Still 5410 Original Instructions Manual Download

Page: 261 / 288

Troubleshooting guide (Hydraulic system)

Abnormal noise

Suction filter restricted.

Renew the filter.

Suction hoses leaking, oil foaming. Tighten lines. Replace suction ho-

ses. Check oil level, top up if nec-

essary.

Incorrect oil viscosity, low oil level

in tank or in hydraulic pump.

Change oil, be sure to use the cor-

rect viscosity, top up oil.

Hydraulic pump or motor failure,

seals defective, causing air intake.

Contact your service partner.

No or too low pres-

sure in system

Pipe broken or leaking.

Replace or tighten line.

Oil of low viscosity, causing high

leakage losses.

Change oil, be sure to use oil of

correct viscosity.

Oil temperature warning lamp illu-

minated.

Check oil level, clean oil cooler.

Pump suction defective, noise.

Change oil, top up oil. Contact your

service partner.

Pump failure, leakages, pressure

valves do not close, valve seat

damage.

Contact your service partner.

Oil pressure fluctuat-

ing

Mast does not extend completely

or retracts slightly after being exten-

ded.

Top up hydraulic oil.

Cause as under abnormal noise.

See abnormal noise.

Pressure limiting valves or boost

pressure valves sticking.

Contact your service partner.

Lift and tilt cylinders have tight

spots.

Contact your service partner.

No oil flow or low oil

flow

Filter restricted (if accompanied by

noise).

Clean or replace filter.

Pipe broken or leaking.

Tighten or replace line.

Hydraulic system overheating.

Check oil level, use specified oil,

clean oil cooler, if needed.

Valves restricted.

Contact your service partner.

Pump failure, leakages, pressure

limiting valves do not close, valve

seat damaged.

Contact your service partner.

Maintenance

Troubleshooting

251

5001 801 1625 EN - 05/2022 - 03

Summary of Contents for 5410

Page 1: ...RCD 120 RCD 140 RCD 150 RCD 160 RCD 180 RCD 100 1200 RCD 120 1200 RCD 140 1200 RCD 150 1200 RCD 160 1200 RCD 180 900 Original instructions 5410 5411 5412 5413 5414 5415 5416 5417 5418 5419 5420 5421 5001 801 1625 EN 05 2022 03 ...

Page 2: ......

Page 3: ...f industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable indus trial trucks for a particular area of applica tion Prerequisites for the safe operation of in dustrial trucks Information on the use of industrial trucks Information on transport initial commission ing and storage of industrial trucks Internet address and...

Page 4: ...a Acquisition Module LED Light Emitting Diode LFM Forklift Data Management LTC Linde Truck Control LVDT Linear Variable Displacement Transformer MCM Motor Control Module PIN Personal Identification Number PPE Personal Protective Equipment RPM Revolutions Per Minute STVZO Straßenverkehrs Zulassungs Ordnung Road Traffic Licensing Regulations VDMA Verband Deutscher Maschinen und Anlagenbau German Eng...

Page 5: ...Copyright and trademark rights 13 Explanation of information symbols used 13 Date of edition and latest update of this manual 15 List of abbreviations 15 Environmental considerations 18 Packaging 18 Disposal of components and batteries 18 EMC Electromagnetic compatibility 19 Servicing and spare parts 19 Modifications and retrofitting 19 Using attachments 21 Using working platforms 21 2 Safety Defi...

Page 6: ...fety regulations for handling consumables 42 Exhaust gases 42 Safety Regulations Relative to Forklift Use 42 Safety regulations in case of accidental lateral tipping 42 Safety regulations when driving 43 Permissible consumables 45 Oils 45 Hydraulic fluid 46 Battery acid 46 Non ionising radiation 47 Medical equipment 47 3 Overview General view of Truck 50 Safety devices and warning labels 51 Contro...

Page 7: ...vice brake 99 Parking brake 100 Override Key 101 Battery access opening 102 Trailer coupling 102 To tow the truck 103 Emergency exit 105 Optional equipment 106 Drive controller 106 5100 040 Multifunction Joystick 108 6240 005 load weight display weight error 100 kg 109 Forklift Data Management LFM 110 Lighting 120 Lighting options 123 BlueSpotTM 126 12v Power 127 24v Power 128 12 24v Power 128 447...

Page 8: ...on system steer mast tilt 184 User instruction 186 Indicator lights 187 Maintenance instructions 189 Mounting instructions for lowering the lifting heads into the end beams of 178 series spreaders 193 Multifunctional handle _ 178 spreader 195 Working with a load 196 Mast lifting device and attachment controls 196 Load centre distance and load capacity 196 Load rating plate 197 Before loading 198 L...

Page 9: ...d foreign objects 237 Locations for jacks when changing wheels 238 Controls 239 Check the parking brake for proper operation 239 Brake control mechanism 239 Driver s seat switch 240 Electrical system 241 Check the battery batteries 241 Check electric cables connectors and connections for condition and tightness 241 Hydraulic system 242 Hydraulic system oil level check 242 Hydraulic system check fo...

Page 10: ...efore taking the truck out of operation 253 Taking the truck out of service note 253 Putting the truck back into service 254 Disposal of old trucks 255 6 Technical data Truck dimensions 258 Overview of type sheets 600mm load centre 259 Overview of type sheets 1200 mm load centre 265 Table of contents VIII 5001 801 1625 EN 05 2022 03 ...

Page 11: ...1 Introduction ...

Page 12: ...cord all basic fork lift truck data in the following table so that it is available if required by the sales network or authorised service centre Type Serial number Date of delivery Introduction 1 Truck data 2 5001 801 1625 EN 05 2022 03 ...

Page 13: ... system are moni tored by the truck controller and status is dis played on the truck status display monitor In addition to the engine the engine control module also monitors itself Depending on the malfunctions failures which occur warning and information displays are displayed on the tuck status display monitor The malfunction is stored in the fault memory and if necessary a safety and emergency ...

Page 14: ...e The cooled air direction pulls ambient clean air from above the rear of the truck and drives warm air down through the engine bay over the engine and finally out at the front Lift mast The standard mast is a double open centre non free lift type with twin lift and tilt cylinders lift chains mounted on each side and are at tached to the carriage Lift movement is achieved when the lift cyl inders ...

Page 15: ...k described in these operat ing instructions conforms with the applicable standards and safety regulations The industrial truck is fitted with state of the art technology Following these operating in structions will allow the industrial truck to be handled safely By complying with the speci fications in these operating instructions the functionality and the approved features of the industrial truc...

Page 16: ...EU UKCA in the United Kingdom UK EAC in the Eurasian Economic Union The conformity marking is applied to the nameplate A declaration of conformity is is sued for the EU and UK markets An unauthorised structural change or addition to the industrial truck can compromise safety thus invalidating the declaration of conformity conformity symbols Introduction 1 Your industrial truck 6 5001 801 1625 EN 0...

Page 17: ...e markets of the European Union the EU candidate countries the EFTA States and Switzerland 2 For the United Kingdom market The declaration of conformity document is supplied with the industrial truck The declara tion shown explains the conformity with the provisions of the EC Machinery Directive and the Supply of Machinery Safety Regulation 2008 2008 No 1597 An unauthorised structural change or ad...

Page 18: ...13 Rated capacity Nameplate variant 2 1 Type 2 Serial number 3 Manufacturer 4 Year of manufacture 5 Unladen mass in kg 6 permissible battery weight in kg for electric trucks only Max Min 7 Own mass self weight in kg without battery 8 Data matrix code 9 Refer to technical data listed in this operating instructions for more de tailed information 10 Conformity marking CE mark for the markets of the E...

Page 19: ...r there to be multiple con formity markings on the nameplate The EAC mark may also be located in the immediate vicinity of the nameplate NOTE Nameplate provided according to collocation requirements Introduction 1 Your industrial truck 9 5001 801 1625 EN 05 2022 03 ...

Page 20: ...se note the definition of the following re sponsible persons operating company and driver Use for purposes other than those described in these operating instructions is prohibited DANGER There is a risk of fatal injury from falling off the truck while it is moving It is prohibited to carry passengers on the truck The truck may not be operated in areas where there is a risk of explosion in areas th...

Page 21: ... do not become distracted Please pay attention to the moving parts of the truck to prevent your hands from being crushed Description of use and climatic conditions Normal use Indoor and outdoor use Ambient temperature of 20 to 40 Altitude of no higher than 2000 m Introduction 1 Use of the truck 11 5001 801 1625 EN 05 2022 03 ...

Page 22: ...n be reordered there as a spare part Personnel responsible for operating and main taining the equipment must be familiar with these operating instructions The operating company see the chapter Def inition of responsible persons must ensure that all operators have received read and un derstood these instructions Thank you for reading and complying with these operating instructions If you have any q...

Page 23: ...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 Please contact your authorised service centre for technical support relating to your truck Copyright and trademark rights These instructions must not be reproduced translated or made accessible to third par ties including as excerpts except wi...

Page 24: ...hered to in order to prevent material damage and or destruc tion NOTE For technical requirements that require special attention ENVIRONMENT NOTE To prevent environmental damage Introduction 1 Information about documentation 14 5001 801 1625 EN 05 2022 03 ...

Page 25: ...the EU working equipment directive BG Berufsgenossenschaft German insurance company for the com pany and employees BGG Berufsgenossenschaftlicher Grundsatz German principles and test specifications for occupational health and safety BGR Berufsgenossenschaftliche Regel German rules and recommendations for occupational health and safety DGUV Berufsgenossenschaftliche Vorschrift German accident preve...

Page 26: ... concentration Maximum permissible air concentrations of a substance at the workplace Max Maximum Highest value of an amount Min Minimum Lowest value of an amount PIN Personal Identification Number Personal identification number PPE Personal protective equipment SE Super Elastic Superelastic tyres solid rubber tyres SIT Snap In Tyre Tyres for simplified assembly without loose rim parts StVZO Straß...

Page 27: ...ion VDMA Verband Deutscher Maschinen und Anla genbau e V German Mechanical Engineering Industry Association WLAN Wireless LAN Wireless local area network Introduction 1 Information about documentation 17 5001 801 1625 EN 05 2022 03 ...

Page 28: ...l of components and batteries The truck is composed of different materials If components or batteries need to be replaced and disposed of they must be disposed of treated or recycled in accordance with regional and national regulations NOTE The documentation provided by the battery manufacturer must be observed when dispos ing of batteries ENVIRONMENT NOTE We recommend working with a waste man age...

Page 29: ...ected again Servicing and spare parts For questions relating to scheduled mainte nance and repairs to forklift trucks please contact the authorised service network The authorised service network has personnel trained by the manufacturer original spare parts and the tools necessary to carry out maintenance and repairs Servicing by the authorised service network and the use of original spare parts r...

Page 30: ...ting the truck The operating company is only permitted to make modifications to the truck independently if the manufacturer goes into liquidation and the company is not taken over by another le gal person The operating company must also fulfil the fol lowing prerequisites Design documents test documents and assembly instructions associated with the modification must be permanently archived and rem...

Page 31: ... CAUTION Attaching a crane arm changes the original intended use of the forklift truck which may not be designed for transporting free swinging suspended loads The use of this kind of equipment requires specific appro val the CE Declaration of Conformity is also required for any forklift trucks fitted with this kind of equip ment If this kind of equipment is to be used you must contact your author...

Page 32: ...Introduction 1 Using working platforms 22 5001 801 1625 EN 05 2022 03 ...

Page 33: ...2 Safety ...

Page 34: ...cation that demonstrably proves their professional ex pertise This proof should consist of a voca tional qualification or a similar document Professional experience indicating that the qualified person has gained practical expe rience of industrial trucks over a proven period during their career During this time this person has become familiar with a wide range of symptoms that require checks to b...

Page 35: ...ed in his rights and duties The driver must be granted the required rights The driver must wear protective equipment protection suit safety footwear safety hel met industrial goggles and gloves that is ap propriate for the conditions the job and the load to be lifted Solid footwear should be worn to ensure safe driving and braking The driver must be familiar with the operating instructions and hav...

