Still RCE16P Li-Ion Original Instructions Manual

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Original instructions

Electric Truck

RCE16P Li-Ion

RCE20P Li-Ion

RCE15 Li-Ion

RCE16 Li-Ion

RCE20 Li-Ion

5430 5431 5433 5434 5436

1292 801 1591 EN - 07/2024 - 04

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Summary of Contents for Still RCE16P Li-Ion

Page 1 Original instructions Electric Truck RCE16P Li-Ion RCE20P Li-Ion RCE15 Li-Ion RCE16 Li-Ion RCE20 Li-Ion 5430 5431 5433 5434 5436 1292 801 1591 EN - 07/2024 - 04...
Page 3: Rules For The Operating Company Of Industrial Trucks
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. 1292 801 1591 EN - 07/2024 - 04 I...
Page 4: Spare Parts List
 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........ 32 Insurance cover on company premises.
Page 7 Table of contents Warning Label Diagram .......... 60 Display unit .
Page 8 Table of contents Electronic regenerative braking .......... 96 Parking brake .
Page 9 Table of contents Maintenance Safety information for inspection and maintenance work ..... . 144 Working at the front of the truck......... . 144 Lifting and jacking up .
Page 10 Technical datasheet ........... . 193 Technical datasheet(RCE16P Li-Ion, RCE20P Li-Ion) ...... 196 Dimensions overview.
Page 11: Introduction
Introduction...
Page 12: Your Industrial Truck
Electric forklift trucks in this range: Three wheels RCE15 Li-Ion、RCE16 models（3W） Li-Ion、RCE20 Li-Ion Four wheels mod- RCE16P Li-Ion、 els（4W） RCE20P Li-Ion The three wheels models (3W) is fitted with a compact steering axle. The compact steering axle offers low energy consumption, while tyre wear is minimal due to mutual compensation by the dual rear wheels.
Page 13 The drive motor is controlled by the forward pedal and reversing switch. Forward and re- verse speeds can be adjusted between stand- still and maximum speed. The driver uses both hands to control steering and various operations, thereby enabling quick direction changes and efficient stacking.
Page 14: General
Introduction Your industrial truck Electrical system The well-protected electronic system is loca- ted on the inside of the interior trim panel, on the back side of the truck. The required power is supplied by the power battery built into the chassis. General The industrial truck described in these operat- ing instructions conforms with the applicable...
Page 15: 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 16: 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 17: 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 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 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 20: 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 21: Operating Steps
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 22: Parking In Temperatures Below -10 °C
Introduction Using the truck – Operation with optional cold store protec- tion: -25°C to 40 ·C. – The minimum ambient temperature for a short period of time (not more than 1 hour) using theforklift under normal outdoor con- ditions -35°C –...
Page 23: 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 24: 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 25: 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 26: 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 27 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 28: 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 29: 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 30 Introduction Environmental considerations 20 1292 801 1591 EN - 07/2024 - 04...
Page 31: Safety
Safety...
Page 32: Safety Guidelines
Safety Safety guidelines Safety guidelines The operating company or the person it has commissioned must ensure that the driver un- derstands all safety information and that all di- rectives and safety regulations are observed. During training, drivers must familiarise them- selves with the following: The operating conditions of the working ●...
Page 33 Safety Safety guidelines DANGER Safety systems (e.g. the seat switch) are in place to ensure safety. Under no circumstances may any safety systems be disabled. CAUTION Various pieces of special equipment are connected to the "speed reduction" special function. This is purely an assistance function, and the driver must not rely solely on this function during operation.
Page 34 Safety Safety guidelines CAUTION Various functions are supported by gas springs. Gas springs are subjected to a high internal pressure of up to 300 bar. Gas springs may be removed only when they are not under tension, and must never be opened without prior instruction.
Page 35: Special Notes For Using Lithium-Ion Batteries
Safety Special notes for using lithium-ion batteries WARNING If a driver has active medical equipment such as a pace maker, defibrillator, cochlear implant, insulin pump or hearing aid, there is a possibility that the capabilities of the driver could be impaired. The operating company must take drivers whose capabilities are restricted due to implanted or body- worn medical equipment into account in the hazard...
