Still RX60-35 - Page 2

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Table of Contents5
Foreword15
Your Truck16
Description of the Truck16
General18
CE Labelling19
EC Declaration of Conformity in Accordance with Machinery Directive20
Accessories21
Labelling Points22
Nameplate24
Production Number24
Stvzo (Road Traffic Licensing Regulations) Information25
Nameplate of a Lithium-Ion Battery25
Using the Truck25
Commissioning25
Proper Usage26
Proper Use During Towing26
Impermissible Use27
Place of Use27
Parking in Temperatures below -10°C28
Using Working Platforms29
Information about the Documentation30
Documentation Scope30
Supplementary Documentation31
Issue Date and Topicality of the Operating Instructions32
Copyright and Trademark Rights32
Explanation of Information Symbols Used32
List of Abbreviations33
Definition of Directions35
Schematic Views35
Environmental Considerations37
Packaging37
Disposal of Components and Batteries37
Safety39
Definition of Responsible Persons40
Operating Company40
Specialist40
Drivers41
Basic Principles for Safe Operation43
Insurance Cover on Company Premises43
Special Features When Using Lithium-Ion Batteries (Variant)44
Changes and Retrofitting47
Changes to the Overhead Guard and Roof Loads49
Warning Regarding Non-Original Parts50
Damage, Defects and Misuse of Safety Systems50
Tyres51
Medical Equipment52
Exercise Caution When Handling Gas Springs and Accumulators53
Length of the Fork Arms53
Residual Risk55
Residual Dangers, Residual Risks55
Special Risks Associated with Using the Truck and Attachments56
Overview of Hazards and Countermeasures58
Danger to Employees61
Safety Tests62
Regular Safety Inspection of the Truck62
Insulation Testing62
Safety Regulations for Handling Consumables64
Permissible Consumables64
Oils64
Hydraulic Fluid65
Battery Acid66
Disposal of Consumables67
Emissions68
Overviews71
General View72
General View of Driver's Compartment74
Shelves and Cup Holders75
Operating Devices and Display Elements76
Display Operating Unit76
Lithium-Ion Battery Display77
Operating Devices for Hydraulic and Traction Functions78
Multi-Lever79
Double Mini-Lever80
Three-Way Mini-Lever81
Four-Way Mini-Lever82
Joystick 4Plus83
Fingertip84
Mini Console85
Operation87
Checks and Tasks before Daily Use88
Visual Inspections and Function Checking88
Climbing in and out of the Truck91
Adjusting the MSG 65/MSG 75 Driver's Seat92
Seat Belt96
Adjusting the Armrest99
Adjusting the Steering Column100
Unlocking the Emergency off Switch101
Operating the Signal Horn102
Driver's Cab103
Checking the Brake System for Correct Function104
Checking the Steering System for Correct Function107
Checking the Emergency off Function108
Checking the Vertical Lift Mast Position (Variant) for Correct Function109
Zero Adjustment of the Load Measurement (Variant)109
Switching on111
Switching on the Key Switch111
Access Authorisation with PIN Code (Variant)113
Display-Operating Unit123
Indicators123
Adjusting the Displays125
Symbols in the Display127
Setting the Date or Time132
Resetting the Daily Kilometres and Daily Operating Hours132
Setting the Language133
Softkeys for Operating Various Equipment Variants133
Blue-Q Efficiency Mode135
Functional Description135
Switching off Additional Consumers136
Switching Efficiency Mode Blue-Q on and off136
Configuring Blue-Q Efficiency Mode137
Driving139
Safety Regulations When Driving139
Roadways141
Setting the Drive Programme144
Selecting the Drive Direction145
Actuating the Drive Direction Switch, Multiple-Lever Version146
Actuating the Drive Direction Switch, Mini-Lever Version146
Actuating the Vertical Rocker Switch for the "Drive Direction", Joystick 4Plus Version147
Actuate the Drive Direction Switch, Fingertip Version147
Actuating the Drive Direction Switch, Mini-Console Version148