Page 36: ... 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 by pulling out the key Safety 2 Definition of terms used for responsible persons 26 5001 801 1625 EN 05 2022 03 ...

Page 37: ...ctural modification can impair the han dling and stability of the industrial truck and can result in accidents Any modifications that adversely affect stabili ty load capacity and the circumferential view from the industrial truck require written appro val by the manufacturer The following components may only be modi fied with prior written approval from the manu facturer Brakes Steering Operating...

Page 38: ...erson The operating company must also fulfil the fol lowing prerequisites Design documents test documents and assembly instructions associated with the modification must be permanently archived and remain accessible at all times The capacity rating plate the decal informa tion the hazard warnings and the operating instructions must be checked to ensure that they are consistent with the modificatio...

Page 39: ... must be reported immediately to the responsible personnel The truck and accessories must never be used before they are correctly reconditioned as they cannot be guaranteed to be safe for operating or driving The safety mechanisms and switches must never be removed or disabled The predefined setpoint values must not be modified Work on the electric installation e g connect ing a radio additional l...

Page 40: ...he operator s daily exposure to vibrations during real operation of the truck these vibrations depend on the conditions of use floor con ditions method of use etc and therefore daily expo sure must be calculated using data from the place of use Wheels and tyres DANGER Risk to stability Failure to observe the following information and in structions can lead to a loss of stability The truck may tip ...

Page 41: ... this does not cause the truck to tilt to one side 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 Contact your authorised service centre re garding t...

Page 42: ...tructed regarding these risks that arise through use of the truck In addition we draw attention to the safety regula tions in these operating instructions Risks can include Escape of consumables due to leakages rupture of lines and containers etc Risk of accident when driving over difficult ground such as gradients smooth or irregu lar surfaces or with poor visibility etc Falling tripping etc when...

Page 43: ...st slipping e g by lashing Always transport unstable loads in suitable containers Always drive slowly when cornering Drive with the load lowered Even with sideshifts align the load as cen trally as possible with the truck and trans port in this position Avoid turning and diagonally driving across slopes or gradients Never have the load facing downhill when travelling on slopes or gradients Pick up...

Page 44: ...use the truck correctly and without the risk of accidents Safety 2 Residual risks 34 5001 801 1625 EN 05 2022 03 ...

Page 45: ...Safety 2 Residual risks 35 5001 801 1625 EN 05 2022 03 ...

Page 46: ...sed persons O Truck not safe for op eration Periodic inspection and rectification of de fects O German Ordinance on Industrial Safety and Health BetrSichV Risk of falling when us ing working platforms Compliance with na tional regulations different national laws O German Ordinance on Industrial Safety and Health BetrSichV and employer s liability in surance associations Impaired visibility due to ...

Page 47: ...the operating in structions O b LPG DGUV regulation 79 observe the operating instructions O When charging the drive battery German Ordinance on Industrial Safety and Health BetrSichV ob serve the operating in structions O VDE 0510 47 DIN EN 62485 3 In particular Ensure adequate ventilation Insulation value with in the permissible range When using battery chargers German Ordinance on Industrial Saf...

Page 48: ... on Industrial Safety and Health BetrSichV No person detection when placing goods in to stock and removing goods from stock Employee training O German Ordinance on Industrial Safety and Health BetrSichV Danger to employees According to the German Ordinance on In dustrial Safety and Health BetrSichV and labour protection law ArbSchG the operat ing company must determine and assess haz ards during o...

Page 49: ...ent must be documented 6 ArbSchG In the case of truck applications involving similar hazard situations the results may be summarised Refer to the chapter entitled Overview of haz ards and countermeasures which provides advice on complying with this regulation The overview specifies the primary hazards that in the event of non compliance are the most frequent causes of accidents If other major haza...

Page 50: ... authorised service centre to perform regular testing on the truck Observe the guidelines for tests carried out on the truck in accordance with FEM 4 004 The operating company is responsible for en suring that any defects are remedied without delay Notify your authorised service centre NOTE In addition observe the national regulations for the country of use Insulation testing The insulation of the...

Page 51: ...age Measurements Nominal volt age UBatt Test values Battery 50 VDC Batt Batt Battery tray 24 volts 1200 Ω 100 VDC 48 volts 2400 Ω 100 VDC 80 volts 4000 Ω Test values for the entire truck Nominal volt age Test voltage Test values for new trucks Minimum values over the duration of the service life 24 volts 50 VDC Min 50 kΩ 24 kΩ 48 volts 100 VDC Min 100 kΩ 48 kΩ 80 volts 100 VDC Min 200 kΩ 80 kΩ Saf...

Page 52: ...fects and assist maintenance personnel The operator trained and authorized to use the forklift must be familiar with the controls and performances of the forklift Any defect squeaking leaks etc must be promptly reported because if neglected it could cause more serious failures defects Carry out the inspections indicated in the chapter on Daily Inspections ENVIRONMENT NOTE Report any oil and or bat...

Page 53: ...g driving Allowing arms and legs to hang outside the truck Leaning the body over the outer contour of the truck Climbing out of the truck Moving the driver s seat Adjusting the steering column Releasing the seat belt Disabling the restraint system Raising the load higher than 300 mm above the ground with the exception of manoeu vring processes during the placement into stock removal from stock of ...

Page 54: ...he truck In this case the driver must only move at walk ing pace and with extra care The truck must be stopped immediately if eye contact with the guide is lost Rear view mirrors are only to be used for ob serving the road area behind the truck and not for reverse travel If visual aids mirror mon itor are necessary to achieve sufficient visi bility it is necessary to practise using them For revers...

Page 55: ...attention WARNING Prolonged intensive contact with the skin can result in loss of skin oils and cause irritation Avoid contact and consumption Wear protective gloves After any contact wash the skin with soap and water and then apply a skin care product Immediately change soaked clothing and shoes WARNING There is a risk of slipping on spilled oil particularly when combined with water Collect spill...

Page 56: ...id injury use appropriate per sonal protective equipment e g pro tective gloves industrial goggles skin protection and skin care products ENVIRONMENT NOTE Hydraulic fluid is a water polluting substance Always store hydraulic fluid in containers com plying with the regulations Avoid spilling Spilt hydraulic fluid should be removed with oil binding agents at once and disposed of ac cording to the re...

Page 57: ...ry acid in line with the applicable regulations Non ionising radiation If the forklift truck is fitted at the factory or at a later date with equipment that emits non ionis ing radiation such as radio transmitters RFID transmitters data terminals scanners etc the compatibility of this equipment with medi cal devices such as pacemakers and hearing aids must be tested and verified Medical equipment ...

Page 58: ...Safety 2 Medical equipment 48 5001 801 1625 EN 05 2022 03 ...

Page 59: ...3 Overview ...

Page 60: ...Radiator Grille Counterweight Steer axle Battery isolator Battery compartment 1 2 3 4 5 6 7 8 9 Adblue filler Fuel filler Drive axle Forks Fork carriage Lift cylinder Lift chains 10 11 12 13 14 15 16 Overview 3 General view of Truck 50 5001 801 1625 EN 05 2022 03 ...

Page 61: ... electrical danger label 25 km h Label read the operating manual Still logo 1 2 3 4 5 6 7 8 9 10 11 12 Made in China label for export with CE UK CA Importer for UK Still logo Tyre pressure label Nameplate Still logo Label read the operating manual Wheel torque card Label read the operating manual symbol insert ISO 3287 16x12 13 14 15 16 17 18 19 20 21 22 Overview 3 Safety devices and warning label...

Page 62: ...tion lever Central control levers joysticks Driver controller option 1 2 3 4 5 6 7 8 Parking brake switch Horn Armrest Accelerator pedal Brake pedals Clamping screw for steering column adjust ment Multiple function electrical control lever 9 10 11 12 13 14 15 Overview 3 Controls 52 5001 801 1625 EN 05 2022 03 ...

Page 63: ...ous operation on off inter val depends on the drive direction and the washer system is always activated 1 2 3 4 5 6 Roof panel wiper intermittent mode or con tinuous operation on off washer system is activated Rear window heating Strobe beacon Rotating beacon flashing beacon or Blue Spot Blank Blank Blank Blank 7 8 9 10 11 12 13 14 NOTE The configuration of the switch panel and ar rangement of ind...

Page 64: ...Overview 3 Switch panel 54 5001 801 1625 EN 05 2022 03 ...

Page 65: ...4 Operation ...

Page 66: ...ck the oil level in the drive axle Chassis undercarriage Tighten the wheel fastenings Check the tyre pressure Controls Check the brake system Check the steering system Electrics Check the condition of the batteries Hydraulics Check the oil level in the hydraulic system Load lift system Check the lifting system and attachments Operation 4 Service plan before initial commissioning 56 5001 801 1625 E...

Page 67: ... Check the electrical system e g lighting warning units Hydraulics Check the oil level in the hydraulic system Check the truck for leaks visual inspection Load lift system Check forks carriage and mast Regular maintenance Performing the maintenance tasks listed here will increase the availability of your truck and help maintain its value Carry out this work as frequently as possible in accordance ...

Page 68: ... demounting a multi piece rim wheel from a vehicle the operator must completely deflate the tyre by removing the valve core Always check that the tyre is fully deflated using a tyre pressure gauge NOTE the valve may become blocked with ice Check that the valve stem has not frozen DANGER Risk of death due to explosive force Always use a restraining device during tyre defla tion inflation on multi p...

Page 69: ...the valve cores and fully deflate the tyres see warnings DANGER Risk of death due to explosive force Do not allow anyone to enter the area shown in Fig 2 during deflation of the tyre CAUTION Ensure the valve stem has not frozen during defla tion If necessary use antifreeze to prevent the valve stem freezing Use a tyre pressure gauge to ensure the tyres are fully deflated Remove the protection devi...

Page 70: ...ruck with holder 3 under the outer drive wheel Slowly lift the forks until the wheel rests on them Do not touch the inner drive wheel 5 Remove all wheel fasteners 1 3 4 5 d3571099 Operation 4 Wheel removal drive axle 60 5001 801 1625 EN 05 2022 03 ...

Page 71: ...hem Tilt the inner wheel against the holder and secure it Carefully reverse the truck with the tyre clear of the truck Wheel refitting drive axle Refer to you Local National authority guide lines For example OSHA Occupational Safety Health Administration EUWA Association of European Wheel Manufacturers HSE Health Safety Executive CAUTION Wear personal protective equipment PPE Do not carry out thes...

Page 72: ...ce during tyre defla tion inflation on multi piece rim wheels If a restrain ing device is not being used then tyres must be deflated inflated using remote control inflation equip ment and no employees shall remain in the wheel rim separation trajectory zone Mounting an inner drive wheel NOTE Only use tyres approved by the manufacturer Put the inner wheel 5 on the forks of a second truck and secure...

Page 73: ...ub and align it Align the wheel 5 on the hub Slowly lower the forks until the drive wheel sits on the hub Carefully reverse the second truck Install the spacer ring 3 d3571097 3 4 5 d3571099 Operation 4 Wheel refitting drive axle 63 5001 801 1625 EN 05 2022 03 ...

Page 74: ...ean the mating surface on the hub and rim Carefully drive the truck with the wheel 4 to the wheel hub and align it Slide the wheel 4 over the wheel hub Remove the wheel retainer on the holder 3 Align the wheel 4 on the hub 3 d3571097 3 4 5 Operation 4 Wheel refitting drive axle 64 5001 801 1625 EN 05 2022 03 ...

Page 75: ...ed to 680 Nm Tighten the remaining wheel fasteners Torque all wheel fasteners in a diametrical ly opposed pattern Slowly lower the forks Carefully back off the second truck Place protection device around the wheel assembly Operation 4 Wheel refitting drive axle 65 5001 801 1625 EN 05 2022 03 ...

Page 76: ...t of the rim wheel while the tyre is pressurised Remove the protection device Remove the axle support and jack After a wheel has been refitted check the torque every 10 hours until the torque set ting remains constant Check every 100 hours therefater Check tyres for defects every day Check tyre pressures every week 120 degrees 5 0 m 120 degrees 5 0 m Fig 2 Operation 4 Wheel refitting drive axle 66...