Page 36 – Do not connect the battery with the polarity reversed. 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 37: Stability
Safety Stability – Evacuate the location of the fire as quickly as possible. – 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. –...
Page 38 Safety In the case of tip-over The stability of your industrial truck is ensured application or due to incorrect operation, al- if used properly and as intended. Should the ways follow the instructions depicted above. industrial truck tip over during an unapproved 28 1292 801 1591 EN - 07/2024 - ...
Page 39: 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 40: 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 41 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 42: 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 43 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 44: 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 45: 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 46: 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 47: 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 48: 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 49: 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 50 Safety Residual risks use the truck correctly and without the risk of accidents. 40 1292 801 1591 EN - 07/2024 - 04...
Page 51 Safety Residual risks 1292 801 1591 EN - 07/2024 - 04 41...
Page 52: 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 53 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 54: 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 55 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 56: 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 57 Safety Safety tests 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- Component Measurements Test values...
Page 58: 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 59: 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 60: Frequency Characteristics For Vibrations Imparted To The Human Body
Safety Frequency characteristics for vibrations imparted to the human body 3-wheel model (3W) 4-wheel model (4W) 1.5–2.0 tonne model = 68.0 dB(A) = 66.0 dB(A) (without driver's cab) Uncertainty = ±2 dB(A) = ±2 dB(A) NOTE The noise level may be higher or lower than this value when operating the forklift truck.
Page 61: Emergency Exit From Driver's Cab With Windows
Safety Emergency exit from driver's cab with windows Emergency exit from driver's cab with windows CAUTION If the truck is equipped with a driver's cab with doors, DO NOT open the doors until the load is placed on the floor. NOTE If the truck has a driver's cab with a door, a window and glass, it is difficult for the driver...
Page 62: Manually Lowering The Fork Arms With Iso
Safety Manually lowering the fork arms with ISO Manually lowering the fork  arms with ISO The control valve is equipped with an emer- gency lowering screw (1) for manual lowering of the fork carriage. This may be required if a malfunction occurs in the hydraulic system.
Page 63: 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. 1292 801 1591 EN - 07/2024 - 04 53...
Page 64: 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 65: Overview
Overview...
Page 66: 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 Fork carriage Front wheel Forks USB interface Parking brake pedal LED headlights Drive axle Tail lights Non-slip tread...
Page 67: Steering Axle Type
Overview Steering axle type Steering axle type  As shown in the figure on the right, the num- ber (1) shows a 4 wheel (4W) counterweight trucks, and the number (2) shows a 3 wheel (3W) counterweight trucks. – 3 wheel (3W) Counterweight forklift equip- ...
Page 68 Overview Steering axle type – 4 wheel (4W) Counterweight forklift equip-  ped with a swing steering axle as shown on the right. 129203003 58 1292 801 1591 EN - 07/2024 - 04...
Page 69: General View Of Driver's Compartment
Overview General view of driver’s compartment General view of driver’s compartment 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 70: Warning Label Diagram
) Label, Read the operating manual ( For Label, capacity rating plate ( For hook-on heater configuration) side shifter ) Label text, Still + RCE16P/RCE20P Label, Lifting/Lowering Label,Li-ion technology (*Li-ion truck) Label,Side shifting Label text, Still Label, Lifting/Lowering/Tilting...
Page 71 Overview Warning Label Diagram 1292 801 1591 EN - 07/2024 - 04 61...
Page 72: Display Unit
Overview Display unit Display unit Back button Performance mode (PER: Performance, Up button EFF: Efficiency, ECO: Economy) Down button Right turn (the green arrow appears when Enter/modify button the drive direction selection lever is in right Direction turn position). Speed Battery Left turn indicator (the green arrow appears Remaining battery run time...
Page 73: Switch Panel
Overview Switch panel CAN communication symbol (Blue - normal tral position when the truck key switch is CAN communication; red - abnormal CAN opened.) communication) Creep speed mode Error symbol Control unit failure Operator symbol (When this symbol lights Refer to truck documentation up, it indicates that the driver should sit in Motor temperature too high (yellow)/over- the seat )
Page 74: 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 64 1292 801 1591 EN - 07/2024 - 04...
