Still STED forklift Electric trucks RX60-25 RX60-30 RX60-35 Workshop Manual – PDF DOWNLOAD
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Still STED forklift Electric trucks RX60-25 RX60-30 RX60-35 Workshop Manual – PDF DOWNLOAD
Description
Still STED forklift Electric trucks RX60-25 RX60-30 RX60-35 Workshop Manual – PDF DOWNLOAD
FILE DETAILS:
Still STED forklift Electric trucks RX60-25 RX60-30 RX60-35 Workshop Manual – PDF DOWNLOAD
Language : English
Pages : 392
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Still STED forklift Electric trucks RX60-25 RX60-30 RX60-35 Workshop Manual – PDF DOWNLOAD
Documentation
? Display elements – Display
? FleetManager?
? Batteries, lithium-ion technology
Special documentation
? Overview of truck software
? Overview of consumables
? STILL flasher
? FEM 4.004 test log book
? Service information documents
? See Steds-Navigator
Product overview – RX60 25-35
improved field of vision
Roof panels adhesively bonded
All external panelling components are made
of metal
?Drive components:
Powerful AE35-60 drive axle in Standard Performance
variant and High Performance variant
Air-cooled converter on the drive axle
TABLE OF CONTENTS:
Still STED forklift Electric trucks RX60-25 RX60-30 RX60-35 Workshop Manual – PDF DOWNLOAD
01 Truck information
Foreword
Product overview – RX60 2~35
Safety information
Parking the truck so it is secured for service work
Working with harnesses
Working on the electrical system
Emergency lowering
Depressurising the hydraulic circuits
Jacking up the truck, front
Jacking up the truck, rear
Securing the fork carriage
Restrictions and obligations
Speed limitation with a Tensor battery
Penalties for lithium-ion batteries
Operating materials 02
Measuring instruments and testing equipment 02
Tools for repair and cleaning 02
Testing equipment for safety inspections 02
Harnesses and hoists, 1.0 t to 3.5 t 02
Standardised tightening torques for standard-pitch threads and fine-pitch threads 02
Standardised tightening torques for hose fittings 02
Introduction to DiaMon 02
Diagnostics service box 02
Diagnostic set-up 02
Working with DiaMon 02
Error list via DiaMon 02
Error ring buffer 02
Reading out access codes 02
VIII 56378012001 EN – 01/2020
Table of contents
03 Test specifications
Maintenance 03
Maintenance instructions 03
Maintenance – 1000 hours/annually 03
Maintenance – 3000 hours/every two years 03
Safety check, electrics/electronics 03
Intermediate circuit 03
Insulation testing for electric trucks 03
Component insulation testing 03
Insulation testing on the drive battery 03
Li-ion battery, checking that the battery male connector is de-energised 03
Insulation testing the lithium-ion battery 03
Test specification for the Onboard charger (OBC) 03
Test procedure for OBC 03
Safety check, hydraulics 03
Operating speeds for lifting 03
Operating speeds for tilting 03
Operating speeds for lowering 03
Forward tilt safety test 03
Lowering safety test 03
Safety checks of hose assembly 03
21 Drive components
Traction motor 21
General technical data 21
Electrical connections 21
Drive unit 21
Rev sensor 21
Temperature sensor 21
Wheel gear 21
General technical data 21
Removing the wheel gear 21
Wheel gear – replacing the shaft seal 21
Fitting the wheel gear 21
56378012001 EN – 01/2020 IX
Table of contents
22 Axles
Mechanical drive axle 22
General technical data 22
AE35-60 drive axle 22
Traction motor – removing the rotor 22
Traction motor – Replacing the bearing and shaft seal 22
Traction motor – installing the rotor 22
Removing / installing the brake disc set 22
24 Steering systems
Hydraulic steering 24
General technical data 24
Steering system 24
Steering angle sensor 3B 1 24
