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Still RCD40 Original Instructions Manual Download Page 8

Driving on loading bridges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 86

Setting down loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 87

Towed load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 89

Forklift towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 90

Leaving the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 90

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 92

Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 92

Cleaning the electrical system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 94

Lubricate the lift mast and chains with chain spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 95

After washing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 96

Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 97

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 97

Measures to be implemented when decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . 

 97

Recommissioning after storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 98

Permanent decommissioning (scrapping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

 99

5 Maintenance

 

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   102
Personnel qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   103
Preliminary maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   103
Scheduled truck maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   105
Maintenance — 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   105
Maintenance — 1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   107
Maintenance - 3000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   110
Supply table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   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
Changing the engine oil filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   120
Changing the fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   121
Replacing the water trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   121
Draining water in the water trap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   123
Fuel system air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   125
Changing the coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   126
Checking the V-belt tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   128

Table of contents

 

 VI

60128011601 EN - 03/2020

Summary of Contents for RCD40

Page 1: ...Diesel forklift truck RCD40 50 Original instructions 4231 4233 60128011601 EN 03 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: ...10 Specialist 10 Competent person 10 Drivers 10 Safety guidelines 11 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 co...

Page 6: ...trailer to carry the forklift truck 38 Environmental conditions for transport and storage 38 Lifting 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 c...

Page 7: ...travel 67 Brake system 68 Driving brake pedal and inching pedal 68 Operating the service brake 68 Parking 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 plate 74 Before lifting a load 75 Transporting pallets 75 Danger area 75 Transportin...

Page 8: ...rsonnel qualifications 103 Preliminary maintenance operations 103 Scheduled truck maintenance 105 Maintenance 500 hours 105 Maintenance 1000 hours 107 Maintenance 3000 hours 110 Supply table 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 Changing the engine...

Page 9: ...ure 134 Checking the drive axle gearbox oil 136 Fill up the hydraulic oil 136 Checking the hydraulic oil level 136 Changing the suction filter and return filter 137 Replacing the breather filter 138 6 Technical datasheet Dimensions 140 Data sheet RCD40 141 Data sheet RCD50 143 Mast specification 145 Annex 7 Diagrams Electric schematic diagram 156 Hydraulic diagram 157 Table of contents VII 6012801...

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 60128011601 EN 03 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: ...ll 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 purpose by the manufacturer and if they are fitted with the ap propriate trailer coupling The maximum to...

Page 15: ... and in struction handbook and affixes a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or altera tion and the name and address of the or ganization that accomplished those tasks Symbols used The terms DANGER WARNING CAUTION NOTE and ENVIRONMENT NOTE are used in these operating instructi...

Page 16: ... CE labelling to indi cate that the truck complies with the standards and regulations valid at the time of marketing This is confirmed by the issued 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 car...

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: ...uence of the aforementioned substances are not permitted to perform work of any kind on or with the truck Prohibition of use by unauthorised per sons The driver is responsible for the truck during working hours He must not allow unauthor ised persons to operate the truck When leaving the truck the driver must secure it against unauthorised use e g by pulling out the key Safety guidelines It is ess...

Page 22: ...ccumulator it must be depressurised Contact your service partner WARNING Depending on the duration of use and operating time components carrying ex haust gases and exhaust air may be come hot Protective equipment must therefore be worn WARNING The areas in which the truck is operated must be ad equately lit If it is insufficiently lit working spotlights must be in stalled to ensure that the driver...

Page 23: ...ition for using 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 auth...

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 60128011601 EN 03 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 60128011601 EN 03 2020 ...

Page 32: ...ermine 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 NOTE Please note the definition of operating ...

Page 33: ...the op erating company 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 60128011601 EN 03 2020 ...

Page 34: ...Safety 2 Emissions 24 60128011601 EN 03 2020 ...

Page 35: ...3 Overview ...

Page 36: ...General view 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 Overview 3 General view 26 60128011601 EN 03 2020 ...

Page 37: ... wheels Rear weight 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 Overview 3 General view 27 60128011601 EN 03 2020 ...