Page 75 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 76 Overview Relays and fuses overview 66 1292 801 1591 EN - 07/2024 - 04...
Page 77: Operation
Operation...
Page 78: 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 79 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. 1292 801 1591 EN - 07/2024 - 04 69...
Page 80: 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 81: 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 82 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 83: 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 84: 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 85 Operation Seat belt status and performance checks WARNING Risk of accident from sudden adjustment of the seat or of the seat backrest! The inadvertent adjustment of the seat or of the seat backrest can lead to uncon- trolled movements by the driver. The steering or the operating devices can then be actuated unintention- ally.
Page 86 Operation Seat belt status and performance checks NOTE Sitting for long periods of time puts a lot of pressure on the spine. Try to compensate for this by performing regular simple gymnastic movements. Adjusting the seat backrest  – Adjust the backrest using the seat backrest adjuster (4).
Page 87 Operation Seat belt status and performance checks NOTE Even for the driver's cab to fully comply with driver safety systems, the driver should also wear the seat belt all the time. When the truck is on a steep incline, the ●...
Page 88: Seat Belt Monitoring And Alarm Function
Operation Seat belt status and performance checks Seat belt monitoring and alarm  function DANGER The driver must sit in the driver's seat when operat- ing the forklift truck. The seat belt must be worn at all times that the truck is driven! If the forklift truck is started without fastening the seat belt, the LED light shown by the ar-...
Page 89: Operating The Horn
Operation Operating the horn Operating the horn  Sound the horn as a warning signal when working on roads or intersections with low visi- bility. – Press the horn button (1) on the steering wheel to sound the horn. 1292 801 1591 EN - 07/2024 - 04 79...
Page 90: Checking The Brake System For Correct Function
Operation Checking the brake system for correct function Checking the brake system for correct function DANGER Risk of accident in the event of failure of the brake system! If the brake system fails, the truck will be insufficient- ly braked. –...
Page 91 Operation Checking the brake system for correct function – Accelerate the unladen truck in a clear area. – Press the brake pedal (1) firmly. The truck must decelerate noticeably. Checking the parking brake on a gradi- ent or a lorry ramp DANGER Risk to life if the truck rolls away! If the parking brake is not applied, the...
Page 92 Operation Checking the brake system for correct function NOTE When the emergency off switch is actuated, note the following: The electric brake is disabled. The truck no ● longer responds to the command issued by the accelerator pedal. The power steering is no longer available. ●...
Page 93: 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 94: Adjusting The Angle
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 95 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 96: Turn On And Off Lithium Battery
Operation Turn on and off lithium battery Turn on and off lithium battery Turn on the lithium battery  – Open the lithium battery cover as described in chapter"Opening and closing the lithium battery". – Press the power switch button (1) of the lithium battery, and the button will light up with a blue backlight.
Page 97: Switching The Truck On And Off
Operation Switching the truck on and off Switching the truck on and off Starting the truck  – If the truck is a lithium battery model, it is necessary to turn on the lithium battery switch first, for specific steps, see the "Turn on and off the Lithium battery"chapter.
Page 98: Display Unit
Operation Switching the truck on and off NOTE Ensure that the parking brake is fully disen- gaged. The truck cannot be driven until the parking symbol Ⓟ on the display unit has gone out. The truck is now ready for use. NOTE Once the key switch has been switched on, a self-test of the display unit (7) is performed.
Page 99: 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 100 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 101: Performance Mode
Operation Performance mode – 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 102: 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 authorised service partners.
Page 103: 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 104: 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 105: 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 106: 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 107: 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 service partners. 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 108: Checking Battery Level
Operation Checking battery level NOTE Ensure the parking brake is fully disengaged. The truck cannot be driven until the parking symbol Ⓟ on the display unit has gone out. Checking battery level General The battery's discharge status is shown by an LED bar display on the display unit.
Page 109: Battery Cover - Open - Closed
Operation Battery cover — Open - Closed 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: The steering column is at the limit position, ●...
Page 110 Operation Battery cover — Open - Closed – 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 111: Battery Hood Gas Spring
Operation Battery hood gas spring Battery hood gas spring CAUTION The battery hood gas spring comes with locking function. The battery hood will automatically lock af- ter opening, to prevent the battery hood from closing suddenly and causing accident or injury. –...
