Page 1 Original instructions IC Truck Cummins Eu 5 RCD 100 RCD 120 RCD 140 RCD 150 RCD 160 RCD 180 RCD 100 / 1200 RCD 120 / 1200 RCD 140 / 1200 RCD 150 / 1200 RCD 160 / 1200 RCD 180 / 900 5410 5411 5412 5413 5414 5415 5416 5417 5418 5419 5420 5421 5001 801 1624 EN - 07/2024 - ...
Page 3: Rules For The Operating Company Of Industrial Trucks
Internet address and QR code  The information can be accessed at any time by pasting the address https://m.still.de/vdma in a web browser or by scanning the QR code. 5001 801 1624 EN - 07/2024 - 04 I...
Page 4 Preface Abbreviations Below is a list of abbreviations used in this manual Aftertreatment Control Module American Petroleum Institute BITA British Industrial Truck Association Controller Area Network Comon Powertrain Controler Engine Control Module Truck Data Acquisition Module Light Emitting Diode LVDT Linear Variable Displacement Transformer Motor Control Module...
Page 5: Table Of Contents
Table of contents Introduction Truck data ............ 2 Your industrial truck .
Page 6 Table of contents Warning regarding non-original parts ........ 29 Damage, faults .
Page 7 Table of contents Standard equipment .......... 58 Entering and exiting the truck .
Page 8 Table of contents 4210 010 Buddy seat........... . 139 4480 005 Storage unit .
Page 9 Table of contents Maintenance General maintenance .......... 210 Safety information regarding servicing work .
Page 10 Table of contents Driver's compartment.......... 289 Check seat belt for condition and correct operation (option) .
Page 11: Introduction
Introduction...
Page 12: Truck Data
Introduction Truck data Truck data We recommend that you 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 ...
Page 13: Your Industrial Truck
Introduction Your industrial truck Your industrial truck Technical Description General in the control units. It can then be read by a service partner. The 1411 range of fork trucks with Cummins engine offer the ability to lift capacities up Steering to 16 or 18 tonnes, with lift capacities up to 16 tonnes available at 1200 mm load centre, The steering is a hydrostatic power system,...
Page 14 Introduction Your industrial truck pressure compensators which act as safety axle and chassis, Hydraulic operated side valves so that in the event of higher than shifting is available with a choice of fork sec- expected pressure flow is reduced to zero tion, style and attachment type.
Page 15: Battery Access
Introduction Your industrial truck check the truck batteries The guard rails is the standard configuration if ● the truck equipped with the ordinary glass. fill the windscreen washer reservoirs ● Battery access A compartment for battery access is located on the left side of the truck, which allows you General The industrial truck described in these operat- ing instructions conforms with the applicable...
Page 16: Conformity Marking
Introduction Your industrial truck Conformity marking  The manufacturer uses the conformity mark- ing to document the conformity of the industri- al truck with the relevant directives at the time of placing on the market: CE: in the European Union (EU) ●...
Page 17: Declaration That Reflects The Content Of The Declaration Of Conformity
Your industrial truck Declaration that reflects the content of the declaration of conformity Declaration STILL GmbH Berzeliusstraße 10 22113 Hamburg Germany We declare that the specified machine conforms to the most recent valid version of the directives specified below: ...
Page 18: Nameplate
Introduction Your industrial truck Nameplate Nameplate, variant 1  1 Type 2 Serial number 3 Year of manufacture 4 Unladen mass in kg 5 Max. permissible battery weight in kg (for electric trucks only) 6 Min.
Page 19 Introduction Your industrial truck 12 Battery voltage in V 13 Rated capacity NOTE It is possible for there to be multiple con- ● formity markings on the nameplate. The EAC mark may also be located in the ● immediate vicinity of the nameplate.
Page 20: Use Of The Truck
Introduction Use of the truck Use of the truck Commissioning Commissioning is the initial intended use of the truck. The necessary steps for the commissioning vary depending on the model and equipment of the truck. These steps require preparatory work and adjustment work that cannot be per- formed by the operating company.
Page 21: Description Of Use And Climatic Conditions
Introduction Use of the truck removed when the truck is unattended to – Please pay attention to the moving parts of prevent unauthorised use. the truck to prevent your hands from being crushed. – When using this truck, pay attention to the surroundings and do not become distracted.
Page 22: Information About Documentation
Introduction Information about documentation Information about documentation Documentation scope Operating instructions fully and must be available to the driver and ● operator at all times. Operating instructions for attachment parts ● (special equipment) If the operating instructions are lost, the oper- Spare parts list ●...
Page 23: Issue Date And Topicality Of The Operating Instructions
The issue date and the version of these op- erating instructions can be found on the title page. STILL is constantly engaged in the further de- velopment of trucks. These operating instruc- tions are subject to change, and any claims based on the information and/or illustrations contained in them cannot be asserted.
Page 24: Explanation Of Signal Terms Used
Introduction Information about documentation Explanation of signal terms used DANGER Indicates procedures that must be strictly adhered to in order to prevent the risk of fatalities. WARNING Indicates procedures that must be strictly adhered to in order to prevent the risk of injuries. CAUTION Indicates procedures that must be strictly adhered to in order to prevent material damage and/or destruc-...
Page 25: Date Of Edition And Latest Update Of This Manual
Introduction Information about documentation Date of edition and latest update of this manual The publication date of these operating in- structions is printed on the cover sheet. The manufacturer makes continuous efforts to improve its industrial trucks with modifications. The manufacturer reserves the right to make such additions to the contents of the truck's operating instructions in a timely manner.
Page 26 Introduction Information about documentation Abbrevi- Meaning Explanation ation maximum Force Maximum power German authority for monitoring/issuing regulations for worker protection, environ- Gewerbeaufsichtsamt mental protection, and consumer protec- tion Transfer of data packets in wireless net- GPRS General Packet Radio Service works ID no.
Page 27 Introduction Information about documentation Abbrevi- Meaning Explanation ation Verband Deutscher Maschinen- und Anla- German Mechanical Engineering Industry VDMA genbau e. V. Association WLAN Wireless LAN Wireless local area network 5001 801 1624 EN - 07/2024 - 04 17...
Page 28: Environmental Considerations
Introduction Environmental considerations Environmental considerations Packaging During delivery of the truck, certain parts are packaged to provide protection during trans- port. This packaging must be removed com- pletely prior to initial start-up. ENVIRONMENT NOTE The packaging material must be disposed of properly after delivery of the truck.
Page 29: Emc - Electromagnetic Compatibility
Introduction EMC – Electromagnetic compatibility EMC – Electromagnetic compatibility Electromagnetic compatibility (EMC) is a key and secondly checks it for sufficient resistance quality feature of the truck. to electromagnetic interference with reference to the planned usage location . A number of EMC involves electrical measures are taken to ensure the limiting the emission of electromagnetic in-...
Page 30 Introduction Modifications and retrofitting Any modifications that adversely affect the stability, the load capacity or the circumferen- tial view of the truck require written approval from the manufacturer. The following components may only be modi- fied with prior written approval from the manu- facturer: Brakes ●...
Page 31: Using Attachments
Introduction Using attachments Decal information with the following data must be permanently affixed to the truck so that it is clearly visible: Type of modification ● Date of modification ● Name and address of the company that car- ● ried out the modification Using attachments The truck can be equipped with attachments.
Page 32 Introduction Using working platforms 22 5001 801 1624 EN - 07/2024 - 04...
Page 33: Safety
Safety...
Page 34: Definition Of Terms Used For Responsible Persons
Safety Definition of terms used for responsible persons Definition of terms used for responsible persons Operating company The operating company is the natural or legal person or group who operates the truck or on whose authority the truck is used. The operating company must ensure that the truck is only used for its proper purpose and in compliance with the safety regulations set out...
Page 35: Drivers
Safety Definition of terms used for responsible persons Drivers This truck may only be driven by suitable per- sons who are at least 18 years of age, have been trained in driving, have demonstrated their skills in driving and handling loads to the operating company or an authorised represen- tative, and have been specifically instructed to drive the truck.
Page 36 Safety Definition of terms used for responsible persons Prohibition of use by unauthorised per- sons The driver is responsible for the truck during working hours. He must not allow unauthor- ised persons to operate the truck. When leaving the truck, the driver must secure it against unauthorised use, e.g.
Page 37: Basic Principles For Safe Operation
Safety Basic principles for safe operation Basic principles for safe operation Insurance cover on company premises The company premises are very often restric- ted public traffic areas. NOTE It is advisable to review the operational lia- bility insurance so that insurance covers the truck with respect to third parties in the event of damage caused in restricted public traffic areas.
Page 38 Safety Basic principles for safe operation We warn against installing and using restraint systems that have not been approved by the manufacturer. – Contact the authorised service centre be- fore converting or retrofitting the truck. Only the authorised service centre is permit- ted to perform welding work on the industrial truck.
Page 39: Warning Regarding Non-Original Parts
We recommend that you obtain approval from the by STILL. manufacturer and, if applicable, from the relevant regulatory authorities before installing such parts. The manufacturer accepts no liability for any damage caused by the use of non-original parts and non-orig- inal accessories.
Page 40: Vibrations
Safety Basic principles for safe operation NOTE Lower or higher noise values may occur when using industrial trucks， e.g. due to the mode of operation, environmental factors and other sources of noise. Vibrations Vibrations to which the hands and arms are exposed The following value is valid for all truck mod- els:...
Page 41 Safety Basic principles for safe operation The following rules must be observed to en- sure stability: Only use wheels with equal and permitted ● levels of wear to the tyres. Only use tyres of the original tyre type. ● Only use wheels approved by the manufac- ●...
Page 42: Residual Risks
Safety Residual risks Residual risks Residual dangers, residual risks Despite working with care and complying with the standards and regulations, the possibility of other dangers arising when using the truck cannot be ruled out. The truck and all other system components comply with current safety requirements.
Page 43: Special Risks Associated With Using The Truck And Attachments
Safety Residual risks ments, this can lead to an accident. In this case, the manufacturer is exempt from liability. Stability The stability of the truck has been tested to the latest technological standards. If the truck is used in the proper manner and in accord- ance with its intended use, the stability of the truck is guaranteed.
Page 44 Safety Residual risks use the truck correctly and without the risk of accidents. 34 5001 801 1624 EN - 07/2024 - 04...
Page 45 Safety Residual risks 5001 801 1624 EN - 07/2024 - 04 35...
Page 46: Overview Of Hazards And Countermeasures
Safety Residual risks Overview of hazards and countermeasures NOTE This table is intended to help evaluate the hazards in your facility and applies to all drive types. It does not claim to be complete. – Observe the national regulations for the country in which the truck is being used.
Page 47 Safety Residual risks Hazard Course of action Check note Notes √ done - Not applicable Impermissible usage Provide operating in- German Ordinance on (improper usage) structions Industrial Safety and Health (BetrSichV) and German Health and labour protection law (ArbSchG) Written notice of in- German Ordinance on struction to driver Industrial Safety and...
Page 48: Danger To Employees
Safety Residual risks Hazard Course of action Check note Notes √ done - Not applicable DGUV rule 113-001 and observe the oper- ating instructions When operating driverless transport systems Roadway quality inad- Clean/clear roadways German Ordinance on equate Industrial Safety and Health (BetrSichV) Loading equipment in- Reposition load on pal-...