Starting Drive Mode148
Starting Drive Mode, Dual-Pedal Version (Variant)150
Operating the Service Brake153
Parking Brake154
Actuating the Mechanical Parking Brake154
Actuate the Electric Parking Brake156
Malfunctions in the Electric Parking Brake162
Steering169
Reducing Speed When Turning (Curve Speed Control)170
Reducing Speed with a Raised Load (Variant)171
Parking172
Parking the Truck Securely and Switching It off172
Wheel Chock (Variant)173
Lifting174
Lifting System Variants174
Types of Lift Mast174
Lifting System Operating Devices175
Multi-Lever Lifting System177
Controlling the Lifting System Using a Double Mini-Lever178
Controlling the Lifting System Using a Triple Mini-Lever179
Controlling the Lifting System Using a Quadruple Mini-Lever180
Controlling the Lifting System Using the Joystick 4Plus181
Controlling the Lifting System with the Fingertip Console183
Changing the Fork Arms184
Fork Extension (Variant)186
Operation with Reversible Fork Arms (Variant)188
Malfunctions During Lifting Mode189
Hydraulic Blocking Function190
Automatic Lift Cut out (Variant)191
Lift Mast Vertical Position (Variant)192
Handling Loads197
Safety Regulations When Handing Loads197
Before Taking up Load198
Load Measurement (Variant)199
Picking up Loads202
Danger Area203
Transporting Pallets204
Transporting Suspended Loads204
Load Pick up205
Transporting Loads209
Setting down Loads210
Driving on Ascending and Descending Gradients212
Driving on Lifts213
Driving on Loading Bridges214
Attachments215
Fitting Attachments215
Releasing the Pressure from the Hydraulic System217
General Instructions for Controlling Attachments221
Controlling Attachments Using Multi-Lever Operation223
Operating Attachments Using Multi-Lever Controls and the 5Th Function224
Controlling Attachments Using a Double Mini-Lever226
Controlling Attachments Using the Double Mini-Lever and the 5Th Function228
Controlling Attachments Using a Triple Mini-Lever230
Controlling Attachments Using the Triple Mini-Lever and the 5Th Function232
Controlling Attachments Using a Quadruple Mini-Lever234
Controlling Attachments Using the Quadruple Mini-Lever and the 5Th Function236
Controlling Attachments Using the Joystick 4Plus238
Controlling Attachments with Joystick 4Plus and the 5Th Function240
Controlling the Attachments with Fingertip242
Controlling Attachments with Fingertip and the 5Th Function243
Clamp Locking Mechanism (Variant)245
Taking up a Load Using Attachments249
Auxiliary Equipment250
Switching the Lighting on and off250
Switching the Working Spotlight for Reverse Travel on and off251
Switching the Rotating Beacon on and off251
Switching the Hazard Warning System on and off252
Switching the Turn Indicators on and off252
Switching the Double Working Spotlights on and off255
STILL Safetylight (Variant)257
Operating the Windscreen Wiper/Washer258
Filling the Washer System258
Fleetmanager (Variant)259
Shock Recognition (Variant)259
Driver Restraint Systems (Variants)259
Ceiling Sensor (Variant)260
Cab266
Opening the Cab Door266
Closing the Cab Door267
Opening the Side Windows267
Closing the Side Windows267
Operating the Interior Lighting268
Operating the Rear Window Heating269
Radio (Variant)269
Heating System (Variant)270
Push-Up Roof Window (Variant)272
Clipboard (Variant)273
Trailer Operation274
Towed Load274
Coupling Pin in the Counterweight275
Automatic Tow Coupling277
Towing Trailers285
Cold Store Application287
Display Messages290
Display Content290
Error Code Table290
General Messages295
Drive-Specific Messages304
Procedure in Emergencies308
Emergency Shutdown308
Procedure if Truck Tips over309
Emergency Hammer310
Emergency Lowering310
Emergency Operation of the Electric Parking Brake312
Towing313
Connecting and Disconnecting the Battery Male Connector316
