RCD 100-180 Cummins-Eu5 EN Manual

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 - 05/2022 - 02

Preface
Address of manufacturer and 

contact details
STILL GmbH
Berzeliusstraße 10
22113 Hamburg, Germany
Tel. +49 (0) 40 7339-0
Fax: +49 (0) 40 7339-1622
Email: [email protected]
Website: http://www.still.de
Made in China
Rules for the operating com-

pany of industrial trucks
In addition to these operating instructions, a
code of practice containing additional informa-
tion for the operating companies of industrial
trucks is also available.
This guide provides information for handling
industrial trucks:
● Information on how to select suitable indus-
trial trucks for a particular area of applica-

tion
● Prerequisites for the safe operation of in-
dustrial trucks
● Information on the use of industrial trucks
● Information on transport, initial commission-
ing and storage of industrial trucks
Internet 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 - 05/2022 - 02 I

Preface
Abbreviations
Below is a list of abbreviations used in this
manual
ACM Aftertreatment Control Module

API American Petroleum Institute
BITA British Industrial Truck Association
CAN Controller Area Network
CPC Comon Powertrain Controler
ECM Engine Control Module
FDE Truck Data Acquisition Module
LED Light Emitting Diode
LFM Forklift Data Management
LTC Linde Truck Control
LVDT Linear Variable Displacement Transformer
MCM Motor Control Module
PIN Personal Identification Number
PPE Personal Protective Equipment
RPM Revolutions Per Minute
Straßenverkehrs-Zulassungs-Ordnung (Road Traffic Licensing
STVZO
Regulations)
Verband Deutscher Maschinen- und Anlagenbau (German Engi-
VDMA
neering Association)
LS Load Sensing
II 5001 801 1624 EN - 05/2022 - 02

Table of contents
1 Introduction
Truck data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Your industrial truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Conformity marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Declaration that reflects the content of the declaration of conformity . . . . . . . . . . . . . . . 7
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Use of the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Description of use and climatic conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Information about documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Documentation scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Supplementary documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Issue date and topicality of the operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Copyright and trademark rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Explanation of information symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Date of edition and latest update of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
List of abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Disposal of components and batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EMC – Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Servicing and spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Modifications and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Using attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Using working platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2 Safety
Definition of terms used for responsible persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Specialist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic principles for safe operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Insurance cover on company premises. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Modifications and retrofitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5001 801 1624 EN - 05/2022 - 02 III

Table of contents
Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Damage, faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Medical devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Vibrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wheels and tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Residual dangers, residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Special risks associated with using the truck and attachments. . . . . . . . . . . . . . . . . . . . 33
Overview of hazards and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Danger to employees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Safety tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Carrying out regular inspections on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Insulation testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Safety regulations for handling consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exhaust gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Safety Regulations Relative to Forklift Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Safety regulations in case of accidental lateral tipping . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Safety regulations when driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Permissible consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Battery acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Non-ionising radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Medical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Overview
General view of Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Safety devices and warning labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Operation
Service plan before initial commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pre-shift checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Regular maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Wheel removal — drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
IV 5001 801 1624 EN - 05/2022 - 02

Table of contents
Wheel refitting — drive axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Standard equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Entering and exiting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Driver's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Tilt Cab_Face Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Standard driver's seat and comfort driver's seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjusting the armrest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Adjusting the steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Window heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Heating system, air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Display unit-Parker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Starting and stopping the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Joystick with central lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Joystick with single lever operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Service brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Override Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Battery access - opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
To tow the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Drive controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
5100 040 Multifunction Joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6240 005 Load weight display (the weight error of (+ / - 100 kg)) . . . . . . . . . . . . . . . . . 114
Forklift Data Management (LFM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Lighting options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
BlueSpotTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
12v Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
24v Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
12/24v Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Mechless 1DIN truck radio with USB/AUX/Bluetooth . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4470 005 Cab vent fan 24v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4460 005 Illuminated A4 clipboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
4210 010 Buddy seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4480 005 Storage unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5001 801 1624 EN - 05/2022 - 02 V

Table of contents
4450 005 With cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Adjusting the driver's seat with rotating device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7109 005 Fire Extinguisher 2kg in Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Fire suppression system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6310 005 Tire pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Tyre pressure detection system (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7330 015 Reversing warning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1390 010 Plastic wheel stud covers with movement indicator . . . . . . . . . . . . . . . . . . . . 161
Operating optional attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Coil boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Cold Climate Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7306 005 Central lubrication system – steer/mast/tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
User instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Maintenance instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Mounting instructions for lowering the lifting heads into the end beams of 178 series
spreaders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Multifunctional handle _ 178 spreader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Working with a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Mast, lifting device and attachment controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Load centre distance and load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Load rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Before loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Lifting a load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Travelling with load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Depositing the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Before leaving the truck unattended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Loading/transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Hoisting the truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Transporting the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
5 Maintenance
General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Safety information regarding servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Inspection and maintenance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Recommended consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Service plan - Cummins_Eu5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
VI 5001 801 1624 EN - 05/2022 - 02

Table of contents
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Engine indicator light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Filling fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Air filter - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Coolant level - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Checking the engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Fuel filter and oil-water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
Radiator pressure cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Aftertreatment diesel exhaust fluid tank filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Belt tensioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Rubber damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Overhead mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Aftertreatment diesel particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Aftertreatment diesel exhaust fluid injector filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Chassis, bodywork and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Clean the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
Check seat belt for condition and correct operation (option) . . . . . . . . . . . . . . . . . . . . . . 268
Filling the windscreen washer bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Check the condition of structured components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Tighten the wheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Check the tyres for damage and foreign objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Locations for jacks when changing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Check the parking brake for proper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Brake control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Driver’s seat switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Check the battery / batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Check electric cables, connectors and connections for condition and tightness. . . . . . . 275
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Hydraulic system: oil level check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Hydraulic system: check for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Hydraulic tank breather filter - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5001 801 1624 EN - 05/2022 - 02 VII

Table of contents
Load lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Lubricate the mast and tilt cylinder pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Lubricate fork carriage cylinder bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Check the tension of double hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Check and adjust mast chains, lubricate with chain spray . . . . . . . . . . . . . . . . . . . . . . . 280
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Troubleshooting guide (Hydraulic system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Decommissioning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Measures before taking the truck out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Putting the truck back into service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Disposal of old trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
6 Technical data
Truck dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Overview of type sheets - 600 mm load centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Overview of type sheets - 1200 mm load centre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
VIII 5001 801 1624 EN - 05/2022 - 02

1
Introduction
1 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
2 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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
to 16 or 18 tonnes, with lift capacities up to Steering
16 tonnes available at 1200 mm load centre, The steering is a hydrostatic power system,
with lift capacities up to 18 tonnes available which operates the rear wheels with the steer-
at 600 mm. These products are based on ing wheel via the steering cylinder.
3 wheelbases and use modular components,
ensuring the final configured product delivers
the optimum balance between weight and ma- Brake System
noeuvrability. The truck park brake system is a spring ap-
plied, pressure release fail-safe system, con-
Engine trolled by the operator via a switch located on
the arm rest. The park brake will not release
Powered by a new Cummins turbo charged unless the operator has their foot on the serv-
diesel IC engine, The unit is coupled direct- ice brake pedal to ensure safe operation.
ly to the truck`s ZF 'Ergomatic' transmission
which along with the control system controls The service brake is a pressure applied,
power output between the load-dependent hy- spring release system, operated by connected
draulic pumps and motion. pedals located either side of the steering col-
umn.
Some of the heat generated by the engine
is absorbed by the engine coolant flowing Both park and service brake circuits are pow-
through the passages in the cylinder block and ered by a fixed displacement gear pump
cylinder head. Heat is then removed from the mounted on the front of the main work hy-
engine coolant as it flows through the heat draulic pump. This gear pump is fed by the hy-
exchanger. draulic oil reservoir located on the right-hand
side of the truck, The oil passes through a
pressure filter before feeding the controlling
NOTE valves. The excess and return oil flow from
the brake circuits flushes and cools the oil
It is not permitted to make changes to the
engine and its aftertreatment parts. immersed wet disk brakes in the front drive
axle before returning to the oil reservoir via the
return filter.
Electronic engine management
Using sensors, audible and visual warnings
The engine and drive control system are moni- will occur in the event of low brake pressure,
tored by the truck controller and status is dis- or if a fault is present in the brake system.
played on the truck status display monitor.
In addition to the engine, the engine control Hydraulic system
module also monitors itself. Depending on
the malfunctions/failures which occur, warning A single or tandem (depending on truck
and information displays are displayed on the variant) variable displacement, load sensing
tuck status display monitor. The malfunction is work hydraulic pump is mounted directly to
stored in the fault memory and if necessary a the transmission. The back pump feeds both
safety and emergency mode is automatically steering and work hydraulic functions while
selected. If the electronic engine management the front pump (if fitted) feeds the work hy-
control detects a fault, the fault code is stored draulic system. These pumps are fitted with
5001 801 1624 EN - 05/2022 - 02 3

1 Introduction
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.
and the maximum pressure is maintained at
310 bar. Electrical system
An externally mounted in-line priority valve en- The main truck`s electrical system is 24 volts,
sures the steering function has priority over this potential is delivered by two 12 v 95 AH
work hydraulic functions. batteries connected in series, Charge is provi-
The main hydraulic valve is a group of added by the engine mounted alternator and the
vanced CANbus controlled, load-independent charge current is controlled by a solid state
proportional valves and include primary and rectifier.
secondary relief valves that prevent overload
of the hydraulic circuits. Electronic/electrical installation
To improve and enhance the safe design of Parker control system allow:
the hydraulic system the control valves are
fitted with LVDT spool position feedback sen- - sensitive, smooth driving and reversing,
sors which enable the valves to monitor their - automatic engine speed control to match the
own condition and broadcast any errors over hydraulic power requirements,
the CANbus.
- fast service due to self-diagnostics,
The mast lift/lower section incorporate “leak
free” valves to eliminate the possibility of mast - greatest possible operational reliability.
creep when carrying heavy loads.
A combination cooler ensures that the temper- Driving cab
atures are kept optimum for the transmission, The steel frame of the driver`s cab has been
engine water and charge air. The cooling di- constructed to function as the load guard and
rection and cooler location have been careful- has been tested to exceed the International
ly developed with the aim of minimising the safety standards. Driver entry is provided via
size of the cooling pack and maintaining best the steps located to the left side of the truck.
in class cooling performance. The cooled air Steps are also fitted to the right side of the
direction pulls ambient clean air from above truck for access. The right cab door can to be
the rear of the truck and drives warm air down used as an emergency exit and is provided
through the engine bay over the engine and for the use of a passenger where the optional
finally out at the front. passenger seat is fitted and located to the rear
left of the cab floor.
Lift mast The cab and doors have large glazed areas
The standard mast is a double open centre and allow the driver maximum all round visibil-
non-free lift type with twin lift and tilt cylinders, ity during driving and lifting operations.
lift chains mounted on each side and are at- Screen wiper and washers are fitted to the
tached to the carriage. front, top and rear screens with demist func-
Lift movement is achieved when the lift cyl- tions as part of the cab heater or the optional
inders extend and the lift chains pull on the climate control system.
carriage, during this extension the inner mast An optional passenger seat can be fitted in the
section slides inside channels of the outer right rear corner of the cab.
section.
An optional fire extinguisher can be fitted in
The whole mast and carriage assembly is the cab if required.
mounted and pivots on two pins that are fixed
and located within the fabrications of the drive
4 5001 801 1624 EN - 05/2022 - 02

Introduction 1
The guard rails is the standard configuration if ● check the truck batteries
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
to:
General
The industrial truck described in these operat-
ing instructions conforms with the applicable
standards and safety regulations.
The industrial truck is fitted with state-of-the-
art technology. Following these operating in-
structions will allow the industrial truck to be
handled safely. By complying with the speci-
fications in these operating instructions, the
functionality and the approved features of the
industrial truck will be retained.
Get to know the technology, understand it and
use it safely - these operating instructions pro-
vide the necessary information and help to
avoid accidents and to keep the truck ready
for operation beyond the warranty period.
Therefore:
– Before commissioning the industrial truck,
read the operating instructions and follow
the instructions.
– Always follow all the safety information con-
tained in the operating instructions and on
the industrial truck.
5001 801 1624 EN - 05/2022 - 02 5

1 Introduction
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)
● UKCA: in the United Kingdom (UK)
● EAC: in the Eurasian Economic Union
The conformity marking is applied to the

nameplate. A declaration of conformity is is-
sued for the EU and UK markets.
An unauthorised structural change or addition
to the industrial truck can compromise safety,
thus invalidating the declaration of conformity.
conformity symbols
6 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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:
Industrial truck type corresponding to these operating instructions

Model corresponding to these operating instructions
− "Machinery Directive 2006/42/EC" 1)

− "Supply of Machinery Safety Regulations 2008, 2008 No. 1597" 2)
Personnel authorised to compile the technical documents:
See declaration of conformity
STILL GmbH
1) For the markets of the European Union, the EU candidate countries, the EFTA States and
Switzerland.
2) For the United Kingdom market.
The declaration of conformity document is The declaration of conformity must be careful-

supplied with the industrial truck. The declara- ly stored and made available to the responsi-
tion shown explains the conformity with the ble authorities if necessary. It must also be
provisions of the EC Machinery Directive and handed over to the new owner if the industrial
the Supply of Machinery Safety Regulation truck is sold on.
2008, 2008 No. 1597.
An unauthorised structural change or addition
to the industrial truck can compromise safety,
thus invalidating the declaration of conformity.
5001 801 1624 EN - 05/2022 - 02 7
1 Introduction
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. permissible battery weight in kg
(for electric trucks only)
7 Own mass (self weight) in kg without
battery
8 Manufacturer
9 Refer to technical data listed in this
operating instructions for more de-
tailed information
10 CE label
11 Rated drive power in kW
12 Battery voltage in V
13 Rated capacity
Nameplate, variant 2 
1 Type
2 Serial number
3 Manufacturer
4 Year of manufacture
5 Unladen mass in kg
6 permissible battery weight in kg (for
electric trucks only) Max./Min.
7 Own mass (self weight) in kg without
battery
8 Data matrix code
9 Refer to technical data listed in this
operating instructions for more de-
tailed information
10 Conformity marking: CE mark for the
markets of the EU, the EU candidate
countries, the EFTA States and Swit-
zerland UKCA mark for the United
Kingdom market EAC mark for the
Eurasian Economic Union market
11 Rated drive power in kW
8 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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.
NOTE
Nameplate provided according to collocation
requirements.
5001 801 1624 EN - 05/2022 - 02 9

1 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. See also
the chapter entitled "Definition of responsible
persons".
– To commission the truck, contact the au-
thorised service centre.
Improper use
The operating company or driver, and not the
manufacturer, is liable for any hazards caused
by improper use.
NOTE
Please note the definition of the following re-
sponsible persons: "operating company" and
"driver".
Use for purposes other than those described
in these operating instructions is prohibited.
DANGER
There is a risk of fatal injury from falling
off the truck while it is moving!
– It is prohibited to carry passengers on
the truck.
The truck may not be operated in areas where

there is a risk of explosion, in areas that cause
corrosion or in areas that are particularly dus-
ty.
Stacking or unstacking on inclined surfaces or
ramps is not permitted.
Precautions
– Do not drive on steep slopes, to prevent the – The truck must be switched off when left
load from slipping off. unattended. Key (or key code) must be
10 5001 801 1624 EN - 05/2022 - 02
Introduction 1
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.
Description of use and climatic

conditions
Normal use
● Indoor and outdoor use
● Ambient temperature of -20℃ to +40℃
● Altitude of no higher than 2000 m.
5001 801 1624 EN - 05/2022 - 02 11

1 Introduction
Information about documentation

Documentation scope
● Operating instructions fully and must be available to the driver and
● Operating instructions for attachment parts operator at all times.
(special equipment)
If the operating instructions are lost, the oper-
● Spare parts list ator must immediately request a replacement
These operating instructions describe all from the manufacturer.
measures necessary for the safe operation
The spare parts list can be reordered there as
and proper maintenance of the truck in all
a spare part.
possible variants at the time of printing. Spe-
cial designs to meet customer requirements Personnel responsible for operating and main-
are documented in separate operating instruc- taining the equipment must be familiar with
tions. If you have any questions, please con- these operating instructions.
tact your service centre.
The operating company (see the chapter “Def-
Enter the production number and the year of inition of responsible persons”) must ensure
production located on the nameplate in the that all operators have received, read and un-
field provided: derstood these instructions.
Production no. ........................................... Thank you for reading and complying with
these operating instructions. If you have any
Year of produc-
questions or suggestions for improvements, or
tion ...................................................
if you have found any faults, please contact
Please quote these numbers for all technical your service centre.
enquiries.
Operating instructions are provided with each
truck. These instructions must be stored care-
Supplementary documentation
This industrial truck can be fitted with a Custo-
mer Option (CO) that deviates from the stand-
ard equipment and the variants.
This CO may consist of:
● Special sensors
● A special attachment
● A special towing device
● Customised attachments
When fitted with a CO, the industrial truck is

provided with additional documentation. This
may take the form of an insert or separate
operating instructions.
The original operating instructions for this
industrial truck are valid for the operation
of standard equipment and variants with-
out restriction. The operational and safety
12 5001 801 1624 EN - 05/2022 - 02
Introduction 1
information in the original operating instruc-

tions continues to be valid in its entirety un-
less it is countermanded in this additional doc-
umentation.
The requirements for the qualification of per-
sonnel as well as the time for maintenance
may vary. This is defined in the additional doc-
umentation.
– If you have any questions, contact your au-
thorised service centre.
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.
Please contact your authorised service centre
for technical support relating to your truck.
Copyright and trademark rights

These instructions must not be reproduced,
translated or made accessible to third par-
ties—including as excerpts—except with the
express written approval of the manufacturer.
Explanation of information sym-

bols 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.
5001 801 1624 EN - 05/2022 - 02 13

1 Introduction
CAUTION
Indicates procedures that must be strictly adhered to
in order to prevent material damage and/or destruc-
tion.
NOTE
For technical requirements that require special
attention.
ENVIRONMENT NOTE
To prevent environmental damage.
14 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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, and therefore re-
serves the right to implement changes and to
accept no claims concerning the information
provided in this manual.
To receive technical assistance, please con-
tact the service centre authorised by your
closest manufacturer.
List of abbreviations
This list of abbreviations applies to all types
of operating instructions. Not all of the abbre-
viations that are listed here will necessarily
appear in these operating instructions.
Abbrevi-
Meaning Explanation
ation
German implementation of EU occupation-
ArbSchG Arbeitsschutzgesetz
al health and safety directives
Betr- German implementation of the EU working
Betriebssicherheitsverordnung
SichV equipment directive
German insurance company for the com-
BG Berufsgenossenschaft
pany and employees
German principles and test specifications
BGG Berufsgenossenschaftlicher Grundsatz
for occupational health and safety
German rules and recommendations for
BGR Berufsgenossenschaftliche Regel
occupational health and safety
DGUV Berufsgenossenschaftliche Vorschrift German accident prevention regulations
Confirms conformity with product-specific
CE Communauté Européenne
European directives (CE labelling)
Commission on the Rules for the Approval International commission on the rules for
CEE
of the Electrical Equipment the approval of electrical equipment
DC Direct Current Direct current
DFÜ Datenfernübertragung Remote data transfer
DIN Deutsches Institut für Normung German standardisation organisation
EG European Community
EN European standard
European Federation of Materials Han-
FEM Fédération Européene de la Manutention
dling and Storage Equipment
5001 801 1624 EN - 05/2022 - 02 15

1 Introduction
Abbrevi-
Meaning Explanation
ation
Fmax maximum Force Maximum power
German authority for monitoring/issuing
regulations for worker protection, environ-
GAA Gewerbeaufsichtsamt
mental protection, and consumer protec-
tion
Transfer of data packets in wireless net-
GPRS General Packet Radio Service
works
ID no. Identification number
International Organization for Standardi-
ISO International standardisation organisation
zation
Uncertainty of measurement of sound
KpA
pressure levels
LAN Local Area Network Local area network
LED Light Emitting Diode Light emitting diode
Lp Sound pressure level at the workplace
Average continuous sound pressure level

LpAZ
in the driver's compartment
Distance of the centre of gravity of the
LSP Load centre of gravity
load from the front face of the fork backs
Maximum permissible air concentrations
MAK Maximum workplace concentration
of a substance at the workplace
Max. Maximum Highest value of an amount
Min. Minimum Lowest value of an amount
PIN Personal Identification Number Personal identification number
PPE Personal protective equipment
SE Super-Elastic Superelastic tyres (solid rubber tyres)
Tyres for simplified assembly, without
SIT Snap-In Tyre
loose rim parts
German regulations for approval of vehi-
StVZO Straßenverkehrs-Zulassungs-Ordnung
cles on public roads
Ordinance on hazardous materials appli-
TRGS Technische Regel für Gefahrstoffe
cable in the Federal Republic of Germany
Confirms conformity with the product-spe-
UKCA United Kingdom Conformity Assessed cific directives that apply in the United
Kingdom (UKCA labelling)
Verband der Elektrotechnik Elektronik In-
VDE German technical/scientific association
formationstechnik e. V.
VDI Verein Deutscher Ingenieure German technical/scientific association
16 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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 - 05/2022 - 02 17

1 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.
Disposal of components and

batteries
The truck is composed of different materials. If
components or batteries need to be replaced
and disposed of, they must be:
● disposed of,
● treated or
● recycled in accordance with regional and
national regulations.
NOTE
The documentation provided by the battery
manufacturer must be observed when dispos-
ing of batteries.
ENVIRONMENT NOTE
We recommend working with a waste man-

agement company for disposal purposes.
18 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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-
electromagnetic compatibility of the truck .
terference to a level that ensures the trou-
blefree operation of other equipment in the
environment. CAUTION
● ensuring sufficient resistance to external The EMC regulations for the truck must be observed.
electromagnetic interference so as to guar- When replacing truck components the protective
antee proper operation at the planned us- EMC components must be installed and connected
age location under the electromagnetic in- again.
terference conditions to be expected there .
An EMC test thus firstly measures the elec-
tromagnetic interference emitted by the truck
Servicing and spare parts

For questions relating to scheduled mainte-
nance and repairs to forklift trucks, please
contact the authorised service network.
The authorised service network has personnel
trained by the manufacturer, original spare
parts and the tools necessary to carry out
maintenance and repairs.
Servicing by the authorised service network
and the use of original spare parts retain the
technical properties of the forklift truck in the
long term.
Only original spare parts provided by the man-
ufacturer may be used for maintenance and
repairs performed on forklift trucks. The use
of non-original spare parts invalidates the war-
ranty and renders the customer responsible
for any accidents due to the incompatibility of
the non-original parts.
Modifications and retrofitting

If the truck will be used for work that is not
listed in the directives or in these instructions,
convert or retrofit the truck for this purpose
as required. Any structural modification can
impair the handling and stability of the truck,
and can result in accidents.
5001 801 1624 EN - 05/2022 - 02 19

1 Introduction
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
● Steering
● Operating devices
● Safety systems
● Equipment variants
● Attachments
The truck may only be converted with written

approval from the manufacturer. If necessary,
obtain approval from the relevant authorities.
– Only the authorised service centre is per-
mitted to perform welding work on the truck.
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.
The operating company is only permitted to
make modifications to the truck independently
if the manufacturer goes into liquidation and
the company is not taken over by another le-
gal person.
The operating company must also fulfil the fol-
lowing prerequisites:
● Design documents, test documents and
assembly instructions associated with the

modification must be permanently archived
and remain accessible at all times.
● The capacity rating plate, the decal informa-
tion, the hazard warnings and the operating

instructions must be checked to ensure that
they are consistent with the modifications
and must be amended if required.
● Modifications must be designed, checked
and implemented by a design office that

specialises in industrial trucks. The design
office must comply with the standards and
directives valid at the time that modifica-
tions are made.
20 5001 801 1624 EN - 05/2022 - 02

Introduction 1
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.
Please ask your authorised service centre
about using these attachments. The following
points must be addressed during the consulta-
tion:
● Is the attachment suitable for the truck?
● How will the attachment affect the load ca-
pacity of the truck? A residual load capacity

rating plate must be created
CAUTION
Attaching a crane arm changes the original intended
use of the forklift truck, which may not be designed
for transporting free-swinging suspended loads. The
use of this kind of equipment requires specific appro-
val; the CE Declaration of Conformity is also required
for any forklift trucks fitted with this kind of equip-
ment. If this kind of equipment is to be used, you
must contact your authorised service centre.
Using working platforms

WARNING
The use of working platforms is regulated by national
law. The use of working platforms is only permitted
by virtue of the jurisdiction in the country of use.
– Observe national legislation.
– Before using working platforms, consult the na-
tional regulatory authorities.
5001 801 1624 EN - 05/2022 - 02 21

1 Introduction
Using working platforms
22 5001 801 1624 EN - 05/2022 - 02

2
Safety
2 Safety
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
in these operating instructions.
The operating company must ensure that all
users read and understand the safety informa-
tion.
The operating company is responsible for the
scheduling and correct performance of regular
safety checks.
We recommend that the national performance
specifications are adhered to.
Specialist
A qualified person is defined as a service en-
gineer or a person who fulfils the following
requirements:
● A completed vocational qualification that
demonstrably proves their professional ex-

pertise. This proof should consist of a voca-
tional qualification or a similar document.
● Professional experience indicating that the
qualified person has gained practical expe-

rience of industrial trucks over a proven
period during their career During this time,
this person has become familiar with a wide
range of symptoms that require checks to
be carried out, such as based on the results
of a hazard assessment or a daily inspec-
tion
● Recent professional involvement in the field
of the industrial truck test in question and

an appropriate further qualification are es-
sential. The qualified person must have ex-
perience of carrying out the test in question
or of carrying out similar tests. Moreover,
this person must be aware of the latest
technological developments regarding the
industrial truck to be tested and the risk be-
ing assessed
24 5001 801 1624 EN - 05/2022 - 02

Safety 2
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. Specific knowledge of the truck
to be operated is also required.
The training requirements under §3 of the
Health and Safety at Work Act and §9 of the
plant safety regulations are deemed to have
been satisfied if the driver has been trained
in accordance with BGG (General Employers'
Liability Insurance Association Act) 925. Ob-
serve the national regulations for your country.
Driver rights, duties and rules of behav-

iour
The driver must be trained in his rights and
duties.
The driver must be granted the required rights.
The driver must wear protective equipment
(protection suit, safety footwear, safety hel-
met, industrial goggles and gloves) that is ap-
propriate for the conditions, the job and the
load to be lifted. Solid footwear should be
worn to ensure safe driving and braking.
The driver must be familiar with the operating
instructions and have access to them at all
times.
The driver must:
● have read and understood the operating
manual
● have familiarised himself with safe opera-
tion of the truck

● be physically and mentally able to drive the
truck safely
DANGER
The use of drugs, alcohol or medications that affect
reactions impair the ability to drive the truck!
Individuals under the influence of the aforementioned
substances are not permitted to perform work of any
kind on or with the truck.
5001 801 1624 EN - 05/2022 - 02 25

2 Safety
Prohibition of use by unauthorised per-

sons
The driver is responsible for the truck during
working hours. He must not allow unauthor-
ised persons to operate the truck.
When leaving the truck, the driver must secure
it against unauthorised use, e.g. by pulling out
the key.
26 5001 801 1624 EN - 05/2022 - 02

Safety 2
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.

If the industrial truck will be used for work
that is not listed in the directives or in these in-
structions, the industrial truck must be conver-
ted or retrofitted for this purpose as required.
Any structural modification can impair the han-
dling and stability of the industrial truck, and
can result in accidents.
Any modifications that adversely affect stabili-
ty, load capacity and the circumferential view
from the industrial truck require written appro-
val by the manufacturer.
The following components may only be modi-
fied with prior written approval from the manu-
facturer:
● Brakes
● Steering
● Operating devices
● Safety systems
● Equipment variants
● Attachments
The industrial truck may be converted only

with written approval by the manufacturer. If
necessary, obtain approval from the relevant
authorities.
– Only the authorised service centre is per-
mitted to perform welding work on the in-
dustrial truck.
5001 801 1624 EN - 05/2022 - 02 27

2 Safety
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.
DANGER
Risk of explosion from additional holes
in the area surrounding the battery!
Explosive gases can escape and can
lead to potentially fatal injuries if they
explode. Sealing bores with plugs is not
sufficient to prevent gas from escaping.
– Do not drill holes in the area sur-
rounding the battery.
The operating company is permitted to make

modifications to the industrial truck independ-
ently only if the manufacturer goes into liqui-
dation and is not taken over by another legal
person.
The operating company must also fulfil the fol-
lowing prerequisites:
● Design documents, test documents and
assembly instructions associated with the

modification must be permanently archived
and remain accessible at all times.
● The capacity rating plate, the decal informa-
tion, the hazard warnings and the operating

instructions must be checked to ensure that
they are consistent with the modifications
and must be amended if required.
● Modifications must be designed, checked
and implemented by a design office that

specialises in industrial trucks. The design
office must comply with the standards and
directives valid at the time that modifica-
tions are made.
Decal information with the following data must
be permanently affixed to the industrial 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
28 5001 801 1624 EN - 05/2022 - 02

Safety 2
Warning regarding non-original parts

Original parts, attachments and accessories CAUTION
are specially designed for this truck. We draw
your attention to the fact that parts, attach- The installation or use of such products may have a
negative impact on the design of the truck and thus
ment parts and accessories supplied by other impair active or passive driving safety.
companies have not been tested or approved
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.
Damage, faults
Any damage or faults observed on the truck or Work on the electric installation (e.g. connect-
the accessories must be reported immediately ing a radio, additional lights or other accesso-
to the responsible personnel. The truck and ries) is permitted only with the approval of the
accessories must never be used before they manufacturer.
are correctly reconditioned as they cannot be
guaranteed to be safe for operating or driving.
The safety mechanisms and switches must
never be removed or disabled. The predefined
setpoint values must not be modified.
Medical devices
The operation of medical devices, for example
pacemakers or hearing aids, can be impaired.
Check with your doctor or manufacturer if
the medical devices are sufficiently protected
against electromagnetic interference.
Emissions
Noise emission values
Calculated during the test cycle performed in
accordance with standard EN 12053
Acoustic pressure level on the driver's compartment

ECH 15 LPAZ <70
5001 801 1624 EN - 05/2022 - 02 29

2 Safety
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:
● Vibration characteristics < 2.5 m/s2
NOTE
It is mandatory to specify the hand-arm vibra-
tions, even where the values do not indicate
any danger, as in this case.
CAUTION
The value expressed above can be used to compare
forklift trucks of the same category. It cannot be
used to determine the operator's daily exposure to
vibrations during real operation of the truck; these
vibrations depend on the conditions of use (floor con-
ditions, method of use etc.) and therefore daily expo-
sure must be calculated using data from the place of
use.
Wheels and tyres

DANGER
Risk to stability!
Failure to observe the following information and in-
structions can lead to a loss of stability. The truck
may tip over — risk of accident!
The following factors can lead to a loss of

stability and are therefore prohibited:
● Wheels not approved by the manufacturer
● Excessive wear to the tyres
● Tyres of inferior quality
● Changes to the wheel rims
● Combination of wheels from different manu-
facturers
30 5001 801 1624 EN - 05/2022 - 02

Safety 2
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-
turer.
● Only use high-quality products.
When changing wheels, always ensure that

this does not cause the truck to tilt to one side
(e.g. always replace right and left wheels at
the same time). Changes must only be made
following consultation with the manufacturer.
Wheels approved by the manufacturer can be
found on the spare parts list. If other wheels
are to be used, authorisation from the manu-
facturer must be obtained beforehand.
– Contact your authorised service centre re-
garding this matter.
5001 801 1624 EN - 05/2022 - 02 31

2 Safety
Residual risks
Residual risks
Residual dangers, residual risks
Despite careful working and compliance with
standards and regulations, the occurrence of
other risks when using the truck cannot be
entirely excluded.
The truck and all other system components
comply with current safety requirements. Nev-
ertheless, even when the truck is used for
its proper purpose and all instructions are fol-
lowed, some residual risk cannot be excluded.
Even beyond the narrow danger areas of the
truck itself, a residual risk cannot be excluded.
Persons in this area around the truck must
exercise a heightened degree of awareness,
so that they can react immediately in the event
of any malfunction, incident or breakdown etc.
WARNING
All persons that are in the vicinity of the truck must
be instructed regarding these risks that arise through
use of the truck.
In addition, we draw attention to the safety regula-
tions in these operating instructions.
Risks can include:

● Escape of consumables due to leakages,
rupture of lines and containers etc.

