Still RCD 25 Plus Original Instructions Manual
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Still RCD 25 Plus Original Instructions Manual

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Original instructions
IC Truck
RCD 25 Plus
RCD 30 Plus
RCD 35 Plus
5227 5228 5229 5321 5322 5323
1289 801 1521 EN - 09/2023  -  05

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Summary of Contents for Still RCD 25 Plus

  • Page 1 Original instructions IC Truck RCD 25 Plus RCD 30 Plus RCD 35 Plus 5227 5228 5229 5321 5322 5323 1289 801 1521 EN - 09/2023  -  05...
  • 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. 1289 801 1521 EN - 09/2023  -  05  I...
  • Page 4  You can request to download the spare parts list by copying and pasting the address https:// sparepartlist.still.eu into a web browser or by scanning the QR code shown to the side. On the web page, enter the following pass-...

  • Page 5: Table Of Contents

    Table of contents   Introduction   Your industrial truck ...........  2 Technical description.
  • Page 6 Table of contents   Basic principles for safe operation........ 26 Insurance cover on company premises.
  • Page 7 Table of contents   Safety regulations when driving......... .  53 Safety regulations in case of accidental lateral tipping .
  • Page 8 Table of contents   Inching control ............ 86 Starting on an incline .
  • Page 9 Table of contents   Storing the truck............ 132 Shutting down and storing the truck .
  • Page 10 Table of contents   Internal combustion engine - Doosan D24 EU5 ...... 168 Checking the engine oil level.
  • Page 11 Table of contents   Replacing the return oil filter .......... 195 Checking the hydraulic oil level .

  • Page 13: Introduction

    Introduction...

  • Page 14: Your Industrial Truck

    IC trucks in this range: the steering wheel turns the rear wheels by means of the steering cylinder. RCD 25 Plus, RCD 30 Plus, RCD 35 Plus Steering is possible even when the engine is Drive system stopped, although it requires additional effort to turn the steering wheel.

  • Page 15: General

    Introduction Your industrial truck The required power is supplied by the 12 V, 80 Ah battery built into the chassis. 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.

  • Page 16: 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 17: 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 18: Nameplate

    Introduction Your industrial truck Nameplate  1   Nameplate 2   Manufacturer 3   Model/Product no./Year of manufac- ture 4   Unladen mass 5   Battery weight (max./min.) 6   Service weight 7   Placeholder for "Data matrix code" 8   Conformity marking: CE mark for the markets of the EU, the EU candidate countries, the EF-...

  • Page 19: 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 20: Intended Use

    Introduction Using the truck Intended use The industrial truck may be used only for its provided so that trucks can drive over these intended purpose. obstacles with as few bumps as possible. The industrial truck is intended for moving and Industrial trucks may only be used on road- lifting the loads specified on the capacity rat- ways that do not have bends that are too...

  • Page 21: Improper Use

    Introduction Using the truck Attachments Mounting the attachment and connecting the energy supply for power-driven attachments Attachments may only be used for their inten- must only be performed by authorised person- ded purpose. Drivers must be taught how to nel in accordance with the information provi- operate the attachments.

  • Page 22: Precautions

    Introduction Using the truck When driving, do not place any part of your Drive a loaded truck in reverse when going body outside the confines of the truck, lean on downhill. the edge of the truck or attempt to jump onto When raising a spreader, ensure that there is another truck or object.

  • Page 23: Using Working Platforms

    Introduction Using the truck – Ambient temperature in tropical and Nordic regions ranging from -20 °C to +45 °C. – Use at up to 2000 m above sea level. Using working platforms  WARNING The use of working platforms is regulated by national law.

  • 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: Stability

    Safety Stability Stability Turning on and driving diagonally across Stability is guaranteed if your industrial truck is ● descents or ascents used according to its intended use. Driving on descents or ascents with the ● The following actions may jeopardise stability: load on the downhill side Driving with a raised load Loads that are too wide...

  • Page 35: 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 36: 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 37 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 38: 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 39 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 40: 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 41: Damage, Defects And Misuse Of Safety Systems

    Safety Basic principles for safe operation ries) is permitted only with the approval of the manufacturer. Damage, defects and misuse of safety systems Damage or other defects on the truck or at- tachment must be reported to the supervisor or responsible fleet manager immediately so that they can have the defect rectified.

  • Page 42: Length Of The Fork Arms

    Safety Basic principles for safe operation The following factors can lead to a loss of stability and are therefore prohibited: Different tyres on the same axle, e.g. pneu- ● matic tyres and superelastic tyres Tyres not approved by the manufacturer ●...

  • Page 43: Exercise Caution When Handling Gas Springs And Accumulators

    Safety Basic principles for safe operation If the fork arms are too short, the load may fall off the arms after it has been picked up. In ad- dition, be aware that the load centre of gravity may shift as a result of dynamic forces, such as braking.

  • Page 44: 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 45: 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 46 Safety Residual risks use the truck correctly and without the risk of accidents.  34 1289 801 1521 EN - 09/2023  -  05...
  • Page 47 Safety Residual risks 1289 801 1521 EN - 09/2023  -  05  35...

