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5195 series Electric Reach Truck Operating Instructions Models R17SX, R22SX, R15SXD North America 5195 series – 51958011540 rv02 US - 08/2020...
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With ten production plants worldwide and an extensive network of sales partners, we are at your serv- ice around the clock and around the world. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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This manual - and any excerpts thereof - may not be reproduced, translated or transmitted in any form to third parties without the express written permission of the manufacturer. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Operators must under- Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Indicates a potentially hazardous situation which if occur. not avoided could result in death or serious injury. DANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Place a “Do Not Operate” tag on the truck, remove the key and alert your supervisor. The Truck may not be placed back into service until necessary repairs are made. F284 04-2013 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
DANGER Risk of injury! Watch for people in your work area because they may not watch for you, even if you have lights or alarms. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Avoid running over loose objects Travel with the forks near the floor, tilted back on the roadway surface. to cradle any load whenever possible. Never Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
● tion must be taken when using an unloaded ward or mast extended. truck as well as a loaded one. Never travel with mast extended. ● Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Do not block access to fire or emer- tor is more than 25 ft (7.5 m) away, or out of gency equipment. sight of the truck, the key should be re- moved. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Batteries may only be charged, serviced, or ● changed by properly trained personnel. Al- ways follow all instructions provided by the manufacturers of the battery, charger, and forklift truck. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Spilled oil should be removed with oil-bind- ● ing agents at once and disposed of accord- ing to local regulations. If recycling is not possible, dispose of used ● oil according to local regulations. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Spilled hydraulic oil should be removed with ● oil-binding agents at once and disposed of according to local regulations. If recycling is not possible, dispose of used ● hydraulic oil according to local regulations. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Also shut off power when leaving truck unattended. Block wheels if truck is parked on an incline. 0009385125 Rev00 Failure to comply with these warnings will create an unreasonable risk of injury to yourself and others. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
This decal warns personnel not to stand or walk on, or under, the forks at any time. This applies to operators as well as all others. 0009384600 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
KEEP HANDS CLEAR, ation. The decal warns personnel to keep SERIOUS INJURY COULD RESULT. 0009384603 hands clear of these areas at all times. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
FAILURE TO MAINTAIN A CLEAR VIEW IN THE DIRECTION OF TRAVEL COULD RESULT IN SERIOUS INJURY OR DEATH. THE OPERATOR IS RESPONSIBLE FOR THE SAFE OPERATION OF THIS VEHICLE. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
The draulic fluid from the cylinders faster than power modules regulate current to the motors would occur under gravity alone. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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CAN bus circuit. A second CAN bus stabilized low voltage to the display and work- circuit connects the main control unit to the ing power to optional equipment. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
When the key switch is turned on, the display unit first con- ducts a self-test and then transmits informa- tion. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Overview Controls Controls 5195 04102019-03 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Lift limit function (optional equipment) * The travel axis and mast control axis may be reversed as a special option. Always refer to the Travel / Mast control symbol. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Overview Decal and Data Plate Location Decal and Data Plate Loca- tion Exterior 24 VOLT ONLY 0009384649 36 VOLT ONLY 0009384649 5195 04102019-01 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Warning Decal, Stand-up Rider optional EE rated protection for hazardous Decal, Operator Manual Location environments) Plate, UL Classification Decal, "Snowflake" (only on trucks equipped with optional cold storage protection) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
C and the load range (MAX and MIN) for the battery in center of gravity must be within the pounds and kilograms. corresponding values shown in col- umns A, B, and D. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Overview Definition of directions Definition of directions Forward Right Reverse Left Directions as seen from the driving position; the load is at the front. 1346 10042017-02 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Overview Definition of directions Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
10 hours until no further loosening is de- tected. See the procedure for checking wheels and tires in the Maintenance section. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Pull upward on the adjusting lever (1) to un- lock the adjustment mechanism. Push down or lift up on the armrest assem- bly until a comfortable position is found. Release the adjusting lever. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
This window is the default window after the start sequence is complete. This window dis- plays the steering angle both graphically and numerically in degrees. Operating hours are shown to the right. 5215 02182019-03 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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These menus are selected with the scroll keys and the enter key. 5215 02182019-05 Display settings Language Four choices - highlight with scroll keys and press the enter key. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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It may be cleared by pressing the back key. The first fault in the list will be highlighted. Press enter to read the fault description. 5215 02182019-06 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