● Risk of accident when driving over difficult
ground such as gradients, smooth or irregu-

lar surfaces, or with poor visibility etc.
● Falling, tripping etc. when moving on the
truck, especially in wet weather, with leak-

ing consumables or on icy surfaces
● Fire and explosion risks due to batteries
and electrical voltages

● Human error resulting from failure to ob-
serve the safety regulations,

● Unrepaired damage or defective and worn
components,
● Insufficient maintenance and testing
● Use of incorrect consumables
● Exceeding test intervals
The manufacturer is not held responsible for

accidents involving the truck caused by the
failure of the operating company to comply
32 5001 801 1624 EN - 05/2022 - 02

Safety 2
Residual risks
with these regulations either intentionally or

carelessly.
Stability
The stability of the truck has been tested to
the latest technological standards and is guar-
anteed provided that the truck is used properly
and according to its intended purpose. These
standards only take into account the dynamic
and static tipping forces that can arise during
specified use in accordance with the operat-
ing rules and intended purpose. However, the
danger of exceeding the moment of tilt due to
improper use or incorrect operation and losing
stability can never be excluded.
The loss of stability can be avoided or mini-
mised by the following actions:
– Always secure the load against slipping,
e.g. by lashing.
– Always transport unstable loads in suitable
containers.
– Always drive slowly when cornering.
– Drive with the load lowered.
– Even with sideshifts, align the load as cen-
trally as possible with the truck and trans-
port in this position.
– Avoid turning and diagonally driving across
slopes or gradients.
– Never have the load facing downhill when
travelling on slopes or gradients.
– Pick up only loads of the approved width.
– Always take great care when transporting
suspended loads.
– Do not drive over ramp edges or steps.
Special risks associated with us-

ing the truck and attachments
Approval from the manufacturer and attach-
ment manufacturer must be obtained each
time the truck is used in a manner that falls
outside the scope of normal use, and in cases
where the driver is not certain that he can
5001 801 1624 EN - 05/2022 - 02 33

2 Safety
Residual risks
use the truck correctly and without the risk of

accidents.
34 5001 801 1624 EN - 05/2022 - 02

Safety 2
Residual risks
5001 801 1624 EN - 05/2022 - 02 35

2 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.
Hazard Course of action Check note Notes

√ done
- Not applicable
Truck equipment does Testing O If in doubt, consult the
not comply with local responsible factory in-
regulations spectorate or employ-
ers' liability insurance
association
Driver's lack of skills or Driver training (sit-on O DGUV principle
qualifications and stand-on) 308-001
VDI 3313 driver's li-
cence
Usage by unauthorised Access with key only O
persons for authorised persons
Truck not safe for op- Periodic inspection O German Ordinance on
eration and rectification of de- Industrial Safety and
fects Health (BetrSichV)
Risk of falling when us- Compliance with na- O German Ordinance on
ing working platforms tional regulations Industrial Safety and
(different national Health (BetrSichV) and
laws) employer's liability in-
surance associations
Impaired visibility due Application planning O German Ordinance on
to load Industrial Safety and
Health (BetrSichV)
Contamination of Assessment of diesel O Technical Regulations
breathable air exhaust gases for Hazardous Sub-
stances (TRGS) 554
and the German Or-
dinance on Industri-
al Safety and Health
(BetrSichV)
Assessment of LPG O German threshold lim-
exhaust gases it values list (MAK-
Liste) and the German
Ordinance on Industri-
al Safety and Health
(BetrSichV)
36 5001 801 1624 EN - 05/2022 - 02

Safety 2
Residual risks

√ done
- Not applicable
Impermissible usage Provide operating in- O German Ordinance on
(improper usage) structions Industrial Safety and
Health (BetrSichV) and
German Health and
labour protection law
(ArbSchG)
Written notice of in- O German Ordinance on
struction to driver Industrial Safety and
Health (BetrSichV) and
German Health and
labour protection law
(ArbSchG)
German Ordinance on O
Industrial Safety and
Health (BetrSichV), ob-
serve the operating in-
structions
When fuelling
a) Diesel German Ordinance on O
Industrial Safety and
Health (BetrSichV), ob-
serve the operating in-
structions
b) LPG DGUV regulation 79, O
observe the operating
instructions
When charging the German Ordinance on O VDE 0510-47
drive battery Industrial Safety and (= DIN EN 62485-3): In
Health (BetrSichV), ob- particular
serve the operating in- - Ensure adequate
structions ventilation
- Insulation value with-
in the permissible
range
When using battery German Ordinance on O German Ordinance on
chargers Industrial Safety and Industrial Safety and
Health (BetrSichV), Health (BetrSichV) and
DGUV rule 113-001 DGUV rule 113-001
and observe the oper-
ating instructions
When parking LPG German Ordinance on O German Ordinance on
trucks Industrial Safety and Industrial Safety and
Health (BetrSichV), Health (BetrSichV) and
DGUV rule 113-001
5001 801 1624 EN - 05/2022 - 02 37

2 Safety
Residual risks

√ done
- Not applicable
DGUV rule 113-001
and observe the oper-
ating instructions
When operating driverless transport systems
Roadway quality inad- Clean/clear roadways O German Ordinance on
equate Industrial Safety and
Health (BetrSichV)
Loading equipment in- Reposition load on pal- O German Ordinance on
correct/slipped let Industrial Safety and
Health (BetrSichV)
Unpredictable driving Employee training O German Ordinance on
behaviour Industrial Safety and
Health (BetrSichV)
Routes blocked Mark routes O German Ordinance on
Keep roadways clear Industrial Safety and
Health (BetrSichV)
Routes intersect Announce right-of-way O German Ordinance on
rule Industrial Safety and
Health (BetrSichV)
No person detection Employee training O German Ordinance on
when placing goods in- Industrial Safety and
to stock and removing Health (BetrSichV)
goods from stock
Danger to employees
According to the German Ordinance on In-
dustrial Safety and Health (BetrSichV) and
labour protection law (ArbSchG), the operat-
ing company must determine and assess haz-
ards during operation, and establish the labour
protection measures required for employees
(BetrSichVO). The operating company must
therefore draw up appropriate operating in-
structions (§ 6 ArbSchG) and nominate a per-
son who is responsible for these operating
instructions. Drivers must be informed of the
operating instructions that apply to them.
NOTE
Please note the definition of the following re-
sponsible persons: "operating company" and
"driver".
38 5001 801 1624 EN - 05/2022 - 02

Safety 2
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. The
same applies to attachments with their own
CE labelling and UKCA labelling. The operat-
ing company must, however, select the type
and equipment of the trucks so as to comply
with the local provisions for deployment.
The result of the hazard assessment must
be documented (§ 6 ArbSchG). In the case
of truck applications involving similar hazard
situations, the results may be summarised.
Refer to the chapter entitled "Overview of haz-
ards and countermeasures", which provides
advice on complying with this regulation. The
overview specifies the primary hazards that,
in the event of non-compliance, are the most
frequent causes of accidents. If other major
hazards are present as a result of the specific
operating conditions, these hazards must also
be taken into consideration.
The conditions of use for trucks are broadly
similar in many plants, so the hazards can be
summarised in one overview. Observe the in-
formation provided by the relevant employers'
liability insurance association on this subject.
5001 801 1624 EN - 05/2022 - 02 39

2 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. In addition, the
truck must be thoroughly checked for damage
that may have been caused by improper use.
A test log must be created. The results of the
inspection must be retained at least until a
further two inspections have been carried out.
The inspection date is indicated by an adhe-
sive label on the truck.
– Arrange for the authorised service centre to
perform regular testing on the truck.
– Observe the guidelines for tests carried out
on the truck in accordance with FEM 4.004.
The operating company is responsible for en-
suring that any defects are remedied without
delay.
– Notify your authorised service centre.
NOTE
In addition, observe the national regulations
for the country of use.
Insulation testing
The insulation of the truck must have sufficient
insulation resistance. For this reason, insula-
tion testing in accordance with DIN EN 1175
and DIN 43539, VDE 0117 and VDE 0510
must be conducted at least once yearly as
part of the FEM testing.
The insulation testing results must be at least
the test values given in the following two ta-
bles.
– For insulation testing, contact the author-
ised service centre.
40 5001 801 1624 EN - 05/2022 - 02

Safety 2
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
test voltage age UBatt
50 VDC 24 volts > 1200 Ω
Batt+
Battery 100 VDC Battery tray 48 volts > 2400 Ω
Batt-
100 VDC 80 volts > 4000 Ω
Test values for the entire truck

Nominal volt- Minimum values over the
Test voltage Test values for new trucks
age duration of the service life
24 volts 50 VDC Min. 50 kΩ > 24 kΩ
5001 801 1624 EN - 05/2022 - 02 41

2 Safety
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 NOx components contained in the
exhaust gas
Modern exhaust gas treatment systems (e.g. catalyt-
ic converters, particle filters or comparable systems)
can clean exhaust gases in a way that reduces the
health hazard and risk of poisoning when operating
the truck.
– Observe the national laws and regulations when
using trucks with an internal combustion engine in
entirely or partially enclosed working areas.
– Always ensure sufficient ventilation.
Safety Regulations Relative to Forklift Use

● The operator must familiarize himself with
the forklift to be able to better describe any ENVIRONMENT NOTE
defects and assist maintenance personnel.
Report any oil and/or battery fluid leaks: they
The operator, trained and authorized to use
are dangerous and highly polluting.
the forklift, must be familiar with the controls
and performances of the forklift.
● Any defect (squeaking, leaks, etc.) must be CAUTION
promptly reported because, if neglected, it If you notice a burning smell, stop the forklift and turn
could cause more serious failures/defects. off the engine, then disconnect the battery.
● Carry out the inspections indicated in the
chapter on "Daily Inspections".
Safety regulations in case of accidental lateral tipping

If as a result of incorrect manoeuvring the c) Remain firmly seated, grip the steering
truck appears to be tipping over sideways, wheel and dig your heels in. Wait until the
carefully follow the instructions below: truck has reached a stable position before
leaving the truck.
a) Do not leave the forklift truck.
b) Tilt your head forward and move your body
in the opposite direction to which the forklift is
tipping.
42 5001 801 1624 EN - 05/2022 - 02

Safety 2
Safety regulations when driving

Driving conduct
The driver must follow the public rules of the
road when driving in company traffic.
The speed must be appropriate to the local
conditions.
For example, the driver must drive slowly
around corners, in tight passageways, when
driving through swing-doors, at blind spots, or
on uneven surfaces.
The driver must always maintain a safe brak-
ing distance from vehicles and persons in
front, and must always have the truck under
control. Stopping suddenly, turning quickly
and overtaking at dangerous or blind spots
must be avoided.
– Initial driving practice must be carried out in
an empty space or on a clear roadway.
The following are forbidden during driving:
● Allowing arms and legs to hang outside the
truck
● Leaning the body over the outer contour of
the truck
● Climbing out of the truck
● Moving the driver's seat
● Adjusting the steering column
● Releasing the seat belt
● Disabling the restraint system
● Raising the load higher than 300 mm above
the ground (with the exception of manoeu-

vring processes during the placement into
stock/removal from stock of loads)
● Using electronic devices, for example ra-
dios, mobile phones etc.
WARNING
The use of multimedia and communication equip-
ment as well as playing these devices at an exces-
sive volume during travel or when handling loads
can affect the operator's attention. 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 - 05/2022 - 02 43

2 Safety
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.
Particularly for reverse travel, the driver must
be sure that the driving lane is clear.
When transporting goods that impair visibility,
the driver must drive the truck in reverse.
If this is not possible, a second person acting
as a guide must walk in front of the truck.
In this case the driver must only move at walk-
ing pace and with extra care. The truck must
be stopped immediately if eye contact with the
guide is lost.
Rear-view mirrors are only to be used for ob-
serving the road area behind the truck and not
for reverse travel. If visual aids (mirror, mon-
itor) are necessary to achieve sufficient visi-
bility, it is necessary to practise using them.
For reverse travel using visual aids, extra care
should be taken.
When using attachments, special conditions
apply; see the chapter entitled "Fitting attach-
ments".
Any glass (variant, e.g. windscreen) and mir-
rors must always be clean and free of ice.
44 5001 801 1624 EN - 05/2022 - 02

Safety 2
Permissible consumables
WARNING Refer to the maintenance data table for the
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! There is a risk of slipping on spilled oil, particularly
when combined with water!
– Follow the statutory regulations
– Collect spilled oil immediately using an oil-binding
– Do not allow oils to come into contact
agent and dispose of it in accordance with regula-
with hot motor parts.
tions.
– No smoking, fires or flames!
ENVIRONMENT NOTE
DANGER
Oils are toxic! Oils are water pollutants!
– Avoid contact and consumption
Always store oil in containers that comply with
– In case of inhalation of steam or
fumes, breathe fresh air immediately.
the applicable regulations.
– After contact with the eyes, rinse thor- Avoid spilling oils.
oughly with water (for at least 10 mi-
nutes) and then consult an eye spe- Collect spilt oil immediately using an oil bind-
cialist. ing agent and dispose of it in accordance with
– If swallowed, do not induce vomiting. regulations.
Seek immediate medical attention.
Dispose of old oils according to the applicable
regulations.
WARNING
Prolonged intensive contact with the skin
can result in loss of skin oils and cause
irritation.
– Avoid contact and consumption.
– Wear protective gloves!
– After any contact, wash the skin with
soap and water and then apply a skin
care product.
– Immediately change soaked clothing
and shoes.
5001 801 1624 EN - 05/2022 - 02 45

2 Safety
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.
– Do not spill these fluids! Always store hydraulic fluid in containers com-
plying with the regulations.
– Follow the statutory regulations
– Do not allow the fluids to come into Avoid spilling.
contact with hot motor parts.
Spilt hydraulic fluid should be removed with
– Do not allow to come into contact with
oil-binding agents at once and disposed of ac-
the skin.
cording to the regulations.
– Avoid inhaling the spray
– Penetration of pressurised fluids into Dispose of old hydraulic fluid according to reg-
the skin is particularly dangerous if ulations.
these fluids escape at high pressure
due to leaks in the hydraulic system.
In case of such injury, seek medical
advice immediately.
– To avoid injury, use appropriate per-
sonal protective equipment (e.g. pro-
tective gloves, industrial goggles, skin
protection and skin care products).
Battery acid
WARNING
Battery acid contains dissolved sulphuric
acid. This is toxic.
– Avoid touching or swallowing the bat-
tery acid at all costs.
– In case of injury, seek medical advice
immediately.
46 5001 801 1624 EN - 05/2022 - 02

Safety 2
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.
– Do not allow any acid to get onto
clothing or skin or into the eyes. If this
does happen, rinse immediately with
plenty of clean water.
– In case of injury, seek medical advice
immediately.
– Immediately rinse away spilt battery
acid with plenty of water.
– Follow the statutory regulations.
ENVIRONMENT NOTE
– Dispose of used battery acid in line with the

applicable regulations.
Non-ionising radiation
If the forklift truck is fitted at the factory or at a
later date with equipment that emits non-ionis-
ing radiation (such as radio transmitters, RFID
transmitters, data terminals, scanners etc.),
the compatibility of this equipment with medi-
cal devices (such as pacemakers and hearing
aids) must be tested and verified.
Medical equipment
When a driver is wearing medical equipment,
e.g. heart pacemaker or hearing aids, the op-
eration of this equipment may be affected.
A doctor or the manufacturer of the medi-
cal equipment should be asked whether the
equipment is sufficiently protected against
electromagnetic interference.
5001 801 1624 EN - 05/2022 - 02 47

2 Safety
Medical equipment
48 5001 801 1624 EN - 05/2022 - 02

3
Overview
3 Overview
General view of Truck
General view of Truck
1 Lift Mast 10 Adblue® filler

2 Cab 11 Fuel filler
3, 4 Hydraulic cooler, Radiator 12 Drive axle
5 Radiator Grille 13 Forks
6 Counterweight 14 Fork carriage
7 Steer axle 15 Lift cylinder
8 Battery isolator 16 Lift chains
9 Battery compartment
50 5001 801 1624 EN - 05/2022 - 02

Overview 3
Safety devices and warning labels
Safety devices and warning labels
1 Type label 13 Made in China label (for export with CE/UK-

2 label 'lwa 105dB cab with no glazing CA)
3 Label,read the operating manual 14 Importer (for UK)
4 Diesel oil indicator sticke 15 Still logo
5 label 'adblue 16 Tyre pressure label
6 label 'SAE 10W-30 17 Nameplate
7 label 'BATTERY ISOLATOR 18 Still logo
8 “Do not stand under forks” label 19 Label,read the operating manual
9 label - electrical danger 20 Wheel torque card
10 label '25 km/h 21 Label,read the operating manual
11 Label,read the operating manual 22 symbol insert 'ISO 3287-16x12
12 Still logo
5001 801 1624 EN - 05/2022 - 02 51

3 Overview
Controls
Controls
1 Steering wheel 9 Parking brake switch

2 Turn indicator 10 Horn
3 Ignition key switch 11 Armrest
4 Heater control (Climate control) 12 Accelerator pedal
5 Storage area 13 Brake pedals
6 Direction lever 14 Clamping screw for steering column adjust-
7 Central control levers (joysticks) ment
8 Driver controller (option) 15 Multiple function electrical control lever
52 5001 801 1624 EN - 05/2022 - 02

Overview 3
Switch panel
Switch panel
The switch panel is mounted at the top right 7 Roof panel wiper - intermittent mode or con-
of the overhead guard. tinuous operation on/off (washer system is
1 Terminal board light and interior lighting activated)
2 Standard or higher lighting 8 Rear window heating
3 Working spotlight position 1/2 9 Strobe beacon
4 Working spotlight position 3/4 or working 10 Rotating beacon, flashing beacon or Blue-
spotlight position 5/6 Spot
5 Working spotlight position 7/8 11 Blank
6 Front windscreen wiper and rear window 12 Blank
wiper — continuous operation on/off (inter- 13 Blank
val depends on the drive direction and the 14 Blank
washer system is always activated)
NOTE
The configuration of the switch panel and ar-
rangement of individual switches may vary,
depending on the version. Observe the switch
symbols.
5001 801 1624 EN - 05/2022 - 02 53

3 Overview
Switch panel
54 5001 801 1624 EN - 05/2022 - 02

4
Operation
4 Operation
Service plan before initial commissioning
Service plan before initial commissioning

Engine
Fill up with fuel
Fill up with Adblue and check for leaks
Check the engine oil level
Check the engine coolant level
Gearbox
Check the oil level in the gearbox
Check the oil level in the drive axle
Chassis undercarriage
Tighten the wheel fastenings
Check the tyre pressure
Controls
Check the brake system
Check the steering system
Electrics
Check the condition of the batteries
Hydraulics
Check the oil level in the hydraulic system
Load lift system
Check the lifting system and attachments
Pre-shift checks
Engine
Check the fuel level
Check AdBlue® fluid level
Check the engine oil level
Check the engine coolant level
Check the truck for leaks (visual inspection)
Chassis, bodywork and fittings
Check that the adjusting mechanism on the steering column is secure
Check the condition of the driver's seat and seat belt (visual inspection)
Washer system: Check the fill level in the container, check the wipers
Chassis
Check the tyres and rims (profile, external damage, air pressure and tightness of wheel fasten-
ers)
Check the condition of the antistatic belt (only when using tyres that are not antistatic)
Controls
56 5001 801 1624 EN - 05/2022 - 02

Operation 4
Regular maintenance
Check the service brake system

Checking the parking brake system
Check the traction controller
Electrical system
Check the electrical system (such as lighting, alarm system)
Hydraulics
Check the truck for leaks (visual inspection)
Load lifting system
Check the pallet fork and door frame for damage (such as bending, cracks, wear etc.)
Regular maintenance
Performing the maintenance tasks listed here
will increase the availability of your truck and
help maintain its value. Carry out this work as
frequently as possible in accordance with the
application conditions.
● Clean the truck.
● Drain water from the fuel pre-filter.
● Clean and lubricate all pivots, bearings and
hinges.
● Clean and lubricate the steering axle
(please check the Servive plan tablefor

mentainance time).
● Tighten the wheel fastenings (after each in-
stance of maintenance or repair, and after

100 operating hours at the latest).
● Clean the lift mast chain and apply chain
spray.
Wheel removal — drive axle

Refer to your Local / National authority
guidelines.
For example: OSHA (Occupational Safety &
Health Administration)/ EUWA (Association of
European Wheel Manufacturers/ HSE (Health
& Safety Executive).
CAUTION
Wear personal protective equipment (PPE).
Do not carry out these procedures without PPE.
5001 801 1624 EN - 05/2022 - 02 57

4 Operation
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.
DANGER
Before demounting a multi-piece rim wheel from a
vehicle the operator must completely deflate the tyre
by removing the valve core. Always check that the
tyre is fully deflated using a tyre pressure gauge.
NOTE: the valve may become blocked with ice.
Check that the valve stem has not frozen.
DANGER
Always use a restraining device during tyre defla-
tion/inflation on multi-piece rim wheels. If a restrain-
ing device is not being used then tyres must be
deflated/inflated using remote control inflation equip-
ment and no employees shall remain in the wheel
rim separation trajectory zone.
DANGER
Fully deflate the tyre before carrying out a thorough
examination of suspected damage to any wheel or
tyre.
Removing an outer drive wheel

– Park the truck on level ground in a safe
working area.
– Chock the wheels.
– Isolate the ignition/batteries.
– Jack up the truck at the jack points and se-
cure with an axle support device. DO NOT
RELY ON JUST THE JACK.
58 5001 801 1624 EN - 05/2022 - 02

Operation 4
– Place a protection device around the wheel 

assembly being removed.
– Remove the valve cores and fully deflate 

the tyres (see warnings). 120 degrees
m
DANGER
50
Do not allow anyone to enter the area shown in Fig 2
during deflation of the tyre.
CAUTION
Ensure the valve stem has not frozen during defla-
tion.
If necessary use antifreeze to prevent the valve stem
freezing.
50
m
– Use a tyre pressure gauge to ensure the 120 degrees

tyres are fully deflated.
Fig 2
– Remove the protection device.
5001 801 1624 EN - 05/2022 - 02 59

4 Operation
– Carefully drive the forks of a second fork 

truck with holder (3) under the outer drive
wheel.
– Slowly lift the forks until the wheel rests on 3
them. (Do not touch the inner drive wheel
4
(5)).
5
d3571099
– Remove all wheel fasteners (1). 
60 5001 801 1624 EN - 05/2022 - 02

Operation 4
Wheel refitting — drive axle
– Tilt outer wheel (4) against holder (3) and 

secure it.
– Carefully reverse the truck with the tyre and
deposit it. 3
4
Removing an inner drive wheel
– Remove the outer drive wheel.
– Carefully drive the forks of a second fork 

truck with a holder (3) under the inner drive
wheel (5). 3
– Slowly lift the forks until the wheel rests on

them.
– Tilt the inner wheel against the holder and
secure it.
– Carefully reverse the truck with the tyre
clear of the truck.
d3571097

Refer to you Local / National authority guide-
lines.
For example: OSHA (Occupational Safety &
Health Administration)/ EUWA (Association of
European Wheel Manufacturers/ HSE (Health
& Safety Executive).
CAUTION
Wear personal protective equipment (PPE).
Do not carry out these procedures without PPE.
5001 801 1624 EN - 05/2022 - 02 61

4 Operation
DANGER
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.
DANGER
Always use a restraining device during tyre defla-
tion/inflation on multi-piece rim wheels. If a restrain-
ing device is not being used then tyres must be
deflated/inflated using remote control inflation equip-
ment and no employees shall remain in the wheel
rim separation trajectory zone.
Mounting an inner drive wheel
NOTE
Only use tyres approved by the manufacturer.
– Put the inner wheel (5) on the forks of a 
second truck and secure it on the holder
(3).
– Clean the mating surface on the hub and 3
rim.
4
5
d3571099
62 5001 801 1624 EN - 05/2022 - 02

Operation 4
– Carefully drive the truck with the wheel (5) 

to the wheel hub and align it.
3
d3571097
– Align the wheel (5) on the hub. 

– Slowly lower the forks until the drive wheel
sits on the hub.
– Carefully reverse the second truck. 3
4
– Install the spacer ring.
5
d3571099
5001 801 1624 EN - 05/2022 - 02 63

4 Operation
Mounting an outer drive wheel

– Put the outer wheel on the forks of a sec- 
ond truck and secure it in place.
3
– Clean the mating surface on the hub and
rim.
d3571097
– Carefully drive the truck with the wheel (4) 

to the wheel hub and align it.
– Slide the wheel (4) over the wheel hub.
– Remove the wheel retainer on the holder 3
(3). 4
– Align the wheel (4) on the hub.
64 5001 801 1624 EN - 05/2022 - 02

Operation 4
– Seat the wheel assembly onto the hub by 

tightening 10 wheel fasteners diametrically
opposed to 680 Nm.
– Tighten the remaining wheel fasteners .
– Torque all wheel fasteners, in a diametrical-
ly opposed pattern.
– Slowly lower the forks.
– Carefully back off the second truck.
– Place protection device around the wheel 

assembly.
5001 801 1624 EN - 05/2022 - 02 65

4 Operation
– Ensure the trajectory zone is kept clear. 

– Inflate the tyres to 10 bar at the filler valves. 120 degrees
– Inspect the wheel assembly to ensure the
m
50
lock ring is correctly seated.
DANGER
Do not hammer any part of the rim wheel while the
tyre is pressurised.
– Remove the protection device.

– Remove the axle support and jack.
50
– After a wheel has been refitted, check the
m
torque every 10 hours until the torque set- 120 degrees
ting remains constant. Check every 100 Fig 2

hours therefater.
– Check tyres for defects every day.
– Check tyre pressures every week.
66 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
Standard equipment
Mirrors
CAUTION
Risk of collision.
Do not operate the truck if visibility is impaired.
Rear view mirrors should be cleaned and ad-

justed to suit the operator before commence-
ment of operation, and it should be noted that
they are only provided for checking the vicinity
of the truck before moving off, and to monitor
the rear traffic area.
Reversing is only allowed with a direct view in
the reverse direction of travel.
Entering and exiting the truck

Entering the cab
– Open the cab door.
– Use handrails where fitted to climb the
steps and enter the cab.
– Enter the cab in a forward direction.
– Close the cab door.
Exiting the cab
– Exit the cab in a backwards direction.
– Use handrails where fitted to climb down
the steps and exit the cab.
WARNING
Risk of injury from entering and exiting the truck in-
correctly.
Face the truck when entering and exiting.
5001 801 1624 EN - 05/2022 - 02 67

4 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).
– Press the button(7) inside the cab to re-
lease the door. Pull the door outwards.
Closing the cab door
NOTE
To make it easier to close the door, open the
side window slightly.
– Lift lever (1) inside the cab, or pull down the
lever on the door retainer (3) to release (2).
Pull the door outwards.
– Grip the rod (4) and pull the door towards
you until the interlock engages.
Opening/closing the side window

– Press button (1) or (2).
– Keep the knob pressed, slide the side win-
dow into the desired position until it engag-
es in one of the grooves (6).
68 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
To tilt the cab forward

CAUTION
When tilting, if the cab strikes the lift mast, the cab
will be damaged.
Before tilting the cab, ensure that the lift mast is tilted
fully forward.
NOTE
If the truck is equipped with a lift mast tilt an-
gle potentiometer, there is a safety option to
prevent the lift mast from tilting fully forward.
● Starting from the -10° position, the lift mast
tilts forward by 5° and then stops.