  • Page 48: 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 49 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 50: 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 51 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 52: Safety Tests

    Safety Safety tests Safety tests Carrying out regular inspections  on the truck 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, the technical condi- tion of the truck must be completely tested with regard to accident safety.

  • Page 53: Checking The Diesel Engine Emissions

    Safety Safety tests Measuring the insulation resistance of the electrical system NOTE Nominal battery voltage < test voltage < 500 V. – Ensure that all voltage sources have been disconnected from the circuit to be tested. – Measure the insulation resistance with a suitable measuring device.

  • Page 54: 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 55: Oils

    Safety Safety regulations for handling consumables  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 56: Diesel Fuel

    Safety Safety regulations for handling consumables  WARNING Prolonged intensive contact with the skin can result in dryness and irritate the skin! – Avoid contact and consumption. – Wear protective gloves. – After any contact, wash the skin with soap and water, and then apply a skin care product.
  • Page 57 Safety Safety regulations for handling consumables  WARNING Diesel fuel is toxic! – Avoid contact and swallowing. – If vapour or fumes are inhaled, ad- minister fresh air immediately. – After contact with the eyes, rinse thor- oughly (for at least 10 minutes) with water and then consult an eye spe- cialist.

  • Page 58: Coolant And Cooling Fluid

    Safety Safety regulations for handling consumables Coolant and cooling fluid  WARNING Coolant and cooling fluid can be hazard- ous to your health and the environment! Coolants are chemical corrosion inhib- itors and cooling system protecting agents such as Glysantin. The cooling fluid is an appropriate mixture of water and coolant.
  • Page 59 Safety Safety regulations for handling consumables  WARNING Brake fluid is hazardous to your health! Brake fluid irritates the eyes and can dry out the skin upon prolonged contact. – Coat your hands with a protective skin cream prior to starting work. –...

  • Page 60: Disposal Of Consumables

    Safety Noise level Disposal of consumables Any spillage of fluids such as hydraulic oil, ● ENVIRONMENT NOTE brake fluid or gear lubricant oil must be immediately soaked up with an oil-binding Materials that have to be disposed of follow- agent. ing maintenance, repair and cleaning must The regulations for disposal of used oil are be systematically collected and disposed of in...

  • Page 61: Exhaust Gases

    Safety Exhaust gases NOTE The indicated vibration frequency imparted to the human body cannot be used to determine the actual frequency load when operating the truck. This frequency load depends on operat- ing conditions (road surface conditions, oper- ating modes etc.) and must therefore be deter- mined according to site conditions, if necessa- Exhaust gases  CAUTION...

  • Page 62: Heat

    Safety Heat Heat  DANGER Risk of burns due to hot exhaust gases! Exhaust gases or components that carry exhaust gases (e.g. exhaust pipes) can become so hot that direct body contact can cause burns to the skin and materi- als that are too close can be burnt or singed.

  • Page 63: Manually Lowering The Fork Arms With Iso

    Safety Manually lowering the fork arms with ISO – The emergency hammer (1)is behind the  driver's seat on the left pillar of the cab.  CAUTION Glass splinters may cause injuries. Remove glass splinters carefully. – Take the emergency hammer (1) carefully break the rear window.

  • Page 64: Safety Regulations Relative To Forklift Use

    Safety Safety Regulations Relative to Forklift Use – Refit the foot plate and the joystick base cover. Safety Regulations Relative to Forklift Use The operator must familiarize himself with ● ENVIRONMENT NOTE the forklift to be able to better describe any defects and assist maintenance personnel.

  • Page 65: 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. 1289 801 1521 EN - 09/2023  -  05  53...

  • Page 66: 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 67: Overview

    Overview...

  • Page 68: General View

    Overview General view General view Lift mast Bonnet Handhold Diesel filler port Drive direction selection lever Steering axle Steering column adjustment screw Counterweight Fork carriage Rear cover Forks Forklift rear combination lights Drive axle Overhead guard Non-slip tread Steering wheel Driver's seat Headlight  56...

  • Page 69: Controller And Display Unit

    Overview Controller and display unit Controller and display unit Driving brake pedal Switch panel Inching control pedal Key switch Parking brake pedal Display unit Drive direction selection lever Accelerator pedal/throttle Clamping screw for adjusting the steering Attachment operating lever (optional) column Attachment operating lever (optional) Horn button...

  • Page 70: Warning Label Diagram

    Label, Refuel here Label, Lifting points Oil index signage labels Label, Read the operating manual Label, noise level Label text, Still + RCD 25/30/35 plus Label, scald prevention warning Label, Lifting points Label, prick the hand warning Label, driving warning...

  • Page 71: Display Unit

    Overview Display unit Display unit 1289 801 1521 EN - 09/2023  -  05  59...

