Still Electric Forklift Truck RX60-25 RX60-30 RX60-35 WORKSHOP MANUAL – PDF DOWNLOAD
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Still Electric Forklift Truck RX60-25 RX60-30 RX60-35 WORKSHOP MANUAL – PDF DOWNLOAD
Language : English
Pages :378
Downloadable : Yes
File Type : PDF
Size:21.1 MB
TABLE OF CONTENTS:
Still Electric Forklift Truck RX60-25 RX60-30 RX60-35 WORKSHOP MANUAL – PDF DOWNLOAD
Table of contents
00 Product information
Foreword 00- 1
Product overview forthe RX6025-35 00- 1
Safetyinformation 00- 2
Parking the truck so itis secured for servicework 00- 2
Working onthe electrical system i 00- 3
Jacking up the frontofthetruck LL 00- 3
Jackinguptherearofthetruck iL 00- 4
Securing theforkcarriage 00- 6
01 Service
Maintenance 01-1
Maintenance instructions LL 01-1
Maintenance — 1000 hours/annually 01- 3
Maintenance – 3000 hours/everytwoyears 01- 5
TOOlS 01- 6
Measuring and testingequipment 01- 6
Harnessesand hoists 01-7
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01- 8
Standardised tightening torques for hose fittings 01- 8
Product overview forthe RX6025-35 00- 1
Safetyinformation 00- 2
Parking the truck so itis secured for servicework 00- 2
Working onthe electrical system i 00- 3
Jacking up the frontofthetruck LL 00- 3
Jackinguptherearofthetruck iL 00- 4
Securing theforkcarriage 00- 6
01 Service
Maintenance 01-1
Maintenance instructions LL 01-1
Maintenance — 1000 hours/annually 01- 3
Maintenance – 3000 hours/everytwoyears 01- 5
TOOlS 01- 6
Measuring and testingequipment 01- 6
Harnessesand hoists 01-7
Standardised tightening torques for standard-pitch threads and fine-pitch threads 01- 8
Standardised tightening torques for hose fittings 01- 8
02 Diagnostics
IntroductiontoDiaMon 02- 1
STEDS-Navigator 02- 1
CANboxdiagnostics 02- 2
Diagnosticset-up 02- 3
StartingDiaMon 02- 4
STEDS-Navigator 02- 1
CANboxdiagnostics 02- 2
Diagnosticset-up 02- 3
StartingDiaMon 02- 4
WorkingwithDiaMon 02- 5
Reading outand clearingtheerrorlist 02- 5
Readingoutaccesscodes LL 02- 6
Reading outand clearingtheerrorlist 02- 5
Readingoutaccesscodes LL 02- 6
Workingusing ABE 02- 7
Readerrorlist 02- 7
Readerrorlist 02- 7
Electricalconnections 11-1
Tractiondrive 11- 2
Tractionmotor 1- 4
Speed sensor 11- 6
Pin Sensor 11- 6
Temperature SEeNSOr i 11- 8
Temperature sensor KTY84 11- 8
Tractiondrive 11- 2
Tractionmotor 1- 4
Speed sensor 11- 6
Pin Sensor 11- 6
Temperature SEeNSOr i 11- 8
Temperature sensor KTY84 11- 8
22 Mechanical drive axle
Driveaxle EC35 22-1
General technicaldataCarraroEC35 22- 1
Drive axle 22- 3
Drive axle without pump motor Removal and installation 22- 4
Drive axle with pump motor Removal and installation 22-7
Wheeldrive 22-10
Differential gearboxandbrake iL 22-14
Removal of the differential gearboxandbrake 22-16
Installation of the differential gearboxandbrake 22-19
General technicaldataCarraroEC35 22- 1
Drive axle 22- 3
Drive axle without pump motor Removal and installation 22- 4
Drive axle with pump motor Removal and installation 22-7
Wheeldrive 22-10
Differential gearboxandbrake iL 22-14
Removal of the differential gearboxandbrake 22-16
Installation of the differential gearboxandbrake 22-19
31 Chassis
Frame 31-1
Batterydoor 31-1
Batterylock 31- 2
Batterydoorsensor LLL 31- 4
Batterydoor 31-1
Batterylock 31- 2
Batterydoorsensor LLL 31- 4
Counterweight 31- 5
Counterweight 31- 5
Counterweight 31- 5
42 Steering system
Hydraulicsteering 42-1
Generaltechnicaldata 42-1
Steering system LL 42- 2
Steering—errordetection LL 42- 4
Steeringunit 42- 5
Priorityvalve 42- 8
Generaltechnicaldata 42-1
Steering system LL 42- 2
Steering—errordetection LL 42- 4
Steeringunit 42- 5
Priorityvalve 42- 8
Steering wheel and steeringcolumn 42-10
Steering column LL LL 42-10
Steeringanglesensor3B01 LLL 42-12