● To tilt the lift mast forward to the maximum
tilt angle of 15°, the driver must first return

the operating lever to the neutral position
and then tilt the operating lever forward.
– Raise the forks approximately 3 feet (1 m)
and tilt the lift mast fully forward.
5001 801 1624 EN - 05/2022 - 02 69

4 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 
forward. Push and hold the switch, until the
cab is fully tilted.
– Once the cab is raised, pull strut rod (3) up 

and secure it in the trough to prevent the
cab from falling.
WARNING
The cab is heavy and can cause injury if someone is
below the cab during lowering.
Stand clear of the cab and do not approach when it
is partially tilted, or being raised or lowered. The cab
must be locked in the fully tilted position, and the tilt
handle must be properly inserted into the safety ring
before maintenance can begin.
70 5001 801 1624 EN - 05/2022 - 02

Operation 4
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. Push and hold the switch, until the cab
is fully lowered.
5001 801 1624 EN - 05/2022 - 02 71

4 Operation
Standard equipment
Standard driver's seat and com-

fort driver's seat
WARNING
If the seat is not adjusted correctly, this may cause
injury to the driver's back. The setting devices for the
driver's seat must not be used during operation of
the truck.
Before commissioning the truck each time and when-
ever changing drivers, adjust the seat to correspond
to the driver's weight and make sure that the settings
have all engaged properly. Do not place any objects
in the driver's rotation range.
NOTE
Sitting for long periods of time puts a lot of
pressure on the spine. This pressure can be
relieved by performing simple therapeutic ex-
ercises at regular intervals.
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.
– Allow the lever (1) to engage.
Adjusting the seat backrest

– Push the lever (2) upwards and hold it in
place.
– Move the seat backrest forwards or back-
wards until a comfortable seat position for
the driver is found.
– Release the lever (2).
72 5001 801 1624 EN - 05/2022 - 02

Operation 4
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).
Adjust the driver's weight as necessary.
– Pull out the lever (3).
Move the lever to set the driver's weight for
the suspension.
– Move the lever (3) upwards for a heavier
weight.
– Move the lever (3) downwards for a lighter
weight.
Adjusting the lumbar support (only with 

a comfort driver's seat)
NOTE
The lumbar support enables the seat backrest
contour to be optimally adapted to the driver's
body.
– Turn the knob (5) to the left or right.
The extent to which the lower and upper areas
of the backrest are curved is adjusted individu-
ally.
5001 801 1624 EN - 05/2022 - 02 73

4 Operation
Standard equipment
Activating the seat heater (comfort driv- 

er's seat only)
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
– Push the switch (6a) upwards to activate
the seat heater.
– Push the switch (6a) downwards to deacti-
vate the seat heater.
NOTE
The maximum temperature is predefined.
Adjusting the armrest 
– Sit on the driver's seat and release clamp-

ing screw (1).
– Move armrest (2) upwards/downwards and
forwards/backwards until the arm is com-
fortably supported and the joysticks (3) can
be easily reached.
– Tighten clamping screw (1).
74 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
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.
Before attempting to drive the truck, ensure that the
steering column is screwed firmly in place with the
clamping screw (2).
Angle adjustment
– Undo the clamping screw (2) anticlockwise. 
– Move the steering wheel (1) into the re-
quired position.
– Tighten the clamping screw (2) clockwise.
Height adjustment
– Undo the clamping screw (2) anticlockwise.
– Move the steering wheel (1) into the re-
quired position by pulling it upwards or
pushing it downwards.
– Tighten the clamping screw (2) clockwise.
Seat belt
DANGER
There is a risk to life if the driver leaves
the vehicle in an uncontrolled manner.
For this reason, the seat belt must al-
ways be worn when operating the truck!
The seat belt should only be worn by
one person.
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.
5001 801 1624 EN - 05/2022 - 02 75

4 Operation
Standard equipment
NOTE
Driver's cabs with fixed closed doors or brack-
et doors meet the safety requirements for driv-
er restraint systems. The seat belt may also
be used. It must, however, be fastened when
driving with doors that are open or have been
removed. PVC doors do not constitute a driver
restraint system. For trucks with the "speed
reduction" special function, the seat belt must
be worn even at the reduced speed.
The automatic blocking mechanism prevents
the belt from being extended whenever the in-
dustrial truck is on a steep slope. It is then not
possible to pull the belt any further out of the
retractor. To release the automatic blocking
mechanism, carefully move the industrial truck
so that it is no longer positioned on a slope.
While using the truck (e.g. driving, operating
the lift mast etc.), the driver should adopt a
sitting position as far back as possible so
that his/her back rests against the seat back-
rest. The automatic blocking mechanism for
the belt retractor offers sufficient freedom of
movement on the seat for normal use of the
truck.
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).
– Check seat belt tension.
The belt must fit close to the body.
Unfastening the seat belt

– Push the red button (5) on the buckle (4).
– Manually feed the buckle guide (1) back in-
to the retractor (3).
76 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
NOTE
The automatic blocking mechanism may be
triggered if the web belt runs in too quickly and
the buckle guide strikes the housing. The web
belt cannot be pulled out with the usual force.
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.
1 2
d3961038c
Heating system, air conditioning

Heating operation
Operating options:
● Manual heating operation
● Automatic heating operation
5001 801 1624 EN - 05/2022 - 02 77

4 Operation
Standard equipment
Operating devices of the heating sys-  1 2

tem
● Cab air nozzle (1)
● Function display (2)
● Turning knob (3) for setting the vent posi-
tions: window defrosting - footwell ventila- 0
1 2 3
4
tion
● Push button (4) for switching the automatic
heating on and off
AUTO
● Turning knob (5) for adjusting the blower

levels: levels 1 to 4
● Turning knob (6) for temperature control:
left-hand end position ≙ cold / right-hand
end position ≙ hot
● Left and right cab air nozzles (not shown)
6 5 4 3 d3961028c
Manual heating operation

Push button (4) for automatic operation must  1 2
be switched off.
Switching on the heating system
– Turn the turning knob (5).
The blower is switched on and the air flow is 1 2 3
set to the selected level.

0 4
Normal heating operation: AUTO
– Use the turning knob (6) to adjust the tem-

perature.
– Use the turning knob (5), the turning knob
(3) and the left and right cab air nozzles to
adjust the temperature and the temperature
distribution. 6 5 4 3 d3961028c
Settings for demisting the windows
– Turn the turning knob (6) to hot (right-hand
end position).
– Turn the turning knob (3) to window defrost-
ing (left-hand end position).
– Turn the turning knob (5) to level 4.
– Open the left and right cab air nozzles and
direct the vents towards the windscreen.
78 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
Automatic heating operation

– Use the turning knob (6) to adjust the tem-  1 2
perature.
– Press the push button (4).
The automatic heating is switched on and the
function display (2) illuminates in green. The
blower level is now controlled automatically. 1 2 3
0 4
NOTE AUTO
If the position of the turning knob (5) for the

blower levels is changed, the heating system
automatically switches to "manual heating op-
eration".
CAUTION 6 5 4 3 d3961028c
If the function display (2) flashes five times after
switching on and then goes out, there is an error with
the automatic heating.
Contact your service partner.
Heating/air conditioning operation

Operating options:
● Manual air conditioning operation
● Automatic air conditioning operation
● Manual heating operation
● Automatic heating operation
CAUTION
Damage to the compressor!
Switch on the air conditioning every four weeks for at
least ten minutes to prevent seizing of the bearings
in the compressor.
The air conditioning must be serviced once a year by
the service partner.
It is normal for condensation water to build up

in the hoses and under the truck when the air
conditioning is in operation.
5001 801 1624 EN - 05/2022 - 02 79

4 Operation
Standard equipment
Operating devices for heating/air condi-  7 8

tioning operation
● Cab air nozzle (7)
● Turning knob (9) for setting the vent posi-
tions: window defrosting - footwell ventila- 0
1 2 3
4
tion
● Push button (10) for switching the automatic
function on and off AC AUTO
● Turning knob (11) for adjusting the blower

levels: levels 1 to 4
● Push button (12) for switching the air condi-
tioning on and off
● Turning knob (14) for temperature control: 14 13 12 11 10 9
left-hand end position ≙ cold / right-hand
d3961029c
end position ≙ hot

● Left and right cab air nozzles (not shown)
Manual air conditioning operation

Push button (10) for automatic operation must  7 8
be switched off.
Switching on the air conditioning
The blower is switched on and the air flow is 1 2 3

0 4
– Press the push button (12). AC AUTO
The air conditioning is switched on and the

function display (13) lights up green.
The air conditioning works only when the en-
gine is running and the turning knob (11) is
switched on (level 1 to 4). The fans on the
condenser in the roof are switched on as nec- 14 13 12 11 10 9 d3961029c
essary. It is possible for these fans to come to
a standstill from time to time.
CAUTION
the air conditioning.
80 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
Normal heating and air conditioning opera-
tion:
perature.
adjust the temperature and the temperature
distribution.
NOTE
On cool, humid days, the heater and air con-
ditioning can be used to dehumidify the air
in the cab. By operating the heater and the
air conditioning simultaneously, the heater can
counteract the cooling effect. This produces a
more pleasant temperature inside the cab and
prevents misting of the windows.
Settings for maximum cooling in the cab
– Switch on the air conditioning.
– Turn the turning knob (14) to cold (left-hand
end position).
– Open the left and right cab air nozzles.
– Close the windows and doors.
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.
5001 801 1624 EN - 05/2022 - 02 81

4 Operation
Standard equipment
Automatic air conditioning operation

– Use the turning knob (14) to adjust the tem-  7 8
perature.
– Press the push button (10).
The automatic air conditioning is switched on
and the function displays (8) and (13) illumi-
nate in green. The blower level is now control- 1 2 3
0 4
led automatically.
The air conditioning operates only if the en- AC AUTO
gine is running. The fans on the condenser in

the roof are switched on as necessary. It is
possible for these fans to come to a standstill
from time to time.
NOTE 14 13 12 11 10 9 d3961029c
If the position of the turning knob (11) for the

blower levels is changed or push button (10)
is used to switch off the automatic function,
the air conditioning automatically switches
to "manual air conditioning operation". If the
push button (12) is used to switch off the air
conditioning, the air conditioning automatically
switches to "automatic heating operation".
CAUTION
If the function displays (8) or (13) flash five times
after switching on and then go out, there is an error
with the automatic heating/air conditioning or with the
air conditioning.
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.
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.
82 5001 801 1624 EN - 05/2022 - 02
Operation 4
Standard equipment
Manual heating operation

– The push button (12) for the air conditioning  7 8
and the push button (10) for the automatic
mode must be switched off.
Switching on the heating system
1 2 3
The blower is switched on and the air flow is

0 4

AC AUTO
Normal heating operation:
perature.
adjust the temperature and the temperature 14 13 12 11 10 9 d3961029c
distribution.
Settings for demisting the windows
– Turn the turning knob (14) to hot (right-hand
end position).
– Turn the turning knob (9) to window defrost-
ing (left-hand end position).
– Open the left and right cab air nozzles and
direct the vents towards the windscreen.
Automatic heating operation

The push button (12) for the air conditioning
must be switched off.
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. The
function display (8) illuminates in green. The
blower level and temperature are controlled
automatically.
5001 801 1624 EN - 05/2022 - 02 83

4 Operation
Standard equipment
NOTE
If the position of the turning knob (11) for
the blower levels is changed, the heating sys-
tem automatically switches to "manual heating
operation". Windscreen defrosting can be per-
formed only in manual mode.
CAUTION
the automatic heating.
Display unit-Parker
The touchscreen display unit is mounted to the top right-hand side of the cabin. It is positioned
within the driver’s field of vision and provides centralised information about all functions of the
truck. Once the key switch has been switched on, a self-test of the display unit is then performed.
During the self-test, all indicator lights and the displays are activated.
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.
84 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
Icon Description
1 Mast angle 16 Engine error indicator light (low)

2 Load weight display 17 Engine error indicator light (high)
3 Time display 19 Speed gear
4 Parking brake 20 Fuel gauge
5 Engine oil pressure warning light 21 Urea gauge
6 Preheat light 22 Engine RPM gauge
7 Engine oil level 23 Driving speeds
8 DEF alarm light 24 Easy interface switching
9 DPF alarm light 25 One touch weighing
10 DEF limit torque indicator 30 Service interface
11 Exhaust temperature alarm light 31 Engine interface
12 DEF alarm light 32 Transmission interface
13 Transmission oil level light 33 Hydraulic Interface
14 DPF regeneration indicator light 34 Weighing interface
15 Coolant level 35 System parameter interface
5001 801 1624 EN - 05/2022 - 02 85

4 Operation
Standard equipment
Engine interface 
When DPF require regeneration, start regen-
eration by pushing the (1) button on the dis-
play unit
Transmission interface 
86 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
Frequent cold starts increase wear.
– Sit on the driver's seat.
– Fasten the seat belt (if seat belt is fitted).
5001 801 1624 EN - 05/2022 - 02 87

4 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".
Electrical system start-up.
– Turn the key to position "II".
You have to wait for the display to boot up to
start the truck
As soon as the engine starts:
– Release the key. Do not engage the starter
continuously for more than 30 seconds.
88 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
– The forklift will display the screen when it 

starts.
– The display unit will then show the tachom-
eter screen displaying: engine rpm, fuel lev-
el, Adblue® level, neutral and park brake
status.
CAUTION
Danger of poisoning!
Do not leave the engine running in unventilated
areas.
If the engine fails to start:

– Ensure that the preheating process is com-
plete. Depending on the truck version, tem-
perature and altitude, preheating may re-
quire up to one minute or more. Once the
preheating process is complete, engage the
starter until the engine runs at idle speed.
Do not engage the starter continuously for
more than 30 seconds.
NOTE
A block against repeat starting is active and
the engine cannot be started.
– Always leave the ignition switched on until
the symbol goes out.
– 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".
The engine speed is controlled automatically,
depending on the load on the engine.
NOTE
Do not allow the engine to warm up at idling
speed. When under load, drive the truck at a
brisk speed. The engine will quickly reach its
operating temperature.
5001 801 1624 EN - 05/2022 - 02 89

4 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.
Do not switch off engine under full load, but rather
allow it to run on for a few minutes at low speed.
– Remove your foot from the accelerator ped-

al (3).
– Apply park brake by pressing park brake 
switch (1)
– Move the direction selection lever to the 

neutral position.
– Turn the ignition key to the zero position.
NOTE
The brake is applied automatically when the
engine is switched off.
– Remove the ignition key when leaving the
truck.
90 5001 801 1624 EN - 05/2022 - 02

Operation 4
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 data
sheet were derived from the tractive force of
the truck and they apply only for crossing ob-
stacles and for short differences in level.
Always accommodate your driving style to suit
the conditions of the roadway (rough surfaces,
etc), especially hazardous work areas and the
load.
CAUTION
Danger of damage to the cab door.
Ensure the cab door is secured in the closed posi-
tion.
CAUTION
Danger of accident while reversing.
Take extra care.
Rear view mirrors should be cleaned and ad-

justed to suit the operator before commence-
ment of operation, and it should be noted that
they are only provided for checking the vicinity
of the truck before moving off, and to monitor
the rear traffic area. Reversing is only allowed
with a direct view in the reverse direction of
travel.
– Always look in the direction of travel and
have an adequate overview of the road
ahead, including to the sides when steering.
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.
5001 801 1624 EN - 05/2022 - 02 91

4 Operation
Standard equipment
The truck should then only be driven at walk-

ing speed with particular caution being exer-
cised. If visibility aids are required (e.g. mir-
rors, camera/monitor), to ensure adequate
sight, then training should be given for driving
with these aids.
– Start the engine using ignition key.
– Elevate the forks slightly and tilt the mast
back.
– Release park brake by depressing service
brake pedal and then pressing the park
brake switch.
NOTE
Applying the footbrake while releasing the
park brake prevents unintentional truck move-
ment.
Single pedal
Forward travel
– Ensure that the pedal area inside the cabin 
is clear of obstruction and debris before at-
tempting to drive the truck.
– Push direction lever (2) forward.
– Depress accelerator pedal (4) gently. Truck
speed depends on how far the pedal is de-
pressed.
NOTE
Quick flooring of the accelerator pedal is not
recommended as the maximum acceleration
rate is controlled automatically.
Reverse travel
– Pull direction lever (2) back.
– Depress accelerator pedal (4). The truck
will reverse at a speed depending on the
position of the accelerator pedal.
NOTE
Stopping the truck first before reverse travel.
Stopping
92 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
– 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.
Shut down the engine if making a longer
stop. When leaving the truck unattended,
remove the ignition key (1).
Joystick with central lever opera-

tion
WARNING
There is a risk of becoming trapped be-
tween parts due to the moving lift mast
or attachment.
For this reason, never reach into or enter
the lift mast or the area between the lift
mast and the truck.
The lifting system and attachments must
only ever be used for their intended pur-
pose.
Drivers must be trained in how to oper-
ate the lifting system and attachments.
Take note of the maximum lift height.
NOTE
Extreme loading of the internal combustion
engine leads to a slight delay in executing
the working hydraulics due to the associated
decrease in the number of revolutions. Where
the engine is loaded for an extended period,
the joystick must be switched to the neutral
position in order to release the working hy-
draulics again.
5001 801 1624 EN - 05/2022 - 02 93

4 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).
– Take note of the switching symbols with di-
rectional arrows.
The joystick must always be operated gently,
and never in a jerking motion. The deflection
of the joystick is used to determine the lift-
ing/lowering and tilting speed. Once the joy-
stick is released, it automatically returns to its
initial position.
NOTE
Joysticks only function when the engine is run-
ning and the driver is sitting in the driver's
seat.
Lifting the fork carriage 
DANGER
When lifting and lowering the fork arms, there is an
increased risk of falling and crushing.
For this reason, do not step onto the raised fork
arms.
– Push the joystick (1) to the right.
Lowering the fork carriage

– Push the joystick (1) to the left.
94 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.). Observe the working pres-
sure and operating instructions for the attach-
ment. An additional joystick (cross lever) is
fitted for operating these attachments.
CAUTION
Attachments alter the load capacity and stability 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
stability ensures safe operation.
NOTE
The methods of operating the attachments de-
scribed here are examples. The configuration
of the joystick may vary depending on your
truck's equipment.
– Take note of the switching symbols with di- 
rectional arrows.
5001 801 1624 EN - 05/2022 - 02 95

4 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.
The sideshift moves to the right.
Operating the fork prong positioner 
NOTE
To prevent damage, do not operate the fork
prong positioner with a load or when the fork
arms are on the ground. Do not use the fork
prong positioner as a clamp.
The fork arms move outwards.
The fork arms move inwards.
96 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
When turning, the actual centre of gravity of
the load must therefore not be more than
100 mm (truck rated capacity below 6300 kg)
or 150 mm (truck rated capacity between
6300 kg and 10,000 kg) outside the pivot
point!
NOTE
Ensure that there is sufficient distance when
turning to prevent damage.
rectional arrows.
– Push the joystick (2) to the left. 
The truck moves anti-clockwise.
The truck moves clockwise.
5001 801 1624 EN - 05/2022 - 02 97

4 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.

rectional arrows.
98 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
The lifting system and attachments must only

ever be used for their intended purpose.
Drivers must be trained in how to operate the
lifting system and attachments.
Take note of the maximum lift height.
Operating the lifting and tilting equip- 

ment
– Observe the symbols with directional ar-
rows.
The joystick must always be operated gently,
and never in a jerking motion. The deflection
of the joystick is used to determine the lift-
ing/lowering and tilting speed. Once the joy-
stick is released, it automatically returns to its
initial position.
NOTE
Joysticks only function when the engine is run-
ning and the driver is sitting in the driver's
seat.
5001 801 1624 EN - 05/2022 - 02 99

4 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.
Lowering the fork carriage

Tilting the lift mast forwards 

NOTE
If the truck equipped with a mast angle poten-
tiometer, there is a safety option to prevent
mast tilting forward fully.
● Tilting the mast forward starting at -10°, the
mast will move forward 5°, then stops.

● Only when the driver returns the joystick to
the neutral position and tilt forward again,

the mast will continue to move to the maxi-
mum forward degree of 15°.

Operating attachments
Attachments can be fitted to the truck as spe-
cial equipment (e.g. sideshift, fork prong posi-
tioner, rotator, clamp etc.). Observe the work-
ing pressure and operating instructions for the
attachment. Additional joysticks are fitted for
operating these attachments.
100 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
NOTE
The methods of operating the attachments de-
scribed here are examples. The configuration
of the joystick may vary depending on your
truck's equipment.
– Observe the symbols with directional ar- 
rows.
Operating the sideshift 
NOTE
Do not operate the sideshift when the fork
arms are on the ground.
The sideshift moves to the left.
The sideshift moves to the right.
5001 801 1624 EN - 05/2022 - 02 101

4 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.
The fork arms move outwards.
The fork arms move inwards.
Operating the rotator (optional equip- 

ment)
DANGER
Danger of instability of the truck.
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.
When turning, the actual centre of gravity of
the load must therefore not be more than
100 mm (truck rated capacity below 6300 kg)
or 150 mm (truck rated capacity between
6300 kg and 10,000 kg) outside the pivot
point!
NOTE
Ensure that there is sufficient distance when
turning to prevent damage.
– Observe the symbols with directional ar-
rows.
102 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
– Push the joystick (5) forwards. 

The truck moves anti-clockwise.
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. a bale clamp), a lockable joystick must be used.
If your truck is not fitted with this equipment, please

rectional arrows.
Steering
Hydrostatic steering means that very little ef-
NOTE
fort is required to turn the steer wheels of the
truck. This is particularly advantageous when The truck is fitted with steering acceleration
driving in narrow aisles. which automatically adjusts the turning speed
according to the speed that the steering wheel
– Start the truck. is turned.
– Turn the steering wheel to the left and right
through the full cycle.
5001 801 1624 EN - 05/2022 - 02 103

4 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.
slowly, the truck will not return to its original
direction. – Do not continue to operate the truck with
faulty steering.
– Always look at the direction of the truck. Do
not rely on the steering wheel position.
Horn 
Operating the horn

When operating at blind corners and junctions,
a horn serves as warning signal.
– Press the horn button(1) on the armrest.
Service brake 
To operate the service brake:

– Release accelerator pedal (3) and allow it to
return to its rest position.
– Depress either brake pedal (4).
CAUTION
In case of an emergency, switching off the ignition
key (2) will apply the handbrake, bringing the truck to
a complete stop and disabling all hydraulic functions.
104 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
To apply the parking brake manually:
– To apply the parking brake, press brake
pedal(4) and hold parking brake switch (1)
until the parking brake warning symbol on
the truck display monitor illuminates.
– To release the parking brake, depress serv-
ice brake pedal (4) and then press parking
brake switch (1). This is a safety system to
prevent unintended release of the parking
brake.
WARNING
Risk of accident.
If the braking system is becoming faulty or worn,
contact your authorised dealer. Do not drive your
truck with faulty brakes.
Automatic parking brake operation

– Set up the automatic parking brake func-
tion.
NOTE
Specialist knowledge is required for setting up
the automatic parking brake function. Contact
your service partner.
If set up the automatic parking brake function:
When forward or reverse gear is selected, and
the throttle pedal is pressed, the parking brake
indicator will extinguish.
When stationary, with the service brake ap-
plied and in gear, following a period of 5 or
more than 5 seconds, the parking brake will
automatically engage and the indicator will
flash.
5001 801 1624 EN - 05/2022 - 02 105
4 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
Don't parking the truck on an unattended incline.
Override Key 
The truck management system will detect

faults in the system and forces the truck to
a 'limp home' condition or will stop the function
causing the fault. Using the override key, the
operator can operate the truck for a short time
to return to a safe condition.
NOTE
Override key(1) may only be used by author-
ised persons who can estimate and bear re-
sponsibility for the safety risk when lowering
the load.
CAUTION
Exercise extreme caution. Some safety features are
disabled when the override key is activated.
106 5001 801 1624 EN - 05/2022 - 02

Operation 4
Standard equipment
Battery access - opening 
– Batteries are located in a compartment on

the rear left side of the truck.
– Check that door swing area is free from ob-
struction.
– Open door.
Battery access - closing

– Close door.
Batteries - isolate 
The battery isolator is located to the rear of
the battery access compartment.
– To isolate the batteries, rotate handle (1)
90° anti clockwise. The batteries are now
isolated.
– To restore battery power, return handle (1)
to original position.
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.
5001 801 1624 EN - 05/2022 - 02 107

4 Operation
Standard equipment
To tow the truck
1 Caliper body 9 Piston

1a O-ring seal 10 Thrust bolt
2 Circlip 11 Magnet
3 Wrench (24/30 mm) 12 Friction pad
4 Screw-cap 13 Friction pad
5 Allen key wrench (8/10 mm) 14 Guide bolt
6 Adjusting screw 15 Split-pin
7 Lock-nut 16 Castellated nut
8 Spring stack 17 Bleed nipple
NOTE
Read and understand this maintenance pro-
cedure before starting any work. If you are
unsure of any aspect of this procedure, con-
tact your service partner.
Safety conditions
The maintenance procedures that follow may
involve the assembly and or movement
of heavy hydraulic equipment, excitation of
108 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
Emergency release of parking brake

DANGER
Risk of crush injuries and or death
Do not work on or under a truck unless it is preven-
ted from any movement.
– Park truck on suitable level ground.

– Before any maintenance is started, make
sure the truck is completely immobilised,
(not able to move).
– Place chocks under wheels.
– Remove ignition key from cab of truck.
– Do not allow unauthorized personnel to en-
ter the cab.
WARNING
Risk of personal injury.
Brake disc rotors and friction pads can become very
hot.
– make sure all component parts are cool be-

fore starting any maintenance.
– Release screw-cap (4).
– Release lock-nut (7).
NOTE
40 to 70 Nm is required to release the brake
using adjustment screw (6).
– Turn adjustment screw (6) anticlockwise un-
til brake disc rotor is free.
– If the truck is to remain in this condition
for any length of time, refit screw-cap (4)
5001 801 1624 EN - 05/2022 - 02 109

4 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.
– Exit the cab in a backwards direction.
– Use handrails where fitted to climb down
the steps and exit the cab.
WARNING
Risk of injury from entering and exiting the truck in-
correctly.
Face the truck when entering and exiting.
110 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
Optional equipment
Drive controller  2
1
NOTE
The truck status display unit can be navigated
in two ways, described below is using the but-
tons on the armrest.
d1411039
The drive controller is operated using the rota- 

ry/push button (2), the "Back" button (1) and
the "Switch" button (3).
Turning the rotary/push button 

Turning the rotary/push button to the left or
right allows the following actions to be carried
out:
● Scroll between menu items
● Change values continuously or in incre-
ments (brightness, digit value or numerical

value)
5001 801 1624 EN - 05/2022 - 02 111

4 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
limits)
● Assign or overwrite favourite position
● Select function or display after entering the
PIN code
● Delete programmed values
● Delete favourite
● Set new time/date or PIN code
● Reset consumption
"Back" button 
Briefly pressing the "Back" button allows the
following actions to be carried out:
● Go back one menu level
● Acknowledge a message
"Switch" button 
Briefly pressing the "Switch" button allows the
following actions to be carried out:
● Switch between favourites
● Jump from the menu item to the favourites
last used
112 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
5100 040 Multifunction Joystick

Joystick 4Plus modular concept (Elo- 
bau)
1 KION Basis Module

2 Multifunction Lever
3 Multifunction Lever with housing for Coun-
terbalance trucks
4 Multifunction Lever with housing for Reach
trucks
5 Electronic Module with CAN
Actuation buttons 
1 Signal-horn
2 Tilting
3 Function button
4 Drive direction
5 Side shift
5001 801 1624 EN - 05/2022 - 02 113

4 Operation
Optional equipment
Controlled axes 
Power Supply
Operating voltage
9V
(min.)
Nominal Voltage 12V / 24V
Operating voltage
38V
(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 ΔT up to 60K
EMC immunity according to EN12895 36V/m
ESD:
15kV from 150pF
Contact discharge to the sensor housing (CD)
25kV from 150pF
Air discharge (AD)
Magnetic field immunity: 1000 A/m 3s (0Hz)
Tested according to EN61000-4-8 Level 5: 30 A/m 3s (50Hz)
6240 005 Load weight display 

(the weight error of (+ / - 100
kg))
Determining and displaying the load

weight
To increase the accuracy of the load weight
display, the following conditions must be met:
● The truck must be on a flat, level surface
and must be stationary
● The lift mast must be in a vertical position
● The hydraulic oil in the truck must be at
operating temperature
● The fork carriage must not be raised more
than 1.70 m above the ground The load
weight display does not show reliable val-
ues at heights above 1.70 m
● The raised load must be stationary
114 5001 801 1624 EN - 05/2022 - 02
Operation 4
Optional equipment
NOTE
Reliable display of the load weight cannot be
guaranteed for light loads of less than 100 kg.
Forklift Data Management (LFM)

6430 005 Linde ac: Access Control PIN 
The truck data acquisition (FDE) input device 4
(1) is located in the armrest console (3).
The input device has a 12-digit keypad (2).
With the standard setting, a 5-digit PIN is allo-
cated to the respective driver to ensure that
the truck can only be operated by authorised
personnel.
The truck can only be started after entering 1
this PIN and possibly a status code (depend- 2
ing on the setting).
3
NOTE
d3941466a
The PIN can be extended from 5 to 8 digits.
Before entering the PIN, contact your fleet
manager to check the number of digits in the
PIN and to find out about the truck settings.
Truck data acquisition - standard setting 

(PIN)
4
Log in and start the engine:
– Apply the parking brake.
– Open armrest support (4) sideways to the
right
1
2
3
d3941466a
5001 801 1624 EN - 05/2022 - 02 115

4 Operation
Optional equipment
– Press the Reset button (8) (or any other 

button) to activate the input device from
standby mode
NOTE
If a number button is pressed to activate the
device, this number is registered as the first
digit of the PIN.
LED (5) and LED (6) flash green alternately.
NOTE
If no PIN is entered, the input device reverts
to standby mode after 60 seconds (factory set-
ting). This delay time can be changed. Contact
your fleet manager.
– Enter personal PIN (factory setting =
0 0 0 0 0 ).
LED (5) and LED (6) both illuminate green. 
NOTE
If an incorrect PIN is entered, LED (5) and
LED (6) flash red. After a delay time, the
input device reverts to login mode and the
two LEDs flash green alternately. The delay
time increases each time an incorrect PIN is
entered. If you make a mistake when enter-
ing the PIN, the PIN entry can be aborted by
pressing the Reset button (8).
116 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
– Turn turning knob (9) to switch setting "II" 

and start the engine
NOTE
If the truck does not start properly the first
time, the starting procedure can be repeated
until turning knob (9) is returned to the zero
position and the PIN is no longer saved follow-
ing the elapse of the delay time.
NOTE
If LED (5) illuminates red and LED (6) illumi-
nates green, the data must be read out. Inform
your fleet manager immediately.
– Close armrest support (4)
Switch off the engine and log out: 
CAUTION
Unwarranted use by unauthorised personnel.
When parking and leaving the truck, the driver must
log out.

