PDF Workshop Manual STILL RX60-60 RX60-70 RX60-80 Electric forklift - 2 MB
The complete workshop manual for the STILL STED Electric forklift truck series, including models RX60-60, RX60-70, and RX60-80.
This comprehensive guide contains all the technical data, repair procedures, and schematics needed for service and maintenance.
It is the definitive resource for qualified technicians to perform in-depth repairs and keep these powerful electric forklifts running efficiently.
This manual is essential for any professional workshop.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 3 ---
............................................ - 5
...................................................... - 6
...................................................... - 6
...................................................... - 7
............................................... - 7
........................................................ - 8
........................................... - 9
........................................................ - 11
..................................................... - 13
.......................................................... - 14
......................................................... - 15
........................................... - 1
............................................... - 1
............................................... - 2
....................................................... - 4
......................................... - 5
........................................... - 1
...... .................................... .......... - 1
............................................ - 1
...................................................... - 3
............................................. - 4
........................................ - 5
........................................... - 8
.................................... - 11
................................................ . - 15
..................................................... - 15
....................................... - 16
.............................................. - 18
........................................ - 20
........................................................ - 22
....................................... - 23
56358012001 EN - 02/2017 IX
--- Page 4 ---
Releasing the tension from a at spiral spring suddenly
can damage the spring.
Only release the tension of the at spiral spring using
tensioning device 0009419010.
If a spring breaks, do not open the spring assembly.
Position the spring cover sheet on the spring cas-
sette. Weld together using permanent welded
seams all the way round.
Oil must not be allowed to penetrate the sewage
system or the ground. Dispose of the spring assembly.
56358012001 EN - 02/2017 -5
--- Page 5 ---
a
Maintenance work must be carried out in accor-
dance with the following maintenance intervals.
The intervals are designed for standard use.
Depending on the application conditions of the
truck, shorter maintenance intervals can be set,
on agreement with the operating company.
These factors may call for shorter maintenance
intervals:
Contaminated, poor quality roads
Dusty or salty air
High air humidity
Extremely high or low ambient temperatures,
or extreme changes in temperature
Multi-shift operation with a high duty cycle
Speci c national regulations for the truck or
individual components
For maintenance tasks, only use original spare
parts, and only use consumables that have been
prescribed in the overview of consumables.
56358012001 EN - 02/2017 -1
--- Page 6 ---
Slotted nut spanner
Use Planetary transmission
Part number 399 900 7079
Claw extractor
2 washers 12.4 x 24 x 2
2 washers 8.4 x 24 x 2
2 M8 hexagon nuts
Torque wrench up to 400 Nm
Locking ring pliers
Press-in device
Torque multiplier
Hotplate
Tension belt; width 80 mm, length at least 2 m
Tool kit - 0009418102
(1
Release tool
)
(2
Hexagon nut
)
(3
Locking pin
)
(4
Test gauge
)
Tensioning device, 1 set - 0009419010
56358012001 EN - 02/2017 -11
--- Page 7 ---
Switch on the truck and wait until the standard
screen appears in the display.
Press buttons 6 and 7 simultaneously.
The display will change to the password
screen. Enter the password for the service
level and con rm by pressing button 9 .
Determine the unique password; see the
chapter entitled "Reading out access codes".
Once the password has been successfully
entered, the display will switch to the CON-
FIGURATION menu.
Press button 6 or 7 until ERROR LIST is
displayed in a framed eld. Con rm the entry
by pressing button 9 .
The display changes to the ERROR LIST
MODE menu.
Press button 6 or 7 until SERVICE is dis-
played in a framed eld. Con rm the entry by
pressing button 9 .
The display changes to the ERROR LIST
menu.
Selection of the relevant controller. For device IDs, see the chapter entitled "Overview
A .... Z, a ... z
of controllers"
* Errors for all controllers are displayed.
1 The active errors are displayed
2 All errors that have occurred since the last error reset are displayed
3 All stored errors are displayed
.
The framed eld DEVICE is activated. Use
button 6 or 7 to make the selection and
con rm by pressing button 9 .
The framed eld TYPE is activated. Make a
selection and con rm in this eld too.
The START display is activated. Press button
9 to start generating the error list.
