Still RCG40 Original Instructions Manual Download Page 7

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Check the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission oil level inspection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the drive axle gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Change the LP Gas tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fill the LPG tank*. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel-Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using the truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the tap of the gas bottle or gas tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Opening the gas cylinder or LPG tank* shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . .

Climbing on/off the forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment of the driver’s seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fastening the seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the position of steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lighting and turn indicator switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning horn; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction selection lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing direction of travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving brake pedal and inching pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Closing the gas cylinder or LPG tank* shutoff valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting system and attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating the lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handling loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations when handing loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load centre distance and load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Capacity plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting pallets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Danger area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting suspended loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents

60118011601 EN - 09/2020

Summary of Contents for RCG40

Page 1: ...LPG forklift truck RCG40 RCG50 Original instructions 4234 4236 60118011601 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: ...fety regulations 12 Safety guidelines 12 Exhaust gases 13 Ground condition for using the truck 14 Safety Regulations Relative to Forklift Use 14 Residual dangers residual risks 15 Safety regulations when driving 16 Safety regulations in case of accidental lateral tipping 17 Commissioning of LPG fuelled trucks 17 General safety rules for liquid gas 18 Exercise caution when handling gas springs and ...

Page 6: ...r 36 Nameplate 37 Engine plate 38 Location of the decals 40 4 Use and Operation Truck transport and lifting 44 Use a truck or flatbed trailer to carry the forklift truck 44 Environmental conditions for transport and storage 44 Loading and unloading the truck 45 Commissioning the truck 47 Remaining ready for operation 48 Pre shift checks 48 Checking the cap on the high pressure relief valve on the ...

Page 7: ... wheel 70 Ignition device 71 Lighting and turn indicator switch 72 Warning horn 73 Direction selection lever 74 Start the engine 74 Driving 75 Forward 77 Reversing 77 Speed switch 78 Changing direction of travel 78 Driving brake pedal and inching pedal 79 Operating the service brake 80 Parking brake 81 Closing the gas cylinder or LPG tank shutoff valve 82 Lifting system and attachments 83 Operatin...

Page 8: ...s to be implemented when decommissioning 110 Recommissioning after storage 111 Permanent decommissioning scrapping 112 5 Maintenance General information 114 Personnel qualifications 115 Preliminary maintenance operations 115 Scheduled truck maintenance 117 Maintenance 500 hours 117 Maintenance 1000 hours annually 119 Maintenance 3000 hours 122 Supply table 125 Providing access to maintenance point...

Page 9: ...axle gearbox oil 143 Wheel replacement procedure 143 Change brake system liquid 145 Fill up the hydraulic oil 145 Checking the hydraulic oil level 146 Changing the suction filter and return filter 146 Replacing the breather filter 147 6 Technical datasheet Dimensions 150 VDI Datasheet for RCG40 151 VDI Datasheet for RCG50 153 Mast specification 155 Annex 7 Diagrams Electric schematic diagram for D...

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 60118011601 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: ...eer s expert in industrial trucks and their safety maintains a permanent record of the de sign test s and implementation of the mod ification or alteration approves and makes appropriate changes to the capacity plate s decals tags 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...

Page 16: ...fety additional symbols are also used Please take these different symbols into consideration CE labelling The manufacturer uses 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 t...

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: ...ed by unauthor ised persons Only trained persons and those authorised for opera tion may have access to the industrial truck DANGER Safety systems e g the seat switch are there for safety Safety systems must never be disabled regardless of the kind DANGER Any additional bores or welding to the overhead guard will compromise its rigidity It is therefore strictly prohibited to drill holes in the ove...

Page 23: ...equipment e g pace makers or hearing aids these may be impaired Check with a doctor or the medical equipment manu facturer whether the equipment is sufficiently protec ted against electromagnetic interference NOTE If your truck is equipped with a fire extinguish er make sure that you familiarise yourself with it in case of an emergency Handling informa tion is provided on the fire extinguisher Exh...

