Still RCE 25 Original Instructions Manual
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Still RCE 25 Original Instructions Manual

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Original instructions
Electric Truck
RCE 25
RCE 25 Li-Ion
5444 5445
5001 801 1626 EN - 10/2023  -  04

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Summary of Contents for Still RCE 25

  • Page 1 Original instructions Electric Truck RCE 25 RCE 25 Li-Ion 5444 5445 5001 801 1626 EN - 10/2023  -  04...
  • Page 3 Internet address and QR code  The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 5001 801 1626 EN - 10/2023  -  04  I...

  • Page 5: Table Of Contents

    Table of contents   Introduction   Your industrial truck ...........  2 Technical description.
  • Page 6 Table of contents   Definition of terms used for responsible persons...... 27 Specialist .
  • Page 7 Table of contents   Overview   General view ............ 54 Controller and display unit .
  • Page 8 Table of contents   Brake system ............ 88 Brake system information .
  • Page 9 Table of contents   Maintenance   Safety information for inspection and maintenance work ..... .  130 Inspection and maintenance data ........ 131 Recommended fuels and oils .
  • Page 10 Table of contents   Hydraulics ............ 162 Checking the hydraulic system for leaks .

  • Page 11: Introduction

    Introduction...

  • Page 12: Your Industrial Truck

    Electric forklift trucks in this range: A joystick is used to control the lifting, lowering RCE 25, RCE 25 Li-Ion and tilting movements. There is also another joystick for operating If you require further information on the differ- other accessories.

  • Page 13: General

    Introduction Your industrial truck General The industrial truck described in these operat- ing instructions conforms with the applicable standards and safety regulations. The industrial truck is fitted with state-of-the- art technology. Following these operating in- structions will allow the industrial truck to be handled safely.

  • Page 14: Conformity Marking

    Introduction Your industrial truck Conformity marking  The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...

  • Page 15: Declaration That Reflects The Content Of The Declaration Of Conformity

    Your industrial truck Declaration that reflects the content of the declaration of conformity         Declaration     STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany             We declare that the specified machine conforms to the most recent valid version of the directives specified below:  ...

  • Page 16: Declarations Of Conformity In Accordance With Directive Red 2014/53/Eu

    Introduction Your industrial truck Declarations of conformity in accordance with directive RED 2014/53/EU The manufacturers of the radio equipment in- stalled in the industrial truck declare that the radio equipment corresponds to the Directive RED 2014/53/EU. Nameplate  1   Nameplate 2   Manufacturer 3  ...

  • Page 17: Serial Number

    Introduction Your industrial truck Serial number  xx xxxx x xxxxx The serial number is used to identify the truck. The serial number is shown on the nameplate. Quote the serial number for all technical ques- tions. The serial number contains the following co- ded information: Production location Model...

  • Page 18: Using The Truck

    Introduction Using the truck Using the truck Commissioning Commissioning is the initial intended use of the truck. The necessary steps for the commissioning vary depending on the model and equipment of the truck. These steps require preparatory work and adjustment work that cannot be per- formed by the operating company.

  • Page 19: Intended Use

    Introduction Using the truck Intended use The industrial truck may be used only for its Industrial trucks may only be used on road- intended purpose. ways that do not have bends that are too sharp, gradients that are too steep or entran- The industrial truck is intended for moving and ces that are too narrow or low.

  • Page 20: Improper Use

    Introduction Using the truck Attachments Modifications, in particular attachments or conversions, are not permitted to be made to Attachments may only be used for their inten- the industrial truck without the manufacturer's ded purpose. Drivers must be taught how to approval.
  • Page 21 Introduction Using the truck Do not overload the truck (by exceeding the Always sound the horn when approaching rated load indicated on the load designation blind spots. plate). Overloading can affect braking distan- The truck and attachments must only be used ces, truck stability and the strength of the lift for authorised applications.

  • Page 22: Precautions

    Introduction Using the truck Precautions – Do not drive on steep slopes, to prevent the – When using this truck, pay attention to the load from slipping off. surroundings and do not become distracted. – The truck must be switched off when left –...

  • Page 23: Parking In Temperatures Below -10 °C

    Introduction Using the truck Parking in temperatures below -10 °C  CAUTION Batteries may freeze or switch off! If the truck is parked in an ambient temperature of below -10°C for an extended period, the batteries will cool down. For lead-acid batteries, the electrolyte can freeze and damage the batteries.

  • Page 24: Information About Documentation

    Introduction Information about documentation Information about documentation Documentation scope Operating instructions fully and must be available to the driver and ● operator at all times. Operating instructions for attachment parts ● (special equipment) If the operating instructions are lost, the oper- Spare parts list ●...

  • Page 25: Issue Date And Topicality Of The Operating Instructions

    The issue date and the version of these op- erating instructions can be found on the title page. STILL is constantly engaged in the further de- velopment of trucks. These operating instruc- tions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.

  • Page 26: Explanation Of Signal Terms Used

    Introduction Information about documentation Explanation of signal terms used  DANGER Indicates procedures that must be strictly adhered to in order to prevent the risk of fatalities.  WARNING Indicates procedures that must be strictly adhered to in order to prevent the risk of injuries.  CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruc-...

  • Page 27: Date Of Edition And Latest Update Of This Manual

    Introduction Information about documentation Date of edition and latest update of this manual The publication date of these operating in- structions is printed on the cover sheet. The manufacturer makes continuous efforts to improve its industrial trucks, and therefore re- serves the right to implement changes and to accept no claims concerning the information provided in this manual.
  • Page 28 Introduction Information about documentation Abbrevi- Meaning Explanation ation maximum Force Maximum power German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless net- GPRS General Packet Radio Service works ID no.

  • Page 29: Definition Of Directions

    Introduction Information about documentation Abbrevi- Meaning Explanation ation Verband Deutscher Maschinen- und Anla- German Mechanical Engineering Industry VDMA genbau e. V. Association WLAN Wireless LAN Wireless local area network Definition of directions  The directions "forwards" (1), "backwards" (3), "right" (2) and "left" (4) refer to the installation position of the parts as seen from the driver's compartment;...

  • Page 30: Environmental Considerations

    Introduction Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.

  • Page 31: Safety

    Safety...

  • Page 32: Safety Guidelines

    Safety Safety guidelines Safety guidelines The operating company or the person it has  DANGER commissioned must ensure that the driver un- Safety systems (e.g. the seat switch) are in place to derstands all safety information and that all di- ensure safety. rectives and safety regulations are observed.
  • Page 33 Safety Safety guidelines Working on the truck Safety information for electromagnetic compatibility  DANGER  WARNING Any additional bores or welding on the overhead guard will compromise its rigidity. In operating areas with magnetic fields that have a It is therefore strictly prohibited to drill bores in the magnetic flux density greater than 5 mT, unintention- overhead guard or to perform welding work on it.

