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Still RCD25 Original Instructions Manual Download Page 5

1 Introduction

 

Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 2

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 3

Impermissible use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 4

Description of use and climatic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 5

Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 5

CE labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 6

EMC – Electromagnetic compatibility  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 7

EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . 

 8

2 Safety

 

Definition of terms used for responsible persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 10

Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 10

Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 10

Competent person. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 10

Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 10

Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 12

General safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 12

Exhaust gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 13

Ground condition for using the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 13

Safety Regulations Relative to Forklift Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 13

Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 14

Safety regulations when driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 15

Safety regulations in case of accidental lateral tipping . . . . . . . . . . . . . . . . . . . . . . . . 

 16

Exercise caution when handling gas springs and accumulators . . . . . . . . . . . . . . . . . 

 16

Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 17

Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 17

Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 18

Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 19

Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 20

Disposal of consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 20

Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 21

Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 21

Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 22

Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 22

Table of contents

 

 III

60068011601 EN - 09/2020

Summary of Contents for RCD25

Page 1: ...Diesel forklift truck RCD25 RCD30 RCD35 Original instructions 4221 4222 4223 60068011601 EN 09 2020 ...

Page 2: ......

Page 3: ...ompanies of 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 a...

Page 4: ......

Page 5: ...afety regulations 12 Exhaust gases 13 Ground condition for using the truck 13 Safety Regulations Relative to Forklift Use 13 Residual dangers residual risks 14 Safety regulations when driving 15 Safety regulations in case of accidental lateral tipping 16 Exercise caution when handling gas springs and accumulators 16 Safety regulations for handling consumables 17 Permissible consumables 17 Oils 18 ...

Page 6: ...ng the truck with a crane 39 Commissioning the truck 40 Remaining ready for operation 41 Pre shift checks 41 Daily checks before use 41 Seat belt status and performance checks 42 Checking the condition of the tyres 43 Check the wheel nuts for correct condition 44 Check the condition and operation of chain 45 Checking the coolant level 46 Check the engine oil level 48 Check the brake fluid level 49...

Page 7: ...king brake 69 Lifting system and attachments 70 Operating the lifting device 70 Operating attachments 71 Handling loads 73 Safety regulations when handing loads 73 Load centre distance and load capacity 73 Capacity Chart 74 Transporting pallets 75 Danger area 75 Transporting suspended loads 76 Adjusting the fork arm distance 77 Picking up a load 78 Transporting loads 82 Driving on ascending and de...

Page 8: ...le 113 Providing access to maintenance points 114 Opening the bonnet 114 Closing the bonnet 115 Installing and removing the bottom plate 116 Maintenance service 118 Changing the engine oil 118 Replacing the engine oil filter 120 Replacement of Coolant 121 Cleaning the radiator checking for leaks 124 Cleaning the air filter 124 Change the air filter 126 Draining water from the fuel filter 127 Air b...

Page 9: ...n filter 138 Replacing the breather filter 139 6 Technical datasheet Dimensions 142 VDI Datasheet for RCD25 143 VDI Datasheet for RCD30 145 VDI Datasheet for RCD35 147 Mast specifications 149 Annex 7 Diagrams Electric schematic diagram for Doosan D24 engine with ISO3691 function 162 Hydraulic diagram 163 Table of contents VII 60068011601 EN 09 2020 ...

Page 10: ......

Page 11: ...1 Introduction ...

Page 12: ... record 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 60068011601 EN 09 2020 ...

Page 13: ...s shall be sufficiently paved level and free of objects Drain channels and rail ways crossings etc shall be levelled and if necessary covered with ramps in such a way that they can be driven over without bumps as far as possible Industrial trucks shall only be used on routes without sharp curves excessive slopes and gates which are too narrow or too low Inclines used by industrial trucks shall not...

Page 14: ...d load of the indus trial truck carrying capacity and load moment combined with the attachments shall not be exceeded refer to additional capacity rating plate Modifications in particular attachments or conversions are not permitted to be made to the industrial truck without the manufacturer s approval Trailers Industrial trucks may only be used to tow trail ers if they are intended for this purpo...

Page 15: ...lure to comply can risk the lives of others and or cause major damage to equipment WARNING Means that failure to comply can result in the risk of serious physical injury and or major damage to equipment CAUTION Means that failure to comply can result in the risk of major damage to equipment or destruction NOTE This means that particular attention must be paid to the specific technical meaning be c...

Page 16: ...ed EC declaration of conformity The CE labelling is attached to the nameplate An independent structural change or addition to the truck can compromise safety thus inva lidating the EC declaration of conformity The EC declaration of conformity must be carefully stored and made available to the re sponsible authorities CE Symbol Introduction 1 CE labelling 6 60068011601 EN 09 2020 ...

Page 17: ...he electromagnetic in terference conditions to be expected there An EMC test thus firstly measures the electro magnetic interference emitted by the truck and secondly checks it for sufficient resistance to electromagnetic interference with reference to the planned usage location A number of electrical measures are taken to ensure the electromagnetic compatibility of the truck CAUTION The EMC regul...

Page 18: ...his machine conforms to RED Directive 2014 53 EU in the latest version This declaration of conformity is issued under the sole responsibility of the manufacturer Person authorised to compile the technical file in accordance with the named directives See EC declaration of conformity In addition we hereby declare that the equipment conforms to the requirements of the Direc tive for Noise Emissions 2...

Page 19: ...2 Safety ...

Page 20: ...s person has become familiar with a wide range of symptoms that require checks to be carried out such as based on the results of a hazard assessment or a daily inspec tion Recent professional involvement in the field of the industrial truck test in question and an appropriate further qualification are es sential The qualified person must have ex perience of carrying out the test in question or of ...

Page 21: ...nditions 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 have access to them at all times The driver must have read and understood the operating manual have familiarised himself with safe opera tion of the truck be physically and mentally able to drive the truck safely DANGER The use ...

Page 22: ... the truck and noti fy the authorised service centre Maintain appropriate distances from high voltage overhead cables Comply with the safety distances established by the compe tent authorities Never raise loads using just one fork arm Position the load on the fork carriage or in such a way that the centre of gravity of the load is as close as possible to the fork car riage The load must be positio...

Page 23: ...ing the truck In order for the truck to be used suitable ground must have the following characteris tics Even and level Hard Sturdy Free of obstacles Properly prepared for the purpose Safety Regulations Relative to Forklift Use The operator must familiarize himself with the forklift to be able to better describe any defects and assist maintenance personnel The operator trained and authorized to us...

Page 24: ... safety regulations Unrepaired damage or defective and worn components Insufficient maintenance and testing Use of incorrect consumables Exceeding test intervals The manufacturer is not held responsible for accidents involving the truck caused by the failure of the operating company to comply with these regulations either intentionally or carelessly Stability The stability of the truck has been te...