  • Page 72: Switch Panel

    Overview Switch panel Back button Fasten seat belt symbol Up button Engine oil pressure symbol Down button Parking brake symbol Enter/modify button Direction Left turn Engine warning symbol Maintenance time Hydraulic oil temperature super high Date Intake air preheating Time Air filter alarm Right turn CAN communication symbol (Blue -CAN...

  • Page 73: Relays And Fuses Overview

    Overview Relays and fuses overview  CAUTION The above switches may be displayed, depending on your actual configuration. Relays and fuses overview Relay and fuse box installation position – The relay and fuse box are located under  the foot pedal. They can be accessed by removing the foot pedal.
  • Page 74 Overview Relays and fuses overview Relay and fuse definitions: 100 A/32 V Charging fuse 60 A/32 V Preheating fuse 40 A/32 V KL30 master fuse 60 A/32 V Starter fuse 40 A/32 V Comprehensive driver's cab power supply 15 A/32 V Main relay fuse 10 A/32 V Key switch fuse 10 A/32 V Main relay output 10 A/32 V Sidelight fuse 10 A/32 V...
  • Page 75 Overview Relays and fuses overview Relay and fuse definitions ( Truck with Doosan engine) Relay and fuse definitions: 120 A/32 V Charging fuse 60 A/32 V Preheating fuse 40 A/32 V KL30 master fuse 60 A/32 V Starter fuse 40 A/32 V Comprehensive driver's cab power supply 15 A/32 V Main relay fuse 10 A/32 V Key switch fuse 10 A/32 V...
  • Page 76 Overview Relays and fuses overview  64 1289 801 1521 EN - 09/2023  -  05...

  • Page 77: Operation

    Operation...

  • Page 78: Service Plan Before First Start

    Operation Service plan before first start Service plan before first start Internal combustion engine Check the coolant level. Check the fuel level. Check the engine oil level. Check the parts and wiring connections. Check the truck for leaks (visual inspection). Drive mechanism and transmission system Check the drive axle/transmission gear oil level.

  • Page 79: Pre-Shift Checks

    Operation Pre-shift checks Pre-shift checks Carrying out the following checks as part of your daily routine will help to keep the fork- lift truck in good condition. These checks are supplemental and do not replace periodic maintenance work. 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-...

  • Page 80: Daily Inspection Items

    Operation Daily inspection items Daily inspection items Internal combustion engine Check coolant level, engine oil level and fuel level. Check whether the grease at the positions requiring grease is sufficient. Check for leakage of oil, water and air. Check whether the external connectors and accessories are well connected and tightened. Check whether the fan and belt are too tight or too loose.
  • Page 81 Operation Daily inspection items Hydraulic system Check the oil level. Visually inspect the truck for leaks. Lifting system Check the safety fittings on the fork arms and carriage. Special equipment Check wear and functionality of the sideshift and attachments (in accordance with the proce- dures stipulated by the manufacturer).

  • Page 82: 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 83: 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 84 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 85 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 86: 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 87: 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 88: 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 89 Operation Adjusting the steering column 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. 1289 801 1521 EN - 09/2023  -  05  77...

  • Page 90: 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 91 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 92 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 93 Operation Keypad（*Option） 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 94: Starting The Engine

    Operation Starting the engine Starting the engine Starting the engine  DANGER Risk of poisoning! Do not allow the engine to run in unventilated areas. NOTE Where possible, avoid frequently starting and stopping the engine over short periods of time, since this prevents the internal combustion en- gine from reaching its operating temperature.
  • Page 95 If the engine fails to start: When restarting the engine, wait for at least 1 minute between successive attempts to save the battery. If the engine still fails to start after three attempts, have it inspected by qualified technical personnel. The engine speed is adjusted automatically based on the size of the load.

  • Page 96: Engine Shutdown

    Operation Starting the engine NOTE Do not allow the engine to warm up by idling. Running at moderate load and varying speed will bring the engine and hydraulic system up to normal operating temperature within a short time. Engine shutdown  CAUTION Do not stop the engine when it is running at full load.

  • Page 97: Driving

    Operation Driving Driving Driving NOTE The truck can only be driven with the driver's seat under load. – Switch on the engine.  – Gently open the fork carriage and slightly tilt the lift mast backwards. – Release the parking brake pedal (5).  CAUTION It is generally not permitted to drive on long gradi- ents over 31% (unladen) due to specified minimum...

  • Page 98: Changing The Drive Direction

    Operation Driving – Smoothly press the accelerator pedal (3). The reverse speed of the truck changes in proportion to the pedal stroke. NOTE When the manual direction lever is shifted into forward or reverse gear, the vehicle remains at low idling speed and may move forwards or backwards even when the accelerator pedal is not depressed.

  • Page 99: Starting On An Incline

    Operation Driving – Steadily depress the inching control pedal  (4). – When fully depressed, the inching control pedal acts like a service brake. Starting on an incline  DANGER Do not park the forklift truck on an incline. If special circumstances make it absolutely necessary to park on an incline, take precautions to protect the truck, such as using wheel chocks.

