift truck RX60-25-35 RX60-40-50 Workshop manual – PDF DOWNLOAD
Table of contents
00 Product information
Foreword 00- 1
Aboutthe RXB0-25-50 00- 1
Safetyinstructions 00- 4
Parking the truck so itis secured for servicework 00- 4
Working onthe electrical system i 00- 5
Jacking up the frontofthetruck LL 00- 5
Jackinguptherearofthetruck iL 00- 6
Securing theforkcarriage 00- 8
01 Service
Maintenance 01-1
Maintenance instructions LL 01-1
Maintenance — 1000 hours/annually 01- 3
Maintenance – 3000 hours/everytwoyears 01- 5
Tool 01- 6
Measuring and testingequipment 01- 6
Harnessesand hoists 01-7
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01- 8
Standardised tightening torques for hose fittings 01- 8
Aboutthe RXB0-25-50 00- 1
Safetyinstructions 00- 4
Parking the truck so itis secured for servicework 00- 4
Working onthe electrical system i 00- 5
Jacking up the frontofthetruck LL 00- 5
Jackinguptherearofthetruck iL 00- 6
Securing theforkcarriage 00- 8
01 Service
Maintenance 01-1
Maintenance instructions LL 01-1
Maintenance — 1000 hours/annually 01- 3
Maintenance – 3000 hours/everytwoyears 01- 5
Tool 01- 6
Measuring and testingequipment 01- 6
Harnessesand hoists 01-7
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01- 8
Standardised tightening torques for hose fittings 01- 8
02 Diagnostics
IntroductiontoDiaMon 02- 1
STEDS-Navigator 02- 1
CANboxdiagnostics 02- 2
Diagnosticset-up 02- 3
StartingDiaMon 02- 4
STEDS-Navigator 02- 1
CANboxdiagnostics 02- 2
Diagnosticset-up 02- 3
StartingDiaMon 02- 4
WorkingwithDiaMon 02- 5
Reading outand clearingtheerrorlist 02- 5
Readingoutaccesscodes LL 02- 6
Reading outand clearingtheerrorlist 02- 5
Readingoutaccesscodes LL 02- 6
Workingusing ABE 02- 7
Readerrorlist 02- 7
Clearingerrorlists 02- 9
Readerrorlist 02- 7
Clearingerrorlists 02- 9
11 Electrical motor
Traction motor 11-1
Generaltechnicaldata 11-1
Electricalconnections LL 11-1
Tractiondrive 11- 2
Traction motor 11- 4
Speed sensor 11- 6
Pin Sensor 11- 6
Temperature SEeNSOr i 11- 8
Temperature sensor KTY84 11- 8
22 Mechanical drive axle
Driveaxle EC35-EC50 22- 1
General technicaldataCarraroEC35 22- 1
General technical data CarraroEC50 22- 3
Drive axle 22- 5
Drive axle without pump motor Removal and installation 22- 6
Drive axle with pump motor Removal and installation 22- 9
Wheeldrive 22-12
Differential gearboxandbrake i 22-16
Removal of the differential gearboxandbrake 22-18
Installation of the differential gearboxandbrake 22-21
31 Chassis
Chassis 31- 1
Batterydoor 31-1
Battery lock 31- 2
Batterydoorsensor 31- 4
Counterweight 31- 5
Counterweight 31-5
34 Driver’s compartment
Overheadguard 34-1
Overhead guard 34- 1
Removing the overheadguard i 34-
Installingthe overhead guard 34-
42 Steering system
Hydraulicsteering iL 42-1
Generaltechnicaldata 42- 1
Steering system 42-
Tractiondrive 11- 2
Traction motor 11- 4
Speed sensor 11- 6
Pin Sensor 11- 6
Temperature SEeNSOr i 11- 8
Temperature sensor KTY84 11- 8
22 Mechanical drive axle
Driveaxle EC35-EC50 22- 1
General technicaldataCarraroEC35 22- 1
General technical data CarraroEC50 22- 3
Drive axle 22- 5
Drive axle without pump motor Removal and installation 22- 6
Drive axle with pump motor Removal and installation 22- 9
Wheeldrive 22-12
Differential gearboxandbrake i 22-16
Removal of the differential gearboxandbrake 22-18
Installation of the differential gearboxandbrake 22-21
31 Chassis
Chassis 31- 1
Batterydoor 31-1
Battery lock 31- 2
Batterydoorsensor 31- 4
Counterweight 31- 5
Counterweight 31-5
34 Driver’s compartment
Overheadguard 34-1
Overhead guard 34- 1
Removing the overheadguard i 34-
