Still STED forklift Electric trucks Incl. lithium-ion technology RX60-25 RX60-30 RX60-35 Workshop Manual  – PDF DOWNLOAD

Description

Still STED forklift Electric trucks Incl. lithium-ion technology RX60-25 RX60-30 RX60-35 Workshop Manual  – PDF DOWNLOAD

FILE DETAILS:

Still STED forklift Electric trucks Incl. lithium-ion technology RX60-25 RX60-30 RX60-35 Workshop Manual  – PDF DOWNLOAD

Language : English
Pages : 416
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Still STED forklift Electric trucks Incl. lithium-ion technology RX60-25 RX60-30 RX60-35 Workshop Manual  – PDF DOWNLOAD

Foreword
Product overview for the RX60 25-35

A “lithium-ion technology” variant of the RX60 series has been available since December 2017. The truck must be ordered with the “Li-Ion ready” setup pre-installed to ensure that the lithium- ion battery can communicate with the truck. The truck is converted from lead-acid battery operation to lithium-ion battery operation via parameterisation. A truck that does not have “Li-Ion ready” setup pre-installed can only be retrofitted for a very high price.

Advantages of lithium-ion technology:

• High efficiency of up to 95% (ratio of discharge current quantity/charging current quantity)
• The service life is two to three times longer than with conventional lead batteries
• High number of charging cycles (at least 2500)
• No negative effects caused by partial charging; no memory effect
• Short charging times (full charge in approx. 1.5 hours)
• Fast intermediate charging (60% only takes approx. 30 minutes)
• Battery replacement with replacement batteries is not necessary
• No additional maintenance costs

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Still STED forklift Electric trucks Incl. lithium-ion technology RX60-25 RX60-30 RX60-35 Workshop Manual  – PDF DOWNLOAD