56358012001 EN - 02/2017 -7
--- Page 8 ---
Each traction motor is monitored by a tempera-
ture sensor.
The temperature sensors (2) are embedded in
the motor stator windings. The connection lines
of the temperature sensors are connected to the
terminal board of the motor via the connector plug
(1).
The signals are evaluated in the respective
converter.
Type KTY 84-130
Power supply Approx. 1.7 mA
Observe the polarity of the temperature sensors
when installing and testing them. Reverse pola-
rity causes erroneous measured values at higher
temperatures.
Red X13/1 X152/12 Positive Temp-MCT+
Blue X13/2 X152/14 Negative Temp-MCT- Black cathode ring
Red X11/1 X151/12 Positive Temp-MCT+
Blue X11/2 X151/14 Negative Temp-MCT- Black cathode ring
.
Improperly conducted insulation testing can destroy
the temperature sensor.
Before insulation testing, the temperature sensor must
be bridged at its connections.
The resistance of the temperature sensor in-
creases as the temperature of the stator winding
increases. The resistance value can be checked
at the two connections of the temperature sensor.
Disconnect the connector plug at the terminal
board.
Connect a multimeter to the pins on the plug.
The negative potential of the multimeter must
56358012001 EN - 02/2017 -7
--- Page 9 ---
Unscrew the M6 x 12 socket head screws
from the speed sensor and pull out the speed
sensor.
Unscrew the two M8 x 20 socket head screws
from the bearing shield.
Place puller device on the
bearing shield and secure the puller device
to the motor housing using two M16 x 110
socket head screws.
Screw tensioning screws with
the nuts and the washers into the extraction
bores on the bearing shield.
Tighten the nuts on the tensioning screws.
Release the bearing shield with the rotor and
carefully pull out the bearing shield.
Remove the puller device.
The rotor is heavy.
During removal, put a support below the rotor or use a
dismantling device.
Do not damage the stator winding during removal.
Take the rotor straight out of the motor housing.
56358012001 EN - 02/2017 -9
--- Page 10 ---
The counterweight is a solid cast component that
differs in design according to the type carrier,
depending on the load-bearing capacity, chassis
and steering axle.
The counterweight is attached to the chassis us-
ing mounting screws. The number, arrangement
and tightening torques of the mounting screws
can vary; refer to the table below.
Hexagon head screw
M24 x 90-10.9-ISO 4017
6341-6344 15 930 Nm
Spring washer
24, DIN 6796
.
56358012001 EN - 02/2017 -3
--- Page 11 ---
Steering angle sensor 3B1 is tted to the steering
axle and records the current steering angle. This
information controls the speed and the torque
behaviour of both drive sides when cornering.
The number of revolutions of the traction motor
on the inside of curve is reduced according to the
steering lock.
Behaviour when a steering lock is greater than 70
degrees:
1 Curve sensor
The traction motor on the inside of the curve
2 Cable guide
rotates in a forward direction; however it does
so only very slowly.
For safety reasons, the steering angle sensor has
two output signals (guide signal and reference
signal). The steering angle sensor is connected
to the truck control unit via a 4-pin plug.
The sensor disc is in an axial and twistproof
position on the steering pivot pin. The steering
angle sensor is screwed onto the steering axle by
means of a cover.
In the event of incorrect signals, the power sup-
ply, the connector plug and the line connection
must be checked. It is possible to check the two
output signal frequencies using an appropriate
multimeter.
3B02/1 5-V supply X104/1 X44/14
3B02/2 Signal 2 (left-hand steering) X104/2 X44/10
3B02/3 Signal 1 (right-hand steering) X104/3 X44/27
3B02/4 GND analogue X104/4 X44/42
.
The two output signals from the steering angle
sensor operate in opposite directions. They have
a constant frequency of:
Guide signal 280 Hz (signal A)
Reference signal 200 Hz (signal B)
Depending on the position of the steering axle,
the time for which the output signals are switched
on varies from 10% to 90%.
The truck control unit constantly monitors all
signals and generates error messages in the
event of incorrect or implausible values.
56358012001 EN - 02/2017 -9
--- Page 12 ---
tappet via a brake cable pull and a de ection
lever. The brake valve can be operated manually
by actuating the hand pump (7).