After the key switch has been switched on, the display unit performs a self-test. All indicator lights are extinguished on the display unit after approximately 4 seconds. The truck is now ready for use. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
For optional configuration, move it toward the forks. The direction contactor should close with an audible sound and the parking brake symbol in the display should go out. The driving speed Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Move the multifunction handle to the oppo- site direction of travel. The truck will be electrically braked until sta- tionary. If the handle is not released, the truck will then accelerate in the new direction. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
The truck will slow to a stop faster than if the handle is simply released. After stopping, the truck will accelerate in the new direction un- less the handle is then released. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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If the truck is on, the parking brake symbol will appear in the dis- play unit whenever the parking brake is en- gaged. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
The horn is used as a warning signal, e.g. at blind spots and junctions. Press the horn button (1) on the multifunc- tion handle to sound the horn. 1346 10232017-08 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
To resume operation, ensure that the multi- function handle is released to the neutral posi- tion. Twist the emergency stop button slightly until it springs out to the normal position. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Move the multifunction handle in the desig- nated lowering direction. For standard con- figuration this will be toward the forks. For optional configuration, move it toward the left side of the truck. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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The symbols below the line refer to sideshift control. 1346 10232017-01 Tilting forward Press the button (3). Tilting back Press the button (4). 1346 10232017-02 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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(6) on the side of the multifunction han- dle opposite the tilt and sideshift switches. Note the symbol in position (7) on the multi- function handle. 5195 04222019-02 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
(if applicable), load, and unevenness and gradi- ent of the ground. Do not rely on the same pre-set angle for all condi- tions. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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The forks can now be tilted normally with the tilt button. Briefly depress button (2) again to reacti- vate the tilt memory function as required. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
A cooling fan for the operator is available as an option. The fan is mounted to the overhead guard at the rear support leg. Use toggle switch (1) to turn the fan on or off. 06252020-01 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
The alarm can also be configured to operate as a travel alarm. In this case it will operate in both for- ward or reverse. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Make sure all terminal caps are in place and in good condition. Position a battery stand beside the truck to receive the battery. Ensure that its height is Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Install the remaining battery retainer. Adjust the lateral adjustment stop if necessary to ensure the battery is secure. Plug the battery plug (1) into the battery connector socket(2). Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Remove the battery plug (1) from the con- necting socket (2). Attach the connector plug of the external battery charger to the battery plug (1). Switch on the battery charger. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
After the lowering is complete, turn the screw back in clockwise and tighten to 11 ft- lb (15 Nm). This must be done to restore normal mast operation. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Lift the rear of the chassis just enough for the drive wheel to clear the floor and no more. Do not allow any personnel to occupy the truck during towing. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Towing the truck requires a towing vehicle with suffi- cient tractive power and braking force for the truck mass. Do not exceed 1.5 mph (2.5km/hr) during towing. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
To secure the truck to a load surface for transport, a total of eight wooden wedges and suitable tension belts must be used. Position two wooden blocks at the front of Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Pad the straps at the point where they contact the upper edge of the battery retainer plates to prevent chaf- ing. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Ensure that slings or any other lifting equip- ment will remain clear of any sharp edges, hydraulic lines or hoses, or attached items such as lights or brackets throughout the lifting process. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Lubricate battery terminals with acid-free Put forklift truck into service. grease. (Follow instructions of battery man- ufacturer .) Apply a suitable contact spray to all ex- posed electrical contacts . Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Operation Long term storage Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
This does not effectiveness of the protective equipment ac- require training as described above. cording to established principles for testing forklift trucks. Any evaluation of safety must be Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Lift chains on trucks used in the food industry must be lubricated with an oil approved for the Clean lift chains with a paraffin derivative food industry. such as petroleum ether. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
The truck must not be operated maintenance process except for individual mainte- nance activities that specifically require otherwise. until such repairs are complete. This list does not cover attachments or other truck modifica- Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Place a “Do Not Operate” tag on the truck, remove the key and alert your supervisor. The Truck may not be placed back into service until necessary repairs are made. F297 10-2017 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Check battery retention Ensure that all battery retention devices are in place, undamaged, and hold the battery firmly. Check battery connector Inspect the battery connector and its cables for damage. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Overview section of this manual. Refer to the decal descriptions in the Safety section of this manual if necessary. Any dam- aged or unreadable decals must be replaced. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Inspect all wheels for damage. Check multifunction handle bellows Inspect the flexible bellows on the multifunc- tion handle for correct position and condition. Torn or otherwise damaged bellows must be replaced. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
