Rico HSD-EX-60 Operating Manual

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OPERATING MANUAL

HSD-EX-60

DO NOT REMOVE THIS MANUAL FROM THIS UNIT

Part Number: OIM-HSDEX60-2019

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Summary of Contents for Rico HSD-EX-60

Page 1 OPERATING MANUAL HSD-EX-60 DO NOT REMOVE THIS MANUAL FROM THIS UNIT Part Number: OIM-HSDEX60-2019...
Page 2: Table Of Contents
Operating Manual: HSD-EX-60 Contents Forward ..................3 To OWNERS, USERS, and OPERATORS: ....... 3 Safety Symbols ................4 Know the Equipment ..............5 Look Where You are Going ............5 Know Your Loads ............... 5 Protect Yourself, Fasten Your Seat Belt! ........6 Hazardous Locations ..............
Page 3 Operating Manual: HSD-EX-60 Steering ..................41 Auto Power Off ................. 42 Operator Presence System (OPS) ........... 42 Load Handling, General ............43 Load Handling Controls ............44 Load Handling, Engaging and Disengaging a Load ....45 Load Handling, Traveling ............48 Highway Truck, Railroad Cars, and Docks .......
Page 4: Forward
Operating Manual: HSD-EX-60 Forward To OWNERS, USERS, and OPERATORS: The safe and efficient operation of a lift truck requires skill and alertness on the part of the operator. To develop the skill required, the operator must: • Receive training, pursuant to OSHA 1910.178(l), in the proper operation of THIS truck.
Page 5: Safety Symbols
Operating Manual: HSD-EX-60 Safety Symbols The following symbols and words indicate safety information in this manual: WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury and property damage.
Page 6: Know The Equipment
INSPECT truck before use. • DO NOT operate if truck needs repair. Tag truck and remove key. Repair truck before use. Always use RICO Approved parts when making repairs. Replacement parts must meet or exceed the specifications of the original equipment manufacturer.
Page 7: Protect Yourself, Fasten Your Seat Belt
Operating Manual: HSD-EX-60 Protect Yourself, Fasten Your Seat Belt! • AVOID bumps, holes, loose materials, and slippery areas. • AVOID sudden movements. Operate all controls smoothly. • NEVER turn on, or angle across an incline. Travel slowly. • TRAVEL on inclines with load uphill or unloaded with mast downhill.
Page 8: Model Description
Operating Manual: HSD-EX-60 Model Description Figure 1. Diagram of Major Components 1. Overhead Guard 2. Seatbelt 3. Mast 4. Load Backrest Extension 5. Carriage 6. Forks 7. Drive Tires 8. Steer Tires 9. Counterweight...
Page 9: General
Operating Manual: HSD-EX-60 General The lift truck covered in this Operating Manual has solid rubber tires (often called cushion tires) that are pressed onto the rim. A battery supplies power for the traction motor, hydraulic pump motor, control panel, and display panel.
Page 10 Operating Manual: HSD-EX-60 Figure 2. EX Motor Enclosure 1. EX Motor Enclosure 2. EX Motor Enclosure Lid 3. Traction Motor 4. Hydraulic Pump Motor 5. Hydraulic Pump...
Page 11 Operating Manual: HSD-EX-60 The truck covered in this Operating Manual is equipped with manual hydraulic levers to operate load handling functions. Forward or reverse movements are controlled by a direction control switch located on the left side of the first lever.
Page 12 Operating Manual: HSD-EX-60 Figure 4. Seat Components 1. Seatbelt 2. Weight Adjustment Knob 3. Ride Position Indicator 4. Forward/Backward Adjustment Lever 5. Backrest Angle Adjustment Lever 6. Hip Restraint Bracket 7. Swivel Latch Release Lever...
Page 13: Operator Protection Equipment
If a load backrest extension that is different from the one installed on your truck is required, contact RICO Manufacturing or your RICO dealer. See Figure 1...
Page 14: Protection Against Mechanical Sparks
Operating Manual: HSD-EX-60 Protection Against Mechanical Sparks The periphery of the truck covered in this Operating Manual is protected from mechanical sparks by means of bumpers or cladding constructed of non-sparking materials. See Figure 5 DO NOT operate the truck in a hazardous location if the non- sparking material is missing or worn through to the underlying ferrous metals.