Page 25: ...an exces sive volume during travel or when handling loads can affect the operator s attention There is a risk of acci dent Do not use devices during travel or when handling loads Set the volume so that warning signals can still be heard WARNING In areas where use of mobile phones is prohibited use of a mobile phone or radio telephone is not per mitted Switch off the devices Visibility when driving...

Page 26: ... springs Gas springs are complex components that are subject to high internal pressures up to 300 bar They may under no cir cumstances be opened unless instructed to do so and may be installed only when not under pressure If required the authorised service centre will de pressurise the gas spring in accordance with the reg ulations before removal Gas springs must be dep ressurised before recycling...

Page 27: ...nsumables may result in a risk of injury death or damage to the environment Observe the safety regulations when handling such materials The permissible materials required for opera tion can be found in the supply table in the chapter entitled Maintenance Safety 2 Safety regulations for handling consumables 17 60068011601 EN 09 2020 ...

Page 28: ...id 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 Spilt oil should be removed immediately with oil binding agents and disposed of according to the regulations ENVIRONMENT NOTE Oil...

Page 29: ... if these fluids escape at high pressure due to leaks in the hydraulic system In case of such injury immediate medical assistance is required To avoid 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 that co...

Page 30: ...pilt battery acid with plenty of water Follow the statutory regulations ENVIRONMENT NOTE Dispose of used battery acid in line with the applicable regulations Disposal of consumables ENVIRONMENT NOTE Materials that accumulate during repair main tenance and cleaning must be collected prop erly and disposed of in accordance with the national regulations for the country in which the truck is being use...

Page 31: ...osed 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 agement company for disposal purposes Safety 2 Environmental considerations 21 60068011601 EN 09 2020 ...

Page 32: ...se levels at the truck cannot be used to determine the noise emissions at workplaces according to the most recent version of Directive 2003 10 EC daily personal noise pollution If required these noise emissions must be determined di rectly at the workplaces under the actual con ditions present further sources of noise par ticular application conditions sound reflec tions by the operating company N...

Page 33: ...at the actual place of use in accordance with Directive 2002 44 EC in or der to consider all additional influences such as driving route intensity of use etc are con sidered NOTE Please note the definition of operating com pany in the sense of responsible persons Safety 2 Emissions 23 60068011601 EN 09 2020 ...

Page 34: ...Safety 2 Emissions 24 60068011601 EN 09 2020 ...

Page 35: ...3 Information about the truck ...

Page 36: ...iew General front view Fork arms Mast Front wheels Driver s Seat Overhead guard 1 2 3 4 5 Tilt cylinder Forward Right Backwards Left 6 A D I S Information about the truck 3 General forklift view 26 60068011601 EN 09 2020 ...

Page 37: ...eight Rear lights Trailer coupling Overhead guard Mast 1 2 3 4 5 6 Steering wheel Control panel Engine bonnet Exhaust pipe Filler cap for fuel tank 7 8 9 10 11 Information about the truck 3 General forklift view 27 60068011601 EN 09 2020 ...

Page 38: ...elerator pedal Driving brake pedal Inching pedal Seat 1 2 3 4 5 6 Direction reverser A4 paper folder Light switch direction indicator light switch Operating handle Display unit Cup holder 7 8 9 10 11 12 Information about the truck 3 Instrumentation and controls 28 60068011601 EN 09 2020 ...

Page 39: ...e oil pressure indicator light 1 2 3 4 5 6 7 8 Water separator light indicator light DPF regeneration disabled indicator light Red light Battery charging indicator light Engine error light indicator light Red light DPF regeneration indicator light Exhaust temperature warning light Yellow light DPF regeneration request indicator light Yellow light 9 10 11 12 13 14 Information about the truck 3 Inst...

Page 40: ...tion number is used to identify the truck It can be found on the nameplate and must be referred to in all technical questions The production number contains the following coded information 1 Production location 2 Model 3 Year of manufacture 4 Sequential number 7090_921 004 xx xxxx x xxxxx 1 2 3 4 Information about the truck 3 Truck identification 30 60068011601 EN 09 2020 ...

Page 41: ...only Ballast weight in kg for electric forklift trucks only 1 2 3 4 5 6 7 Refer to the technical data listed in these op erating instructions for more detailed infor mation CE labelling Nominal drive power in kW Battery voltage in V Rated capacity in kg 8 9 10 11 12 The truck can be identified from the informa tion on the nameplate Information about the truck 3 Truck identification 31 60068011601 ...

Page 42: ...number The engine code and manufacturing number are engraved in the position 1 These num bers are necessary to request quality assur ance or to order parts Product name Year of manufacture Serial Number After new representative specification 1 2 3 4 Information about the truck 3 Truck identification 32 60068011601 EN 09 2020 ...

Page 43: ...Location of the decals Information about the truck 3 Location of the decals 33 60068011601 EN 09 2020 ...

Page 44: ...n Adding coolant 1 2 3 4 5 6 7 8 9 10 11 12 Warning sign Danger due to shearing Warning sign Danger due to overheating of radiator Warning sign Danger due to shearing Danger to the driver s head with engine hood not fully closed Sound pressure level Warning sign Read the operating instruction for lifting by lifting gear attachment point Warning sign Preventing water into the electrical parts Warni...

Page 45: ...truck is tipping over Brace feet Hold on tight Lean in the opposite direction to which the truck is tipping Manufacturer s name 24 Information about the truck 3 Location of the decals 35 60068011601 EN 09 2020 ...

Page 46: ...Information about the truck 3 Location of the decals 36 60068011601 EN 09 2020 ...

Page 47: ...4 Use and operation ...

Page 48: ...ly Tilt the lift mast forward NOTE The fork arms must be resting on the ground Apply the parking brake as described in chapter entitled Parking brake Use two wedges to block each of the front and rear wheels to prevent rolling Use ropes to secure the forklift truck on the truck CAUTION Also use ropes to secure the mast in the case that the mast shall be disassembled during the transport Environmen...

Page 49: ...pacity rating marked on the crane nameplate Never walk under a suspended load CAUTION Use a spreader and crane with sufficient load capaci ty to lift the truck For the weight of the truck see the manufacturer s nameplate NOTE Before lifting the truck fasten the slings to the given lifting points These lifting points are not specifically marked on the truck Lower the lift mast completely and tilt i...

Page 50: ...t not touch the overhead guard or any other installed equipment when the truck is being lifted DANGER The overhead guard will be damaged if it is contac ted by lifting equipment that is under tension from lifting This can result in later failure of the over head guard and the risk of severe injury or death Ensure that no part of any lifting equipment con tacts the overhead guard during lifting Com...