right
– Press the Log IN/OUT button (7)
The engine is switched off, and LED (5) and
LED (6) go out.
– Turn turning knob (9) to switch setting "0"
NOTE
If the driver leaves the driver's seat, the en-
gine and power supply are switched off after
a delay time elapses. If the driver switches off
the engine using turning knob (9), the truck
can be started during a delay time without
re-entering the PIN. This delay time can be
changed. Contact your fleet manager.
5001 801 1624 EN - 05/2022 - 02 117

4 Operation
Optional equipment
Activate the power supply: 

– Press and hold the Log IN/OUT button (7) for
longer than 2 seconds
LED (5) lights up yellow and LED (6) flashes
green.
The engine is switched off.
– Turn turning knob (9) to switch setting "I"
The power supply remains switched on for ap-
prox. 60 seconds (e.g. for lighting).
Truck data acquisition - special setting 

(PIN and status code)
4
Log in and start the engine:
right
1
2
3
d3941466a
118 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
– Press the Reset button (8) (or any other 

button) to activate the input device from
standby mode
NOTE
If a number button is pressed to activate the
device, this number is registered as the first
digit of the PIN.
LED (5) and LED (6) flash green alternately.
NOTE
If no PIN is entered, the input device reverts
to standby mode after 60 seconds (factory set-
ting). This delay time can be changed. Contact
your fleet manager.
– Enter personal PIN (factory setting =
0 0 0 0 0 ) and status code.
Therefore, for a properly set-up truck, the PIN

should be as follows: 0 0 0 0 0 0 .
LED (5) and LED (6) both illuminate green. 
NOTE
If an incorrect PIN is entered, LED (5) and
LED (6) flash red. After a delay time, the
input device reverts to login mode and the
two LEDs flash green alternately. The delay
time increases each time an incorrect PIN is
entered. If you make a mistake when enter-
ing the PIN, the PIN entry can be aborted by
pressing the Reset button (8).
5001 801 1624 EN - 05/2022 - 02 119

4 Operation
Optional equipment

NOTE
position and the PIN is no longer saved follow-
ing the elapse of the delay time.
NOTE
CAUTION
log out.

right
– Press the Log IN/OUT button (7)
LED (6) go out.
NOTE
re-entering the PIN. This delay time can be
changed. Contact your fleet manager.
120 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment

– Press and hold the Log IN/OUT button (7) for
longer than 2 seconds
green.
Status code
NOTE
The status code indicates the status of the
truck.
The following codes are available:
● 0 = truck OK
● 1 = request service (truck cannot be star-
ted)
● 2 = request maintenance (truck can be
started)
● 3 = Problem with driving
● 4 = Problem with lifting
● 5 = Problem with steering
● 6 = Accident damage
● 7 = User-defined
Status messages 7 , 8 and 9 can be defined

individually by the user. Contact your fleet
manager to find out the definition of these sta-
tus messages.
NOTE
If you only notice one of these statuses (e.g.
a problem with driving) after having entered
status code 0 (truck OK), you must log out.
5001 801 1624 EN - 05/2022 - 02 121

4 Operation
Optional equipment
– Press the Reset button (8) 

– Log in again with status message 3 (prob-
lem with driving)
6430 010 Linde ac: Access Control 

RFID Dual
4
The truck 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 strip card) must be placed.
The truck can only be started once the trans-
ponder has been placed onto the reading
area. 1
10
3
d3941469a
122 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
Log in and start the engine: 

right
– Place the valid transponder onto the read-
ing area (10)
Data is read in, and LED (5) and LED (6) both
illuminate green.
– Remove transponder.
NOTE
If LED (5) and LED (6) flash red, the trans-
ponder was invalid or there was a reading
error. After a delay time, the input device re-
verts to login mode and the two LEDs flash
green alternately. The delay time increases
each time an invalid transponder is used. The
input device is reactivated automatically when
a valid transponder is placed on the reading
area and read in. LED (5) and LED (6) both
illuminate green.
NOTE
position and the engine can no longer be star-
ted following the elapse of the delay time.
NOTE
5001 801 1624 EN - 05/2022 - 02 123

4 Operation
Optional equipment
CAUTION
log out.

right
– Place the valid transponder onto the read-
ing area (10)
LED (6) go out.
– Remove transponder.
NOTE
placing a valid transponder on the reading
area again. This delay time can be changed.
Contact your fleet manager.
– Place a valid transponder on the reading
area (10) and hold it there for longer than
2 seconds
green.
124 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
NOTE
If another valid transponder is placed on the
reading area within 60 seconds, the engine
can be started again.
LED condition display

Function: LED (5) LED (6)
Standby mode Off Off
Flashes green alternately Flashes green alternately
Input prompt: PIN/transponder
with LED (6) with LED (5)
No error when reading in PIN/transpond-
Illuminates green Illuminates green
er; engine can be started
Error when reading in PIN/transponder;
Flashes red Flashes red
engine cannot be started
Transition to standby mode Illuminates red once Illuminates green once
Power supply active for 60 seconds Lights up yellow Flashes green
Data read-out required - memory 90%
Flashes red Illuminates green
full
Data read-out required - memory 100%
Illuminates red Illuminates green
full
Speed reduction via shock sensor Flashes red slowly Flashes green slowly
Lighting
NOTE
The arrangement of the individual switches on
the console on the upper right-hand side of
the overhead guard may vary, depending on
the version. Observe the switch symbols.
5001 801 1624 EN - 05/2022 - 02 125

4 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
go.
The interior lighting (7) is switched on.
– Press the push button(8). 

– The interior lighting (9) is switched on.
NOTE
If the pressure switch (8) has previously been
actuated, the two interior lights (7) and (9)
may be switched on and off via toggle switch
(1).
126 5001 801 1624 EN - 05/2022 - 02

Operation 4
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
go.
The dipped beams, sidelights and licence
plate lamps are switched on.
Switching on the working spotlight

– Press toggle switch (3) or (4) (depending on
the version).
Switching on the hazard warning sys-

tem
– Press the toggle switch (5).
Switching on the rotating beacon/flash- 

ing beacon
Depending on the equipment, there are three
different versions.
Version 1
– Press the toggle switch (6).
Set the toggle switch (6):
● Level 0: light "OFF"
● Level 1: light "ON" for reverse travel
● Level 2: light in continuous operation
Version 2
– Switch on the key switch.
The light is always in operation.
Version 3
– Switch on the key switch and press the re-
verse pedal.
The light is in operation for reverse travel only.
NOTE
If the truck is to be operated on public roads,
the rotating beacon/flashing beacon must be
switched off.
5001 801 1624 EN - 05/2022 - 02 127

4 Operation
Optional equipment
Switching on the direction indicators 

– Push lever (10) up.
The direction indicators flash on the right of 11
the truck. Indicator (11) flashes. 10
– Push lever (10) down.
The direction indicators flash on the left of the
truck. Indicator (11) flashes.
d1411058
Lighting options
NOTE
The arrangement of the individual switches on
the console on the upper right-hand side of
the overhead guard may vary, depending on
the version. Observe the switch symbols.
Switching on the full road lighting

– Press the toggle switch(2) 
● 6100 005 Full road lighting
● 6100 010 Full road lighting (with stone
guards)
Set the toggle switch(2)：
● Level 0 : Light "OFF"
● Level 1 : open the low beam
● Level 2 : open the high beam
128 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
Open the rear lights only

● 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.
– Press the toggle switch (3) 
● 6103 005 Mast mounted front facing lamps
● 6103 010 Mast mounted front facing LED
lamps
● 6105 005 Mast mounted front facing lamps
>5m mast
● 6105 010 Mast mounted front facing LED
lamps >5m mast
Open the cab mounted rear facing

lamps
● 6104 005 Cab mounted rear facing lamps
● 6104 010 Cab mounted rear facing LED
lamps
5001 801 1624 EN - 05/2022 - 02 129

4 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. The two are parallel con-
nections.
Open the reverse warning light

When the forklift is reversed, the reverse
warning lights will automatically light up. But
LED Reverse warning light need switch.
The optional model is as follows :
● 6104 015 Reverse warning light x 2
● 6104 020 LED Reverse warning light x 2
130 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
BlueSpotTM
NOTE
Customers can choose Bluespot Front & Rear
or Bluespot Rear according to the needs .
The BlueSpotTM 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.
The BlueSpotTM is mounted above on the 

right-hand or left-hand support on a support
mounting. It projects a high-power dot of light
or arrow (LED technology) onto the ground. It
is not affected by jolts and vibrations. The sys-
tem allows pedestrians to notice an approach-
ing truck at an early stage.
NOTE
The BlueSpotTM can be installed for forwards
and reverse travel.
CAUTION
Do not look directly into the BlueSpotTM.
Switching on the BlueSpotTM

Depending on the equipment fitted, there are
two different ways to activate the BlueSpotTM:
Version 1（When choosing 7118 005 Blue-
spot Rear）
– Switch on the key switch.
BlueSpotTM is always in operation.
5001 801 1624 EN - 05/2022 - 02 131

4 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: BlueSpotTM OFF ;
● Level 1: BlueSpotTM ON .
NOTE
If the truck is to be operated on public roads,
the BlueSpotTM must be switched off.
12v Power 
The optional types are as follows :

● 4412 020 1x12V - 20mm
132 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
24v Power 

● 4412 015 1x24V - 20mm
12/24v Power 

● 4412 030 2x12/24V - 20mm
5001 801 1624 EN - 05/2022 - 02 133

4 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.
Description
– Robust mechless 1DIN 24 Volt car radio
with USB(2x)/Bluetooth/AUX
– Fixed panel with well legible LCD display
– Ideal for trucks due to 24 V direct connec-
tion
– Clear, lucid and easy to use
– Integrated Bluetooth hands-free system
with external microphone
– A2DP Bluetooth audio playback
– MP3 playback via USB port
– Front AUX input
– 2 channel amplifier with 2 x 40 W (max.)
– Rotary control for volume
– RDS
– Steering wheel control input (interfaces for
many vehicles optional)
– ISO terminal
– i-Mode: Select the tracks on your i-Phone
directly via the control buttons of the radio
Specifications
Fixed panel with LCD display
Front USB/AUX, rear USB
Bluetooth firmware updatable via USB
A2DP Bluetooth audio playback
MP3 playback via USB
134 5001 801 1624 EN - 05/2022 - 02

Operation 4
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
RDS
Phone mute
Last memory
Last position
Dimensions (W x H x D): 186 x 56 x 95 mm
4470 005 Cab vent fan 24v 
Position
The fan is mounted on the left column of the
cab
Switch
Set the fan switch(2)
● Level 0: "OFF"；
● Level 1: low speed；
● Level 2: high speed。
1 Support fan
2 Switch
3 Fan
4 Socket head screw
5001 801 1624 EN - 05/2022 - 02 135

4 Operation
Optional equipment
4460 005 Illuminated A4 clip- 

board
1 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.
136 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
1 Document holder
5001 801 1624 EN - 05/2022 - 02 137

4 Operation
Optional equipment
Additional storage and cup holder 
2 Cup holder
3 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.
1 With cup holder
Adjusting the driver's seat with

rotating device
● 4202 005 Rotating Seat Plate – 10 deg to
right
● 4202 010 Rotating Seat Plate – 17 deg to
right
138 5001 801 1624 EN - 05/2022 - 02

Operation 4
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. This allows the driver to main-
tain an ergonomic seating position.
When driving forwards for long distances, it is
recommended that you return the seat to the
straight-ahead position.
The rotating device is maintenance free.
– Pull locking lever (1) backwards. 
The rotating device is enabled and allows the
seat to be swivelled, either by:
● 10° to the right, lockable at 0° and 10°
or
● 17° to the right, lockable at 0° and 17°
– Turn the driver's seat to the right and allow
the locking bolt to engage audibly in the
interlock.
Safety equipment
7105 005 Absent Driver Isolator
Absent driver isolator will automatically brake
when the forklift is stopped for 5 seconds.
NOTE
In the process of forklift upslope or downhill,
this function can prevent the occurrence of
slope sliding.
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4 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.
– After hearing a buzzer behind the cab, Tie
up the seat belt.
– Then open the key switch to the 2 Level
and the forklift can start normally.
7109 005 Fire Extinguisher 2kg 

in Cab
NOTE
If the truck is equipped with the Fire suppres-
sion system, make sure that you familiarise
yourself with how to use it in the event of an
emergency.
NOTE
The period of validity for the extinguisher is 5
years. If there is something wrong on the de-
vice, please contact with the authorised deal-
er.
140 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
Fire suppression system

7110 005 Automatic fire suppression
system with additional manual activa-
tion switch in the cabin
Location of the switch 
The main function of the switch:
● Power status indicator: the green power in-
dicator lights after normal power supply on.

● Fire suppression system line detection
function: When the Fire suppression sys-

tem line is not connected or shorted circuit
to ground, the yellow indicator lights and
the buzzer sounds and flash once about 5s.
After the circuit back to normal, it will be
recovered automatically.
● Manual fire fighting capabilities: Crash the
button cover and hold the switch for 1-2

seconds to start the fire suppression sys-
tem.
● Fire suppression feedback function: The
red indicator lights and the buzzer sounds

after spraying fire suppression device is ac-
tivated.
● 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 - 05/2022 - 02 141

4 Operation
Optional equipment
Maintenance 
The blasting fuse of the fire suppression sys-
tem should be checked whether ageing when
doing the regular maintenance.
142 5001 801 1624 EN - 05/2022 - 02

Operation 4
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. At this time,
make sure the transmitter to be programmed
has not been screwed onto the valve yet.
Screw on transmitters until the programming
has been finished and the monitor returns to
normal mode.
Each transmitter has 4 groups of ID, for exam-
ple when program the transmitter with ID of
001 001 001 158 to front right tire position, the
user only needs to input the last 3 digits “158”.
Monitor will record the rest 3 groups of ID au-
tomatically. Operation steps are as following:
– After monitor is powered, the screen will 
display “NSP”, press P for 3 seconds to
access the system programming mode, the
first interface is for ID programming as
shown below:
– Press any of the four arrow keys to choose
the tire position which needs to be program-
med with a transmitter.
– Then press S for 3 seconds to start pro- 

gramming and the digit flashes, then press
up or down arrow key to adjust the number.
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4 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 

which flashes. Press up or down arrow key
to adjust the value.
– When finish programming these 3 digits,
press S for 3 seconds to save with the
screen flashes twice, beep buzzes twice.
Then it will automatically switch to next tire
position.
– Repeat the above operations to program ID
of other transmitters.
Standard Pressure Programming

– When finish programming ID, press P to
access the standard pressure programming
mode.
– Then press any of the four arrow keys to 
choose the desired tire position.
– Then press S for 3 seconds to set the first 

digit which flashes. Press up or down arrow
key to adjust the value to 1.
144 5001 801 1624 EN - 05/2022 - 02

Operation 4
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 

number, press → to program the third digit
which flashes and then press up or down
arrow key to adjust the value to 5. Then
press S for 3 seconds to save the setting.
NOTE
The default standard pressure is set to 100 psi
in factory.
System Time Programming
NOTE
The system clock was preset in the factory.
It is the base of the alarm record, user can
check the current date and time as follows:
– 1. When finish programming the standard 

pressure, press P to access interface for
inquiry and programming of time/date, the
first interface displays the year, 1 07 stands
for the year 2007:
– Press ↓ key to access the second interface, 

211 stands for November.
5001 801 1624 EN - 05/2022 - 02 145

4 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, 

533 stands for 33 mins.
Under any interface of system time inquiry,
press S for 3 seconds to start programming.
For example change the year to “09”, under
the year interface, press S for 3 seconds, the
second digit flashes, press up or down arrow
key to adjust the value. Then press → key,
the third number flashes, then press the up or
down arrow key to adjust the value to“9”. At
last press S for 3 seconds to save the change
with screen flashes twice and beep buzzes
twice. Then it automatically switches to next
interface for programming.
Programming of Temperature and Pres-

sure Unit
– After program the system time, press P to 
access interface for programming tempera-
ture and pressure unit. The first interface
displays the temperature unit.
146 5001 801 1624 EN - 05/2022 - 02

Operation 4
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 “℃” starts
flashing. Press up or down arrow key to
select the needed temperature unit.
After select the desired unit, press S key for 3 
seconds to save with the beep buzzes twice.
Temperature unit will stop flashing.
Deletion of transmitter ID
– When finish programming temperature and 
pressure unit, press P to access the trans-
mitter deletion interface. Only the program-
med and received transmitter will be shown
and only the last 3 ID digits will be shown:
– Press any of the four arrow keys to locate
the tire position to be deleted.
– Press S key for 3 seconds to delete with the
screen flashes twice and beep buzzes twice
to confirm the deletion. Then it automatical-
ly switches to next transmitter location.
NOTE
After programming, press P key for 3 seconds
to return to normal mode.
System Function
– Full-time Monitoring
TPMS ST@HD can monitor the tire pressure
and temperature whether the vehicle is run-
ning or parked. Therefore to keep the driver
informed of the tire state and realize full-time
monitoring.
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4 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.
Treatment:
press any key to stop the audible alarm. The
red alarm lamp remains on and the display
reverts to the normal mode. At this time user
should properly adjust the tire pressure to the
normal level. The red alarm lamp goes off only
when the tire pressure returns to the normal
level.
– Low pressure level 1 alarm 
Function:
the system will issue low pressure level 1
alarm when the tire pressure is 12.5% lower
than the standard.
Alarm mode:
the alarm lamp flashes, low pressure level 1
alarm icon, tire position icon and the audible
alarm turn on together.
Treatment:
reverts to the normal mode. At this time the
user should adjust the tire pressure to normal
level as soon as possible. The red alarm lamp
goes off only when the tire pressure returns to
normal level.
Function:
alarm when the tire pressure is 25% lower
than the standard.
Alarm mode:
148 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment

Treatment:
reverts to the normal mode. The user should
slow down the vehicle and drive to a service
shop to inflate the tire. The red alarm lamp
goes off only when the tire pressure returns to
normal level.
Function:
alarm when the tire pressure is 50% lower
than the standard.
Alarm mode:
Treatment:
reverts to the normal mode. The user should
slow down the vehicle and replace the tire with
a spare tire. The red alarm lamp goes off only
when the tire pressure returns to normal level.
– High Temperature Alarm 
Function:
When the temperature around the transmitter
equals or exceeds 90℃, the system will issue
the high temperature alarm.
Alarm mode:
the alarm lamp and temperature value flashes,
tire position icon and the audible alarm turn on
together.
Treatment:
reverts to the normal mode. The driver should
slow down and properly cool down the tire.
The red alarm lamp goes off automatically
when the temperature returns to normal level.
5001 801 1624 EN - 05/2022 - 02 149

4 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. Then slow
down and check the correspondent tire.
– Transmitter Trouble Alarm 
Function:
If one transmitter fails to work, or the monitor
cannot receive the data because of the RF
interference for 20 minutes, the system will
issue a transmitter trouble alarm.
Alarm mode:
the audible alarm turns on, the red alarm lamp
flashes, and transmitter trouble alarm icon ap-
pears.
Treatment:
press any key to stop the audible alarm. Then
the system reverts to the normal mode.
NOTE
The red alarm lamp goes off automatically
when the communication between the trans-
mitter and monitor returns to normal state.
Auxiliary Functions in Normal Mode

Alarm Record Inquiry
150 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
– Under alarm record inquiry interface, Press
→ key to check through the record. If there
is no operation within 3 seconds, it will auto-
matically display the record data (pressure,
temperature and time) in turn, each data
displays 3 seconds.
Pressure 
Temperature 
Time (year) 
5001 801 1624 EN - 05/2022 - 02 151

4 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.
152 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
Tyre pressure detection system 

(new)
1 External sensor
2 Host
3 Hub
4 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.
● The sensor uses a separate display, mak-
ing installation easy. The relay module can
be placed directly inside the vehicle.
● The entire package in easy to install and
maintain.
● The system can warn when the tyre pres-
sure is too low or too high, when the tem-
perature of the tyres is too high and when
there is a slow air leak.
Technical data
1 Display
Frequency 433.9 MHz 2 Sensor
Operating 3 Relay module
5V
Display voltage
Operating
-20–70℃
temperature
Frequency 433.9 MHz
Operating
2.2–3.3 V
Sensor voltage
Operating
-40-125 ℃
temperature
5001 801 1624 EN - 05/2022 - 02 153

4 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. 
154 5001 801 1624 EN - 05/2022 - 02

Operation 4
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 - 05/2022 - 02 155

4 Operation
Optional equipment
Replacing the battery

– Remove the anti-tamper shim. 
– Use a cover-opening wrench to open the 

external cover.
156 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
– When turned on, the system displays data
from the previous use. The data updates as
soon as the tyres start to turn.
– Tyre pressure increases as the temperature
of the tyre rises when moving.
– The system matches automatically and can
be used direct from the factory.
– Press “◄” or “►” to display tyre pressure or
temperature.
Factory settings
Pressure unit Bar
Tyre pressure upper
11.0 bar
limit
Tyre pressure lower
9.0 bar
limit
High temperature
75℃
warning value
Entering and exiting setup
5001 801 1624 EN - 05/2022 - 02 157

4 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.
– If the system is not operated for 60 seconds
in setup or matching mode, the system will
beep four times and then exit setup mode.
Setup options
Press and hold “SET” for 3 seconds to enter
setup mode, then press “SET” again to select
from the following four options:
– Upper pressure limit: press and hold “SET” 
to enter setup mode as shown in the figure:
when “11.0” flashes, press “◄” or “►” to se-
lect the pressure value.
– Lower pressure limit: after entering setup 

mode, press “SET” again as shown in the
figure: when “9.0” flashes, press “◄” or “►”
to select the pressure value.
158 5001 801 1624 EN - 05/2022 - 02

Operation 4
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- 

by mode, press “SET” 5 times in succes-
sion. After hearing three beeps or the pro-
duction date, as shown in the figure: the
tyre flashes but the number does not flash,
showing selection options for tyres 1-6.
Press “◄” or “►” to select the tyre number,
then press “SET” once. The tyre and num-
ber will flash together and ID number setup
will be shown. Press “◄” or “►” to select the
ID number, then press “SET” once.
WARNING
Do not use this product while driving.
Exit the vehicle and check the tyres as soon as pos-
sible when the system issues a warning.
Tyre pressure and temperature will increase when
driving.
Do not rely solely on this product for tyre safety. You
should carry out regular tyre checks.
5001 801 1624 EN - 05/2022 - 02 159

4 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
● 30CM danger zone
7160 990 The sensors are installed on the 

counterweight of the truck.
160 5001 801 1624 EN - 05/2022 - 02

Operation 4
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. Observe the working pressure and
operating instructions for the attachments.
5001 801 1624 EN - 05/2022 - 02 161

4 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.
CAUTION
Danger of damage to equipment.
Attachments not supplied with the truck may only be
employed if an authorised dealer ascertains that safe
operation is assured in respect of load capacity and
stability.
NOTE
If the installation of an attachment changes
the normal sequence of operation as descri-
bed in this manual, follow the instructions sup-
plied by truckmaker or the manufacturer of
the attachment. If the customer desires the
attachment operation with the central control
levers, a label showing the movements possi-
ble with the control levers must be affixed on
the screen to the right of the driver.
Coil boom
Integrally mast mounted
● 3670 005 Coil Boom – 1000mm long (177)
● 3670 010 Coil Boom – 1000mm long (178)
● 3670 015 Coil Boom – 1000mm long (179)
NOTE
These operating instructions or excerpts
thereof may only be copied, translated or
transmitted to third parties after prior written
approval by the manufacturer.
NOTE
The operating company or driver, and not the
manufacturer, is liable if the truck is used in a
manner that is not permitted.
162 5001 801 1624 EN - 05/2022 - 02

Operation 4
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
long(177)
● 3670 110 FF Coil boom - 1000 mm
long(178)
● 3670 115 FF Coil boom - 1000 mm
long(179)
CAUTION
Adjust all operating functions accordingly when maxi-
mum weight is being handled.
Danger of damage to equipment and personnel.
5001 801 1624 EN - 05/2022 - 02 163

4 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.
1 Engine Pre-heater
2 Hydraulic Oil Pre-heater
3 Battery Heaters
4 Diesel Fuel Heater
5 Cabin Pre-heater
Engine Pre-heater 
220v, 150w (x2) Heater Pad.
Mounted on brackets and contacting the oil
pan.
164 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
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4 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
● 4409 015 Cab Pre-heater 110 V
– Press the switch (1) 

The second selection: 4409 005 Webasto Wa-
ter Heater .
166 5001 801 1624 EN - 05/2022 - 02

Operation 4
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. The
display changes at high speed when the (1)
and(2) buttons are pressed for more than 2
seconds.
– Whenever the power supply to the timer
is disconnected, all previously programmed
settings will be lost.
Switching On:
– Manually: by pressing the "Manual Opera-
tion" (3)button (continuous heating mode).
The heating time and the symbol for heating
operation are displayed. The heating time
display disappears after 10 seconds.
– Automatically: upon reaching the preset
starting time for heating. The program num-
ber and the symbol for heating are dis-
played.
Switching Off:
– Manually: by pressing the "Manual Opera-
tion" (3)button.
– Automatically: via the programmed end
time. The display field goes out when the
heating time expires.
Setting the Time
– This function is not available when heating
mode is active! Press and hold the (4)but-
ton. Press the "Forward" (2)or "Reverse"(1)
button as well. The time of the day is dis-
played and the clock symbol flashes.
– Set the time via the "Forward"(2) or "Re-
verse"(1) buttons. The set time is saved
when the display goes out or by pressing
the button.
Viewing the Time:
– Press the "Forward"(2) or "Reverse"(1) but-
ton.
Program Start of Heating
5001 801 1624 EN - 05/2022 - 02 167

4 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.
Default start settings:
Time 1: 06:00 hours or 6:00 am;
Time 2: 16:00 hours or 4:00 pm;
Time 3: 22:00 hours or 10:00 pm
CAUTION
The default settings are overwritten when new val-
ues are entered. The preset times are saved until
changed. The default settings are restored when the
timer is disconnected from the on-board power sup-
ply.
Deactivate Preset Time:

– Briefly press the (4)button.
Select Preset Time:
– Press the button (4)within 10 seconds un-
til the program number with the required
preset time is displayed. The active mode
(heating ) and the program number flash.
Set Heating Duration Time:
– Press and hold the (4)button. Press the
"Forward"(2) or "Reverse"(1) button as well.
Release both buttons. The time and clock
symbol are displayed.
– Press and hold the (4)button again. Press
the "Forward"(2) or "Reverse"(1) button as
well. Release both buttons. The preset time
is displayed and the heating symbol and
ventilation symbol flash.
– Set the heating time via the "Forward"(2) or
"Reverse"(1) buttons. The set heating time
is saved when the display goes out or by
pressing the (4)button.
168 5001 801 1624 EN - 05/2022 - 02

Operation 4
Optional equipment
CAUTION
The default settings are restored when the timer is
disconnected from the on-board power supply. In this
case, the timer will revert to the default heating dura-
tion time setting of 30 minutes.
Set Remaining Time:

– The active remaining time can be changed
between 10 minutes and 60 minutes via the
"Forward"(2) or "Reverse"(1) buttons when
heating mode is active.
Changing the Operating Mode
CAUTION
Ventilation mode is not available on the BlueHeat
heater. The ventilation mode is only available with
certain heater versions. This information is provi-
ded in the event mode of operation is inadvertently
changed. Press the (4)button. Press the(4) button
again and hold it. The last mode (heating or venti-
lation ) is displayed. Press the "Forward"(2) or "Re-
verse"(1) button as well to change back and forth
between heating or ventilation mode.
Mains Power Connection 

The optional model is as follows :
● 6400 010 Ext. Power supply - 110V
● 6400 020 Ext. Power supply - 240V
CAUTION
110/230v 3 pin female socket mounted in the battery
box for easy connection to mains power.
CAUTION
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 - 05/2022 - 02 169

4 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.
Electrify preheater socket. 