  • Page 100: Parking

    Operation Steering system Parking – Release the accelerator pedal (2) and re-  duce the vehicle speed. – Smoothly depress the service brake pedal (3) to the fullest extent possible until the truck comes to a complete stop. – Move the manual reverse operating lever (1) into the centre position.

  • Page 101: Brake System

    Operation Brake system Brake system NOTE We recommend that drivers familiarise them- selves with the efficacy of the braking appa- ratus when the forklift truck is not carrying a load. Operate the forklift truck slowly on an uncrowded road surface to test travelling func- tions.

  • Page 102: 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 103 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 104: Bonnet - Open - Closed

    Operation Bonnet — Open - Closed – 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 105 Operation Bonnet — Open - Closed – Pull the latch handle on the bonnet upwards  to open the latch. The bonnet will automati- cally open.  CAUTION Do not lean over the bonnet. The bonnet will pop open to a certain height. –...

  • Page 106: Gas Spring With Locking Function - Optional

    Operation Gas spring with locking function — optional Gas spring with locking func- tion — optional  CAUTION For vehicles equipped with gas spring and locking function, the gas spring will automatically lock after opening, to prevent the bonnet from closing suddenly and causing accident or injury.
  • Page 107 Operation Diesel Particulate Filter Regeneration (For Eu5 Truck） DPF Lamp and Switch – High Exhaust System Temperature  Lamp(1) This lamp notifies the driver when hot exhaust gas is being discharged from the engine dur- ing DPF regeneration. Be sure to keep the area around the exhaust manifold free of flam- mable materials.
  • Page 108 Operation Diesel Particulate Filter Regeneration (For Eu5 Truck） NOTE Before regeneration, ensure that there is suffi- cient diesel fuel and AdBlue® (urea solution) in the tank. If is not sufficient, top up the fuel and AdBlue® before starting regeneration. DPF regeneration consists of active regener- ation which occurs while driving and forced regeneration which is activated manually by the driver.
  • Page 109 Operation Diesel Particulate Filter Regeneration (For Eu5 Truck） 4) DPF soot level 111 ~ 120%: Forced ● regeneration is induced + decrease in en- gine power and Active regeneration is try to start. Notify the driver that forced regenera- tion needs to be performed. 5) DPF soot level 120% or higher: Regener- ●...
  • Page 110 Operation Diesel Particulate Filter Regeneration (For Eu5 Truck） Conditions for forced regeneration (Manual Regeneration): 1) Coolant (engine oil) temperature: 40° or ● higher 2) Engine rpm: Idling ● 3) Parking brake engaged ● Order of forced regeneration (Manual Re- generation): –...

  • Page 111: 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 112: 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.  DANGER There is an increased risk of falling and tilting when the lift mast is lifted.For this reason, do not step...
  • Page 113 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 114: 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 115 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 116 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 117: 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 118: 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 119: 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 120: 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 121: 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 122 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 123 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 124 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  112 1289 801 1521 EN - 09/2023  -  05...

  • Page 125: 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 126: 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 127 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 128: 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 129: Driving On Loading Bridges

    Operation Transporting loads Driving on loading bridges   DANGER Risk of accident if the truck crashes! Steering movements can cause the tail end to veer off the loading bridge towards the edge. This may cause the truck to crash. The lorry driver and the truck driver must agree on the lorry's departure time.

  • Page 130: Driving On Lifts

    Operation Transporting loads Driving on lifts  The driver may only use this truck on lifts with a sufficient rated capacity and for which the operating company has been granted authori- sation.  DANGER There is a risk to life if you are crushed or run over by the truck.

  • Page 131: Leaving The Truck Temporarily

    Operation Transporting loads 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) – Lift out the towing pin (1).  – Place the towing pin into the connector tube.

  • Page 132: 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 133 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 134: 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 135 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 136: Use A Truck Or Flatbed Trailer To Carry The Forklift Truck

    Operation Operation in special operating situations Use a truck or flatbed trailer to  carry the forklift truck – Lower the lift mast completely. – Tilt the lift mast forward. NOTE The fork arms must be resting on the ground. –...

  • Page 137: Towing

    Operation Operation in special operating situations  NOTE If the mast is removed from the forklift truck, fasten the forklift truck to the truck by tying ropes to the towing device and to the left and right sides of the overhead guard.  DANGER A slipping rope may cause the forklift truck to slide! The forklift truck must be securely tied down to pre-...
  • Page 138 Operation Operation in special operating situations  CAUTION Risk of component damage! If you remove the battery male connector with the key switch switched on (under load), an arc will be produced. This can lead to corrosion at the contacts, which considerably shortens their service life. –...

  • Page 139: Loading And Unloading The Truck

    Operation Operation in special operating situations – With the help of a guide, attach the towing vehicle to the truck. – Secure the tow bar to the tow coupling of the towing vehicle and the truck. – Sit in the driver's seat in the truck to be towed, and fasten the safety belt.
  • Page 140 Operation Operation in special operating situations – Eye bolt dimensions are as follows:  M30 x 3.5 2015  128 1289 801 1521 EN - 09/2023  -  05...