Page 77: ...wed with a direct view in the reverse direction of travel Entering and exiting the truck Entering the cab Open the cab door Use handrails where fitted to climb the steps and enter the cab Enter the cab in a forward direction Close the cab door Exiting the cab Open the cab door Exit the cab in a backwards direction Use handrails where fitted to climb down the steps and exit the cab Close the cab do...

Page 78: ...e cab door NOTE To make it easier to close the door open the side window slightly Lift lever 1 inside the cab or pull down the lever on the door retainer 3 to release 2 Pull the door outwards Grip the rod 4 and pull the door towards you until the interlock engages Opening closing the side window Press button 1 or 2 Keep the knob pressed slide the side win dow into the desired position until it eng...

Page 79: ...nsure that the lift mast is tilted fully forward NOTE If the truck is equipped with a lift mast tilt an gle potentiometer there is a safety option to prevent the lift mast from tilting fully forward Starting from the 10 position the lift mast tilts forward by 5 and then stops To tilt the lift mast forward to the maximum tilt angle of 15 the driver must first return the operating lever to the neutr...

Page 80: ...ull strut rod 3 up and secure it in the trough to prevent the cab from falling WARNING The cab is heavy and can cause injury if someone is below the cab during lowering Stand clear of the cab and do not approach when it is partially tilted or being raised or lowered The cab must be locked in the fully tilted position and the tilt handle must be properly inserted into the safety ring before mainten...

Page 81: ...ough and return it to its original position Push lowering button 2 of the electrical switch to lower the cab into working posi tion Push and hold the switch until the cab is fully lowered Operation 4 Standard equipment 71 5001 801 1625 EN 05 2022 03 ...

Page 82: ...Sitting for long periods of time puts a lot of pressure on the spine This pressure can be relieved by performing simple therapeutic ex ercises at regular intervals Longitudinal adjustment Pull the lever 1 upwards Move the driver s seat backwards or for wards on the rails to find the most comforta ble position for the driver in relation to the steering wheel and the accelerator pedals Allow the lev...

Page 83: ...lever 3 Move the lever to set the driver s weight for the suspension Move the lever 3 upwards for a heavier weight Move the lever 3 downwards for a lighter weight Adjusting the lumbar support only with a comfort driver s seat NOTE The lumbar support enables the seat backrest contour to be optimally adapted to the driver s body Turn the knob 5 to the left or right The extent to which the lower and ...

Page 84: ...h 6a upwards to activate the seat heater Push the switch 6a downwards to deacti vate the seat heater NOTE The maximum temperature is predefined Adjusting the armrest Sit on the driver s seat and release clamp ing screw 1 Move armrest 2 upwards downwards and forwards backwards until the arm is com fortably supported and the joysticks 3 can be easily reached Tighten clamping screw 1 Operation 4 Stan...

Page 85: ...lamping screw 2 anticlockwise Move the steering wheel 1 into the re quired position by pulling it upwards or pushing it downwards Tighten the clamping screw 2 clockwise Seat belt DANGER There is a risk to life if the driver leaves the vehicle in an uncontrolled manner For this reason the seat belt must al ways be worn when operating the truck The seat belt should only be worn by one person WARNING...

Page 86: ...nism carefully move the industrial truck so that it is no longer positioned on a slope While using the truck e g driving operating the lift mast etc the driver should adopt a sitting position as far back as possible so that his her back rests against the seat back rest The automatic blocking mechanism for the belt retractor offers sufficient freedom of movement on the seat for normal use of the tr...

Page 87: ...er Switching on the rear window heating Press push button 1 Dummy 2 test Dummy 1 test The rear window heating is switched off Dummy 1 test The rear window heating is in operation for a further 15 minutes Heating system air conditioning Heating operation Operating options Manual heating operation Automatic heating operation 1 2 d3961038c Operation 4 Standard equipment 77 5001 801 1625 EN 05 2022 03...

Page 88: ... system Turn the turning knob 5 The blower is switched on and the air flow is set to the selected level Normal heating operation Use the turning knob 6 to adjust the tem perature Use the turning knob 5 the turning knob 3 and the left and right cab air nozzles to adjust the temperature and the temperature distribution Settings for demisting the windows Turn the turning knob 6 to hot right hand end ...

Page 89: ...or with the automatic heating Contact your service partner Heating air conditioning operation Operating options Manual air conditioning operation Automatic air conditioning operation Manual heating operation Automatic heating operation CAUTION Damage to the compressor Switch on the air conditioning every four weeks for at least ten minutes to prevent seizing of the bearings in the compressor The a...

Page 90: ... off Switching on the air conditioning Turn the turning knob 11 The blower is switched on and the air flow is set to the selected level Press the push button 12 The air conditioning is switched on and the function display 13 lights up green The air conditioning works only when the en gine is running and the turning knob 11 is switched on level 1 to 4 The fans on the condenser in the roof are switc...

Page 91: ... the cab By operating the heater and the air conditioning simultaneously the heater can counteract the cooling effect This produces a more pleasant temperature inside the cab and prevents misting of the windows Settings for maximum cooling in the cab Switch on the air conditioning Turn the turning knob 14 to cold left hand end position Turn the turning knob 11 to level 4 Open the left and right ca...

Page 92: ...ir conditioning the air conditioning automatically switches to automatic heating operation CAUTION If the function displays 8 or 13 flash five times after switching on and then go out there is an error with the automatic heating air conditioning or with the air conditioning Contact your service partner NOTE Condensation water in the evaporator can cre ate a musty smell Switching off the air condi ...

Page 93: ...knob 14 to hot right hand end position Turn the turning knob 9 to window defrost ing left hand end position Turn the turning knob 11 to level 4 Open the left and right cab air nozzles and direct the vents towards the windscreen Automatic heating operation The push button 12 for the air conditioning must be switched off Use the turning knob 14 to adjust the tem perature Press the push button 10 and...

Page 94: ... display unit is mounted to the top right hand side of the cabin It is positioned within the driver s field of vision and provides centralised information about all functions of the truck Once the key switch has been switched on a self test of the display unit is then performed During the self test all indicator lights and the displays are activated NOTE Versions of the display unit icon arrangeme...

Page 95: ...generation indicator light Coolant level 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Engine error indicator light low Engine error indicator light high Speed gear Fuel gauge Urea gauge Engine RPM gauge Driving speeds Easy interface switching One touch weighing Service interface Engine interface Transmission interface Hydraulic Interface Weighing interface System parameter interface 16 17 19 20 21 22 23 24...

Page 96: ...Engine interface When DPF require regeneration start regen eration by pushing the 1 button on the dis play unit Transmission interface Operation 4 Standard equipment 86 5001 801 1625 EN 05 2022 03 ...

Page 97: ... 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 Frequent cold starts increase wear Sit on the driver s seat Fasten the seat belt if seat belt is fitted Operation 4 Standard equipment 87 5001 801 1625 EN 05 2022 03 ...

Page 98: ... a self test All displays light up for approx 2 seconds and the operat ing hours until the next service are displayed for 5 seconds on the display unit If any sym bol flashes or lights up the preset service in terval has been exceeded The maintenance work that is due must be performed Contact your service partner Turn the key to position II You have to wait for the display to boot up to start the ...

Page 99: ...fails to start Ensure that the preheating process is com plete Depending on the truck version tem perature and altitude preheating may re quire up to one minute or more Once the preheating process is complete engage the starter until the engine runs at idle speed Do not engage the starter continuously for more than 30 seconds NOTE A block against repeat starting is active and the engine cannot be ...

Page 100: ...ure Switching off the engine CAUTION For engines with a turbocharger there is a risk that the high speed of the turbocharger shaft 100 000 rpm at full load could cause the shaft bear ing to run dry through lack of lubrication thus dam aging it Do not switch off engine under full load but rather allow it to run on for a few minutes at low speed Remove your foot from the accelerator ped al 3 Apply p...

Page 101: ...d minimum brake applications and truck stability characteristics The climbing ability rates given in the data sheet were derived from the tractive force of the truck and they apply only for crossing ob stacles and for short differences in level Always accommodate your driving style to suit the conditions of the roadway rough surfaces etc especially hazardous work areas and the load CAUTION Danger ...

Page 102: ...g transpor ted drive the truck with the load trailing If this is not possible a second person shall walk in front of the truck as a guide The truck should then only be driven at walk ing speed with particular caution being exer cised If visibility aids are required e g mir rors camera monitor to ensure adequate sight then training should be given for driving with these aids Start the engine using ...

Page 103: ...rator pedal 4 The truck will reverse at a speed depending on the position of the accelerator pedal NOTE Stop the truck before driving in reverse Stopping Release accelerator pedal 4 and press the brake pedal When dismounting from the truck with the engine running for example in order to briefly perform some action in close vicinity to the truck opening a gate unhitching a trailer etc always apply ...

Page 104: ...ng system and attachments Take note of the maximum lift height Operating the lifting and tilting equip ment Observe the symbols with directional ar rows The joystick must always be operated gently and never in a jerking motion The deflection of the joystick is used to determine the lift ing lowering and tilting speed Once the joy stick is released it automatically returns to its initial position N...

Page 105: ...ting the mast forward starting at 10 the mast will move forward 5 then stops Only when the driver returns the joystick to the neutral position and tilt forward again the mast will continue to move to the maxi mum forward degree of 15 Tilting the lift mast backwards Pull the joystick 2 backwards Operating attachments Attachments can be fitted to the truck as spe cial equipment e g sideshift fork pr...

Page 106: ...e truck NOTE The methods of operating the attachments de scribed here are examples The configuration of the joystick may vary depending on your truck s equipment Observe the symbols with directional ar rows Operating the sideshift NOTE Do not operate the sideshift when the fork arms are on the ground Push the joystick 3 forwards The sideshift moves to the left Pull the joystick 3 backwards The sid...

Page 107: ...Only pick up loads such that they can be turned in the load centre of gravity If loads are picked up off centre the residual load capacity may be exceeded when making a turning movement When turning the actual centre of gravity of the load must therefore not be more than 100 mm truck rated capacity below 6300 kg or 150 mm truck rated capacity between 6300 kg and 10 000 kg outside the pivot point N...

Page 108: ... contact your service partner Take note of the switching symbols with di rectional arrows Steering Hydrostatic steering means that very little ef fort is required to turn the steer wheels of the truck This is particularly advantageous when driving in narrow aisles Start the truck Turn the steering wheel to the left and right through the full cycle NOTE The truck is fitted with steering acceleratio...

Page 109: ... quires too much effort or if there is too much play in the steering Do not continue to operate the truck with faulty steering Horn Operating the horn When operating at blind corners and junctions a horn serves as warning signal Press the horn button 1 on the armrest Service brake To operate the service brake Release accelerator pedal 3 and allow it to return to its rest position Depress either br...

Page 110: ...vent unintended release of the parking brake WARNING Risk of accident If the braking system is becoming faulty or worn contact your authorised dealer Do not drive your truck with faulty brakes Automatic parking brake operation Set up the automatic parking brake func tion NOTE Specialist knowledge is required for setting up the automatic parking brake function Contact your service partner If set up...

Page 111: ...will detect faults in the system and forces the truck to a limp home condition or will stop the function causing the fault Using the override key the operator can operate the truck for a short time to return to a safe condition NOTE Override key 1 may only be used by author ised persons who can estimate and bear re sponsibility for the safety risk when lowering the load CAUTION Danger of personal ...

Page 112: ...y access compartment To isolate the batteries rotate handle 1 90 anti clockwise The batteries are now isolated To restore battery power return handle 1 to original position Trailer coupling NOTE The trailer coupling should only be used to tow light trailers inside the plant working area Lift tow pin 1 Place towbar in coupling recess Push tow pin 1 down to engage the draw bar and the lower retainin...

Page 113: ...lit pin Castellated nut Bleed nipple 9 10 11 12 13 14 15 16 17 NOTE Read and understand this maintenance pro cedure before starting any work If you are unsure of any aspect of this procedure con tact your service partner Safety conditions The maintenance procedures that follow may involve the assembly and or movement of heavy hydraulic equipment excitation of Operation 4 Standard equipment 103 500...