Page 112: Safety Regulations For Handling The Lithium-Ion Battery
Operation Safety regulations for handling the lithium-ion battery Safety regulations for han- dling the lithium-ion battery First-aid measures WARNING Risk of injury! Escaping gases can lead to breathing difficulties. Course of action required if gases or liquids escape – Immediately ventilate the area or go out into the fresh air;...
Page 113 Operation Safety regulations for handling the lithium-ion battery WARNING Risk of crushing/shearing! The battery is very heavy. There is a risk of serious injury if any parts of the body are caught under the battery. If parts of the body are wedged between the battery door and the edge of the chassis when the battery door is closed, this could lead to injuries.
Page 114: Connecting The Rechargeable Battery To An External Charger
Operation Connecting the rechargeable battery to an external charger – Observe the information provided by the battery manufacturer regarding the proce- dure in the event of a fire. Battery weight and dimensions DANGER Risk of tipping due to change in battery weight! The battery weight and dimensions affect the stability of the truck.
Page 115: Parking Brake Pedal
Operation Connecting the rechargeable battery to an external charger Certain requirements must be strictly followed when charging the battery using an external charger: Only use the battery charger and charging ● characteristic curve permitted in the battery specifications. – Lower the fork carriage fully. The fork arms must touch the ground.
Page 116 Operation Connecting the rechargeable battery to an external charger 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 117: Check Rechargeable Battery Condition (Lithium-Ion Battery)
Operation Check rechargeable battery condition (lithium-ion 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 (lithium-ion battery).
Page 118: 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 119: 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 –...
Page 120 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 also be attached to the back of the attachment operating lever.
Page 121: 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 122 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 123 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 service partners. 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 124: 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 125: 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 126: 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 fork arms is strictly pro- hibited. 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 127: Determining Visibility Conditions When Driving With A Load
Operation Transporting loads Determining visibility conditions when driving with a load 6301_003-167 Area that is not visible (max. 1085 mm) Load Load height (in driving position) Driver's eye level 4000 mm (distance to the front from the rear corner of the load when it is positioned on the fork carriage in the driving position) The driver's field of vision can be severely limited when driving with a larger load (Y) or...
Page 128: 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 129: 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 130 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 131 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 132 Operation Transporting loads – Lower the load while maintaining ground  clearance. 5060_003-102 – Tilt the lift mast backwards.  The load can be transported. 5060_003-101 122 1292 801 1591 EN - 07/2024 - 04...
Page 133: 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 134: 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 135 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 136: Driving On Ascending And Descending Gradients
Operation Transporting loads Driving on ascending and de-  scending gradients DANGER Risk of fatal injury! 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 137: Driving Onto Lifts
Operation Transporting loads – Always place loads into stock and remove loads from stock on a horizontal plane. Driving onto lifts  The driver may only use this truck on lifts with a sufficient load capacity and for which the operating company has been granted authori- sation (refer to the section entitled "Definition of responsible persons").
Page 138: Driving On Loading Bridges
Operation Transporting loads – Park the truck securely in the lift and switch it off to prevent uncontrolled movements of the load or the truck. Driving on loading bridges  DANGER Risk of accident from the truck crashing! Steering movements can cause the rear of the truck to veer off the loading bridge towards the edge.
Page 139: Tow Coupling
Operation Transporting loads – Drive slowly and carefully on the loading bridge. 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 140: Before Exiting The Truck
Operation Transporting loads CAUTION If the truck moves, there is danger of accidents. – Never park the truck on an uphill or downhill slope with a gradient greater than 8%. If necessary, the truck should also be secured on the side facing downhill.
Page 141 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 142: 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 143 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 144: 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 145 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 146: 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 147 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 148 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 149 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 150: 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 service part-...
Page 151: Maintenance Intervals
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 152: 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 153: Maintenance
Maintenance...
Page 154: 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 155: Lifting And Jacking Up
Maintenance Lifting and jacking up CAUTION Possibility of damage to the ceiling! – Note the maximum lift height of the lift mast. Securing the lift mast against tilting backwards DANGER Risk of accident! This work must only be performed by an authorised service technician.