00 Product information
Foreword
Product overview for the RX60 25-35
Safety information
Parking the truck so it is secured for service work
Working on the electrical system
Jacking up the front of the truck
Jacking up the rear of the truck
Securing the fork carriage
Restrictions and obligations
Penalties
Speed limitation with a Tensor battery
Speed limitation for legal use on public roads
Maintenance 01
Maintenance instructions 01
Maintenance – 1000 hours/annually 01
Maintenance – 3000 hours/every two years 01
Operating materials 01
Measuring instruments and testing equipment 01
Harnesses and hoists, 1.0 t to 3.5 t 01
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01
Standardised tightening torques for hose fittings 01
02 Diagnostics
Introduction to DiaMon
STEDS-Navigator
Diagnostics service box
Diagnostic set-up
Starting DiaMon
Working with DiaMon
Error list via DiaMon
Reading out access codes
Working using the ABE
Read error list
Clearing error lists
VIII 56338012001 EN – 04/2020
Table of contents
11 Electric motor
Traction motor 11
General technical data 11
Electrical connections 11
Traction drive 11
Traction motor 11
Sensors 11
Pin sensor 11
Temperature sensor PT1000 11
Temperature sensor KTY84 11
22 Mechanical drive axle
Drive axle EC35 22
General technical data Carrara EC 35 22
Drive axle 22
Drive axle without pump motor Removal and installation 22
Drive axle with pump motor Removal and installation 22
Wheel drive 22
Service brake 22
Removing/installing the service brake 22
Differential gearbox and brake 22
Removal of the differential gearbox and brake 22
Installation of the differential gearbox and brake 22
Basic setting of the brake system 22
Testing the brake system 22
30 Chassis, bodywork and fittings
Chassis 30
Working with gas springs 30
Battery door 30
Battery lock 30
Battery door sensor 30
Counterweight 30
Counterweight 30
Table of contents
42 Steering system
Hydraulic steering 42
General technical data 42
Steering system 42
Steering – error detection 42
Steering unit 42
Priority valve 42
Steering wheel and steering column 42
Steering column 42
Steering angle sensor 3B01 42
Steering angle-dependent handling performance – CSC 42
CSC – functional test 42
Steering axle 42
General technical data 42
Swing axle 42
Swing axle curve switch 42
Removing/installing the swing axle 42
Wheel hub 42
Steering angle 42
Tie rod 42
Axle stub 42
50 Operating devices
Accelerator pedal 50
Accelerator pedal, generation 2 50
Accelerator – single-pedal 50
Accelerator – dual pedal, generation 2 50
Brake actuation 50
Brake actuation 50
Brake sensor 50
Parking brake switch 1 S3 50
Changing the brake cable for the service brake 50
Brake cable change, handbrake 50
Actuating force of the handbrake 50
Electric parking brake 50
Electric parking brake 50
Function 50
X 56338012001 EN – 04/2020
Table of contents
Cause and effect 50
Design and system description 50
Maintenance instructions 50
Checking the brake 50
Calibration and functional test 50
Changing the parking brake cable 50
Limit position switch 50
Drive unit Installation and removal 50
Central lubrication device Installation and removal 50
Hydraulic actuation 50
Hand lever 50
Joystick 4Plus 50
Axle assignment – Joystick 4Plus 50
Generation 2 mini-lever 50
Axle assignment – the mini-lever 50
Tip switch 50
Axle assignment – fingertip switch 50
56 Display elements
Operating console 56
Turn indicator module for the drive direction, generation 2 56
Display 56
Display and operating unit, generation 2 (ABE 2) 56
ABE 2 Installation and removal 56
60 Electrics/electronics
General 60
General technical data 60
Overview of the controllers 60
Electrical system 60
Electrical components 60
Switch-on process for the electrical system 60
Software compatibility 60
PAN process 60
Parameter management 60
Error ring buffer 60
Temperature monitoring for the traction motor- 80 V 60
Temperature monitoring for the traction motor converter 60
56338012001 EN – 04/2020 XI
Table of contents
Pump motor temperature monitoring
Temperature monitoring for the pump motor converter
Available driving behaviour
Revolution-controlled vs. torque-regulated
Blue-Q = IQ
Starting current boost
Stopping on a slope
Electrical checks
Intermediate circuit
Insulation testing for electric trucks
Insulation testing on the drive battery
Insulation testing the lithium-ion battery
Component insulation testing
Wiring
CAN bus system
CAN bus connections
Power cables
Maintenance guidelines for power cables
Repair – Contact elements
Electrical system
Fuse box
Fuses
Contactor
Sensor system
Vertical lift mast position
Tilt angle sensor 7B46
Load measurement
Load measurement pressure sensor
Additional electrical installation
7A21 converter PCB
Option Board
CAN-Power-Port (CPP)
CPP 1/CPP 3
CPP2B
CPP battery carrier (CPP5)
Relay-Power-Port
XII 56338012001 EN – 04/2020
Table of contents
64 Electronic controls
Truck control unit 64
Main Control Unit (MCU 2) 64
Main Control Unit (MCU) Removal and installation 64
Supply Unit (SU 2) 64
Supply Unit (SU) Removal and installation 64
Converter 64
Inverters 64
SAC converter – 80 Volt 64
Inverters Removal and installation 64
69 Batteries and accessories
Battery male connector 69
Battery plug 69
Battery male connector for lithium-ion batteries 69
Maintenance work for appliance plugs 69
Repair – Battery male connector contacts 69
Working with reducer sleeves 69
Lead acid battery 69
General technical data 69
Battery 69
2014 discharge indicator 69
Lithium-ion technology 69
Working on lithium-ion batteries 69
General technical data 69
Battery management system (BMS) 69
Diagnostic 69
Battery display 69
Battery discharge indicator for a lithium-ion battery 69
Battery charge 69
Battery discharge 69
Course of action for a deeply discharged battery 69
Checking that the battery male connector is de-energised 69
Removing/installing the battery cable 69
Converting from a lead-acid battery to a lithium-ion battery 69
56338012001 EN – 04/2020 XIII
Table of contents
70 Hydraulics
General 70
General technical data 70
Hydraulic oil 70
Depressurising the hydraulics 70
Lifting operating speeds 70
Lowering operating speeds 70
Tilting operating speeds 70
Safety check 70
Forward tilt safety test 70
Lowering safety test 70
Safety checks of hose assembly 70
Basic hydraulics 70
Basic hydraulics 70
Steering hydraulics 70
Working hydraulics 70
Hydraulic tank 70
Hydraulic oil 70
Return line filter 70
Breather filter 70
Intake filter 70
High-pressure filter 70
Conical nipple fittings (CNF) 70
Bolted joint 70
71 Working hydraulics
Pump-motor unit 71
General technical data 71
Pump unit 71
Electrical connections 71
Temperature sensor pump motor 71
Pump motor Removal and installation 71
Hydraulic pump 71
Hydraulic pump Removal and installation 71
XIV 56338012001 EN – 04/2020
Table of contents
Tilt cylinder 71
Mast tilt 71
Tilt cylinder Removal and installation 71
Changing the set of seals, 2000-5000 kg 71
Auxiliary hydraulics 71
Attachments 71
Second operating function for attachments 71
Clamp locking mechanism with servo hydraulics 71
Clamp locking mechanism for hand levers 71
Accumulator 71
Accumulator 71
Checking the accumulator 71
76 Valves
Hand lever 76
General technical data 76
Hand lever valve block 76
Emergency lowering 76
Hydraulic transmitter 76
Valve block Removal / installation 76
Directional control valve block 76
Check valve for hydraulics blocking function 76
Servo hydraulics 76
General technical data 76
Servo hydraulics valve block 76
Manual lowering 76
Directional control valve block 76
80 Load lift system
Lift mast bearing 80
Carraro Malis mast bearing 80
81 Malis lift mast
Lift mast 81
General technical data 81
Hose safety valve of triplex mast 81
Support roller play ( 108/117 /130) 81
Load chains – Checking and cleaning 81
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Table of contents
Run-out barrier 81
Working on lift masts 81
Lift mast – Removal 81
Lift mast – Installation 81
Telescopic lift mast 81
Telescopic lift mast (130 MaLiS) 81
Adjusting the load chains Telescopic lift mast (130 MaLiS) 81
Removing the support rollers in the lift mast 81
Assembling the lift mast after replacing the support rollers 81
Outer load chains and chain rollers 81
NiHo lift mast 81
NiHo lift mast (130 MaLiS) 81
Adjusting the load chains NiHo lift mast (130 MaLiS) 81
Triplex lift mast 81
Triple lift mast (130 MaLiS) 81
Adjusting the outer load chains Triple lift mast (130 MaLiS) 81
Adjusting the middle load chain Triple lift mast (130 MaLiS) 81
Removing the support rollers 81
Assembling the lift mast after replacing the support rollers 81
Outer load chains and chain rollers 81
Middle load chain and chain roller 81
Lift cylinder 81
Lift jack 81
Working on lift cylinders 81
Removing and installing the outer cylinders 81
Disassembling/assembling the outer cylinder 81
Middle cylinder 81
Disassembling/assembling the middle cylinder 81
End position damping, type B (bottom) 81
End position damping, type A (top) 81
84 Load support
Fork carriage 84
Removing and installing the fork carriage 84
Fork wear protection 84
XVI 56338012001 EN – 04/2020
Annex
X Circuit diagrams
Hydraulics
Hydraulic circuit diagram Multi-levers
Hydraulic circuit diagram Servo hydraulics

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