Page 114: ... started make sure the truck is completely immobilised not able to move Place chocks under wheels Remove ignition key from cab of truck Do not allow unauthorized personnel to en ter the cab WARNING Risk of personal injury Brake disc rotors and friction pads can become very hot make sure all component parts are cool be fore starting any maintenance Release screw cap 4 Release lock nut 7 NOTE 40 to ...

Page 115: ...e right side cab door can be used as the emergency exit Open the cab door Exit the cab in a backwards direction Use handrails where fitted to climb down the steps and exit the cab Close the cab door WARNING Risk of injury from entering and exiting the truck in correctly Face the truck when entering and exiting Operation 4 Standard equipment 105 5001 801 1625 EN 05 2022 03 ...

Page 116: ...ing the rota ry push button 2 the Back button 1 and the Switch button 3 Turning the rotary push button Turning the rotary push button to the left or right allows the following actions to be carried out Scroll between menu items Change values continuously or in incre ments brightness digit value or numerical value d1411039 1 2 Operation 4 Optional equipment 106 5001 801 1625 EN 05 2022 03 ...

Page 117: ... overwrite favourite position Select function or display after entering the PIN code Delete programmed values Delete favourite Set new time date or PIN code Reset consumption Back button Briefly pressing the Back button allows the following actions to be carried out Go back one menu level Acknowledge a message Switch button Briefly pressing the Switch button allows the following actions to be carr...

Page 118: ...le Multifunction Lever Multifunction Lever with housing for Coun terbalance trucks Multifunction Lever with housing for Reach trucks Electronic Module with CAN 1 2 3 4 5 Signal horn Tilting Function button Drive direction Side shift 1 2 3 4 5 Operation 4 Optional equipment 108 5001 801 1625 EN 05 2022 03 ...

Page 119: ...immunity Tested according to EN61000 4 8 Level 5 1000 A m 3s 0Hz 30 A m 3s 50Hz 6240 005 load weight display weight error 100 kg Determining and displaying the load weight To improve the accuracy of the displayed load weight the following conditions must be met The forklift must be on a smooth level sur face and must be stationary The lift mast must be placed in the vertical position The hydraulic...

Page 120: ...cquisition FDE input device 1 is located in the armrest console 3 The input device has a 12 digit keypad 2 With the standard setting a 5 digit PIN is allo cated to the respective driver to ensure that the truck can only be operated by authorised personnel The truck can only be started after entering this PIN and possibly a status code depend ing on the setting NOTE The PIN can be extended from 5 t...

Page 121: ...TE If a number button is pressed to activate the device this number is registered as the first digit of the PIN LED 5 and LED 6 flash green alternately NOTE If no PIN is entered the input device reverts to standby mode after 60 seconds factory set ting This delay time can be changed Contact your fleet manager Enter personal PIN factory setting 0 0 0 0 0 1 2 3 4 d3941466a Operation 4 Optional equip...

Page 122: ...borted by pressing the Reset button 8 Turn turning knob 9 to switch setting II and start the engine NOTE If the truck does not start properly the first time the starting procedure can be repeated until turning knob 9 is returned to the zero position and the PIN is no longer saved follow ing the elapse of the delay time NOTE If LED 5 illuminates red and LED 6 illumi nates green the data must be rea...

Page 123: ... supply are switched off after a delay time elapses If the driver switches off the engine using turning knob 9 the truck can be started during a delay time without re entering the PIN This delay time can be changed Contact your fleet manager Activate the power supply Press and hold the Log IN OUT button 7 for longer than 2 seconds LED 5 lights up yellow and LED 6 flashes green Turn turning knob 9 ...

Page 124: ...vate the device this number is registered as the first digit of the PIN LED 5 and LED 6 flash green alternately NOTE If no PIN is entered the input device reverts to standby mode after 60 seconds factory set ting This delay time can be changed Contact your fleet manager Enter personal PIN factory setting 0 0 0 0 0 and status code Therefore for a properly set up truck the PIN should be as follows 0...

Page 125: ...borted by pressing the Reset button 8 Turn turning knob 9 to switch setting II and start the engine NOTE If the truck does not start properly the first time the starting procedure can be repeated until turning knob 9 is returned to the zero position and the PIN is no longer saved follow ing the elapse of the delay time NOTE If LED 5 illuminates red and LED 6 illumi nates green the data must be rea...

Page 126: ...delay time elapses If the driver switches off the engine using turning knob 9 the truck can be started during a delay time without re entering the PIN This delay time can be changed Contact your fleet manager Activate the power supply Press and hold the Log IN OUT button 7 for longer than 2 seconds LED 5 lights up yellow and LED 6 flashes green Turn turning knob 9 to switch setting 0 The engine is...

Page 127: ...fined 9 User defined Status messages 7 8 and 9 can be defined individually by the user Contact your fleet manager to find out the definition of these sta tus messages NOTE If you only notice one of these statuses e g a problem with driving after having entered status code 0 truck OK you must log out Press the Reset button 8 Log in again with status message 3 prob lem with driving Operation 4 Optio...

Page 128: ...the right Place the valid transponder onto the read ing area 10 Data is read in and LED 5 and LED 6 both illuminate green Remove transponder NOTE If LED 5 and LED 6 flash red the trans ponder was invalid or there was a reading error After a delay time the input device re verts to login mode and the two LEDs flash green alternately The delay time increases each time an invalid transponder is used T...

Page 129: ...l When parking and leaving the truck the driver must log out Apply the parking brake Open armrest support 4 sideways to the right Place the valid transponder onto the read ing area 10 The engine is switched off and LED 5 and LED 6 go out Remove transponder Close armrest support 4 Turn turning knob 9 to switch setting 0 NOTE If the driver leaves the driver s seat the en gine and power supply are sw...

Page 130: ... alternately with LED 5 No error when reading in PIN transpond er engine can be started Illuminates green Illuminates green Error when reading in PIN transponder engine cannot be started Flashes red Flashes red Transition to standby mode Illuminates red once Illuminates green once Power supply active for 60 seconds Lights up yellow Flashes green Data read out required memory 90 full Flashes red Il...

Page 131: ...witch the toggle switch 1 as far as it will go The interior lighting 7 is switched on Press the push button 8 The interior lighting 9 is switched on NOTE If the pressure switch 8 has previously been actuated the two interior lights 7 and 9 may be switched on and off via toggle switch 1 Operation 4 Optional equipment 121 5001 801 1625 EN 05 2022 03 ...

Page 132: ... on the rotating beacon flash ing beacon Depending on the equipment there are three different versions Version 1 Press the toggle switch 6 Set the toggle switch 6 Level 0 light OFF Level 1 light ON for reverse travel Level 2 light in continuous operation Version 2 Switch on the key switch The light is always in operation Version 3 Switch on the key switch and press the re verse pedal The light is ...

Page 133: ...nt of the individual switches on the console on the upper right hand side of the overhead guard may vary depending on the version Observe the switch symbols Switching on the full road lighting Press the toggle switch 2 6100 005 Full road lighting 6100 010 Full road lighting with stone guards Set the toggle switch 2 Level 0 Light OFF Level 1 open the low beam Level 2 open the high beam d1411058 10 ...

Page 134: ...the customers to choose Press the toggle switch 3 6103 005 Mast mounted front facing lamps 6103 010 Mast mounted front facing LED lamps 6105 005 Mast mounted front facing lamps 5m mast 6105 010 Mast mounted front facing LED lamps 5m mast Open the cab mounted rear facing lamps Press the toggle switch 13 6104 005 Cab mounted rear facing lamps 6104 010 Cab mounted rear facing LED lamps Operation 4 Op...

Page 135: ...o the pedal and toggle switch on the panel The two are parallel con nections Open the reverse warning light When the forklift is reversed the reverse warning lights will automatically light up But LED Reverse warning light need switch Press the toggle switch 10 The optional model is as follows 6104 015 Reverse warning light x 2 6104 020 LED Reverse warning light x 2 Operation 4 Optional equipment ...

Page 136: ...a high power dot of light or arrow LED technology onto the ground It is not affected by jolts and vibrations The sys tem allows pedestrians to notice an approach ing truck at an early stage NOTE The BlueSpotTM can be installed for forwards and reverse travel CAUTION Do not look directly into the BlueSpotTM Switching on the BlueSpotTM Depending on the equipment fitted there are two different ways t...

Page 137: ...ettings for the toggle switch Level 0 BlueSpotTM OFF Level 1 BlueSpotTM ON NOTE If the truck is to be operated on public roads the BlueSpotTM must be switched off 12v Power The optional types are as follows 4412 020 1x12V 20mm Operation 4 Optional equipment 127 5001 801 1625 EN 05 2022 03 ...

Page 138: ...24v Power The optional types are as follows 4412 015 1x24V 20mm 12 24v Power The optional types are as follows 4412 030 2x12 24V 20mm Operation 4 Optional equipment 128 5001 801 1625 EN 05 2022 03 ...

Page 139: ... 2x Bluetooth AUX Fixed panel with well legible LCD display Ideal for trucks due to 24 V direct connection Clear lucid and easy to use Description Robust mechless 1DIN 24 Volt car radio with USB 2x Bluetooth AUX Fixed panel with well legible LCD display Ideal for trucks due to 24 V direct connec tion Clear lucid and easy to use Integrated Bluetooth hands free system with external microphone A2DP B...

Page 140: ... USB AUX rear USB Bluetooth firmware updatable via USB A2DP Bluetooth audio playback MP3 playback via USB MP3 ID3 display track artist album MP3 folder and file display MP3 song file character search 4 channels x 40 W max Rotary control for volume System EQ PLL tuner with 18 FM and 6 AM presets 2 channels x 2 V line out ISO terminal 24 Volt direct connection RDS Phone mute Last memory Last positio...

Page 141: ... clip board Open the illuminated A4 clipboard Press the toggle switch 1 The light on the side of illuminated A4 clip board 1 is bright Illuminated A4 clipboard 1 Operation 4 Optional equipment 131 5001 801 1625 EN 05 2022 03 ...

Page 142: ...he right rear of the cab 4480 005 Storage unit Includes document holder 1 additional stor age 3 and cup holder 2 Document holder This document holder has a lighting function Document holder 1 Operation 4 Optional equipment 132 5001 801 1625 EN 05 2022 03 ...

Page 143: ...h cup holder NOTE When the cup holder and the fire extinguisher is all needed The cup holder is placed on the door frame on the left of the cab Cup holder Storage 2 3 With cup holder 1 Operation 4 Optional equipment 133 5001 801 1625 EN 05 2022 03 ...

Page 144: ...ersonnel The truck can only be started after entering this PIN and possibly a status code depend ing on the setting NOTE The PIN can be extended from 5 to 8 digits Before entering the PIN contact your fleet manager to check the number of digits in the PIN and to find out about the truck settings Truck data acquisition standard setting PIN Log in and start the engine Apply the parking brake Open ar...

Page 145: ...set ting This delay time can be changed Contact your fleet manager Enter personal PIN factory setting 0 0 0 0 0 LED 5 and LED 6 both illuminate green NOTE If an incorrect PIN is entered LED 5 and LED 6 flash red After a delay time the input device reverts to login mode and the two LEDs flash green alternately The delay time increases each time an incorrect PIN is entered If you make a mistake when...

Page 146: ...anted use by unauthorised personnel When parking and leaving the truck the driver must log out Apply the parking brake Open armrest support 4 sideways to the right Press the Log IN OUT button 7 The engine is switched off and LED 5 and LED 6 go out Close armrest support 4 Turn turning knob 9 to switch setting 0 NOTE If the driver leaves the driver s seat the en gine and power supply are switched of...

Page 147: ...The engine is switched off Turn turning knob 9 to switch setting I The power supply remains switched on for ap prox 60 seconds e g for lighting Truck data acquisition special setting PIN and status code Log in and start the engine Apply the parking brake Open armrest support 4 sideways to the right 1 2 3 4 d3941466a Operation 4 Optional equipment 137 5001 801 1625 EN 05 2022 03 ...