Page 24: ...rator trained and authorized to use the forklift must be familiar with the controls and performances of the forklift Any defect squeaking leaks etc must be promptly reported because if neglected it could cause more serious failures defects Carry out the inspections indicated in the chapter on Daily Inspections ENVIRONMENT NOTE Report any oil and or battery fluid leaks they are dangerous and highly...

Page 25: ... 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 26: ...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 27: ...ated previously manual shut off cock Suitable for safe use on vehicles designed as indicated above Compliant with the requirements regarding containers under pressure currently in force in the country in which the truck is used Subjected to any tests provided for by the requirements referred to above Accompanied by an appropriate card certi fying its origin When making the connection check the com...

Page 28: ...than air and diffuse on the ground Vapours spread over large areas and can cause fires and reignition LPG trucks and LPG cylinders must only be operated and parked or stored in well ventilated areas DANGER Risk of explosion Do not smoke during maintenance work on LPG systems and make sure that there are no open flames stoves lanterns or similar items located in the vicinity Use only anti static tr...

Page 29: ... the liquid gas system with an open flame Ensure that the engine is adjusted so as to produce only a minimum quantity of noxious gases in the exhaust Frozen parts of the system must be thawed out only with hot water hot sandbags or the like Open flames incandescent objects etc may cause explosions When any single part of the system is being replaced the manufacturer s installation in structions mu...

Page 30: ...ay from ignition sources and heat sources Protect containers against sunlight Lock containers when stored and keep out of the reach of children Exercise caution when handling gas springs and accumulators WARNING Gas springs are under high pressure Improper re moval results in an elevated risk of injury For ease of operation various functions on the truck can be supported by gas springs Gas springs...

Page 31: ...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 21 60118011601 EN 09 2020 ...

Page 32: ...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 33: ... 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 34: ...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 35: ...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 25 60118011601 EN 09 2020 ...

Page 36: ...ty WARNING When LP gas leaks out there is an immediate dan ger of explosion resulting in the risk of burns This is particularly the case when leaks occur on the LPG system the engine does not start or starts poorly For this reason it is absolutely forbidden to remove the evaporator cap 1 and have the cap 1 installed by qualified dealer staff if missing forbidden to manipulate the LPG system in any...

Page 37: ...s ad ditional units etc may produce different val ues Noise emissions The values were determined based on meas uring procedures from the standard EN 12053 Safety of industrial trucks Test methods for measuring noise emissions based on EN12001 and EN ISO 3744 and the require ments of EN ISO 4871 This machine emits the following sound pres sure level Continuous sound pressure level in the driv er s ...

Page 38: ... value of accel eration on the seat The following value is valid for all truck mod els Driver s seat Measurement uncertainty RCG50 1 66 m s2 0 3 m s2 Tests have indicated that the amplitude of the hand and arm vibrations on the steering wheel or the operating devices in trucks is less than 2 5 m s2 There are therefore no measure ment guidelines for these measurements The personal vibration load on...

Page 39: ...ear After repair work that may affect operational safety After changes that may affect operational safety After breaks in operation of more than one year The following will be checked proper condi tion the possibility of leakages function in stallation and the functionality of the safety de vices The results from the inspection must be recor ded in an inspection document in accordance with BGG 936...

Page 40: ...The operating company is responsible for en suring any defects are remedied without de lay In the event of defects notify the author ised service centre Safety 2 Safety tests 30 60118011601 EN 09 2020 ...

Page 41: ...3 Information about the truck ...

Page 42: ...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 32 60118011601 EN 09 2020 ...

Page 43: ...iew Rear wheels Rear weight Rear lights Trailer coupling Overhead guard 1 2 3 4 5 Mast Steering wheel Control panel Engine bonnet 6 7 8 9 Information about the truck 3 General forklift view 33 60118011601 EN 09 2020 ...

Page 44: ...ter 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 9 10 11 12 13 14 15 16 Information about the truck 3 Instrumentation and controls 34 60118011601 EN 09 2020 ...

Page 45: ...ight 1 2 3 4 5 6 7 8 Water separator light indicator light not applied for LPG truck DPF regeneration disabled indicator light Red light not applied for LPG truck Battery charging indicator light Engine error light indicator light Red light DPF regeneration indicator light Exhaust temperature warning light Yellow light not applied for LPG truck DPF regeneration request indicator light Yellow light...