Position : In battery box.
170 5001 801 1624 EN - 05/2022 - 02

Operation 4
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
protecting electrical appliances and wires.
7306 005 Central lubrication

system – steer/mast/tilt
Main components
The central lubrication system has two ver-
sions: a pneumatic plunger pump and an elec-
trical gear pump.
A pneumatic plunger pump system has the 
following components.
1 Pump unit.
2 Grease lines from the metering units to the
individual grease points.
3 Air lines to the pump.
4 Brake-counter, if installed.
5 Installation bracket for the pump (not shown).
5001 801 1624 EN - 05/2022 - 02 171

4 Operation
Optional equipment
An electrical gear pump system has the fol- 

lowing components
The CompAlube pump unit

The pump unit is the heart of the CompAlube
greasing system. It is a very compact unit in
which the most important components are in-
tegrated. The pump unit requires virtually no
maintenance and is easy to install and put into
service.
Maintenance
Introduction
The maintenance of the Groeneveld CompA-
lube greasing system can be combined with 1 Pump unit.
the normal maintenance on the vehicle or the 2 Grease lines from the metering units to the
machine. individual grease points.
3 Electrical cable to the pump.
4 Installation bracket for the pump (not shown).
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).
● Check the grease level in the grease car-
tridge (replace the cartridge time or refill the
cartridge through the filling connection).
● Check the pump unit for damage and leak-
age.
● Check the grease lines for damage and
leakage.
● Check the condition of the grease points on
the vehicle. There must be sufficient fresh
grease present.
● Perform a test cycle to check the system
operation. Note that every time you perform
a test cycle a small amount of grease is
supplied to the grease points (do not per-
form a test cycle too often).
172 5001 801 1624 EN - 05/2022 - 02

Operation 4
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 
and how it's intended to be operated. This in-
struction should help the driver to quickly ob-
tain maximum productivity from the truck and
spreader.
● The models 178SP1000 empty container
handlers are designed for the safe handling
of empty containers by vertical twist locks,
which are entered into the top pockets of
the containers corner castings.
● The spreader engages the container from
the top by inserting the twist locks into the
top pockets of the corner castings.
● The spreaders have a capacity of 8 tons
and can handle empty 20' ISO containers.
● Various heights of container ( 8ft,8ft6",9ft,
9ft6") can be handled by these spreaders.
● The floating heads can slide up and down 1 Transmission frame
giving the spreader mechanical pile slope, 2 main beam
which enables the angle of the spreader to 3 The swing arm lock button
be moved up and down 1.5°in the 20ft posi- 4 The swing arm lock button
tion. The pile slope feature gives the driver
the possibility of entering the highest twist
lock first and then lowering the spreader
until the twist lock at the other end of the
spreader enters the corner casting at the
opposite end of the container.
5001 801 1624 EN - 05/2022 - 02 173

4 Operation
Optional equipment
Indicator lights
There are three indicator lights on the spread- 
er.
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” (The twist locks are both
located correctly in the corner castings of the
container and the spreader has been lowered
so that it rests, unsupported on the container)
when the yellow light has switched on it is
then possible to activate the twist locks to the
Locked position. As long as the yellow light
is NOT switched on the twist lock activation
circuit is inactive.
Red - ”NOT LOCKED” (Both twist locks have
turned to the Not Locked position and the
spreader can be safely lifted and removed
from the container.)
Starting work with the spreader

Each work shift should be started by making
a visual check of the unit (this must be part
of the daily routine.) Possible damage will in
this way be discovered at an early stage and
enable repairs to be carried out at much lower
cost.
WARNING
Never use the unit unless all safety devices function
correctly.
– Check the operation of the twist locks and

of the ”LOCKED” and ”NOT LOCKED”.
– Activate the twist locks to the ”NOT
LOCKED” position.
Lifting a container
– With the twist locks in the Not Locked po-
sition drive the machine up to a stack of
containers and raise the spreader until it is
possible to enter one of the twist locks into
the top aperture of one of the containers
upper corner castings. Raise or lower the
174 5001 801 1624 EN - 05/2022 - 02

Operation 4
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
until the spreader rests unsupported on
the container with the twist locks in the
corner castings. In this position the yellow
indicator light on the rear of the spreader
should switch on. This situation is termed
as the spreader being Seated and the yel-
low light tells the driver that the spreader is
now ready to have the twist locks activated
so that they lock onto the container.
– Press the lock button. The twist locks will
turn and the indicator light will show that
they are in the Locked mode. The white
light will switch on indicating that it is safe to
lift the container.
● If neither the Green (Locked light) nor the
Red (Not locked) light switches on, then the
lift interrupt function will be activated which
will stop the truck from lifting.
● The spreader PCB (printed circuit board) is
equipped with a unit that will cause the indi-
cator lights to flash in cases where a sensor
is not correctly adjusted or if a sensor is
faulty.
● If a seated sensor is either incorrectly ad-
justed or if one of the seated sensors if faul-
ty, the seated light only will flash and warn
the driver that something is wrong.
● If either the Locked or the Not Locked sen-
sors are badly adjusted or faulty then both
the Locked and Not Locked lights will flash
simultaneously.
NOTE
In cases where the indicator lights flash the
systems should be investigated and corrected
immediately. Never use a spreader with faulty
safety systems.
Detach a container
When detaching a container, find a suitable
level site on which to unload the container.
(The trucks mast should be as near to vertical
as possible during the depositing of a contain-
er) Lower the spreader slowly until it rests un-
supported on the container and the Seated
5001 801 1624 EN - 05/2022 - 02 175

4 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.
The spreader is in the Not Locked mode and
is ready for picking up the next container.
Maintenance instructions
Multipurpose grease (EP2)
Position 1 
Twistlock assemblies
● No of grease points 4 per spreader.
● Interval-every 500 hours.
● 1 grease nipple per sleeve (see arrow “A”).
● 1 grease nipple per twistlock (see arrow
“B”).
● Check for wear and possible damage of the
twistlook and twistlook sleeve replace if in
doubt.
176 5001 801 1624 EN - 05/2022 - 02

Operation 4
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
nylon wear pads and replace before metal
to metal contact between the carriage and
the spreader frame occurs.
● No greasing necessary.
5001 801 1624 EN - 05/2022 - 02 177

4 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.
– Twist locks are wearing parts and need in- 

specting on a regular basis. Lubrication of
the twist locks is recommended at monthly
intervals and it is also recommended that
they are inspected for wear and damage at
the same time.
178 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
Generally it is recommended that twist locks
be replaced after a max. use of 5000 working
hours or 80 000 TWL-cycles.
– The extension cylinder support has wear
pads under it. These should also be inspec-
ted on a regular basis and replaced when
their thickness is reduced to minimum 18
mm.
– Maintenance of the stop cylinders if fitted,
consists of checking all mounting bolts for
tightness and inspection for leakage from
the cylinder.
– The side shift wear pads should be inspec-
ted for wear at the same time as lubrication
is carried out. The wear pads should be
replaced when their thickness is reduced to
minimum 18 mm.
– Other recommended spreader maintenance
is:
● Inspect the main spreader components for
damage, cracks and distortion.
● Check the signal and safety systems for
correct operation.
● Check the hydraulic pressures periodically.
● Check all hydraulic cylinders for leakage
and reseal if necessary.
● Inspect all hydraulic hoses for damage and
leakage. Replace if faulty.
5001 801 1624 EN - 05/2022 - 02 179

4 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.
– Lift the head high enough to allow the ho-
ses and cable to be lowered into the vertical
end beam so that the string drops through
the support half way down the inside of the
end beam.
– Lower the head into the end beam and at
the same time draw the hoses and cable
through the support by pulling them through
with the string.
– it should be noted that ,when removing the
heads from the end beams ,care should
taken that the electric plug and the hose
ends do not get caught on the support and
subsequently become damaged.
– Feed the string through the short tube
bend(1) in the side of the end beam
and draw the hoses anf cable up through
the tube and out through the side of the
beam ,where they can be connected to the
hoses and cable that run in the energy
chain.
– Make sure that the hoses and cable(2)
make an even bend that can move up and
down with the movement of the heads.
– Removal of the heads is the revers of the
above procedure but care must be taken
to ensure that the hoses have been discon-
nected from the energy chain and that they
have been pushed back into the end beam
so that they hang straight down before the
heads lifted out.
Storage of spreaders where it is necessary to
have the spreader standing outside for periods
longer than 3 months
When storing an 178 spreader for longer peri-
ods of time, the following precautions should
be taken:
180 5001 801 1624 EN - 05/2022 - 02

Operation 4
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.
● All grease points must be pumped full of
molybdenum saturated grease.
● Grease all sliding surfaces by brushing on a
suitable layer of grease.
● Grease all sliding surfaces by brushing on a
suitable layer of grease.
● Where possible it would be advisable to
equip the electric box with a heater (this
could be a small electric bulb for ex. 40 watt
which is allowed to burn constantly).
● Spray all electric connections both inside
and outside of the box with a self- drying
lubricant. This will efficiently protect electric
connections against corrosion.
CAUTION
Efficient rust inhibitors often dry with time and should
therefore be removed by a solvent before using the
spreader again. Failure to do this can cause damage
to the seals of the cylinders with subsequent leakage
to follow.
5001 801 1624 EN - 05/2022 - 02 181

4 Operation
Optional equipment
Multifunctional handle _ 178 spreader
182 5001 801 1624 EN - 05/2022 - 02

Operation 4
Working with a load
Working with a load

Mast, lifting device and attachment controls
CAUTION lever is moved determines the lifting, lowering
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.
thorised applications. The operator must be trained
in the handling of the lifting device and attachments
NOTE
Always move the central control lever (joy-
stick) smoothly and slowly. How far the control Observe the symbols with direction arrows.
Load centre distance and load

capacity
Before lifting goods, the relationship between
the weight, load centre of gravity distance and
maximum lift height of the goods must be un-
derstood.
– Load centre distance refers to the distance 
between the vertical plane of the fork arms
and the centre of gravity of the loads (1).
NOTE
The centre of gravity is not necessarily located
at the centre of the load.Load capacity refers
to the weight of loads that can be safely lifted
to a required height within the given load cen-
tre distance.
5001 801 1624 EN - 05/2022 - 02 183

4 Operation
Working with a load
Load rating plate

DANGER
The parameters in the load diagram and on the
labels apply to compact, uniform loads. These load
limits must not be exceeded. Exceeding the load
limits will affect the stability of the forklift truck and
the strength of the lift mast.
Refer to the load rating label before lifting goods. If
attachments are fitted, refer to the load rating label
for the attachment.
Label examples: 
Load centre of gravity distance 600 mm
Lift height: 6000 mm
– Draw a vertical line from the 600 mm
load centre of gravity distance coordinate
to where it crosses the diagonal line repre-
senting the 6000 mm lift height.
– The reading at the point where the coordi-
nate intersects with the horizontal line that
passes through this point of intersection is
1 Maximum lift load (unit: kg (kilogrammes))
the maximum permitted load. 2 Lift height (unit: mm (millimetres))
3 Forklift model (based on truck model and lift
– In this case, the reading for the maximum mast series)
permitted load is 1000 kg 4 Load centre of gravity distance from fork
surface (unit: mm [millimetres])
Corresponding loads relative to other lift
heights and load centre of gravity distances
can also be obtained in this way. This value
relates to an evenly distributed load on two
fork arms.
184 5001 801 1624 EN - 05/2022 - 02

Operation 4
Working with a load
Before loading
– Before lifting goods, check the load diagram 
on the right-hand side of the driver's seat
(1).
– If the truck is fitted with attachments, check
the load diagram on the right-hand side of
the driver's seat (2).
DANGER
The parameters in the load diagram and on the
labels apply to compact, uniform loads. These load
limits must not be exceeded. Exceeding the load
limits will affect the stability of the forklift truck and
the strength of the lift mast.
The maximum load is determined by the lift height
and load centre.
NOTE
Before transporting under the following condi-
tions, attention should be given to the load
limits and your authorised dealer should be
contacted.
● Eccentric load or swinging goods
● Lift mast tilted forwards or goods high
above the ground during transport
● Load centre of gravity distance is exces-
sively long
● Before operating attachments
● Before transporting loads in a wind force of
6 and upwards
5001 801 1624 EN - 05/2022 - 02 185

4 Operation
Working with a load
Lifting a load 
DANGER
Danger due to falling load. Risk of fatal
injury in the area of the extended lift
mast.
There must be no-one in the working
area when moving loads.
Always drive the truck with the load low-
ered and tilted to the rear. Look out for
people.
– Approach the load to be lifted as carefully

and accurately as possible.
– Put the mast in the vertical position.
– Lift or lower the fork carriage to the correct
height.
– If necessary, adjust the fork spread.
– Carefully insert the forks under the load so
that load is centred and contacts the fork
face, if possible. Do not touch adjacent
loads.
– Elevate the mast until the load rests on the
forks.
– Tilt the mast back slightly. 
– Release the parking brake.
– Operate the lift truck in reverse until the
load is clear.
– Tilt the mast fully back.
– Lower the mast to the travelling position.
NOTE
If the truck is equipped with duplex mast or
triplex mast, the line break safety valve will
be locked when the attachment is under the
impact load and the mast lower function is
disabled, to resume the lower function, just lift
the mast a little.
186 5001 801 1624 EN - 05/2022 - 02

Operation 4
Working with a load
Travelling with load

– Do not travel with the load laterally dis- 
placed (e.g. with a sideshift).
– Transport the load near the ground.
d3591067
– 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.
NOTE
When the forks are fully lowered the truck
speed is restricted and braking performance
is adjusted accordingly. Normal speeds and
functions are restored when the forks are
raised.
– Always travel with the load uphill on up-
grades and down grades, never travel or
turn across a slope.
5001 801 1624 EN - 05/2022 - 02 187

4 Operation
Working with a load
Depositing the load 
– Approach the stack or device receiving the

load as carefully and as accurately as pos-
sible.
– Elevate the fork carriage to the correct
height.
– Put the mast in the vertical position.
– Carefully move into the stack.
– Lower the load on to the stack, until the 

forks are clear of the load.
– Reverse the truck away from the stack until
clear.
– Lower the mast to the travel position.
WARNING
Danger of personal injury and damage to property.
Never leave the truck unattended with the load ele-
vated.
188 5001 801 1624 EN - 05/2022 - 02

Operation 4
Working with a load
Before leaving the truck unatten- 

ded
– Deposit the load and lower the fork car-
riage.
– Tilt the mast to the vertical position, the
forks must touch the ground.
– Stop the engine and remove the ignition
key.
– Lock the cab doors.
5001 801 1624 EN - 05/2022 - 02 189

4 Operation
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.
WARNING
Danger of personal injury and damage.
Do not step under the elevated load!
Attach lifting slings at the four points shown.
– Attach appropriate load rings to lifting points 

(3 & 4).
NOTE
If the truck is fitted with a 5 m mast or lower,
use upper lifting point (5). If the truck is fitted
with 5 m mast or higher use lifting point (4).
– Attach two appropriate lifting shackles to
the front lifting points (4 or 5) (see note
above).
– Attach the slings to crane hook (1).
CAUTION
After attaching slings to the lifting hook, safety lock
(2) must close to prevent 'lash slip'.
When the truck is hoisted the slings must not foul the
cabin or any attachments fitted.
WARNING
Danger of truck tipping over and damage to truck
lifting points.
The maximum angle for sling (1) is 40°. The maxi-
mum angle for sling (2) is 16°. Do not exceed these
angles.
190 5001 801 1624 EN - 05/2022 - 02

Operation 4
– 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.
Only use transportation equipment with sufficient
load capacity. For the truck weight, see the manufac-
turer's dataplate.
CAUTION
The minimum required strength of ropes/chains is
5 tonnes.
CAUTION
When transporting the truck, check that the truck is
properly supported on blocks and securely fastened
with load chains.
Transportation by loader truck

When the height of the mast is high, it must
usually be removed.
5001 801 1624 EN - 05/2022 - 02 191

4 Operation
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.
– Attach appropriate load chains to the tie 

down points as shown, and to appropriate
tie down points on the transport equipment.
When the height of the mast is low, it does
not need to be removed.
NOTE
The inner mast, outer mast, fork and fork car-
riage must be secured using suitable ropes to
prevent them from shaking during transporta-
tion.
192 5001 801 1624 EN - 05/2022 - 02

Operation 4
– 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 

ropes. As shown in the figure, attach 2
ropes to the tie down points at positions (1)
and (2) on both sides, cross over the ropes
and attach them to the appropriate tie down
points on the transport equipment.
5001 801 1624 EN - 05/2022 - 02 193

4 Operation
– 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.
– 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.
– As shown in the figure, attach ropes to 

the driver’s cab tie down points and secure
them to the appropriate tie down points on
the transport equipment.
194 5001 801 1624 EN - 05/2022 - 02

Operation 4
Using wooden wedges to immobilise

the truck
– Use wooden wedges (1) to immobilise the 
front and rear of the vehicle.
5001 801 1624 EN - 05/2022 - 02 195

4 Operation
196 5001 801 1624 EN - 05/2022 - 02

5
Maintenance
5 Maintenance
General maintenance
General maintenance
Safety information regarding servicing work
Your truck will only remain ready for operation CAUTION
at all times if the small number of servicing
tasks are performed at regular intervals and in The truck must always be properly labelled.
accordance with the information in the operat- Missing or damaged identification plates and/or ad-
ing instructions. hesive labels must be replaced. For details of the
location or order number, please consult the spare
Only qualified persons authorised by the man- parts catalogue.
ufacturer may carry out servicing work.
You can agree to have this work performed ENVIRONMENT NOTE
on the basis of a contract with your service
partner. Observe information regarding the use of con-
sumables.
Whenever performing work, the truck must be
parked on a flat surface and secured so that it
cannot roll away. The engine must be switch- Service intervals
ed off and the switch key removed. The specified service intervals are subject to
When working with the fork carriage and/or the operating conditions and application con-
lift mast raised, make sure they are secured ditions, as well as the consumables in use.
against accidental dropping. In certain circumstances, the service intervals
can be changed.
Whenever work is carried out at the front of
the forklift truck, the lift mast must be secured In all cases, the "Regular Service" must be
to prevent it tilting backwards. performed once per year.
No modifications, in particular attachment or In the case of operation in extreme conditions

conversion, should be made to your forklift (e.g. heat, cold or dust), the service intervals
truck without the manufacturer's approval. must be reduced.
All work on the truck must be followed by a Contact your service partner.
function check and a test run.
WARNING
Any doors fitted could fall shut during the work and
trap staff.
Open doors fully and prevent them from closing.
Inspection and maintenance data

Aids / Fluids and lubri-
No Assembly Filling capacity / Settings
cants
1 Engine Engine oil 26.6 l
2 Fuel tank Diesel Approx. 250 l
3 Adblue tank Adblue Approx. 40 l
198 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
General maintenance
4 Cooling system Antifreeze / water Approx. 17 l

Working hydraulic sys-
5 Hydraulic oil Approx. 180l
tem oil tank
6 Transmission Transmission oil Approx. 20 l
7 Drive axle Gear oil Approx. 25 l

8 Battery Maintenance free Maintenance free
9 Tyres Air 10 bar
10 Wheel nuts 680 Nm
Lift chains / mast chan-
11 Linde chain spray As required
nels
Recommended consumables
NOTE
The use of consumables that are not recom-
mended may invalidate your warranty. If you
have any questions, please contact your au-
thorized dealer.
Diesel fuel
WARNING
Do not mix petrol, ethanol or ethanol/petrol blends
with diesel. Doing so may cause an explosion.
CAUTION
The tolerances of the diesel fuel injection system are
extremely precise. Therefore, it is extremely impor-
tant to keep the fuel clean and free of dirt and water.
Dirt or water in the fuel system may cause serious
damage to the fuel pump and injector.
CAUTION
Light fuel oil may reduce fuel economy or damage
fuel system components.
5001 801 1624 EN - 05/2022 - 02 199

5 Maintenance
General maintenance
CAUTION
Do not use diesel fuel mixed with motor oil in en-
gines equipped with aftertreatment systems. Other-
wise, the maintenance intervals of the aftertreatment
system will be shortened.
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.
Once the engine has been optimised, an ex-
haust aftertreatment system can be used to
reduce emissions to a level that complies with
Tier 4 Final/Stage IV off-road emission stand-
ards. Ultra-low sulphur diesel (ULSD) must
be used; the sulphur content limit for this is
15 ppm in the United States and 10 ppm in
Europe. Failure to do so will result in perma-
nent damage to the engine and the aftertreat-
ment system in a short period of time. Such
damage will cause the engine to become inop-
erable and affect the warranty for the engine.
ASTM S-15 defines ultra-low sulphur diesel
(ULSD) as diesel fuel with a maximum sulphur
content of 0.0015% (15 ppm). There are no
acceptable alternatives.
When the working temperature is below 0°C
[32°F], acceptable performance can be ach-
ieved using a mix of Grades 2D and 1D diesel
fuel.
The following table lists acceptable fuel alter-
natives for this engine.
Acceptable fuel - Cummins® fuel system

Grade Grade Grade
1D die- 2D die- 1K kero- Jet-A Jet-A1 JP-5 JP-8 Jet-B JP-4 CITE
sel (1) (2) sel (2) sene
200 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
General maintenance
Does Does Does Does Does Does Does Does

not not not not not not not not
Accept- Accept-
meet meet meet meet meet meet meet meet
able able
standar standar standar standar standar standar standar standar
ds ds ds ds ds ds ds ds
48-34(3) 40-24(3) 50-35(3) 51-37(3) 51-37(3) 48-36(3) 51-37(3) 57-45(3) 57-45(3) 57-45(3)
● 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
commercial petrol stations is a mixture of
Grades 1D and 2D diesel, which is accepta-
ble for use.
● 3. British Thermal Unit (BTU)/American Pe-
troleum Institute (API) gravity - Fuels with
a low API gravity have a high BTU. As a
rule of thumb, for every rise in API gravity of
10 degrees, the BTU will reduce by 3-5%;
for every rise in fuel temperature of one
degree, the API gravity will also increase
by 0.7 degrees. The reduction in BTU is
approximately equal to the percentage of
power loss. Using a fuel with a higher API
gravity will result in a higher than normal
level of fuel consumption.
"A" indicates the fuel meets standards only
when the fuel lubricity is sufficient. This means
that the BOCLE measured using the ASTM
D6078 Scuffing Load Ball-on-Cylinder Lubrici-
ty Evaluator (SLBOCLE) should be 3100 or
higher. The ASTM D6079/ISO 12156 high fre-
quency reciprocating rig (HFRR) can also be
used to measure lubricity. With this method,
the fuel wear mark diameter must be less than
or equal to 0.45 mm [0.02 in].
NOTE
When the working temperature is below 0°C
[32°F], Cummins recommends a minimum die-
sel cetane value of 45, and a minimum value
of 42 when the working temperature is above
0°C [32°F].
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5 Maintenance
General maintenance
NOTE
Using diesel with a cetane value below the
recommended minimum will cause starting dif-
ficulties, instability and large amounts of white
smoke. To ensure normal engine operation
in low temperature environments, the correct
diesel cetane value must be clearly specified.
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. With this method, the
fuel wear mark diameter must be less than or
equal to 0.45 mm [0.02 in].
Original equipment manufacturers (OEMs) are
required to place eye-catching labels on the
dashboard (or panel) and near all fuel filling
openings that indicate "Only use ultra-low sul-
phur diesel" or "Ultra-low sulphur diesel only".
A ULSD/biodiesel blend supplied by a
BQ-9000 certified supplier with a mixture ratio
of B20 (20% biodiesel) can be used.
Diesel exhaust fluid recommendations

and specifications
WARNING
Tampering with or disassembling any part of the af-
tertreatment system is illegal. It is also illegal to use
a Diesel exhaust fluid (DEF) that does not meet the
specifications provided or to use a truck/equipment
that runs without diesel exhaust fluid (DEF).
WARNING
Diesel exhaust fluid (DEF) contains urea. Keep these
substances away from eyes. Should these substan-
ces come into contact with eyes, rinse immediately
with plenty of water for at least 15 minutes. Do not
inhale. If the diesel exhaust fluid is accidentally in-
haled, consult a doctor immediately.
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Maintenance 5
General maintenance
WARNING
Do not attempt to make diesel exhaust fluid by mix-
ing agricultural-grade urea with water. Agricultural-
grade urea does not meet the required specifications
and may damage the aftertreatment system.
The use of diesel exhaust fluid in accordance

with ISO 22241-1 is required. There are no
acceptable alternatives.
NOTE
The DIN 70070 standard can be referenced in
some locations. The diesel exhaust fluid spec-
ification limit given in this standard is the same
as ISO 22241-1.
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; unauthorised modifications to the
engine or aftertreatment system. Cummins is
also not responsible for malfunctions caused
by the use of incorrect diesel exhaust fluid or
water, dirt or other contaminants in the diesel
exhaust fluid.
American Petroleum Institute (API)-certified 
DEF is highly recommended for engines with
SCR technology operating in the US and Can-
ada. As shown in the diagram, this type of
diesel exhaust fluid can be identified by the
symbol on the container/meter.
Fleetguard® diesel exhaust fluid is recom-
mended to ensure proper use of the diesel
exhaust fluid (DEF). Fleetguard® is available
in a variety of container sizes, from small to
bulk.
Other common names for diesel exhaust fluid
(DEF):
● Urea
● AUS 32 (aqueous urea solution 32)
● AdBlue
● Nitrogen oxide reducing agent
● Catalyst solution
● DEF
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5 Maintenance
General maintenance
Regardless of how the diesel exhaust fluid is

referred to, it must comply with the specifica-
tions specified in the overview section of this
procedure.
Storage
NOTE
The following information is for reference only
and should be used as a guideline. There are
many factors that determine the shelf life of
diesel exhaust fluid (DEF), with temperature
and time being the two main decisive factors.
When in doubt, check the concentration of the
diesel exhaust fluid (DEF), refer to the test
section of this procedure, or replace it with
a well-known, premium diesel exhaust fluid
(DEF).
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 23°F and
77°F (-5°C to 25°C)
● Stored in a sealed container to avoid con-
tamination
● Avoid direct sunlight
Under these conditions, the minimum shelf life
of DEF is 18 months. If the storage temper-
ature is higher and storage period is longer
than the ideal conditions, then the shelf life will
be reduced by six months for every 5°C [9°F]
higher than the maximum storage temperature
specified above.
Long-term storage in trucks (more than six
months) is not recommended. If long-term
storage is required, it is recommended that
the diesel exhaust fluid is periodically tested to
ensure that the concentration does not exceed
the specifications. Perform the test in this pro-
cedure.
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Maintenance 5
General maintenance
NOTE
In order to prevent deterioration of the diesel
exhaust fluid (DEF) during storage in the DEF
tank, locate and plug the vents of the DEF
tank to isolate it from the atmosphere.
Manipulation
Diesel exhaust fluid is harmless to handle;
however, DEF may corrode certain materials
over time, such as carbon steel, iron, zinc,
nickel, copper, aluminium and magnesium.
● Ensure that only approved containers are
used to transport and store the diesel ex-
haust fluid. Polyethylene and polypropylene
containers are recommended.
● If the diesel exhaust fluid overflows, imme-
diately rinse and clean with water. If the
diesel exhaust fluid overflows, immediately
rinse and clean with water.
● Avoid prolonged contact with skin. If contact
with skin occurs, immediately wash the skin
with soap and water. If not rinsed immedi-
ately, the diesel exhaust fluid will dry and
leave a white film that is more difficult to
wash off.
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.
Prior to using containers, funnels or other re-
ceptacles for dispensing, handling or storing
diesel exhaust fluid, ensure they are thorough-
ly cleaned to remove any contaminants and
then rinse with distilled water.
NOTE
Do not use tap water to rinse the containers
used to transport the diesel exhaust fluid. Tap
water pollutes the diesel exhaust fluid. If distil-
led water is not available, first rinse with tap
water and then re-rinse with diesel exhaust
fuel.
Handling
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5 Maintenance
General maintenance
If handling of DEF is required, verify the

regulations stipulated by the local authorities
regarding proper handling processes and re-
quirements.
Testing
The correct concentration of diesel exhaust
fluid is critical to proper operation of the en-
gine and the aftertreatment system.
Test the concentration of the diesel exhaust
fluid using a Cummins Diesel Exhaust Fluid
Refractometer (service tool part no. 4919554).
Follow the instructions that are supplied with
the service tool.
Urea concentration percentage: 32.5 +/- 1.5%
The above specification allows for tolerance,
variability and calibration of the refractometer
when testing concentrations of diesel exhaust
fluid.
If the concentration of diesel exhaust fluid
does not meet this specification, drain the die-
sel exhaust fluid tank, rinse with distilled water
and refill with new and/or well-known, premi-
um diesel exhaust fluid. Re-check the concen-
tration of diesel exhaust fluid.
The concentration of the diesel exhaust fluid
must be checked under the following condi-
tions:
● The truck has been stored for a long period
of time.
● It is suspected that water has been added
to the diesel exhaust fluid tank.
Contaminant/treatment solution is incorrect
CAUTION
Do not add water or any other liquid other than as
specified to the diesel exhaust fluid (DEF) tank. Fail-
ure to do so may cause damage to the aftertreatment
system.
If incorrect liquids are added to the diesel ex-

haust fluid tank, including but not limited to:
● Water
● Diesel fuel
● Hydraulic oil
● Coolant
● Windshield washer fluid
206 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
General maintenance
contact your authorized dealer to determine

the correct repair procedure.
If only water has been added to the diesel
exhaust fluid (DEF) tank, drain the diesel ex-
haust fluid, rinse with distilled water, and refill
with new and/or well-known, premium diesel
exhaust fluid. Re-check the concentration of
diesel exhaust fuel after refilling. Perform the
test in this procedure.
Freezing
CAUTION
Do not add any chemicals/additives to the diesel ex-
haust fluid to prevent freezing. If chemicals/additives
are added to the diesel exhaust fluid, it may result in
damage to the aftertreatment system.
Diesel exhaust fluid freezes at around -11°C

[12°F]. The vehicle's diesel exhaust fluid sys-
tem is designed to meet this characteristic and
does not require any intervention by the vehi-
cle operator.
Engine oil grades for Cummins engines

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
durability. If the intervals for replacing the oil
and filters are extended in excess of recom-
mended values, the service life of the engine
will be reduced due to factors including corro-
sion, deposit build-up and wear. Follow the
below procedure to determine the appropriate
oil change interval for your application.
NOTE
This responsibility is borne by the user. If
these recommendations are ignored, the war-
ranty will be affected.
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5 Maintenance
General maintenance
CAUTION
The sulphur content of fuel should not exceed 0.5%
(mass). If the sulphur content is greater than 0.5%,
please contact your authorized dealer.
API: American Petroleum Institute

CES: Cummins® Engineering Standard
It is recommended to use Society of Auto-
motive Engineers (SAE) 15W-40 heavy-du-
ty engine oil that complies with or exceeds
CES 20081 and American Petroleum Institute
(API) CJ-4, such as Valvoline Premium Blue™
(USA) or Valvoline Premium Blue® Extra (In-
ternational).
To determine if the engine oil complies with
CES 20081, check the label on the back of the
oil bottle for the CES 20081 specification. If
bulk oil is required, please contact the supplier
for the oil specification and ensure that it com-
plies with CES 20081.
The following illustration also shows the API
service symbol found on oil bottles. The up-
per part of the symbol indicates the applicable
oil type. The middle part indicates the SAE
oil viscosity grade. The following table shows
how to compare CES to API grade.
CES API 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. In addition to complying with API
CJ-4/SL, it is important to ensure that the en-
gine oils also comply with CES 20081.
It is recommended to use 15W-40 multi-grade
oil for normal applications at ambient tempera-
tures above -15°C [5°F]. Using multi-grade oil
can reduce sediment build up and improve en-
gine cranking performance in low temperature
conditions, as well as improve engine durabili-
ty at high temperatures by maintaining lubrica-
tion. As has already been proven, using multi-
grade oil can reduce oil consumption by about
208 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
General maintenance
30% compared to single-grade oil. Therefore,

the use of multi-grade oil is very important to
ensure that the engine meets the applicable
emission requirements.
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.
The use of "synthetic engine oil" is permitted

