Still STED forklift Electric trucks incl. lithium-ion technology RX60-35 RX60-35 600 RX60-40 RX60-40 600 RX60-50 RX60-50 600 Workshop Manual – PDF DOWNLOAD

Description

Still STED forklift Electric trucks incl. lithium-ion technology RX60-35 RX60-35 600 RX60-40 RX60-40 600 RX60-50 RX60-50 600 Workshop Manual – PDF DOWNLOAD

FILE DETAILS:

Still STED forklift Electric trucks incl. lithium-ion technology RX60-35 RX60-35 600 RX60-40 RX60-40 600 RX60-50 RX60-50 600 Workshop Manual – PDF DOWNLOAD

Language : English
Pages : 394
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Still STED forklift Electric trucks incl. lithium-ion technology RX60-35 RX60-35 600 RX60-40 RX60-40 600 RX60-50 RX60-50 600 Workshop Manual – PDF DOWNLOAD

Documentation

Special documentation

Foreword
Product overview for the RX60 40-50

A “lithium-ion technology” variant of the RX60-40-50 series has been available since 2018. 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. The “Li-Ion ready” setup can be retrofitted in trucks that do not have it pre-installed.

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 RX60-35 RX60-35 600 RX60-40 RX60-40 600 RX60-50 RX60-50 600 Workshop Manual – PDF DOWNLOAD

00 Product information
Foreword
Product overview for the RX60 40-50
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
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
EC35-EC50 drive axle 22
General technical data Carrara EC 50 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
General technical data – Type carrier 6330 42
Swing axle 42
Swing axle, reinforced for LP600 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
Table of contents
Electric parking brake 50
Electric parking brake 50
Function 50
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
Direction indicator module (Fabli) 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 6326 – 6330 60
Overview of the controllers 60
Electrical system 60
Electrical components 60
Switching on procedure for the electrical system 60
Software compatibility 60
Table of contents
Parameter management
Error ring buffer
Temperature monitoring for the traction motor – 80 V
Temperature monitoring for the traction motor converter
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
Component insulation testing
Checking that the battery male connector is de-energised
Insulation testing the lithium-ion battery
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
Table of contents
CPP 1/CPP 3 60
CPP2B 60
CPP battery carrier (CPP5) 60
Relay-Power-Port 60
64 Electronic controls
Truck control unit 64
MCU generation 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
Table of contents
Removing/installing the battery cable 69
Converting from a lead-acid battery to a lithium-ion battery 69
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 56348012001 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
Changing the set of seals 5000 kg – LSP 600 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 EC50 and EC50I mast bearings 80
81 Lift mast
Lift mast 81
General technical data 81
Hose safety valve of triplex mast 81
Support roller play (150) 81
56348012001 EN – 04/2020 XV
Table of contents
Load chains – Checking and cleaning
Working on lift masts
Lift mast – Removal
Lift mast – Installation
Telescopic lift mast
Telescopic lift mast (150)
Removing the support rollers in the lift mast
Assembling the lift mast after replacing the support rollers
Adjusting the load chains Telescopic lift mast (150)
Triplex lift mast
Triple mast (150)
Adjusting the outer load chains Triple mast (150)
Load chain adjustment midpoint Triple mast (150)
Lift cylinder
Lift jack
Working on lift cylinders
Outer cylinder
84 Load support
Fork carriage
Fork carriage – Removing in an upwards direction
Fork carriage – Removing in a downwards direction
Annex
X Circuit diagrams
Hydraulics
Hydraulic circuit diagram Multi-levers
Hydraulic circuit diagram Servo hydraulics

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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