  • Page 141: Lifting The Truck With A Crane

    Operation Operation in special operating situations Lifting the truck with a crane 1289 801 1521 EN - 09/2023  -  05  129...
  • Page 142 Operation Operation in special operating situations  DANGER When lifting the truck with a crane, there is a risk of accident and fatal injury if personnel are in the working area of the crane. When using a crane to lift the truck, pay particular attention to ensure that no personnel are in the vicini- ty of the crane.
  • Page 143 Operation Operation in special operating situations  WARNING Risk of serious injury from falling truck. Never walk or stand underneath suspended loads.  DANGER The overhead guard will be damaged if it is con- tacted by lifting equipment that is under tension from lifting.

  • Page 144: Storing The Truck

    Operation Storing the truck Storing the truck Shutting down and storing the truck  CAUTION Component damage due to incorrect storage! If the truck is stored or shut down incorrectly for more than two months, it may suffer corrosion damage. If the truck is parked in an ambient temperature of less than –10°C for an extended period, the battery will cool down.

  • Page 145: Returning To Service After Decommissioning

    Operation Storing the truck – To relieve the strain on the load chains, lower the fork onto a suitable supporting surface, e.g. a pallet. – Check the hydraulic oil level and top up if required. – Apply oil or grease thinly to all uninsulated moving parts.
  • Page 146 Operation Storing the truck – Check the engine oil for condensation water and replace if necessary. – Check if there is any condensation water in the hydraulic oil and replace the oil if neces- sary. – Change the brake fluid. –...

  • Page 147: 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 148 Operation Disposal of old trucks  136 1289 801 1521 EN - 09/2023  -  05...

  • Page 149: Maintenance

    Maintenance...

  • Page 150: 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 151: General Information

    Maintenance General information General information  DANGER Risk of fatal poisoning! It is dangerous to leave the engine running in en- closed spaces. The engine consumes oxygen and emits carbon dioxide, carbon monoxide and other poisonous gases. There is a risk of fatal poisoning! –...

  • Page 152: Common Rail Engine Safety Warnings

    In the event of a leak, switch off the truck immediate- running. ly and contact an authorised dealer. The pressure in the fuel system may still be as high Maintenance work on the engine must be carried out as several hundred bar, even after the engine has by authorised professional technicians.

  • Page 153: Engine Emission Requirements (*China Iv)

    Common rail pipe accordance with the maintenance plan. Use instruments to test the parts and components after every 3000 hours of use. If they still meet the emission requirements, no replacement is needed. NOTE  CAUTION...

  • Page 154: Inspection And Maintenance Data

    Maintenance Inspection and maintenance data Inspection and maintenance data Consumable/equip- Components Filling quantity/settings ment Distilled water acid- Battery As required free grease Hydraulic system standard, duplex and triplex masts — Hydraulic oil all lift heights Drive wheel Torque value 558 Nm Wheels Steering wheel Torque value 210Nm...

  • Page 155: Recommended Fuels And Oils

    Maintenance Recommended fuels and oils Recommended fuels and oils ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. Quanti- Model specifications Remarks ty/L Hydraulic HLP68   Gear oil Gearbox oil ‘85W/90-GL-5   Gearbox oil Gearbox oil 8#   As re- Diesel fuel DIESEL-GB252-87  ...

  • Page 156: Regular Maintenance

    Maintenance Regular maintenance  WARNING Our trucks are not allowed to be filled with biodiesel. Regular maintenance The following maintenance will help in improv- ing the truck condition and ensure its function- ality. Complete this work as regularly as possible, in accordance with the operating environment.

  • Page 157: Service Plan (Weichai Wp3.2)

    Maintenance Service plan (Weichai WP3.2) Service plan (Weichai WP3.2) First service schedule (Weichai WP3.2) 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 158: Hour Service Plan ( Or At Least Once Every 6 Months )

    Maintenance Service plan (Weichai WP3.2) 500 hour service plan ( or at least once every 6 months )   At operating hours 500   1000   1500   2000   2500   3000   3500   4000   4500   5000  ...

  • Page 159: 1000 Hour Service Plan ( Or At Least Once Every 1 Year )

    Maintenance Service plan (Weichai WP3.2) 1000 hour service plan ( or at least once every 1 year )   At operating hours 1000   2000   3000   4000   5000   Carried 6000   7000   8000   9000   10000  ...
  • Page 160 Maintenance Service plan (Weichai WP3.2)   At operating hours 1000   2000   3000   4000   5000   Carried 6000   7000   8000   9000   10000   11000   12000              ...
  • Page 161 Maintenance Service plan (Weichai WP3.2)   At operating hours 1000   2000   3000   4000   5000   Carried 6000   7000   8000   9000   10000   11000   12000              ...

  • Page 162: 2000 Hour Service Plan ( Or At Least Once Every 2 Year )

    Maintenance Service plan (Weichai WP3.2) 2000 hour service plan ( or at least once every 2 year )   At operating hours Carried 2000   4000   6000   8000   10000   12000   14000        ...