Page 49 Safety Residual risks The design and equipment of the truck comply with the standards and directives required for CE conformity. The design and equipment al- so comply with the standards and directives necessary for the UKCA compliance that is required in the United Kingdom. The design and equipment are therefore not part of the required scope of the hazard assessment.
Page 50: Safety Tests
Safety Safety tests Safety tests Carrying out regular inspections  on the truck The operating company must ensure that the truck is checked by a specialist at least once a year or after particular incidents. As part of this inspection, the technical condi- tion of the truck must be completely tested with regard to accident safety.
Page 51 Safety Safety tests The exact procedure for this insulation testing is described in the workshop manual for this truck. NOTE The truck's electrical system and drive batter- ies must be checked separately. Test values for the drive battery Recommended Nominal volt- Component Measurements Test values...
Page 52: Safety Regulations For Handling Consumables
Safety Safety regulations for handling consumables Safety regulations for handling consumables Exhaust gases CAUTION Risk to health from exhaust gases! Exhaust gases from internal combustion engines are harmful to your health. In particular, the soot particles contained in the diesel exhaust gas can cause cancer. Letting the combustion engine idle runs a risk of poisoning from the CO, CH and NO components contained in the...
Page 53: Safety Regulations When Driving
There is a risk of accident! – Do not use devices during travel or when handling loads. – Set the volume so that warning signals can still be heard. 5001 801 1624 EN - 07/2024 - 04 43...
Page 54: Visibility When Driving
Safety Safety regulations for handling consumables 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 The driver must look in the drive direction and have a sufficient view of the driving lane.
Page 55: Permissible Consumables
Safety Safety regulations for handling consumables Permissible consumables Refer to the maintenance data table for the WARNING permissible substances necessary for opera- Consumables can be dangerous. tion. It is necessary to follow the safety regulations when handling these substances. Oils DANGER WARNING Oils are flammable!
Page 56: Hydraulic Fluid
Safety Safety regulations for handling consumables Hydraulic fluid WARNING ENVIRONMENT NOTE During operation of the forklift truck, hy- draulic fluids are pressurised and are Hydraulic fluid is a water-polluting substance! hazardous to your health. Always store hydraulic fluid in containers com- –...
Page 57: Non-Ionising Radiation
Safety Non-ionising radiation WARNING Battery acid contains dissolved sulphuric acid. This is corrosive. – When working with battery acid, use appropriate PSA (rubber gloves, apron, protection goggles). – When working with battery acid, nev- er wear a watch or jewellery. –...
Page 58 Safety Medical equipment 48 5001 801 1624 EN - 07/2024 - 04...
Page 59: Overview
Overview...
Page 60: General View Of Truck
Overview General view of Truck General view of Truck Lift Mast Adblue® filler Fuel filler 3, 4 Hydraulic cooler, Radiator Drive axle Radiator Grille Forks Counterweight Fork carriage Steer axle Lift cylinder Battery isolator Lift chains Battery compartment 50 5001 801 1624 EN - 07/2024 - 04...
Page 61: Safety Devices And Warning Labels
Made in China label (for export with CE/UK- label 'lwa 105dB cab with no glazing Label,read the operating manual Importer (for UK) Diesel oil indicator sticke Still logo label 'adblue Tyre pressure label label 'SAE 10W-30 Nameplate label 'BATTERY ISOLATOR Still logo “Do not stand under forks”...
Page 62: Control Components
Overview Control components Control components Steering wheel Horn Turn indicator Handhold Key switch/start switch Accelerator pedal Heater control (climate control) Brake pedal Storage area Clamping screw for steering column adjust- Direction lever ment Central control levers (joysticks) Multiple function electrical control lever Driver control unit (optional) Emergency off switch Parking brake switch...
Page 63: Switch Panel
Overview Switch panel Switch panel The switch panel is mounted at the top right Roof panel wiper - intermittent mode or con- tinuous operation on/off (washer system is of the overhead guard. activated) Terminal board light and interior lighting Rear window heating Standard or higher lighting Strobe beacon Working spotlight position 1/2...
Page 64 Overview Switch panel 54 5001 801 1624 EN - 07/2024 - 04...
Page 65: Operation
Operation...
Page 66: Service Plan Before Initial Commissioning
Operation Service plan before initial commissioning Service plan before initial commissioning Engine Fill up with fuel Check engine oil level Check engine coolant level Fill with Adblue® and check for leaks Drive mechanism and transmission system Check the oil level in the gearbox Check the level of drive axle oil.
Page 67: Pre-Shift Check Item
Operation Pre-shift check item Pre-shift check item Engine Check fuel level Check AdBlue® fluid level Check engine oil level Check engine coolant level Check the forklift for leaks (visual inspection) Visually inspect whether the engine emits black smoke. If there is black smoke, contact an authorised service partner immediately.
Page 68: Standard Equipment
Operation Standard equipment Standard equipment Entering and exiting the truck Entering the cab – Open the cab door. Both left and right cab doors are equipped  with gas springs to limit movement when the cab door is fully open. –...
Page 69: Driver's Cab
Operation Standard equipment Driver's cab Opening the cab door – Push handle (3) upwards.  – Open driver's door outwards. Secure the cab's door – Open the door.  – Open the door fully rearward until spring loaded plunger(8) locks into retainer(9). –...
Page 70: Tilt Cab_Face Lift
Operation Standard equipment Follow a similar procedure to close the side window. Opening the quarter window – Pull the lever (5) forwards.  The window will open. – Push the lever (5) backwards. The window will close. Tilt Cab_Face Lift The cab can be tilted forward to allow access to the engine compartment.
Page 71 Operation Standard equipment – Switch off the engine and exit the cab. – Remove any loose components from the cab. – Open the battery case, the switch is inside the battery case. – Push electrical switch (1) to tilt the cab fully ...
Page 72 Operation Standard equipment To lower the cab – Remove strut rod (3) from the trough and  return it to its original position. – Push lowering button (2) of the electrical  switch to lower the cab into working posi- tion.
Page 73: Standard Driver's Seat And Comfort Driver's Seat
Operation Standard equipment Standard driver's seat and com- fort driver's seat WARNING Risk of accident when adjusting the seat during trav- el. Back injury possible due to incorrect seat adjust- ment. Do not adjust the driver's seat while driving. – Before starting up the truck and whenever chang- ing drivers, adjust the seat for the individual weight of the driver.
Page 74 Operation Standard equipment Setting the driver's weight  NOTE The relevant driver's weight must be set when the driver's seat is occupied. – Check the weight setting in the inspection window (4). The correct driver's weight has been set when the arrow is in the centre position in the in- spection window (4).
Page 75: Luxury Driver's Seat With Automatic Weight Setting
Operation Standard equipment Activating the seat heater (only with a  comfort driver's seat) Variant 1 – Push the switch (6) downwards to activate the seat heater. – Push the switch (6) upwards to deactivate the seat heater. NOTE The maximum temperature is predefined. Variant 2 –...
Page 76 Operation Standard equipment Longitudinal adjustment  – Pull the lever (1) upwards. – Move the driver's seat backwards or for- wards on the rails to find the most comforta- ble position for the driver in relation to the steering wheel and the accelerator pedals. –...
Page 77: Adjusting The Lumbar Support
Operation Standard equipment Adjusting the lumbar support  NOTE The lumbar support enables the seat backrest contour to be optimally adapted to the driver's body. – Press button (6). The extent to which the upper area of the backrest is curved is adjusted individually. –...
Page 78: Adjusting The Armrest
Operation Standard equipment Luxury active driver's seat with auto-  matic weight setting The luxury active driver's seat is operated in the same way as the luxury driver's seat. The only difference is the way in which the seat heater is activated. Activating the seat heater (luxury active driver's seat) –...
Page 79: Adjusting The Steering Column
Operation Standard equipment comfortably supported and the joysticks (3) can be easily reached. – Tighten the clamping screw (1). Adjusting the steering column DANGER Safe driving is not guaranteed with the clamping screw open. Only adjust the steering column when the vehicle is stationary.
Page 80 Operation Standard equipment WARNING The seat belt must function perfectly. For this reason, the belt should not become twisted, trapped or tangled. The belt buckle and belt retractor should be protected from foreign bodies, damage and dirt. NOTE Driver's cabs with fixed closed doors or brack- et doors meet the safety requirements for driv- er restraint systems.
Page 81 Operation Standard equipment Fastening the seat belt – Pull the seat belt (2) smoothly out of the  retractor to the left. – Position belt over the lap, not over the stomach. – Snap the buckle guide (1) into place in the buckle (4).
Page 82: Display Unit-Parker
Operation Standard equipment Display unit-Parker Mast angle Engine error indicator light (low) Load weight display Engine error indicator light (high) Time display Speed gear Parking brake Fuel gauge Engine oil pressure warning light Urea gauge Preheat light Engine RPM gauge Engine oil level Driving speeds DEF alarm light...
Page 83: Engine Interface
Operation Standard equipment NOTE Versions of the display unit icon arrangement layout may vary due to continuous updates and improvements to the product. Display unit for reference purposes only, actual specifica- tions apply. Engine interface  When DPF requires regeneration, start regen- eration by pushing the (1) button on the dis- play unit.
Page 84: Starting And Stopping The Engine
Operation Standard equipment Hydraulic interface  Starting and stopping the engine Starting the engine DANGER Danger of poisoning! Do not leave the engine running in un- ventilated areas. NOTE Where possible, avoid frequently starting and stopping the engine over short periods of time, since this prevents the internal combustion en- gine from reaching its operating temperature.
Page 85 Operation Standard equipment – Move the actuating lever (joystick and drive  direction (15)) into the neutral position. – Apply park brake (if not already applied) by  pressing park brake switch (1) – Insert ignition key into the ignition and start- ing switch and turn it from the zero position to position "I".
Page 86 – Then try to restart. To protect the battery, wait at least one minute between each starting procedure. If the engine still does not start after a third attempt to start it, refer to the section entitled "Troubleshoot- ing - diesel engine".
Page 87 Operation Standard equipment Switching off the engine CAUTION For engines with a turbocharger, there is a risk that the high speed of the turbocharger shaft (≥ 100,000 rpm at full load) could cause the shaft bear- ing to run dry through lack of lubrication, thus dam- aging it.
Page 88: Emergency Off Switch
Operation Standard equipment Emergency off switch  The emergency off switch can only be used in emergency situations and must not be discon- nected during emergency stops. WARNING Risk of accident. When the emergency off switch(1) is pressed, the parking brake is automatically applied, causing the vehicle to come to an emergency stop.
Page 89: Driving
Operation Standard equipment Driving CAUTION Risk of truck tip over. Before driving on steeper slopes, consult your serv- ice partner. Travel on long slopes over 15% is not allowed as a rule due to the prescribed minimum brake applications and truck stability characteristics. The climbing ability rates given in the technical datasheet were derived from the tractive force of the truck and they apply only for crossing...
Page 90 Operation Standard equipment When driving, ensure that the road ahead is clear. If goods obstructing vision are being transpor- ted, drive the truck with the load trailing. If this is not possible, a second person shall walk in front of the truck as a guide. The truck should then only be driven at walk- ing speed with particular caution being ex- ercised.
Page 91: Joystick With Central Lever Operation
Operation Standard equipment NOTE Stop the truck before driving in reverse. Stopping – Release accelerator pedal (4) and press the brake pedal. – When dismounting from the truck with the engine running, for example, in order to briefly perform some action in close vicinity to the truck (opening a gate, unhitching a trailer etc.), always apply the parking brake using switch (3) and release the seat belt.