Page 15 Operating Manual: HSD-EX-60 Figure 5. Typical Protection Against Mechanical Sparks 1. Truck Body: Aluminum Bumpers on Sides 2. Rear Counterweight: Aluminum Bumper on Back 3. Drive Hub: Aluminum Cap 4. Steer Hub: Aluminum Cap 5. Drive Tire Fender: Brass Cladding on Sides 6.
Page 16: Nameplate
Operating Manual: HSD-EX-60 Nameplate Figure 6. Nameplate WARNING Any changes to the truck, its tires, or its equipment can affect its capacity, stability, or safe operation. If the truck equipment— including the battery—does not match that shown on the Nameplate, the truck must not be operated.
Page 17: Safety Labels
It is important that all safety labels are present a legible. If a label is missing or cannot be read, contact RICO Manufacturing or your RICO dealer. Replacement part numbers can be found in your truck’s maintenance manual.
Page 18 Operating Manual: HSD-EX-60 Figure 7 Figure 8 Notice of FM approval. Identification of the hazardous locations the truck is tested and approved to operate in per NFPA Standard 505. Figure 9 Figure 10 Warning against servicing EX marker on both sides and electrical equipment in a rear of truck.
Page 19 Operating Manual: HSD-EX-60 Figure 14 Mast warning. Figure 13 Figure 15 Tip-over warning. No passengers warning. Figure 16 Mast crush hazard warning. Figure 17 Figure 18 MAX capacity warning. Pinch or crush point hazard.
Page 20: Operator Controls
Operating Manual: HSD-EX-60 Operator Controls Figure 19. Operator Controls...
Page 21 Operating Manual: HSD-EX-60 1. Horn Button • Push horn button to warn pedestrians and others when approaching intersections and other blind areas. 2. Accelerator Pedal • Push down on the accelerator pedal to increase the speed of the truck. 3. Display Panel •...
Page 22: Display Panel Features
Operating Manual: HSD-EX-60 Display Panel Features Figure 20. Display Panel Keys...
Page 23 Operating Manual: HSD-EX-60 1. 1 Key • When an operator is in the Password Screen, if enabled, for entering passwords, this key allows entry of the number 1 for password purposes. • Once a password has been successfully entered, or if a password is not required, the display panel will go to the Operator Screen.
Page 24 Operating Manual: HSD-EX-60 3. 2 and 3 Keys • When an operator is in the Password Screen, if enabled, for entering passwords, these keys allow entry of the number 2 and 3 for password purposes. • Once a password has been successfully entered, or if a password is not required, the display panel will go to the Operator Screen.
Page 25 Operating Manual: HSD-EX-60 6. Pound Key • If the Operator Checklist is enabled on the lift truck, the Pound Key is used to indicate an issue with the current item in the list. See Operator Checklist in the Operating Procedures section for more information on using the Operator Checklist.
Page 26: Display Panel - Screen And Warning And Indicator Lights
Operating Manual: HSD-EX-60 Display Panel – Screen and Warning and Indicator Lights Item Function Indicator Light, There are four performance modes to Performance Mode choose from. Each mode changes acceleration and speed. The tortoise icon on the top decreases the performance mode and the hare on the bottom increases the performance mode.
Page 27 Operating Manual: HSD-EX-60 Item Function Warning Light, WARNING Fasten Seatbelt Always fasten seat belt when operating the lift truck. Serious injury may occur if seat belt is not fastened. This icon will stay illuminated for approximately 10 seconds when the...
Page 28 Operating Manual: HSD-EX-60 Item Function Indicator Light, CAUTION Battery Discharge DO NOT operate the lift truck when the Indicator (BDI) battery icon is flashing. Continued operation with a low battery can cause damage to the battery and lift truck. A bar graph, representing the Battery...
Page 29 Operating Manual: HSD-EX-60 Item Function Indicator Light, The direction indicator lights indicate Parking Brake Not which direction the lift truck is set to Applied, travel. The corresponding direction Direction Indicators arrow (up for Forward, down for Reverse) will illuminate. When the parking brake is disengaged, the N or Arrow (based on direction selected) will appear.
Page 30 Operating Manual: HSD-EX-60 Item Function Warning Light, The service due icon will illuminate Service Due Light when either an active fault is present in the system or when scheduled maintenance is due or almost due, if lift truck is equipped with this feature.