  • Page 34: Data Security

    Safety Data security Data security Input unit with a transponder less communication with a global navigation satellite system. For input units with a chip or a chip card, the Communication with a global navigation satel- access code is transmitted wirelessly. lite system, such as GPS, can theoretically be The wireless technology for the transponder is interrupted or manipulated.
  • Page 35 Safety Special notes for using lithium-ion batteries Permissible lithium-ion batteries – Use only lithium-ion batteries that have been approved by STILL for use with this truck. Declaring the use of lithium-ion batter- We recommend that the operating company informs the local fire brigade of the planned use of trucks fitted with lithium-ion batteries.

  • Page 36: Stability

    Safety Stability – Ventilate the location of the fire well, as the resulting combustion gases are corrosive if inhaled. – Inform the fire brigade that lithium-ion bat- teries are affected by the fire. – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire.

  • Page 37: Definition Of Terms Used For Responsible Persons

    Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Specialist A qualified person is defined as a service en- gineer or a person who fulfils the following requirements: A completed vocational qualification that ● demonstrably proves their professional ex- pertise.

  • Page 38: Drivers

    Safety Definition of terms used for responsible persons Drivers This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised represen- tative, and have been specifically instructed to drive the truck.
  • Page 39 Safety Definition of terms used for responsible persons Prohibition of use by unauthorised per- sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use, e.g.

  • Page 40: Basic Principles For Safe Operation

    Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company premises The company premises are very often restric- ted public traffic areas. NOTE It is advisable to review the operational lia- bility insurance so that insurance covers the truck with respect to third parties in the event of damage caused in restricted public traffic areas.
  • Page 41 Safety Basic principles for safe operation We warn against installing and using restraint systems that have not been approved by the manufacturer. – Contact the authorised service centre be- fore converting or retrofitting the truck. Only the authorised service centre is permit- ted to perform welding work on the industrial truck.

  • Page 42: Changes To The Overhead Guard And Roof Loads

    We recommend that you obtain approval from the by STILL. manufacturer and, if applicable, from the relevant regulatory authorities before installing such parts. The manufacturer accepts no liability for any damage caused by the use of non-original parts and non-orig- inal accessories.

  • Page 43: Medical Devices

    Safety Basic principles for safe operation ries) is permitted only with the approval of the manufacturer. Medical devices The operation of medical devices, for example pacemakers or hearing aids, can be impaired. Check with your doctor or manufacturer if the medical devices are sufficiently protected against electromagnetic interference.

  • Page 44: Damage, Defects And Misuse Of Safety Systems

    Safety Basic principles for safe operation (e.g. always replace right and left wheels at the same time). Changes must only be made following consultation with the manufacturer. Wheels approved by the manufacturer can be found on the spare parts list. If other wheels are to be used, authorisation from the manu- facturer must be obtained beforehand.

  • Page 45: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Basic principles for safe operation safely on the fork arms may move forwards and fall. If the fork arms are too long, they can catch on loading units behind the load that is to be picked up. These other loading units then fall over when the load is raised.

  • Page 46: Residual Risks

    Safety Residual risks Residual risks Residual dangers, residual risks Despite working with care and complying with the standards and regulations, the possibility of other dangers arising when using the truck cannot be ruled out. The truck and all other system components comply with current safety requirements.

  • Page 47: Special Risks Associated With Using The Truck And Attachments

    Safety Residual risks ments, this can lead to an accident. In this case, the manufacturer is exempt from liability. Stability The stability of the truck has been tested to the latest technological standards. If the truck is used in the proper manner and in accord- ance with its intended use, the stability of the truck is guaranteed.
  • Page 48 Safety Residual risks use the truck correctly and without the risk of accidents.  38 5001 801 1626 EN - 10/2023  -  04...
  • Page 49 Safety Residual risks 5001 801 1626 EN - 10/2023  -  04  39...

  • Page 50: Overview Of Hazards And Countermeasures

    Safety Residual risks Overview of hazards and countermeasures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.
  • Page 51 Safety Residual risks Hazard Course of action Check note Notes √ done - Not applicable Impermissible usage Provide operating in- German Ordinance on (improper usage) structions Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver Industrial Safety and...

  • Page 52: Danger To Employees

    Safety Residual risks Hazard Course of action Check note Notes √ done - Not applicable DGUV rule 113-001 and observe the oper- ating instructions When operating driverless transport systems Roadway quality inad- Clean/clear roadways German Ordinance on equate Industrial Safety and Health (BetrSichV) Loading equipment in- Reposition load on pal-...
  • Page 53 Safety Residual risks The design and equipment of the truck comply with the standards and directives required for CE conformity. The design and equipment al- so comply with the standards and directives necessary for the UKCA compliance that is required in the United Kingdom. The design and equipment are therefore not part of the required scope of the hazard assessment.

  • Page 54: Safety Tests

    Safety Safety tests Safety tests Regular safety inspection of the  truck Safety inspection based on time and ex- traordinary incidents The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, a complete check of the technical condition of the truck must be performed with regard to accident safe-...
  • Page 55 Safety Safety tests – For insulation testing, contact the author- ised service centre. The exact procedure for this insulation testing is described in the workshop manual for this truck. NOTE The truck's electrical system and drive batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt-...

  • Page 56: Safety Regulations For Handling Consumables

    Safety Safety regulations for handling consumables Safety regulations for handling consumables Permissible consumables Refer to the maintenance data table for the  WARNING permissible substances necessary for opera- Consumables can be dangerous. tion. It is necessary to follow the safety regulations when handling these substances.

  • Page 57: Disposal Of Consumables

    Safety Noise level  WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, use appropriate PSA (rubber gloves, apron, protection goggles). – When working with battery acid, nev- er wear a watch or jewellery. –...

  • Page 58: Frequency Characteristics For Vibrations Imparted To The Human Body

    Safety Frequency characteristics for vibrations imparted to the human body NOTE The noise level may be higher or lower than this value when operating the forklift truck. Dif- fering tasks and external factors may lead to an increase in noise levels. Frequency characteristics for vibrations imparted to the hu- man body...

  • Page 59: Manually Lowering The Fork Arms With Iso

    Safety Manually lowering the fork arms with ISO NOTE If the truck has a driver's cab with a door, a window and glass, it is difficult for the driver to open the door from the side when the truck encounters a fault in narrow passages. In the event of such dire danger, the driver can exit the truck via the rear window.