Page 92 Operation Standard equipment Operating the lifting and tilting equip-  ment NOTE On the version with central lever operation, moving the joystick to an intermediate position (approx. 45°) will activate both functions at the same time (e.g. lifting and tilting). –...
Page 93: Operating Attachments
Operation Standard equipment Tilting the lift mast forwards  – Push the joystick (1) forwards. Tilting the lift mast backwards – Pull the joystick (1) backwards. Operating attachments Attachments can be fitted to the truck as spe- cial equipment (e.g. sideshift, fork prong posi- tioner, clamp etc.).
Page 94 Operation Standard equipment Operating the sideshift  NOTE To prevent damage, do not operate the side- shift when the fork arms are on the ground. – Push the joystick (2) to the left. The sideshift moves to the left. – Push the joystick (2) to the right. The sideshift moves to the right.
Page 95: Operating The Rotator
Operation Standard equipment Operating the rotator (optional equip-  ment) DANGER Stability jeopardised. Only pick up loads such that they can be turned in the load centre of gravity. If loads are picked up off-centre, the residual load capacity may be exceeded when making a turning movement.
Page 96 Operation Standard equipment Operating the clamp (optional equip-  ment) DANGER Increased risk of accident from a falling load. For attachments that hold a load by exerting pres- sure on it (e.g. a bale clamp), a lockable joystick must be used. If your truck is not fitted with this equipment, please contact your service partner.
Page 97: Joystick With Single Lever Operation
Operation Standard equipment Joystick with single lever opera- tion WARNING There is a risk of becoming trapped be- tween parts due to the moving lift mast or attachment. Never reach into or enter the lift mast or the area between the lift mast and the truck.
Page 98 Operation Standard equipment Lifting the fork carriage  DANGER When lifting and lowering the fork arms, there is an increased risk of falling and crushing. Do not step onto the raised fork arms. – Pull the joystick (1) backwards. Lowering the fork carriage –...
Page 99 Operation Standard equipment CAUTION Danger of instability of the truck. Attachments that are not supplied with the truck may only be used if the service partner has confirmed that the arrangement in terms of load capacity and stabili- ty ensures safe operation. Attachments alter the load capacity and stability of the truck.
Page 100 Operation Standard equipment Operating the fork positioner  NOTE To prevent damage, do not operate the fork positioner with a load or when the fork arms are on the ground. Do not use the fork posi- tioner as a clamp. –...
Page 101: Steering
Operation Standard equipment – Push the joystick (5) forwards.  The truck moves anti-clockwise. – Pull the joystick (5) backwards. The truck moves clockwise. Operating the clamp (optional equip-  ment) DANGER Increased risk of accident from a falling load. For attachments that perform a clamping function (e.g.
Page 102: Horn
Operation Standard equipment CAUTION NOTE Risk of accident. To avoid unnecessary tyre wear, turn the Do not rely on the steering wheel position. steering only when the truck is moving. Contact your service partner if steering re- If the steering wheel is turned to the left three quires too much effort or if there is too much times quickly, and then three times to the right play in the steering.
Page 103: Parking Brake
Operation Standard equipment WARNING This action should only be attempted in an emergen- cy and could result in the truck becoming unstable and / or the loss of load from the fork arms. Parking brake  The parking brake is operational at speeds below 3 km/h, the switch (1) is mounted in the front of the armrest.
Page 104: Particulate Filter Regeneration
Operation Standard equipment NOTE The interval time can be adjusted. Contact your service partner to do the adjustment. CAUTION Danger of personal injury and damage to the truck. Always check that the park brake (manual or auto- matic) is applied before leaving the truck. CAUTION Danger of personal injury and damage to the truck.
Page 105 Operation Standard equipment Passive regeneration Passive regeneration takes place when the exhaust gas temperature naturally increases enough such that the soot collected by the af- tertreatment diesel particulate filter (DPF) oxi- dises faster than the soot can be collected. Passive regeneration usually occurs when the truck is travelling at high speeds and/or under heavy loads.
Page 106 Operation Standard equipment Thus, if dust has built up in the particulate  filter, manual regeneration must be performed once engine regeneration indicator light (1) start flashing. NOTE Regeneration must be performed as soon as possible after a warning has been issued. This extends the service life of the particulate filter.
Page 107 Operation Standard equipment plastic, fabric, compressed air canisters, hy- draulic lines, etc.). Ensure that there are no gases or vapours ● in the vicinity that could burn, explode or cause a fire (e.g. liquefied petroleum gas [LPG], petrol vapours, oxygen, nitrous ox- ide).
Page 108 Operation Standard equipment Starting regeneration – Press the display instrument starting regen-  eration button (1), the manual regeneration indicator light (2) will turn on and remains Once manual regeneration has been initi- ● ated, the engine speed will increase and the turbocharger noise will increase.
Page 109: Override Switch
Operation Standard equipment – Release the parking brake. – Actuate the accelerator pedal or joystick. NOTE After interrupting regeneration, regeneration must be requested again. Override switch  The forklift management system will detect a fault in the system, force the forklift into "fault protection"...
Page 110: Window Heater
Operation Standard equipment Window heater Switching on the rear window heating – Press push button (1).  Dummy (2) test. – Dummy (1) test. The rear window heating is switched off. – Dummy (1) test. The rear window heating is in operation for a further 15 minutes.
Page 111 Operation Standard equipment Manual heating operation Push button (4) for automatic operation must  be switched off. Switching on the heating system – Turn the turning knob (5). The blower is switched on and the air flow is set to the selected level. Normal heating operation: –...
Page 112 Operation Standard equipment CAUTION If the function display (2) flashes five times after switching on and then goes out, there is a malfunc- tion affecting the automatic heating. Contact your service partner. Switching off heating operation – Turn the turning knob (5) to level 0. The heating operation is switched off.
Page 113 Operation Standard equipment Operating devices for heating/air condi-  tioning operation Cab air nozzle (7) ● Function display (8) ● Turning knob (9) for setting the vent posi- ● tions: window defrosting − footwell ventila- tion Push button (10) for switching the automatic ●...
Page 114 Operation Standard equipment NOTE Condensation water in the evaporator can cre- ate a musty smell. Switching off the air condi- tioning ten minutes before completing the jour- ney and keeping the blower running will dry out the condensation water, thus preventing the musty smell.
Page 115 Operation Standard equipment Automatic air conditioning operation – Use the turning knob (14) to adjust the tem-  perature. – Presh the push button (10). The automatic air conditioning is switched on and the function displays (8) and (13) illumi- nate in green.
Page 116 Operation Standard equipment NOTE A significant difference between the internal temperature and the outside temperature in- creases the physical stress put on the driv- er. To reduce the risk of illness, the differ- ence between the internal temperature and the outside temperature must not exceed six degrees.
Page 117 Operation Standard equipment Automatic heating operation The push button (12) for the air conditioning  must be switched off. – Use the turning knob (14) to adjust the tem- perature. – Press the push button (10) and then press the push button (12). The automatic heating is switched on and the automatic air conditioning is switched off.
Page 118: Battery Access - Opening
Operation Standard equipment NOTE When the automatic air conditioning or the automatic heating is switched on and the po- sition of turning knob (11) is set to level 0, the position of turning knob (11) for the blower level must first be changed and then turned to level 0 to switch off heating/air conditioning operation.
Page 119: Trailer Coupling
Operation Standard equipment Trailer coupling  NOTE The trailer coupling should only be used to tow light trailers inside the plant working area. – Lift tow pin (1). – Place towbar in coupling recess. – Push tow pin (1) down to engage the draw- bar and the lower retaining hole.
Page 120: To Tow The Truck
Operation Standard equipment To tow the truck Caliper body Piston O-ring seal Thrust bolt Circlip Magnet Wrench (24/30 mm) Friction pad Screw-cap Friction pad Allen key wrench (8/10 mm) Guide bolt Adjusting screw Split-pin Lock-nut Castellated nut Spring stack Bleed nipple NOTE Read and understand this maintenance pro- cedure before starting any work.
Page 121 Operation Standard equipment hydraulic systems and movement of heavy ve- hicles. It is the responsibility of all personnel concerned with these procedures to maintain safe working practices. NOTE Unless otherwise stated all component parts must be inspected at disassembly for re-use if serviceable.
Page 122: Emergency Exit
Operation Standard equipment hand tight to protect the mechanism from contaminants. NOTE Before the truck can be used, the parking brake must be re-adjusted - refer to the train- ing manual. Emergency exit The right side cab door can be used as the emergency exit.
Page 123: Optional Equipment
Operation Optional equipment Optional equipment Drive controller  NOTE The truck status display unit can be navigated in two ways, described below is using the but- tons on the armrest. The drive controller is operated using the rota-  ry/push button (2), the "Back" button (1) and the "Switch"...
Page 124 Operation Optional equipment Pressing the rotary/push button  Briefly pressing the rotary/push button allows the following actions to be carried out: Select menu item ● Activate or deactivate a function ● Acknowledge a message ● Pressing the rotary/push button for longer than two seconds activates the following functions: Program position (tilt angle, lift height, lift ●...
Page 125: 5100 040 Multifunction Joystick
Operation Optional equipment 5100 040 Multifunction Joystick Joystick 4Plus modular concept (Elo-  bau) KION Basis Module Multifunction Lever Multifunction Lever with housing for Coun- terbalance trucks Multifunction Lever with housing for Reach trucks Electronic Module with CAN Actuation buttons ...
Page 126: 6240 005 Load Weight Display (The Weight Error Of (+ / - 100 Kg))
Operation Optional equipment Controlled axes  Power Supply Operating voltage (min.) Nominal Voltage 12V / 24V Operating voltage (max.) Power consumption 1,8W (max.) Multifunction Lever Environmental specification Environmental Conditions Protection class IP65 (mounted) Storage Temperature -35°C to +85°C Environmental temperature -35°C to +75°C Suitable for cold store application...
Page 127: Forklift Information Management
Operation Optional equipment NOTE Reliable display of the load weight cannot be guaranteed for light loads of less than 100 kg. Forklift information management Access control PIN  The forklift data acquisition (FDE) input device (1) is located in the armrest console (3). The input device has a 12-digit keypad (2).
Page 128 Operation Optional equipment – Press the button (8) (or any other Reset  button) to activate the input unit from stand- by mode NOTE If a number button is pressed to activate the device, this number is registered as the first digit of the PIN.
Page 129 Operation Optional equipment – Turn rotating knob (9)to switch setting "II"  and start the engine NOTE If the forklift does not start correctly the first time, you can start it again before rotating knob (9) returns to zero. The PIN code will not be kept once the delay time has elapsed.
Page 130 Operation Optional equipment Activate the power supply:  – Press and hold the button (7) for Log in/ESC more than 2 seconds. LED (5) lights up yellow, and LED (6) flashes green. – Turn rotating knob (9) to switch setting "0" The engine is switched off.
Page 131 Operation Optional equipment – Press the button (8) (or any other Reset  button) to activate the input unit from stand- by mode NOTE If a number button is pressed to activate the device, this number is registered as the first digit of the PIN.
Page 132 Operation Optional equipment – Turn rotating knob (9)to switch setting "II"  and start the engine NOTE If the forklift does not start correctly the first time, you can start it again before rotating knob (9) returns to zero. The PIN code will not be kept once the delay time has elapsed.