Page 38: ...operation lever Forward tilting and back tilting operating handle 1 2 3 4 5 6 7 8 Lifting and lowering operating handle Lighting and direction indicator switch Driver s seat Steering wheel Horn button Direction selection lever Cup holder Fixtures operating lever DPF reprocessing switch 9 10 11 12 13 14 15 16 17 Overview 3 Instrumentation and controls 28 60128011601 EN 03 2020 ...

Page 39: ...ght Engine 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 Overview 3 Instrumentatio...

Page 40: ...he production 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 Overview 3 Truck identification 30 60128011601 EN 03 2020 ...

Page 41: ...t trucks 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 Overview 3 Truck identification 31 60128011601 EN 03 2020...

Page 42: ...ht 7 only applies to elec tric forklift trucks Engine plate The engine plate 1 is fixed to the cylinder head cover or the crankcase The type 2 engine no 3 and performance data are attached to the engine plate Overview 3 Truck identification 32 60128011601 EN 03 2020 ...

Page 43: ...Location of the decals Overview 3 Location of the decals 33 60128011601 EN 03 2020 ...

Page 44: ...ake when leaving the truck 1 2 3 4 5 6 7 8 9 10 Passengers are not allowed Do not jump off if the truck is tipping over Brace feet Hold on tight Lean in the opposite direction to which the truck is tipping Decal information Hydraulic oil tank Warning sign Danger due to overheating of radiator Warning sign Danger due to shearing Sound pressure level Warning sign Danger due to shearing Danger to the...

Page 45: ...Decal information Caution Read the oper ating instruction Decal information Capacity rating plate 20 21 Nameplate Manufacturer s name 22 23 Overview 3 Location of the decals 35 60128011601 EN 03 2020 ...

Page 46: ...Overview 3 Location of the decals 36 60128011601 EN 03 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: ...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 Commi...

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 60128011601 EN 03 2020 ...

Page 56: ...ustry 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 is unscrewed Check coolant level when the engine is cold and switched off Use and operation 4 Remain...

Page 57: ...iator water tank cover by loosening two screws 1 Carefully unscrew the radiator cap 2 Check whether the radiator is filled to the top with coolant NOTE To perform 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 Use and operation 4 Remaining ready for operation 47 60128011601 EN 03 2020 ...

Page 58: ...ng the engine oil level Stop the truck and ensure it is parked on a level surface Open the bonnet Take out the dipstick 1 and wipe with a clean cloth Fully reinsert the dipstick Remove the dipstick The oil level should be between the upper 2 and lower 3 mark ings on the dipstick NOTE If necessary open the oil filler cap 4 and add oil Fully reinsert the dipstick Use and operation 4 Remaining ready ...

Page 59: ...late Run the truck in neutral for 3 5 minutes Take out the dipstick 1 and wipe with a clean cloth Fully reinsert the dipstick Take out the dipstick The oil level should be between the upper and lower marks on the dipstick scale If necessary add trans mission oil via the oil inlet Fully reinsert the dipstick DANGER Take care not to touch moving parts during this op eration Use and operation 4 Remai...

Page 60: ...se 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 engine cover Screw the oil cap with ...

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 60128011601 EN 03 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 60128011601 EN 03 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 60128011601 EN 03 ...

Page 72: ...ction selection lever in centre position between FORWARDS and REVERSE REVERSE direction selection lever pulled backwards into position B Adjusting the position of steering wheel 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 ...

Page 73: ...es Insert the switch key 1 and turn it to posi tion Ⅰ hold the switch key in this position until the lamp 2 goes out Turn 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...

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 300mm 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 Start the engine Release the parking brake 1 and the cor responding LED 2 will turn off Use and opera...

Page 76: ... pedal 4 to set off Forward Put the direction lever into the forward di rection Smoothly press the accelerator pedal The speed of the forklift truck accelerates in relation to the increase in pedal travel Reversing Place the direction lever in the reverse di rection Use and operation 4 Driving 66 60128011601 EN 03 2020 ...

Page 77: ...a complete stop Move the lever 3 in the opposite direction of travel A FORWARDS B BACK WARDS then press the accelerator pedal 2 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 for...

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: ...king brake a warning signal sounds This signal even sounds if the truck has al ready been switched off and the ignition and stop key has been removed Actuating the parking brake Pull down the parking brake lever 1 until the lock position is reached and the parking brake indicator light comes on Releasing the parking brake Release the parking brake lever 1 The parking brake will return to its origi...