Page 156: Inspection And Maintenance Data
Maintenance Inspection and maintenance data The truck must be raised and jacked up for various types of maintenance work. The au- thorised service centre must be informed that this is to take place. Safe handling of the truck and the corresponding hoists is described in the truck's workshop manual.
Page 157 Maintenance Inspection and maintenance data WARNING Unless approved by the manufacturer, customers are prohibited from disassembling the bolts of the over- head guard. Inspection and maintenance data (4W) Consuma- Components Filling quantity/settings ble/equipment Distilled water As required Battery Acid-free grease As required Cleaning apparatus Motor: Traction mo-...
Page 158 Maintenance Inspection and maintenance data WARNING Unless approved by the manufacturer, customers are prohibited from disassembling the bolts of the over- head guard. 148 1292 801 1591 EN - 07/2024 - 04...
Page 159: Recommended Fuels And Oils
Maintenance Recommended fuels and oils Recommended fuels and oils Recommended fuels and oils (3W) ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. Quantity Component Original oil/fluid International standard name 1.6 (0.8 on left Gear oil SAE80W-90 API-GL5 Drive axle and right) ...
Page 160 Maintenance Recommended fuels and oils Recommended fuels and oils (4W) ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. Quantity Component Original oil/fluid International standard name Gear oil (braking pad side) SAE80W-90 API-GL5 Drive axle Gear oil (differential side) SAE80W-90 API-GL5 Hydraulic oil (standard 3000 ...
Page 161 Maintenance Recommended fuels and oils NOTE Using oil of a lower grade than that specified in the table may damage the truck and will void the warranty. 1292 801 1591 EN - 07/2024 - 04 151...
Page 162: 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 163: Service Plan Table
Maintenance Service plan table Service plan table Maintenance precautions Servicing work requires specialised knowledge and special tools. Please contact your authorised service partners 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 164: 1000 Hour Service Plan
Maintenance 1000 hour service plan 1000 hour service plan At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Drive mechanism and transmission system. ...
Page 165 Maintenance 1000 hour service plan At operating hours Carried 1000 2000 4000 5000 7000 8000 10000 11000 13000 14000   Check the truck battery in accordance with manufacturer guidelines. ...
Page 166: 3000 Hour Service Plan
Maintenance 3000 hour service plan 3000 hour service plan At operating hours Carried 3000 6000 9000 12000 15000 18000 21000 24000 27000 30000   This servicing work to be performed every 3000 hours or every 3 years. ...
Page 167: Drive Mechanism And Transmission System
Maintenance Drive mechanism and transmission system Drive mechanism and transmission system Checking the oil level of the re-  duction gearbox – Drive the truck until the oil plug (2) is in the lower, vertical down position ("6 o'clock" position). The oil level plug(1) should then be located obliquely above the oil plug (2).
Page 168: Change The Reduction Gearbox Oil
Maintenance Drive mechanism and transmission system Change the reduction gearbox Change the gearbox oil (remove the wheels) NOTE Follow the regulations for the safe handling of oil and lubricating grease. – Operate the truck until the retarder is slight-  ly warm.
Page 169: Check For Leaks And Check The Mounting Between The Reduction Gearbox And The Drive Motor
Maintenance Drive mechanism and transmission system – Tighten the oil level port (1) and the fill plug (4). – Change the gear oil in the reduction gear- box on the other side. – Fit the wheels and lower the truck. NOTE Refer to the Inspection and maintenance da- ta chapter for the screw torque and gear oil...
Page 170 Maintenance Drive mechanism and transmission system – Prop up using a square timber. – Check that the wheels are able to turn free-  ly and remove all obstructions. – Change abraded or damaged tyres. A minimum tread depth is not required with solid rubber tyres.
Page 171: Check The Tyre Inflation Pressure
Maintenance Drive mechanism and transmission system Electrostatic charging is prevented by means of an antistatic belt, which is attached to the chassis under trucks with light-coloured tyres (non-marking tyres), while its free end trails along the ground. Antistatic belts are made of a synthetic con- ductive material.
Page 172: Changing Wheels
Maintenance Drive mechanism and transmission system Changing wheels DANGER Risk of tipping. Tyres must be the same type, from the same manu- facturer and have identical dimensions and profiles. CAUTION Note the weight of the truck. Only use hydraulic jacks with a load capacity at least equal to the weight of the forklift truck.