Page 46: ...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 36 60118011601 EN 09 2020 ...

Page 47: ...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 37 60118011601 ...

Page 48: ...allast weight 7 only applies to elec tric forklift trucks Engine plate Engine Model Name and Number Label The engine model name and engine code number are written in this label 1 Information about the truck 3 Truck identification 38 60118011601 EN 09 2020 ...

Page 49: ...raved 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 39 60118011601 EN 09 2020 ...

Page 50: ...Location of the decals Information about the truck 3 Location of the decals 40 60118011601 EN 09 2020 ...

Page 51: ...l information Adding coolant Warning sign Hood roll hand warning 1 2 3 4 5 6 7 8 9 10 11 12 13 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 electri...

Page 52: ...Information about the truck 3 Location of the decals 42 60118011601 EN 09 2020 ...

Page 53: ...4 Use and Operation ...

Page 54: ...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 55: ...der the raised truck Use NON MET ALLIC slings Make sure that the lifting capacity of the slings is suitable for the weight of the truck To raise the truck it is necessary to remove the LPG bottle and associated support DANGER DO NOT SMOKE in the vicinity of the truck when re moving the bottle and putting it back To remove LPG bottle proceed as fol lows Open the bottle cover 1 by releasing the leve...

Page 56: ...iven lifting points These lifting points are not specifically marked on the truck Lower the lift mast completely and tilt it fully backwards Remove the two rubber grommets 7 from the openings in the counterweight Remove the counterweight grid 6 Attach a sling 2 able to at least bear the weight of the forklift truck enter from the original area of counterweight grid 7 come out from the two openings...

Page 57: ...ing 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 Commissioning the truck CAUTION Do not use the forklift truck before it has been com missioned by a service engineer authorized by the manufacturer CAUTION The forklift truck may be commissioned only by a service...

Page 58: ...orrect operation of the valve DANGER If the cap is missing or damaged gas may escape uncontrollably In such cases do not put the truck into operation Close the bottle immediately and contact the author ised service centre Daily checks before use The following checks must be performed on a daily basis in order to keep your truck in good condition and to operate safely These checks supplement and do...

Page 59: ...exhaust system for leaks Check the LPG system for damage check that the screw joints are securely seated and check for leaks using leak detection spray Or if the fault appears L01 L03 please aslo check these condition Check the shut off valve if L01 fault appears Check brake oil level Check the fuel level and clips Check transmission oil level Check axle oil level Engine oil level checking procedu...

Page 60: ...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 61: ...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 62: ...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 63: ... 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 53 60118011601 EN 09 2020 ...

Page 64: ...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 65: ...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 66: ...vel 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 Check condition of engine oil If it is pollu ...

Page 67: ...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 68: ...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 69: ...ed on the LPG tank is the expiry date LPG tank with an expired inspection date must not be taken into operation NOTE Observe the safety regulations for LP gas ve hicles Gas tank may only be changed by trained staff WARNING Do not smoke when changing gas tank and extin guish all naked lights and fires Change LP gas tank only in well ventilated spaces and not in the vicinity of pits Shut off the eng...

Page 70: ...p engine by turn the switch key Loosen the union nut 2 carefully a little bit and only for a short time pressure reduc tion NOTE The union nut has a left hand thread Unscrew the union nut fully and remove the hose Pull out the ring pull 4 and loosen the bracket Use and Operation 4 Change the LP Gas tank 60 60118011601 EN 09 2020 ...

Page 71: ...o that the connecting fitting of the shutoff valve on the gas bottle faces towards the bottom Replacement bottles according to GB 17259 2009 CAPACITY Replacement bottle 15 kg Reconnect the hose as specified Check for leaks with leakage spray accord ing to the inspection and maintenance in structions Use and Operation 4 Change the LP Gas tank 61 60118011601 EN 09 2020 ...