Page 148: ...your fleet manager Enter personal PIN factory setting 0 0 0 0 0 and status code Therefore for a properly set up truck the PIN should be as follows 0 0 0 0 0 0 LED 5 and LED 6 both illuminate green NOTE If an incorrect PIN is entered LED 5 and LED 6 flash red After a delay time the input device reverts to login mode and the two LEDs flash green alternately The delay time increases each time an inco...

Page 149: ...anted use by unauthorised personnel When parking and leaving the truck the driver must log out Apply the parking brake Open armrest support 4 sideways to the right Press the Log IN OUT button 7 The engine is switched off and LED 5 and LED 6 go out Close armrest support 4 Turn turning knob 9 to switch setting 0 NOTE If the driver leaves the driver s seat the en gine and power supply are switched of...

Page 150: ...owing codes are available 0 truck OK 1 request service truck cannot be star ted 2 request maintenance truck can be started 3 Problem with driving 4 Problem with lifting 5 Problem with steering 6 Accident damage 7 User defined 8 User defined 9 User defined Status messages 7 8 and 9 can be defined individually by the user Contact your fleet manager to find out the definition of these sta tus message...

Page 151: ...ta acquisition FDE input device 1 is located in the armrest console 3 The input device features a reading area 10 onto which the corresponding transponder chip or magnetic strip card must be placed The truck can only be started once the trans ponder has been placed onto the reading area 1 10 3 4 d3941469a Operation 4 Optional equipment 141 5001 801 1625 EN 05 2022 03 ...

Page 152: ...ansponder is used The input device is reactivated automatically when a valid transponder is placed on the reading area and read in LED 5 and LED 6 both illuminate green Turn turning knob 9 to switch setting II and start the engine NOTE If the truck does not start properly the first time the starting procedure can be repeated until turning knob 9 is returned to the zero position and the engine can ...

Page 153: ...re switched off after a delay time elapses If the driver switches off the engine using turning knob 9 the truck can be started during a delay time without placing a valid transponder on the reading area again This delay time can be changed Contact your fleet manager Activate the power supply Place a valid transponder on the reading area 10 and hold it there for longer than 2 seconds LED 5 lights u...

Page 154: ... 60 seconds Lights up yellow Flashes green Data read out required memory 90 full Flashes red Illuminates green Data read out required memory 100 full Illuminates red Illuminates green Speed reduction via shock sensor Flashes red slowly Flashes green slowly Joystick with central lever opera tion WARNING There is a risk of becoming trapped be tween parts due to the moving lift mast or attachment For...

Page 155: ...r operation moving the joystick to an intermediate position approx 45 will activate both functions at the same time e g lifting and tilting Take note of the switching symbols with di rectional arrows The joystick must always be operated gently and never in a jerking motion The deflection of the joystick is used to determine the lift ing lowering and tilting speed Once the joy stick is released it ...

Page 156: ... e g sideshift fork prong posi tioner clamp etc Observe the working pres sure and operating instructions for the attach ment An additional joystick cross lever is fitted for operating these attachments CAUTION Attachments alter the load capacity and stability of the truck Attachments that are not supplied with the truck may only be used if the service partner has confirmed that the arrangement in ...

Page 157: ...t NOTE To prevent damage do not operate the side shift when the fork arms are on the ground Push the joystick 2 to the left The sideshift moves to the left Push the joystick 2 to the right The sideshift moves to the right Operation 4 Optional equipment 147 5001 801 1625 EN 05 2022 03 ...

Page 158: ...ick up loads such that they can be turned in the load centre of gravity If loads are picked up off centre the residual load capacity may be exceeded when making a turning movement When turning the actual centre of gravity of the load must therefore not be more than 100 mm truck rated capacity below 6300 kg or 150 mm truck rated capacity between 6300 kg and 10 000 kg outside the pivot point NOTE En...

Page 159: ...t hold a load by exerting pres sure on it e g a bale clamp a lockable joystick must be used If your truck is not fitted with this equipment please contact your service partner Take note of the switching symbols with di rectional arrows Adjusting the driver s seat with rotating device 4202 005 Rotating Seat Plate 10 deg to right 4202 010 Rotating Seat Plate 17 deg to right Operation 4 Optional equi...

Page 160: ...n The rotating device is maintenance free Pull locking lever 1 backwards The rotating device is enabled and allows the seat to be swivelled either by 10 to the right lockable at 0 and 10 or 17 to the right lockable at 0 and 17 Turn the driver s seat to the right and allow the locking bolt to engage audibly in the interlock Safety equipment 7105 005 Absent Driver Isolator Absent driver isolator wil...

Page 161: ...ind the cab Tie up the seat belt Then open the key switch to the 2 Level and the forklift can start normally 7109 005 Fire Extinguisher 2kg in Cab NOTE If the truck is equipped with the Fire suppres sion system make sure that you familiarise yourself with how to use it in the event of an emergency NOTE The period of validity for the extinguisher is 5 years If there is something wrong on the de vic...

Page 162: ... flash once about 5s After the circuit back to normal it will be recovered automatically Manual fire fighting capabilities Crash the button cover and hold the switch for 1 2 seconds to start the fire suppression sys tem Fire suppression feedback function The red indicator lights and the buzzer sounds after spraying fire suppression device is ac tivated Failure protection function Function mod ules...

Page 163: ...Maintenance The blasting fuse of the fire suppression sys tem should be checked whether ageing when doing the regular maintenance Operation 4 Optional equipment 153 5001 801 1625 EN 05 2022 03 ...

Page 164: ...or exam ple when program the transmitter with ID of 001 001 001 158 to front right tire position the user only needs to input the last 3 digits 158 Monitor will record the rest 3 groups of ID au tomatically Operation steps are as following After monitor is powered the screen will display NSP press P for 3 seconds to access the system programming mode the first interface is for ID programming as sh...

Page 165: ...e screen flashes twice beep buzzes twice Then it will automatically switch to next tire position Repeat the above operations to program ID of other transmitters Standard Pressure Programming When finish programming ID press P to access the standard pressure programming mode Then press any of the four arrow keys to choose the desired tire position Then press S for 3 seconds to set the first digit w...

Page 166: ...e setting NOTE The default standard pressure is set to 100 psi in factory System Time Programming NOTE The system clock was preset in the factory It is the base of the alarm record user can check the current date and time as follows 1 When finish programming the standard pressure press P to access interface for inquiry and programming of time date the first interface displays the year 1 07 stands ...

Page 167: ... digit flashes press up or down arrow key to adjust the value Then press key the third number flashes then press the up or down arrow key to adjust the value to 9 At last press S for 3 seconds to save the change with screen flashes twice and beep buzzes twice Then it automatically switches to next interface for programming Programming of Temperature and Pres sure Unit After program the system time...

Page 168: ...e and pressure unit press P to access the trans mitter deletion interface Only the program med and received transmitter will be shown and only the last 3 ID digits will be shown Press any of the four arrow keys to locate the tire position to be deleted Press S key for 3 seconds to delete with the screen flashes twice and beep buzzes twice to confirm the deletion Then it automatical ly switches to ...

Page 169: ...el 1 alarm Function the system will issue low pressure level 1 alarm when the tire pressure is 12 5 lower than the standard Alarm mode the alarm lamp flashes low pressure level 1 alarm icon tire position icon and the audible alarm turn on together Treatment press any key to stop the audible alarm The red alarm lamp remains on and the display reverts to the normal mode At this time the user should ...

Page 170: ...atment press any key to stop the audible alarm The red alarm lamp remains on and the display reverts to the normal mode The user should slow down the vehicle and replace the tire with a spare tire The red alarm lamp goes off only when the tire pressure returns to normal level High Temperature Alarm Function When the temperature around the transmitter equals or exceeds 90 the system will issue the ...

Page 171: ...smitter fails to work or the monitor cannot receive the data because of the RF interference for 20 minutes the system will issue a transmitter trouble alarm Alarm mode the audible alarm turns on the red alarm lamp flashes and transmitter trouble alarm icon ap pears Treatment press any key to stop the audible alarm Then the system reverts to the normal mode NOTE The red alarm lamp goes off automati...

Page 172: ...0 is the most recent alarm record Under alarm record inquiry interface Press key to check through the record If there is no operation within 3 seconds it will auto matically display the record data pressure temperature and time in turn each data displays 3 seconds Pressure Temperature Time year Operation 4 Optional equipment 162 5001 801 1625 EN 05 2022 03 ...

Page 173: ...month Time date Time hour Time minute Then it will display the next alarm record in the same way as above Press P and S at the same time to exit Operation 4 Optional equipment 163 5001 801 1625 EN 05 2022 03 ...

Page 174: ...icle The entire package in easy to install and maintain The system can warn when the tyre pres sure is too low or too high when the tem perature of the tyres is too high and when there is a slow air leak Technical data Display Frequency 433 9 MHz Operating voltage 5 V Operating temperature 20 70 Sensor Frequency 433 9 MHz Operating voltage 2 2 3 3 V Operating temperature 40 125 External sensor Hos...

Page 175: ...range 0 12 bar Pressure ac curacy 0 1 bar Temperature accuracy 1 Sensor installation Unscrew the valve dust cap Screw on the anti tamper hexagon nut Operation 4 Optional equipment 165 5001 801 1625 EN 05 2022 03 ...

Page 176: ...rew on the sensor Close the hexagon nut by turning in the op posite direction NOTE After installing spray with soapy water to check for leaks Operation 4 Optional equipment 166 5001 801 1625 EN 05 2022 03 ...

Page 177: ...Replacing the battery Remove the anti tamper shim Use a cover opening wrench to open the external cover Operation 4 Optional equipment 167 5001 801 1625 EN 05 2022 03 ...

Page 178: ... soon as the tyres start to turn Tyre pressure increases as the temperature of the tyre rises when moving The system matches automatically and can be used direct from the factory Press or to display tyre pressure or temperature Factory settings Pressure unit Bar Tyre pressure upper limit 11 0 bar Tyre pressure lower limit 9 0 bar High temperature warning value 75 Entering and exiting setup Operati...

Page 179: ... times and then exit setup mode Setup options Press and hold SET for 3 seconds to enter setup mode then press SET again to select from the following four options Upper pressure limit press and hold SET to enter setup mode as shown in the figure when 11 0 flashes press or to se lect the pressure value Lower pressure limit after entering setup mode press SET again as shown in the figure when 9 0 fla...

Page 180: ...h showing selection options for tyres 1 6 Press or to select the tyre number then press SET once The tyre and num ber will flash together and ID number setup will be shown Press or to select the ID number then press SET once WARNING Do not use this product while driving Exit the vehicle and check the tyres as soon as pos sible when the system issues a warning Tyre pressure and temperature will inc...

Page 181: ...ors Segmented regions are close to the obstacle distance 150CM security zone 120CM security zone 100CM warning area 80CM warning area 60CM warning area 30CM danger zone 7160 990 The sensors are installed on the counterweight of the truck Operation 4 Optional equipment 171 5001 801 1625 EN 05 2022 03 ...

Page 182: ... indicator Plastic wheel stud covers with movement indi cator 1 can prevent bolts from rusting Operating optional attachments Attachments can be installed as optional equipment Observe the working pressure and operating instructions for the attachments Operation 4 Optional equipment 172 5001 801 1625 EN 05 2022 03 ...

Page 183: ...w the instructions sup plied by truckmaker or the manufacturer of the attachment If the customer desires the attachment operation with the central control levers a label showing the movements possi ble with the control levers must be affixed on the screen to the right of the driver Coil boom Integrally mast mounted 3670 005 Coil Boom 1000mm long 177 3670 010 Coil Boom 1000mm long 178 3670 015 Coil...

Page 184: ...nd of coil boom 3670 105 FF Coil boom 1000 mm long 177 3670 110 FF Coil boom 1000 mm long 178 3670 115 FF Coil boom 1000 mm long 179 CAUTION Adjust all operating functions accordingly when maxi mum weight is being handled Danger of damage to equipment and personnel Operation 4 Optional equipment 174 5001 801 1625 EN 05 2022 03 ...