  • Page 60: Safety Regulations Relative To Forklift Use

    Safety Safety Regulations Relative to Forklift Use – Slowly turn the emergency lowering screw about 1.5 turns anticlockwise using a hexa- gon socket wrench. – Gently push the joystick until the forks are completely lowered. – After it is lowered, turn back the emergency lowering screw clockwise with 40 Nm tight- ening torque.

  • Page 61: Safety Regulations When Driving

    There is a risk of accident! – Do not use devices during travel or when handling loads. – Set the volume so that warning signals can still be heard. 5001 801 1626 EN - 10/2023  -  04  51...

  • Page 62: Safety Regulations In Case Of Accidental Lateral Tipping

    Safety Safety regulations in case of accidental lateral tipping  WARNING In areas where use of mobile phones is prohibited, use of a mobile phone or radio telephone is not per- mitted. – Switch off the devices. Visibility when driving The driver must look in the drive direction and have a sufficient view of the driving lane.

  • Page 63: Overview

    Overview...

  • Page 64: General View

    Overview General view General view Lift mast Rear cover Lift cylinder Driver's seat Handhold Multilever Steering wheel Overhead guard Reversing handle Display unit Steering column adjustment screw Rear wheel (steering wheel) Fork carriage Front wheel (load wheel) Forks USB interface Parking brake pedal LED headlights Drive axle...

  • Page 65: Controller And Display Unit

    Overview Controller and display unit Controller and display unit Steering column adjustment screw Driver's seat Steering wheel Brake pedal Horn button Accelerator pedal Lighting control handle Lifting device lever Switch panel Tilting device lever Emergency off switch Attachment lever (optional) Display unit Attachment lever (optional) USB interface...

  • Page 66: Warning Label Diagram

    ) Label, Read the operating manual ( For Label, capacity rating plate ( For hook-on heater configuration) side shifter ) Label text, Still + RCE25 Label, Lifting/Lowering Label,Li-ion technology (*Li-ion truck) Label,Side shifting Label text, Still Label, Lifting/Lowering/Tilting...

  • Page 67: Display Unit

    Overview Display unit Display unit Back button Remaining battery run time Up button Hour meter Down button Low charge Enter/modify button Additional information Direction Error symbol Speed Operator symbol Left turn Fasten seat belt symbol Maintenance time Battery cover open symbol Date Parking brake symbol Performance mode...

  • Page 68: Switch Panel

    Overview Switch panel Refer to truck documentation KCDU connection symbol (for KEYS diag- Motor temperature too high (yellow)/over- nostics) heated (red) KCCU cloud server connection symbol (al- Battery charging symbol lows normal data uploading) CAN communication symbol (Blue - normal Maintenance indicator (lights up when main- CAN communication;...

  • Page 69: Relays And Fuses Overview

    Overview Relays and fuses overview Relays and fuses overview Relay  Signs Function 5N20 Flasher Reversing relay Parking relay Motor fan relay Module fan relay 5001 801 1626 EN - 10/2023  -  04  59...
  • Page 70 Overview Relays and fuses overview Fuses  Signs Specifications Function 80V/10A Key and main contactor signal 32V/10A Module control unit and drive motor speed sensor 32V/10A Display unit, diagnostics 32V/10A Horn, fan, flasher Brake lights, USB charging port, reversing lights, reversing beep- 32V/10A er, combination switch Spare (lead-acid battery models), BMS auxiliary battery (lithium-...

  • Page 71: Operation

    Operation...

  • Page 72: Service Plan Before First Start

    Operation Service plan before first start Service plan before first start Drive mechanism and transmission system Check the drive axle/transmission gear oil level. Check and tighten the wheel nuts. Check the tyre pressure (if fitted with optional pneumatic tyres). Check the functionality of the service brake and parking brake. Check the drive functions (forward and reverse).
  • Page 73 Operation Pre-shift checks NOTE If, when carrying out the daily checks, you discover a defect or you are unsure whether the truck will function properly, do not use the truck and contact the technical service depart- ment. 5001 801 1626 EN - 10/2023  -  04  63...

  • Page 74: Daily Inspection Items

    Operation Daily inspection items Daily inspection items Drive mechanism and transmission system Check the tyre and rim (for damage to the profile and outer section). Check the drive axle/transmission gear oil level. Check the tyre pressure (if fitted with optional pneumatic tyres). Test the functionality of the service brake and parking brake.

  • Page 75: Periodic Inspection Items

    Operation Periodic inspection items Periodic inspection items  CAUTION Carrying out periodic inspections of the vehicle is supplemental to periodic servicing work and plays an important role in keeping the vehicle in good working order. Please carry out periodic inspections accord- ing to the content of the "Table of first service checks"...
  • Page 76 Operation Troubleshooting guide Fault Possible reason Solution 1. The battery plug is not connec- 1. Check the battery plug and connect it if ted. necessary. 2. The emergency off switch is 2. Pull up the emergency off switch. pressed. 3. The key switch is in position 3.

  • Page 77: Mounting/Dismounting

    Operation Mounting/dismounting Mounting/dismounting   WARNING Always face the vehicle when climbing off the forklift to prevent injury to legs and back. NOTE Do not grip the steering wheel or joysticks when climbing on/off the forklift. After completing the daily checks on the forklift truck, carry out the following procedure to be- gin using it: –...

  • Page 78: Seat Belt Status And Performance Checks

    Operation Seat belt status and performance checks Seat belt status and performance checks Checking condition and performance  DANGER  CAUTION For safety reasons, the condition and protective The seat belt must be replaced if it is cracked, worn ability of the seat belt must be checked on a daily or has been damaged in an accident.
  • Page 79 Operation Seat belt status and performance checks between driver, steering wheel, accelerator pedal and operating levers is found. – Retract the adjustment handle (1). Setting the driver's weight  NOTE The individual driver's weight must be set with the driver sitting in the seat. –...
  • Page 80 Operation Seat belt status and performance checks Fastening the seat belt  DANGER There is a risk to life if the driver loses control of the vehicle. The seat belt must be worn at all times that the truck is driven! The seat belt must only be used by one person at any time.

  • Page 81: Seat Belt Monitoring And Alarm Function

    Operation Seat belt status and performance checks – Slowly pull the seat belt (3) out from the  retractor (1). – Place the seat belt around the waist, no higher than the abdomen. – Press the seat belt latch plate (2) into the latch (4).