Page 72: ...he use of LP gas and the safety instructions of the LPG station The LPG tank may only be filled by qualified persons WARNING No smoking and no naked lights and fires when filling LPG tanks CAUTION While removing the filling pistol a small quantity of gas streams out As this can cause frostbite always put on protective gloves NOTE We recommend to top up gas before begin ning work as long as the tru...

Page 73: ...illing pistol control immediately and terminate the filling procedure Turn off the pump motor and the main shut off valve at the LPG station CAUTION The LP gas tank may only be filled until the metering valve shuts off and not according to the reading on the fuel level gauge 2 Carefully remove the pistol from the filler valve 4 Screw the cap on the filler valve CAUTION If problems or special incid...

Page 74: ... is loose ALWAYS check the level of engine coolant by ob serving the reserve tank Failure to comply will result in death or serious in jury WARNING Burn hazard Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply will result in death or serious in jury CAUTION Coolant hazard Wear eye protection and rubber gloves when you handl...

Page 75: ...lant and water per the mixing in structions on the coolant container 3 Water quality is important to coolant per formance We recommends that soft dis tilled or demineralized water be used to mix with coolants 4 NEVER mix extended or long life cool ants and conventional green coolants 5 NEVER mix different types and or col ors of extended life coolants 6 Replace the coolant according to Sched uled ...

Page 76: ...ER The opening and closing of the tap must be carried out without the aid of any tools in order to avoid the risk of explosions due to sparks Opening the gas cylinder or LPG tank shutoff valve WARNING If the truck has been parked in an enclosed space for a long time ventilatewell before switching on the electrical system Slowly open the shutoff valve 1 of the liq uefied gas cylinder or the LPG tan...

Page 77: ... CAUTION Do not climb on or off the truck from the right hand side unless it is an emergency Adjustment of the driver s seat CAUTION Slide the driver s seat to find the best operating posi tion relative to the steering wheel the accelerator and braking pedals and the joystick Before starting the truck and whenever changing drivers adjust the seat to match the driver s weight and make sure that the...

Page 78: ...al driver In order to ach ieve the best seat suspension setting the driv er should perform the adjustment whilst sitting on the seat Adjust the suspension to your individual comfort using the adjusting knob 3 Fastening the seat belt DANGER Even when using an approved restraint system there is some residual risk that the driver might be injured if the truck tips over This risk of injury can be redu...

Page 79: ...n fastening it Only use the seat belt to secure one person Have any malfunctions repaired by the STILL service centre Smoothly pull the seat belt 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 se...

Page 80: ... 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 retractor to excessive heat when thawing out Do not u...

Page 81: ... in the centre position neutral The ignition key has three positions Position 0 Key removal position no circuit powered except for horn stop lights seat and ISO PCB Position Ⅰ All circuits are powered Position Ⅱ Engine starting 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 Use and Operation...

Page 82: ...on 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 Using the truck 72 60118011601 EN 09 2020 ...

Page 83: ...hts 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 Using the truck 73 60118011601 EN ...

Page 84: ... fasten the seat belt Ensure that the cab doors or the driver restraint system installed on the truck is closed Ensure that the direction selection lever if present is in the central position neutral Insert the switch key 1 and turn it to posi tion 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 o...

Page 85: ...gine 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 engine running in or der to warm up the engine Warm up the engine by using the truck at a low speed for a few minutes Driving CAUTION When using mirrors ensure that the rear view mirror is only used for monitoring the traffic behind the ...

Page 86: ...ty belt Start the engine Release the parking brake 1 and the cor responding LED 2 will turn off Move direction selection lever 3 in the re quired drive direction A FORWARDS B BACKWARDS Use and Operation 4 Using the truck 76 60118011601 EN 09 2020 ...

Page 87: ...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 Steadily press the accelerator pedal The speed of the forklift truck accelerates in relation to the increase in pedal travel Use and Operation 4 Using the truck 77 60118011601 EN 09 2020 ...

Page 88: ...to drive with load please choose the low speed and press the LOW gear 2 CAUTION Please choose the gear depends on your drive con dition Change the gear when the truck stops Changing direction of travel To change direction release the accelerator pedal 2 Press the service brake pedal 1 until the truck comes to a complete stop Use and Operation 4 Using the truck 78 60118011601 EN 09 2020 ...