Page 133: Status Code
Operation Optional equipment Activate the power supply:  – Press and hold the button (7) for Log in/ESC more than 2 seconds. LED (5) lights up yellow, and LED (6) flashes green. – Turn rotating knob (9) to switch setting "0" The engine is switched off.
Page 134 Operation Optional equipment – Press button (8). Reset  – Log in again with status message (prob- lem with driving) Access Control RFID Dual  The forklift data acquisition (FDE) input device (1) is located in the armrest console (3). The input device features a reading area (10) onto which the corresponding transponder (chip or magnetic stripe card) must be placed.
Page 135 Operation Optional equipment Log in and start the engine:  – Apply the parking brake. – Open the armrest support (4) sideways to the right – Place the valid transponder onto the read- ing area (10). Data is read in, and LED (5) and LED (6) both light up green.
Page 136 Operation Optional equipment Switch off the engine and log out:  CAUTION Unwarranted use by unauthorised personnel. When parking and leaving the forklift, the driver must log out. – Apply the parking brake. – Open the armrest support (4) sideways to the right –...
Page 137: Led Status Display
Operation Optional equipment NOTE If another valid transponder is placed on the reading area within 60 seconds, the engine can be started again. LED status display Function: LED (5) LED (6) Standby mode LED (6) flashes green al- LED (5) flashes green al- Input prompt: PIN/transponder ternately ternately...
Page 138 Operation Optional equipment Switching on the terminal board and in-  terior lighting – Move the toggle switch (1) to the centre position. The terminal board lighting is switched on. – Switch the toggle switch (1) as far as it will The interior lighting (7) is switched on.
Page 139 Operation Optional equipment Switching on the lighting  – Move the toggle switch (2) to the centre position. The sidelights and licence plate lamp are switched on. – Switch the toggle switch (2) as far as it will The dipped beams, sidelights and licence plate lamps are switched on.
Page 140: Lighting Options
Operation Optional equipment Switching on the direction indicators  – Push lever (10) up. The direction indicators flash on the right of the truck. Indicator (11) flashes. – Push lever (10) down. The direction indicators flash on the left of the truck.
Page 141 Operation Optional equipment Open the rear lights only – Press the toggle switch(4)  6100 015 Rear lights only ● 6100 020 Rear lights only (with stone ● guards) Open the mast mounted front facing lamps NOTE According to the height of the frame, the mast lamp has different positions for the customers to choose.
Page 142 Operation Optional equipment Open the step lights – Version 1: press the toggle switch next to  the pedal (1)； – Version 2: Press the toggle switch(12)。  6106 005 Step lights ● 6106 010 Step lights (LED) ● NOTE There are two ways to open the step lights, the toggle switch next to the pedal and toggle switch on the panel.
Page 143: Bluespot Tm
Operation Optional equipment BlueSpot NOTE Customers can choose Bluespot Front & Rear or Bluespot Rear according to the needs . The BlueSpot comprises a visual warning  unit that enables the early detection of trucks in driving areas with low visibility (such as drive lanes and high racks), as well as at blind junctions.
Page 144: Power
Operation Optional equipment Version 2（When choosing 7118 015 Blue- spot Front & Rear） – Move the toggle switch (7)  Switch settings for the toggle switch : Level 0: BlueSpot OFF ; ● Level 1: BlueSpot ON . ● NOTE If the truck is to be operated on public roads, the BlueSpot must be switched off.
Page 145: Power
Operation Optional equipment 24v Power  The optional types are as follows : 4412 015 1x24V - 20mm ● 12/24v Power  The optional types are as follows : 4412 030 2x12/24V - 20mm ● 5001 801 1624 EN - 07/2024 - 04 135...
Page 146: Mechless 1Din Truck Radio With Usb/Aux/Bluetooth
Operation Optional equipment Mechless 1DIN truck radio with  USB/AUX/Bluetooth 4401 005 FM Radio/USB/Bluetooth ● 4401 010 FM Radio/CD/USB/Bluetooth ● 4401 015 DAB Radio/USB/Bluetooth ● Robust mechless 1DIN 24 Volt truck radio with USB(2x)/Bluetooth/AUX Fixed panel with well legible LCD display Ideal for trucks due to 24 V direct connection Clear, lucid and easy to use.
Page 147: 4470 005 Cab Vent Fan 24V
Operation Optional equipment MP3 ID3 display: track, artist, album MP3 folder and file display MP3 song/file/character search 4 channels x 40 W (max.) Rotary control for volume System EQ PLL tuner with 18 FM and 6 AM presets 2 channels x 2 V line-out ISO terminal, 24 Volt direct connection Phone mute Last memory...
Page 148: 4460 005 Illuminated A4 Clipboard
Operation Optional equipment 4460 005 Illuminated A4 clip-  board Illuminated A4 clipboard Open the illuminated A4 clipboard – Press the toggle switch(1)；  – The light on the side of illuminated A4 clip-  board (1) is bright. 138 5001 801 1624 EN - 07/2024 - ...
Page 149: 4210 010 Buddy Seat
Operation Optional equipment 4210 010 Buddy seat  The buddy seat(1)is located in the right rear of the cab. 4480 005 Storage unit Includes document holder(1), additional stor- age(3) and cup holder(2). Document holder  This document holder has a lighting function. Document holder 5001 801 1624 EN - 07/2024 - ...
Page 150: 4450 005 With Cup Holder
Operation Optional equipment Additional storage and cup holder  Cup holder Storage 4450 005 With cup holder  NOTE When the cup holder and the fire extinguisher is all needed , The cup holder is placed on the door frame on the left of the cab. With cup holder 4202 085 Deluxe Fabric Height Adjustable Heated Suspension...
Page 151 Operation Optional equipment Mechanical lumbar support; Seatbelt with orange webbing and buckle switch; Seat switch (operator presence detector); Fore-and aft adjustment: 210 mm; Seat heating Backrest angle measured 12°，seat angle measured 6° WARNING Incorrect seat adjustment may cause injury to the driver's back.
Page 152 Operation Optional equipment Adjusting the seat backrest  – Pull the lever (2) up and hold. – Swivel the seat backrest (1) forwards or backwards to find a comfortable seat posi- tion for the driver. – Release the lever (2). e3871497a Adjusting the backrest extension ...
Page 153 Operation Optional equipment Setting the driver's weight  NOTE The individual driver's weight must be set when the driver's seat is under load. – Sit on the driver's seat. – Check the weight adjustment in the inspec- tion window (1). The correct driver's weight has been set when the arrow is in the centre position in the in- spection window (1).
Page 154: Adjusting The Driver's Seat With Rotating Device
Operation Optional equipment Adjusting the lumbar support  The lumbar support enables the seat backrest contour to be adapted as effectively as possi- ble to the driver's body. – Turn the turning knob to the left or right. The extent to which the lower and upper areas of the backrest are curved is adjusted individu- ally.
Page 155: Safety Equipment
Operation Optional equipment CAUTION The driver's seat must not swivel while the industrial truck is in use. It should therefore be ensured that the rotating de- vice is locked. The driver's seat with rotating device offers better rear visibility during reverse travel over long distances.
Page 156: Fire Extinguisher In The Cabin
Operation Optional equipment 7105 010 Absent Driver Shutdown Before the factory, the system is set to the driver no longer seat for 3 minutes, the engine automatically stops turning. and forklift flame- out. 7105 015 Seatbelt Sequence Interlock – Open the key switch to the 1 Level when the driver sits on the seat.
Page 157: Fire Suppression System
Failure protection function: Function mod- ● ules isolated from each other, even if the switch occurs functional failure, the system still ensure the effectiveness of the manual- ly start function. 7110 010 Automatic fire suppression  system 5001 801 1624 EN - 07/2024 - 04...
Page 158 Operation Optional equipment Maintenance  The blasting fuse of the fire suppression sys- tem should be checked whether ageing when doing the regular maintenance. 148 5001 801 1624 EN - 07/2024 - 04...
Page 159: 6310 005 Tire Pressure Monitoring System
Operation Optional equipment 6310 005 Tire pressure monitor- ing system The monitor is fixed on the right side in the  cabin. Programming of Monitor Programming of Transmitter ID NOTE If the user wants to program a new transmit- ter into the monitor, the operation should be finished in programming mode.
Page 160 Operation Optional equipment – Once finish programming of the first digit,  press → to start programming the second digit which flashes. Press up or down arrow key to adjust the number. – Press → again to program the third digit ...
Page 161 Operation Optional equipment – Once finished programming the first num-  ber, press → to program the second digit which flashes and then press up or down arrow key to adjust the value to 0. – Once finished programming the second ...
Page 162 Operation Optional equipment – Press the ↓ key to access the third inter-  face, 312 stands for 12th day. – Press the ↓ key to access the fourth inter-  face, 416 stands for 16 O’clock. – Press the ↓ key to access the fifth interface, ...
Page 163: System Function
Operation Optional equipment At this time, press up or down arrow key to  switch to the pressure unit interface. – Under any interface displaying temperature or pressure, press S key for 3 seconds to start programming. Take change the tem- perature unit as an example: under the tem- perature unit interface, press S key for 3 seconds, the temperature unit “℃”...
Page 164 Operation Optional equipment – High Pressure Alarm  Function： the system will issue the high pressure alarm when the tire pressure is 25% higher than the standard. Alarm mode: the alarm lamp flashes, high pressure warning icon, tire position icon and the audible alarm turn on together.
Page 165 Operation Optional equipment the alarm lamp flashes, low pressure level 2 alarm icon, tire position icon and the audible alarm turn on together. Treatment: press any key to stop the audible alarm. The red alarm lamp remains on and the display reverts to the normal mode.
Page 166 Operation Optional equipment – Quick Leak Alarm  Function: the system will issue a quick leak alarm when the pressure drops more than 2.8 psi within 12 seconds. Alarm mode: the alarm lamp flashes and the audible alarm turns on, the tire position icon flashes. Treatment: press any key to stop the audible alarm and the system reverts to normal mode.
Page 167 Operation Optional equipment – Under normal mode or pressure inquiry in-  terface, press P and S at the same time for 3 seconds to access the alarm record inquiry interface. The screen with “0” is the most recent alarm record. –...
Page 168 Operation Optional equipment Time (month)  Time (date)  Time (hour)  Time (minute)  Then it will display the next alarm record in the same way as above. – Press P and S at the same time to exit. 158 5001 801 1624 EN - 07/2024 - ...
Page 169: Tyre Pressure Detection System (New)
Operation Optional equipment Tyre pressure detection system  (new) External sensor Host Repeater Product installation status  The sensor is external and can be locked ● onto the valve, resolving the issue of being unable to install a built-in sensor on the tyre valve.
Page 170 Operation Optional equipment Pressure 0–12 bar range Pressure ac- ±0.1 bar curacy Temperature ± 1℃ accuracy Sensor installation – Unscrew the valve dust cap.  – Screw on the anti-tamper hexagon nut.  160 5001 801 1624 EN - 07/2024 - 04...
Page 171 Operation Optional equipment – Screw on the sensor.  – Close the hexagon nut by turning in the op-  posite direction. NOTE After installing, spray with soapy water to check for leaks. 5001 801 1624 EN - 07/2024 - 04 161...
Page 172 Operation Optional equipment Replacing the battery – Remove the anti-tamper shim.  – Use a cover-opening wrench to open the  external cover. 162 5001 801 1624 EN - 07/2024 - 04...