  • Page 82: Operating The Horn

    Operation Operating the horn arrow in the display unit will flash. If the vehi- cle speed is above 4 km/h at this time, the beeper will also sound. Different monitoring modes can be set using the diagnostic software so that the forklift truck gradually slows down to a standstill (0 km/h) or is restricted to creep speed (2 km/h).

  • Page 83: Checking The Steering System For Correct Function

    Operation Checking the steering system for correct function Checking the steering system  for correct function  DANGER If the hydraulics fail, there is a risk of accident as the steering characteristics have changed. – Do not operate the truck if it has a defective steer- ing system.

  • Page 84: Emergency Off Switch

    Operation Emergency off switch Adjusting the angle – Loosen the clamping screw (1) anti-clock-  wise. – Move the steering column into the required position. – Tighten the clamping screw (1) clockwise. Emergency off switch  DANGER This switch button is the primary power switch. Do not disconnect this switch when performing an emergency stop.
  • Page 85 Operation Emergency off switch Pulling up the emergency off switch – Pull up the emergency off switch (1). This  will cause the truck's electrical system to start conducting. The truck is ready for use. NOTE The truck is only operational after correctly pulling up the emergency off switch.

  • Page 86: Keypad（*Option

    Operation Keypad（*Option） Keypad（*Option） RFID Keypad – The truck is equipped with an RFID Keypad  with driver identification system. The instal- lation position is as shown on the right:  CAUTION For details, please refer to the chapter "RFID Keypad usage and settings". RFID Keypad usage and set- tings.
  • Page 87 Operation Keypad（*Option） Unlocking with a password  – Turn on the key switch, and a red indicator (R) on the keypad will light up. – Enter the correct driver password and press button. The red indicator (R) will be off and the green indicator (G) will lights up. –...
  • Page 88 Operation Keypad（*Option） – Enter the 3-digit function code 0 0 4 press the button. – Enter an existing 5-digit driver password. – Press to delete the password, or press to cancel the deletion. Press and hold the button for 1 second to exit the administrator mode.

  • Page 89: Switching The Truck On And Off

    Operation Switching the truck on and off and both the red indicator and green indica- tor will blink. If an unbound ID card is bound to a bound ● driver number (00–99), the ID card original- ly bound to the driver number will become invalid.
  • Page 90 Operation Switching the truck on and off – Depress the parking brake pedal (9). The pedal will rebound and the parking brake will disengage. – Observe the display unit (7). NOTE Ensure that the parking brake is fully disen- gaged. The truck cannot be driven until the parking symbol Ⓟ...
  • Page 91 Operation Switching the truck on and off – Push down the emergency off switch (6) if necessary. * = Optional 5001 801 1626 EN - 10/2023  -  04  81...

  • Page 92: Setting The Display Unit

    Operation Setting the display unit Setting the display unit Setting the main interface – Long press the Enter/Modify button the display unit to access the settings page. – The settings page contains the following  four setting items: Display settings ●...
  • Page 93 Operation Setting the display unit – Access the "Date format" settings  menu to change the date format. (month.day.year 24-hour, day.month.year 24-hour, month/day/year 12-hour) – Access the "Date" settings menu to change  the date. – Access the "Time" settings menu to change ...
  • Page 94 Operation Setting the display unit – Access the "system information" to read the  system information of the display unit, such as the vehicle model and the software ver- sion of the display unit. NOTE The "Display settings" are settings for use by customers, whereas the other settings are for use by technicians.

  • Page 95: Driving

    Operation Driving Driving Driving  CAUTION For reasons of stability and minimum braking dis- tance, do not use the forklift truck on a long slope with a gradient of more than 15%. If you need to use the forklift truck on slopes with higher gradients, please first consult your dealer.

  • Page 96: Forward Travel

    Operation Driving – Sit down on the driver's seat (10) (Only then  is the seat switch under the driver's seat activated). – Fasten the seat belt. – Pull up the emergency off switch (6) if nec- essary. – Make sure that the parking brake pedal (9) is actuated.

  • Page 97: Reverse Travel

    Operation Driving Reverse travel  – Set the reversing handle (16) to the reverse position. – Smoothly depress the right-hand accelera- tor pedal (12). The display unit displays the reversing sym- bol. Driving speed accelerates in relation to the increase in pedal travel. NOTE Rapidly depressing the pedal will not change the acceleration, as the maximum acceleration...

  • Page 98: Brake System

    Operation Brake system Brake system Brake system information  WARNING  WARNING Risk of accident or casualties if brake system is faul- The braking characteristics of the truck are influ- enced by the viscosity of the oil, among other things. Using a different oil (with a different viscosity) to that Your truck should not be used under any circumstan- prescribed by the manufacturer will affect braking ces if the brake system is faulty.

  • Page 99: Electronic Regenerative Braking

    Operation Brake system Electronic regenerative braking  – Release the accelerator pedal (1) so that the pedal returns to the neutral position. En- ergy is recovered and a braking effect is produced. This truck is equipped with the automatic brake control system. Slowly or quickly releas- ing the accelerator pedals to the neutral posi- tion allows the braking effect to be sensitively controlled, from gentle to hard braking.

  • Page 100: Parking Brake

    Operation Brake system Parking brake  WARNING If there is a fault with the braking system or system parts are worn, contact your authorised authorized dealer. The forklift truck must not be operated if there are problems with the braking system. Applying the parking brake NOTE The truck can be started regardless of wheth-...

  • Page 101: Battery Cover - Open - Closed

    Operation Battery cover — Open - Closed NOTE Ensure the parking brake is fully disengaged. The truck cannot be driven until the parking symbol Ⓟ on the display unit has gone out. Battery cover — Open - Closed NOTE This vehicle has been designed to avoid in- terference with the upper rear section of the overhead guard when the battery cover is opened in the following situations:...

  • Page 102: Checking Battery Level

    Operation Checking battery level – Pull the latch handle on the battery cover to  the left to open the latch. The battery cover will automatically open.  CAUTION Do not lean too close to the battery cover, as it will spring open to a certain height.

  • Page 103: Charging Precautions (Lead-Acid Battery)

    Operation Charging precautions (lead-acid battery) The green LEDs go out one after another as  the battery discharges (each bar represents 10% of the battery capacity).  CAUTION Repeated deep discharging of the battery can cause irreparable damage. When the red LED flashes, the battery must be charged immediately.

  • Page 104: Connecting The Rechargeable Battery To An External Charger

    Operation Connecting the rechargeable battery to an external charger  CAUTION  CAUTION No metal objects should be placed on the battery. Always charge and maintain the lithium-ion battery in accordance with instructions from the manufacturer. Be careful of short-circuiting the battery! Do not fill up with electrolytes before charging.
  • Page 105 Operation Connecting the rechargeable battery to an external charger – Press the emergency off switch (1).  Lead acid batteries – Open the battery cover.  – Remove the battery male connector (1) from the forklift power connector(2). – Connect the external charger plug to the battery connector (1).