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 60128011601 EN 03 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: ...long Before using attachments Capacity plate DANGER The parameters in the load diagram and on the la bels apply to compact uniform loads These load limits must not be exceeded Exceeding the load limits will affect the stability of the forklift truck and the strength of the lift mast Refer to the CAPACITY CHART before lifting goods If attachments are fitted refer to the load rating label for the at...

Page 85: ...re of gravity before operating attachments loads at wind force 6 and higher Transporting pallets As a rule loads e g pallets must be trans ported individually Transporting multiple loads at the same time is only permitted when instructed by the supervisor and when the technical requirements have been met The driver must ensure proper condition of the load Only safely and carefully positioned loads...

Page 86: ...uck immediately Secure the truck against use by unauthorised par ties DANGER Danger of death from falling loads Never walk or stand underneath suspended loads Transporting suspended loads Before transporting suspended loads consult the national regulatory authorities in Germa ny the employer s liability insurance associa tions National regulations may place restrictions on these operations Contact...

Page 87: ... harness cannot shift or release unintentionally and cannot be damaged When transporting suspended loads suita ble devices e g guy wires or supporting poles must be available so that accompa nying persons can guide suspended loads and prevent the loads from swinging Take particular care to ensure that there is no one in the drive direction in the driving lane If despite this the load begins to swi...

Page 88: ...ne of the grooves on the fork carriage using the knob 2 CAUTION For greater load stability the distance between the two fork arms must be as large as possible while re maining consistent with the lifting points of the load so that the load centre of gravity is between the fork arms CAUTION For greater load stability the position of the fork arms must be as symmetrical as possible with re spect to ...

Page 89: ...neath suspended loads or raised fork arms Never exceed the maximum load values specified on the capacity rating plate Otherwise stability cannot be guaranteed Only store pallets that do not exceed the specified maximum size Damaged loading equipment and incorrectly formed loads must not be stored Attach or secure the load to the lifting ac cessory so that the load cannot move or fall Store the loa...

Page 90: ...aised 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 load does not slip CAUTION Component damage possible When inserting the fork into the racking ensure that the racking and load are not damaged Insert the fork as far under the load as pos sible using the brake Inching peda...

Page 91: ...e 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 of tipping Lower the load before tilting the lift mast Lower the load while maintaining ground clearance 6210_800 008 5060_003 102 Use and operat...

Page 92: ...are now uncoupled from the engine Pull the lift operating lever as far back as possible The truck begins to lift Depress the accelerator pedal 2 to in crease the engine speed This action in creases the lifting speed In this way the lifting speed can be controlled using the ac celerator pedal 5060_003 101 Use and operation 4 Handling loads 82 60128011601 EN 03 2020 ...

Page 93: ...st tilted for ward is not permitted Only drive with the load lowered Lower the load until ground clearance is reached not over 300 mm Only drive with the lift mast tilted backwards Drive slowly and carefully round corners NOTE Observe the information in the chapter entitled Steering Always accelerate and brake gently NOTE Observe the information in the chapter entitled Operating the service brake ...

Page 94: ...ted to drive on ascending and descending gradients that are marked as traffic routes and that can be used safe ly Ensure that the ground to be traversed is clean and provides a good grip Do not turn on ascending and descending gradients Do not drive onto or along ascending and descending gradients at an angle Do not park the truck on ascending or de scending gradients In case of emergency secure t...

Page 95: ... is not permit ted Always place loads into stock and remove loads from stock on a horizontal plane Driving on lifts The driver may only use this truck on lifts with a sufficient rated capacity and for which the operating company has been granted authori sation DANGER There is a risk to life if you are crushed or run over by the truck There must be no personnel already in the lift when the truck is...

Page 96: ...curely in the lift to prevent uncontrolled movements of the load or the truck Driving on loading bridges DANGER Risk of accident if the truck crashes Steering movements can cause the tail end to veer off the loading bridge towards the edge This may cause the truck to crash The lorry driver and the truck driver must agree on the lorry s departure time Before driving across a loading bridge ensure t...