Connecting the Battery Male Connector316
Disconnecting the Battery Male Connector317
Handling the Lead-Acid Battery318
Safety Regulations for Handling the Battery318
Maintaining the Battery321
Checking the Battery Condition, Acid Level and Acid Density323
Checking the Battery Charge Status324
Charging the Battery324
Charging the Battery with the Battery Charging Flap327
Equalising Charging to Preserve the Battery Capacity331
Handling the Lithium-Ion Battery334
Safety Regulations for Handling the Lithium-Ion Battery334
Lithium-Ion Batteries "GGS Li-Ion 80 V" 24.1 Kwh and 60 Kwh337
Display Messages on the Display-Operating Unit338
Regulations for Storing Lithium-Ion Batteries338
Checking the Battery Charge Status341
Charging the Battery344
Replacing and Transporting the Battery346
General Information on Replacing the Battery346
Changing to a Different Battery Type347
Converting to Lithium-Ion Batteries347
Opening/Closing the Battery Cover349
Special Notes for Installing the Lithium-Ion Battery352
Replacing the Battery Using Forklift Truck or Pallet Truck352
Replacing the Battery Using a Change Frame (Variant)355
Replacing the Battery with the Hydraulic Battery Carrier359
Transporting the Lead-Acid Battery by Crane367
Transporting the Lithium-Ion Battery by Crane368
Cleaning the Truck369
Cleaning the Electrical System371
Cleaning Load Chains371
Cleaning the Windows372
After Cleaning372
Transporting the Truck374
Transport374
Crane Loading376
Decommissioning380
Decommissioning and Storing the Truck380
Returning to Service after Decommissioning382
Maintenance385
Safety Regulations for Maintenance386
General Information386
Working on the Hydraulic Equipment386
Working on the Electrical Equipment386
Safety Devices387
Set Values387
Lifting and Jacking up387
Working at the Front of the Truck388
General Maintenance Information390
Personnel Qualifications390
Information for Carrying out Maintenance390
Maintenance - 1000 Hours/Annually393
Maintenance - 3000 Hours/Every Two Years397
Ordering Spare Parts and Wearing Parts397
Quality and Quantity of the Required Operating Materials397
Lubrication Plan398
Maintenance Data Table400
Providing Access to Maintenance Points403
Removing and Installing the Valve Cover403
Opening the Fuse Box403
Preserving Operational Readiness405
Lubricating the Joints and Controls405
Checking the Battery Interlock and Battery Cover405
Maintaining the Seat Belt407
Checking the Driver's Seat408
Maintaining Wheels and Tyres409
Servicing the Steering Axle411
Checking the Battery413
Checking the Fuses413
Replacing Fuses415
Checking the Hydraulic Oil Level417
Checking the Hydraulic System for Leak Tightness418
Lubricating the Lift Mast and Roller Track419
Greasing the Automatic Tow Coupling419
Preserving Operational Readiness for Cold Store Application422
Replacing the Heater Filter Mat422
1000-Hour Maintenance/Yearly Maintenance425
Other Tasks425
Checking the Cable Connections425
Checking the Hydraulic Oil Level of the Hydraulic Battery Carrier425
Lubricating the Slide Elements427
Oiling the Catch Rails427
Checking the Lift Cylinders and Connections for Leaks429
Checking Fork Arms430
Checking the Reversible Fork Arms430
Checking the Double Pedal431
Checking the Battery Changeover Frame431
Technical Data433
Dimensions434
VDI Datasheet for RX60-25 and RX60-25/600436
VDI Datasheet for RX60-25L and RX60-25L/600440
VDI Datasheet for RX60-30 and RX60-35444
VDI Datasheet for RX60-30L and RX60-30L/600448
Ergonomic Dimensions452
Information about the Lead-Acid Battery453
Information about the Lithium-Ion Battery455
Fuse Assignment456
Fuse Assignment Standard Equipment456
Fuse Assignment Equipment Variants457

Still RX60-35 - Page 2

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