  • Page 106: Check Rechargeable Battery Condition, Electrolyte Level And Specific Gravity (Lead-Acid Battery)

    Operation Check rechargeable battery condition, electrolyte level and specific gravity (lead-acid battery). – Connect the external charger plug to the  lithium battery connector (1). – Switch on charger.  CAUTION When inserting the battery plug, make sure that the plug is fully seated. Check rechargeable battery condition, electrolyte level and specific gravity (lead-acid...
  • Page 107 Operation Check rechargeable battery condition, electrolyte level and specific gravity (lead-acid battery).  CAUTION Deep discharge (more than 20% of the battery rated capacity) will cause the battery life to shorten.  CAUTION Always use and maintain the lithium-ion battery in accordance with instructions from the manufacturer. 5001 801 1626 EN - 10/2023  - ...

  • Page 108: Lifting Devices And Attachments

    Operation Lifting devices and attachments Lifting devices and attachments Operating the lifting device  WARNING There is a risk of being trapped between parts due to the movement of the lift mast or attachments. Never stand near or enter the lift mast, or the area between the lift mast and the truck.

  • Page 109: Operating Attachments

    Operation Lifting devices and attachments Lifting the fork carriage  – Push lever (1)back. Lowering the fork carriage – Push lever (1)forwards. Tilting the lift mast forward – Push the lever (2)forwards. Tilting the lift mast backwards – Pull lever (2)back. e129304008s  DANGER There is an increased risk of falling and tilting when...
  • Page 110 Operation Lifting devices and attachments NOTE After installing each attachment, a label should be attached to the battery cover spec- ifying the truck's load capacity after the instal- lation.An attachment operating note should al- so be attached to the back of the attachment operating lever.

  • Page 111: Transporting Loads

    Operation Transporting loads Transporting loads Load centre distance and load capacity Before lifting goods, the relationship between the weight, load centre of gravity distance and maximum lift height of the goods must be un- derstood. – Load centre distance refers to the distance ...
  • Page 112 Operation Transporting loads The load capacity of a truck depends on: Type of the lift mast (standard, duplex, tri- ● plex) Lifting height of the installed lift mast ● Tyres of the front axle ● Whether attachments or additional equip- ●...
  • Page 113 Operation Transporting loads Capacity rating plate Fork arms dimensions: Maximum width, maximum thickness and maximum length, in mm Note: If larger fork arms are used, an additional capacity rating plate is required. Please contact your authorised dealer. Identification of attachments: Integral sideshift (ISS), suspended sideshift (SS) Lift mast types: Standard lift mast S, duplex lift mast D, triplex lift mast T Truck model name Symbol of load gravity centre...

  • Page 114: Additional Capacity Rating Plate

    Operation Transporting loads Load capacity example:  Load centre of gravity distance: 600 mm (9). Load lift height: 4145 mm (10). – Locate the intersection of the column of the 600 mm load centre of gravity distance and the row of the 4145 mm lift height. In this example, the maximum permissible load capacity is 2000 kg (11).

  • Page 115: Adjusting The Fork Spacing

    Operation Transporting loads NOTE The additional capacity rating plate has differ- ent data for different truck series, lift mast series, and attachments. Please refer to the "Capacity rating plate" chapter on how to read the additional capacity rating plate. Adjusting the fork spacing ...

  • Page 116: Picking Up A Load

    Operation Transporting loads Picking up a load  DANGER  DANGER Fall and crush hazard There is a risk of crushing as the lift mast or attachments may move. Standing on the forks is strictly prohibi- ted. For this reason, never reach into or enter the lift mast, or the area between the lift It is strictly prohibited to use the forks, mast and the forklift.

  • Page 117: Transporting Pallets

    Operation Transporting loads Transporting pallets  As a rule, loads (e.g. pallets) must be trans- ported individually. Transporting multiple loads at the same time is only permitted: when instructed by the supervisor and ● when the technical requirements have been ●...

  • Page 118: Picking Up A Load

    Operation Transporting loads  DANGER Loss of stability! Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over. – When transporting suspended loads, observe the following instructions. Instructions for transporting suspended loads: Swinging loads must be prevented by using ●...
  • Page 119 Operation Transporting loads equipment and incorrectly formed loads must not be stored. – Attach or secure the load to the lifting ac- cessory so that the load cannot move or fall. – Store the load so that the specified aisle width is not reduced by protruding parts.
  • Page 120 Operation Transporting loads – Insert the fork as far under the load as pos-  sible. Stop the truck as soon as the fork back is resting on the load. The load centre of gravity must be midway between the fork arms.
  • Page 121 Operation Transporting loads – Lower the load while maintaining ground  clearance. 5060_003-102 – Tilt the lift mast backwards.  The load can be transported. 5060_003-101 5001 801 1626 EN - 10/2023  -  04  111...

  • Page 122: Transporting Loads

    Operation Transporting loads Transporting loads  NOTE Observe the information in the chapter entitled "Safety regulations when driving".  DANGER The higher a load is lifted, the less stable it be- comes. The truck can tip over. The load can fall. There is an increased risk of accidents.

  • Page 123: Setting Down Loads

    Operation Transporting loads – Never drive with a load protruding to the  side (e.g. with the sideshift)! Setting down loads  DANGER Risk of accident due to changed moment of tilt! Please note that the lift mast can be tilted far enough forward with a raised load to cause the truck to tip over.
  • Page 124 Operation Transporting loads – Drive up to the stack with the load lowered  in accordance with regulations. – Set the lift mast to vertical. – Lift the load to the stacking height. – Approach the rack at a moderate speed. NOTE The tilt speed of the lift mast in this truck is significantly higher than for previous products...

  • Page 125: Driving On Ascending And Descending Gradients

    Operation Transporting loads Driving on ascending and de-  scending gradients  DANGER Danger to life! Driving on ascending and descending gradients car- ries special dangers! – Always follow the instructions below. – On ascending and descending gradients, the load must be carried facing uphill. –...

  • Page 126: Tow Coupling

    Operation Transporting loads Tow coupling If the truck breaks down, it can be towed using the tow coupling. The tow coupling can only be used for hauling light loads in factory areas. (Pay attention to accident prevention and comply with technical safety regulations) –...