Steering angle-dependent handling performance — CSC 42-14
Steering column LL LL 42-10
Steeringanglesensor3B01 LLL 42-12
Steering angle-dependent handling performance — CSC 42-14
CSC—functionaltest 42-15
Steeringaxle 42-19
Generaltechnicaldata 42-19
Swingaxle 42-20
Swingaxlecurveswitch 42-21
Removing/installingthe swingaxle 42-22
Wheelhub 42-24
Steeringangle 42-26
Tierod 42-27
Axlestub 42-28
Steeringaxle 42-19
Generaltechnicaldata 42-19
Swingaxle 42-20
Swingaxlecurveswitch 42-21
Removing/installingthe swingaxle 42-22
Wheelhub 42-24
Steeringangle 42-26
Tierod 42-27
Axlestub 42-28
49 Brake system
Mechanical servicebrake lL 49- 1
Changing the brake cable Servicebrake 49- 1
Servicebrake LL 49- 2
Removing/installing the servicebrake 49- 3
Changing the brake cable Servicebrake 49- 1
Servicebrake LL 49- 2
Removing/installing the servicebrake 49- 3
Handbrake 49- 5
Brake cable change, handbrake 49- 5
Actuating force ofthehandbrake 49- 7
Parking brake switch 1S3 49- 8
Brake cable change, handbrake 49- 5
Actuating force ofthehandbrake 49- 7
Parking brake switch 1S3 49- 8
Electric parkingbrake 49-10
Electricparkingbrake 49-10
Function 49-11
Causeandeffect 49-13
Designand systemdescription 49-15
Maintenanceinstructions LL 49-17
Checkingthebrake 49-18
Calibration and functionaltest 49-20
Changing the parkingbrakecable 49-23
Limitpositionswitch 49-26
Drive unit Installationandremoval 49-28
Central lubrication device Installationandremoval 49-30
Electricparkingbrake 49-10
Function 49-11
Causeandeffect 49-13
Designand systemdescription 49-15
Maintenanceinstructions LL 49-17
Checkingthebrake 49-18
Calibration and functionaltest 49-20
Changing the parkingbrakecable 49-23
Limitpositionswitch 49-26
Drive unit Installationandremoval 49-28
Central lubrication device Installationandremoval 49-30
Singlepedal
Accelerator—single-pedal
Deadmanswitch7S13
Accelerator—single-pedal
Deadmanswitch7S13
Dualpedal
Accelerator —dual pedal 2nd generation
Operatingdevices
Handlever
Joystick4Plus
Axle assignment -Joystick4Plus LL
Generation2mini-lever
Axle assignment-themini-lever
Tipswitch
Axle assignment -fingertipswitch
Handlever
Joystick4Plus
Axle assignment -Joystick4Plus LL
Generation2mini-lever
Axle assignment-themini-lever
Tipswitch
Axle assignment -fingertipswitch
56 Display elements
Operatingconsole
Direction indicatormodule (Fabli)
Display
Display and operating unit, generation2(ABE2)
Display and operating unit, generation2(ABE2)
ABE 2 Installationandremoval
60 Electrics/electronics
General
Generaltechnicaldata
Overviewofthecontrollers
Electrical system
Electricalcomponents
Switch-on process for the electrical system
Software compatibility
PANDProcess ii
Parametermanagement
Errorringbuffer
Intermediate circuit
Insulation testing for electrictrucks
Insulation testingonthe drivebattery
Componentinsulationtesting
Temperature monitoring for the traction motor-80V
Generaltechnicaldata
Overviewofthecontrollers
Electrical system
Electricalcomponents
Switch-on process for the electrical system
Software compatibility
PANDProcess ii
Parametermanagement
Errorringbuffer
Intermediate circuit
Insulation testing for electrictrucks
Insulation testingonthe drivebattery
Componentinsulationtesting
Temperature monitoring for the traction motor-80V
Pump motor temperature monitoring 60-23
Temperature monitoring for the pump motorconverter 60-25
Available drivingbehaviour 60-26
Revolution-controlled vs torque-regulated 60-26
Blue-Q=1Q 60-27
Startingcurrentboost LL 60-28
Stoppingonaslope 60-28
WINING 60-30
CANDuUs system 60-30
CANbusconnections 60-32
Powercables 60-34
Maintenance guidelines forpowercables 60-35
Repair-Contactelements 60-35
Electrical system 60-37
FUSE DOX 60-37
Fuses 60-37
Contactor 60-38
Sensorsystem 60-40
Vertical lift mast position 60-40