Page 185: ...d with a suitable 110 220v converter when required Engine Pre heater 220v 150w x2 Heater Pad Mounted on brackets and contacting the oil pan Engine Pre heater Hydraulic Oil Pre heater Battery Heaters Diesel Fuel Heater Cabin Pre heater 1 2 3 4 5 Operation 4 Optional equipment 175 5001 801 1625 EN 05 2022 03 ...

Page 186: ...draulic oil heater 500 W 6407 020 Hydraulic oil heater 1000 W 220v Depending on tank size 6403 010 Battery Heaters 220v 190w x4 Self adhesive Silicone Mats Size 300x100x1 5mm Operation 4 Optional equipment 176 5001 801 1625 EN 05 2022 03 ...

Page 187: ...witch Cabin Pre heater NOTE There are two options to preheat the cab The first selection Cab Pre heater 4409 010 Cab Pre heater 220 V 4409 015 Cab Pre heater 110 V Press the switch 1 The second selection 4409 005 Webasto Wa ter Heater Operation 4 Optional equipment 177 5001 801 1625 EN 05 2022 03 ...

Page 188: ...time display disappears after 10 seconds Automatically upon reaching the preset starting time for heating The program num ber and the symbol for heating are dis played Switching Off Manually by pressing the Manual Opera tion 3 button Automatically via the programmed end time The display field goes out when the heating time expires Setting the Time This function is not available when heating mode i...

Page 189: ...e Preset Time Briefly press the 4 button Select Preset Time Press the button 4 within 10 seconds un til the program number with the required preset time is displayed The active mode heating and the program number flash Set Heating Duration Time Press and hold the 4 button Press the Forward 2 or Reverse 1 button as well Release both buttons The time and clock symbol are displayed Press and hold the...

Page 190: ...tion is inadvertently changed Press the 4 button Press the 4 button again and hold it The last mode heating or venti lation is displayed Press the Forward 2 or Re verse 1 button as well to change back and forth between heating or ventilation mode Mains Power Connection The optional model is as follows 6400 010 Ext Power supply 110V 6400 020 Ext Power supply 240V CAUTION 110 230v 3 pin female socke...

Page 191: ... control switch press set button for 3 5 seconds to enter setting page adjust the number to 35 C by triangular button then press set button to finish setting Position In battery box Electrify preheater socket Position In battery box Operation 4 Optional equipment 181 5001 801 1625 EN 05 2022 03 ...

Page 192: ...t ensure the safe operation In case of overloading or abnormal operation of electrical appliances if a fault occurs the circuit breaker will automat ically turn off the switch to play the role of protecting electrical appliances and wires Electrical steering function Quickly press the switch 1 button twice Operation 4 Optional equipment 182 5001 801 1625 EN 05 2022 03 ...

Page 193: ... the screen it means the electrical steering is starting NOTE You can only rest your arm on the left armrest and it cannot withstand the full weight of the human body You must not use the left arm rest to prop up your body while adjusting your sitting position Operation 4 Optional equipment 183 5001 801 1625 EN 05 2022 03 ...

Page 194: ...used to clean the radiator When the temperature reaches the value required by the forced heat dissipation the cooling fan will then rotate in the normal direction achieving heat dissipation by suc tioning air This can be used for the normal heat dissipation 7306 005 Central lubrication system steer mast tilt Main components The central lubrication system has two ver sions a pneumatic plunger pump ...

Page 195: ...bined with the normal maintenance on the vehicle or the machine CAUTION The automatic greasing system significantly reduces the time and effort spent on manual greasing How ever do not forget that universal joints for instance must still be greased by hand Periodic check Pump unit Grease lines from the metering units to the individual grease points Air lines to the pump Brake counter if installed ...

Page 196: ...wing is a description of the spreader and how it s intended to be operated This in struction should help the driver to quickly ob tain maximum productivity from the truck and spreader The models 178SP1000 empty container handlers are designed for the safe handling of empty containers by vertical twist locks which are entered into the top pockets of the containers corner castings The spreader engag...

Page 197: ... it is then possible to activate the twist locks to the Locked position As long as the yellow light is NOT switched on the twist lock activation circuit is inactive Red NOT LOCKED Both twist locks have turned to the Not Locked position and the spreader can be safely lifted and removed from the container Starting work with the spreader Each work shift should be started by making a visual check of t...

Page 198: ...twist locks will turn and the indicator light will show that they are in the Locked mode The white light will switch on indicating that it is safe to lift the container If neither the Green Locked light nor the Red Not locked light switches on then the lift interrupt function will be activated which will stop the truck from lifting The spreader PCB printed circuit board is equipped with a unit tha...

Page 199: ...ight for Not Locked will illuminate It is now possible to lift the twist locks free of the corner castings and reverse the machine away from the con tainer The spreader is in the Not Locked mode and is ready for picking up the next container Maintenance instructions Multipurpose grease EP2 Position 1 Twistlock assemblies No of grease points 4 per spreader Interval every 500 hours 1 grease nipple p...

Page 200: ... 500 HOURS No greasing necessary Position 3 Upper side shift slider pads and lower side shift slider pads Every 500 hours or check for wear of the nylon wear pads and replace before metal to metal contact between the carriage and the spreader frame occurs No greasing necessary Operation 4 Optional equipment 190 5001 801 1625 EN 05 2022 03 ...

Page 201: ...be replaced when their thickness is reduced to minimum 18 mm Twist locks are wearing parts and need in specting on a regular basis Lubrication of the twist locks is recommended at monthly intervals and it is also recommended that they are inspected for wear and damage at the same time Operation 4 Optional equipment 191 5001 801 1625 EN 05 2022 03 ...

Page 202: ... cylinders if fitted consists of checking all mounting bolts for tightness and inspection for leakage from the cylinder The side shift wear pads should be inspec ted for wear at the same time as lubrication is carried out The wear pads should be replaced when their thickness is reduced to minimum 18 mm Other recommended spreader maintenance is Inspect the main spreader components for damage cracks...

Page 203: ...t on the support and subsequently become damaged Feed the string through the short tube bend 1 in the side of the end beam and draw the hoses anf cable up through the tube and out through the side of the beam where they can be connected to the hoses and cable that run in the energy chain Make sure that the hoses and cable 2 make an even bend that can move up and down with the movement of the heads...

Page 204: ...liding surfaces by brushing on a suitable layer of grease Where possible it would be advisable to equip the electric box with a heater this could be a small electric bulb for ex 40 watt which is allowed to burn constantly Spray all electric connections both inside and outside of the box with a self drying lubricant This will efficiently protect electric connections against corrosion CAUTION Effici...

Page 205: ...Multifunctional handle _ 178 spreader Operation 4 Optional equipment 195 5001 801 1625 EN 05 2022 03 ...

Page 206: ...automatically when re leased NOTE Observe the symbols with direction arrows 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 between the vertical plane of the fork arms and the centre of gravity of the loads 1 NOTE The c...

Page 207: ...it crosses the diagonal line repre senting the 6000 mm lift height The reading at the point where the coordi nate intersects with the horizontal line that passes through this point of intersection is the maximum permitted load In this case the reading for the maximum permitted load is 1000 kg Corresponding loads relative to other lift heights and load centre of gravity distances can also be obtain...

Page 208: ...ability of the forklift truck and the strength of the lift mast The maximum load is determined by the lift height and load centre NOTE Before transporting under the following condi tions attention should be given to the load limits and your authorised dealer should be contacted Eccentric load or swinging goods Lift mast tilted forwards or goods high above the ground during transport Load centre of...

Page 209: ...forks under the load so that load is centred and contacts the fork face if possible Do not touch adjacent loads Apply the parking brake Elevate the mast until the load rests on the forks Tilt the mast back slightly Release the parking brake Operate the lift truck in reverse until the load is clear Tilt the mast fully back Lower the mast to the travelling position NOTE If the truck is equipped with...

Page 210: ...de Operate the truck in reverse if the load be ing transported is stacked so high as to ob struct forward vision NOTE When the forks are fully lowered the truck speed is restricted and braking performance is adjusted accordingly Normal speeds and functions are restored when the forks are raised Always travel with the load uphill on up grades and down grades never travel or turn across a slope d359...

Page 211: ...vertical position Carefully move into the stack Lower the load on to the stack until the forks are clear of the load Reverse the truck away from the stack until clear Lower the mast to the travel position WARNING Danger of personal injury and damage to property Never leave the truck unattended with the load ele vated Operation 4 Working with a load 201 5001 801 1625 EN 05 2022 03 ...

Page 212: ...ad and lower the fork car riage Tilt the mast to the vertical position the forks must touch the ground Apply the parking brake Stop the engine and remove the ignition key Lock the cab doors Operation 4 Working with a load 202 5001 801 1625 EN 05 2022 03 ...

Page 213: ...s fitted with a 5 m mast or lower use upper lifting point 5 If the truck is fitted with 5 m mast or higher use lifting point 4 Attach two appropriate lifting shackles to the front lifting points 4 or 5 see note above Attach the slings to crane hook 1 CAUTION After attaching slings to the lifting hook safety lock 2 must close to prevent lash slip When the truck is hoisted the slings must not foul t...

Page 214: ...nsportation equipment with sufficient load capacity For the truck weight see the manufac turer s dataplate CAUTION The minimum required strength of ropes chains is 5 tonnes CAUTION When transporting the truck check that the truck is properly supported on blocks and securely fastened with load chains Transportation by loader truck When the height of the mast is high it must usually be removed Opera...

Page 215: ...uck Attach appropriate load chains to the tie down points as shown and to appropriate tie down points on the transport equipment When the height of the mast is low it does not need to be removed NOTE The inner mast outer mast fork and fork car riage must be secured using suitable ropes to prevent them from shaking during transporta tion Operation 4 Loading transporting 205 5001 801 1625 EN 05 2022...

Page 216: ...ast must be removed Secure the truck using ropes Secure the front of the vehicle using 8 ropes As shown in the figure attach 2 ropes to the tie down points at positions 1 and 2 on both sides cross over the ropes and attach them to the appropriate tie down points on the transport equipment Operation 4 Loading transporting 206 5001 801 1625 EN 05 2022 03 ...

Page 217: ...wn in the figure attach 2 ropes to the tie down points at the rear of the vehicle cross over the ropes and attach them to the appropriate tie down points on the transport equipment As shown in the figure attach ropes to the driver s cab tie down points and secure them to the appropriate tie down points on the transport equipment Operation 4 Loading transporting 207 5001 801 1625 EN 05 2022 03 ...

Page 218: ...Using wooden wedges to immobilise the truck Use wooden wedges 1 to immobilise the front and rear of the vehicle Operation 4 Loading transporting 208 5001 801 1625 EN 05 2022 03 ...

Page 219: ...5 Maintenance ...

Page 220: ...in particular attachment or conversion should be made to your forklift truck without the manufacturer s approval All work on the truck must be followed by a function check and a test run WARNING Any doors fitted could fall shut during the work and trap staff Open doors fully and prevent them from closing CAUTION The truck must always be properly labelled Missing or damaged identification plates an...

Page 221: ...s 680 Nm 11 Lift chains mast chan nels Linde chain spray As required Recommended consumables NOTE The use of consumables not recommended may invalidate your warranty If in doubt con tact your Linde service partner Diesel fuel Only use commercially available sulphur free diesel fuel which complies with the following standards EN 590 as of 2010 maximum 0 001 sul phur by weight 10 ppm ASTM D975 maxim...

Page 222: ...Change clothing that is soiled with AdBlue immediately If allergic reactions occur seek medical help immediately Keep AdBlue out of the reach of children Only use AdBlue in accordance with DIN 70070 ISO 22241 Do not use any additives If AdBlue comes into contact with painted or aluminium surfaces when filling the tank rinse the affected area immediately with plenty of water The terms Urea and DEF ...

Page 223: ...pper copper alloys unalloyed steel galvanised steel If AdBlue is stored in these types of contain er constituents of these metals may dissolve and damage the exhaust gas after treatment beyond repair Only use containers made of the following ma terials to store AdBlue CrNi steel in accordance with DIN EN 10 088 1 2 3 Mo CrNi steel in accordance with DIN EN 10 088 1 2 3 Polypropylene Polyethylene D...