Page 31 Operating Manual: HSD-EX-60 Item Function Warning Light, CAUTION Motor Temperature DO NOT operate the lift truck when the High Warning motor temperature is too high. Damage to the hydraulic system can occur. This icon will illuminate and stay illuminated when one of the following...
Page 32: Operating Procedures
Operating Manual: HSD-EX-60 Operating Procedures ALWAYS make sure the parking brake is fully applied before leaving the lift truck. If the parking brake is not applied when the operator gets out of the seat or turns the lift truck OFF, an alarm will sound for 60 seconds.
Page 33: Stability And Center Of Gravity
Operating Manual: HSD-EX-60 This basic principle is used for picking up a load. The ability of the lift truck to handle a load is discussed in terms of center of gravity and both forward and side stability. Stability and Center of Gravity...
Page 34 Operating Manual: HSD-EX-60 The center of gravity, and therefore the stability of the loaded lift truck, is affected by a number of factors, such as size, weight, shape, and position of the load; the height to which the load is raised;...
Page 35: Capacity (Weight And Load Center)
Operating Manual: HSD-EX-60 Capacity (Weight and Load Center) The capacity of the lift truck is shown on the Nameplate. The capacity is listed in terms of weight and load center. The weight is specified in kilograms and pounds. The load center is specified in millimeters and inches.
Page 36 Operating Manual: HSD-EX-60 At the beginning of each shift and before operating the truck, make the following checks: Walk-Around Inspection • Forks: Properly secured, not bent or cracked, brass cladding is not missing or badly worn. • Lift Chains: In place and free of excessive wear or damage.
Page 37 Operating Manual: HSD-EX-60 Do not turn lift truck power on nor operate the lift truck, including any of its functions or attachments, from any place other than the designated operator's position. The seat belt is installed to help the operator stay on the truck if the lift truck tips over.
Page 38: Startup Procedure
Operating Manual: HSD-EX-60 Operational Inspection • Seatbelt: Properly latched and free of cuts, fraying, or other damage. • Seat: Locked in position. • Display Panel: Indicator lights are working. • Battery: Sufficiently charged. • Parking Brake: Disengages and engages. •...
Page 39: Lift Truck Interlocks
Operating Manual: HSD-EX-60 If the SRO circuit does not operate correctly, have the Master Controller checked by authorized service technician. Lift Truck Interlocks Certain operator actions, if not performed correctly while operating the lift truck, will cause either the traction motor or hydraulic functions to become disabled.
Page 40 Operating Manual: HSD-EX-60 The following discussion lists basic procedures applicable to lift truck operation: 1. AUTHORIZED AND TRAINED OPERATOR ONLY. This means the operator must be trained to drive the lift truck and it means that the operator must thoroughly understand the procedures for lift truck operation.
Page 41: Drive And Direction Changes
Operating Manual: HSD-EX-60 operator is set at the midpoint of the 80 mm (3.5 in.) suspension. • The handle can be turned as shown to increase or decrease the weight resistance, pull handle out before turning. As the handle is turned the "stiffness" of the suspension can be felt to increase or decrease depending on which way the handle is turned.
Page 42: Steering
Operating Manual: HSD-EX-60 To move the lift truck, select a direction, release the parking brake, and push down on the accelerator pedal. Steering Lift trucks can tip over even at very slow speeds. The combination of speed and the sharpness of a turn can cause a tip-over. A lift truck is less stable when the forks are elevated, with or without a load.
Page 43: Auto Power Off
Operating Manual: HSD-EX-60 Do not turn on an incline. To reduce the possibility of a tip-over, a lift truck must not be driven across an incline. When possible, keep both hands on the steering wheel. During most loading or unloading operations, the operator steers with the left hand.
Page 44: Load Handling, General
Operating Manual: HSD-EX-60 Load Handling, General 1. The capacity is the maximum load that the lift truck can handle for the load condition shown on the Nameplate. The operator must know whether or not a load is within the maximum capacity of the lift truck before the load is handled.
Page 45: Load Handling Controls
Operating Manual: HSD-EX-60 Load Handling Controls The LIFT and TILT functions are controlled by separate manual levers. The speed of the hydraulic functions is controlled by the position of the control levers. The farther the manual hand lever is moved from the NEUTRAL position, the faster the speed of the hydraulic function.