Page 51: ...onents installed on the truck Make sure that seat switch is working cor rectly Check that the brakes work correctly checking their travel and efficiency Check the tyre pressure and wear condi tions Visually inspect wheels for correct tight ness Make sure that the lights work correctly if applicable Visually check that the chains are taut Make sure that the start stop key works cor rectly Check tha...

Page 52: ...t belt must be replaced if it is cracked worn or has been damaged in an accident Carefully check the connection between the seat belt and the seat Carefully check the connection between the seat and the panel cover below NOTE Only when the driver sits on the seat the fork lift can be operated Push the lever 1 on the front left hand side of the engine bonnet upwards with your left hand Open the bon...

Page 53: ...key removed Checking the condition of the tyres Superelastic tyres Superelastic tyres must be changed before the profile reaches the maximum wear al lowed The maximum wear of the tyre manu facturer is indicated by a line on the side 1 along the circumference of the tyre DANGER If the forklift truck is used on wet or slippery surfa ces replace the tyres before the thickness of the tread drops below...

Page 54: ...rmed or whether the hole for the rim is larger re tighten with torque spanner if yes Replace the rim when there is serious deformation If the markings are difficult to recognize check if there is any gap As the arrows show between the joint face of the rims and nuts Re tighten with torque spanner if gap exits Check the wheels and rims for wear and deformation change the tyres if there is any defor...

Page 55: ... Stop using the forklift immediately when the hinge pins of chain rotate before operation Lift and lower the lifting mast without load for one round to check the operation of lift ing chain for any abnormal sound or block Use and operation 4 Remaining ready for operation 45 60068011601 EN 09 2020 ...

Page 56: ...stry please use lubricating grease in place of spray During operation or maintenance stop us ing the forklift if there is any crack of chain plate Checking the coolant level DANGER Risk of burns When the engine is hot the radiator is under pressure and hot coolant can spray out if the radiator cap 1 is unscrewed Check coolant level when the engine is cold and switched off Use and operation 4 Remai...

Page 57: ...erform this check the truck must be parked on a level surface If necessary add coolant in line with the specifications given in the chapter entitled Supply table Screw the radiator cap 1 back on secure ly Frequently check the coolant level in the supplementary tank 2 Make sure the coolant level indicates be tween the upper limit and the lower limit on the supplementary tank Replenish it if there i...

Page 58: ...Min level B on the dipstick CAUTION Risk of engine damage Insufficient engine lubrication can cause engine dam age An insufficient oil level or the use of engine oil with different specifications can lead to the failure of engine lubrication Only use engine oil in line with the supply table Add oil to the max oil level if the oil level is below the Min level Fully re insert the dipstick Close the ...

Page 59: ...ng Check the small vent hole in the brake oil container frequently to make sure that it is not clogged with dust Transmission oil level inspection procedure NOTE Check the transmission level with the trans mission in neutral the oil hot at least 40 C and with the truck on level ground Ensure the forklift truck is stopped on a lev el surface Remove the bottom plate Run the truck in neutral for 3 5 ...

Page 60: ...of the oil level aperture NOTE Please refer to the chapter on replacing the drive axle gearbox oil for steps to take when adding gear oil Checking the hydraulic oil level ENVIRONMENT NOTE Please follow the instructions for handling disposal of fluids and lubricants NOTE The oil level should only be checked with the lift mast vertical and the fork carriage lowered Apply the parking brake Open the e...

Page 61: ...ap 1 and refuel Close the fuel tank cap 1 CAUTION Risk of damage to injection system due to entering air Do not allow the tank to empty entirely if possible so that no air can enter the injection system 1896 1 Diesel fuel Specifications CAUTION Risk of component damage if non approved fuels are used Use only approved fuels with the following specifica tions If non approved fuels are used complianc...

Page 62: ...o exceed 0 35 by volume Less than 0 1 is prefer red Total aromatics content should not exceed 35 by volume Less than 30 is prefer red PAH polycyclic aromatic hydrocarbons content should be below 10 by volume Metal content of Na Mg Si and AI should be equal to or lower than 1 mass ppm Test analysis method JPI 5S 44 95 Lubricity Wear mark of WS 1 4 should be Max 0 018 in 460 μ m at HFRR test NOTE Bi...

Page 63: ...ngine life Prevent dirt and debris from contaminating engine coolant Carefully clean the radiator cap and the surrounding area before you remove the cap NEVER mix different types of engine cool ants This may adversely affect the proper ties of the engine coolant Engine coolant specifications Use a Long Life Coolant LLC or an Extended Life Coolant ELC that meets or exceeds the following guidelines ...

Page 64: ... dismounting the forklift First place your left foot on the step Grip the handrail or overhead guard beam and mount the truck from the left hand side Use the step and handrail or overhead guard beam to dismount from the left hand side CAUTION Do not mount or dismount the truck from the right hand side unless it is an emergency Use and operation 4 Mounting dismounting 54 60068011601 EN 09 2020 ...

Page 65: ...E Remaining in a sitting position for long periods of time puts a great amount of pressure on the spine Make sure this pressure is reduced by bending forwards frequently Moving the driver s seat Lift the lever 1 and hold Push the driver s seat into the desired posi tion Release the lever Ensure that the driver s seat is securely en gaged Adjusting the seat backrest Do not put pressure on the seat ...

Page 66: ... might be injured if the truck tips over This risk of injury can be reduced through the combined use of the re straint system and the seat belt In addition the seat belt protects against the consequences of rear end collisions and falling off a ramp We therefore recommend that you al so use the seat belt DANGER Only bracket doors or full cabs with closed sturdy doors constitute a driver restraint ...

Page 67: ...t out of the belt retractor 2 and fasten over the thighs with a close fit to the body NOTE Sit as far back as possible so that your back is leaning against the seat backrest The auto matic blocking mechanism permits sufficient freedom of movement on the seat Insert the buckle 3 into the seat belt socket 1 Check the tension of the seat belt The belt should fit closely around your body Fastening on ...

Page 68: ...eased force pull the seat belt around 10 15 mm out of the retractor to dis engage the blocking mechanism Slowly allow the seat belt to retract again Protect the seat belt from dirt for example by covering it Malfunction due to cold weather condi tions If the buckle or belt retractor is frozen thaw them out and dry them thoroughly to pre vent recurrence CAUTION Do not subject buckle or belt retract...

Page 69: ...ting position Start up To start the engine insert the key turn it to position Ⅱ and release it as soon as the engine starts the key will go back to posi tion Ⅰ Starting at cold temperature Insert the key in the switch and turn it to po sition Ⅰ The pre heater will start automati cally and the warning light 1 will come on Wait for the warning light 1 to go out then turn the key to position Ⅱ and re...