Page 224: ...y guidelines Do not allow oil to get into the sewage system or seep into the ground Due to the disposal problem the required spe cial tools and knowledge the engine oil and filter change should be performed by your au thorised dealer option Viscosity of oil NOTE Variations in these characteristics may occur with future improvements Oil operating temperatures Since the viscosity of lubricants varie...

Page 225: ...ed or mixed costly damage can result Driveline oils Gearbox Recommended oil is Shell Spirax S4 TXM SAE 10W 30 UTTO Only use oils accord ing to ZF List of lubricants TE ML 03 go to www zf com for Powershift transmissions 3 WG 116 131 161 171 Only the above men tioned oils are approved by the manufacturer If other hydraulic oils are used or mixed costly damage can result Drive axle Recommended SAE 8...

Page 226: ...reeze by volume This corresponds to antifreeze protec tion down to 37 Do not exceed 55 by volume antifreeze down to approximately 45 The heat dissipation and antifreeze may other wise be negatively affected If there is a loss of coolant do not top it up by using only wa ter but also add an approved corrosion inhibi tor antifreeze agent Good quality water is important for cooling system performance...

Page 227: ... intake and exhaust lines for leaks Transmission Change oil filter Check the transmission pumps valves and lines for leaks Check the axle mounting Chassis frame Check steering axle wheel hub Hydraulics Change brake pressure filter Change brake return filter Change bypass hydraulic return filter Change cooler return filter Check the oil level in the hydraulic system Check the hydraulic system pumps...

Page 228: ...Load lift system Clean and lubricate the mast and tilt cylinder pivots and bearings Clean lubricate and check for proper operation of the side shift function Lubricate the lift mast bearings Additional servicing work every 1000hours Engine Replacement of engine oil and oil filter Check whether the belt is worn or damaged and replace it if necessary Replacement of fuel filter Check engine and brack...

Page 229: ...tion and ensure there is no excessive play Operating devices Check the functionality of the braking system park brake and service brake Check the functionality of the absent driver seat switch if fitted Electrics Check the condition of the electric cables cable connectors and connections and check that they are securely fitted Check the condition of the batteries Hydraulics Change the brake pressu...

Page 230: ...y filter element Additional servicing work every 3000 h Engine Changement of coolant Check and adjust valve clearance Replacement of DEF filter Replacement of DEF oil absorbing filter Hydraulics Change the hydraulic breather filter Change the brake suction filter Change the hydraulic oil Check the hydraulic pump mounting bolts Load lift system Check the forks Check the mounting of the mast Check t...

Page 231: ...t device Change the lift chains at least every 6000 hours or when 2 stretch has been attained Final tasks Reset the maintenance counters Carry out a functional test including a test drive Affix a maintenance sticker Maintenance 5 Service plan 221 5001 801 1625 EN 05 2022 03 ...

Page 232: ...engine oil to contact hot engine compo nents Use care when adding oil to avoid spilling CAUTION Incorrect oil can damage the engine Use only oil that meets the specifications given in the Fluid and Lubricant Specifications section CAUTION Overfilling the engine with oil can cause engine dam age Do not overfill the engine with oil Drain excess en gine oil if necessary After adding oil replace the f...

Page 233: ... tank filler cap is located on the left side of the truck 1 Remove fuel cap Fill the tank with clean diesel fuel see rec ommended fuels Refit the filler cap NOTE Maximum fuel capacity 250 l approx Filling Adblue NOTE Stop the engine before filling Adblue CAUTION Risk of skin irritation Wear personal protective equipment when filling Adblue Ensure adequate ventilation Avoid contact with skin or eye...

Page 234: ...etec tion of system the Adblue lamp lights up after 60 min for 60 min the engine power is normal 60 min after detection the Adblue lamp flashing and the LIM lamp lights up the tor que reduction to 75 of peak torque 180 min after detection the Adblue lamp flashing and the LIM lamp lights up the tor que reduction to 50 of peak torque and the maximum speed is reduced to 60 230 min after detection the...

Page 235: ... severe inducement 0 Adblue 2 5 The Adblue lamp flash ing and the LIM lamp flashing and the STOP ENGINE lamp shining The power begins the final inducement Adblue 0 The Adblue lamp flashing and the LIM lamp flashing and the STOP EN GINE lamp shining The power is final in ducement NOTE The display also use the error codes to indi cate the warning information NOTE This power reduction is self healing...

Page 236: ...ngine per formance Regular filter servicing is essential for the engine Tilt the cab and open the engine access cover Release clamps on filter casing 1 and re move filter end cover 4 Pull out the air filter element 2 and safety element 3 Inspect and re use if serviceable Replace if necessary Coolant level check Checking the coolant level CAUTION Risk of scalding Do not remove the filler cap if the...

Page 237: ...in the filter When the engine is started the battery must have sufficient charge to bleed the fuel system Bleed the fuel prefilter with water separator on the vehicle before bleeding the fuel circuit on the engine Use the manual fuel pump integra ted in the fuel prefilter to do so Bleeding the fuel system with a fuel pre filter on the chassis frame NOTE Dispose of the water fuel mixture in an envi...

Page 238: ... Tighten bleed screw 5 NOTE If there was no fuel in the fuel tank press manual fuel pump 4 again until there is notice able resistance Tighten the fuel tank filler cap Then bleed the fuel circuit on the engine as described under Bleeding the fuel system on the engine Bleeding the fuel system on the engine Fuel filter on the engine without fuel hand pump Turn the key to the start position in the ig...

Page 239: ...ximately 1 minute operate fuel hand pump 1 by handle 2 until there is no ticeable pressure in fuel hand pump 1 Screw handle 2 into fuel hand pump 1 until hand tight Start the engine within 5 seconds using en gine start engine stop button 4 Press and hold the button until the engine is running at an increased engine speed If the engine does not start or does not run at an increased engine speed rep...

Page 240: ...heating before carry ing out work to the fuel system Always wear protective gloves ENVIRONMENT NOTE Dispose of the water fuel mixture in an envi ronmentally responsible manner If the indicator lamp lights up drain the fuel filter with water separator immediately Other wise the engine may be damaged CAUTION Call Linde service engineer carry out this mainte nance work Park the vehicle safely and sec...

Page 241: ...ified specialist workshop Check that drain plug 2 is closed When the engine is running and drain plug 2 is open fuel is lost through drain hose 1 If the indicator lamp does not go out after draining drain the fuel filter again If the indicator lamp does not go out af ter draining for the second time consult Linde service engineer and have the cause checked immediately Maintenance 5 Bleeding and dr...

Page 242: ...gine must be run ning Tilt the cab and open the engine access covers Remove dipstick 1 and wipe with a clean cloth Fully re insert dipstick 1 and remove it again The oil level should be between the Min and Max markings Add oil if required Replace engine covers and lower the cab NOTE When transmission oil level is low a warning is displayed on the truck status display unit the engine management sys...

Page 243: ...otective clothing and eye protection must be worn Clean the cabin floor and ensure that no deb ris is allowed to obstruct the operation of the pedals Clean especially the oil filler areas and the lubrication points prior to servicing When cleaning with compressed air remove sticking dirt with a cold cleaner When cleaning the truck with de greasing sol utions allow sufficient time for the cleaner t...

Page 244: ... chlorinated fluids can be a direct cause of damage to the chain NOTE Trucks in service in the food industry must be lubricated with an oil approved for the food industry instead of chain spray Check seat belt for condition and correct operation option NOTE For safety reasons the condition and proper operation of the retention system should be inspected regularly monthly Under extreme operating co...

Page 245: ...ck Seat belts must be applied before operation of the truck After an accident the seat belt must be re newed In the case of seat belts attached to the operator seat the seat and mounting of the seat must also be inspected by qualified personnel Nuts and bolts should be checked regularly for tightness An unstable seat can indicate loose bolts or other faults If malfunctions in the operation of the ...

Page 246: ...sher bottle Open battery access door to access the washer bottle 1 Open filler cap 2 top up if necessary Replace filler cap 2 Close battery access door Maintenance 5 Chassis bodywork and fittings 236 5001 801 1625 EN 05 2022 03 ...

Page 247: ...e the mast lift and tilt cylinders an chor and bearing points for damage wear missing lock bolts metal fatigue etc Examine the bearings for damage missing retaining rings and abnormal wear Tighten the wheel nuts CAUTION Danger of accident During initial operation and after each wheel change the wheel fasteners must be tightened before starting work and thereafter every 10 service hours until they ...

Page 248: ... be 25 000 kg minimum CAUTION Danger of accident When working under the truck secure the chassis with wooden blocks do not rely just on the jack NOTE The truck should only be jacked up at jacking points indicated When jacking up the front of the truck chock the rear wheels To jack up front of truck place jack under drive axle mounting plate or the centre of the drive axle To jack up rear of truck ...

Page 249: ...se checks must take place every service interval PLUS after any component replace ment PLUS after any adjustment Check the operation and adjustment of brake pedals NOTE Ensure brake pedal movement is not obstruc ted Adjust the brake pedal stops to allow cor rect operation Start the engine and test the handbrake switch off the engine Start the engine test the foot brake switch off the engine NOTE S...

Page 250: ...d when the driver leaves the seat while driving When this happens the transmission will disengage and the truck will come to rest quickly To reset the switch Sit back on the driver s seat Put the gear lever into neutral Select forward or reverse gear Normal operation is restored Maintenance 5 Controls 240 5001 801 1625 EN 05 2022 03 ...

Page 251: ...ctrolyte Remove any corrosion on battery terminals and check the connections for tight seating Tighten the terminals and coat with non acidic grease Check electric cables connectors and connections for condition and tightness Examine cable connections for looseness and corrosion Inspect the earth lead for loose connection Examine the electrical wiring for chaffing and loose connections NOTE Corrod...

Page 252: ... Observe the sight glass and fill to maximum Hydraulic tank capacity 180 l approx d1411020 1 Hydraulic system check for leaks WARNING Risk of burns and scolds Beware of hot engine and exhaust components Wear protective equipment NOTE It is necessary to ensure that all relevant pipes are disconnected and take preventive meas ures to disconnect pipes before opening the radiator It is suggested that ...

Page 253: ...uck should be at normal operating tem perature and the oil level should be correct Raise and lower the mast twice in quick suc cession before performing this check Slowly unscrew breather filter 1 located on the top of the hydraulic oil tank allowing the air to escape before removing fully NOTE In a dusty atmosphere it may be necessary to renew the filter earlier If air is not heard to escape repl...

Page 254: ...w grease is visible at the bearing CAUTION Danger of accident Refer to safety notes on securing the mast when working on the front of the machine Lubricate the tilt cylinder pivots NOTE Lubricate with grease according to the lubri cant recommendations Lubricate tilt cylinder pivots 2 two points Access to the bottom two points is from the side of the tilt cylinder recess under the cab Access to the...

Page 255: ...e clearance at slider pads 1 fit ted to the base of the fork carriers Slider pads 1 should be changed when clearance exceeds 2 mm Lubricate the fork roller bearings Lubricate the fork roller bearings 2 Four points each fork carrier Lubricate with grease gun until new grease is visible at the bearing Lubricate the fork lower rollers Lubricate the fork lower rollers 3 Lubricate with grease gun until...

Page 256: ...h and therefore must be checked and adjusted as necessary on the left and right sides of the mast Clean the mast chains Put the mast vertical Remove split pin 1 Release locknuts 2 Using nuts 3 adjust the chains to allow a clearance of 12 mm 1 2 inch between the fork heels and the floor Tighten locknuts 2 Fit new split pin 1 NOTE Ensure both chains are adjusted equally Spray channel surfaces pulley...

Page 257: ...NOTE Trucks in service in the food industry must be lubricated with an oil approved for the food industry instead of chain spray Maintenance 5 Load lifting system 247 5001 801 1625 EN 05 2022 03 ...

Page 258: ... the diesel fuel are inadequate due to paraf fin separation Malfunctions resulting from paraffin sep aration can be corrected by warming the entire fuel system e g by parking the vehicle in a heated area Refuel with winter fuel The engine oil viscosity is incor rect Alter the engine oil viscosity to the con ditions of use If the engine does not start after another attempt have the cause traced and...