  • Page 127: Before Exiting The Truck

    Operation Transporting loads – Depress the parking brake pedal (1) until it  reaches the locked position. – The parking symbol Ⓟ on the display unit  comes on and remains lit. The truck is braked.  WARNING Make sure that the truck does not move. NOTE When leaving the truck temporarily, be sure to keep the truck under constant supervision.
  • Page 128 Operation Transporting loads   DANGER Do not switch off the truck by turning the key when the truck is moving.  DANGER The handbrake must be applied and the key re- moved before exiting the vehicle. Do not leave the truck on a ramp except in emergency situations. In such case, place chocks (3) under the front wheels to immobilise the vehicle.

  • Page 129: Operation In Special Operating Situations

    Operation Operation in special operating situations Operation in special operating situations Transport  CAUTION Danger of material damage from overloading! If the truck is driven onto a means of transport, the load capacity of the means of transport, the ramps and loading bridges must be greater than the actual total weight of the truck.
  • Page 130 Operation Operation in special operating situations  DANGER Risk of accident from the truck crashing! Steering movements can cause the tail end to veer off the loading bridge towards the edge. This may cause the truck to crash. – Before driving over a loading bridge, ensure that it is installed and secured properly.

  • Page 131: Towing

    Operation Operation in special operating situations Towing   DANGER The brake system on the towing vehicle may fail. There is a risk of accident! If the brake system of the towing vehicle is not ade- quately sized, the vehicle may not brake safely or the brakes may fail.
  • Page 132 Operation Operation in special operating situations  DANGER People can be crushed between the truck and tow- ing vehicle during manoeuvring. There is danger of death! The towing vehicle may only be manoeuvred and the tow bar may only be attached using a second person as a guide.

  • Page 133: Crane Loading

    Operation Operation in special operating situations – Where possible, activate the restraint sys- tems provided. – Release the parking brake. – Select a towing speed that allows the truck and towing vehicle to be effectively braked and controlled at all times. –...
  • Page 134 Operation Operation in special operating situations Hooking on the lifting straps  6321_003-069  CAUTION Harnesses may damage the truck's paintwork! Harnesses may damage paintwork by chafing and pressing on the surface of the truck. Particularly hard or sharp-edged harnesses, such as wires or chains, can quickly damage the surface.
  • Page 135 Operation Operation in special operating situations – Set the length of the harnesses so that the  lifting eye (6) is vertically above the truck's centre of gravity. This ensures that the forklift truck hangs level when lifting it. – Connect the lifting straps to the lifting eye and insert the safety device (7).

  • Page 136: Storing The Truck

    Operation Storing the truck Storing the truck Taking the truck out of operation If the truck will not be used for over two NOTE months, place it in a very well ventilated, frost- free, clean and dry room. Additionally, the If the forklift truck is not in use for over 6 steps below should be followed: months, contact your authorised dealer in or-...
  • Page 137 Operation Storing the truck During the maintenance process, please make NOTE sure that the forklift truck is stationary on flat ground and that it does not slide. If the forklift truck is used in an extreme envi- ronment (such as excessive heat, excessive Lower the fork carriage and slowly tilt the lift cold or areas with high dust concentrations), mast forward until the truck is stationary.

  • Page 138: Disposal Of Old Trucks

    Operation Disposal of old trucks Disposal of old trucks smeared parts, as well as for tyres including The disposal of old trucks is regulated in di- fire protection measures. Suitable storage rective 2000/53/EC from the European Parlia- tanks for fluids such as fuel, AdBlue® (urea ment and Council.

  • Page 139: Maintenance

    Maintenance...

  • Page 140: Safety Information For Inspection And Maintenance Work

    Maintenance Safety information for inspection and maintenance work Safety information for inspection and maintenance work The industrial truck will only remain ready for  WARNING operation at all times if the maintenance and Any side doors fitted could fall shut during mainte- inspection tasks are performed at regular in- nance work and trap staff.

  • Page 141: Inspection And Maintenance Data

    Maintenance Inspection and maintenance data Inspection and maintenance data Consumable/equip- Filling quantity/set- Components ment tings Distilled water As required Battery Acid-free grease As required Electric motors: Cleaning apparatus for Drive motor As required electrical equipment Hydraulic motor Hydraulic system Standard mast 20L Standard, duplex and Hydraulic oil Duplex mast 20L...
  • Page 142 Maintenance Inspection and maintenance data Hexagon head bolt M10x1, 25x30-8.8- Tightening torque 49 N.m Transmission gear in- Hexagon head Tightening torque stallation bolt M10x1, 25x25-8.8- 49 N.m Tightening torque Hexagon head bolt 195 N.m M16x70-8.8-ZNS Installation of the drive Hexagon head bolt Tightening torque axle M22x1, 5x55-8.8-ZLS 570 N.m...

  • Page 143: Recommended Fuels And Oils

    Maintenance Recommended fuels and oils Recommended fuels and oils ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. Quantity Component Original oil/fluid International standard name   Gear oil SAE80W-90 API-GL5 Drive axle 0.25   For brake fluid reservoir DOT4 brake fluid  ...

  • Page 144: Regular Maintenance

    Maintenance Regular maintenance Regular maintenance The following maintenance will help in improv- ing the truck condition and ensure its function- ality. The user need complete this work as regularly as possible, in accordance with the operating environment. Clean the truck (as required). ●...

  • Page 145: Table Of First Service Checks

    Maintenance Table of first service checks Table of first service checks Maintenance precautions Servicing work requires specialised knowledge and special tools. Please contact your authorised dealer immediately. Preparations Clean the truck (as required). Check that all labels are complete and legible. Read and delete error content.
  • Page 146 Maintenance Table of first service checks Conduct the first maintenance after 1000 operating hours, or at least 12 months. Lubricate the driver's seat guide. Check seat belt condition and correct operation. Electrical system Check the working condition of the fan and clean the fan. Check the power module for dirt and clean if necessary.

  • Page 147: Service Plan Table

    Maintenance Service plan table Service plan table Maintenance precautions Servicing work requires specialised knowledge and special tools. Please contact your authorised dealer immediately. Preparations Clean the truck (as required). Check that all labels are complete and legible. Read and delete error content. Reset the maintenance interval.
  • Page 148 Maintenance Service plan table Perform additional maintenance every 1000 operating hours or at least once every 1 year (primarily for checks)   (Unless bracketed information states otherwise) Check the pedal group for ease of movement, and lubricate. Lubricate the driver's seat guide. Check seat belt condition and correct operation.
  • Page 149 Maintenance Service plan table Perform additional maintenance every 3000 operating hours or at least once every 3 years   (Unless bracketed information states otherwise)   Drive mechanism and transmission system Change the gear oil. Hydraulic system Replace the breather filter. Replace the suction filter insert.