Page 70: ...nition key is in position Ⅰ Direction indicators When the lever 1 is moved into position R the right indicator light lights up When the lever 1 is moved into position L the left indicator light lights up R Turn Right N Neutral L Turn Left Use and operation 4 Switches 60 60068011601 EN 09 2020 ...

Page 71: ... lights front head lights and also rear lights Lamp switch 0 OFF 1st 2nd Clearance lamp OFF ON ON Front headlights OFF OFF ON Rear combination lights OFF OFF ON Warning horn The horn allows the driver to draw attention to his and his truck s presence if necessary Press the button 1 in the centre of the steering wheel to actuate the horn OM0200_4 1 Use and operation 4 Switches 61 60068011601 EN 09 ...

Page 72: ...backwards into position B Adjusting the steering column DANGER Only adjust the steering column when the truck is stationary Angle adjustment Pull down the handle 1 clockwise Move the steering column into the required position Pull back the handle anti clockwise to its original position Start the engine Sit in the driver s seat and fasten the seat belt Ensure that the cab doors or the driver restra...

Page 73: ...the switch key to position Ⅱ Release the switch key as soon as the engine starts NOTE If the engine does not start stop the starting procedure and try again later Wait at least one minute between start attempts in order to avoid running down the battery If the engine still does not start after three attempts do not try to start the engine again Instead contact your authorised service centre OM1826...

Page 74: ...rticle filters or comparable systems can clean exhaust gases in a way that reduces the health hazard and risk of poisoning when operating the truck Observe the national laws and regulations when using trucks with an internal combustion engine in entirely or partially enclosed working areas Always ensure sufficient ventilation DANGER Risk to health from exhaust gases Do not leave the truck with the...

Page 75: ...st backwards and lower the fork arms to the ground around 30cm CAUTION Check the safety around the forklift and sound the horn before starting the truck NOTE The drive functions of the truck are only acti vated when the driver s seat is occupied Sit in the driver s seat and fasten the safety belt Release the parking brake 1 and the cor responding LED 2 will turn off Start the engine Use and operat...

Page 76: ... Move direction selection lever 3 in the re quired drive direction A FORWARDS B BACKWARDS Gently press the accelerator pedal 4 to set off Use and operation 4 Driving 66 60068011601 EN 09 2020 ...

Page 77: ...ravel A FORWARDS B BACK WARDS then press the accelerator pedal 1 The forklift truck will now accelerate in the new drive direction DANGER Using operating lever to directly reverse the operat ing direction of the forklift truck during operation is strictly prohibited Reversing direction during opera tion will result in damage to the forklift truck Use and operation 4 Driving 67 60068011601 EN 09 20...

Page 78: ...ts of the truck are possible when you actuate the inching ped al 1 lightly if the accelerator pedal is actu ated as well Actuate the pedal 1 in order to move the truck gradually even if the en gine is running at full capacity Operating the service brake Braking and stopping DANGER At speeds that are too high there is a danger that the truck could slip or overturn The braking distance of the truck ...

Page 79: ...and is functional Parking brake The parking brake must be actuated every time the driver exits the truck To actuate the parking brake press the parking brake pedal 1 with foot The cor responding indicator light on the display unit illuminates Pull the locking switch 2 to release the parking brake pedal NOTE If the driver exits the truck without actuating the parking brake a warning signal sounds T...

Page 80: ...ng system and at tachments Keep in mind the maximum lift height Take note of the switching symbols with ar rows Operation of the control lever must be slow and steady Lifting lowering and tilting speeds depend on the range of motion of the control level The control lever will automatically return to neutral when released Lifting the fork carriage DANGER If any danger occurs when raising the lift m...

Page 81: ...clips etc Please do not ex ceed the working pressure of attachments dur ing operation and ensure that operation is in compliance with datasheets One or two addi tional control levers can be installed to operate attachments NOTE Below is a description of attachment opera tions The forklift truck can be configured with different operating levers Take note of the switching symbols with ar rows Use an...

Page 82: ...e ground Push the control lever 3 forwards and move to the left Push the control lever 3 backwards and move to the right Operating fixtures Push the control lever 4 forwards to open the jig Push the control lever 4 backwards to clamp the jig Use and operation 4 Lifting system and attachments 72 60068011601 EN 09 2020 ...

Page 83: ...anteed DANGER Risk of accident from falling or crushing Do not step onto the forks Do not lift people Never grab or climb on moving parts of the truck DANGER Risk of accident from a falling load When transporting small items attach a load safe ty guard variant to prevent the load from falling on the driver Use a closed roof covering variant in addition Load centre distance and load ca pacity Befor...

Page 84: ...horised deal er before operating Before lifting irregular loads or goods that sway Where the load centre of gravity distance is excessively long Before using attachments Capacity Chart For example Truck model RCD25 with single tyre Load centre 500 mm Lift height 5000 mm In this case the maximum load capacity is 2500 kg Before loading make sure that the dimen sions and weight of the load are within...

Page 85: ...nt its load carrying equip ment e g attachments or the load Also in cluded are the areas where loads could fall or working equipment could fall or be lowered DANGER Risk of injury Do not step on the fork DANGER Risk of injury Do not step under the raised forks DANGER People may be injured in the danger area of the truck The danger area of the truck must be completely clear of all personnel except ...

Page 86: ... right angles to the direc tion of travel Risk of crushing of guide persons Reduced visibility DANGER Loss of stability Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over When transporting suspended loads observe the following instructions Instructions for transporting suspended loads Swinging loads must be prevented by using the proper driving spe...

Page 87: ... the load begins to swing en sure that no person is placed at risk DANGER Risk of accidents When transporting hanging loads never perform or end driving and load movements abruptly Never drive on slopes with a suspended load Transporting containers holding fluids as hanging loads is not permitted Adjusting the fork arm distance Raise the knob 2 and rotate it by 90 Use and operation 4 Handling load...

Page 88: ...s possible with re spect to the centre of the fork carriage Picking up a load DANGER The truck may tip over if the load is too heavy Before picking up the load check that the dimen sions and weight of the load lie within the permitted range for the truck This information can be found on the capacity rating plate DANGER There is a risk to life caused by a falling load or if parts of the truck are b...

Page 89: ...re is a greater risk of the load slip ping when the load is raised or lowered The load centre of gravity and the moment of tilt change when the load slips The truck may tip forwards Only tilt the lift mast forwards with a raised lifting accessory when it is directly above the stack When the lift mast is tilted forward take particular care to ensure that the truck does not tip forwards and that the...