The valve block (3) contains an accumulator
charging section that provides the pressure for
the brake section and for the internal pilot control
of the valve. The diaphragm accumulator (5) acts
as an energy storage system that supplies the
required volume ow rate for releasing the brake.
Two pressure sensors (4) continuously monitor
the pressure values.
The left-hand pump motor with its ange-
mounted hydraulic pump (2) supplies the brake
section with the required hydraulic oil.
The spring-operated brakes are tted with com-
pression springs (4) that apply force to the pistons
(3) when depressurised. The brake discs (1) are
actuated as a result. The brake is applied.
When the truck is switched on and the parking
brake is not actuated, the available system
pressure acts on the pistons. As a result, the
compression springs are compressed suf ciently
to free up the brake discs. The brake is released.
The latches of the parking brake in the end po-
sitions de ne the two statuses "brake released"
(0% braking torque) and "brake applied" (100%
braking torque).
Actuating the service brake activates the brake
valve. Depending on the travel of the tappet 1 Brake discs
rod, the pressure in the braking system either 2 Cylinder chamber
increases or decreases. The system pressure 3 Piston
decreases in line with the actuation distance and 4 Compression springs
the force exerted by the compression springs
increases as the pressure falls. It is therefore
possible for the braking characteristics of the
truck to be regulated in a controlled manner using
the brake pedal.
56358012001 EN - 02/2017 -3
--- Page 13 ---
Supply voltage X16/4 - X16/8 11.05 - 12.05 The sensor is adjusted for
C1 accelerator not actuated X16/4 - X16/3 5.5 - 6.5 the accelerator pedal by the
C2 accelerator not actuated X16/4 - X16/2 5.5 - 6.5 manufacturer. It is not possible
to perform a subsequent
C1 accelerator fully actuated X16/4 - X16/3 8.2 - 11.0
adjustment.
C2 accelerator fully actuated X16/4 - X16/2 1.0 - 3.8 In the event of a fault, the entire
GND breakdown detection 11.5 accelerator pedal must be
VCC breakdown detection 0.5 replaced.
.
The difference in voltage between the transmit-
ter's inactive position (N) and maximum actuation
(max) is referred to as the potentiometer voltage
increase.
At maximum actuation, the voltage must be at
least and up to a maximum of higher
than in the neutral position (N).
Voltage increase too small The maximum speed is not reached
No problem for the evaluation
The maximum speed is reached but not exceeded.
Voltage increase too large
The end range of the voltage increase is ignored by the
controller (dead travel)
Voltage increase signi cantly too large Detection of breakdown with corresponding error message
.
56358012001 EN - 02/2017 -7
--- Page 14 ---
Lower
Lift
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
Tilt backward
Tilt forward
Tilt forward
Tilt backward
Lift
Lower
Auxiliary hydraulics 1
Auxiliary hydraulics 1
Auxiliary hydraulics 2
Auxiliary hydraulics 2
.
56358012001 EN - 02/2017 -17
--- Page 15 ---
For retro tting, it may be necessary to change
the truck central control MCU/TCU; see Electrical
Connections
The direction of travel asher module is con-
nected to the truck central control MCU/TCU via
the 4-pin CAN bus plug X45.
Since June 2007, the plug X45 has no longer
formed part of standard equipment for the truck
central control MCU/TCU.
X45/1 CAN r H
X45/2 CAN r L
X45/3 - CAN supply
X45/4 GND F
Park the vehicle safely.
Disconnect the battery plug with electric forklift
trucks
Remove the steering wheel
Remove the console from the housing
Unscrew the size 8 TORQUE screw (3)
Unscrew the two cross-recessed screws (1)
and (2)
Disconnect plug X45
Remove the console from the steering column
Connect plug X45
Connect the console to the housing
Tightly screw in the two cross-recessed
screws (1) and (2)
Tightly screw in the size 8 TORQUE screw (3)
Attach the steering wheel
Connect the battery plug in electric fork lift
trucks.
Perform an operational test.
56358012001 EN - 02/2017 -3
--- Page 16 ---
For hand lever only
2.-5. Hydraulic sensor
Variant
6. Mast vertical
.
A deactivated PAN process can lead to unde ned
faults in the truck.
The PAN process must always be activated.