Tittanglesensor7B46 60-41
Load measurement LL 60-44
Load measurement pressure SeNSOr LL 60-46
Additional electrical installation 60-47
TA21converterPCB 60-47
Option Board 60-48
CAN-Power-Port (CPP) 60-50
CPP 1/CPP 3 60-50
CPP 2B 60-52
CPP battery carrier (CPPS) 60-53
Relay-Power-Port 60-54
Temperature monitoring for the pump motorconverter 60-25
Available drivingbehaviour 60-26
Revolution-controlled vs torque-regulated 60-26
Blue-Q=1Q 60-27
Startingcurrentboost LL 60-28
Stoppingonaslope 60-28
WINING 60-30
CANDuUs system 60-30
CANbusconnections 60-32
Powercables 60-34
Maintenance guidelines forpowercables 60-35
Repair-Contactelements 60-35
Electrical system 60-37
FUSE DOX 60-37
Fuses 60-37
Contactor 60-38
Sensorsystem 60-40
Vertical lift mast position 60-40
Tittanglesensor7B46 60-41
Load measurement LL 60-44
Load measurement pressure SeNSOr LL 60-46
Additional electrical installation 60-47
TA21converterPCB 60-47
Option Board 60-48
CAN-Power-Port (CPP) 60-50
CPP 1/CPP 3 60-50
CPP 2B 60-52
CPP battery carrier (CPPS) 60-53
Relay-Power-Port 60-54
64 Electronic controls
Traction and working hydraulicscontrol 64- 1
Main Control Unit (MCU 2) 64- 1
Main Control Unit (MCU) Removal and installation 64- 2
SUPPIYUNIL(SU2) ooo 64- 4
Supply Unit (SU) Removal and installation 64- 5
Main Control Unit (MCU 2) 64- 1
Main Control Unit (MCU) Removal and installation 64- 2
SUPPIYUNIL(SU2) ooo 64- 4
Supply Unit (SU) Removal and installation 64- 5
Converter
Inverters
SACconverter—80Volt
Inverters
SACconverter—80Volt
Inverters Removal and installation
69 Batteries and accessories
Battery
2014 dischargeindicator LL
Batteryplug
Maintenance guidelines for applianceplugs
Repair – Battery male connectorcontacts
2014 dischargeindicator LL
Batteryplug
Maintenance guidelines for applianceplugs
Repair – Battery male connectorcontacts
Working withreducersleeves
70 Hydraulics
General
Generaltechnicaldata
Depressurisingthe hydraulics
Lifting operatingspeeds
Lowering operatingspeeds LL
Generaltechnicaldata
Depressurisingthe hydraulics
Lifting operatingspeeds
Lowering operatingspeeds LL
Tilting operatingspeeds LL
Safetycheck
Forwardftiltsafetytest
Loweringsafetytest iL
Forwardftiltsafetytest
Loweringsafetytest iL
Safety checks ofhoseassembly
Basichydraulics
Basichydraulics
Steering hydraulics
Working hydraulics
Hydraulictank
Hydraulicoil
Returnlinefilter
Breatherfilter
Intakefilter
High-pressurefilter
Conical nipple fittings (CNF)
Boltedjoint LL
Basichydraulics
Steering hydraulics
Working hydraulics
Hydraulictank
Hydraulicoil
Returnlinefilter
Breatherfilter
Intakefilter
High-pressurefilter
Conical nipple fittings (CNF)
Boltedjoint LL
Pump-motorunit 71-1
Generaltechnicaldata 71-1
Pumpunit 71-1
Electricalconnections LLL 71- 2
Pump motor temperature sensor LL 71- 3
Pump motor Removal and installation 71-5
Hydraulic pump 71- 6
Hydraulic pump Removal and installation 71- 7
Generaltechnicaldata 71-1
Pumpunit 71-1
Electricalconnections LLL 71- 2
Pump motor temperature sensor LL 71- 3
Pump motor Removal and installation 71-5
Hydraulic pump 71- 6
Hydraulic pump Removal and installation 71- 7
Tilteylinder 71-10
Masttilt 71-10
Tilt cylinder Removal and installation 71-11
Changing the set of seals2200-5000kg-LSP 500 71-12
Masttilt 71-10
Tilt cylinder Removal and installation 71-11
Changing the set of seals2200-5000kg-LSP 500 71-12
Auxiliary hydraulics 71-15
Attachments 71-15
Second operating function forattachments 71-18
Clamp locking mechanismwith servo hydraulics 71-18
Clamp locking mechanismforhandlevers 71-20
Attachments 71-15
Second operating function forattachments 71-18
Clamp locking mechanismwith servo hydraulics 71-18
Clamp locking mechanismforhandlevers 71-20
Accumulator 71-22
Accumulator 71-22
Checkingtheaccumulator 71-23