Installingthe overhead guard 34-
42 Steering system
Hydraulicsteering iL 42-1
Generaltechnicaldata 42- 1
Steering system 42-
Steering—errordetection LL 42- 4
Steering unit 42- 5
6S3 diaphragm pressureswitch 42- 7
Priority valve 42-10
Steering wheel and steeringcolumn 42-12
Steeringcolumn 42-12
Steeringanglesensor3B01 LL 42-14
Steering angle-dependent handling performance —CSC 42-16
CSC —functionaltest 42-17
Steeringaxle 42-21
Generaltechnicaldata 42-21
General technical data-Typecarrier6330 42-21
Swingaxle 42-23
Swing axle, reinforced forLP600 La 42-24
Swingaxlecurveswitch 42-24
Removing/installingthe swingaxle 42-25
Wheelhub 42-28
Steeringangle 42-30
Tierod 42-31
Axlestub 42-32
Steering unit 42- 5
6S3 diaphragm pressureswitch 42- 7
Priority valve 42-10
Steering wheel and steeringcolumn 42-12
Steeringcolumn 42-12
Steeringanglesensor3B01 LL 42-14
Steering angle-dependent handling performance —CSC 42-16
CSC —functionaltest 42-17
Steeringaxle 42-21
Generaltechnicaldata 42-21
General technical data-Typecarrier6330 42-21
Swingaxle 42-23
Swing axle, reinforced forLP600 La 42-24
Swingaxlecurveswitch 42-24
Removing/installingthe swingaxle 42-25
Wheelhub 42-28
Steeringangle 42-30
Tierod 42-31
Axlestub 42-32
49 Brake installation
Mechanical servicebrake lL 49- 1
Changing the brake cable Servicebrake 49- 1
Servicebrake 49- 2
Removing/installingthe servicebrake 49- 3
Changing the brake cable Servicebrake 49- 1
Servicebrake 49- 2
Removing/installingthe servicebrake 49- 3
Handbrake 49- 5
Brake cable change, handbrake 49- 5
Actuating force ofthe handbrake 49- 7
Parking brake switch 183 49- 8
Brake cable change, handbrake 49- 5
Actuating force ofthe handbrake 49- 7
Parking brake switch 183 49- 8
Electric parkingbrake LL 49-10
Electricparkingbrake 49-10
Function 49-11
Causeandeffect 49-13
Design and systemdescription 49-15
Maintenance instructions LL 49-17
Checkingthebrake 49-18
Electricparkingbrake 49-10
Function 49-11
Causeandeffect 49-13
Design and systemdescription 49-15
Maintenance instructions LL 49-17
Checkingthebrake 49-18
Calibration and functionaltest
Changing the parkingbrakecable
Limitpositionswitch oo
Drive unit Installationandremoval
Changing the parkingbrakecable
Limitpositionswitch oo
Drive unit Installationandremoval
Central lubrication device Installationand removal
50 Driver’s controls
Brakepedal
Brakesensor
Brakesensor
Singlepedal
Accelerator—single-pedal iL
Dead manswitch7S13
Accelerator—single-pedal iL
Dead manswitch7S13
Doublepedal
Accelerator—dual pedal 2nd generation
Accelerator —dual pedal 1stgeneration
Accelerator—dual pedal 2nd generation
Accelerator —dual pedal 1stgeneration
Driver’scontrols i
Handlever
Joystick4Plus
Axle assignment -Joystick4Plus LL
Joystick
Joystickoperation
Generation Tmini-lever
Generation2mini-lever
Generation 2 mini-leverActuation
Tipswitch
Handlever
Joystick4Plus
Axle assignment -Joystick4Plus LL
Joystick
Joystickoperation
Generation Tmini-lever
Generation2mini-lever
Generation 2 mini-leverActuation
Tipswitch
Axleassignment LL
56 Display elements
Operatingconsole
Direction indicatormodule (Fabli)
Direction indicatormodule (Fabli)
Drive direction tum indicatordisplay
Display
Display operating unit (ABE 1) Generation1
ABE 1 Installationandremoval
Display and operating unit, generation2(ABE2)
Display operating unit (ABE 1) Generation1
ABE 1 Installationandremoval
Display and operating unit, generation2(ABE2)
ABE 2 Installationandremoval
60 Electrics / Electronics
General 60- 1
General technical data 6321-6325 60- 1
General technical data 8326-6330 0 60- 3
Overviewofthecontrollers 60- 4