Page 90: ...increased by adjust ing the engine speed Refer to the chapter en titled Increasing the lifting speed DANGER Risk of accident Beware of any people in the danger area CAUTION Component damage possible Ensure that the roadway behind you is clear Move backwards carefully and slowly until the load is clear of the racking Brake gen tly DANGER Never tilt the lift mast with a raised load due to the risk o...

Page 91: ... Lower the load while maintaining ground clearance Tilt the lift mast backwards The load can now be transported 5060_003 102 5060_003 101 Use and operation 4 Handling loads 81 60068011601 EN 09 2020 ...

Page 92: ...using the ac celerator pedal Transporting loads NOTE Observe the information in the chapter entitled Safety regulations when driving DANGER The higher a load is lifted the less stable it be comes The truck can tip over or the load can fall increasing the risk of accident Driving with a raised load and the lift mast tilted for ward is not permitted Only drive with the load lowered Lower the load un...

Page 93: ...ntitled Steering Always accelerate and brake gently NOTE Observe the information in the chapter entitled Operating the service brake Never drive with a load protruding to the side e g with the sideshift 6210_800 013 6210_800 014 Use and operation 4 Handling loads 83 60068011601 EN 09 2020 ...

Page 94: ... gradients at an angle Do not park the truck on ascending or de scending gradients In case of emergency secure the truck with wedges so that the truck does not roll away Reduce the driving speed on descending gradients It is not permitted to drive on long ascending and descending gradients greater than 15 due to the specified minimum braking and sta bility values Before driving on ascending and de...

Page 95: ...l weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the at tachment variant nameplate and if neces sary by weighing the load to be lifted Add the determined unit weights to obtain the actual total weight of the truck Tare weight 1 Ballast weight variant 2 Attachment net weight variant Weight of the load to be lifted 100 kg allowance for drive...

Page 96: ... Ensure that the vehicle onto which you will be driving is secured to prevent it from shifting and that it can support the load of the truck Determining the actual total weight Park the truck securely Determine the unit weights by reading the truck nameplate and if necessary the at tachment variant nameplate and if neces sary by weighing the load to be lifted Add the determined unit weights to obt...

Page 97: ...a raised load in storage with the lift mast tilted forwards e g in a rack with sloping racking channels an ad ditional load capacity diagram must be created because the stability will be affected Please contact the authorised service centre WARNING Risk of accident from a falling load If the fork or the load remains suspended during low ering the load may fall When removing a load from storage mov...

Page 98: ...ok behind Move the truck back until the fork arms can be lowered without touching the stack Lower the fork to the ground clearance po sition Tilt the lift mast backwards and drive away 6210_800 016 Use and operation 4 Handling loads 88 60068011601 EN 09 2020 ...

Page 99: ...ust not exceed the rated capacity If the existing towed load corresponds to the rated capacity of the truck no load may be transported on the fork at the same time The load can be distributed be tween the fork and the trailer Check the load distribution and adjust it to corre spond to the rated capacity Observe the permissible rigidity value of the tow coupling CAUTION Risk of damage to components...

Page 100: ...g The forklift can be towed in case of break down using the tow coupling 1 Before tow ing models with reversing lever on the steering wheel check that this lever 2 is in the central position CAUTION During the towing operation the operator must be on board the forklift in order to perform the steering and braking operations and the engine must be running Leaving the truck Before leaving the truck ...

Page 101: ...uck without having first applied the parking brake 1 and removed the key NEVER park the truck on a gradient or slope The truck may only be parked on a slope in emergency situations In this case suitable wheel chocks must be positioned under the front wheels NOTE The truck has a warning sound that is activa ted when the truck is parked but the parking brake has not been applied The signal will soun...

Page 102: ...plat forms to reach inaccessible areas Washing the truck exterior CAUTION There is a risk of short circuit if water penetrates the electrical system Strictly adhere to the following steps Prior to cleaning switch off the power sup ply to the electrical system Do not spray electrical components and the covers on these components directly with water WARNING Failure to follow these instructions could...

Page 103: ...ctly adhere to the following steps Regularly remove all deposits accumula tions of foreign materials in the vicinity of hot components Do not place combustible materials in the engine compartment DANGER Risk of fire Flammable fluids can be ig nited by hot components on the truck Strictly adhere to the following steps Do not use flammable fluids for cleaning Observe the manufacturer s guidelines fo...

Page 104: ...ing open ings and their surroundings and the lubri cating nipples before lubricating NOTE Please note The more often the truck is cleaned the more frequently it must be lubri cated Cleaning the electrical system CAUTION Cleaning electrical system parts with wa ter can damage the electrical system Cleaning electrical system parts with water is forbidden Use dry cleaning materials in accord ance wit...

Page 105: ... s safety instructions Additives may not be used if using a steam nozzle Immediately blow the chain dry after clean ing to remove water both on the chain sur face and inside the hinge pins Move the chain several times during the blow drying process Immediately apply chain spray and keep the chain moving while doing so NOTE The lifting chains are a safety component The use of cold cleaning agents c...

Page 106: ...up the truck in accordance with the regulations CAUTION Risk of short circuits If any moisture has penetrated into the electrical system despite the precautionary measures tak en the system must first be dried using com pressed air 7311_003 058 Use and operation 4 Cleaning 96 60068011601 EN 09 2020 ...

Page 107: ...rriage To relieve the strain on the load chains lower the fork car riage onto a suitable supporting surface e g a pallet Check hydraulic oil level and top up if re quired Apply a thin layer of oil or lubricating grease to all unpainted parts as corrosion protec tion Lubricate all lubrication points listed in the chapter entitled Summary table of mainte nance operations Spray all exposed electrical...

Page 108: ...aning Oil joints and controls Check battery condition and acid density recharge if necessary Restore engine to normal condition accord ing to regulations of engine manufacturer Check engine oil for condensed water and change if necessary Check hydraulic oil for condensation water change if necessary Carry out the checks and tasks that are to be performed before daily use Put the truck into operati...

Page 109: ...th regulations contact the authorised sales network or the recycling companies authorised for scrapping ENVIRONMENT NOTE In particular batteries fluids oils fuels lubri cants etc electrical and electronic compo nents and rubber components must be dis posed of in compliance with specific local reg ulations for each type of material Use and operation 4 Decommissioning 99 60068011601 EN 09 2020 ...

Page 110: ...Use and operation 4 Decommissioning 100 60068011601 EN 09 2020 ...

Page 111: ...5 Maintenance ...