Accumulator 71-22
Checkingtheaccumulator 71-23
76 Valves
Handlever 76- 1
Generaltechnicaldata 76- 1
Handlevervalveblock 76- 2
Emergencylowering 76- 3
Hydraulictransmitter 76- 4
Valve block Removal /installation 76- 6
Directional control valve block 76- 8
Check valve for hydraulics blocking function 76-10
Generaltechnicaldata 76- 1
Handlevervalveblock 76- 2
Emergencylowering 76- 3
Hydraulictransmitter 76- 4
Valve block Removal /installation 76- 6
Directional control valve block 76- 8
Check valve for hydraulics blocking function 76-10
Servohydraulics 76-11
Generaltechnicaldata 76-11
Servo hydraulics valveblock 76-12
Manuallowering 76-13
Directional control valve block 76-14
Generaltechnicaldata 76-11
Servo hydraulics valveblock 76-12
Manuallowering 76-13
Directional control valve block 76-14
Liftmast 81- 1
Generaltechnicaldata 81- 1
Hose safety valve of triplexmast 81- 2
Supportroller play (108/117/130) 81- 5
Load chains- Checkingandcleaning 81- 6
Run-outbarrier 81- 8
Workingonliftmasts 81- 9
Liftmast-Removal 81- 9
Litmast-Installation 81-10
Generaltechnicaldata 81- 1
Hose safety valve of triplexmast 81- 2
Supportroller play (108/117/130) 81- 5
Load chains- Checkingandcleaning 81- 6
Run-outbarrier 81- 8
Workingonliftmasts 81- 9
Liftmast-Removal 81- 9
Litmast-Installation 81-10
Telescopicliftmast 81-13
Telescopicliftmast(130MaLiS) 81-13
Adjusting the load chains Telescopic lift mast (130MaLiS) 81-14
Removing the supportrollersintheliftmast 81-15
Assembling the lift mast after replacing the supportrollers 81-16
Outer load chainsandchainrollers 81-17
Telescopicliftmast(130MaLiS) 81-13
Adjusting the load chains Telescopic lift mast (130MaLiS) 81-14
Removing the supportrollersintheliftmast 81-15
Assembling the lift mast after replacing the supportrollers 81-16
Outer load chainsandchainrollers 81-17
NiHoliftmast 81-19
NiHoliftmast (130 MaLiS) i 81-19
Adjusting the load chains NiHo lift mast (130 MaLiS) 81-21
NiHoliftmast (130 MaLiS) i 81-19
Adjusting the load chains NiHo lift mast (130 MaLiS) 81-21
Triplexliftmast 81-22
Triple liftmast (130MaLiS) 81-22
Adjusting the outer load chains Triple lift mast (130MaLiS) 81-24
Adjusting the middle load chain Triple lift mast (130 MaLiS) 81-25
Removingthe supportrollers 81-26
Assembling the lift mast after replacing the supportrollers 81-29
Outer load chainsand chainrollers 81-31
Middle load chainand chainroller 81-33
Triple liftmast (130MaLiS) 81-22
Adjusting the outer load chains Triple lift mast (130MaLiS) 81-24
Adjusting the middle load chain Triple lift mast (130 MaLiS) 81-25
Removingthe supportrollers 81-26
Assembling the lift mast after replacing the supportrollers 81-29
Outer load chainsand chainrollers 81-31
Middle load chainand chainroller 81-33
Lifteylinder 81-35
Liftjack 81-35
Working onlifteylinders 81-36
Removing and installingthe outercylinders 81-36
Disassembling/assembling the outercylinder 81-41
Middle cylinder 81-44
Liftjack 81-35
Working onlifteylinders 81-36
Removing and installingthe outercylinders 81-36
Disassembling/assembling the outercylinder 81-41
Middle cylinder 81-44
Disassembling/assembling the middlecylinder 81-45
End position damping of outercylinder L 81-48
Middle cylinderenddampener 81-49
End position damping of outercylinder L 81-48
Middle cylinderenddampener 81-49
84 Load support
Fork carriage-2500-3500 il 84- 1
Removing and installing the fork carriage 84- 1
Forkwear protection 84- 4
Removing and installing the fork carriage 84- 1
Forkwear protection 84- 4
Annex
X Circuit diagrams
Hydraulics X- 2
Hydraulic circuit diagram Multi-levers X- 2
Hydraulic circuit diagram Servo hydraulics X- 4
Hydraulic circuit diagram Multi-levers X- 2
Hydraulic circuit diagram Servo hydraulics X- 4
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