Page 173: Product Introduction
Operation Optional equipment – Replace with a new button cell battery.  – Re-install the sensor.  Product introduction – The host is connected to the on-board ACC power supply. – Press and hold “◄”+“►” to turn on and off. –...
Page 174: Setup Options
Operation Optional equipment – In standby mode, press and hold “SET” for 3 seconds. The system will beep twice and then enter setup mode. – In setup mode, press and hold “SET” for 3 seconds. The system will beep four times and then exit setup mode.
Page 175 Operation Optional equipment – Upper temperature limit: after entering set-  up mode, press “SET” again twice, as shown in the figure: when the temperature “75” flashes, press “◄” or “►” to select the temperature value. – Switching tyres (use with caution): in stand- ...
Page 176: 7330 015 Reversing Warning System
Operation Optional equipment 7330 015 Reversing warning  system The reversing warning system is consist of buzzer, controller, sensors. Segmented regions are close to the obstacle distance: 150CM security zone ● 120CM security zone ● 100CM warning area ● 80CM warning area ●...
Page 177: 1390 010 Plastic Wheel Stud Covers With Movement Indicator
Operation Optional equipment 6433 010 The buzzer is installed at the rear of  the driver cabin. 1390 010 Plastic wheel stud  covers with movement indicator Plastic wheel stud covers with movement indi- cator(1) can prevent bolts from rusting Operating optional attachments Attachments can be installed as optional equipment.
Page 178: Coil Boom
Operation Optional equipment NOTE Affix a label indicating the truck load capacity with attachment, and a symbol label of the respective attachment on the windscreen to the right of the driver for every attachment. Symbols on the label can vary, depending on the controlled function.
Page 179 Operation Optional equipment – Observe labels (2) on coil boom (3) for load  centre and load lift height information. – This is another flat face carrier mounted  kind of coil boom. 3670 105 FF Coil boom - 1000 mm ●...
Page 180: Cold Climate Options
Operation Optional equipment Cold Climate Options  NOTE All mains powered heating devices are 220v rated, and the truck will come supplied with a suitable 110/220v converter when required. Engine Pre-heater Hydraulic Oil Pre-heater Battery Heaters Diesel Fuel Heater Cabin Pre-heater Engine Pre-heater ...
Page 181 Operation Optional equipment Hydraulic Oil Pre-heater  6407 010 Hydraulic oil heater - 500 W ● 6407 020 Hydraulic oil heater - 1000 W ● 220v Depending on tank size 6403 010 Battery Heaters  220v, 190w (x4) Self-adhesive Silicone Mats Size - 300x100x1.5mm.
Page 182 Operation Optional equipment 6404 010 Diesel Fuel Pre-filter  24v, 350w. Heater cartridge with internal temperature controlled switch. Cabin Pre-heater NOTE There are two options to preheat the cab. The first selection: Cab Pre-heater. 4409 010 Cab Pre-heater 220 V ●...
Page 183 Operation Optional equipment – Use Oval timer to set heating time, please  see below for Oval timer operation. Operation: – Operation of the timer is designed so that the symbols flash rapidly in the setting mode. If no button is pressed within 5 sec- onds, the displayed time will be saved.
Page 184 Operation Optional equipment – Press the (4)button. Press the "Forward"(2) or "Reverse"(1) buttons within 10 seconds until the required time for starting heating operation is displayed. – If a different program number is required, the(4) button must be pressed within 10 seconds.
Page 185: Mains Power Connection
If required, a 110/230v converter secured and hidden above battery box, and remains with truck. CAUTION All trucks are fitted with “Safety Cut-out Relay” to stop the engine being started when pre-heaters are still connected to the mains electricity. 5001 801 1624 EN - 07/2024 - 04 175...
Page 186 Operation Optional equipment Cold climate package instruction – This should be set before installed.  Electrify the temperature control switch, press "set" button for 3-5 seconds to enter setting page, adjust the number to 35°C by triangular button, then press "set" button to finish setting. Position : In battery box.
Page 187: 7306 005 Central Lubrication System - Steer/Mast/Tilt
Operation Optional equipment Circuit breaker should be switched on in  the first time. Position : Under radiator The circuit breaker can cut off and connect the load circuit, and cut off the fault circuit, ensure the safe operation. In case of overloading or abnormal operation of electrical appliances, if a fault occurs, the circuit breaker will automat- ically turn off the switch to play the role of...
Page 188 CAUTION The automatic greasing system significantly reduces the time and effort spent on manual greasing. How- ever, do not forget that universal joints, for instance, must still be greased by hand. Periodic check Check the grease-pressure indicator (must ● be green) or the control lamp (must not be lit).
Page 189: User Instruction
Operation Optional equipment WARNING If you use a high-pressure air or water gun to clean the vehicle, do not spray directly onto the greasing system pump unit. Water oo dirt might enter the pump unit through the vent openings. User instruction The following is a description of the spreader ...
Page 190: Indicator Lights
Operation Optional equipment Indicator lights There are three indicator lights on the spread-  Green - ”LOCKED” (Both twist locks are com- pletly engaged and locked into the corner castings of the container.) It is safe to lift the container. Yellow - ”SEATED”...
Page 191 Operation Optional equipment other end of the spreader until the opposite twistlock is lined up with the corner. – Casting at the opposite end of the contain- er. The spreader should now be lowered un- til the spreader rests unsupported on the container with the twist locks in the corner castings.
Page 192: Maintenance Instructions
Operation Optional equipment light illuminates and then activate the twist locks to the Not Locked position. The twist locks will turn and the red indicator light for Not Locked will illuminate. It is now possible to lift the twist locks free of the corner castings and reverse the machine away from the con- tainer.
Page 193 Operation Optional equipment Position 2  End beam slider pads Check for wear and possible damage of the ● twistlook and twistlook sleeve replace if in doubt. Interval-every 500 HOURS ● No greasing necessary ● Position 3  Upper side shift slider pads and lower side shift slider pads Every 500 hours or check for wear of the ●...
Page 194: General Maintenance Instructions
Operation Optional equipment General maintenance instructions – The nylon wear pads should be inspected  for wear at the same time as their tracks are lubricated. The pads should be replaced when their thickness is reduced to minimum 18 mm. –...
Page 195 Operation Optional equipment – Should be replaced if this dim. is less  than 25mm, The drawing shows where the heads of the twist locks wear. When the worn part exceeds the area indicated by cross- hatching the twist locks should be replaced.
Page 196: Mounting Instructions For Lowering The Lifting Heads Into The End Beams Of 178 Series Spreaders
Operation Optional equipment Mounting instructions for lower-  ing the lifting heads into the end beams of 178 series spreaders. – To start with it is better to tie a 2 meter long piece of string round the hoses and cable that stick out of the bottom of the head and attach a nut to the other end of the string.
Page 197 Operation Optional equipment All chromed piston rods must be activated ● to the closed position so that the rods are stored inside the cylinder where this is pos- sible. If it is not possible to retract the rod into the cylinder (for example the twist- lock cylinders) then the exposed part of the chromed rod should be sprayed with a rust inhibitor similar to.
Page 198: Multifunctional Handle _ 178 Spreader
Operation Optional equipment Multifunctional handle _ 178 spreader 188 5001 801 1624 EN - 07/2024 - 04...
Page 199: Working With A Load
Operation Working with a load Working with a load Mast, lifting device and attachment controls lever is moved determines the lifting, lowering CAUTION and tilting speed. The control lever returns Danger of damage to the truck. to the neutral position automatically when re- Use the lifting device and attachments only for au- leased.
Page 200 Operation Working with a load DANGER Risk of loss of stability. The parameters on the capacity rating plate apply to compact and uniform loads. These load limits must not be exceeded. Exceeding the load limits will affect the stability of the forklift and the strength of the fork arms and lift mast.
Page 201: Label Example
Operation Working with a load and the vertical plane of the fork arms), the height of the gravity centre and the lift height. NOTE The capacity rating plate below is only an ex- ample. Label example:  Load centre of gravity distance 1700mm Lift height: 6500mm –...
Page 202: Additional Capacity Rating Plate
Operation Working with a load Additional capacity rating plate DANGER Risk of loss of stability. Using attachments will restrict the load capacity. Therefore, an additional capacity rating plate must be attached to a position that is visible to the driver. If the plate is missing, or if any information about the truck, attachments and load capacity does not match the actual value, please contact your service partner.
Page 203: Lifting A Load
Operation Working with a load DANGER DANGER Incorrectly positioned loads pose a risk of falling. Overloading and tipping hazard Loads should be arranged so that they do not project Strictly adhere to the permissible load indicated on beyond the truck loading area and cannot slip, topple the load rating plate.
Page 204: Travelling With Load
Operation Working with a load face, if possible. Do not touch adjacent loads. – Apply the parking brake. – Elevate the mast until the load rests on the forks. – Tilt the mast back slightly.  – Release the parking brake. –...
Page 205: Transporting Suspended Loads
Operation Working with a load – Always travel with the load uphill on up-  grades and down grades, never travel or turn across a slope. – If visibility is reduced work with a guide. – Operate the truck in reverse if the load be- ing transported is stacked so high as to ob- struct forward vision.
Page 206 Operation Working with a load DANGER Loss of stability! Slipping or swinging suspended loads can lead to a loss of stability and cause the truck to tip over. – When transporting suspended loads, observe the following instructions. Instructions for transporting suspended loads: Swinging of the load must be prevented ●...
Page 207: Deposit The Load
Operation Working with a load Deposit the load  DANGER There is a risk of accident when the lift mast is tilted forwards. The load's centre of gravity and the tilting moment may change when the lift mast tilts forwards or the load slides.
Page 208: Before Leaving The Truck Unattended
Operation Working with a load Before leaving the truck unatten-  – Deposit the load and lower the fork car- riage. – Tilt the mast to the vertical position, the forks must touch the ground. – Apply the parking brake. –...
Page 209: Loading/Transporting
Operation Loading/transporting Loading/transporting Hoisting the truck  NOTE When loading the truck by crane make sure nobody are within the working range of the crane! Only use hoisting equipment and load- ing crane with sufficient lifting capacity. For the truck weight see the manufacturer's name plate.
Page 210: Transporting The Truck
Operation Loading/transporting – Observe maximum sling angles when hoist-  ing the truck. Transporting the truck WARNING Danger of damage and personal injury. Do not step under the elevated load. – When loading the truck make sure a safe distance is observed. CAUTION Danger of damage.
Page 211 Operation Loading/transporting When transporting in a loader truck, heavy chains or ropes are required. In this case, six chains are usually sufficient to secure the fork- lift truck. – Six load chains are required to secure the  forklift truck. –...
Page 212 Operation Loading/transporting – Six load chains are required to secure the  forklift truck. Transportation by freight container When transporting the truck in a freight con- tainer, the mast must be removed. Secure the truck using ropes – Secure the front of the vehicle using 8 ...
Page 213 Operation Loading/transporting – As shown in the figure, attach 2 ropes to the  tie down points at the rear of the vehicle, cross over the ropes and attach them to the appropriate tie down points on the transport equipment. –...
Page 214 Operation Loading/transporting Using wooden wedges to immobilise the truck – Use wooden wedges (1) to immobilise the  front and rear of the vehicle. 204 5001 801 1624 EN - 07/2024 - 04...