Electrical system 60- 5
Electricalcomponents 60- 5
Switching on procedure for the electricalsystem 60- 7
Software compatibility 60-12
PAN DrOCESS «oo 60-13
Parametermanagement LLL 60-14
Errorring buffer 60-15
Intermediate circuit 60-16
Insulation testing forelectrictrucks 60-17
Insulation testingonthedrivebattery 60-19
Componentinsulationtesting 60-20
Temperature monitoring for the traction motor-80V 60-22
Temperature monitoring for the traction motorconverter 60-24
Pump motor temperature monitoring LL 60-25
Temperature monitoring for the pump motorconverter 60-26
Available drivingbehaviour 60-28
Drive mode — driving behaviour Description 60-28
BlUe-Q=1Q 60-30
General technical data 6321-6325 60- 1
General technical data 8326-6330 0 60- 3
Overviewofthecontrollers 60- 4
Electrical system 60- 5
Electricalcomponents 60- 5
Switching on procedure for the electricalsystem 60- 7
Software compatibility 60-12
PAN DrOCESS «oo 60-13
Parametermanagement LLL 60-14
Errorring buffer 60-15
Intermediate circuit 60-16
Insulation testing forelectrictrucks 60-17
Insulation testingonthedrivebattery 60-19
Componentinsulationtesting 60-20
Temperature monitoring for the traction motor-80V 60-22
Temperature monitoring for the traction motorconverter 60-24
Pump motor temperature monitoring LL 60-25
Temperature monitoring for the pump motorconverter 60-26
Available drivingbehaviour 60-28
Drive mode — driving behaviour Description 60-28
BlUe-Q=1Q 60-30
WING 60-32
CANDbus system 60-32
CANDbusconnections 60-34
Powercables LL 60-36
Maintenance guidelines forpowercables 60-37
Repair-Contactelements 60-37
CANDbus system 60-32
CANDbusconnections 60-34
Powercables LL 60-36
Maintenance guidelines forpowercables 60-37
Repair-Contactelements 60-37
Electrical system 60-39
Fusebox 60-39
FUSES 60-39
Contactor 60-40
Fusebox 60-39
FUSES 60-39
Contactor 60-40
Sensorsystem 60-42
Vertical liftmast position 60-42
Tiltanglesensor7B46 60-43
Tittangle sensorparameters 60-45
Vertical liftmast position 60-42
Tiltanglesensor7B46 60-43
Tittangle sensorparameters 60-45
Installation of the vertical lift mast position
Load measurement
Load measurement
Load measurement pressure Sensor LL
Additional electrical installation
7A21converterPCB
OptionBoard
CAN-Power-Port (CPP)
CPP1/CPP 3
7A21converterPCB
OptionBoard
CAN-Power-Port (CPP)
CPP1/CPP 3
CPP battery carrier (CPP5)
Relay-Power-Port
Relay-Power-Port
64 Electronic controllers
Traction and working hydraulics control
Main Control Unit(MCU)
MCUwithservohydraulics
MCUgeneration2 i
Main Control Unit (MCU) Removal and installation
SupplyUnit (SU)
Supply Unit (SU) Removal and installation
Main Control Unit(MCU)
MCUwithservohydraulics
MCUgeneration2 i
Main Control Unit (MCU) Removal and installation
SupplyUnit (SU)
Supply Unit (SU) Removal and installation
Inverters
Inverters
Converter LAC-80Volt
SACconverter—80Volt
Inverters
Converter LAC-80Volt
SACconverter—80Volt
Battery
2014 dischargeindicator LL
Dischargeindicator
Batteryplug
Maintenance guidelines for applianceplugs
Repair – Battery male connectorcontacts
Working withreducersleeves
2014 dischargeindicator LL
Dischargeindicator
Batteryplug
Maintenance guidelines for applianceplugs
Repair – Battery male connectorcontacts
Working withreducersleeves
70 Hydraulics
General 70- 1
Generaltechnicaldata 70- 1
Hydraulicoil 70- 3
Depressurising the hydraulics 70- 4
Litingoperatingspeeds LL 70- 6
Loweringoperatingspeeds LL 70- 7
Tiltingoperatingspeeds 70- 7
Generaltechnicaldata 70- 1
Hydraulicoil 70- 3
Depressurising the hydraulics 70- 4
Litingoperatingspeeds LL 70- 6