In the truck, the PAN process ensures that the
truck control unit (MCU / TCU) always operates
all available controllers in the truck according to
the current parameters.
Each time the truck is started, the PAN process
ensures that the checksums of the individual
controllers are compared with the checksums
saved in the truck control unit (MCU / TCU).
In the event of parameter changes, software
changes or changes of individual controllers,
the PAN process ensures that the relevant
controllers and the truck control unit (MCU / TCU)
process the changes correctly.
It is essential that the PAN process always
remains activated, otherwise the necessary
checksum comparisons and adjustments cannot
be carried out.
Error pro le generated when a PAN process is
not being performed correctly:
After switching on, the display of the display
operating unit remains frozen on the welcome
screen.
Please wait appears in the display during
operation
The current status of the PAN process can be
checked via the truck diagnostics.
F4: Monitoring
Status
Status PAN
.
56358012001 EN - 02/2017 -5
--- Page 17 ---
Boosting the starting current increases the start-
ing torque from stationary.
The starting current boost is activated by means
of parameterisation. The driving behaviour
always applies for all drive programs and cannot
be changed by the driver.
The current boost is active at every start-up for a
maximum of 3 seconds, as long as the truck does
not move.
The "Stopping on a slope" driving behaviour is
switched on as standard. The driving behaviour
is set once and applies to all drive programs.
Effects that occur only when the driver is sitting
and the seat contact switch is actuated:
Function switched on
The driver is sitting on the seat, the truck
is positioned on the slope and does not roll
downhill.
Function switched off
The driver is sitting on the seat, the truck
is positioned on the slope and rolls slowly
downhill at a regulated speed of 1 cm/sec.
The truck remains in position on the slope if the
drive direction is neutral and the driver gently
actuates the accelerator.
56358012001 EN - 02/2017 -15
--- Page 19 ---
A CAN bus (Controller Area Network) is a "linear
network" that comprises multiple participants
based on microcontrollers. Due to the signal level
technology used and the special structure of the
data telegram, the CAN bus system is extremely
resistant to interference at high transfer speeds.
Depending on the truck, there are several discon-
nected CAN bus systems that are used to transfer
data between the controllers.
In CAN bus systems, re ections at the ends of the
wires can cause errors in the signal transmission.
Resistors are placed in the wires to dampen these
re ections. This is called "termination".
Depending on the truck and the installed CAN bus
participants, these resistors are used in different
ways.
Terminating resistors of approx. 120 de ne
the start point and end point of the CAN
bus. In between the start and end points are
additional, high-ohmic CAN bus participants,
usually decoupled with a resistor of approx.
40 k .
Terminating resistors can be tested when the
truck is switched off.
In newer truck generations, resistors of vary-
ing size are placed in one of the CAN bus
participants (such as the truck control unit) via
software. These resistors terminate the CAN
bus as required.
It is not possible to test these resistors, as they
are deactivated via the software when the truck
is switched off.
The signals used are "difference signals". The
difference is measured between the "CAN_L"
and "CAN_H" signals.
If both signals are at an idle level of 2.5 V, there
is no "difference signal". A '"0 information"' is
transmitted.
If the "CAN_H" signal is increased to 3.5 V and
the "CAN_L" signal is simultaneously dropped to
1.5 V, a "difference signal " of 2 V is produced. A
'"1 information"' is transmitted.
56358012001 EN - 02/2017 -25
--- Page 20 ---
Fuse box A22 is a modular unit and includes the
following components:
Plug for the 12-volt supply for the additional
electrical installations
Fuses
Relay
The relay cannot be replaced separately
X166 6-pin Control cables MCU
A1 +12 V to CPP 1
A2 +12 V to CPP 3
X162
B1 +12 V to option board A22
B2 +12 V to CPP 2
A1 +12 V to U2-OUT (voltage transformer)
A2 +12 V to U4-OUT (voltage transformer)
X167
B1 +12 V to U3-OUT (voltage transformer)
B2 +12 V to U5-OUT (voltage transformer)
A1 +12 V to U1-OUT (voltage transformer)
A2 GND
X171
B1 Fan 9M6/1
B2 Cooling water pump 9M17/2
1 +12 V socket
X172
2 Unassigned
1 +12 V to servo hydraulics to MCU-X48/14
X174
2 Unassigned
1F16 10 A Servo hydraulics (joystick)
1F10 10 A Cooling water pump 9M17
4F01 10 A Signal horn 4H1
9F03 10 A Option board
9F32 15 A +12 V socket
9F33 15 A Unassigned
9F34 20 A Fan 9M6
5F12 20 A CPP 2 (front)
5F11 30 A CPP 1 (roof)
5F13 30 A CPP 3 (seat)
4K01 Must not Signal horn 4H1
9K17 be replaced Fan 9M6
9K38 individually Cooling water pump 9M17
.