Page 46: Load Handling, Engaging And Disengaging A Load
Operating Manual: HSD-EX-60 This warning applies not only to the operator but also a helper. A helper must not be near the load or lift mechanism while the operator is attempting to handle a load. The lift mechanism has moving parts with close clearances that can cause serious injury.
Page 47 Operating Manual: HSD-EX-60 2. Move forward slowly until the forks are in position under the load. The forks must support at least two-thirds (2/3) of the length of the load. Make sure that the load is centered between the forks.
Page 48 Operating Manual: HSD-EX-60 6. If the load is being removed from a stack, slowly move the lift truck away from the stack. When the load is clear of the stack, lower the load for traveling. Always travel with the load as low as possible and tilted backward.
Page 49: Load Handling, Traveling
Operating Manual: HSD-EX-60 8. Move Forward slowly. When the load is in position, lower the load on to the stack or the rack. Lower the forks just enough to remove them from under the load. Do not lower the forks so that they will drag on the surface under the load.
Page 50 Operating Manual: HSD-EX-60 a load is more likely to tip sideways, especially in a turn, than a lift truck with a load carried in the lowered position. 3. For better visibility with large loads, travel with the load trailing, but always keep a proper lookout in the direction of travel.
Page 51 Operating Manual: HSD-EX-60 6. Anytime the lift truck is moving, keep arms, legs, etc., inside the operator's compartment. Arms and legs outside the machine can be injured when passing obstructions. 7. Avoid bumps, holes, slick spots, and loose materials that may cause the lift truck to swerve or tip.
Page 52: Highway Truck, Railroad Cars, And Docks
Operating Manual: HSD-EX-60 Highway Truck, Railroad Cars, and Docks Watch the "tail-swing." Remember when travelling in the forward direction and the steering wheel is turned to move the lift truck away from the edge of the dock the rear will swing toward the edge.
Page 53 Operating Manual: HSD-EX-60 Make sure that the railroad car brakes are set, and the wheels are blocked while loading or unloading. Do this so that the railroad car will not move due to the movement of the lift truck in and out of the railroad car.
Page 54: Attachments
Operating Manual: HSD-EX-60 Attachments If an attachment is installed on the lift truck, make sure the operating instructions are available and understood before operating the attachment. Attachments must be removed or installed by trained personnel only. Stopping Stop the lift truck as gradually as possible. Hard braking and wheel sliding can cause the load to fall off of the forks and damage the load or hurt someone.
Page 55: Parking
Operating Manual: HSD-EX-60 Parking Never apply parking brake while truck is moving. The operator must never leave a lift truck in a condition so that it can cause damage and injury. When parking the lift truck, do the following operations: 1.
Page 56: Maintenance
Operating Manual: HSD-EX-60 Maintenance Repairs and adjustments that are not correct can make a dangerous operating condition. DO NOT operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a DO NOT OPERATE tag in the operator's area.
Page 57: How To Move A Disabled Lift Truck
Operating Manual: HSD-EX-60 How to Move a Disabled Lift Truck Use extra care when towing a lift truck if there is a problem with any of the following: • Brakes do not operate correctly. • Steering does not operate correctly.
Page 58: How To Put A Lift Truck On Blocks
Operating Manual: HSD-EX-60 5. Release the parking brake. 6. Tow the lift truck slowly. How to Put a Lift Truck on Blocks The lift truck must be put on blocks for some types of maintenance and repair. The removal of the following assemblies will cause large changes in the center of gravity: mast and drive assembly, battery, or the counterweight.
Page 59: How To Raise The Steering Tires
Operating Manual: HSD-EX-60 How to Raise the Steering Tires 1. Apply the parking brake. Put blocks on both sides (front and back) of the drive tires to prevent movement of the lift truck. See Figure 21 2. Use a hydraulic jack to raise the steering tires. Make sure that the jack has a capacity of at least 2/3 of the total weight of the lift truck as shown on the Nameplate.
Page 60: Maintenance Schedule
Operating Manual: HSD-EX-60 Maintenance Schedule X = Check (Replace, Repair, or Lubricate if Necessary) C = Change L = Lubricate Tires Parking Brake Service Brake Brake Fluid SAE J-1703 (DOT 3) Lift Chains SAW 10W-30 Forks Speed Control Pedal Multipurpose Grease...