(made using API Category 3 or 4 basic materi-
als), but it has the same performance and vis-
cosity limitations as petroleum (mineral)-based
engine oils. The time interval for changing the
synthetic engine oil must be the same as for
petroleum (mineral)-based engine oils.
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.
It is recommended to use API Category 3
and 4 synthetic engine oils for Cummins® en-
gines operating at ambient temperatures be-
low -25°C [-13°F]. Synthetic 0W-30 engine
oils that comply with API Category 3 and 4
standards can be used when operating at am-
bient temperatures no higher than 0°C [32°F].
0W-30 multi-viscosity oils do not provide the
same level of fuel dilution prevention as higher
grade multi-grade oils. Cylinder wear may in-
crease when using 0W-30 oils under high load
conditions.
The oil film of these oils is thinner than
that of 15W-40 oils, so the high-quality Fleet-
guard® filter must be used at temperatures
of 20°C [70°F] or above. Some oil suppliers
may state that these oils provide better fuel
economy. Cummins does not endorse nor
object to any products not manufactured by
Cummins. These statements are between the
customer and the oil supplier. The oil supplier
must promise that the oil will provide satisfac-
5001 801 1624 EN - 05/2022 - 02 209

5 Maintenance
General maintenance
tory performance for Cummins® engines, oth-

erwise the oil should not be used.
The oil film of these oils is thinner than
that of 15W-40 oils, so the high-quality Fleet-
guard® filter must be used at temperatures
of 20°C [70°F] or above. Some oil suppliers
may state that these oils provide better fuel
economy. Cummins does not endorse nor
object to any products not manufactured by
Cummins. These statements are between the
customer and the oil supplier. The oil supplier
must promise that the oil will provide satisfac-
tory performance for Cummins® engines, oth-
erwise the oil should not be used.
Use of break-in oil in new engines
Using specialised break-in oil with new or rein-
stalled Cummins® engines is not recommen-
ded. Use the same type of oil during the
break-in period as during normal operation.
Use of aftermarket oil additives
Use of aftermarket oil additives is not recom-
mended. The premium full-additive engine oil
technology currently in use is very mature,
and the precise amount of additives mixed into
the oil meets strict requirements. These oils
meet the performance characteristics of lubri-
cant industry standards. The use of aftermar-
ket oil additives to improve engine oil perform-
ance is not necessary and, in some cases,
may reduce the ability of the finished engine to
protect the engine.
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
+ 59 + 15 10W-30
bient temperatures above -15°C [5°F]. Using

5W-30 10W-40 15W-30
+ 50 + 10 0W-30 5W-40 10W-50 15W-40 20W-50
multi-grade oil can reduce sediment build up

+ 41 +5 0W-40 5W-50 10W-60 15W-50 20W-60
+ 32 0
and improve engine cranking performance in + 23 -5
- 10
+ 14
low temperature conditions, as well as im- +5 - 15
prove engine durability at high temperatures -4 - 20
- 25
- 13
by maintaining lubrication. As has already
been proven, using multi-grade oil can reduce
oil consumption by about 30% compared to
d1411049
single-grade oil. Using multi-grade oil can

therefore ensure that engines meet applicable
emission requirements. Although the preferred
viscosity grade is 15W-40, multi-grade oils
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Maintenance 5
General maintenance
with lower viscosities can be used in cold cli-

mates.
Oils with 10W-30 viscosities must meet the
3.5 cSt minimum high temperature/high shear
viscosity, as well as Cummins® and Mack™
test requirements for piston ring/cylinder liner
wear. They are therefore suitable for tempera-
ture ranges greater than 10W-30 engine oils
that meet the earlier API performance classi-
fication requirements. The oil film of these
oils is thinner than that of 15W-40 oils, so
the highest quality Fleetguard® filter must be
used at temperatures of over 20°C [70°F].
Some oil suppliers may state that these oils
provide better fuel economy.
NOTE
Oil additives of any kind must not be added to
any of the above mentioned engine oils. Their
use jeopardizes the warranty.
Mixing of different oil brands should be avoi-
ded.
Hydraulic oil
The recommended hydraulic oils are Shell
Spirax S4 TXM and SAE 10W-30 UTTO。
If it is difficult to obtain imported hydraulic oils,
use a similar high-quality UTTO oil of a differ-
ent brand.
If in doubt, contact your authorized service
partner. Oil industry representatives should al-
so be checked with your authorized service
partner.
Only the above-mentioned oils are approved
by the manufacturer. If other hydraulic oils are
used or mixed, costly 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. Only the
above-mentioned oils are approved by the
5001 801 1624 EN - 05/2022 - 02 211

5 Maintenance
General maintenance
manufacturer. If other hydraulic oils are used

or mixed, costly damage can result.
Drive axle
Recommended (SAE 85W/140) hypoid gear
oils corresponding to MIL-L 2105 B/API GL5,
MIL-L 2105 C/D/API GL 5.
NOTE
Important – On axles with self-locking differen-
tials, a noise is produced if normal oils are
used. In case of abnormal noises and in case
of a jerky roll off of the tyres, use gear oil
EP with additives of the “Limited Slip” type
conforming to specification M 2C - 104 A
Lubricating grease
Linde heavy duty grease with additives EP
and MOS2. Designation according to DIN
51825-KPF 2K-20 (see the Parts Catalogue
for the order number). Any mixing with grease
types other than lithium-based greases is not
allowed.
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.
Low-silicate antifreeze/coolants that comply
with ASTM D4985 (GM6038M technical spec-
ifications) are not applicable for extended
maintenance intervals.
We recommend filling the cooling system with
a mixture of high-quality water and pure anti-
freeze at a 50/50 ratio, or pure coolant.
Using high-quality water is essential for main-
taining the performance of the cooling system.
Excessive levels of calcium and magnesium
will cause scaling problems, and excessive
chloride and sulphates can cause corrosion in
the cooling system.
212 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
General maintenance
Water quality
Calculated using (Ca-
Calcium and magne- CO3 + MgCO3);
sium (hardness) maximum content is
170 ppm.
Calculated using (CI);
Chlorides
content is 40 ppm.
Calculated using
Sulphates (SO4); content is
100 ppm.
We recommend using Fleetguard® Compleat.

Two forms of ethylene glycol (ethylene and
propylene) can be used.
Pure antifreeze must be mixed with high-qual-
ity water in a 50/50 ratio (operating range of
40-60%). The freezing point of the 50/50 ra-
tio pure antifreeze and water mixture is -36°C
[-33°F] and the boiling point is 108°C [226°F],
which completely satisfies the requirements
for North America. At a concentration of 68%,
glycol antifreeze coolant reaches the actual
minimum freezing point. If the concentration is
higher, the freezing point of the solution will
also increase, which increases the possibility
of silicone formation.
A refractometer must be used to accurately
measure the freezing point of the antifreeze.
Use the Fleetguard® Refractometer (part no.
C2800).
Do not use a floating hydrometer. The data
obtained using a floating hydrometer is incor-
rect.
Do not use sealing additives in the coolant
system. The use of sealing additives will result
in:
● The formation of blockages in the low cool-
ant flow area
● Blockages in the radiator and oil cooler
● Possible damage to the water pump seals
Do not use soluble oil in the cooling system.
The use of soluble oil will result in:
● Corrosion of brass and copper
● Damage to heat exchange surfaces
● Damage to seals and hoses
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5 Maintenance
General maintenance
Battery grease
Non-acidic grease (pole grease).
Chain spray
Linde chain spray.
Electrical contact grease

For use on all electrical connections.
214 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Service plan
Service plan
Service plan - Cummins_Eu5
Note regarding servicing work
Specialist knowledge is required for servicing work. Special tools may also be required.
Preparatory tasks
Clean the truck
first service jobs 100h.

Engine
Check the condition of the radiator
Check cooling system hoses for tightness and leaks
Change engine oil and oil filter
Transmission
Change oil filter
Check the transmission, pumps, valves and lines for leaks
Check the axle mounting.
Check steer axle hub
Hydraulics
Change brake pressure filter
Change brake return filter
Change bypass hydraulic return filter
Change cooler return filter
Check the hydraulic system, pumps, valves and lines for leaks
Check the pre-load of the mast hoses.
Maintenance every 750 operating hours.
Engine
Check radiator cap
Check whether the belt is worn or damaged and replace it if necessary.
Check battery and battery cable
5001 801 1624 EN - 05/2022 - 02 215

5 Maintenance
Service plan
Maintenance every 750 operating hours.

Change the fuel filter
Change fuel pre-filter
Change engine oil and oil filter.
Clean engine.
Clean and lubricate all bearings, pivots and joints.
Clean and lubricate door hinges.
Clean and lubricate the steering axle.
Load lift system
Clean and lubricate the mast and tilt cylinder pivots and bearings.
Clean, lubricate and check for proper operation of the side shift function.
Lubricate the lift mast bearings.
Additional maintenance every 1500 operating hours.
Engine
Check DEF filter
Check DEF injection unit filter, change it if needed
Check rubber damper.
Change of air filter element and safety filter element.

Transmission
Change the transmission oil and filter
Check the transmission ,lines for leasks
Change gearbox oil

Check the condition and function of the seat belt. (if fitted)
216 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Service plan

Check the mounting of the chassis
Check the axle mounting
Check the cab mountings
Check functionality of cab tilt.
Check security of cab tilt pump handle and safety lock pin.
Check condition of welded structures / components.
Check and adjust the steer stops if necessary.
Check mounting of the steer axle and steering king pin.
Check pedals for smooth operation and ensure there is no excessive play.
Check steering axle wheel hub

Operating devices
Check the functionality of the braking system. (park brake and service brake)
Check the functionality of the absent driver seat switch.
Electrics
Check the condition of the electric cables, cable connectors and connections, and check that
they are securely fitted
Check the condition of the batteries.
Hydraulics
Change the brake pressure filter
Change the brake return filter
Change the bypass hydraulic filter
Change the cooler return filter
Check the hydraulic system, drive motors, pumps, valves and lines for leaks
Check the pre-load of the double hoses.
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5 Maintenance
Service plan

Load lift system
Check the condition of the lift mast, lift mast chain, lift cylinders and end stops, and check that
they are correctly mounted and working correctly
Check the fork arms and arm safety devices
Engine
Change coolant

Hydraulics
Change the hydraulic breather filter
Change the brake suction filter
Change the hydraulic oil
Check the hydraulic pump mounting bolts.
Load lift system
Check the forks
Check the mounting of the mast
Check the tension of mast hoses.
Engine
Adjust the valve clearance to the rated value
Change DEF filter.
Load lift system
Replace the lift chains. (at least every 6000 hours or when 2 % stretch has been attained)
218 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Service plan
Final tasks
Clear the error memory
Reset the maintenance counters
Carry out a functional test, including a test drive
Affix a maintenance sticker.
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5 Maintenance
Engine
Engine
Engine indicator light
The following only refers to the engine indi-
cator light controlled by the Engine Control
Module (ECM). Equipment manufacturers can
supply additional indicator lights.
NOTE
Boot and then allow the switch and selec-
tive catalytic reducer (SCR)/exhaust system
to clean the indicator light. This works in the
same way as other Cummins system diesel
particle filters (DPF). Some OEMs, documents
and tools may refer to these parameters as
“post-processing diesel particle filter regenera-
tion” or “post-processing regeneration” param-
eters.
WAIT TO START indicator light 

Before starting the engine, the WAIT TO
START indicator light will come on when the
air intake heating device needs to heat incom-
ing air.
The time that the WAIT TO START indicator
light is on will vary depending on the ambient
temperature.
For vehicles equipped with engine starter mo-
tor protection features, another function of the
"WAIT TO START" indicator light is to flash on
and off for 2 minutes when the starter motor
has been engaged for 30 seconds or more.
The WAIT TO START indicator light looks like
this:
● WAIT TO START label text that flashes on
and off
● Symbol resembling the picture
● The colour of the symbol or label text may
be different, depending on the manufactur-
er. However, they are usually red or light
yellow.
220 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
CHECK ENGINE indicator light 

When conditions permit, when an engine first
needs maintenance, the CHECK ENGINE in-
dicator light will come on.
The CHECK ENGINE indicator light is light
yellow and looks like this:
● Flashing WARNING or CHECK ENGINE la-
bel text
● The engine symbol resembles that in the
picture
The CHECK ENGINE indicator light comes
with another function: the indicator light will
connect with the key switch and flash for
30 seconds if any of the following conditions
apply: This flashing function refers to the
MAINTENANCE indicator light. The MAINTE-
NANCE indicator light may flash for any of the
following reasons:
● Maintenance is needed (if using a mainte-
nance monitor)
● Checks have found water in the fuel.
● Coolant level is low.
STOP ENGINE indicator light 

The STOP ENGINE indicator light means that
you need to stop the engine when it is safe to
do so. The engine should be turned off before
repairs are carried out.
For engines that use engine stop protection
features, the engine will automatically stop af-
ter 30 seconds if the STOP ENGINE indicator
light is flashing. A flashing STOP ENGINE in-
dicator light warns the operator to stop the
engine as soon as possible.
The STOP ENGINE indicator light is red and
looks like this:
● Flashing STOP or STOP ENGINE label text
● The centre shows a stop engine symbol
with an exclamation mark resembling that
in the picture
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5 Maintenance
Engine
SCR SYSTEM CLEANING indicator 

light
The SCR SYSTEM CLEANING indicator light
means that the post-processing SCR system
needs to be cleaned.
The SCR system cleaning indicator light
means that the SCR system needs cleaning
at the next available opportunity. The process
is performed as follows:
– Change to a more challenging work cycle
(such as driving on a road) for at least 20
minutes
– Carry out fixed SCR/exhaust system clean-
ing.
NOTE
Fixed SCR/exhaust system cleaning is a nor-
mal operation; it is not maintenance that a
service provider needs to perform.
When the SCR SYSTEM CLEANING indica- 
tor light stays on and is accompanied by
the WARNING or CHECK ENGINE indicator
light, it means that the post-processing SCR
needs to be cleaned immediately. If you do
not take the appropriate measures, engine
performance will automatically be restricted.
– You need to carry out fixed SCR/exhaust
system cleaning when these indicator lights
are on.
NOTE
If you do not carry out fixed SCR/exhaust
system cleaning, the STOP ENGINE indicator
light will come on and you will need to send
the vehicle to a Cummins® specialist repair
shop.
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Maintenance 5
Engine
HIGH EXHAUST SYSTEM TEMPERA- 

TURE indicator light
WARNING
When this light comes on, the exhaust temperature
may reach 800°C [1500 °F], which is enough to ig-
nite or melt common materials and cause burns.
When the HIGH EXHAUST SYSTEM TEM-

PERATURE light comes on, it means that the
exhaust is at a high temperature. During nor-
mal engine operation or SCR/exhaust system
cleaning, this indicator light may come on.
NOTE
The OEM determines whether the HIGH EX-
HAUST SYSTEM TEMPERATURE indicator
light is installed in the vehicle. The OEM also
sets the temperature, speed and other condi-
tions at which indicator lights will come on.
Refer to the equipment manufacturer’s main-
tenance information for additional information
on indicator lights
When this indicator light is on, ensure that the
exhaust pipe is not directly facing any com-
bustible or explosive surfaces or materials.
● Have the exhaust gas outlet facing away
from people and any combustible, meltable
or explosive substances.
● No objects should be placed within 0.6 m
[2 ft] of the exhaust gas outlet.
● No combustible, meltable or explosive ob-
jects should be within 1.5 m [5 ft] of the
exhaust outlet (such as petrol, wood, paper,
plastic, fabric, compressed air canisters or
hydraulic lines).
● In an emergency, switch off the engine to
stop the exhaust flow.
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5 Maintenance
Engine
NOTE
The HIGH EXHAUST SYSTEM TEMPERA-
TURE indicator light does not mean that any
vehicle or engine maintenance is required; it
merely warns the vehicle operator that the ex-
haust is at a high temperature. It is common
for the HIGH EXHAUST SYSTEM TEMPER-
ATURE indicator light to flash on and off or
turn off during normal vehicle operation after
completing an SCR/exhaust system clean on
the engine.
AFTERTREATMENT DIESEL EX- 

HAUST FLUID indicator light
When the AFTERTREATMENT DIESEL EX-
HAUST FLUID indicator light is on, or is flash-
ing, it indicates that the diesel exhaust fluid
(DEF) level is low.
NOTE
The OEM determines whether there is an AF-
TERTREATMENT DIESEL EXHAUST FLUID
indicator light installed in the vehicle. The
OEM determines the fluid level at which the
indicator light will come on. Refer to the equip-
ment manufacturer’s maintenance information
for more information about indicator lights.
HAUST FLUID indicator light is on, it indicates
that DEF has fallen below initial warning lev-
els. This can be fixed by adding DEF to the
DEF tank.
NOTE
We recommend completely filling the DEF
tank no matter which fault you are resolving.
HAUST FLUID indicator light is flashing on
and off, it indicates that DEF has fallen below
critical warning levels. This can be fixed by
adding DEF to the DEF tank.
NOTE
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Maintenance 5
Engine
A flashing AFTERTREATMENT DIESEL EX- 

HAUST FLUID indicator light combined with
illuminated WARNING or CHECK ENGINE in-
dicates that diesel engine exhaust fluid levels
have fallen below the derating level. Engine
performance will automatically be restricted.
This can be fixed by adding DEF to the DEF
tank.
If you do not take corrective measures, engine
performance will be restricted a step further to
level two derating.
NOTE
Allowing the DEF tank to run dry will cause the
aftertreatment DEF injection system to stop in-
jecting. This failure state may result in an error
code being displayed as the current status.
If you do not take corrective measures within
30 seconds of the CHECK ENGINE indicator
light coming on, the engine will enter the final
derating level. At this level, the accelerator
may lock, or the engine may stop and restart-
ing will be restricted.
NOTE
If the engine has been off or idling for a long 
time and the DEF gauge shows empty, the
STOP ENGINE indicator light will come on
along with the AFTERTREATMENT DIESEL
EXHAUST FLUID indicator light flashing and
the CHECK ENGINE indicator light coming
on. The engine will enter the final derating
level. This may include being locked at low
idle speed or engine stop and restrictions on
restarting.
NOTE
The above applications may be very different
when applied to some emergency vehicles.
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5 Maintenance
Engine
NOTE
To cancel the final derating level, the DEF
tank must be filled until the gauge reads 10%
or above.
NOTE
SCR SYSTEM CLEANING DISABLED 

(INHIBIT) indicator light
The SCR SYSTEM CLEANING DISABLED
(INHIBIT) indicator light means the switch
is inhibited from operating, so automatic
and manual (non-task) SCR/exhaust system
cleaning cannot take place.
The SCR SYSTEM CLEANING DISABLED
(INHIBIT) indicator light comes on to show
that the switch has been inhibited from operat-
ing, so automatic and manual (non-task) SCR/
exhaust system cleaning cannot take place.
This can be corrected by changing the inhibit
switch into permission mode.
NOTE
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.
226 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
Stop the engine before filling fuel. No smoking

or naked flames when filling fuel. Do not spill
or allow fuel to contact hot parts.
– Turn the ignition off.
– The fuel tank filler cap is located on the left 
side of the truck (1).
– Remove fuel cap
– Fill the tank with clean diesel fuel (see rec-
ommended fuels).
– Refit the filler cap.
NOTE
Maximum fuel capacity - 250 l (approx).
Air filter - check

WARNING
Risk of choking.
Do not start the engine with the filter element re-
moved.
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
the air filter.
CAUTION
Risk of engine damage.
Do not continue to work with a blocked filter.
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5 Maintenance
Engine
A dirty filter element decreases engine per-

formance. Regular filter servicing is essential
for the engine.
– Tilt the cab and open the engine access 
1
cover.
– Release clamps on filter casing (1) and re-
move filter end cover (4).
– Pull out the air filter element (2) and safety
element (3).
2 3
– Inspect and re-use if serviceable. Replace if
necessary.
d1411034
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
checked.
228 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
– Open cooler cap(1) and inspect the cool- 

ant's level and quality.
Checking the engine oil level

CAUTION
Risk of personal injury.
Follow the instructions for handling fluids and lubri-
cants.
When checking the oil level, the engine must be in a
horizontal position to ensure that the measured value
is accurate.
A correct reading can only be obtained when the
engine is off.
Wait at least 15 minutes after the engine has been
switched off before checking the oil level. This time
allows the oil to flow back to the oil sump.
– Park the forklift on level ground.

– Tilt the cabin.
– Remove the dipstick from the engine.
– Use a clean cloth to dry the dipstick.
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5 Maintenance
Engine
– Re-insert the dipstick, and remove it once 

more. The oil level should be between the
two marks on the dipstick.
– If necessary, top up the oil.
– Remove the filler cap from the filling open-
ing. Pour oil into the filling opening until a
suitable level of oil is reached.
Engine oil capacity of a standard engine (six-
cylinder): 6.7 litre engines (high-capacity oil
pan)
Applies only to oil pan 23.7 L

Overall system 26.2 L
Between maximum
and minimum oil level
8.56 L
markings (on the en-
gine oil dipstick)
– Replace the cap and return the cabin to its

original position.
WARNING
Engine oil is a flammable substance.
Do not allow engine oil to come into contact with
engine components that are hot. When adding oil,
take care to avoid leakage.
CAUTION
Using the wrong oil can damage the engine.
Only use oil meeting the specifications noted in the
“Specifications for Fluids and Lubricants” section.
CAUTION
Adding excessive oil to the engine may result in
damage to the engine.
Do not add too much oil into the engine. Drain ex-
cess engine oil, if necessary.
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.
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Maintenance 5
Engine
Radiator
Check there is no dirt or debris blocking the 
radiator (CAC) chip. Check for cracks, holes
or other damage. If you find damage, please
contact your authorized dealer.
Fuel filter and oil-water separa- 

tor
General
This engine uses a dual fuel filter system.
The pressure fuel filter is only used for filter-
ing; pressure is applied to it from the gear
pump installed on the engine fuel pump.
NOTE
Some types of applications use the filter
mounted on the pressure side of the undercar-
riage.
The suction fuel filter is an oil-water separator.
It is positioned between the gear pump instal- 1 The fuel filter
2 The oil-water separator
led on the engine fuel pump and the OEM
fuel tank. This filter is not pressurised, but it
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.
5001 801 1624 EN - 05/2022 - 02 231

5 Maintenance
Engine
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. The fuel system
can be filled using a manual injection pump.
For refuelling steps, see the refuelling section
of this procedure.
Preparation procedure
WARNING
The fuel is flammable. When working on the fuel
system, ensure that there are no cigarettes, open
flames, lights, electric arc devices and switches in
the work area and that the area is ventilated to mini-
mise the possibility of serious injury or death.
Do not drain the fuel system when the engine is hot;
this can cause fuel to splash onto the hot exhaust
manifold and cause a fire.
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. To reduce the possibility
of arcing, remove the negative (-) battery cable first
and connect it last.
Wear suitable safety glasses and a protective mask
when using compressed air. Flying debris and dirt
may cause personal injury.
Wear safety glasses or a protective mask as well as
protective clothing when using steam cleaners. Hot
steam can cause serious personal injury.
CAUTION
Clean the area around the filter before disassembly.
Dirt or debris may cause damage to the fuel system.
– Disconnect the battery cables.

– Clean the area around the fuel filter.
– If necessary, disconnect the water-in-fuel
sensor wiring harness.
232 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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.
– Disconnect the wiring harness from the wa-

ter-in-fuel sensor, if fitted.
– Loosen and remove the fuel filter.
– Ensure that sealing ring (1) is not stuck in 
the filter base.
– If necessary, use the O-ring removal tool to
remove the seal.
Installation
CAUTION
Do not use a pre-filled pressurised fuel filter unless
you are using a clean block-type plug. Fill the fuel
system after installing the fuel filter. Pre-filling the
pressurised fuel filter may cause debris to enter
the fuel system and damage the fuel system compo-
nents.
NOTE
If applicable, use a clean block-style plug to
plug the filter prior to assembly and pre-fill the
pressure and suction sides of the filter with
clean fuel. You cannot put fuel directly into the
filter because this will allow unfiltered fuel to
enter the system and cause damage to fuel
system components.
– Use the correct fuel filter.
– Use clean engine oil to lubricate the fuel
filter’s O-ring seal.
CAUTION
If the filter is put on too tight, it can distort the thread
and cause damage to the filter or filter housing.
– If fitted, connect the water-in-fuel sensor.
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5 Maintenance
Engine
– The engine warning lights will come on if

the water-on-fuel sensor is not compatible
or is disconnected.
Final steps
WARNING
– If necessary, connect the wiring harness to

the water-in-fuel sensor.
– Connect the battery cables.
Filling
WARNING
The fuel pump high pressure fuel lines and fuel rails
contain highly pressurised fuel. Never loosen any
pipe connections while the engine is running. Doing
so may result in personal injury and damage to prop-
erty.
CAUTION
Do not engage the starter motor for more than 30
seconds at a time. Leave an interval of 2 minutes
between each attempt at starting the engine.
NOTE
Some vehicles are fitted with engine starter
motor protection features. If the starter motor
is engaged for 30 seconds or more without the
engine starting up, the starter motor will lock
to prevent operation and to allow the starter
motor to cool down properly. At this time, the
WAIT TO START indicator light will flash on
and off for two minutes, if fitted. The starter
motor will be allowed to run again after the
indicator light has stopped flashing.
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Maintenance 5
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.
– Rotate anticlockwise to unlock the manual
fuel injection pump handle. Apply pressure
to the fuel injection pump lever until you feel
firm amount resistance and cannot depress
the lever further (approximately 140 to 150
times [for a dry filter]) or 20 to 60 times [for
a pre-filled filter]).
– Lock the manual fuel injection pump lever.
– Start the engine. If the engine does not
start after 30 seconds, disconnect the key
switch.
– Apply pressure to the fuel injector pump
again and repeat the above steps until the
engine starts.
– The engine may not run smoothly for the
first few minutes after starting up and may
produce an increased noise level. This is
normal and is due to air being expelled from
the system.
NOTE
After changing the fuel filter, error code 559
may be displayed due to the presence of air in
the system. It is necessary to run the engine
until all the air has been expelled and use the
INSITE™ service tool to clear the error code
before dispatching the vehicle.
– Run the engine. Check for leaks.
5001 801 1624 EN - 05/2022 - 02 235

5 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.
WARNING
To reduce the possibility of personal injury, skin
should be protected from direct contact with hot oil.
When the specified time to change the oil is

reached, both the oil and filter should be re-
placed. See the maintenance procedures to
find the correct replacement interval for your
application type.
NOTE
For most engines, use a container that holds
at least 20 litres [21 quarts] of oil. Some en-
gines may be equipped with an increased ca-
pacity sump, which requires a container that
holds 28 litres of oil.
– Run the engine until the water temperature
reaches 60°C [140°F].
– Shut the engine off.
– Remove the oil drain plug. Immediately
drain the oil to ensure that all oil and sus-
pended dirt in the engine is removed.
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Maintenance 5
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.
Installation
Using the correct oil filter.
CAUTION
If there is no oil in the filter before oil is pumped into
the filter when starting the engine, the engine may be
damaged due to lack of lubrication.
– Coat the surface of the filter gasket with

clean 15W-40 oil.
– Fill the filter with clean 15W-40 oil.
– Coat the sealing surface of the gasket with
a thin layer of oil before installing the filter.
NOTE
Be careful not to allow debris to enter the filter
along with the oil. If using an oil supply with a
metal or plastic seal under the cover, remove
the seal carefully. Using a knife or sharp ob-
ject to puncture the seal may result in debris
entering the oil container.
CAUTION
Excessive mechanical tightening of the filter can
damage the thread or the filter element seal.
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5 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. If damaged, use a
new sealing washer.
– Install the oil sump drain plug.
Industrial application type:
Steel oil sump drain plug torque

Nm ft-lb
M18 60 Min. 44
M22 80 Min. 59
Cast aluminium oil sump drain plug torque

Nm ft-lb
M22 60 Min. 44
NOTE
The Cummins® engine uses premium 15W-40
thickened motor oils such as Valvoline® Pre-
mium Blue® or similar.
– Use a clean engine oil to top the engine up
to an appropriate level.
NOTE
The total system capacity is the sum of the oil
sump capacity and the oil filter capacity.
Some application types use have small differ-
ences in the capacity of the oil sumps used,
so the total oil capacity must be adjusted ac-
cordingly. If you have any questions, please
contact your authorized dealer.
– Allow the engine to idle and check the drain
plug for leaks. If the oil filter seal has been
replaced, check the seal for leaks.
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Maintenance 5
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.
– Shut the engine off. Wait approximately 5
minutes for the oil to recirculate from the
upper part of the engine. Check the oil level
again.
If necessary, add oil to the high oil level (H)
mark on the oil gauge.
Radiator pressure cap

General
This cooling system uses a pressure cap to
prevent the coolant from boiling. Ensure you
know the right radiator pressure cap for your
application type.
Incorrect or faulty pressure caps will result in
loss of coolant and overheating of the engine.
Checking if you can continue to use the 

pressure cap
Ensure you are using the correct radiator
pressure cap.
– Check the rubber seal of the pressure cap
for damage.
– Check the radiator filler neck for the pres-
ence of cracks or other damage.
Test the radiator cap pressure. The pressure
cap must indicate that it can seal properly at
pressures of 14 kPa [2 psi]. If not, it must be
replaced. Incorrect or faulty pressure caps will
result in loss of coolant and overheating of the
engine.
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5 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.
NOTE
We recommend using coolant that complies
with the Cummins Emission Solution (CES)
14604 or 14439 standards.
NOTE
Do not use sealing additives to fix leaks in the
cooling system. This will cause blockages in
the cooling system and impede coolant flow,
causing the engine to overheat.
The engine coolant level must be checked ev-
ery day.
CAUTION
Do not add cold coolant to the engine when the en-
gine is hot. This will damage the engine casting. Wait
until the engine coolant has reached 50°C [120°F] or
less before adding coolant.
For some types of applications in coolant re-

covery systems, check that the coolant inside
the recovery tank is at an appropriate level to
ensure the engine temperature.
Many coolant recovery/expansion tanks are
made from semi-transparent material so you
can check the coolant level without removing
the radiator cap.
NOTE
Some radiators have two filler necks. Both fill-
er necks must be filled when discharging the
cooling system.
When not using coolant recovery system ap-
plications, the top water tank of the radiator is
used to check and top up coolant levels. Do
240 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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.
Discharging
WARNING
– Park the vehicle on a level surface.