Page 215: Decommissioning The Truck
Operation Decommissioning the truck Decommissioning the truck Measures before taking the truck out of operation If the truck is taken out of operation for over 2 NOTE months, it must be parked in a well ventilated, frost-free, clean and dry room and the follow- Do not use plastic foil as this enhances the ing measures must be carried out.
Page 216: Putting The Truck Back Into Service
Operation Decommissioning the truck Putting the truck back into service – Thoroughly clean the truck as described in NOTE the maintenance section of this manual. The digital clock display must be reset when- – Lubricate the truck. ever the battery isolator has been used. –...
Page 217: Disposal Of Old Trucks
Operation Decommissioning the truck Disposal of old trucks smeared parts, as well as for tyres including The disposal of old trucks is regulated in di- fire protection measures. Suitable storage rective 2000/53/EC from the European Parlia- tanks for fluids such as fuel, AdBlue® (urea ment and Council.
Page 218 Operation Decommissioning the truck 208 5001 801 1624 EN - 07/2024 - 04...
Page 219: Maintenance
Maintenance...
Page 220: General Maintenance
Maintenance General maintenance General maintenance Safety information regarding servicing work The truck will remain ready for operation at WARNING all times only if the small amount of servicing Risk of injury due to the doors falling shut. work is performed at regular intervals and in accordance with the information in the operat- Open doors and prevent them from closing.
Page 221: Recommended Consumables
Maintenance General maintenance Transmission Transmission oil Approx. 20 l Drive axle Gear oil Approx. 25 l Battery Maintenance free Maintenance free Tyres 10 bar 10 Wheel nuts 680 Nm Lift chains / mast chan- Chain spray As required nels Recommended consumables NOTE Using consumables of a lower grade than that recommended in the table may damage...
Page 222 Maintenance General maintenance CAUTION For the aftertreatment system to work properly, a diesel fuel with a very low sulphur content must be used. Failure to use an ultra-low-sulphur diesel fuel may cause damage to the aftertreatment system. We recommend using ASTM Grade 2D fuel. Optimum engine performance can be ach- ieved using Grade 2D diesel.
Page 223 Maintenance General maintenance 1. Any adjustments made to the fuel system ● to compensate for the decrease in perform- ance caused by the use of alternative fuels are not covered by the warranty. 2. The winter blend diesel fuel supplied by ●...
Page 224 Maintenance General maintenance NOTE All fuels permitted for use are required to have sufficient fuel lubricity. This means that the BOCLE measured using the ASTM D6078 Scuffing Load Ball-on-Cylinder Lubricity Eval- uator (SLBOCLE) should be 3100 or higher. The ASTM D6079 ISO 12156 High Frequency Reciprocating Rig (HFRR) can also be used to measure lubricity.
Page 225 Maintenance General maintenance Cummins is not responsible for any malfunc- tion or damage caused by illegal operation or negligence. These include, but are not limi- ted to, use of diesel exhaust fluid without the correct designation; lack of aftertreatment maintenance; improper storage or shutdown methods;...
Page 226 Maintenance General maintenance DEF has a certain shelf life, both in the die- sel exhaust fluid tank of the truck and in stor- age/bulk/transport containers. The following conditions are ideal for maintain- ing DEF quality and shelf life during long-term transport and storage: Storage temperature between -5°C and ●...
Page 227 Maintenance General maintenance NOTE Allow spilled diesel exhaust fluid to air dry or wipe only with a cloth. The spilled DEF will leave behind a white residue. Failure to prop- erly clean spilled diesel exhaust fluid may re- sult in an incorrect diagnosis of a leakage in the diesel exhaust fluid injection system.
Page 228 Maintenance General maintenance The concentration of the diesel exhaust fluid must be checked under the following condi- tions: The vehicle has been stored for a long peri- ● od of time It is suspected that water has been added ● to the diesel exhaust fluid tank.
Page 229 Maintenance General maintenance Engine oil grade CAUTION If the intervals for replacing the oil and filters are ex- tended in excess of recommended values, the serv- ice life of the engine will be reduced due to factors including corrosion, deposit build-up and wear. Using high-quality engine oil and changing the oil and filters at suitable intervals are key fac- tors in maintaining engine performance and...
Page 230 Maintenance General maintenance oil type. The middle part indicates the SAE oil viscosity grade. The following table shows how to compare CES to API grade. Notes Minimum oil CES-20081 CJ-4/SL grade re- quired. NOTE Engine oils that comply with API CJ-4/SL may not comply with the requirements of CES 20081.
Page 231 Maintenance General maintenance Viscosity of oil  Although the preferred viscosity grade is 15W-40, multi-grade oils with lower viscosities can be used in cold climates. Refer to the at- tached diagram. All oils with a viscosity grade below 15W-40 must also comply with CES 20081 requirements.
Page 232: Hydraulic Oil
Maintenance General maintenance Oil operating temperatures  °F °C + 86 + 30 The first recommendation is to use 15W-40 + 77 + 25 multi-grade oil for normal applications at am- + 68 + 20 10W-30 + 59 + 15 bient temperatures above -15°C [5°F].
Page 233 Maintenance General maintenance Only the above-mentioned oils are approved by the manufacturer. If other hydraulic oils are used or mixed, serious damage can result. Driveline oils Gearbox The recommended hydraulic oils are Shell Spirax S4 TXM and SAE 10W-30 UTTO。 Only use oils on ZF-List of Lubricants TE- ML 03 (see www.zf.com) for Powershift trans- missions 3 WG-116/131/161/171.
Page 234 Maintenance General maintenance Coolant Use of a fully proportioned antifreeze/coolant that comply with the Cummins Engineering Standard (CES) 14603 is recommended. Typically, antifreeze/coolants that comply with American Society for Testing and Materials (ASTM) 4985 (GM6038M technical specifica- tion) or ASTM D6210 can be used in engines covered in this manual.
Page 235: Common Rail Engine Safety Warnings
In the event of leakage, switch off the truck immedi- running. ately and contact a service partner. The pressure in the fuel system may still be as high Maintenance work on the engine must be carried out as several hundred bar, even after the engine has by authorised professional technicians.
Page 236: Service Plan
Maintenance Service plan Service plan Regular maintenance The following maintenance will help improve the forklift's condition and ensure it works properly. Operators shall carry out this maintenance work as often as possible, in accordance with the operating environment. Clean the forklift (as required). ●...
Page 237: Service Plan Table
Maintenance Service plan Service plan table Note on servicing work Servicing work requires specialised knowledge and special tools. Please contact an authorised service partner Preparations Clean the forklift as required. Check that all labels are complete and legible. Read out and delete error memory. Reset the maintenance interval Conduct maintenance after the first 100 hours of operation Engine...
Page 238 Maintenance Service plan Conduct maintenance every 750 hours of operation Engine Check the radiator cover Check the belt for wear or damage, replace as required Check the battery and battery cables Change the fuel filter Change the fuel pre-filter Change the engine oil and filter. Clean engine Check whether the engine emits black smoke.
Page 239 Maintenance Service plan Conduct maintenance every 1500 hours of operation (additional maintenance items) Check the drive axle and retaining bolts Check the steering axle hub Check and adjust the steer stops if necessary Check mounting of the steer axle and steering king pin Check the functionality of the braking system (park brake and driving brake) Chassis and bodywork Check the condition of the chassis mount...
Page 240 Maintenance Service plan Conduct maintenance every 2250 hours of operation (additional maintenance items) Engine Change the coolant Conduct maintenance every 3000 hours of operation (additional maintenance items) Engine Replace the turbocharger* Replace the air intake throttle valve* Change the common rail pipe* Change the injector* Change the injection pump* Replace the diesel oxidation catalyst (DOC)*...
Page 241 Use instruments to test the parts and components after 3000 hours of use or every 5 years. If they still meet the emission requirements, no replacement is needed. 5001 801 1624 EN - 07/2024 - 04...
Page 242 Maintenance Service plan 232 5001 801 1624 EN - 07/2024 - 04...
Page 243: Preparatory Tasks
Maintenance Service plan Preparatory tasks Clean the truck NOTE How often the truck needs cleaning depends on its use. If used with very aggressive media like salt water, fertilizer, chemicals, cement, etc., the truck should be cleaned carefully and more often. WARNING Danger of damage to the bearings Hot steam or intensive degreasing solutions should...
Page 244 Maintenance Service plan – Clean the chain using paraffin derivatives such as washing petrol, wear protective clothing and observe the manufacturer’s safety notes. – When using a steam jet, use without using additives. – After cleaning, blow dry the chain at once to remove any water in the chain links and on the surface.
Page 245: Engine
Maintenance Engine Engine Filling fuel CAUTION Danger of costly damage to the engine. Components that are damaged due to incor- rect fuel filling are not covered by warranty. Filling fuel CAUTION Risk of fire. Follow local regulations for handling diesel fuel. Stop the engine before filling fuel.
Page 246 Maintenance Engine Wear a protective mask for all service work carried out on the air intake system. CAUTION Risk of damage to the air filter. Do not clean the filter element. – Clean the filter casing with a damp cloth. If a warning message is displayed on the truck status display unit stating the air filter is blocked, stop the engine at once and renew...
Page 247: Coolant Level - Check
Maintenance Engine Coolant level - check Checking the coolant level CAUTION Risk of scalding! Do not remove the filler cap if the reservoir is hot or when the engine is running. Follow the instructions for handling fluids and lubricants. NOTE When the coolant level is too low or the cool- ant is too hot, the truck status display monitor will display a warning, coolant level must be...
Page 248 Maintenance Engine – Park the forklift on level ground. – Tilt the cabin. – Remove the dipstick from the engine. – Use a clean cloth to dry the dipstick. – Re-insert the dipstick, and remove it once  more. The oil level should be between the two marks on the dipstick.
Page 249: Radiator
Maintenance Engine CAUTION Running the engine when the oil level is below the L (low oil level) indicator or above the H (high oil level) indicator is strictly prohibited, as this can lead to a deterioration in engine performance or damage to the engine.
Page 250: Preparation Procedure
Maintenance Engine works as a vacuum. Use the following steps to measure the maximum inlet pressure and test the suction fuel filter. NOTE Some types of applications use the engine- mounted suction filter. Filling the fuel system: a certain amount of air will be introduced into the fuel system when servicing or changing fuel and/or high-pres- sure fuel system components.
Page 251: Installation
Maintenance Engine Removal WARNING Diesel fuel may be flammable, depending on the en- vironment. To reduce the risk of fire that could result in serious personal injury, death or property damage, do not allow smoking, sparks or open flames in the area (for example, beacons, electrical switches or welding equipment) when inspecting the fuel system, or performing maintenance or repairs.
Page 252: Final Steps
Maintenance Engine – The engine warning lights will come on if the water-on-fuel sensor is not compatible or is disconnected. Final steps WARNING Explosive gases may escape from the battery. To reduce the possibility of injury, make sure the engine compartment is well ventilated before carrying out maintenance on the battery.
Page 253 Maintenance Engine NOTE To prevent damage to the manual injection pump seals, electronics spray cleaner, or equivalent, and compressed air should be used to clean the fuel pump head and injec- tion pump before filling the fuel system. – After cleaning the filter or draining the fuel tank: ensure that there is fuel in the fuel tank.