56358012001 EN - 02/2017 -35
--- Page 21 ---
All silicate-free coolant additives can be mixed cooling system must therefore always be kept
together without a problem. topped up with coolant additives throughout
Qualities G 30, G 30 +, G 33 and G 34 are all the year.
silicate-free Particularly in tropical countries, the coolant
increases operational safety by increasing the
Note that the different colours of the coolant
boiling point in heavily loaded engines.
additives can create an unde ned mixed colour.
This makes it dif cult to identify the coolant Frost protection must be ensured down to
additive easily. This can cause problems with around -25 °C (in countries with an Arctic
the manufacturer in the event of a warranty claim. climate, down to around -35 °C).
In hot countries or even during warm seasons,
It is recommended that you always use the same
the coolant concentration must not be reduced
coolant quality as found in the cooling system. It
by adding water. The percentage of coolant
is also recommended that you continue to use the
additive must always be at least 40%.
same quality that has been used in the cooling
system for a long time, even after a complete If greater frost protection is required for
re ll. climatic reasons, the percentage of coolant
additive can be increased to up to 60% (frost
protection down to around -40°C). At a higher
concentration, the frost protection and cooling
effect are reduced.
Coolant additives prevent freezing, corrosion- Dispose of the used coolant in an environmen-
related damage and limescale deposits. They tally friendly manner. It must not be re-used.
also increase the boiling temperature. The
56358012001 EN - 02/2017 -45
--- Page 22 ---
Manufacturer STILL
Voltage 80 V
Rated current 400 A
Code letter
Cooling Water-cooled
.
Batt (GND-L)
+ U-Batt after main contactor
U Field connection to motor
V Field connection to motor
W Field connection to motor
X150 2U04 to 2M02, left-hand pump motor
X151 1U06 to 1M01, right-hand traction motor
X152 1U07 to 1M02, left-hand traction motor
X153 2U03 to 2M01, right-hand pump motor
Pin 1 Speed sensor, GND-L
Pin 2 GND-F from SU
Pin 3 Speed sensor signal, phase 1
Pin 4 CAN H connected to SU
Pin 5 Speed sensor signal, phase 2
Pin 6 CAN L connected to SU
Pin 7 Speed sensor, 10 V
Pin 8 24 V from SU
Pin 9 Monitoring U
Pin 10 Enable signal from SU
Pin 11 Monitoring V
Pin 12 + temperature sensor for motor
Pin 13 Monitoring W
Pin 14 temperature sensor for motor
.
56358012001 EN - 02/2017 -9
--- Page 23 ---
1 640-A truck harness 1
2 640-A battery harness 1
3 Bracket for latching the battery door when open 1
4 Support for securing the cable to the chassis 1
5 Support for routing the cable around the corner of the chassis 1
6 Cable guide on the housing for the contactor stand (PDU) 1
7 Support for stop with rubber buffer 1
8 Charger adapter for the battery harness 1
1, 3 Socket head screw, M8x45-912-8.8 4
1, 3 Washer, M8-9021-A2S 4
1, 3 Polystop nut, M8 4
7 Hexagon head screw, M6x20-933-8.8 2
7 Washer, M6-6796-A2S 2
Cable tie 10
.
To perform the conversion, the battery must be
removed from the truck. A second truck with
a suf cient load capacity is necessary for this
purpose.
Assistance from a second person is helpful when
installing the truck harness because the 120-mm2
cables are very heavy and awkward.
Park the truck securely.
Lower the lift mast. Tilt the lift mast forwards.
Disconnect the battery male connector.
Remove the battery using a second truck.
Remove the upper panelling on the battery
door (1).