Priority valve 24
Steering axle 24
General technical data 24
Swing axle 24
Steering angle sensor 3B02 24
Removing/installing the steering axle 24
Wheel hub – Replacing the bearings and sealing ring 24
Replacing the track rod, bearings and sealing ring 24
26 Brake system
Service brake 26
Structure of the brake system 26
Service brake 26
Actuating the service brake 26
Brake sensor 1 B2 26
Parking brake 26
eFSB parking brake 26
eFSB control unit 26
eFSB system description 26
Brake test 26
STILL
X 56378012001 EN – 01/2020
Table of contents
31 Chassis and bodywork
Counterweight 31
Counterweight 31
Ballast weight 31
Overhead guard 31
Overhead guard bearings 31
Repairing the roof panels 31
Battery door 31
Battery door 31
Pre-assembling the hinge and battery door 31
Adjusting the battery door 31
Battery door sensor 1 S27 31
Working with gas springs 31
41 Interior
Panelling and interior covers 41
Panels on the driver’s compartment 41
43 Operating units
Pedal groups 43
Accelerator pedal, generation 2 43
Dual pedal, generation 2 43
Operating devices 43
Drive direction selector and indicator module, generation 3 43
Working hydraulics controls 43
Hand lever 43
Joystick 4Plus 43
Mini-lever 2 43
Fingertip switch 43
44 Display elements
Display-operating unit 44
Display and operating unit ABE 3 44
Error lists via ABE 3 44
Parameters via ABE 3 44
Calibration via ABE 44
56378012001 EN – 01/2020 XI
Table of contents
61 Wiring
Standard 61
CAN bus system 61
CAN bus connections 61
Diagnostic connector X50 61
Earth wires in the truck 61
Power 61
Maintenance guidelines for power cables 61
62 Electrics/electronics components
Electrical system 62
General technical data 62
Overview of electrical components 62
Switch-on process for the electrical system 62
Transmitters and sensors 62
Sensor overview for lift mast functions 62
Lift mast functions with lift height sensor 6B32 62
Tilt angle sensor 7B46 62
Lift height switch 7B41 62
Lifting stage switch 7B43 62
Installation positions for the lifting stage switch 7B43 62
Pressure sensor for lifting 7B45 62
Differential pressure sensors for tilting 7B4 7 and 7B48 62
LED lift height sensor 6B32 62
Aligning the LED lift height sensor 62
Cooling system 62
Cooling system 62
Fans 62
Removing the air ducts and the fans 62
Installing the air ducts and the fans 62
64 Control units
Traction controller 64
Truck control unit MCU 3 64
Removing/installing the MCU 3 64
Power distributor POU (AS) 64
XII 56378012001 EN – 01/2020
Table of contents
Current sensor Mini-SU (A43) 64
Contactor 1 K 1 64
Converter 64
Converter 64
Converter SAC 2.0 64
SAC-TP converter 64
Removing/installing converters 64
Auxiliary control units 64
Fuse boxA21 64
Fuses 64
CAN distributor 64
Standard CPP 64
CPP 3 (seat) 64
Optionboard (AS) 64
65 Energy supply
Voltage transformer 65
Voltage converter 65
Battery male connector 65
Battery male connector for lead batteries and Li-Ion Ready 65
Battery male connector for lithium-ion batteries 65
Maintenance work for appliance plugs 65
Repair – Battery male connector contacts 65
Working with reducer sleeves 65
Lead acid battery 65
General technical data 65
Battery 65
Lithium-ion technology 65
Working on lithium-ion batteries 65
General technical data 65
Battery management system (BMS) 65
Diagnostic 65
Battery display 65
Battery discharge 65
Table of contents
Course of action for a deeply discharged battery 65
Removing/installing the battery cable 65
Battery charger 65
Onboard charger (OBC) in the truck 65
Onboard charger (A32) 65
Cooling fans 65
Fan controller 65
Charger socket in the truck 65
Wiring 65
Charging cable 65
66 Assistance system
Tilt-angle-dependent functions 66