Page 89: ... the forklift truck is not carrying a load Operate the forklift truck slowly on an un crowded road surface to test travelling func tions Driving brake pedal Press the brake pedal 2 to slow or stop the truck At the same time the brake lights come on Inching pedal If the inching pedal 1 is depressed the en gine is disengaged at the beginning of the pedal travel The service brake begins to grip when ...

Page 90: ...er conditions and the level of contamination on the roadway Always choose a driving speed that will provide a sufficient stopping distance Take the foot off the accelerator pedal 1 Press the brake pedal 2 until the truck is stationary Actuate the parking brake to keep the fork lift truck braked Procedure in the event of failure of the service brake Bring the truck to a standstill by actuating the ...

Page 91: ...king 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 original posi tion and the parking brake indicator light will turn off DANGER The forklift truck must not be operated if there are problems with the braking system If there is a fault with the braking...

Page 92: ...is freezing park the truck as far as possible in closed rooms e g garages be cause liquefied petrol gas evaporates suffi ciently at temperatures over 5 C pro pane respectively 5 C propane butane to start the engine CAUTION Do not park the truck in halls or garages in the imme diate vicinity of equipment radiating heator near heat ers Use and Operation 4 Using the truck 82 60118011601 EN 09 2020 ...

Page 93: ...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 94: ...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 95: ...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 85 60118011601 EN 09 2020 ...

Page 96: ...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 97: ...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 attachment For example Truck model RCG50 with single tyre Load centre 500 mm Lift height 5500 mm In this case the maximum load capacity is 5000 kg Before loading make su...

Page 98: ...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 may be transported Danger area The danger area is the area in which people are at risk d...

Page 99: ...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 the relevant authori ties DANGER Suspended loads that begin to swing can res...

Page 100: ...e 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 swing en sure that no person is pl...

Page 101: ...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 102: ...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 103: ...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 104: ...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 105: ...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 95 60118011601 EN 09 2020 ...

Page 106: ...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 107: ...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 108: ... 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 109: ...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 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 104 60118011601 EN 09 2020 ...

Page 115: ...lat 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 116: ...tly 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 for...

Page 117: ...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 118: ... 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 119: ...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 109 60118011601 EN 09 2020 ...

Page 120: ...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 121: ...ning 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 operatio...

Page 122: ...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 112 60118011601 EN 09 2020 ...

Page 123: ...5 Maintenance ...

Page 124: ...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 125: ...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 126: ...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 116 60118011601 EN 09 2020 ...

Page 127: ...e 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 LPG system Check the LPG system for damage check that the scr...

Page 128: ...ast Check load chains for damage and wear adjust and lubricate the load chains Check mast bearings for damage and lubricate Check the tightening torque Check mast profiles for damage and wear Lubricate the mast profiles Maintenance 5 Scheduled truck maintenance 118 60118011601 EN 09 2020 ...

Page 129: ... the tightening torques of 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 Change the axle oil Internal combustion engine Change the engine oil and filter Check the condition of the internal combustion engine visual inspec...

Page 130: ...cal system Check the fuses Check lighting and indicator lights Check all power cable connections Hydraulics Check the condition of the hydraulic system and check for correct function and leaks Replace the filter cartridge for the hydraulic oil Check that the hydraulics blocking function Isolation valve is working correctly Change the hydraulic oil every 2000 hours Lift mast Check the load chains f...

Page 131: ...ge or on the attachment Check the fork arms for wear Lubricate the rolling tracks and fork carriage runners Special equipment Heating system Check the fresh air filter Heating system Check for damage observe the manufacturer s maintenance in structions Check the attachments for wear and damage observe the manufacturer s mainte nance instructions Check the trailer coupling for wear and damage obser...

Page 132: ...r 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 Check the condition...

Page 133: ...rvice brake Check and adjust parking brake Check the oil level of the brake system Change the brake oil Electrical system Check the fuses Check lighting and indicator lights Check all power cable connections Hydraulics Check hydraulic system for condition correct function and leaks Replace the filter cartridge for the hydraulic oil Check that the hydraulics blocking function Isolation valve is wor...