Remove the panelling above the battery (2).
Disassemble the front right-hand panelling (3).
Remove the panelling from the front structure
(4).
Remove the bottom plate.
56358012001 EN - 02/2017 -7
--- Page 24 ---
Two temperature sensors are installed in the
centre of the battery, as this is where the highest
temperatures are to be expected. The sensors
are designated as measurement 1 and measure-
ment 2.
The higher temperature value of the two mea-
surements controls the fan and the LED display.
The limits and the hystereses can be parame-
terised separately for the temperature and fan
stages.
56358012001 EN - 02/2017 -17
--- Page 25 ---
The right-hand pump motor is only switched The temperature sensors of the pump motors
on once the working hydraulics (lifting, tilting, provide the signal for opening the bypass valve
auxiliary hydraulics, oil cooling) are actuated. In to the oil cooler. In the truck control unit (MCU),
this mode, the speeds of the two pump motors a theoretically increased oil temperature is cal-
are precisely synchronised. Synchronising the culated using the temperature signals from the
speed reduces noise. pump motors. It is only at this point that the by-
pass valve opens and the oil is conveyed to the
oil cooler.
56358012001 EN - 02/2017 -9
--- Page 26 ---
Tighten the functional nut (1) until you clearly
feel an increase in connection strength,
Hold the socket (7) together when doing so
In the event of leaks at the screw joint, the
sealing ring (2) can be removed from the free
pipe end and replaced
56358012001 EN - 02/2017 -19
--- Page 27 ---
1 Tappet 8 Segment springs
2 Clamping screw 9 Sealing roller
3 Flange cover 10 Annular gear segment
4 Retaining pin 11 Annular gear
5 Thrust washer I 12 Housing ring
6 Pinion shaft 13 End cover
7 Pinion gear segment
Noise in the hydraulic pump - Check the radial seal ring in the
Hydraulic oil is frothy pump motor
- Check the O-ring between the
The hydraulic system has leaks
intake hose and the hydraulic
Hydraulic functions are slow to and is sucking in air
pump
respond - Mechanical damage in the
hydraulic pump
.
56358012001 EN - 02/2017 -9
--- Page 28 ---
00 Crossbar switch index for setpoint value limiter, analogue input
2B Four-way mini-lever
A 10 042
3A In RX60-25-50 (6321 6330) Duplicate mini-lever
3A Fingertip
00 Crossbar switch index for setpoint value limiter, digital input
A 10 043
31 In RX60-25-50 (6321 6330)
2B Four-way mini-lever
Crossbar switch index for setpoint value
3A Duplicate mini-lever
A 10 044 limiter, analogue input
3A Fingertip
00 In RX60-25-50 (6321 6330)
31 Crossbar switch index for setpoint value limiter, digital input
A 10 045
00 In RX60-25-50 (6321 6330)
2B Four-way mini-lever
Crossbar switch index for universal output
A 10 04D 3A Duplicate mini-lever
1
2B Fingertip
.
56358012001 EN - 02/2017 -19
--- Page 29 ---
Seal off the connections on the distributor of
the hose pulley using union nut 0009510108
and stopper 0009527004.
Cover the fork arms and the hose pulley with
plastic.
The plastic protects the hose pulley against
damage.
Position the fork arms under the hose pulley.
Secure the hose pulley to the fork arms using
a tensioning belt.
Stud bolts can be damaged.
During removal, ensure that the stud bolts are aligned
with the mounting bores. Do not tilt the lift mast.
Take out and remove the hose pulley.
Do not loosen the locking pins.
Cover the fork arms with plastic.
Secure the hose pulley to the fork arms using
a tensioning belt.
56358012001 EN - 02/2017 -29
--- Page 30 ---
Remove the wiper from hose guide 1 and 2.
Remove the rotation seals. Do not damage
the groove base or the edges of the groove. To
remove, carefully insert a scriber in the seal.
Incorrectly tted seals are often the reason for
hose pulleys leaking; t the sealing rings with
the speci ed pliers; press down using your
ngers
Kinked seals no longer seal reliably, therefore
avoid kinks
Use your nger or carefully insert the stator to
check the seal is seated correctly in the rotor
Assembly sequence:
Single Double
auxiliary auxiliary