Page 254: Oil And Filter
Maintenance Engine Oil and filter Discharge WARNING Some state and federal agencies in the United States have determined that used motor oils are carcinogenic and can cause reproductive diseases. Avoid inhaling oil vapour, accidental swallowing and prolonged exposure to used oil. If the oil is no longer used, it should be disposed of in accordance with local environmental regulations.
Page 255 Maintenance Engine Removal – Clean the area around the oil filter housing.  – Use the oil filter wrench to remove the oil filter. – Clean the surface of the filter housing gas- ket. NOTE The O-ring may be stuck to the filter base. Make sure this O-ring is removed before in- stalling a new filter.
Page 256 Maintenance Engine – Install the filter into the oil filter housing.  Tighten the filter until the seals touch the surface of the filter holder. – After the gasket touches the filter housing, tighten by a further 3/4 to 1 turn. Filling Clean and check the thread and sealing sur- face of the oil drain plug.
Page 257: Radiator Pressure Cap
Maintenance Engine NOTE Engine oil pressure must be displayed on the meter within 15 seconds of starting the en- gine. If the oil pressure is not displayed within 15 seconds, immediately turn off the engine to avoid engine damage. Confirm that the sump oil level is correct.
Page 258: Cooling System
Maintenance Engine Cooling system General WARNING Do not open the radiator pressure cap when the en- gine is hot. Wait until the coolant temperature has dropped to 50°C [120°F] before removing the pres- sure cap. Otherwise, the high temperature coolant or steam may cause personal injury.
Page 259 Maintenance Engine not remove the radiator cap when the cooling system is hot. Check and refill the cooling system when it has cooled down enough to touch (lower than 49°C [120°F]). Coolant level should remain in the lower part of the filling opening. You should only refill using Cummins' recommen- ded pre-mix ratio coolant.
Page 260 Maintenance Engine WARNING The coolant is poisonous. Do not allow children or pets to come into contact with coolant. If the coolant is no longer to be used, it should be disposed of in accordance with local environmental regulations. – Open the radiator drain valve and the drain valve at the bottom of the engine oil cooler housing to drain the cooling system.
Page 261 Maintenance Engine WARNING The coolant is poisonous. Do not allow children or pets to come into contact with coolant. Handle cool- ant in accordance with local laws and regulations. WARNING Do not stand near the reserve water tank or radiator when running the engine with the pressure cap re- moved.
Page 262 Maintenance Engine – Set all cab heater switches to high to allow coolant to flow through the heater core at maximum flow. The blower must be turned When the cooling system filling cap is re- moved: Run the engine at a low idling speed for 2 ●...
Page 263 Maintenance Engine WARNING Do not stand near the reserve water tank or radiator when running the engine with the pressure cap re- moved. If the vehicle is fitted with a filling door on the side of the reserve water tank, it must remain closed, as the coolant will expand.
Page 264 – Shut the engine off Allow the cooling sys- tem temperature to fall to 50°C [122°F]. – Drain the cooling system. NOTE If the drained water is still very dirty, you will need to flush the system again until the drained water is clean. Filling CAUTION...
Page 265 Maintenance Engine – If applicable, open the manual vent valve  before filling the cooling system. – You must close the manual vent valve after proper filling has been completed. CAUTION Do not use water as a coolant on its own. Only using water as a coolant will cause corrosion damage to the engine.
Page 266 If there is still coolant left from the system after the filling, it indicates that there are air pockets, which must be bled from the system before the vehicle can be used again.
Page 267 Maintenance Engine – Do not start the engine. Wait for 2 to 3 mi- nutes to allow the system to naturally vent the air and stabilise the coolant level. – Fill with a 50/50 mixture to return the cool- ant level to the cold full mark. –...
Page 268: Aftertreatment Diesel Exhaust Fluid Tank Filter
Maintenance Engine Aftertreatment diesel exhaust fluid tank filter General The diesel exhaust fluid (DEF) injector filter is a 40-micron filter used to prevent foreign sub- stances suspended in the DEF from getting into the injection system. Debris can cause permanent damage and premature failure in the aftertreatment DEF injector.
Page 269 DEF tank fil- ter and the O-ring. Cleaning and checking whether the unit can still be used NOTE Check for dirt and debris in the filling opening filter. This filter is the first point of contact with other filters.
Page 270: Belt Tensioner
Maintenance Engine – If there are cracks, check the aftertreatment DEF injector filter. NOTE Discard the DEF tank filter after completing the check. Assembly – Install O-ring (1) into the socket on the DEF  tank sensor hose. – Plug the DEF tank filter inlet port into the DEF tank sensor hose.
Page 271 Maintenance Engine If the tensioner arm stop blocks are still in con-  tact with the spring housing stop blocks after replacing the belt, replace the tensioner. With the belt removed, check whether there is any contact between the tensioner arm stop blocks and spring housing stop blocks.
Page 272: Drive Belt
Maintenance Engine Check the position of the drive belt on the belt  tensioner pulley. The belt should be positioned in the centre, or close to the centre, of the belt pulley. Misalignment of the belt, either too far forward or too far back, may result in wear to the belt, belt slipping or uneven wear to the tensioner bushing.
Page 273: Toothed Belt
Maintenance Engine Toothed belt Belts should be checked daily. If the belt is cracked, worn or has parts missing, it should be replaced. Small cracks are acceptable. Adjust belts with smooth, shiny surfaces; this shows that the belt is slipping. After correctly installing and tightening the belt, the belt pul- ley and belt will wear evenly.
Page 274 Maintenance Engine NOTE This chart does not apply to automatic belt tensioners. A belt is considered old when it has been used for 10 minutes or more. If the old belt tension is less than the mini- mum, tighten the belt to the old belt tension maximum.
Page 275: Rubber Damper
Maintenance Engine Rubber damper Checking Check the marking lines (A) on the damper  hub (B) and inertial component (C). If the devi- ation between the two lines exceeds 1.59 mm, the damper must be replaced. Check the rubber components for signs of ageing.
Page 276 Maintenance Engine – Use the keyboard tool (part number  5299073) to rotate the crankshaft until no.1 cylinder is at top dead centre (TDC). – The TDC indicator light is on the shock ab- sorber. – Align the shock absorber to get the TDC ...
Page 277 Maintenance Engine – If TDC is not marked on the shock absorb-  er or crankshaft speed indicator ring, align the large notch on the crankshaft speed in- dicator ring with the 5-o’clock position (2). You will see the locating pin (1) at the 9 o’clock position.
Page 278 Maintenance Engine If you can feel a certain resistance when the feeler slides between the jumper plate and rocker arm bearing, the clearance is correct. – Insert the feeler gauge between the jump- er plate and rocker arm bearing (overhead mechanism).
Page 279: Aftertreatment Diesel Particulate Filter
DOC exhaust pipe. Maintenance and checks If the aftertreatment DPF has been removed and cleaned and is deemed to still be usa- ble (in accordance with “Aftertreatment Diesel Oxidation Catalyst and Aftertreatment Diesel Particulate Filter Continued Use Guidelines”, Bulletin Number 4021600), then the aftertreat- ment DPF should be returned to Cummins.
Page 280: Aftertreatment Diesel Exhaust Fluid Injector Filter
Maintenance Engine The aftertreatment diesel oxidation catalyst Authorized service providers do not endorse (DOC) the ash-cleaning functions of localised air- The aftertreatment diesel particulate filter cleaning machines. All DPFs that need the (DPF) have ash cleaned from them should be re- The decomposition reaction tube turned to a authorized service provider in ex- The selective catalytic reducer (SCR)
Page 281 Maintenance Engine Preparation procedure WARNING Diesel exhaust fluid (DEF) contains urea. Do not allow this substance to get into your eyes. Should these substances come into contact with eyes, rinse immediately with plenty of water for at least 15 mi- nutes.
Page 282 DEF injector, regardless of their condition. Cleaning and checking whether the unit can still be used – Check the aftertreatment DEF injector filter cap for cracks or holes that may form leaks in the DEF channel.
Page 283 Maintenance Engine – Replace the entire aftertreatment DEF in- jector unit if the thread of the DEF injector unit is damaged. NOTE Never operate the vehicle after removing the DEF cap. Clean the cap and thread of the new after- treatment DEF injector with warm water and a clean cloth.
Page 284: Running Gear And Drive Train
Maintenance Running gear and drive train Running gear and drive train Transmission oil level check CAUTION Follow the precautions for handling fluids and lubri- cants. Wear protective equipment. NOTE Check the oil at operating temperature >40°C and with engine running. Do not check when the engine is cold.
Page 285: Tighten The Wheel Fasteners
Maintenance Running gear and drive train CAUTION Risk of death due to explosive force. Refer to Wheel and Tyre removal and fitting proce- dures. – Check the tyres for signs of damage or wear - visual check. – Renew worn or damaged tyres. Tighten the wheel fasteners ...
Page 286: Wheel Removal - Drive Axle
Maintenance Running gear and drive train CAUTION Risk of accident. When working under the truck, secure the chassis with wooden blocks. Do not rely solely on the jack. NOTE The truck should only be jacked up at jacking points indicated (↑). When jacking up the front of the truck, chock the rear wheels with plastic blocks.
Page 287 Maintenance Running gear and drive train DANGER Risk of death due to explosive force. Always ensure that the multi-piece rim wheel has been raised off the ground by methods of hydrauli- cally raising the vehicle before deflating/inflating the multi-piece rim wheel. Secure the raised truck with an axle support device.
Page 288 Maintenance Running gear and drive train – Place a protection device around the wheel  assembly being removed. – Remove the valve cores and fully deflate  the tyres (see warnings). 120 degrees DANGER Risk of death due to explosive force. Do not allow anyone to enter the area shown in Fig.
Page 289 Maintenance Running gear and drive train – Carefully drive the forks of a second truck  with holder (3) under the outer drive wheel. – Slowly lift the forks until the wheel rests on them. (Do not touch the inner drive wheel(5).) d3571099 –...
Page 290: Wheel Refitting - Drive Axle
Maintenance Running gear and drive train – Tilt outer wheel (4) against holder (3) and  secure it. – Carefully reverse the truck with the tyre and deposit it. Removing an inner drive wheel – Remove the outer drive wheel. –...
Page 291 Maintenance Running gear and drive train DANGER Risk of death due to explosive force. Always ensure that the multi-piece rim wheel has been raised off the ground by methods of hydrauli- cally raising the vehicle before deflating/inflating the multi-piece rim wheel. Secure the raised truck with an axle support device.
Page 292 Maintenance Running gear and drive train – Carefully drive the truck with the wheel (5)  to the wheel hub and align it. d3571097 – Align the wheel (5) on the hub.  – Slowly lower the forks until the drive wheel sits on the hub.
Page 293 Maintenance Running gear and drive train Mounting an outer drive wheel – Put the outer wheel on the forks of a sec-  ond truck and secure it in place. – Clean the mating surface on the hub and rim. d3571097 –...
Page 294 Maintenance Running gear and drive train – Tighten the wheel fastenings in a cross pat-  tern to the required torque and place the wheel assembly on the hub. NOTE Please refer to the Inspection and Mainte- nance Data table for the front wheel nut tor- que.
Page 295: Check The Parking Brake For Proper Operation
Maintenance Running gear and drive train – Make sure the track area is clear.  – Inflate the tyres to 10 bar at the inflation 120 degrees valve. – Inspect the wheel assembly to ensure the lock ring is correctly seated. DANGER Risk of death due to explosive force.