Page 112: ...rs in order to guarantee that the truck remains in a good safe operating condition and that it fulfils all technical specifications CAUTION The intervals for the various maintenance tasks to be carried out on a regular basis must be shortened ac cordingly if the truck is used in particularly severe conditions such as In dusty environments At temperatures below zero For particularly heavy duty work...

Page 113: ...le maintenance work such as checking the hydraulic oil level may be carried out by untrained personnel A qualification such as those held by a competent person is not re quired to carry out this work The required tasks are described in the chapter entitled Remaining ready for operation Preliminary maintenance op erations Carry out the following steps before perform ing maintenance operations Park ...

Page 114: ...of severe electric shock Disconnect the negative connecting terminal from the battery before performing any work on the electrical system Maintenance 5 Preliminary maintenance operations 104 60068011601 EN 09 2020 ...

Page 115: ...tyres for wear and check the air pressure if necessary Check the wheels for damage Internal combustion engine Change the engine oil and filter Check the cooling system for leaks and correct function Check the coolant and top up if necessary Replace the air filter insert Fuel system Change the fuel filter Check the fuel lines and clips Steering and steering axle Lubricate the rear wheel bearings Lu...

Page 116: ...ating hours 500 1500 2500 3500 4500 5500 6500 7500 8500 9500 Carried out Check mast profiles for damage and wear Lubricate the mast profiles Maintenance 5 Scheduled truck maintenance 106 60068011601 EN 09 2020 ...

Page 117: ... the wheel nuts Check tyres for wear and check the air pressure if necessary Check wheels for damage Torque converter Change the gearbox oil for the torque converter Replace the gearbox oil filter for converter gear Drive axle Drive axle Check mounting check for leaks and clean cooling fins Change the axle oil Internal combustion engine Change the engine oil and the engine oil filter Check the con...

Page 118: ...rking correctly Change the hydraulic oil every 2000 hours Lift mast Check load chains for damage and wear adjust and lubricate Check mast bearings for damage and lubricate Check the tightening torque Check mast profiles for damage and wear and lubricate Check lift cylinders and connections for damage and leaks Check guide pulleys for damage and wear Check support rollers and chain rollers for dama...

Page 119: ...k the fresh air filter Heating system Check for damage observe the manufacturer s maintenance in structions Check attachments for wear and damage observe manufacturer s maintenance in structions Check trailer coupling for wear and damage observe manufacturer s maintenance instructions Maintenance 5 Scheduled truck maintenance 109 60068011601 EN 09 2020 ...

Page 120: ...f the wheel nuts Check tyres for wear and check the air pressure if necessary Check wheels for damage Torque converter Change the gearbox oil for the torque converter Replace the gearbox oil filter for converter gear Drive axle Drive axle Check mounting check for leaks and clean cooling fins Change the axle oil Internal combustion engine Change the engine oil and the engine oil filter Check the co...

Page 121: ... function Isolation valve is working correctly Lift mast Check load chains for damage and wear adjust and lubricate Check mast bearings for damage and lubricate Check the tightening torque Check mast profiles for damage and wear and lubricate Check lift cylinders and connections for damage and leaks Check guide pulleys for damage and wear Check support rollers and chain rollers for damage and wear...

Page 122: ... the fresh air filter Heating system Check for damage observe the manufacturer s maintenance in structions Check attachments for wear and damage observe manufacturer s maintenance in structions Check trailer coupling for wear and damage observe manufacturer s maintenance instructions Maintenance 5 Scheduled truck maintenance 112 60068011601 EN 09 2020 ...

Page 123: ... lubricating grease fittings 0 05KG Lubricating grease NLGL 2 lithium grease Drive axle 6L Gear oil 15 49 GL 5 85W 90 25 49 GL 5 80W 90 For cold storage use Cooling system Radiator water tank 11L Coolant water See section Engine cool ant Specifications Reservoir box 0 9L Coolant water Fuel 2 0 2 5T 20L 3 5T 23L Diesel See section Diesel fuel Specifications WARNING Use of products with specificatio...

Page 124: ...d if it is not in its forward most position Slide the driver s seat all the way forwards CAUTION Move the steering column 1 as far for wards as possible and secure see section entitled Adjusting the steering column Slide the driver s seat 2 all the way for ward see section entitled Adjustment of the driver s seat Maintenance 5 Providing access to maintenance points 114 60068011601 EN 09 2020 ...

Page 125: ...o replace the gas spring contact the authorised service centre Closing the bonnet WARNING When closing the bonnet there is a risk of crushing When closing the bonnet nothing must come be tween the bonnet and the edge of the chassis Do not grasp any edges Always close the bonnet by grasping one of the handles in each hand Press the red button 4 Pull down the bonnet until the lock audibly engages Sl...

Page 126: ...tor is located underneath the bottom plate Open the bonnet Remove the rubber mat 1 Raise the bottom plate slightly Pull out the bottom plate under the brake pedal and set it down upright Remove the floor plate and place it in a se cure location Installing the bottom plate WARNING Risk of crushing between the bottom plate and the frame edge If limbs or objects are between the bottom plate and frame...

Page 127: ... Carefully guide the bottom plate down and close Insert the rubber mat Close the bonnet Maintenance 5 Providing access to maintenance points 117 60068011601 EN 09 2020 ...

Page 128: ...affect lubrication Avoid overfilling Overfilling may result in white smoke over speed or internal damage CAUTION Please pay attention to environmental protection Dispose of used oil according to related laws and regulations Failure to comply with laws and regula tions will result in serious damage to the environ ment Comply with EPA guidelines or government meas ures for the correct handling of ha...

Page 129: ...l drain plug 2 and allow the oil to flow into the collection container When the oil has been drained completely replace the oil drainage plug Component Tightening torque Drain plug 3 kgf m Dispose of the used oil properly Filling up with engine oil Ensure that the engine is in a horizontal po sition Maintenance 5 Maintenance service 119 60068011601 EN 09 2020 ...

Page 130: ...engine oil Exceeding the upper limit of the oil level gauge may cause engine faults If you have exceeded the upper limit of the oil gauge drain it until the engine oil level is indicated between the upper limit and the lower limit of the oil level gauge Do not use unspecified engine oil additives Replacing the engine oil filter Remove the oil filter 1 Disassemble oil filter 1 with the filter wrenc...

Page 131: ... 200 hours Genuine LCC coolant 3 years or 6 000 hours DANGER Never open the radiator cap while the engine is overheated If the radiator cap is opened while the engine is overheated hot water will spurt out and may cause serious burns Open the radiator cap after ensuring that the engine has been cooled sufficiently Mark and separately manage the containers for storing coolant from beverage containe...