Page 61 Operating Manual: HSD-EX-60 X = Check (Replace, Repair, or Lubricate if Necessary) C = Change L = Lubricate Brake Pedal Linkage Multipurpose Grease Fork Pins and Guides SAE 10W-30 Hydraulic Tank Breather Contactors Steering Kingpins Multipurpose Grease Wheel Bearings Multipurpose Grease...
Page 62: Maintenance Procedures
Operating Manual: HSD-EX-60 Maintenance Procedures Inspect the lift truck after every eight hours or daily before use. Put the lift truck on a level surface. Lower the carriage and forks and turn the power switch to the OFF position. Apply the parking brake.
Page 63 Operating Manual: HSD-EX-60 Inspection of Mast and Attachments Lower the lift mechanism completely. Never allow any person under a raised carriage. DO NOT put any part of your body in or through the lift mechanism unless all parts of the mast are completely lowered, and the lift truck motor is OFF.
Page 64 Operating Manual: HSD-EX-60 5. Visually inspect hoses/fittings for hydraulic leaks; hose covers for cuts, cracks, or exposed reinforcement; defective/broken clamping devices or sheaves; and proper tracking during operation. Adjust/repair/replace hose/ components as necessary. 6. Check that lift chains are correctly lubricated. Use SAE 10W- 30 engine oil to lubricate lift chains.
Page 65 Operating Manual: HSD-EX-60 Battery Enclosure Make sure the battery enclosure is closed and locked prior to driving the truck into a hazardous location. Note: A padlock is installed on the battery enclosure lid to prevent its opening by unauthorized personnel in hazardous locations.
Page 66 Operating Manual: HSD-EX-60 Battery Metal on the battery can cause a short circuit and possible damage or injury. The acid in the electrolyte can cause injury. If the electrolyte is spilled, use water to flush the area. Make the acid neutral with a solution of sodium bicarbonate (soda).
Page 67 Operating Manual: HSD-EX-60 Hydraulic System Never operate the pump without oil in the hydraulic system. The operation of the hydraulic pump without oil will damage the pump. NOTE: The dipstick/fill is located under the rear floor plate, on the left side of the operator compartment. Remove the floor mat and rear floor plate for access to the dipstick/fill.
Page 68 Operating Manual: HSD-EX-60 Check the hydraulic oil level when the oil is at operating temperature, the carriage is lowered, the mast is vertical, and the power switch is in the OFF position. Add hydraulic oil only as needed. If more hydraulic oil is added than the FULL level, the hydraulic oil will leak from the breather during operation.
Page 69 Operating Manual: HSD-EX-60 Parking Brake Make sure the service brakes operate correctly before checking the operation of the parking brake. Check the operation of the parking brake. The parking brake, when in good condition and correctly adjusted, will hold a lift truck with a capacity load on a 15% grade [a slope that increases 1.5 meters in 10 meters (1.5...
Page 70 Operating Manual: HSD-EX-60 The inner and intermediate weldments and the carriage must lower completely. Raise the forks 1 m (3 ft) with a capacity load. The inner weldment and carriage must raise smoothly. Lower the forks. All moving components must lower smoothly.
Page 71 Operating Manual: HSD-EX-60 Batteries generate explosive fumes when they are being charged. Keep fire, sparks, and burning material away from the battery charger area. Prevent sparks from the battery connectors. Charge batteries only in the special area for charging batteries.
Page 72 Operating Manual: HSD-EX-60 Use the fold-down lifting handle to open the enclosure lid. 5. Secure enclosure lid in the opened position using the padlock. Lock padlock in place prior to placing any part of your body under the lid. 6. Disconnect the battery connector and move it to a position so that it will not be damaged during battery removal.
Page 73 Operating Manual: HSD-EX-60 Figure 22. Battery Removal Battery Installation When a replacement battery is installed, make sure its size and weight are within the limits established by the truck’s nameplate. When installed, there should be a maximum of 13 mm (0.50 in) total clearance around the parameter of the battery.
Page 74 Operating Manual: HSD-EX-60 4. Once closed, reinstall the pad lock. The pad lock key should be kept in a designated area to prevent unauthorized personnel from opening the battery enclosure in a hazardous location. 5. Close and latch the hood. Slide the seat to the desire position.