Page 296: Clean And Lubricate The Steering Axle
Maintenance Running gear and drive train – Check the operation and adjustment of brake pedals. NOTE Ensure brake pedal movement is not obstruc- ted. – Adjust the brake pedal stops, to allow cor- rect operation. – Start the engine and test the handbrake, switch off the engine.
Page 297 Maintenance Running gear and drive train Lubricate with lubricating grease. Please refer to the "Recommended fuels and oils table" chapter. – Lubricate the connecting rods and steering  knuckles by adding grease via the grease nipples. – Fill grease gun with grease until fresh grease overflows.
Page 298: Chassis And Bodywork
Maintenance Chassis and bodywork Chassis and bodywork Filling the windscreen washer  bottle – Open battery access door to access the washer bottle (1). – Open filler cap (2) top up if necessary. – Replace filler cap (2). – Close battery access door. Check the condition of structured components tion should cover all areas of the main CAUTION...
Page 299: Driver's Compartment
Maintenance Driver's compartment Driver's compartment Check seat belt for condition and  correct operation (option) NOTE For safety reasons the condition and proper operation of the retention system should be inspected regularly (monthly). Under extreme operating conditions this check is required daily before taking the truck into operation.
Page 300: Driver's Seat Switch
Maintenance Driver's compartment Nuts and bolts should be checked regularly for tightness. An unstable seat can indicate loose bolts or other faults. If any malfunctions in the operation of the seat are detected (e.g. seat cushioning), contact your service partner immediately to eliminate the cause.
Page 301: Electrical System
Maintenance Electrical system Electrical system Check the battery / batteries CAUTION Battery electrolyte is very caustic. Avoid any contact with battery electrolyte. If electro- lyte comes into contact with clothing, skin or eyes, flush the areas in question immediately with water. In case of eye contact see a doctor at once! Neutralize any spilled battery acid immediately! –...
Page 302: Hydraulic System
Maintenance Hydraulic system Hydraulic system Hydraulic system: oil level check  – Park the truck on level ground and lower the forks to the ground. – Check sight glass (1) on the right side of the chassis. Add oil if necessary. NOTE Mast should be vertical when checking oil lev- d1411020...
Page 303: Hydraulic Tank Breather Filter - Check
Maintenance Hydraulic system – Park the truck. – Check the lift, tilt and steering cylinders for leaks. – Tilt the cab. – Replace porous hoses. – Open the radiator cover. – Check lines for scuffing and replace if nec- – Check all connections between the oil tank, essary.
Page 304: Lifting System
Maintenance Lifting system Lifting system Lubricate the mast and tilt cylin- der pivots Lubricate the mast pivot pins  CAUTION Danger of damage to the truck. Take the weight off each pivot pin in turn using a suitable jack to ensure the optimum ingress of grease.
Page 305: Lubricate Fork Carriage Cylinder Bearings
Maintenance Lifting system Lubricate fork carriage cylinder  bearings NOTE Ensure that the forkspread is retracted suffi- ciently to allow access to the greasing points. – Lubricate the universal carriage cylinders bearing (1). Two points each cylinder. – Lubricate with grease gun until new grease is visible at the bearing.
Page 306: Check The Tension Of Double Hoses
Maintenance Lifting system Check the tension of double ho-  – The tension of the double hoses should be 5-10 mm per meter, referred to initial length. – Adjust the tension of the hoses to the specified dimension by sliding them in the clamps.
Page 307: Lubricate The Lift Mast Bearings
Maintenance Lifting system NOTE Trucks in service in the food industry must be lubricated with an oil approved for the food industry instead of chain spray. Lubricate the lift mast bearings – Use a grease gun to fill the lift mast bear- ...
Page 308 Maintenance Lifting system 298 5001 801 1624 EN - 07/2024 - 04...
Page 309: Troubleshooting
Maintenance Troubleshooting Troubleshooting Troubleshooting guide (Hydraulic system) Abnormal noise Suction filter restricted. Renew the filter. Suction hoses leaking, oil foaming. Tighten lines. Replace suction ho- ses. Check oil level, top up if nec- essary. Incorrect oil viscosity, low oil level Change oil, be sure to use the cor- in tank or in hydraulic pump.
Page 310 Maintenance Troubleshooting Hydraulic oil tempera- Oil level too low or oil cooler defec- Check oil level, if necessary top ture too high tive. up oil. Clean cooler and check for leaks. If defective, contact your service partner. Pump failure, valves leaking. Contact your service partner.
Page 311: Technical Data
Technical data...
Page 312: Truck Dimensions
Technical data Truck dimensions Truck dimensions 302 5001 801 1624 EN - 07/2024 - 04...
Page 313: Overview Of Type Sheets - 600 Mm Load Centre
Overview of type sheets - 600 mm load centre Overview of type sheets - 600 mm load centre All data refers to standard equipment with standard lift masts. All data must be observed without fail. 1 Key data Manufacturer Still RCD100Ds/600 RCD120Ds/600 ...
Page 314 Technical data Overview of type sheets - 600 mm load centre 2 Weight RCD140Ds 19082 RCD150Ds 19253 RCD160Ds 19721 RCD180Ds 21591 RCD100Ds 23150/3149 RCD120Ds 26163/2290 RCD140Ds 30496/2586 Axle load with front/rear load RCD150Ds 31500/2753 RCD160Ds 32935/2786 RCD180Ds 36144/3447 RCD100Ds 8327/7971 RCD120Ds 8375/8078 RCD140Ds 9570/9511...
Page 315 Technical data Overview of type sheets - 600 mm load centre 3 Wheels, chassis frame RCD150Ds、 RCD160Ds、 RCD180Ds RCD100Ds、 [mm] RCD120Ds、 RCD140Ds、 Rear track width 1970 RCD150Ds、 RCD160Ds、 RCD180Ds RCD100Ds、 [mm] RCD120Ds RCD140Ds、 Rolling radius RCD150Ds、 RCD160Ds、 RCD180Ds 4 Basic dimensions Lift mast/fork carriage tilt, forwards/backwards α/β...
Page 316 Technical data Overview of type sheets - 600 mm load centre 4 Basic dimensions RCD140Ds、 RCD150Ds、 2004 RCD160Ds、 RCD180Ds RCD100Ds、 [mm] RCD120Ds RCD140Ds、 4.12 Coupling height RCD150Ds、 RCD160Ds、 RCD180Ds RCD100Ds、 [mm] 5984 RCD120Ds RCD140Ds 6066 4.19 Total length RCD150Ds、 6316 RCD160Ds RCD180Ds 6516 RCD100Ds、...
Page 317 Technical data Overview of type sheets - 600 mm load centre 4 Basic dimensions RCD140Ds、 RCD150Ds、 620 / 2220 RCD160Ds、 RCD180Ds RCD100Ds、 [mm] RCD120Ds Ground clearance with load under lift RCD140Ds、 4.31 mast RCD150Ds、 RCD160Ds、 RCD180Ds RCD100Ds、 [mm] RCD120Ds Ground clearance at centre of wheel- RCD140Ds、...
Page 318 Technical data Overview of type sheets - 600 mm load centre 5 Performance data RCD100Ds km/h 27.9/29.1 RCD120Ds 27.6/29.1 RCD140Ds 28.3/30.2 Driving speed with/without load RCD150Ds 28.3/30.2 RCD160Ds 28.1/30.1 RCD180Ds 28.1/29.8 RCD100Ds、 RCD120Ds、 0.40/0.42 RCD150Ds Lifting speed with/without load RCD140Ds、 0.37/0.40 RCD180Ds RCD160Ds 0.37/0.42...
Page 319 Technical data Overview of type sheets - 600 mm load centre 7 Drive/engine Engine manufacturer/model Cummins B6.7 Eu5 Engine power rating in accordance with ISO 1585 Nominal speed 2200 Number of cylinders/displacement 6/6700 8 Other Torque converter Traction controller type Working pressure for attachments Oil flow for attachments l/min 5-130...
Page 320: Overview Of Type Sheets - 1200 Mm Load Centre
Overview of type sheets - 1200 mm load centre Overview of type sheets - 1200 mm load centre All data refers to standard equipment with standard lift masts. All data must be observed without fail. 1 Key data Manufacturer Still RCD100Ds/ 1200 RCD120Ds/ 1200 RCD140Ds/...
Page 321 Technical data Overview of type sheets - 1200 mm load centre 2 Weight RCD140Ds 22113 RCD150Ds 21981 RCD160Ds 22785 RCD100Ds 27238/2036 RCD120Ds 30464/2261 Axle load with front/rear load RCD140Ds 33565/2548 RCD150Ds 34553/2428 RCD160Ds 36156/2629 RCD100Ds 10141/9133 RCD120Ds 10769/9956 Axle load without front/rear load RCD140Ds 10394/11719 RCD150Ds...
Page 322 Technical data Overview of type sheets - 1200 mm load centre 3 Wheels, chassis frame RCD100Ds、 [mm] RCD120Ds、 Rear track width RCD140Ds、 1970 RCD150Ds、 RCD160Ds RCD100Ds、 [mm] RCD120Ds、 Rolling radius RCD140Ds、 RCD150Ds、 RCD160Ds 4 Basic dimensions Lift mast/fork carriage tilt, forwards/backwards α/β...
Page 323 Technical data Overview of type sheets - 1200 mm load centre 4 Basic dimensions RCD140Ds 7516 RCD150Ds、 7766 RCD160Ds RCD100Ds [mm] 4584 RCD120Ds 4916 4.20 Length including fork back RCD140Ds 5116 RCD150Ds、 5366 RCD160Ds RCD100Ds、 2565 RCD120Ds、 4.21 Total width RCD140Ds、...
Page 324 Technical data Overview of type sheets - 1200 mm load centre 4 Basic dimensions RCD100Ds [mm] 6186 RCD120Ds 6422 Aisle width for pallet 1000 x 1200 cross- 4.33 RCD140Ds 6641 wise RCD150Ds、 6883 RCD160Ds RCD100Ds [mm] 6386 RCD120Ds 6622 Aisle width for pallet 800 x 1200 length- 4.34 RCD140Ds 6841...
Page 325 Technical data Overview of type sheets - 1200 mm load centre 5 Performance data RCD160Ds 102.1/105.2 RCD100Ds 34.4/58.5 RCD120Ds 30.2/53.0 Climbing capability with/without load RCD140Ds 30.3/55.6 RCD150Ds 29.4/56.0 RCD160Ds 27.8/53.4 5.10 Service brake Wet disc 6 Battery voltage, rated capacity RCD100Ds、...
Page 326: Description Of Technical Datasheet
Technical data Description of technical datasheet Description of technical data- sheet CAUTION The parameters listed in the technical datasheet are examples of parameters for a specific configuration model in this range and are for reference only. The model configuration delivered to the user may differ from the technical datasheet.
Page 327 Index Check the parking brake for proper opera- tion......Activating the seat heater... . Check the tension of double hoses.
Page 328 Index Driver's seat (luxury driver's seat with auto- matic weight setting)....65 Hazards and countermeasures..Activating the seat heater... 67 Heating/air conditioning operation.
Page 329 Index Lowering the fork carriage Overview of type sheets - 600 mm load centre..... . Central lever operation... . . 82 Single lever operation.
Page 330 Index Side window Tilting the lift mast forwards Closing......Central lever operation... . . 83 Opening.
Page 332 STILL GmbH 5001 801 1624 EN - 07/2024 - 04...

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