Page 132: ...et the air be dis charged from radiator and press the hose con nected to it to discharge the air inside Start the engine to let the cooling fan rotate 2 or 3 times When the engine is warmed up increase the engine RPM two or three times Stop engine and wait until engine is cooled Remove the radiator drain plug and drain water Repeat the above mentioned processes from 1 to 8 until the drained water ...

Page 133: ...engine at idle after starting When cooling fan is running and coolant is circulated remove radiator cap and replen ish coolant through the inlet Replenish coolant until the cooling fan ro tates 3 5 times Replenish coolant to the upper limit of the supplementary tank and then install radiator cap Operate the engine at idle until the cooling fan rotates 2 3 times Stop the engine and wait until the e...

Page 134: ...net Clean the radiator 1 Clean the radiator fins using a suitable brush and blow them out using compressed air max 2 bar Check the radiator and coolant hoses for leaks and tighten the clips if necessary CAUTION Risk of engine damage If the cooling fluid level is low this indicates a leak in the cooling system Check whether the leakage has been eliminated If not notify the authorised service centre...

Page 135: ...maintenance on the engine and using compressed air or pressur ised water jets in order to prevent dust flying debris compressed air or pressurised water or gas from damaging your eyes Failure to follow this instruction may result in injury Clean the air filter element If the filter insert is damaged heavily soiled or oily replace it with a new insert CAUTION The air filter insert requires more fre...

Page 136: ...ilter 2 in the air filter housing 3 Refit the air filter cover and tighten the air filter head cover onto the air filter housing Change the air filter Open the buckle 5 and remove the filter cover 4 Maintenance 5 Maintenance service 126 60068011601 EN 09 2020 ...

Page 137: ...drain the wa ter from it Otherwise moisture may flow into the fuel unit of the engine resulting in critical faults in the fuel injection pump the fuel injection pipe the common rail and injectors In addition the per formance of the fuel filter may be degraded or damaged Fuel may be drained when water is drained from the fuel filter Fuel is highly inflammable Fire may occur when you smoke or use fi...

Page 138: ... loosen the air discharge valve 2 on top of the fuel filter Pump with the pump handle 3 until fuel is discharged through the air discharge valve 3 Turn clockwise and fasten the air discharg ing valve 3 Changing the fuel filter Arrange the engine filter to prevent any in terference Remove the WIFS water in fuel sensor connector from the fuel filter Maintenance 5 Maintenance service 128 60068011601 ...

Page 139: ...gine A new fuel filter should be installed without fuel in it Do not reuse old fuel in to the New fuel filter Never add fuel in the used fuel filter or fuel tank to a new fuel filter Apply oil to the gasket of the fuel filter Turn the fuel filter clockwise until its gasket reaches the cap of the fuel filter Tighten the fuel filter to 3 4 Maintenance 5 Maintenance service 129 60068011601 EN 09 2020...

Page 140: ...If so the belt must be replaced with a new one The belt shall also be replaced in case it is damaged or worn out due to other external causes It is required to check if the micro V belt has any issues associated with crack oiling overheating or abrasion Tension needs not be measured separately since an auto tensioner is applied that auto matically controls the tension of the belt If necessary tens...

Page 141: ...alue make sure that the needle of the measuring instrument is returned back to the original position Number of Ribs Belt width Tension N 6 20 98 21 74 300 380 Changing the hydraulic transmis sion crude oil filter ENVIRONMENT NOTE Please follow the instructions for disposal of fluids and lubricants NOTE Place a container under the crude oil filter to collect oil flowing out of the transmission Remo...

Page 142: ...t the floorplate Replacing the fine hydraulic trans mission oil filter ENVIRONMENT NOTE Please handle liquids and lubricating oil in ac cordance with instructions NOTE If transmission oil flows out a collection con tainer should be placed underneath the fine oil filter Remove the bottom plate Unscrew the fine oil filter 1 from the hy draulic transmission Install a new fine oil filter until tightly...

Page 143: ...operly dispose of the waste hydraulic oil Unscrew the filler cap 1 Add transmission oil through a filler pipe Use the dipstick to check the transmission oil level which should reach the upper mark on the dipstick Reinstall the floorplate Start the engine and run it in neutral for a while After the engine stops running re check the oil level which should be be tween the upper and lower marks on the...

Page 144: ... plugs of the oil filler port 1 and oil level hole 2 Fill the gearbox with new gear oil until oil flows out of the oil level hole NOTE The high viscosity of gear oil means that it takes time for new oil to fill the gaps in the gearing It is therefore preferable to use a pressurised filling tool otherwise the filling process will take a relatively long time Even when oil flows out of the filler por...

Page 145: ...l positioning it in such a way that any inflation valve is always on the outside Tighten the fastening nuts following the three stage sequence indicated in the rele vant paragraph Tighten the nuts slightly so that the wheel rests well on the hub Tighten the nuts to 50 of the prescribed torque Raise the truck to free the supports Remove the supports Lower the truck to the ground Tighten the wheel n...

Page 146: ...ck resting it on stable and solid supports 2 Be careful not to rest it on the cylinder feed pipes Completely unscrew the nuts 1 and pull off the wheel Fit the new wheel positioning it in such a way that any inflation valve is always on the outside Tighten the fastening nuts following the three stage sequence indicated in the rele vant paragraph Tighten the nuts slightly so that the wheel rests wel...

Page 147: ...the brake out of order serious consequences and so on Fill up the hydraulic oil Unscrew the oil cap 1 assembly Fill up with hydraulic oil through the oil inlet Use the dipstick to check the oil level The oil level should reach the upper marking on the dipstick Close the bonnet Start the engine and run it for a while Check the oil level again Check the seals Checking the hydraulic oil level ENVIRON...

Page 148: ...al level When required fill the hydraulic oil up to the upper marking Re fit the oil dipstick Safely refit the engine cover Changing the suction filter ENVIRONMENT NOTE Please follow the instructions for disposal of fluids and lubricants NOTE The hydraulic oil will flow out Place an oil pan under the filter Open the engine cover Remove the pedal pad and bracket Slacken off the fastening bolts and ...

Page 149: ...e handle liquids and lubricating oil in ac cordance with instructions Open the bonnet Unscrew the breather filter 2 and dipstick and remove Remove the dipstick and balls on the dip stick base from the breather filter and mount onto the new the breather filter Screw the breather filter and dipstick back into position Close the bonnet NOTE Respirators may need to be replaced more frequently in dusty...

Page 150: ...Maintenance 5 Maintenance service 140 60068011601 EN 09 2020 ...

Page 151: ...6 Technical datasheet ...

Page 152: ...Dimensions Technical datasheet 6 Dimensions 142 60068011601 EN 09 2020 ...