– Before beginning maintenance, switch off
equipment connected to the heating sys-
tem's coolant flow valve, so that the en-
gine is separated from the vehicle’s cooling
system. This will prevent heater circuit out-
put and reduce the chances of the refilling
process producing gas pockets.
– In some types of applications (where there
are several feet of piping and multiple heat-
er cores), it may be difficult to expel the air.
NOTE
If you change the coolant or flush the cooling
system, the coolant flow valve will need to re-
main open and connected to the heating sys-
tem to fully drain the system.
NOTE
Any special requirements for coolant draining
or refilling may be marked on the cooling sys-
tem access port or near the vehicle's refill lid.
– Remove all filler caps from the cooling sys-
tem to allow the coolant to completely drain.
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5 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. For
most applications, a 57 litre [15 gallon] drain
pan in sufficient.
– Close the drain valve once the cooling sys-
tem is fully drained.
– Check for damaged hoses and loose or
damaged hose clamps. Replace as needed.
– Check the radiator for leaks, damage or
scale. Clean or replace as needed.
Flushing
CAUTION
The system must be properly filled to prevent airlock,
which could result in severe engine damage. When
filling, air must be expelled from the engine coolant
channel. Allow 2 to 3 minutes for the air to be expel-
led, then add the mixture until the liquid level reaches
the top.
Be sure to bleed air while in the process of

refilling.
● Some one-way thermostat ball valves allow
air to escape through the thermostat when
the thermostat is turned off.
● The vent connector is connected to the
top water tank/coolant recovery tank of the
cooling system and is located near the wa-
ter outlet.
A refill speed of at most 19 litres [5 gallons]
per minute is enough to completely expel the
air.
NOTE
Do not fit the radiator cap. During this process,
the engine should run without the pressure
cap on.
242 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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. 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.
WARNING
Do not operate the engine when the pressure cap is
removed and the temperature exceeds 93°C [200°F].
This may result in engine damage due to pump cavi-
tation and local boiling.
CAUTION
Before replenishing the coolant, allow the system to
return to ambient temperature. This will ensure that
sufficient coolant is supplied to the pump whenever it
is in operation.
CAUTION
Before the vehicle is returned to service, do not re-
lease system pressure when the system is hot to
immediately “top up” the system. The system will not
be able to produce the required pressure through
coolant expansion. This may result in engine dam-
age due to pump cavitation and local boiling.
Use Restore™ and Restore Plus™ mix solu-

tion (or market equivalents) to fill the cooling
system to regulation capacity or level.
– Unless otherwise noted, all shutoff valves
must be returned to the open position once
the system has been completely refilled be-
fore draining begins. This will help to ensure
that as much air is bled from the cooling
system as possible.
– 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.
– Add water until the liquid reaches the full
(FULL) mark.
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5 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
on.
When the cooling system filling cap is re-
moved:
● Run the engine at a low idling speed for 2
minutes
● Turn off the engine and add water until the
level reaches the FULL mark
When the cooling system filling cap is re-
moved:
● Start the engine.
NOTE
After starting the cold engine, slowly increase
the engine speed (rpm) to provide the bear-
ings with adequate lubrication and stabilise
the oil pressure.
– Run the engine at high idling speed until the
thermostat turns on.
– Allow the engine to run at a low idling speed
for 2 minutes before turning it off. This is
to cool the piston, cylinder, bearings and
turbocharger parts.
– Turn off the engine and check the cool-
ant level in accordance with the equip-
ment manufacturer’s servicing information.
Where necessary, bring the level back
down to the full (FULL) mark.
– Install the cooling system filling cap.
– Run the engine for 1 to 1½ hours with
the engine coolant temperature above 80°C
[176°F].
– Turn off the engine. Allow the coolant
temperature to fall to 50° C [122° F] be-
fore draining the cooling system. 排放冷却
系统。
– Drain the cooling system.
244 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
WARNING
CAUTION
NOTE
Do not fit the radiator cap.
– Use good-quality water to fill the cooling
system to the capacity or level recommen-
ded by the equipment manufacturer's main-
tenance information.
– Unless otherwise noted, all shut-off valves
must be returned to the open position when
the system is refilled and the air bleeding
process is about to begin. This will help to
ensure that as much air is bled from the
cooling system as possible.
– Add water until the liquid reaches the full
(FULL) mark.
on.
– When the cooling system filling cap is re-
moved:
minutes
● Turn off the engine and add water until the
level reaches the FULL mark
moved:
● Run the engine at high idling speed until the
thermostat turns on.
5001 801 1624 EN - 05/2022 - 02 245
5 Maintenance
Engine
NOTE
the oil pressure.
– Allow the engine to return to low idle for
2 minutes before turning it off. This is to
cool the piston, cylinder, bearings and tur-
bocharger parts.
– 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
The system must be properly filled to prevent airlock,
which could result in severe engine damage. When
filling, air must be expelled from the engine coolant
channel. Allow 2 to 3 minutes for the air to be expel-
led, then add the mixture until the liquid level reaches
the top.
Ensure that the air is expelled during the filling

process:
● Some one-way thermostat ball valves allow
air to escape through the thermostat when
the thermostat is turned off.
● The vent connector is connected to the
top water tank/coolant recovery tank of the
cooling system and is located near the wa-
ter outlet.
The system is designed for a maximum fill rate
of 19 litres [5 gallons] per minute.
NOTE
Some engines may not be fitted with a manual
vent valve; the valve opens to ensure proper
filling. The upper radiator hose is the usual
position for the vent valve.
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Maintenance 5
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.
WARNING
WARNING
CAUTION
CAUTION
When using the filling door on a vehicle equipped
with a reserve water tank, filling is not recommended
when the system is hot. Although the liquid level
may be replenished to the bottom of the filling door
when the system is hot, there may be insufficient
coolant when the operating temperature is low. This
may result in pump cavitation and will increase the
likelihood of damage to the engine.
CAUTION
Before replenishing the coolant, allow the system to
return to ambient temperature. This will ensure that
sufficient coolant is supplied to the pump whenever it
is in operation.
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5 Maintenance
Engine
CAUTION
If sufficient cooling time is not given after releasing
the pressure from the cooling system when replen-
ishing the coolant, the engine or engine components
may be damaged. System pressure is only produced
when coolant temperature rises. Turning off the cool-
ing system when hot will not produce pressure.
– Remove the cooling system filling cap.

– Fill the cooling system to the specified vol-
ume or level using a mixture of 50% water
and 50% ethylene glycol or propylene gly-
col-based antifreeze.
Sequence of coolant filling and draining operations
NOTE
If all coolant discharged from the system has
been collected, an equal amount or more of
coolant must be added to the system. 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.
Unless otherwise noted, all shut-off valves
must be returned to the open position when
the system is refilled and the air bleeding
process is about to begin. This will help to en-
sure that as much air is bled from the cooling
system as possible.
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Maintenance 5
Engine

– Fill with a 50/50 mixture to return the cool-
ant level to the cold full mark.
on.
moved:
minutes
● Turn off the engine and fill with the 50/50
mixture to return the coolant level to the
cold full mark
– With the radiator pressure cap off:
● Run the engine at a high idling speed until
the thermostat turns on
NOTE
the oil pressure.
– Idle the engine for 2 minutes before turning
it off. This is to cool the piston, cylinder,
bearings and turbocharger parts.
● Shut the engine off
● Add coolant until the liquid level reaches the
hot full mark
● It is the user's responsibility to check the
coolant cold level and top up if necessary
NOTE
Some applications may require an additional
10 minutes of high idle time to fully discharge
all the air in the system.
– Allow the engine to cool down to 50°C
[176°F]. Install the pressure cap. Run the
engine until the water temperature reaches
80°C [176°F] and check for coolant leaks.
5001 801 1624 EN - 05/2022 - 02 249

5 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. The aftertreat-
ment DEF injector is a maintenance item.
NOTE
See the maintenance information for the DEF
tank filter maintenance interval. In ordinary en-
vironments, we recommend changing the DEF
tank filter every 2000 hours. In dusty environ-
ments, we recommend inspecting the filter ev-
ery 1500 hours and changing the filter if it is
dirty.
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. Do not swallow. If you accidentally swallow
DEF, go to hospital immediately.
WARNING
CAUTION
Do not use pressure washers or steam cleaners on
the unit. Pressure washing or steam cleaning can
damage the unit. Use compressed air to remove
loose debris.
– Disconnect the battery.
250 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
– Contact a authorized service provider to re-

move the DEF tank assembly to conduct
maintenance on the DEF reservoir filter.
Removal
NOTE
You should only remove the DEF tank filter
if you discover symptoms that need further in-
vestigation or when it has reached its service
interval.
– Remove the clips from the DEF tank filter 
inlet.
– Remove the DEF tank filter.
NOTE
If you are removing the DEF tank filter as part
of a service interval, discard the 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.
– If you suspect that the DEF injection system
has been contaminated through the DEF,
inspect the DEF tank filter before discarding
the filter.
– Check for evidence of DEF contamination
in the DEF tank filter. Determine whether
contaminated fluid has passed through the
injection system from the filter's appearance
and smell.
– Please contact a authorized dealer for more
information on contaminated DEF.
– Check for debris in the DEF filter. If there
is obvious debris, check the aftertreatment
DEF injector filter.
– Check the DEF tank filter for cracks and
other damage.
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5 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.
– Install the clips onto the notches on the
DEF tank.
WARNING
– Contact a authorized service provider to in-

stall the DEF quality sensor.
– Connect the battery.
Belt tensioner
With the engine off, check the tensioner arm, 
belt pulley and stop block for cracks. If cracks
are discovered, the tensioner must be re-
placed.
With the belt installed, check that the two ten-
sioner arm stop blocks are not in contact with
the spring housing stop blocks. If there is con-
tact with any stop block:
● Verify that the part number of the belt is
correct.
● If an incorrect belt has been installed, re-
place it.
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Maintenance 5
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. If there
is no contact, the tensioner must be replaced.
If the tensioner arm stop blocks are still in 

contact with the spring housing stop blocks
after replacing the belt, the tensioner must be
replaced.
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5 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.
Drive belt
Maintenance and checks
V-ribbed belt
CAUTION
Ensure the engine is switched off and all starting
mechanisms are isolated before carrying out any
checks. Routine belt checks can be carried out using
a suitable opening. Do not remove any protective
covers.
Belts should be checked daily. Check the

belt for intersecting cracks. Horizontal cracks
(along the width of the belt) are acceptable.
Vertical cracks (along the length of the belt)
that intersect with horizontal cracks are not
acceptable. If the belt is worn or parts of the
belt are missing, it should be replaced.
Belt damage may be caused by the following:
● Incorrect tension
● Incorrect specifications and length
● Belt pulley is not aligned
● Incorrect installation
● Poor operating environment
● Oil or grease on the belt.
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Maintenance 5
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.
Belt damage may be caused by the following:
● Incorrect tension
● Incorrect specifications and length
● Belt pulley is not aligned
● Incorrect installation
● Poor operating environment
● Oil or grease on the belt.
Measuring the belt tension at the centre

of the belt pulley
– Select the correct gauge and tension ac-
cording to the width of belt used.
Drive belt tension gauge
SAE belt New belt ten- Old belt ten-

specifications sion sion range*
N N
0.380 in 620 270 to 490
0.440 in 620 270 to 490
1/2 in 620 270 to 490
11/16 in 620 270 to 490
3/4 in 620 270 to 490
7/8 in 620 270 to 490
4 rib 620 270 to 490
5 rib 670 270 to 530
6 rib 710 290 to 580
8 rib 890 360 to 710
10 rib 1110 440 to 890
12 rib 1330 530 to 1070
12 rib K sec-
1330 890 to 1070
tion belt
31 rib 1668 1330 to 1560
5001 801 1624 EN - 05/2022 - 02 255

5 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.
– Alternative method (deflection method) - 
Apply a force of 110 N [25 Ib] on the V-belt
between the pulleys to check the belt ten-
sion. If the deflection from the centre of the
belt pulley for each inch of the belt exceeds
the belt thickness, the belt tension must be
adjusted.
– For toothed belts, make sure the belt ten- 

sion gauge is installed so that the centre
tension bar is directly above the apex of a
tooth. Other positions will result in incorrect
measurements.
256 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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. If the rubber block has been lost or the
elastic component exceeds 3.18 mm below
the metal surface, replace the damper.
Check whether the damper ring on the hub
has moved forward. If it has, replace the
damper.
Overhead mechanism
WARNING

– Remove the rocker arm cover and gasket.
Adjustment
Engine coolant temperature must be below
60 C [140°F]
5001 801 1624 EN - 05/2022 - 02 257

5 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 

pointer at 12 o’clock.
258 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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. Check whether the two
rocker arms of the no. 1 cylinder are loose.
If they are not loose, turn the crankshaft
360 degrees and then check again.
– If both the no.1 rocker arms are loose, then 

proceed to the next step. If the no.1 rocker
arms are not loose, turn the crankshaft 360
degrees and then proceed to the next step.
– Be sure to check the engine designation
plate for the correct valve clearance (over-
head mechanism) technical specifications.
– The engine designation plate is typically lo-
cated on the engine rocker arm cover. How-
ever, it may also be located on the left side
of the gear housing.
If both rocker arms are loose when the no.1
cylinder is at TDC, you can check the below
rocker arm valve clearance (overhead mecha-
nism):
(E = exhaust, I = intake) 1I, 1E, 2I and 3E, 4I
and 5E.
Overhead mechanism inspection limits

mm in
Intake 0.152 Min. 0.006
0.381 Max. 0.015
Exhaust 0.381 Min. 0.015
0.762 Max. 0.030
Checking the overhead mechanism setting

values is generally the first step in trouble-
shooting. As long as the measured clearance
value is within the above range, the settings
do not need to be adjusted during the checks.
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5 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). If the measured value ex-
ceeds specifications, then loosen the lock-
nut and adjust the clearance to nominal
specifications.
Valve clearance (overhead mechanism)

mm in
Intake 0.254 Nominal 0.010
Exhaust 0.508 Nominal 0.020
– Tighten to locknut and measure the clear- 

ance again. (Torque value: 24 n•m [ 212
in-lb ] )
Final steps
WARNING
– Install the rocker arm and gasket covers.

– Run the engine. Check for leaks.
260 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
Aftertreatment diesel particulate

filter
General
WARNING
Substances captured in the split-type diesel particu-
late filter and/or diesel particulate filter may contain
high concentrations of metals. The main metals are
zinc and molybdenum, but controlled multi-ring aro-
matic hydrocarbons may also be included. These
substances must be sorted and processed in accord-
ance with local laws and regulations. In addition,
exhaust filter maintenance must only be carried out
by qualified personnel due to the presence of the
above-mentioned chemical substances and other po-
tentially toxic elements (such as calcium, zinc, phos-
phorus, silicon, sulphur and iron oxide).
CAUTION
The aftertreatment diesel particulate filter core is
composed of brittle material. Do not drop or knock
the side of the aftertreatment system because this
could damage the catalytic core.
This procedure contains general information

due to the wide range of exhaust aftertreat-
ment applications. The images in this docu-
ment do not show all types of applications that
are in use.
The aftertreatment exhaust assembly is com- 
posed of four sections. These sections are:
NOTE
If the aftertreatment DPF needs to be replaced
due to further damage from engine oil or fuel,
then cleaning needs to be carried out from the
turbocharger outlet to the aftertreatment 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.
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5 Maintenance
Engine
Authorized service providers do not endorse 1 The aftertreatment diesel oxidation catalyst
the ash-cleaning functions of localised air- (DOC)
2 The aftertreatment diesel particulate filter
cleaning machines. All DPFs that need the (DPF)
have ash cleaned from them should be re- 3 The decomposition reaction tube
turned to a authorized service provider in ex- 4 The selective catalytic reducer (SCR)
change for a new/ReCon® DPF。 Do not use
unapproved cleaning methods to clean the
DPF.
Aftertreatment diesel exhaust 

fluid injector filter
General
The diesel exhaust fluid (DEF) injector filter
prevents substances suspended in the DEF
from getting into the injection system.
Debris can cause permanent damage and
premature wear to the aftertreatment DEF in-
jector and the aftertreatment injector valve.
The aftertreatment DEF injector is a mainte-
nance item.
Please contact a authorized service provider
regarding incorrect or contaminated DEF han-
dling.
The aftertreatment DEF injector filter is com- 
posed of the following components:
Initial inspection
Locate the aftertreatment DEF injector on the
vehicle; note the round filter cap.
NOTE
The aftertreatment DEF injector may be loca-
ted in different areas, depending on the vehi-
cle. Locate the DEF tank and then follow the
DEF line to locate the aftertreatment DEF unit.
Check the aftertreatment DEF filter cap seals
and the surrounding exhaust area for signs of
leaks.
1 The aftertreatment DEF injector filter cap
DEF leaks leave a white sediment. If you find 2 The aftertreatment DEF injector filter balance
any sediment, see the “Cleaning and Contin- cartridge
3 The aftertreatment DEF injector filter ele-
ued Use Checks” section of this procedure. ment.
262 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Engine
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. Do not swallow. If you accidentally swallow
DEF, go to hospital immediately.
WARNING
WARNING
Once connected, the aftertreatment DEF injector and
DEF lines on the aftertreatment DEF injector valve
will be under low pressure and must not be discon-
nected before the system purification process has
completed while the engine is running or after the
engine has stopped. Disconnecting the DEF lines
while under low pressure may cause DEF to spray
out.
WARNING
Wear suitable safety glasses and a protective mask
when using compressed air. Flying debris and dirt
may cause personal injury.
NOTE
Do not disconnect the vehicle battery before
the DEF system has completed the empty-
ing cycle. Before disassembling and/or discon-
necting any part, wait 5 minutes after the
ignition switch has been turned to OFF (dis-
connected) so that the aftertreatment diesel
exhaust liquid injection system expels the die-
sel exhaust fluid from inside the system. The
emptying cycle is automatic and will work with-
out any intervention. During the emptying cy-
cle, the aftertreatment diesel exhaust fluid in-
jector will emit audible pump pressure noise
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5 Maintenance
Engine
NOTE
Do not use pressure washers or steam clean-
ers on the unit. Use compressed air to remove
loose debris.
Removal
NOTE
There may be DEF residue in the filter hous-
ing. We recommend placing collection con-
tainers under the DEF filter cap.
– Remove the DEF filter cap (1). You can use 
a 27 mm wrench to help remove the cap.
– Remove the aftertreatment DEF filter bal-
ance cartridge (2).
– Remove the old aftertreatment DEF injector
filter element (3). The filter comes with a
one-time repair tool that can assist with re-
moving the filter. Use the appropriate tools
as indicated by the colour of the filter plas-
tic. When you insert the tool, you will hear
a “click” sound indicating that the tool has
connected properly with the filter.
NOTE
The filter element and balance cartridge must
be discarded and replaced with new ones if
you remove them from the aftertreatment 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.
– Check the thread on the aftertreatment DEF
injector cap.
– Replace the aftertreatment DEF injector fil-
ter cap if the thread is damaged.
– Check the thread of the aftertreatment DEF
injector. This is especially important if the
thread cap of the aftertreatment DEF injec-
tor is damaged.
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Maintenance 5
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.
Installation
NOTE
There is no need to lubricate the DEF filter
O-ring.
– Slide the DEF filter balance cartridge (2) 
into the DEF filter element (3)。
– Insert the assembly into the aftertreatment
DEF injector.
– Install and tighten the cap (1). You can use
a 27 mm wrench to install and tighten the
filter cap. (Torque Value: 20 n•m [ 177 in-
lb ] ）
WARNING

– Perform an aftertreatment diesel exhaust
fluid leak test using the INSITE™ e-service
tool engine control module diagnostic test.
– Pre-fill the system. Check for leaks.
5001 801 1624 EN - 05/2022 - 02 265

5 Maintenance
Gearbox
Gearbox
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.
Make sure truck is on level ground. Park brake
on and wheels chocked. Engine must be run-
ning
– Tilt the cab and open the engine access
covers.
– Remove dipstick (1) and wipe with a clean 
cloth.
– Fully re-insert dipstick (1) and remove it
again.
– The oil level should be between the Min. 1
and Max. markings.
– Add oil if required.
– Replace engine covers and lower the cab.
NOTE
When transmission oil level is low a warning is
displayed on the truck status display unit, the
engine management system restricts the truck
to low speed operation. d1411032
266 5001 801 1624 EN - 05/2022 - 02

Maintenance 5

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
be used with utmost care. The grease in sealed
for life bearings may dissolve and leak out. Since
re-greasing is not possible, this will result in damage
to the bearing..
CAUTION
Protect all electrical components and the air filter
intake from the ingress of steam, water etc., when
cleaning.
Protective clothing and eye protection must be worn.
Clean the cabin floor and ensure that no deb-

ris is allowed to obstruct the operation of the
pedals.
Clean especially the oil filler areas and the
lubrication points prior to servicing.
When cleaning with compressed air, remove
sticking dirt with a cold cleaner.
When cleaning the truck with de-greasing sol-
utions, allow sufficient time for the cleaner to
soak in, then flush off with a strong water jet.
After cleaning the engine, allow it to run warm
to dry off and to ensure there are no malfunc-
tions due to water ingress.
Clean and spray the lifting chains
NOTE
The lifting chains must be cleaned if the dust
covering the chain prevents penetration of the
lubricant.
– Place a container under the mast.
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5 Maintenance
– 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. During this procedure the chain
should be moved several times.
– Spray Linde chain spray immediately, move
the chain while spraying by raising and low-
ering the fork carriage.
NOTE
Lifting chains are safety components. The use
of cold cleaners, chemical cleaning agents
and caustic or acidic and chlorinated fluids
can be a direct cause of damage to the chain.
NOTE
Trucks in service in the food industry must be
lubricated with an oil approved for the food
industry instead of chain spray.
Check seat belt for condition and 

3 1
correct operation (option)
NOTE 2
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.
– Pull belt (1) out fully and inspect for fraying.
– Check lock (2) for correct operation and the
retractor for proper return of the belt. d3591093
– Check covers for damage.

– Check the automatic lock.
– Park the truck on level ground.
268 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
– Pull out the belt with a jerk. The automatic

lock should prevent the belt from unrolling
from retractor (3).
– Slide the seat fully forward.
– Tilt the backrest fully forward.
CAUTION
Danger of injury.
Do not operate the truck with a faulty seat belt. Have
a defective seat belt replaced immediately by your
authorised dealer.
To prevent accidents, check that all adjust-

ments are properly engaged before operating
the truck.
Do not operate the seat adjusting devices
while operating the truck.
Seat belts must be applied before operation of
the truck.
After an accident, the seat belt must be in-
spected renewed if necessary. In the case of
seat belts attached to the operator seat, the
seat and mounting of the seat must also be
inspected by qualified personnel.
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.
If the seat belt is not checked, you put your
health in danger and there is a higher risk of
accidents.
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5 Maintenance
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.
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Maintenance 5
Chassis
Chassis
Check the condition of structured components
CAUTION tion should cover all areas of the main
structures and their connections. Attention
Danger of injury or accident. should be given to welds and material ad-
Work on the truck on level ground. Lower the car- joining welds, particularly at changes of
riage, stop the engine and put the parking brake on section, bolted interfaces and sliding pad
when working.
pressure points.
– Examine the mast, lift and tilt cylinders, an-
CAUTION chor and bearing points for damage, wear,
Danger of fall injuries. missing lock bolts, metal fatigue, etc.
This maintenance procedure requires to be carried – Examine the bearings for damage, missing
out at heights of more than 2 metres. Use suitable
access equipment. retaining rings and abnormal wear.
– Examine the structural components of

the truck to assure their integrity. Inspec-
Tighten the wheel nuts 

1
CAUTION
Danger of accident.
During initial operation and after each wheel change,
the wheel fasteners must be tightened before starting
work and thereafter every 10 service hours until they
have settled, i.e. until no further tightening is possi-
ble.
Thereafter check wheel nuts (1) every

100 hours.
Torque all wheel nuts to 680 Nm.
A socket with an extension bar is needed to
tighten the front wheel nuts. d3591090
Check the tyres for damage and

foreign objects
CAUTION
Low tyre inflation pressure reduces tyre service life
and the stability of the truck.
Do not operate the truck with low tyre pressure.
5001 801 1624 EN - 05/2022 - 02 271

5 Maintenance
Chassis
CAUTION
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.
Locations for jacks when chang-

ing wheels
CAUTION
Danger of accident.
Only use a jack with sufficient lifting capacity. The
capacity of the jack should be 25,000 kg minimum.
CAUTION
Danger of accident.
When working under the truck secure the chassis
with wooden blocks, do not rely just 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.
– To jack up front of truck, place jack under 
drive axle mounting plate, or the centre of
the drive axle.
– To jack up rear of truck, place jack under
main plate of steer axle, or the centre of the
steer axle.
d1411057
272 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Controls
Controls
Check the parking brake for
proper operation
– Drive the lift truck with the maximum load
onto a 15 % slope.
– Apply the parking brake. The truck should
not move.
– Release the parking brake.
– Stop the engine. The lift truck should not
move.
NOTE
If the parking brake is not operating correctly,
Brake control mechanism

NOTE
These checks must take place every service
interval, PLUS after any component replace-
ment, PLUS after any adjustment.
– 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.
– Start the engine, test the foot brake, switch
off the engine
NOTE
Specialist knowledge is required to carry out
these procedures, please contact your service
partner.
5001 801 1624 EN - 05/2022 - 02 273

5 Maintenance
Controls
Driver’s seat switch

NOTE
This switch will not prevent the startup of the
truck whether the driver is seated or not.
This is activated when the driver leaves the
seat while driving. When this happens the
transmission will disengage and the truck will
come to rest quickly.
To reset the switch

– Sit back on the driver’s seat.
– Put the gear lever into neutral.
– Select forward or reverse gear.
Normal operation is restored.
274 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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!
– Check the battery / batteries for cracks in

the casings, and leaked electrolyte.
– Remove any corrosion on battery terminals
and check the connections for tight seating.
– Tighten the terminals and coat with non-
acidic grease.
Check electric cables, connectors and connections for condition and

tightness
– Examine cable connections for looseness
NOTE
and corrosion.
– Inspect the earth lead for loose connection. Corroded connections and cracked cables
lead to a drop in voltages, which may cause
– Examine the electrical wiring for chaffing starting difficulties.
and loose connections.
– Remove corrosion and replace cracked ca-
bles.
5001 801 1624 EN - 05/2022 - 02 275

5 Maintenance
Hydraulic system
Hydraulic system
Hydraulic system: oil level check 
– Park the truck on level ground and lower

the forks to the ground.
1
– Check sight glass (1) on the right side of the
chassis. Add oil if necessary.
NOTE
Mast should be vertical when checking oil lev-
el.
d1411020
Adding Hydraulic oil

– Remove hydraulic tank breather/filler (1) to 
add oil.
NOTE
Observe the sight glass and fill to maximum.
Hydraulic tank capacity - 180 l approx.
Hydraulic system: check for leaks

WARNING NOTE
Risk of burns and scolds.
It is necessary to ensure that all relevant pipes
Beware of hot engine and exhaust components. are disconnected and take preventive meas-
Wear protective equipment. ures to disconnect pipes before opening the
radiator. It is suggested that this operation be
performed by Authorized Service Provider.
276 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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.
pumps and control valves for leaks.
– Re-tighten the connections if necessary.
Hydraulic tank breather filter - 

check
NOTE
The truck should be at normal operating tem-
perature, and the oil level should be correct.
Raise and lower the mast twice in quick suc-
cession before performing this check.
– Slowly unscrew breather filter (1) located on
the top of the hydraulic oil tank, allowing the
air to escape before removing fully.
NOTE
In a dusty atmosphere it may be necessary to
renew the filter earlier.
– If air is not heard to escape, replace breath-
er filter (1).
– Discard used filter according to local author-
ity guidelines
5001 801 1624 EN - 05/2022 - 02 277

5 Maintenance
Load lifting system
Load lifting system

Lubricate the mast and tilt cylin-
der pivots
Lubricate the mast pivot pins 
CAUTION
Danger of damage to the truck. 1
Take the weight off each pivot pin in turn using
a suitable jack to ensure the optimum ingress of
grease.
NOTE
Lubricate with grease according to the lubri-
cant recommendations.
– Lubricate mast pivot pin (1) through the
front of the mast.
d3591108
– Lubricate with grease gun until new grease
is visible at the bearing.
CAUTION
Danger of accident.
Refer to safety notes on securing the mast when
working on the front of the machine.
Lubricate the tilt cylinder pivots 
NOTE
Lubricate with grease according to the lubri-
cant recommendations.
– Lubricate tilt cylinder pivots (2), two points.
– Access to the bottom two points is from the
side of the tilt cylinder recess under the cab.
– Access to the top two points is on either
side of the mast.
– Lubricate with grease gun until new grease 2
d3591109
278 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Load lifting system
Lubricate fork carriage cylinder 

bearings 1
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.
d3591110
Check the fork carrier slider pads 

– Check the clearance at slider pads (1), fit- 2
ted to the base of the fork carriers.
– Slider pads (1) should be changed when
clearance exceeds 2 mm.
2
Lubricate the fork roller bearings
– Lubricate the fork roller bearings (2). Four
points each fork carrier
3
1
Lubricate the fork lower rollers
d14011063
– Lubricate the fork lower rollers (3).
5001 801 1624 EN - 05/2022 - 02 279

5 Maintenance
Load lifting system
Check the tension of double ho- 

ses
– 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.
d3591119
Check and adjust mast chains, 

lubricate with chain spray
NOTE
After some time in service the lifting chains
stretch and therefore must be checked and 3
adjusted as necessary on the left and right
sides of the mast.
2
– Clean the mast chains.
– Put the mast vertical.
– Remove split pin (1).
– Release locknuts (2). 1
d3591115
– Using nuts (3), adjust the chains to allow a
clearance of 12 mm (1/2 inch) between the
fork heels and the floor.
– Tighten locknuts (2).
– Fit new split pin (1).
NOTE
Ensure both chains are adjusted equally.
– Spray channel surfaces, pulleys and chains
with Linde chain spray.
280 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Load 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.
5001 801 1624 EN - 05/2022 - 02 281