  • Page 163: 3000 Hour Service Plan ( Or At Least Once Every 3 Years )

    Maintenance Service plan (Weichai WP3.2) 3000 hour service plan ( or at least once every 3 years ) Carried At operating hours   3000   6000   9000   12000   15000         Drive mechanism and transmission system.  ...

  • Page 164: Service Plan (Doosan D24 Eu5)

    Maintenance Service plan (Doosan D24 EU5) Service plan (Doosan D24 EU5) First service schedule ( Doosan D24 EU5 ) 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.

  • Page 165: Hour Service Plan ( Or At Least Once Every 6 Months )

    Maintenance Service plan (Doosan D24 EU5) 500 hour service plan ( or at least once every 6 months )   At operating hours 500   1000   1500   2000   2500   3000   3500   4000   4500   5000  ...

  • Page 166: 1000 Hour Service Plan ( Or At Least Once Every 1 Year )

    Maintenance Service plan (Doosan D24 EU5) 1000 hour service plan ( or at least once every 1 year )   At operating hours 1000   2000   3000   4000   5000   Carried 6000   7000   8000   9000  ...
  • Page 167 Maintenance Service plan (Doosan D24 EU5)   At operating hours 1000   2000   3000   4000   5000   Carried 6000   7000   8000   9000   10000   11000   12000            ...
  • Page 168 Maintenance Service plan (Doosan D24 EU5)   At operating hours 1000   2000   3000   4000   5000   Carried 6000   7000   8000   9000   10000   11000   12000            ...

  • Page 169: 3000 Hour Service Plan ( Or At Least Once Every 3 Years )

    Maintenance Service plan (Doosan D24 EU5) 3000 hour service plan ( or at least once every 3 years ) Carried At operating hours   3000   6000   9000   12000   15000         Internal combustion engine.  ...

  • Page 170: 5000 Hour Service Plan

    Maintenance Service plan (Doosan D24 EU5) 5000 hour service plan Carried At operating hours   5000   10000   15000                 Internal combustion engine     Removing DPF Ash and Cleaning the DPF.  ...

  • Page 171: 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 172: Internal Combustion Engine - Weichai

    Maintenance Internal combustion engine - Weichai Internal combustion engine - Weichai Checking the engine oil level – Stop the truck and ensure it is parked on a level surface. – Open the bonnet. – Take out the dipstick (1) and wipe with a ...

  • Page 173: Cleaning The Air Filter Insert

    Maintenance Internal combustion engine - Weichai – Disconnect the inlet hose form the air inlet. – When the engine is running, cover the in- take opening for a short time (e.g. using cardboard or a metal plate). The air filter blockage warning light on the instrument panel should illuminate.

  • Page 174: Emptying The Fuel Filter/Water Trap

    Maintenance Internal combustion engine - Weichai – Clean the inside of the air filter head cover  (1). – Fit the filter insert (2) in the air filter housing (4). – Refit the air filter cover, ensuring that the arrow on the head cover is aligned with the arrow on the air filter housing.
  • Page 175 Maintenance Internal combustion engine - Weichai  WARNING High pressure hazard! Avoid fuel spraying onto the skin from fuel system leakages, such as a ruptured fuel injection line. Fuel sprayed onto the skin can cause serious injury. In the event of spray injuries, seek medical attention immediately.

  • Page 176: Charging The Fuel System

    Maintenance Internal combustion engine - Weichai Carry out the following procedure to empty the fuel filter/water trap: – Place an oil pan under the fuel filter/water trap. – Loosen the drain plug (2) at the bottom of  the fuel filter/water trap. Empty the water contained inside.
  • Page 177 Maintenance Internal combustion engine - Weichai  CAUTION Be environmentally responsible. Dispose of used oil in accordance with applicable laws and regulations. Failure to comply with laws and regulations will result in serious damage to the environment. Comply with EPA guidelines or government meas- ures for the correct handling of hazardous materials (such as oil, diesel and engine coolant).

  • Page 178: Checking And Cleaning The Radiator Fins

    Maintenance Internal combustion engine - Weichai – Loosen the vent port (3) by rotating 2-3  turns. – Press the hand pump (4) until the fuel com- ing out of the vent port contains no bubbles. – Tighten the vent port. –...

  • Page 179: Checking The Coolant Level

    Maintenance Internal combustion engine - Weichai – Loosen the fastening screws (1), then re-  move the guard grille from the radiator. – Carefully remove the radiator (1) from  between the counterweights. Use 28 psi (0.19 MPa, 2 kgf / cm2) or a small amount of compressed air (2) to remove grime and dust from the radiator fins and the radia- tor.

  • Page 180: Internal Combustion Engine - Doosan D24 Eu5

    Maintenance Internal combustion engine - Doosan D24 EU5 Internal combustion engine - Doosan D24 EU5 Checking the engine oil level – Stop the truck and ensure it is parked on a level surface, wait for three minutes after stop. – Open the bonnet. –...