Page 173 Maintenance Drive mechanism and transmission system – Position a jack in the middle of the rear end  of the counterweight. Only jack up the truck from these lifting points. – Loosen all nuts on the wheel to be  changed.
Page 174: Checking The Condition Of The Antistatic Belt
Maintenance Drive mechanism and transmission system Checking the condition of the antistatic belt charged to the ground via the body of a per- DANGER son who touches the truck (electric shock) Risk of fire and explosion possible in the event of or when a spark passes from the truck to an electrostatic discharging.
Page 175: Checking The Brake System
Maintenance Drive mechanism and transmission system Lubricating the steering axle NOTE Lubricate with lubricating grease. Please refer to the " Recommended fuels and oils table " chapter. – Lubricate the connecting rods and steering  knuckles by adding grease via the grease nipples.
Page 176 Maintenance Drive mechanism and transmission system WARNING To prevent use of the brake pedal being impacted: The rubber mat on the floorplate must stay in place and have no upturned edges. The gap between the bottom edge of the brake pedal and the rubber mat must be at least 3 mm to ensure that maximum braking force can be applied.
Page 177: 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 178: 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 179: Checking The Joystick Bellows
Maintenance Driver's cab Checking the joystick bellows  – Check the bellows are positioned correctly and in good condition. – Replace damaged bellows when necessary. 1292 801 1591 EN - 07/2024 - 04 169...
Page 180: Electrics/Electronics
Maintenance Electrics/electronics Electrics/electronics Checking the control 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 181: Inspecting And Maintaining The Lithium-Ion Battery
Maintenance Electrics/electronics Inspecting and maintaining the lithium-ion battery CAUTION For inspecting and maintaining the lithium-ion bat- tery, refer to the lithium-ion battery manufacturer’s user guide. Strictly follow the lithium-ion battery manufacturer’s user guide. Removing battery safety devices There are two safety devices and one charg- ing harness plug holder which must removed, before the battery can be deinstalled.
Page 182: 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 183 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 184: 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 185 Maintenance Electrics/electronics – Install the battery position limiter (1), (2) and  charging harness plug holder (3). 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 186: Hydraulics
Maintenance Hydraulics Hydraulics Checking the hydraulic system for leaks CAUTION Hydraulic hoses become brittle over time! – Do not store hydraulic hoses for more than two years. – Do not use hydraulic hoses for more than two years if they are subject to a high level of wear. –...
Page 187: Checking The Hydraulic Oil Level
Maintenance Hydraulics DANGER Note that the hydraulic pump needs to cool down before inspection or maintenance, otherwise there is a risk of burns. Checking the hydraulic oil level ENVIRONMENT NOTE Follow recommendations regarding the use of consumables. CAUTION Comply with oil level and oil quantity regulations. When checking the hydraulic oil level, ensure that the lift mast is upright and the fork carriage is low- ered.
Page 188 Maintenance Hydraulics – Open the battery hood. On the four-pivot  model (4W), the hydraulic tank (1) is loca- ted on the right-hand side at the rear of the truck. – Unscrew the breather filter (1) and dipstick  (2) together. –...
Page 189: 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. For standard lift masts with a maximum ● height of lower than S3000, fill the hydraulic oil up to the notch (1). For standard lift masts with a maximum ●...
Page 190: 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 191: 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. 1292 801 1591 EN - 07/2024 - 04 181...
Page 192: Lifting System
Maintenance Lifting system Lifting system Changing the fork arms DANGER There is a risk of fatal injury from being run over if the truck rolls away. – Do not park the truck on a gradient. – Apply the parking brake. –...
Page 193 Maintenance Lifting system Removing  – Select the pallet according to the size of the fork arms. – Position the pallet to the front of the fork carriage. – Raise the fork carriage until the lower edges of the fork arms are approx. 3 cm higher than the height of the pallet.
Page 194: Check The Fork Arms And The Fork Arm Quick-Release Apparatus
Maintenance Lifting system Check the fork arms and the fork arm quick-release apparatus – Check the fork arms for significant deforma- tion, wear 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 designed thickness, or to the minimum thickness stipulated by the fork arm or forklift truck manufacturer, and other...