Page 97: ...ed far enough forwards with a raised load to cause the truck to tip over The load centre of gravity and the moment of tilt both 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 forwards take particu lar care to ensure that the truck does not tip for wards and that ...

Page 98: ... with regulations Set the lift mast to vertical Lift the load to the stacking height Drive the truck carefully into the stack Use the brake Inching pedal at the same time Lower the load until it rests securely on the racking Look 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...

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: ...lift 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 exiting the truck lower the ...

Page 101: ... when the truck is moving DANGER NEVER leave the forklift truck 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 Use and operation 4 Leaving the truck 91 60128011601 EN 03 2020 ...

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 60128011601 EN 03 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 60128011601 EN 03 2020 ...

Page 110: ...Use and operation 4 Decommissioning 100 60128011601 EN 03 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 60128011601 EN 03 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 60128011601 EN 03 2020 ...

Page 117: ...k 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 Check the axle oil level and change the axle oil Internal combustion engine Change the engine oil and the engine oil filter Chec...

Page 118: ...ery 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 damage and wear Check the play between the fork...

Page 119: ...ing 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 60128011601 EN 03 2020 ...

Page 120: ...s 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 Check the axle oil level and change the axle oil Internal combustion engine Change the engine oil and the engine oil filte...

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 60128011601 EN 03 2020 ...

Page 123: ...e use 95L for mast exceed ing 4500mm mast Braking system 0 5L Brake fluid DOT 3 Bearings lubricating grease fittings 0 1KG Lubricating grease NLGL 2 lithium grease Drive axle 8L Gear oil 15 49 GL 5 85W 90 25 49 GL 5 80W 90 For cold storage use Cooling system Radiator water tank 10 1L Coolant water See section Engine cool ant Specifications Reservoir box 6 3L Coolant water Fuel 60L Diesel See secti...

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 60128011601 EN 03 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 60128011601 EN 03 2020 ...

Page 128: ...tion Avoid overfilling Overfilling may result in white smoke overspeed or internal damage CAUTION Be environmentally responsible Dispose of used oil in accordance with applicable laws and regulations Failure to comply with laws and regulations will result in serious damage to the environment Comply with EPA guidelines or government meas ures for the correct handling of hazardous materials such as ...

Page 129: ...Tightening torque 14 17 ft lbs 19 6 23 5 N m 2 0 2 4 kgf m Dispose of the used oil properly Filling up with engine oil Ensure that the engine is in a level position Remove the oil filler cap 1 Add the specified amount of oil into the oil inlet on the side of the upper part of the en gine Wait three minutes and check the oil level Add more oil as necessary Replace the oil filler cap 1 and tighten b...

Page 130: ...ce of the engine oil filter Lightly coat the new filter sealing ring with a thin layer of engine oil Hand fit the new filter to the filter cover and turn clockwise until the mounting surface comes into contact with the surface of the filter cover then tighten 3 4 of a turn using a filter wrench NOTE Check the spare parts manual to find the part number of usable engine oil filters Fill the engine w...

Page 131: ... new original spare filter lightly Screw on new filter by hand until the gasket is touching and tighten Tightening torque 10 Nm 12 Nm Vent the fuel system Replacing the water trap Turn off the engine and allow it to cool down Close all oil valves Disconnect the water trap sensor connector 4 Place a container under the water trap Maintenance 5 Maintenance service 121 60128011601 EN 03 2020 ...

Page 132: ...to the new water trap 2 by turning it to the right and tighten by hand Tightening torque 1 6Nm 0 3Nm Wipe clean the surface 1 of the fuel filter and apply a thin layer of diesel oil to the sealing ring of the new filter Fit the new water trap 2 onto the filter cov er Turn to the right until the surface of the filter makes direct contact with the surface of the cover and tighten 1 further turn Tigh...

Page 133: ...praying onto the skin from fuel system leakages such as a ruptured fuel injection line Fuel sprayed onto the skin can cause serious injury In the event of spray injuries seek medical attention imme diately Do not check for fuel leaks with your hands instead use a wooden board or cardboard Please contact an authorised engine dealer for maintenance and re pairs Failure to comply with regulations may...