  • Page 150: Cleaning The Truck

    Maintenance Cleaning the truck Cleaning the truck The frequency with which cleaning is required When cleaning with compressed air, remove depends on the application of the truck. If stubborn contamination with a cold cleaning highly abrasive materials, e.g. salt water, fer- solvent.

  • Page 151: Drive Mechanism And Transmission System

    Maintenance Drive mechanism and transmission system Drive mechanism and transmission system Checking the transmission gear and drive axle for leaks – Remove the rubber mat from the floorplate. – Remove the floorplate. – Check the appearance of the transmission gear and drive axle for evidence of leakage. NOTE If the transmission gear or drive axle is leak- ing, please contact your authorised dealer.

  • Page 152: Checking The Installation Of The Transmission Gear

    Maintenance Drive mechanism and transmission system Checking the installation of the  transmission gear – Check installation of the connecting bolts of the gearbox (1) and drive axle (2). – If necessary, use a torque wrench to re- tighten the bolts. NOTE Check the "...

  • Page 153: Checking The Joystick Bellows

    Maintenance Drive mechanism and transmission system – Check the brake fluid level (1) in the brake  fluid reservoir. If necessary, undo the lid of the brake fluid reservoir (2) and top up with brake fluid. Otherwise, the brakes may fail. Please refer to "Recommended fuels and oils"...

  • Page 154: Checking The Wheels

    Maintenance Drive mechanism and transmission system Checking the wheels Checking for tyre damage Checking for foreign objects in the tyre Secure the truck to prevent movement. – Apply the parking brake. – Put chocks behind the wheels that do not require lifting.

  • Page 155: Check The Tyre Inflation Pressure

    Maintenance Drive mechanism and transmission system Antistatic tyres  NOTE Under certain circumstances, the truck may become electrostatically charged. The charge level depends on a number of factors, such as the type of tyre, air humidity, floor covering etc. Excessive electrostatic charge is noticed ●...

  • Page 156: Tightening The Wheel Nuts

    Maintenance Drive mechanism and transmission system – Check the specific inflation pressures of the tyres. – When necessary, inflate and deflate using the inflation valve. NOTE See the " Inspection and maintenance data " chapter for the specified tyre inflation pres- sures.
  • Page 157 Maintenance Drive mechanism and transmission system  CAUTION When using wheels that are not antistatic, pay atten- tion to the antistatic belt. When changing wheels that are not antistatic, the truck must be equipped with an antistatic belt as these wheels are not electro conductive. The antistatic belt must be in permanent contact with the ground.

  • Page 158: Checking The Condition Of The Antistatic Belt

    Maintenance Drive mechanism and transmission system – Loosen all nuts on the wheel to be  changed. – Lift the truck with a hydraulic jack until the wheel is off the ground. NOTE If front wheels are to be changed, place a chock behind the rear wheels to prevent the truck sliding backwards.

  • Page 159: Clean And Lubricate The Steering Axle

    Maintenance Drive mechanism and transmission system – Check that the antistatic belt is securely – If the antistatic belt is damaged, replace seated on the base of the chassis, check the antistatic belt. the condition and check for wear. Clean and lubricate the steering axle Cleaning the steering axle –...

  • Page 160: Chassis And Bodywork

    Maintenance Chassis and bodywork Chassis and bodywork Checking the connecting bolts of  the drive axle and lift mast – Check the installation of the bolts connect- ing the drive axle to the lift mast. – Retighten if necessary. NOTE Check the "Inspection and maintenance da- ta"...

  • Page 161: Checking The Battery Cover Locking Devices

    Maintenance Chassis and bodywork  WARNING It is strictly forbidden to modify the overhead guard without permission, such as drilling, welding, etc Checking the battery cover lock- ing devices The truck must not be started under any cir- cumstances until the battery cover is fully closed.

  • Page 162: Driver's Cab

    Maintenance Driver's cab Driver's cab Checking the pedal group for  ease of movement and lubricat- ing as required – Remove the rubber mat from the floorplate. – Remove the floorplate. – Check bolt and joint fastenings for secure positioning. –...

  • Page 163: Checking That The Brake System Is Functioning Properly

    Maintenance Driver's cab Checking that the brake system is functioning properly Checking whether the parking brake is  WARNING working normally There is a risk of accident or death if the braking system is faulty. – Drive the truck on a slope with a 15% gradi- ent while transporting a load corresponding The forklift truck must not be driven if the brake sys- tem is defective.

  • Page 164: Electrics/Electronics

    Maintenance Electrics/electronics Electrics/electronics Checking the module for dirt ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. The module is installed inside the truck coun-  terweight. – Engage the parking brake. – Switch off the truck. – Press the emergency off switch. –...

  • Page 165: Checking The Condition Of The Batteries

    Maintenance Electrics/electronics Checking the condition of the batteries – Disconnect the battery male connector and  WARNING battery female connector. There is a risk of chemical burns from the battery electrolyte (sulphuric acid). – Check whether the battery unit connectors are damaged and whether they are firmly Therefore, when handling battery acid, be sure connected.
  • Page 166 Maintenance Electrics/electronics – Safety pin (2)facing counterweight.  Opening the safety bracket – Twist the bracket(1) upwards.  – Slide the bracket(2) in the elongated holes and lift it away. The bracket is secured with a loss prevention cable.  156 5001 801 1626 EN - 10/2023  - ...
  • Page 167 Maintenance Electrics/electronics Removing the safety pin – Twist the safety pin that the bracket faces  upwards. – Pull the safety pin out.  – After opening the safety bracket, removing the safety pin, and you can lift the battery out of the truck.

  • Page 168: Replacing The Battery Using A Suspension Arrangement

    Maintenance Electrics/electronics Replacing the battery using a suspension arrangement Replacing the battery using a suspen- sion arrangement (hoist)  CAUTION Risk of accident. Only use a suspension arrangement with sufficient load capacity that has been approved by the manu- facturer. Use a hoist and lifting hook with sufficient lift capaci- ty (refer to the technical datasheet for the battery weight).
  • Page 169 Maintenance Electrics/electronics – Insert the four hooks on the suspension ar-  rangement into the special lifting holes (3).  WARNING Risk of tipping if the entire suspension arrangement is not lifted. – Carefully lift the battery cover. NOTE The battery can be withdrawn when it is lifted above the sides of the battery compartment.

  • Page 170: Battery Installation

    Maintenance Electrics/electronics – Open the battery cover until the mechanical  locking devices click into the limit position. – Lift the entire battery suspension arrange- ment using the fork arms (3) of the truck. – Use pull cords (2) to secure the suspension arrangement on the fork arms.