Page 259: ...ngine brak ing effect is poor The cause must be established in Linde service engineer Please consult Linde Service engineer Fuel consumption is too high See the operating notes in the fuel consumption section If the problems cannot be fixed consult Linde Service engineer The engine gets too hot according to the coolant tem perature gauge There is not enough coolant in the coolant circuit Add coola...

Page 260: ...and exhaust gas pipe are leaking causing a whistling noise Please consult Linde Service engineer The turbing or compressor wheel is scraping the housing There are foreign objects in the compressor or turbine housing bearing have seized on the rotating parts Call Linde service engineer to check the exhaust gas turbocharger The valve clearance is excessive Please consult Linde Service engineer The p...

Page 261: ...e oil top up oil Contact your service partner Pump failure leakages pressure valves do not close valve seat damage Contact your service partner Oil pressure fluctuat ing Mast does not extend completely or retracts slightly after being exten ded Top up hydraulic oil Cause as under abnormal noise See abnormal noise Pressure limiting valves or boost pressure valves sticking Contact your service partn...

Page 262: ...r oil cooler defec tive Check oil level if necessary top up oil Clean cooler and check for leaks If defective contact your service partner Pump failure valves leaking Contact your service partner Maintenance 5 Troubleshooting 252 5001 801 1625 EN 05 2022 03 ...

Page 263: ... electrical contacts with a suitable contact spray CAUTION Danger of tyre deformation Block up the truck so that all wheels are clear of the ground NOTE Do not use plastic foil as this enhances the formation and collection of condensation wa ter NOTE If the vehicle is to be taken out of operation for a week or more isolate the battery NOTE If the vehicle is to be taken out of operation for over 6 ...

Page 264: ...tion water and change the oil if necessary Check the hydraulic oil for condensation water and change the oil if necessary Reconnect the battery NOTE The digital clock display must be reset when ever the battery isolator has been used Perform the same services as for commis sioning Return the truck to service NOTE If the truck has to be jump started refer to section entitled Jump start procedure Ma...

Page 265: ...r leaking fluids and degreasing cleaning ma terials Suitable storage areas must be available for disassembled and partially oil smeared parts as well as for tyres including fire protection measures Suitable storage tanks for fluids such as fuel AdBlue urea solution engine oil hydraulic oil cooling fluid and fluids from air conditioning sys tems must also be provided In order to dispose of harmful ...

Page 266: ...Maintenance 5 Decommissioning the truck 256 5001 801 1625 EN 05 2022 03 ...

Page 267: ...6 Technical data ...

Page 268: ...Truck dimensions Technical data 6 Truck dimensions 258 5001 801 1625 EN 05 2022 03 ...

Page 269: ...iesel 1 4 Operation Seated 1 5 Load capacity load RCD100 Q t 10 RCD120 12 RCD140 14 RCD150 15 RCD160 16 RCD180 18 1 6 Load centre of gravity RCD100 RCD120 RCD140 RCD150 RCD160 RCD180 c mm 600 1 8 Load distance RCD100 RCD120 x mm 847 RCD140 RCD150 RCD160 RCD180 884 1 9 Wheelbase RCD100 RCD120 RCD140 y mm 3000 RCD150 RCD160 RCD180 3250 2 Weight 2 1 Net weight RCD100 kg 16299 RCD120 16453 RCD140 1908...

Page 270: ...5 11916 3 Wheels chassis frame 3 1 Tyres solid rubber super elastic pneumatic polyurethane p p 3 2 Front tyre size RCD100 RCD120 10 00 x 20 16pr RCD140 RCD150 RCD160 RCD180 12 00 x 20 20pr 3 3 Rear tyre size RCD100 RCD120 10 00 x 20 20pr RCD140 RCD150 RCD160 RCD180 12 00 x 20 20pr 3 4 Wheels number front rear x driven RCD100 RCD120 RCD140 RCD150 RCD160 RCD180 4x 2 3 6 Front track width RCD100 RCD1...

Page 271: ... RCD100 RCD120 h1 mm 3404 RCD140 RCD150 RCD160 RCD180 3736 4 4 Lift RCD100 RCD120 RCD140 RCD150 RCD160 RCD180 h3 mm 4000 4 5 Height with lift mast extended RCD100 RCD120 h4 mm 5329 RCD140 RCD150 RCD160 RCD180 5661 4 7 Height above overhead guard cab RCD100 RCD120 h6 mm 3010 RCD140 RCD150 RCD160 RCD180 3035 4 8 Seated height standing height RCD100 RCD120 h7 mm 1974 RCD140 RCD150 RCD160 RCD180 2004 ...

Page 272: ...h RCD100 RCD120 b1 2530 RCD140 RCD150 RCD160 RCD180 2565 4 22 Fork arm dimensions RCD100 RCD120 s e l mm 90 x 200 x 1400 RCD140 RCD150 RCD160 RCD180 100 x 200 x 1400 4 23 Fork carriage according to ISO 2328 class form A B Hydraulic fork posi tioner 4 24 Fork carriage width RCD100 RCD120 RCD140 RCD150 RCD160 RCD180 b3 mm 2545 4 25 Fork spread RCD100 RCD120 b5 mm 610 2274 RCD140 RCD150 RCD160 RCD180...

Page 273: ...RCD180 6596 4 34 Aisle width for pallet 800 x 1200 length wise RCD100 RCD120 Ast mm 6349 RCD140 6386 RCD150 RCD160 6622 RCD180 6796 4 35 Turning radius RCD100 RCD120 RCD140 Wa mm 4102 RCD150 RCD160 4338 RCD180 4512 4 36 Smallest pivot point distance RCD100 RCD120 RCD140 b13 mm 1362 RCD150 RCD160 RCD180 1405 5 Performance data 5 1 Driving speed with without load RCD100 km h 27 9 29 1 RCD120 27 6 29...

Page 274: ...0 105 9 RCD160 102 7 105 8 RCD180 102 6 105 3 5 7 Climbing capability with without load RCD100 41 3 80 8 RCD120 37 6 79 7 RCD140 29 8 59 3 RCD150 32 2 67 7 RCD160 30 6 65 3 RCD180 30 3 55 6 5 10 Service brake Wet disc 6 Battery voltage rated capacity 6 1 RCD100 RCD120 RCD140 RCD150 RCD160 RCD180 V aH 2 x 12 95 7 Drive engine 7 1 Engine manufacturer model Mercedes MTU 4R1000 7 2 Engine power rating...

Page 275: ...erview of type sheets 1200 mm load centre All data refers to standard equipment with standard lift masts All data must be observed without fail 1 Key data 1 1 Manufacturer Still 1 2 Manufacturer s type designation RCD100 1200 RCD120 1200 RCD140 1200 RCD150 1200 RCD160 1200 1 3 Drive Diesel 1 4 Operation Seated 1 5 Load capacity load RCD100 Q t 10 RCD120 12 RCD140 14 RCD150 15 RCD160 16 1 6 Load ce...

Page 276: ...61 RCD140 33565 2548 RCD150 34553 2428 RCD160 36156 2629 2 3 Axle load without front rear load RCD100 kg 10141 9133 RCD120 10769 9956 RCD140 10394 11719 RCD150 10429 11552 RCD160 10424 12362 3 Wheels chassis frame 3 1 Tyres solid rubber super elastic pneumatic polyurethane p p 3 2 Front tyre size RCD100 RCD120 RCD140 RCD150 RCD160 12 00 x 20 20pr 3 3 Rear tyre size RCD100 RCD120 RCD140 RCD150 RCD1...

Page 277: ...D160 r1 mm 569 4 Basic dimensions 4 1 Lift mast fork carriage tilt forwards backwards α β 15 10 4 2 Height with lift mast retracted RCD100 RCD120 RCD140 RCD150 RCD160 h1 mm 3736 4 4 Lift RCD100 RCD120 RCD140 RCD150 RCD160 h3 mm 4000 4 5 Height with lift mast extended RCD100 RCD120 RCD140 RCD150 RCD160 h4 mm 5661 4 7 Height above overhead guard cab RCD100 RCD120 RCD140 RCD150 RCD160 h6 mm 3035 Tech...

Page 278: ...40 5116 RCD150 RCD160 5366 4 21 Total width RCD100 RCD120 RCD140 RCD150 RCD160 b1 2565 4 22 Fork arm dimensions RCD100 RCD120 s e l mm 100 x 200 x 2400 RCD140 RCD150 RCD160 100 x 250 x 2400 4 23 Fork carriage according to ISO 2328 class form A B Hydraulic fork posi tioner 4 24 Fork carriage width RCD100 RCD120 RCD140 RCD150 RCD160 b3 mm 2545 4 25 Fork spread RCD100 RCD120 b5 mm 620 2220 RCD140 RCD...

Page 279: ...00 Ast mm 6386 RCD120 6622 RCD140 6841 RCD150 RCD160 7083 4 35 Turning radius RCD100 Wa mm 4102 RCD120 4338 RCD140 4512 RCD150 RCD160 4754 4 36 Smallest pivot point distance RCD100 b13 mm 1362 RCD120 RCD140 1405 RCD150 RCD160 1448 5 Performance data 5 1 Driving speed with without load RCD100 km h 28 8 30 1 RCD120 28 4 29 9 RCD140 28 1 29 8 RCD150 27 9 29 8 RCD160 27 7 29 7 5 2 Lifting speed with w...

Page 280: ...e Wet disc 6 Battery voltage rated capacity 6 1 RCD100 RCD120 RCD140 RCD150 RCD160 V aH 2 x 12 95 7 Drive engine 7 1 Engine manufacturer model Mercedes MTU 4R1000 7 2 Engine power rating in accordance with ISO 1585 RCD100 RCD120 kW 129 or above RCD140 RCD150 RCD160 150 or above 7 3 Nominal speed rpm 2200 7 4 Number of cylinders displacement cm3 4 5100 8 Other 8 1 Traction controller type Torque co...

Page 281: ...8 Other 8 4 Noise level at the driver s ear dB A 70 8 5 Tow coupling type model mm 50 Technical data 6 Overview of type sheets 1200 mm load centre 271 5001 801 1625 EN 05 2022 03 ...

Page 282: ...Technical data 6 Overview of type sheets 1200 mm load centre 272 5001 801 1625 EN 05 2022 03 ...

Page 283: ...tension of double hoses 246 Check the tyres for damage and foreign objects 237 Clean the truck 233 Cold Climate Options 175 Commissioning 10 Conformity marking 6 Consumables 45 Oil Safety Information 45 Safety information for handling battery acid 46 Safety information for handling hydraul ic fluid 46 Contact details I Controls 52 Coolant level check 226 Copyright and trademark rights 13 D Damage ...

Page 284: ...her filter check 243 I Improper use 10 Information symbols 13 Inspection and maintenance data 211 Insulation testing 40 Drive battery test values 41 Test values for the truck 41 Insurance cover on company premises 27 Issue date of the operating instructions 13 J Joystick Central lever operation 144 Single lever operation 94 L Lifting a load 199 Lifting the fork carriage Central lever operation 146...

Page 285: ...tion 40 Safety regulations when driving 43 Scope of service Before initial commissioning 56 Scope of the documentation CO solutions 12 Seat belt Fastening 76 Unfastening 76 Service brake 99 Service intervals 210 Service plan 217 Pre shift 57 Regular maintenance 57 Side window Closing 68 Opening 68 Special risks 33 Stability 33 Status code 116 140 Steering 98 Storage unit 132 Switching on the direc...

Page 286: ... Truck data acquisition special setting PIN and status code 114 137 Truck data acquisition standard setting PIN 111 134 U Update of this manual 15 Using working platforms 21 W Warning regarding non original parts 29 Wheels and tyres Safety principles 30 With cup holder 133 Index 276 5001 801 1625 EN 05 2022 03 ...

Page 287: ......

Page 288: ...STILL GmbH 5001 801 1625 EN 05 2022 03 ...

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Still 5410, Original Instructions Manual

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