Page 134: ...hibited If the water separator warning light in the dis play illuminates before the scheduled mainte nance time this is to alert the operator that the quantity of pollutants and water has been ex ceeded The fuel filter water trap contains a sensor that detects the quantity of water and contami nants The sensor will transmit a signal to the alarm lamp in order to alert the operator Carry out the fo...

Page 135: ...se of used oil in accordance with applicable laws and regulations Failure to comply with laws and regulations will result in serious damage to the environment Comply with EPA guidelines or government meas ures for the correct handling of hazardous materials such as oil diesel and engine coolant Consult the local authorities or recycling facility Irresponsible handling of hazardous materials such a...

Page 136: ...ine is at working temperature Steam and hot engine coolant will spurt out and cause serious burns Allow the en gine to cool down before you attempt to remove the radiator cap Securely tighten the radiator cap after you check the radiator Steam can spurt out during engine operation if the cap is loose Failure to comply with the above operating guidance may result in death or serious injury CAUTION ...

Page 137: ...recycling facility Irresponsible handling of hazardous materi als such as dumping hazardous waste into water channels on the ground into ground water or drainage ditches is prohibited NOTE Engine coolant contaminated with rust or scale reduces the cooling effect Even when extended life engine coolant is properly mixed the engine coolant becomes contaminated as its ingredients deteriorate Drain flu...

Page 138: ...un until it reaches op erating temperature Shut down engine Check coolant level in the cooled engine and top up if necessary Checking the V belt tensioning Belt Tension Tension needs not be adjusted separately since an auto tensioner is applied that auto matically controls the tension of the belt A daily check is required to see if the point er of the auto tensioner indicates that it needs to be r...

Page 139: ...ition of the indicator arm 1 Read the measured value at the point of in tersection arrow scale 5 and indicator arm 1 Retighten and repeat the measurement if necessary Replacing the V belt Press tensioning roller with socket wrench in the direction of the arrow until a retaining pin can be fixed in the assembly bore The V ribbed belt is now tension free First pull the V ribbed belt off the smallest...

Page 140: ...ing the insert CAUTION Flying object hazard Wear eye protection when carrying out 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...

Page 141: ...use compressed air to clean the filter casing Ensure that the filter is not damaged during installation and that it is installed in the cor rect direction Install the outer air filter 4 and inner air fil ter insert 5 back into the air filter housing 3 Reinstall the air filter head cover Disconnect the inlet hose form the air inlet When the engine is running cover the in take opening e g using card...

Page 142: ... and washers on the crude oil filter Slowly pull out the crude oil filter so that the oil flows into the container Unscrew the crude oil filter from the oil filter seat Unscrew the fastening nut on the crude oil filter then remove the filter insert Replace it with a new crude oil filter insert Fit the filter insert followed by the bottom cover onto the filter spindle then tighten the nut Refit the...

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 floor plate 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 th...

Page 144: ...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 145: ...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 146: ...ding gear oil Fill up the hydraulic oil Unscrew the oil cap 1 assembly Fill up with hydraulic oil through the oil inlet 90L for mast below 4500mm mast 95L for mast exceeding 4500mm mast 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 h...

Page 147: ...When required fill the hydraulic oil up to the upper marking Re fit the oil dipstick Safely close the engine cover Changing the suction filter and re turn 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 ...

Page 148: ... NOTE Please handle liquids and lubricating oil in ac cordance with instructions Open the bonnet Unscrew the breather filter 1 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 frequent...

Page 149: ...6 Technical datasheet ...

Page 150: ...Dimensions Technical datasheet 6 Dimensions 140 60128011601 EN 03 2020 ...

Page 151: ...ading unladen front rear Kg 2731 3676 Wheels chassis frame Tyres SE Super elastic PN Pneumatic SE Front Tyres Size 300 15 20PR Rear Tyres Size 7 00 12 12PR Front Track Width b10 mm 1180 Rear Track Width b11 mm 1190 Dimension and overall sizes Mast lift forward backward α β 6 12 Mast Minimum Overall Height h1 mm 2390 Free lift h2 mm 150 Lift height h3 mm 3000 Mast Maximum Overall Height h4 mm 4275 ...