Loweringoperatingspeeds LL 70- 7
Tiltingoperatingspeeds 70- 7
Safetycheck 70- 9
Forward tiltsafetytest 70- 9
Lowering safetytest 70- 9
Safety checksofhoseassembly 70-10
Forward tiltsafetytest 70- 9
Lowering safetytest 70- 9
Safety checksofhoseassembly 70-10
Basichydraulics 70-11
Basichydraulics 70-11
Steering hydraulics 70-12
Working hydraulics 70-13
Hydraulictank 70-14
Returnlinefilter 70-14
Breatherfilter 70-16
Suction filter 70-17
Intake filter LL 70-18
High-pressurefilter 70-18
Conical nipple fittings (CNF) 70-19
Boltedjoint 70-19
Basichydraulics 70-11
Steering hydraulics 70-12
Working hydraulics 70-13
Hydraulictank 70-14
Returnlinefilter 70-14
Breatherfilter 70-16
Suction filter 70-17
Intake filter LL 70-18
High-pressurefilter 70-18
Conical nipple fittings (CNF) 70-19
Boltedjoint 70-19
71 Working hydraulics
Pumpunit 71-1
Generaltechnicaldata 71-1
Pumpunit 71-1
Electricalconnections 71-2
Pump motor withoutrevsensor i 71-3
Pump motortemperature sensor LL 71- 3
Pump motor Removal and installation 71- 5
Hydraulicpump 71- 6
Hydraulic pump Removal and installation 7-7
Generaltechnicaldata 71-1
Pumpunit 71-1
Electricalconnections 71-2
Pump motor withoutrevsensor i 71-3
Pump motortemperature sensor LL 71- 3
Pump motor Removal and installation 71- 5
Hydraulicpump 71- 6
Hydraulic pump Removal and installation 7-7
Tilteylinder 71-10
Masttilt 71-10
Masttilt 71-10
Tilt cylinder Removal and installation 71-11
Changing the set of seals2200-5000 kg-LSP500 71-12
Changing the set of seals 5000kg-LSP600 71-14
Auxiliary hydraulics 71-17
Attachments 71-17
Second operating function forattachments 71-20
Clamp locking mechanism with servo hydraulics 71-20
Clamp locking mechanism forhandlevers 71-22
Accumulator 71-24
Accumulator LL 71-24
Checkingtheaccumulator 71-25
76 Valves
Handlever 76- 1
Generaltechnicaldata 76- 1
Handlevervalveblock 76- 2
Emergencylowering LL 76- 3
Hydraulic transmitter 76- 4
Valve block Removal /installation 76- 6
Directional control valve block 76- 8
Check valve for hydraulics blocking function 76-10
Servohydraulics 76-11
Generaltechnicaldata 76-11
Servo hydraulics valve block 76-12
Manuallowering 76-13
Directional control valve block 76-14
Changing the set of seals2200-5000 kg-LSP500 71-12
Changing the set of seals 5000kg-LSP600 71-14
Auxiliary hydraulics 71-17
Attachments 71-17
Second operating function forattachments 71-20
Clamp locking mechanism with servo hydraulics 71-20
Clamp locking mechanism forhandlevers 71-22
Accumulator 71-24
Accumulator LL 71-24
Checkingtheaccumulator 71-25
76 Valves
Handlever 76- 1
Generaltechnicaldata 76- 1
Handlevervalveblock 76- 2
Emergencylowering LL 76- 3
Hydraulic transmitter 76- 4
Valve block Removal /installation 76- 6
Directional control valve block 76- 8
Check valve for hydraulics blocking function 76-10
Servohydraulics 76-11
Generaltechnicaldata 76-11
Servo hydraulics valve block 76-12
Manuallowering 76-13
Directional control valve block 76-14
81 Lift mast – 2500-3500
Liftmast 81- 1
Generaltechnicaldata 81- 1
Mast bearings, Carrarofor STILL liftmast 81- 2
Hose safety valve of triplexmast 81- 4
Supportroller play (108/117/130) 81- 7
Load chains – Checkingand cleaning 81- 8
Run-outbarrier 81- 9
Workingonliftmasts 81-11
Liftmast—removal 81-12
Liftmast—installation 81-13
Generaltechnicaldata 81- 1
Mast bearings, Carrarofor STILL liftmast 81- 2
Hose safety valve of triplexmast 81- 4
Supportroller play (108/117/130) 81- 7
Load chains – Checkingand cleaning 81- 8
Run-outbarrier 81- 9
Workingonliftmasts 81-11
Liftmast—removal 81-12
Liftmast—installation 81-13
Telescopicliftmast 81-16