  • Page 171: Inspecting And Maintaining The Lithium-Ion Battery

    Maintenance Electrics/electronics – Install the battery limit support (*lead-acid  battery) (1). NOTE The battery limit support is used to secure the lead-acid battery. Remove the battery limit support before replacing the battery. The lithi- um-ion battery model doesn't have a battery limit support.

  • Page 172: Hydraulics

    Maintenance Hydraulics Hydraulics Checking the hydraulic system for leaks – Remove the rubber mat from the floorplate. – Remove the floorplate. NOTE Remove the accelerator connection plug from the floorplate. – Check the hydraulic pump of the working and steering hydraulics, valves, hoses and lines for leaks.
  • Page 173 Maintenance Hydraulics – Open the battery cover. The hydraulic oil  tank is located on the rear right-hand side of the forklift truck. – Unscrew the breather filter (1) and dipstick  (2) together. – Use a clean cloth to wipe the dipstick. –...

  • Page 174: Checking The Breather Filter Is Working Normally

    Maintenance Hydraulics – Depending on the different types of mast,  the oil level should reach the corresponding mark on the dipstick. S/D - Standard mast/Duplex mast ● T - Triplex mast ● – When required, fill the hydraulic oil up to the upper notch.

  • Page 175: Checking Installation Of The Tilt Cylinder

    Maintenance Hydraulics – Open the breather filter (1) on the hydraulic  oil tank. Ensure the sound of air escaping from the oil tank is heard. – Replace the breather filter if you do not hear the sound of ventilation. ENVIRONMENT NOTE Dispose of the old breather filter in an environ- mentally friendly manner.

  • Page 176: Lubricating Tilt Cylinder Bearings

    Maintenance Hydraulics Lubricating tilt cylinder bearings  ENVIRONMENT NOTE Observe information regarding the use of con- sumables. – Check and lubricate the tilt cylinder bear- ings. NOTE Refer to the "Recommended fuels and oils" table for oil types.  166 5001 801 1626 EN - 10/2023  -  04...

  • Page 177: Lifting System

    Maintenance Lifting system Lifting system Checking the fork arms and the fork arm quick release apparatus – Check the fork arms for serious deforma- tion, abrasion and damage. E.g.:The thickness of the horizontal and ver- tical sections of the fork arms has been re- duced to 90% of the design thickness, or to the minimum thickness stipulated by the fork arm or forklift truck manufacturer.If the fork...

  • Page 178: Checking The Working Condition And Installation Of The Lift Mast, Lifting Chains And Lift Cylinder

    Maintenance Lifting system Checking the working condition and installation of the lift mast, lifting chains and lift cylinder – Clean the mast channel and lifting chains.  – Check the working status of the lifting chains, along with any signs of abrasion, paying particular attention to the area around the chain wheels.

  • Page 179: Adjusting The Length Of The Lifting Chains And Lubricating Using Chain Spray

    Maintenance Lifting system Adjusting the length of the lift- ing chains and lubricating using chain spray Adjusting the length of the lifting chains*  NOTE Use over time will cause the lifting chains to stretch. Therefore, it is necessary to check and adjust the lengths of both the left and right chains.

  • Page 180: Lubricating The Lift Mast And Chains With Chain Spray

    Maintenance Lifting system Adjusting the length of the lifting chains*  NOTE Use over time will cause the lift chains to stretch, therefore it is necessary to check and adjust their lengths. – Fully lower the lift mast. – Undo the lock nut (1). –...
  • Page 181 Maintenance Lifting system – Place an oil collecting trough under the lift  mast – Carry out cleaning with an alkyl derivative such as an industrial diesel fuel cleaning agent (please comply with the manufactur- er's safety instructions). – Additives may not be used if using a steam nozzle.

  • Page 182: Special Equipment

    Maintenance Special equipment Special equipment Checking the preload of the dou- ble hoses (if equipped with at- tachments) – The double hoses should be preloaded by  stretching them 5-10mm per meter based on their original length. – Move the hoses between the retaining clips so as to adjust the preload to the predeter- mined value.
  • Page 183 Maintenance Special equipment – Add lubricating grease to the oil filling ports  (1), (2) and (3) on the fork carriage until fresh grease overflows from the filling port. NOTE The sideshift forks must be lubricated each time the forklift truck is cleaned. *Optional part 5001 801 1626 EN - 10/2023  - ...
  • Page 184 Maintenance Special equipment  174 5001 801 1626 EN - 10/2023  -  04...

  • Page 185: Technical Datasheet

    Technical datasheet...

  • Page 186: Dimensions Overview

    Technical datasheet Dimensions overview Dimensions overview  176 5001 801 1626 EN - 10/2023  -  04...

  • Page 187: Datasheet

    Technical datasheet Datasheet Datasheet Manufacturer   KION JN KION JN Model   RCE 25 RCE 25 Li-Ion Drive: Electric (battery, power supply...),   Electric Electric diesel, petrol, LPG, AC Operator type: hand, pedestrian, stand-   Seated Seated ing, seated, order-picker...
  • Page 188 Technical datasheet Datasheet Fork dimensions, according to DIN ISO s / e / l 4.22 45x100x1000 45x100x1000 2331 [mm] Fork carriage, according to ISO 2328, 4.23   class/type A, B 4.24 Fork-carriage width b3 [mm] 1040 1040 4.31 Ground clearance, laden, below mast m1 [mm] 4.32 Ground clearance, centre of wheelbase...

  • Page 189: Eco-Design Requirements For Electric Motors And Variable Speed Drives

    Technical datasheet Eco-design requirements for electric motors and variable speed drives Eco-design requirements for electric motors and variable speed drives All motors in this industrial truck are exempt from Regulation (EU) 2019/1781 because these motors do not meet the description giv- en in Article 2 "Scope", Item (1) (a) and be- cause of the provisions in Article 2 (2) (h) "Motors in cordless or battery-operated equip-...
  • Page 190 Technical datasheet Eco-design requirements for electric motors and variable speed drives  180 5001 801 1626 EN - 10/2023  -  04...
  • Page 191 Index   Checking the installation of the drive axle. 142 Checking the joystick bellows..Additional capacity rating plate..Checking the main contactor..154 Address of manufacturer.
  • Page 192 Index   Dimensions overview....176 Insulation testing....Directive RED 2014/53/EU.
  • Page 193 Index   Serial number..... . . Service plan before first start... 62 Packaging.
  • Page 196 STILL GmbH 5001 801 1626 EN - 10/2023  -  04...

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