Page 153: ...g 5820 730 Axle loading unladen front rear Kg 1530 2520 Wheels chassis frame Tyres SE Super elastic PN Pneumatic SE Front Tyres Size 28x9 15 14PR Rear Tyres Size 6 50 10 10PR Front Track Width b10 mm 1000 Rear Track Width b11 mm 970 Dimension and overall sizes Mast lift forward backward α β 6 12 Mast Minimum Overall Height h1 mm 2080 Free lift h2 mm 140 Lift height h3 mm 3000 Mast Maximum Overall ...

Page 154: ...km h 18 18 Lifting speed with without load m s 0 57 0 59 Lowering speed with without load m s 0 48 0 40 Drawbar Pull Tractive Effort at 2km h with without load KN 19 16 Gradeability at 2km h laden unladen 20 20 Service Brake Mechanical Hydraulic Engine Engine Type DOOSAN D24 Engine Power in compliance with ISO 1585 kW 36 4 Rated Number of Revolutions rpm min 2400 Cylinder Number Displacement cm3 4...

Page 155: ...h b10 mm 1000 Rear Track Width b11 mm 970 Dimension and overall sizes Mast lift forward backward α β 6 12 Mast Minimum Overall Height h1 mm 2080 Free lift h2 mm 145 Lift height h3 mm 3000 Mast Maximum Overall Height h4 mm 4273 Overhead Guard Height h6 mm 2110 Seat Height h7 mm 1165 Drawbar Height h10 mm 300 Overall Length I1 mm 3780 Length to Face of Forks I2 mm 2710 Overall Width b1 mm 1225 Fork ...

Page 156: ... 40 Drawbar Pull Tractive Effort at 2km h with without load KN 19 16 Gradeability at 2km h laden unladen 20 20 Service Brake Mechanical Hydraulic Engine Engine Type DOOSAN D24 Engine Power in compliance with ISO 1585 kW 36 4 Rated Number of Revolutions rpm min 2400 Cylinder Number Displacement cm3 4 2400 On board voltage V 12 Others Drive Control Type Hydraulic torque con verter Volume fuel tank L...

Page 157: ...h b10 mm 1060 Rear Track Width b11 mm 970 Dimension and overall sizes Mast lift forward backward α β 6 12 Mast Minimum Overall Height h1 mm 2230 Free lift h2 mm 150 Lift height h3 mm 3000 Mast Maximum Overall Height h4 mm 4273 Overhead Guard Height h6 mm 2110 Seat Height h7 mm 1165 Drawbar Height h10 mm 300 Overall Length I1 mm 3880 Length to Face of Forks I2 mm 2810 Overall Width b1 mm 1285 Fork ...

Page 158: ... 40 Drawbar Pull Tractive Effort at 2km h with without load KN 19 16 Gradeability at 2km h laden unladen 20 20 Service Brake Mechanical Hydraulic Engine Engine Type DOOSAN D24 Engine Power in compliance with ISO 1585 kW 36 4 Rated Number of Revolutions rpm min 2400 Cylinder Number Displacement cm3 4 2400 On board voltage V 12 Others Drive Control Type Hydraulic torque con verter Volume fuel tank L...

Page 159: ...140 6000 2100 2500 3680 7040 140 140 VFM Full free du plex 3000 2500 2500 2080 4040 1425 1080 6 12 3300 2500 2500 2230 4340 1570 1230 3500 2500 2500 2330 4540 1675 1330 4000 2500 2500 2630 5040 1975 1630 6 8 4500 2500 2500 2880 5540 2225 1880 6 6 VFHM Full free triplex 4000 2500 2500 2005 5040 1280 1005 6 6 4350 2500 2500 2130 5390 1405 1130 4500 2500 2500 2180 5540 1455 1180 4700 2500 2500 2245 5...

Page 160: ... 2400 3000 3680 7273 145 145 VFM Full free du plex 3000 3000 3000 2080 4273 1422 852 6 12 3300 3000 3000 2230 4573 1572 1002 3500 3000 3000 2330 4773 1672 1102 4000 3000 3000 2630 5273 1972 1402 6 8 4500 3000 3000 2880 5773 2222 1652 6 6 VFHM Full free triplex 4000 3000 3000 2005 5273 1281 777 6 6 4350 3000 3000 2130 5623 1406 902 4500 3000 3000 2180 5773 1456 952 4700 3000 3000 2245 5973 1521 101...

Page 161: ...2 6 12 3300 3500 3500 2230 4573 1572 1002 3500 3500 3500 2330 4773 1672 1102 4000 3500 3500 2630 5273 1972 1402 6 8 4500 3500 3500 2880 5773 2222 1652 6 6 VFHM Full free triplex 4000 3500 3500 2005 5273 1281 777 6 6 4350 3500 3500 2130 5623 1406 902 4500 3500 3500 2180 5773 1456 952 4700 3500 3500 2245 5973 1521 1017 4800 3500 3500 2280 6073 1556 1052 5000 3500 3500 2423 6273 1699 1195 5400 3500 3...

Page 162: ...Technical datasheet 6 Mast specifications 152 60068011601 EN 09 2020 ...

Page 163: ...4 Cleaning the truck 92 Closing the bonnet 115 Competent person 10 Consumables Disposal 20 Safety information for handling battery acid 20 Safety information for handling oils 18 Safety information for hydraulic fluid 19 Control components 28 D Daily checks before use 41 Danger area 75 Definition of terms used for responsible persons 10 Diesel fuel Specifications 51 Winter operation 52 Dimensions ...

Page 164: ...cking up a load 78 Pre shift checks 41 Production number 30 Prohibition of use by unauthorised persons 11 R Recommissioning after storage 98 Removing the bottom plate 116 Replacement of Coolant 121 Replacing the breather filter 139 Replacing the engine oil filter 120 Replacing the fine hydraulic transmission oil filter 132 Residual dangers 14 Residual risks 14 S Safety regulations when driving 15 ...

Page 165: ...W Warnings 5 Index 155 60068011601 EN 09 2020 ...

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Page 169: ...Diesel forklift truck RCD25 RCD30 RCD35 Original instructions 4221 4222 4223 60068011601 EN 09 2020 ...

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Page 171: ...7 Diagrams ...

Page 172: ...Electric schematic diagram for Doosan D24 engine with ISO3691 function Diagrams 7 Electric schematic diagram for Doosan D24 engine with ISO3691 function 162 60068011601 EN 09 2020 ...

Page 173: ...Hydraulic diagram Diagrams 7 Hydraulic diagram 163 60068011601 EN 09 2020 ...

Page 174: ...Diagrams 7 Hydraulic diagram 164 60068011601 EN 09 2020 ...

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Page 176: ...STILL GmbH 60068011601 EN 09 2020 ...

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