Page 195: 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 196: 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 197: 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 198 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 199: 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 200 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 190 1292 801 1591 EN - 07/2024 - ...
Page 201: Technical Datasheet
Technical datasheet...
Page 202: Technical Datasheet(Rce15 Li-Ion, Rce16 Li-Ion, Rce20 Li-Ion)
Technical datasheet Technical datasheet(RCE15 Li-Ion, RCE16 Li-Ion, RCE20 Li-Ion) Technical datasheet(RCE15 Li-Ion, RCE16 Li-Ion, RCE20 Li- Ion) Dimensions overview 192 1292 801 1591 EN - 07/2024 - 04...
Page 203: Technical Datasheet
Technical datasheet Technical datasheet(RCE15 Li-Ion, RCE16 Li-Ion, RCE20 Li-Ion) Technical datasheet Manufacturer KION JN KION JN KION JN RCE15 Li- RCE16 Li- RCE20 Li- Model Drive: Electric (battery, pow- er supply...), diesel, petrol, Electric Electric Electric Char- LPG, AC acter- Operation...
Page 204 Technical datasheet Technical datasheet(RCE15 Li-Ion, RCE16 Li-Ion, RCE20 Li-Ion) Distance from SIP to centre 4.8.1 l9 [mm] of drive axle 4.12 Tow coupling height [mm] 4.19 Overall length l1 [mm] 3125 3125 3160 Length to the front face of the l2 [mm] 1925 1925...
Page 205 Technical datasheet Technical datasheet(RCE15 Li-Ion, RCE16 Li-Ion, RCE20 Li-Ion) Battery voltage/rated capaci- 76.8V/ 76.8V/ 76.8V/ [V/Ah] ty (5-hour discharge) 228Ah 228Ah 228Ah Battery weight [kg] Energy consumption accord- [kWh/h] ing to DIN EN 16796 Transporting capacity, ac- [t/h] cording to VDI 2198 Energy consumption with specified transporting capaci- [t/kwh]...
Page 206: Technical Datasheet(Rce16P Li-Ion, Rce20P Li-Ion)
Technical datasheet Technical datasheet(RCE16P Li-Ion, RCE20P Li-Ion) Technical datasheet(RCE16P Li-Ion, RCE20P Li-Ion) Dimensions overview 196 1292 801 1591 EN - 07/2024 - 04...
Page 207: Technical Datasheet
Technical datasheet Technical datasheet(RCE16P Li-Ion, RCE20P Li-Ion) Technical datasheet KION KION Manufacturer Jinan Jinan RCE16P RCE20P Model Li-Ion Li-Ion Drive: Electric (battery, power supply...), Electric Electric Charac- diesel, petrol, LPG, AC teristics Operation Seated Seated Rated load capacity...
Page 208 Technical datasheet Technical datasheet(RCE16P Li-Ion, RCE20P Li-Ion) Fork dimensions, according to DIN ISO s / e / l 40x80x1 40x100x 4.22 2331 [mm] 1200 Fork carriage, according to ISO 2328, 4.23 2 A 2 A class/type A, B 4.24 Width of the fork carriage...
Page 209: Eco-Design Requirements For Electric Motors And Variable Speed Drives
Technical datasheet Eco-design requirements for electric motors and variable speed drives NOTE The above datasheet is standard configura- tion forklift truck parameters. For non-standard configuration forklift truck, the parameters may be different. 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-...
Page 210 Technical datasheet Eco-design requirements for electric motors and variable speed drives 200 1292 801 1591 EN - 07/2024 - 04...
Page 211 Index Checking the joystick bellows..Checking the main contactor..170 Additional capacity rating plate..Checking the oil level of the reduction Address of manufacturer.
Page 212 Index Disposal Inspection and maintenance data..Battery......Insulation testing....Components.
Page 213 Index Speed reduction....23 Welding work....Nameplate.
Page 214 Index Update of this manual....Warning Label Diagram....60 Using working platforms....Warning regarding non-original parts.
Page 216 STILL GmbH 1292 801 1591 EN - 07/2024 - 04...

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