  • Page 181: Bleeding Air From The Diesel Filter Fine Filter

    Maintenance Internal combustion engine - Doosan D24 EU5 – Remove the oil cap(2) on the top of the  engine. – Add our recommended genuine oil by di- viding it into several portions for replenish- ment. – Wait for about 1 ~ 2 minutes and then check the engine oil level.

  • Page 182: Emptying Water In The Fuel Filter/Water Trap

    Maintenance Internal combustion engine - Doosan D24 EU5 Emptying water in the fuel fil- ter/water trap  DANGER Risk of fire and explosion! Diesel fuel is highly flammable and explosive under certain conditions. When removing and carrying out maintenance on fuel system components (such as when changing the fuel filter), place an oil pan under the engine oil port.
  • Page 183 Maintenance Internal combustion engine - Doosan D24 EU5  CAUTION Be environmentally responsible. Dispose of used oil in accordance with applicable laws and regulations. Failure to comply with laws and regulations will result in serious damage to the environment. Comply with EPA guidelines or government meas- ures for the correct handling of hazardous materials (such as oil, diesel and engine coolant).

  • Page 184: Checking The Coolant Level

    Maintenance Internal combustion engine - Doosan D24 EU5 NOTE Periodically check the fuel filter and drain ● the water from it. Otherwise, moisture may flow into the fuel unit of the engine, resulting in critical faults in the fuel injection pump, the fuel injection pipe, the common rail, and injectors.

  • Page 185: Drive Mechanism And Transmission System

    Maintenance Drive mechanism and transmission system Drive mechanism and transmission system Replacing the fine hydraulic transmission oil filter ENVIRONMENT NOTE Handle liquids and lubricating oil in accord- ance with the instructions. NOTE If transmission oil flows out, a collection con- tainer should be placed underneath the fine oil filter.

  • Page 186: Clean The Crude Oil Filter Of The Hydraulic Transmission Gear

    Maintenance Drive mechanism and transmission system – Unscrew the fastening screws and washers on the the crude oil filter. – Slowly pull out the crude oil filter so that the oil flows into the container. – Unscrew the crude oil filter from the oil filter seat.

  • Page 187: Changing The Oil Of The Hydraulic Transmission Gear

    Maintenance Drive mechanism and transmission system – Clean the filter screen with a brush. NOTE Replace the filter insert depending on the cir- cumstances (e.g. filter insert damaged). – Refit the crude oil filter to the gearbox using the fastening screws. NOTE If the truck is left idle for extended periods, the filter insert should be cleaned every 5 months.

  • Page 188: Checking The Transmission Gear And Drive Axle For Leaks

    Maintenance Drive mechanism and transmission system – Start the engine and run it in neutral for a while. After the engine stops running, recheck the oil level, which should be be- tween the upper and lower marks on the dipstick. Also check the leak resistance of the oil tank.

  • Page 189: Change The Drive Axle Gearbox Oil

    Maintenance Drive mechanism and transmission system – Take out the dipstick (1) and wipe with a  clean cloth. – Fully reinsert the dipstick. – Remove the dipstick. The oil level should be between the upper and lower markings on the dipstick.

  • Page 190: Checking The Drive Axle Gearbox Oil

    Maintenance Drive mechanism and transmission system NOTE The high viscosity of gear oil means that it takes time for new oil to fill the gaps in the gearing. It is therefore preferable to use a pressurised filling tool; otherwise, the filling process will take longer.

  • Page 191: Check The Installation Of The Engine, Hydraulic Transmission Gear And Drive Axle

    Maintenance Drive mechanism and transmission system Check the installation of the  engine, hydraulic transmission gear and drive axle – Remove the bottom plate. – Check installation of the connecting bolts of the engine, transmission gear and chassis (1), (2), (3), (4). –...

  • Page 192: 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 193: 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 194: 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 195: 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 196 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 197: 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 198: 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 199: 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 200: 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 201 – Check for abnormalities in the depression and return of the inching control pedal – When the inching control pedal is fully de- pressed, the forklift truck should remain still and not move. – Step on the inching control pedal, the serv- ice brake pedal should move down togeth- 1289 801 1521 EN - 09/2023  - ...
  • Page 202 Maintenance Driver's cab – Check that the inching control pedal cable is connected to the transmission without any abnormality NOTE If necessary, the inching control pedal cable needs to be adjusted to ensure the best in- ching control performance. For this operation, please contact the authorized dealer.

  • Page 203: Electrics/Electronics

    Maintenance Electrics/electronics Electrics/electronics Checking the control unit for dirt ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. The module is installed inside the truck's inter- nal combustion engine compartment. – Engage the parking brake. – Switch off the truck. –...

  • Page 204: Checking The Condition And Tightness Of Cables And Connections

    Maintenance Electrics/electronics – If the battery is equipped with a charge in-  dicator (""magic eye""), you can check the charge state and quality of the battery by means of the magic eye on top of the bat- tery. For an explanation of indicator states, see the markings on the battery.