(operate through complete range of motion) CAUTION Excessive noise during hydraulic function operation indicates low hydraulic fluid. This condition must be checked and corrected imme- diately to avoid damage to the hydraulic pump. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
The truck must be switched off while cleaning the fans. The fans can be activated for testing using a laptop computer equipped with Linde diagnos- tic software. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Oil level must reach the bottom of the filler plug opening. Add gearbox oil as required through the filler plug opening.(2). Install the filler plug and tighten to 25 ft-lbs (35 Nm). Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Ensure the floor plate springs are in place and lower the floor plate assembly into posi- tion. Ensure that the floor plate assembly has free movement and strong spring re- turn. Replace the floor mat. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Clean the steering gear (1) and pinion with a rag and cold cleaner and apply fresh grease to the operating range of the gear. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
0.8 inch (20 mm) of the end of the inner up- right (dimension Y). If the distance Y is less than 0.8 inches (20 mm), the chains must be adjusted according to the procedure in the service manual. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Check the mast roller clearance every 500 hours. Pry each roller at position (5) and measure clearance at position (6). If clearance exceeds 0.020 inch (0.5 mm), shimming is re- quired. 5195 04292019-01 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
(1) on each side. On double- reach units, there will be two fittings on each side. Lubricate the sideshifter at the three fittings (2) along the front of the carriage. 5195 05072019-01 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
(based on years in service) listed at the documentation for maintenance requirements. top of each chart. All lubrication and service intervals must be reduced for dusty conditions, large tempera- ture fluctuations or intensive use. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Check the steering turntable bearing for ease of movement and wear. Clean and lubricate the steering gears and check gear play. Check the ease of movement of the steering system. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Check forks for wear or damage and check latch pin operation. Clean, check, and lubricate all pivot pins in the reach unit and tilt mechanism. Clean, check, and lubricate the sideshifter. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Hydraulic system Change the hydraulic oil and replace the breather filter, pressure filter and suction filter. Subsequent tasks Carry out functional test and test drive. Attach maintenance sticker. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Lithium-based grease with MoS2. NOTE Do not mix non-lithium-based greases with lithium-based greases. Chain spray Use a high-quality commercially available penetrating chain spray specifically in- tended for forklift mast chains. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
1F1 (355A) protects the drive motor ● Control Fuses The control fuses are contained in one block in the control fuse box. Fuse identification and amperage is listed in the following illustration and table. Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Pin2) 1.2(Pin17- 5A/58V DC to DC inverter Pin18) 1.3(Pin33- 20A/58V DC to DC inverter (option) Pin34) 1.4(Pin49- 10A/58V Power for VCM Pin50) 1.5(Pin65- 5A/58V Power for steering ECU Pin66) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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5.1(Pin9- 2A/58V Blue spot (option) Pin10) 5.2(Pin25- 5A/58V Cabin fan (option) Pin26) 5.3(Pin41- 5A/58V ID system (option) Pin42) 5.4(Pin57- 10A/58V ID system (option) Pin58) 5.5(Pin73- 5A/58V Camera (option) Pin74) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
Specifications Specifications Specifications Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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102 mm) option 102 mm) option 102 mm) option Number of wheels, front / rear (x = driv- 1x + 1/ 4 1x + 1/ 4 1x + 1/ 4 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Height of outriggers (h8) 6.3 in (160 mm) 6.3 in (160 mm) 6.3 in (160 mm) optional load optional load optional load wheels wheels wheels Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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1.8 in (47 mm) 1.8 in (47 mm) load (m1) Ground clearance, center of wheel- 1.7 in (45 mm) 1.7 in (45 mm) 1.7 in (45 mm) base (m2) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
330 in (8382 149 in (3785 378 in (9601 115 in (2922 0368 to 0376 366 in (9296 161 in (4089 414 in 127 in (3226 0377 to 0385 (10515 mm) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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330 in (8382 149 in (3785 378 in (9601 146 in (3708 4092 to 4097 366 in (9296 161 in (4089 414 in 158 in (4013 4098 to 4904 (10515 mm) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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448 in 170 in (4318 4911 to 4916 (10160 mm) (11379 mm) 425 in 185 in (4699 473 in 182 in (4623 4917 to 4922 (10795 mm) (12014 mm) Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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Driving......Lashing the truck for transport..58 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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New truck, preparing for operation..Torque specification, drive wheel fasteners. 70 Towing the truck....Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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....70 Transport, securing for....58 Operating Instructions - 5195 series – 51958011540 rv02 US - 08/2020...
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KION North America Corporation 5195 series – 51958011540 rv02 US - 08/2020...
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