Mast tilt angle display 66
Tilt end stop damping 66
Automatic mast vertical positioning 66
Load-dependent functions 66
Load measurement and load detection 66
Dynamic Load Control 1 66
Dynamic Load Control 2 66
Lift height-dependent functions 66
Speed reduction at a lift height of 500 mm 66
Lift height display via lift height sensor 6B32 66
Steering angle-dependent functions 66
Steering angle-dependent driving characteristics (CSC) 66
Special functions 66
Shake function 66
67 Embedded software
Truck software 67
Overview of the controllers 67
Software compatibility 67
Parameter management 67
68 Parameterising
Assistance systems 68
Tilt angle-dependent functions 68
Load-dependent functions 68
Dynamic Load Control 68
Hydraulics 68
Axle assignment of the operating devices 68
Input characteristic curves for the operating devices 68
Speed and dynamics of the operating devices 68
71 Basic hydraulics and working hydraulics
Pump-motor unit 71
General technical data 71
Electrical connections 71
Pump-motor unit 71
Pump motor 71
Removing/installing the pump motor 71
Temperature sensor 71
Hydraulic pump 71
General technical data 71
Hydraulic pump 71
Accumulator 71
Accumulator 71
Checking the accumulator 71
Hydraulic oil filter 71
General technical data 71
Return line filter with breather filter 71
Oil temperature sensor 2R17 71
Intake filter 71
High-pressure filter 71
Directional control valve, multi-lever 71
General technical data 71
Basic hydraulics, multi-lever 71
Directional control valve block, multi-lever 71
Removing/installing the valve block 71
56378012001 EN – 01/2020 XV
Table of contents
Directional control valve, servo hydraulics 71
General technical data 71
Basic hydraulics: Servo hydraulics 71
Servo hydraulics valve block 71
Removing/installing the valve block 71
Hydraulic oil 71
Draining the hydraulic oil 71
Changing the hydraulic oil 71
72 Cylinders
Lift cylinder 72
Lift jack 72
Working on lift cylinders 72
Removing / installing outer cylinders 72
Disassembling/assembling the outer cylinder 72
Middle cylinder 72
Disassembling/assembling the middle cylinder 72
End position damping, type B (bottom) 72
End position damping, type A (top) 72
Line break safety valve 72
Tilt cylinder 72
Mast tilt 72
Removing/installing the tilt cylinder 72
Changing the set of seals, 1400 … 2000 kg 72
80 Lifting system
Lift mast, general 80
General technical data 80
Working on lift masts 80
Run-out barrier 80
Removing the lift mast 80
Installing the lift mast 80
Telescopic lift mast 80
Telescopic lift mast (MaLiS Gen2) 80
Adjusting the load chains Telescopic lift mast (Malis Gen2) 80
Removing the support rollers in the lift mast 80
Assembling the lift mast after replacing the support rollers 80
Outer load chains and chain rollers 80
Table of contents
NiHo lift mast 80
NiHo lift mast (MaLIS Gen2) 80
Adjusting the load chains NiHo lift mast (MaLIS Gen2) 80
Triplex lift mast 80
Triple mast (Malis Gen2) 80
Adjusting the outer load chainsTriple mast (MaliS Gen2) 80
Adjusting the middle load chainTriple mast (MaliS Gen2) 80
Removing the support rollers 80
Assembling the lift mast after replacing the support rollers 80
Outer load chains and chain rollers 80
Middle load chain and chain roller 80
84 Lift mast assembly parts
Chains 84
Load chains – Checking and cleaning 84
Support rollers 84
Support roller play ( 108/117 /130) 84
Mast decoupling 84
MaliS Gen2 and AE35-60 lift mast bearings 84
86 Load support
Fork carriage 86
Removing and installing the fork carriage 86
Fork wear protection 86
Attachments integrated 86
Attachments 86
Operating lock for attachments in accordance with ISO 3691 86
Attachments
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