  • Page 205: Checking The Fuse Box

    Maintenance Electrics/electronics – Remove oxides and replace damaged ca- bles. – Refit the bonnet. Checking the fuse box If the lights fail to light up or the electrical equipment does not work, it may be that the corresponding fuse has burnt out. Check the corresponding fuse.

  • Page 206: 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 207: Replacing The Return Oil Filter

    Maintenance Hydraulics – Unscrew the four fastening bolts and wash-  ers on the cover assembly (2), then remove the cover assembly. – Slowly pull out the cover assembly so that the oil can flow back to the tank. – Unscrew the oil suction filter (1) from the cover assembly.

  • Page 208: Checking The Hydraulic Oil Level

    Maintenance Hydraulics Checking the hydraulic oil level ENVIRONMENT NOTE Handle liquids and lubricating oil in accord- ance with the instructions. NOTE The oil level should only be checked with the lift mast vertical and the fork carriage lowered. – Depress the parking brake. –...
  • Page 209 Maintenance Hydraulics – Place a collection container under the right- hand side of the forklift truck. – Open the bonnet. – Unscrew the breather filter and oil dipstick together. – Remove the oil drain plug (1) and washer  from the hydraulic oil tank. –...

  • Page 210: Checking Installation Of The Tilt Cylinder

    Maintenance Hydraulics Checking installation of the tilt  cylinder – Check installation of the tilt cylinder. – Retighten if necessary. NOTE Check the "Inspection and maintenance da- ta" chapter for the specific torque of the con- necting bolts. Lubricating tilt cylinder bearings ...

  • Page 211: 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 212: 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 213: 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 214: 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 215 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 216: 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 217 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 1289 801 1521 EN - 09/2023  - ...
  • Page 218 Maintenance Special equipment  206 1289 801 1521 EN - 09/2023  -  05...

  • Page 219: Technical Datasheet

    Technical datasheet...

  • Page 220: Dimensions Overview

    Technical datasheet Dimensions overview Dimensions overview  208 1289 801 1521 EN - 09/2023  -  05...

  • Page 221: Technical Datasheet ( Weichai)

    Technical datasheet Technical datasheet ( WEICHAI) Technical datasheet ( WEICHAI) KION Jin- KION Jin- KION Jin- Manufacturer   RCD 25 RCD 30 RCD 35 Model marking   Plus Plus Plus Drive: Electric (battery, power supply...), die- Diesel Diesel   Diesel fuel sel, petrol, LPG, AC fuel fuel...
  • Page 222 Technical datasheet Technical datasheet ( WEICHAI) 4.81 Distance from SIP to centre of drive axle l9 (mm) 1018 1018 1018 h10 (m 4.12 Tow coupling height 4.19 Overall length l1 (mm) 3735 3745 3830 Length to the front face of the vertical sec- 4.20 l2 (mm) 2735...
  • Page 223 Technical datasheet Technical datasheet ( WEICHAI) Fuel consumption according to DIN EN 1696 Transporting capacity, according to VDI 2198 Energy consumption with specified trans- porting capacity, according to VDI 2198 12 V/80 12 V/80 7.10 Battery voltage/rated capacitance (V)/(Ah) 12 V/80 Ah Hydraulic Hydraulic Hydraulic...

  • Page 224: Technical Datasheet ( Doosan D24 Eu5 )

    Technical datasheet Technical datasheet ( Doosan D24 EU5 ) Technical datasheet ( Doosan D24 EU5 ) Manufacturer   KION-STILL KION-STILL KION-STILL Manufacturer's type designition   RCD25 Plus RCD30 Plus RCD35 Plus Drive: electric (battery type, mains, ...), diesel, petrol, fuel  ...
  • Page 225 Technical datasheet Technical datasheet ( Doosan D24 EU5 ) 4.22 Fork dimensions ISO 2331 s/e/l(mm) 45/100/1000 45/122/1000 50/150/1000 Fork carriage to ISO 2328， 4.23   class/type A, B 4.24 Fork-carriage width b3(mm) 1040 1100 1100 Ground clearance, laden, be- 4.31 m1(mm) low mast Ground clearance, centre of...
  • Page 226 Technical datasheet Technical datasheet ( Doosan D24 EU5 ) 10.4 Fuel tank, capacity 62.7 62.7 62.7 Sound pressure level at the 10.7 dB(A) driver’s seat NOTE The above datasheet is standard configura- tion forklift truck parameters. For non-standard configuration forklift truck, the parameters may be different.
  • Page 227 Index   Checking the connecting bolts connecting the lift mast to the drive axle..187 Additional capacity rating plate..Checking the control unit for dirt..Address of manufacturer.
  • Page 228 Index   Safety information for handling hydraul- Engine shutdown....84 ic fluid......42 Eye bolts.
  • Page 229 Index   Retrofitting......26 Reverse travel..... . Maintenance intervals.
  • Page 230 Index   Transporting pallets....108 Using working platforms....Transporting suspended loads..Tyres Vibration frequency.
  • Page 232 STILL GmbH 1289 801 1521 EN - 09/2023  -  05...

This manual is also suitable for:

Rcd 30 plusRcd 35 plus

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