Page 134: ...he fork carriage or on the attachment Check fork arms for wear and deformation Lubricate the rolling tracks and fork carriage runners Special equipment Heating system Check 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 an...

Page 135: ...n clude 4500mm mast Hydraulic oil 20 L HV32 For cold storage use 95L for mast exceed ing 4500mm mast 20 L HV32 For cold storage use Bearings lubricating grease fittings 0 05KG 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 15L Coolant water See section Engine cool ant Specifications Reservo...

Page 136: ...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 126 60118011601 EN 09 2020 ...

Page 137: ...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 138: ...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 139: ... Carefully guide the bottom plate down and close Insert the rubber mat Close the bonnet Maintenance 5 Providing access to maintenance points 129 60118011601 EN 09 2020 ...

Page 140: ...fferent brands of oil Mixing different brands of oil will seriously 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 Irresponsible...

Page 141: ...ollect the used oil Remove the oil drain plug 2 and allow the oil to flow into the collection container When the oil has been drained completely Adding the engine oil Ensure that the engine is in a horizontal po sition Fasten the drain plug 2 at a torque of 3 0 kgf m Maintenance 5 Maintenance service 131 60118011601 EN 09 2020 ...

Page 142: ...hand Over tightening may damage the cap Remove the engine oil drain pan from under the engine After this perform the final specification Check if engine oil leaks after starting the engine Start the engine and then stop it when it reaches a normal temperature Wait for 5 10 minutes Check the engine oil level with the oil level gauge CAUTION Adding oil which exceeds the upper limit of the oil level ...

Page 143: ...arily assemble the new oil filter by rotating it by hand Assemble the oil filter with the filter wrench at a torque of 16 20 N m NOTE Please refer to the engine spare parts manual to find the part number of usable engine oil fil ters Fill the engine with engine oil according to the detailed instructions in Filling up with engine oil Replacement of Coolant General genuine coolant 1 year or 1 200 ho...

Page 144: ...gine has been cooled sufficiently Mark and separately manage the containers for storing coolant from beverage containers to avoid confusion If coolant is ingested see a doctor im mediately CAUTION Be careful not to get coolant on any belts or electric apparatus when replacing the coolant Make sure that engine and radiator are cooled Place a container in front of the coolant drain plug 1 Maintenanc...

Page 145: ...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 becomes clear Press the hose connected to the radiator to discharge the air from inside of the radiator and slowly...

Page 146: ...mentary 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 engine and the radiator are cooled After checking the coolant level in the sup plementary tank replenish coolant until the tank level stays between the upper and low er limit without changing NOTE After replenishing coolant check the coolant level of the ...

Page 147: ...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 Close the bonnet Clean the air filter Clogged filter inserts may have an adverse im pact on engine performance Make sure to pe riodically clean the air filter insert Loosen the clip 2 and remove the air filter head ...

Page 148: ...ilure to follow this instruction may result in injury Clean the air filter element every 200 hours If the filter insert is damaged heavily soiled or oily replace it with a new insert CAUTION The air filter insert requires more frequent cleaning when the engine is running in dusty environments Clean the inside of the air filter head cover 1 Fit the filter 3 in the air filter housing 4 Refit the air...

Page 149: ... indicates that it needs to be replaced 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 t...

Page 150: ...lue 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 Remov...

Page 151: ...t the floor plate 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 tightl...

Page 152: ...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 153: ...elimi nary maintenance operations Partially loosen the wheel fastening nuts 1 Raise the back of the truck by jack and ar range supports 2 under the ballast Lower the truck so that it rests on the sup ports 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 thr...

Page 154: ...k in the reverse direction Lift the front end of the truck with the jack and arrange supports 2 on the side of the wheel to be replaced Lower the truck 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 Tig...

Page 155: ...ake and mixed with the brake liquid can cause the brake system seal unit rusty even to the extent 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 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...

Page 156: ...pper and lower markings on the dipstick WARNING The hydraulic oil must be checked while the engine is stopped and the forklift is in horizontal level 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 NO...