Telescopic liftmast (108/117/130) 81-16
Adjusting the load chains Telescopic lit mast (108/117/130) 81-17
Telescopic liftmast (108/117/130) 81-16
Adjusting the load chains Telescopic lit mast (108/117/130) 81-17
NiHoliftmast 81-19
NiHolift mast (108/117/130) 81-19
Adjusting the load chains NiHo lift mast (108/117/130) 81-21
NiHolift mast (108/117/130) 81-19
Adjusting the load chains NiHo lift mast (108/117/130) 81-21
Triplemast 81-23
Triple lift mast (108/117/130) 81-23
Removing the supportrollersintheliftmast 81-25
Assembling the lift mast after replacing the supportrollers 81-28
Outerload chainsandchainrollers 81-30
Middle load chainand chainroller 81-32
Adjusting the outer load chains Triple lift mast (108/117/130) 81-34
Adjusting the middle load chain Triple lift mast (108/117/130) 81-35
Triple lift mast (108/117/130) 81-23
Removing the supportrollersintheliftmast 81-25
Assembling the lift mast after replacing the supportrollers 81-28
Outerload chainsandchainrollers 81-30
Middle load chainand chainroller 81-32
Adjusting the outer load chains Triple lift mast (108/117/130) 81-34
Adjusting the middle load chain Triple lift mast (108/117/130) 81-35
Lifteylinders 81-37
Liftjack 81-37
Workingonlifteylinders 81-38
Outercylinder 81-38
Disassembling/assembling the outercylinder 81-41
Centrecylinder 81-43
Disassembling/assembling the middle cylinder 81-45
End position damping ofoutercylinder 81-48
Middle cylinderenddampener LL 81-49
Liftjack 81-37
Workingonlifteylinders 81-38
Outercylinder 81-38
Disassembling/assembling the outercylinder 81-41
Centrecylinder 81-43
Disassembling/assembling the middle cylinder 81-45
End position damping ofoutercylinder 81-48
Middle cylinderenddampener LL 81-49
81 Lift mast – 4000-5000
Liftmast 81- 1
Generaltechnicaldata 81- 1
Carraro EC50and EC50Imastbearings 81- 1
Hose safety valve of triplexmast 81- 4
Supportrollerplay (150) 81- 7
Load chains – Checkingandcleaning 81- 8
Workingonliftmasts 81-10
Lit mast-Removal 81-11
Lit mast-Installation 81-12
Generaltechnicaldata 81- 1
Carraro EC50and EC50Imastbearings 81- 1
Hose safety valve of triplexmast 81- 4
Supportrollerplay (150) 81- 7
Load chains – Checkingandcleaning 81- 8
Workingonliftmasts 81-10
Lit mast-Removal 81-11
Lit mast-Installation 81-12
Telescopicliftmast 81-14
Telescopicliftmast (150) 81-14
Removing the supportrollersintheliftmast 81-15
Telescopicliftmast (150) 81-14
Removing the supportrollersintheliftmast 81-15
Assembling the lift mast after replacing the supportrollers 81-16
Adjusting the load chains Telescopiclitmast (150) 81-17
Triplemast 81-18
Triplemast (150) 81-18
Adjusting the outer load chains Triple mast (150) 81-19
Load chain adjustment midpoint Triplemast (150) 81-20
Lifteylinders 81-22
Liftjack oe 81-22
Working onliftcylinders 81-23
Outercylinder 81-24
Adjusting the load chains Telescopiclitmast (150) 81-17
Triplemast 81-18
Triplemast (150) 81-18
Adjusting the outer load chains Triple mast (150) 81-19
Load chain adjustment midpoint Triplemast (150) 81-20
Lifteylinders 81-22
Liftjack oe 81-22
Working onliftcylinders 81-23
Outercylinder 81-24
84 Load support
Fork carriage -2500-3500 84- 1
Forkecarriage 84- 1
Fork carriage -4000-5000 84- 3
Fork carriage – Removing in an upwards direction 84- 3
Fork carriage – Removing in adownwards direction 84- 4
Annex
Annex
X Diagrams
Hydraulics X- 2
Hydraulic circuit diagram Multi-levers lL X- 2
Hydraulic circuit diagram Servo hydraulics X- 4
Hydraulic circuit diagram Multi-levers lL X- 2
Hydraulic circuit diagram Servo hydraulics X- 4
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