Page 152: ...oad km h 24 25 Lifting speed with without load m s 0 44 0 53 Lowering speed with without load m s 0 42 0 29 Drawbar Pull Tractive Effort at 2km h with without load KN 25 23 Gradeability at 2km h laden unladen 20 Service Brake Mechanical Hydraulic Engine Engine Type Deutz TCD2 9 L4 Engine Power in compliance with ISO 1585 kW 55 4 Rated Number of Revolutions rpm 2300 Cylinder Number Displacement cm3...

Page 153: ...mension and overall sizes Mast lift forward backward α β 6 12 Mast Minimum Overall Height h1 mm 2390 Free lift h2 mm 150 Lift height h3 mm 3000 Mast Maximum Overall Height h4 mm 4275 Overhead Guard Height h6 mm 2260 Seat Height h7 mm 1315 Drawbar Height h10 mm 380 Overall Length I1 mm 4230 Lenght to Face of Forks I2 mm 3160 Overall Width b1 mm 1485 Fork Arm Dimensions s e l mm 50 150 1070 Fork Car...

Page 154: ...h with without load KN 25 23 Gradeability at 2km h laden unladen 20 Service Brake Mechanical Hydraulic Engine Engine Type Deutz TCD2 9 L4 Engine Power in compliance with ISO 1585 kW 55 4 Rated Number of Revolutions rpm 2300 Cylinder Number Displacement cm3 4 2900 On board voltage 12 Others Drive Control Type Hydraulic torque con vertor Volume fuel tank L Kg 90 75 Towing coupling type DIN PIN Techn...

Page 155: ...50 5000 4000 4000 3440 6275 150 150 VFM Full free duplex 3000 4000 4000 2390 4275 1544 1165 6 12 3300 4000 4000 2540 4575 1694 1315 3500 4000 4000 2640 4775 1794 1415 4000 4000 4000 2890 5275 2044 1665 6 6 VFHM Full free triplex 3620 4000 4000 2145 4895 1299 920 6 6 3920 4000 4000 2245 5195 1399 1020 4350 4000 4000 2390 5625 1544 1165 4500 4000 4000 2441 5775 1595 1216 4700 4000 4000 2507 5975 166...

Page 156: ...ll free duplex 3000 5000 5000 2390 4275 1544 1165 6 12 3300 5000 5000 2540 4575 1694 1315 3500 5000 5000 2640 4775 1794 1415 4000 5000 5000 2890 5275 2044 1665 6 6 VFHM Full free triplex 3620 5000 5000 2145 4895 1299 920 6 6 3920 5000 5000 2245 5195 1399 1020 4350 5000 5000 2390 5625 1544 1165 4500 5000 5000 2441 5775 1595 1216 4700 5000 5000 2507 5975 1661 1282 4800 5000 5000 2540 6075 1694 1315 ...

Page 157: ... the air filter 130 Cleaning the electrical system 94 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 D Daily checks before use 41 Danger area 75 Data sheet RCD40 141 Data sheet RCD50 143 Definition of terms used for responsible ...

Page 158: ...evice 70 Operating the service brake 68 Overview of the driver s compartment 28 P Packaging 22 Parking brake 69 Personnel qualifications 103 Picking up a load 79 Pre shift checks 41 Production number 30 Prohibition of use by unauthorised persons 11 R Rear wheel replacement procedure 134 Recommissioning after storage 98 Removing the bottom plate 116 Replacing the breather filter 138 Replacing the V...

Page 159: ...ansmission oil level inspection proce dure 49 Transporting pallets 75 Transporting suspended loads 76 U Use a truck or flatbed trailer to carry the forklift truck 38 W Warnings 5 Wheel replacement procedure 134 Index 149 60128011601 EN 03 2020 ...

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Page 163: ...Diesel forklift truck RCD40 50 Original instructions 4231 4233 60128011601 EN 03 2020 ...

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Page 165: ...7 Diagrams ...

Page 166: ...Electric schematic diagram Diagrams 7 Electric schematic diagram 156 60128011601 EN 03 2020 ...

Page 167: ...Hydraulic diagram Diagrams 7 Hydraulic diagram 157 60128011601 EN 03 2020 ...

Page 168: ...Diagrams 7 Hydraulic diagram 158 60128011601 EN 03 2020 ...

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Page 170: ...STILL GmbH 60128011601 EN 03 2020 ...

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