Page 157: ... return fil ter 3 from the cover assembly Screw in the new intake filter until tightened Refit the cover assembly to the frame using the fastening screws Refit the bracket and pedal pad Refit the engine cover Replacing the breather filter ENVIRONMENT NOTE Please handle liquids and lubricating oil in ac cordance with instructions Open the bonnet Maintenance 5 Maintenance service 147 60118011601 EN ...

Page 158: ...p 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 environments Maintenance 5 Maintenance service 148 60118011601 EN 09 2020 ...

Page 159: ...6 Technical datasheet ...

Page 160: ...Dimensions Technical datasheet 6 Dimensions 150 60118011601 EN 09 2020 ...

Page 161: ...0 Axle loading unladen front rear Kg 3340 3460 Wheels chassis frame Tyres SE Super elastic PN Pneumatic SE solid tyre 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 Overal...

Page 162: ...tion time laden S 5 7 Acceleration time unladen S 4 9 Service Brake Mechanical Hydraulic Engine Engine Type DOOSAN P34 Engine Power in compliance with ISO 1585 kW 55 2 Rated Number of Revolutions rpm min 2300 Cylinder Number Displacement cm3 4 3400 Emission level according to EU regulation 2016 1628 Stage V Fuel consumption according to VDI 2198 2019 EN16796 kg h 6 Vehicle electrical system voltag...

Page 163: ...40 Axle loading unladen front rear Kg 3140 4220 Wheels chassis frame Tyres SE Super elastic PN Pneumatic SE solid tyre 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 Overa...

Page 164: ...ion time laden S 5 6 Acceleration time unladen S 4 3 Service Brake Mechanical Hydraulic Engine Engine Type DOOSAN P34 Engine Power in compliance with ISO 1585 kW 55 2 Rated Number of Revolutions rpm min 2300 Cylinder Number Displacement cm3 4 3400 Emission level according to EU regulation 2016 1628 Stage V Fuel consumption according to VDI 2198 2019 EN16796 kg h 6 4 Vehicle electrical system volta...

Page 165: ...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 166: ...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 167: ...aning the electrical system 107 Cleaning the radiator checking for leaks 137 Cleaning the truck 105 Clean the air filter 137 Climbing on off the forklift 67 Closing the bonnet 127 Competent person 10 Consumables Disposal 24 Safety information for handling battery acid 24 Safety information for handling oils 22 Safety information for hydraulic fluid 23 D Daily checks before use 48 Danger area 88 De...

Page 168: ...view of the driver s compartment 34 P Packaging 26 Parking brake 81 Personnel qualifications 115 Picking up a load 92 Pre shift checks 48 Production number 36 Prohibition of use by unauthorised persons 11 R Recommissioning after storage 111 Removing the bottom plate 128 Replacement of Coolant 133 Replacing the breather filter 147 Replacing the engine oil filter 133 Replacing the fine hydraulic tra...

Page 169: ...il level inspection proce dure 57 Transporting pallets 88 Transporting suspended loads 89 U Use a truck or flatbed trailer to carry the forklift truck 44 V VDI Datasheet for RCG40 151 VDI Datasheet for RCG50 153 W Warnings 5 Index 159 60118011601 EN 09 2020 ...

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Page 172: ...STILL GmbH 60118011601 EN 09 2020 ...

Page 173: ...LPG forklift truck RCG40 RCG50 Original instructions 4234 4236 60118011601 EN 09 2020 ...

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Page 175: ...7 Diagrams ...

Page 176: ...Electric schematic diagram for Doosan P34 engine with ISO3691 function Diagrams 7 Electric schematic diagram for Doosan P34 engine with ISO3691 function 166 60118011601 EN 09 2020 ...

Page 177: ...Hydraulic diagram Diagrams 7 Hydraulic diagram 167 60118011601 EN 09 2020 ...

Page 178: ...Diagrams 7 Hydraulic diagram 168 60118011601 EN 09 2020 ...

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Page 180: ...STILL GmbH 60118011601 EN 09 2020 ...

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Still RCG40, Original Instructions Manual

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