5 Maintenance
Load lifting system
282 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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. rect viscosity, top up oil.
Hydraulic pump or motor failure, Contact your service partner.
seals defective, causing air intake.
No or too low pres- Pipe broken or leaking. Replace or tighten line.

sure in system Oil of low viscosity, causing high Change oil, be sure to use oil of
leakage losses. correct viscosity.
Oil temperature warning lamp illu- Check oil level, clean oil cooler.
minated.
Pump suction defective, noise. Change oil, top up oil. Contact your
service partner.
Pump failure, leakages, pressure Contact your service partner.
valves do not close, valve seat
damage.
Oil pressure fluctuat- Mast does not extend completely Top up hydraulic oil.
ing or retracts slightly after being exten-
ded.
Cause as under abnormal noise. See abnormal noise.
Pressure limiting valves or boost Contact your service partner.
pressure valves sticking.
Lift and tilt cylinders have tight Contact your service partner.
spots.
No oil flow or low oil Filter restricted (if accompanied by Clean or replace filter.
flow noise).
Pipe broken or leaking. Tighten or replace line.
Hydraulic system overheating. Check oil level, use specified oil,
clean oil cooler, if needed.
Valves restricted. Contact your service partner.
Pump failure, leakages, pressure Contact your service partner.
limiting valves do not close, valve
seat damaged.
5001 801 1624 EN - 05/2022 - 02 283

5 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.
284 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
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. formation and collection of condensation wa-
ter.
– Thoroughly clean the truck.
– Fully elevate the fork carriage several
NOTE
times, tilt the mast forward and back and if
fitted, operate the attachment several times. If the vehicle is to be taken out of operation for
a week or more, isolate the battery.
– Lower the forks on a support until the
chains are slack.
NOTE
– Check the hydraulic oil level and add oil, if
needed. If the vehicle is to be taken out of operation for
over 6 months, contact your service partner
– Add diesel fuel. for further measures.
– Apply a thin film of oil or grease on all un-
painted mechanical parts. Mast and load lifting device removal
– Lubricate the truck as described in the DANGER
maintenance section of this manual.
Danger of damage or injury.
– Check the condition and electrolyte level of
This work must only be carried out by the trained
the battery. Coat the battery terminals with personnel of your authorised dealer. Do not attempt
non-acidic grease. (Follow the instructions to remove the mast or lifting device.
of the battery manufacturer).
– Spray all open electrical contacts with a
suitable contact spray.
CAUTION
Danger of tyre deformation.
Block up the truck so that all wheels are clear of the
ground.
Putting the truck back into service

– Thoroughly clean the truck as described in – Check the engine oil for condensation water
the maintenance section of this manual. and change the oil, if necessary.
– Lubricate the truck. – Check the hydraulic oil for condensation
water and change the oil, if necessary.
– Coat the battery terminals with non-acidic
grease. – Reconnect the battery.
– Check the condition of the battery / batter-
ies.
5001 801 1624 EN - 05/2022 - 02 285

5 Maintenance
– Return the truck to service.

NOTE
The digital clock display must be reset when- NOTE
ever the battery isolator has been used.
– Perform the same services as for commis- If the truck has to be jump started, refer to
section entitled "Jump start procedure".
sioning.
286 5001 801 1624 EN - 05/2022 - 02

Maintenance 5
Disposal of old trucks

The disposal of old trucks is regulated in di- smeared parts, as well as for tyres including
rective 2000/53/EC from the European Parlia- fire protection measures. Suitable storage
ment and Council. tanks for fluids such as fuel, AdBlue® (urea
solution), engine oil, hydraulic oil, cooling
We therefore recommend having this work fluid and fluids from air conditioning sys-
carried out in an approved recycling plant. If tems must also be provided
you would like to carry out this work yourself, ● In order to dispose of harmful substances
you must obtain approval from the relevant from the old trucks, the batteries and LPG
authorities as per articles 9, 10 and 11 of di- container must be removed. The following
rective 75/442/EEC. must also be removed, collected and stored
separately: fuel, AdBlue® (urea solution),
In addition, the following minimum require- engine oil, cooling fluid, hydraulic oil and
ments must be observed: fluids from air conditioning systems
● The locations in which old trucks are stored ● The following parts are to be collected sep-
before treatment must be areas suited to arately and recycled: catalytic converters,
this task with impervious surfaces. These metal components containing copper and
areas are also to be equipped with collec- aluminium, tyres, large plastic components
tion devices and separators for leaking flu- (consoles, fluid containers) and glass
ids and degreasing cleaning materials
● The locations for treatment must be areas
suited to this task with impervious surfa- NOTE

ces. These areas must also be equipped The operating company is responsible for ad-
with collection devices and separators for herence to the directives as well as additional
leaking fluids and degreasing cleaning ma- country-specific regulations.
terials. Suitable storage areas must be
available for disassembled and partially oil-
5001 801 1624 EN - 05/2022 - 02 287

5 Maintenance
288 5001 801 1624 EN - 05/2022 - 02

6
Technical data
6 Technical data
Truck dimensions
Truck dimensions
290 5001 801 1624 EN - 05/2022 - 02

Technical data 6
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
1.1 Manufacturer Still
RCD100Ds/600
RCD120Ds/600
RCD140Ds/600
1.2 Manufacturer's type designation
RCD150Ds/600
RCD160Ds/600
RCD180Ds/600
1.3 Drive Diesel
1.4 Operation Seated
RCD100Ds Q [t] 10
RCD120Ds 12
RCD140Ds 14
1.5 Load capacity/load
RCD150Ds 15
RCD160Ds 16
RCD180Ds 18
RCD100Ds、 c [mm] 600
RCD120Ds、
1.6 Load centre of gravity RCD140Ds、
RCD160Ds、
RCD180Ds
RCD100Ds、 x [mm]
847
RCD120Ds
1.8 Load distance RCD140Ds、
RCD150Ds、
884
RCD160Ds、
RCD180Ds
RCD100Ds、 y [mm]
RCD120Ds、 3000
RCD140Ds
1.9 Wheelbase
RCD150Ds、
RCD160Ds、 3250
RCD180Ds
2 Weight
RCD100Ds kg 16299
2.1 Net weight
RCD120Ds 16453
5001 801 1624 EN - 05/2022 - 02 291

6 Technical data
2 Weight
RCD140Ds 19082
RCD150Ds 19253
RCD160Ds 19721
RCD180Ds 21591
RCD100Ds kg 23150/3149
RCD120Ds 26163/2290
RCD140Ds 30496/2586
2.2 Axle load with front/rear load
RCD150Ds 31500/2753
RCD160Ds 32935/2786
RCD180Ds 36144/3447
RCD100Ds kg 8327/7971
RCD120Ds 8375/8078
RCD140Ds 9570/9511
2.3 Axle load without front/rear load
RCD150Ds 9651/9602
RCD160Ds 9629/10091
RCD180Ds 9675/11916
3 Wheels, chassis frame

Standard tyres: solid rubber, super elastic, pneumatic, polyurethane
3.1 Option tyres (Maximum speed: 25km/h): 1370 035 Super Elastic Solid p/p
Tyre 1200-20/8.5, 1370 020 Super Elastic Solid Tyre 1200-24/8.5
RCD100Ds、 10.00 x 20 /
RCD120Ds 16pr
3.2 Front tyre size RCD140Ds、
RCD150Ds、 12.00 x 20 /
RCD160Ds、 20pr
RCD180Ds
RCD100Ds、 10.00 x 20 /
RCD120Ds 16pr
3.3 Rear tyre size RCD140Ds、
RCD150Ds、 12.00 x 20 /
RCD160Ds、 20pr
RCD180Ds
RCD100Ds、
RCD120Ds、
RCD140Ds、
3.4 Wheels, number, front/rear (x = driven) 4x/2
RCD150Ds、
RCD160Ds、
RCD180Ds
RCD100Ds、 b10 [mm]
3.6 Front track width RCD120Ds、 1874
RCD140Ds、
292 5001 801 1624 EN - 05/2022 - 02

Technical data 6

RCD150Ds、
RCD160Ds、
RCD180Ds
RCD120Ds、
RCD140Ds、
3.7 Rear track width 1970
RCD150Ds、
RCD160Ds、
RCD180Ds
RCD100Ds、 r1 [mm]
539
RCD120Ds
3.8 Rolling radius RCD140Ds、
RCD150Ds、
569
RCD160Ds、
RCD180Ds
4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 15/10
RCD100Ds、 h1 [mm]
3404
RCD120Ds
4.2 Height with lift mast retracted RCD140Ds、
RCD150Ds、
3736
RCD160Ds、
RCD180Ds
RCD100Ds、 h3 [mm]
RCD120Ds、
RCD140Ds、
4.4 Lift 4000
RCD150Ds、
RCD160Ds、
RCD180Ds
RCD100Ds、 h4 [mm]
5329
RCD120Ds
4.5 Height with lift mast extended RCD140Ds、
RCD150Ds、
5661
RCD160Ds、
RCD180Ds
RCD100Ds、 h6 [mm]
3010
RCD120Ds
4.7 Height above overhead guard (cab) RCD140Ds、
RCD150Ds、
3035
RCD160Ds、
RCD180Ds
RCD100Ds、 h7 [mm]
4.8 Seated height/standing height 1974
RCD120Ds
5001 801 1624 EN - 05/2022 - 02 293

6 Technical data
4 Basic dimensions
RCD140Ds、
RCD150Ds、
2004
RCD160Ds、
RCD180Ds
RCD100Ds、 h10 [mm]
550
RCD120Ds
4.12 Coupling height RCD140Ds、
RCD150Ds、
580
RCD160Ds、
RCD180Ds
RCD100Ds、 l1 [mm]
5984
RCD120Ds
RCD140Ds 6066
4.19 Total length
RCD150Ds、
6316
RCD160Ds
RCD180Ds 6516
RCD100Ds、 l2 [mm]
4584
RCD120Ds
RCD140Ds 4666
4.20 Length including fork back
RCD150Ds、
4916
RCD160Ds
RCD180Ds 5071
RCD100Ds、 b1
2530
RCD120Ds
4.21 Total width RCD140Ds、
RCD150Ds、
2565
RCD160Ds、
RCD180Ds
RCD100Ds、
90 x 200 x 1400
RCD120Ds
4.22 Fork arm dimensions RCD140Ds、 s/e/l [mm]
RCD150Ds、 100 x 200 x
RCD160Ds、 1400
RCD180Ds
Hydraulic fork
4.23 Fork carriage according to ISO 2328, class/form A, BHyd
positioner
RCD100Ds、 b3 [mm]
RCD120Ds、
RCD140Ds、
4.24 Fork carriage width 2545
RCD150Ds、
RCD160Ds、
RCD180Ds
RCD100Ds、 b5 [mm]
4.25 Fork spread 610 / 2274
RCD120Ds
294 5001 801 1624 EN - 05/2022 - 02

Technical data 6
4 Basic dimensions
RCD140Ds、
RCD150Ds、
620 / 2220
RCD160Ds、
RCD180Ds
RCD100Ds、 m1 [mm]
172
RCD120Ds
Ground clearance with load under lift RCD140Ds、
4.31
mast RCD150Ds、
200
RCD160Ds、
RCD180Ds
RCD100Ds、 m2 [mm]
346
RCD120Ds
Ground clearance at centre of wheel- RCD140Ds、
4.32
base RCD150Ds、
376
RCD160Ds、
RCD180Ds
RCD100Ds、 Ast [mm]
6149
RCD120Ds
Aisle width for pallet 1000 x 1200 cross- RCD140Ds 6186
4.33
wise RCD150Ds、
6422
RCD160Ds
RCD180Ds 6596
RCD100Ds、 Ast [mm]
6349
RCD120Ds
Aisle width for pallet 800 x 1200 length- RCD140Ds 6386
4.34
wise RCD150Ds、
6622
RCD160Ds
RCD180Ds 6796
RCD100Ds、 Wa [mm]
RCD120Ds、 4102
RCD140Ds
4.35 Turning radius
RCD150Ds、
4338
RCD160Ds
RCD180Ds 4512
RCD120Ds、 1362
RCD140Ds
4.36 Smallest pivot point distance
RCD150Ds、
RCD160Ds、 1405
RCD180Ds
5001 801 1624 EN - 05/2022 - 02 295

6 Technical data
5 Performance data
RCD100Ds km/h 27.9/29.1
RCD120Ds 27.6/29.1
RCD140Ds 28.3/30.2
5.1 Driving speed with/without load
RCD150Ds 28.3/30.2
RCD160Ds 28.1/30.1
RCD180Ds 28.1/29.8
RCD100Ds、 m/s
RCD120Ds、 0.40/0.42
RCD150Ds
5.2 Lifting speed with/without load
RCD140Ds、
0.37/0.40
RCD180Ds
RCD160Ds 0.37/0.42
RCD100Ds、 m/s
RCD120Ds、
0.45/0.40
RCD150Ds、
5.3 Lowering speed with/without load RCD160Ds
RCD140Ds、
0.42/0.38
RCD180Ds
RCD100Ds kN 98.5/100.5
RCD120Ds 98.3/100.6
RCD140Ds 92.8/95.5
5.5 Tractive force with/without load
RCD150Ds 103.0/105.9
RCD160Ds 102.7/105.8
RCD180Ds 102.6/105.3
RCD100Ds % 41.3/80.8
RCD120Ds 37.6/79.7
RCD140Ds 29.8/59.3
5.7 Climbing capability with/without load
RCD150Ds 32.2/67.7
RCD160Ds 30.6/65.3
RCD180Ds 30.3/55.6
5.10 Service brake Wet disc
6.Battery voltage, rated capacity

RCD100Ds、
RCD120Ds、
RCD140Ds、
6.1 V/aH 2 x 12 / 95
RCD150Ds、
RCD160Ds、
RCD180Ds
296 5001 801 1624 EN - 05/2022 - 02

Technical data 6
7 Drive/engine
7.1 Engine manufacturer/model Cummins B6.7 Eu5
7.2 Engine power rating in accordance with ISO 1585 kW 129
7.3 Nominal speed rpm 2200
7.4 Number of cylinders/displacement cm3 6/6700
8 Other
Torque converter
8.1 Traction controller type
3/3
8.2 Working pressure for attachments bar 250
8.3 Oil flow for attachments l/min 5-130
8.4 Noise level at the driver's ear dB (A) 70
8.5 Tow coupling, type/model ∅ (mm) 50

All data refers to standard equipment with standard lift masts.
All data must be observed without fail.
1 Key data
1.1 Manufacturer Still
RCD100Ds/
1200
RCD120Ds/
1200
RCD140Ds/
1.2 Manufacturer's type designation
1200
RCD150Ds/
1200
RCD160Ds/
1200
1.3 Drive Diesel
1.4 Operation Seated
RCD100Ds Q [t] 10
RCD120Ds 12
1.5 Load capacity/load RCD140Ds 14
RCD150Ds 15
RCD160Ds 16
5001 801 1624 EN - 05/2022 - 02 297

6 Technical data
1 Key data
RCD100Ds、 c [mm] 1200
RCD120Ds、
1.6 Load centre of gravity RCD140Ds、
RCD150Ds、
RCD160Ds
RCD100Ds、 x [mm] 884
RCD120Ds
1.8 Load distance RCD140Ds、 929
RCD150Ds、
RCD160Ds
RCD100Ds y [mm] 3000
RCD120Ds、
3250
1.9 Wheelbase RCD140Ds
RCD150Ds、
3500
RCD160Ds
2 Weight
RCD100Ds kg 19273
RCD120Ds 20725
2.1 Net weight RCD140Ds 22113
RCD150Ds 21981
RCD160Ds 22785
RCD100Ds kg 27238/2036
RCD120Ds 30464/2261
2.2 Axle load with front/rear load RCD140Ds 33565/2548
RCD150Ds 34553/2428
RCD160Ds 36156/2629
RCD100Ds kg 10141/9133
RCD120Ds 10769/9956
2.3 Axle load without front/rear load RCD140Ds 10394/11719
RCD150Ds 10429/11552
RCD160Ds 10424/12362

Sdandard tyres: solid rubber, super elastic, pneumatic, polyurethane
3.1 Option tyres (Maximum speed: 25km/h): 1370 035 Super Elastic Solid p/p
Tyre 1200-20/8.5, 1370 020 Super Elastic Solid Tyre 1200-24/8.5
RCD100Ds、
RCD120Ds、
12.00 x 20 /
3.2 Front tyre size RCD140Ds、
20pr
RCD150Ds、
RCD160Ds
298 5001 801 1624 EN - 05/2022 - 02

Technical data 6

RCD100Ds、
RCD120Ds、
12.00 x 20 /
3.3 Rear tyre size RCD140Ds、
20pr
RCD150Ds、
RCD160Ds
RCD100Ds、
RCD120Ds、
3.4 Wheels, number, front/rear (x = driven) RCD140Ds、 4x/2
RCD150Ds、
RCD160Ds
RCD120Ds、
3.6 Front track width RCD140Ds、 1874
RCD150Ds、
RCD160Ds
RCD120Ds、
3.7 Rear track width RCD140Ds、 1970
RCD150Ds、
RCD160Ds
RCD100Ds、 r1 [mm]
RCD120Ds、
3.8 Rolling radius RCD140Ds、 569
RCD150Ds、
RCD160Ds
4 Basic dimensions
4.1 Lift mast/fork carriage tilt, forwards/backwards α/β (°) 15/10
RCD100Ds、 h1 [mm]
RCD120Ds、
4.2 Height with lift mast retracted RCD140Ds、 3736
RCD150Ds、
RCD160Ds
RCD100Ds、 h3 [mm]
RCD120Ds、
4.4 Lift RCD140Ds、 4000
RCD150Ds、
RCD160Ds
RCD100Ds、 h4 [mm]
RCD120Ds、
4.5 Height with lift mast extended RCD140Ds、 5661
RCD150Ds、
RCD160Ds
5001 801 1624 EN - 05/2022 - 02 299

6 Technical data
4 Basic dimensions
RCD100Ds、 h6 [mm]
RCD120Ds、
4.7 Height above overhead guard (cab) RCD140Ds、 3035
RCD150Ds、
RCD160Ds
RCD100Ds、 h7 [mm]
RCD120Ds、
4.8 Seated height/standing height RCD140Ds、 2004
RCD150Ds、
RCD160Ds
RCD100Ds、 h10 [mm]
RCD120Ds、
4.12 Coupling height RCD140Ds、 580
RCD150Ds、
RCD160Ds
RCD100Ds l1 [mm] 6984
RCD120Ds 7316
4.19 Total length, RCD140Ds 7516
RCD150Ds、
7766
RCD160Ds
RCD100Ds l2 [mm] 4584
RCD120Ds 4916
4.20 Length including fork back RCD140Ds 5116
RCD150Ds、
5366
RCD160Ds
RCD100Ds、 b1 2565
RCD120Ds、
4.21 Total width RCD140Ds、
RCD150Ds、
RCD160Ds
RCD100Ds、 s/e/l [mm] 100 x 200 x
RCD120Ds 2400
4.22 Fork arm dimensions RCD140Ds、 100 x 250 x
RCD150Ds、 2400
RCD160Ds
Hydraulic fork
4.23 Fork carriage according to ISO 2328, class/form A, B
positioner
RCD100Ds、 b3 [mm]
RCD120Ds、
4.24 Fork carriage width RCD140Ds、 2545
RCD150Ds、
RCD160Ds
300 5001 801 1624 EN - 05/2022 - 02

Technical data 6
4 Basic dimensions
RCD100Ds、 b5 [mm]
RCD120Ds、
RCD140Ds、 620 / 2220
RCD150Ds、
RCD160Ds
4.25 Fork spread
RCD100Ds、
RCD120Ds、
RCD140Ds、 720 / 2290
RCD150Ds、
RCD160Ds
RCD100Ds、 m1 [mm]
RCD120Ds、
Ground clearance with load under lift
4.31 RCD140Ds、 200
mast
RCD150Ds、
RCD160Ds
RCD100Ds、 m2 [mm]
RCD120Ds、
Ground clearance at centre of wheel-
4.32 RCD140Ds、 376
base
RCD150Ds、
RCD160Ds
RCD100Ds Ast [mm] 6186
RCD120Ds 6422
Aisle width for pallet 1000 x 1200 cross-
4.33 RCD140Ds 6641
wise
RCD150Ds、
6883
RCD160Ds
RCD100Ds Ast [mm] 6386
RCD120Ds 6622
Aisle width for pallet 800 x 1200 length-
4.34 RCD140Ds 6841
wise
RCD150Ds、
7038
RCD160Ds
RCD100Ds Wa [mm] 4102
RCD120Ds 4338
4.35 Turning radius RCD140Ds 4512
RCD150Ds、
4754
RCD160Ds
RCD100Ds b13 [mm] 1362
RCD120Ds、
1405
4.36 Smallest pivot point distance RCD140Ds
RCD150Ds、
1448
RCD160Ds
5001 801 1624 EN - 05/2022 - 02 301

6 Technical data
5 Performance data
RCD100Ds 28.8/30.1
RCD120Ds 28.4/29.9
5.1 Driving speed with/without load RCD140Ds km/h 28.1/29.8
RCD150Ds 27.9/29.8
RCD160Ds 27.7/29.7
RCD100Ds m/s 0.37/0.40
RCD120Ds、
5.2 Lifting speed with/without load RCD140Ds、 0.40/0.42
RCD150Ds
RCD160Ds 0.37/0.42
RCD100Ds m/s 0.42/0.38
RCD120Ds、
5.3 Lowering speed with/without load RCD140Ds、
0.45/0.40
RCD150Ds、
RCD160Ds
RCD100Ds N 93.5/95.5
RCD120Ds 92.9/95.2
5.5 Tractive force with/without load RCD140Ds 102.6/105.3
RCD150Ds 102.4/105.4
RCD160Ds 102.1/105.2
RCD100Ds % 34.4/58.5
RCD120Ds 30.2/53.0
5.7 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、
RCD120Ds、
6.1 RCD140Ds、 V/aH 2 x 12 / 95
RCD150Ds、
RCD160Ds
7 Drive/engine
7.1 Engine manufacturer/model Cummins B6.7 Eu5
7.2 Engine power rating in accordance with ISO 1585 kW 129
7.3 Nominal speed rpm 2200
7.4 Number of cylinders/displacement cm3 6/6700
302 5001 801 1624 EN - 05/2022 - 02

Technical data 6
8 Other
Torque converter
8.1 Traction controller type
3/3
8.2 Working pressure for attachments bar 250
8.3 Oil flow for attachments l/min 5-130
8.4 Noise level at the driver's ear dB (A) 70
8.5 Tow coupling, type/model ∅ (mm) 50
5001 801 1624 EN - 05/2022 - 02 303

6 Technical data
304 5001 801 1624 EN - 05/2022 - 02

Index
A Commissioning. . . . . . . . . . . . . . . . . . . . . 10
Address of manufacturer. . . . . . . . . . . . . . . I Conformity marking. . . . . . . . . . . . . . . . . . . 6
Adjusting the driver's seat with rotating de- Consumables. . . . . . . . . . . . . . . . . . . . . . . 45
vice. . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Oil Safety Information. . . . . . . . . . . . . . 45
Adjusting the steering column. . . . . . . . . . 75 Safety information for handling battery
Air conditioning operation. . . . . . . . . . . . . 79 acid. . . . . . . . . . . . . . . . . . . . . . . . . . 46
Automatic. . . . . . . . . . . . . . . . . . . . . . . 82 Safety information for handling hydraul-
ic fluid. . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual. . . . . . . . . . . . . . . . . . . . . . . . . 80
Contact details. . . . . . . . . . . . . . . . . . . . . . . I
Operating devices. . . . . . . . . . . . . . . . . 80
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Air filter - check. . . . . . . . . . . . . . . . . . . . 227
Coolant level - check. . . . . . . . . . . . . . . . 228
Armrest
Copyright and trademark rights. . . . . . . . . 13
Adjusting. . . . . . . . . . . . . . . . . . . . . . . . 74
Attachments D
Special risks. . . . . . . . . . . . . . . . . . . . . 33 Damage, faults. . . . . . . . . . . . . . . . . . . . . . 29
B Danger to employees. . . . . . . . . . . . . . . . . 38
Date of edition of this manual. . . . . . . . . . 15
Battery
Declaration of conformity. . . . . . . . . . . . . . . 7
Disposal. . . . . . . . . . . . . . . . . . . . . . . . 18
Definition of terms used for responsible
Battery access - closing. . . . . . . . . . . . . . 107
persons. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Battery access - opening. . . . . . . . . . . . . 107
Depositing the load. . . . . . . . . . . . . . . . . 188
Battery acid. . . . . . . . . . . . . . . . . . . . . . . . 46
Description of use and climatic conditions. 11
Before leaving the truck unattended. . . . 189
Display unit-Parker. . . . . . . . . . . . . . . . . . 84
Before loading. . . . . . . . . . . . . . . . . . . . . 185
Disposal
Brake control mechanism. . . . . . . . . . . . 273
Battery. . . . . . . . . . . . . . . . . . . . . . . . . 18
C Components. . . . . . . . . . . . . . . . . . . . . 18
Cab door Disposal of old trucks. . . . . . . . . . . . . . . . 287
closing. . . . . . . . . . . . . . . . . . . . . . . . . 68 Documentation scope. . . . . . . . . . . . . . . . 12
opening. . . . . . . . . . . . . . . . . . . . . . . . . 68 Drive controller
Changes to the industrial truck. . . . . . . . . 27 Operation. . . . . . . . . . . . . . . . . . . . . . 111
Changes to the truck. . . . . . . . . . . . . . . . . 19 Driver rights, duties and rules of behaviour. 25
Chassis, bodywork and fittings. . . . . . . . 267 Drivers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check and adjust mast chains, lubricate Driver's cab. . . . . . . . . . . . . . . . . . . . . . . . 68
with chain spray. . . . . . . . . . . . . . . . . . 280 Driver's seat (standard seat and comfort
Check electric cables, connectors and con- seat). . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
nections for condition and tightness. . . 275 Activating the seat heater (comfort seat
Check seat belt for condition and correct only). . . . . . . . . . . . . . . . . . . . . . . . . . 74
operation (option). . . . . . . . . . . . . . . . . 268 Adjusting the lumbar support (only with
Check the battery / batteries. . . . . . . . . . 275 a comfort seat). . . . . . . . . . . . . . . . . . 73
Check the condition of structured compo- Adjusting the seat backrest. . . . . . . . . 72
nents. . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Longitudinal adjustment. . . . . . . . . . . . 72
Check the parking brake for proper opera- Setting the driver's weight. . . . . . . . . . . 73
tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Driver’s seat switch. . . . . . . . . . . . . . . . . 274
Check the tension of double hoses. . . . . 280 Driving. . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check the tyres for damage and foreign
objects. . . . . . . . . . . . . . . . . . . . . . . . . . 271
E
Clean the truck. . . . . . . . . . . . . . . . . . . . . 267 EC declaration of conformity in accordance
Cold Climate Options. . . . . . . . . . . . . . . . 164 with the Machinery Directive. . . . . . . . . . . 7
5001 801 1624 EN - 05/2022 - 02 305

Index
EMC – Electromagnetic compatibility. . . . 19 J

Emergency exit. . . . . . . . . . . . . . . . . . . . 110 Joystick
Emergency release of parking brake. . . . 109 Central lever operation. . . . . . . . . . . . . 93
Engine Single lever operation. . . . . . . . . . . . . . 99
Starting. . . . . . . . . . . . . . . . . . . . . . . . . 87
Switching off. . . . . . . . . . . . . . . . . . . . . 90 L
Entering and exiting the truck. . . . . . . . . . 67 Lifting a load. . . . . . . . . . . . . . . . . . . . . . 186
Lifting the fork carriage
F
Central lever operation. . . . . . . . . . . . . 94
Filling fuel. . . . . . . . . . . . . . . . . . . . . . . . . 226 Single lever operation. . . . . . . . . . . . . 100
Filling the windscreen washer bottle. . . . 270 Lighting
Fire suppression system. . . . . . . . . . . . . 141 Switching on. . . . . . . . . . . . . . . . . . . . 127
Forklift Data Management. . . . . . . . . . . . 115 List of abbreviations. . . . . . . . . . . . . . . . . . 15
G Load centre distance and load capacity. 183
Load rating plate. . . . . . . . . . . . . . . . . . . 184
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Locations for jacks when changing
General View of Truck. . . . . . . . . . . . . . . . 50
wheels. . . . . . . . . . . . . . . . . . . . . . . . . . 272
H Lowering the fork carriage
Hazards and countermeasures. . . . . . . . . 36 Central lever operation. . . . . . . . . . . . . 94
Heating/air conditioning operation. . . . . . . 79 Single lever operation. . . . . . . . . . . . . 100
Automatic air conditioning operation. . 82 Lubricate fork carriage cylinder bearings. 279
Automatic heating operation. . . . . . . . . 83 Lubricate the mast and tilt cylinder pivots. 278
Manual air conditioning operation. . . . . 80 M
Manual heating operation. . . . . . . . . . . 83
Mast and load lifting device removal. . . . 285
Operating devices. . . . . . . . . . . . . . . . . 80
Mast, lifting device and attachment con-
Heating operation. . . . . . . . . . . . . . . . . . . 77
trols. . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Automatic. . . . . . . . . . . . . . . . . . . . . . . 79
Measures before taking the truck out of op-
Manual. . . . . . . . . . . . . . . . . . . . . . . . . 78 eration. . . . . . . . . . . . . . . . . . . . . . . . . . 285
Operating devices. . . . . . . . . . . . . . . . . 78 Medical devices. . . . . . . . . . . . . . . . . . . . . 29
Hoisting the truck. . . . . . . . . . . . . . . . . . . 190 Medical equipment. . . . . . . . . . . . . . . . . . . 47
Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hydraulic fluid. . . . . . . . . . . . . . . . . . . . . . 46
Hydraulic system: check for leaks. . . . . . 276 N
Hydraulic system: oil level check. . . . . . . 276 Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic tank breather filter - check. . . . 277
O
I Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Improper use. . . . . . . . . . . . . . . . . . . . . . . 10 Operating attachments
Information symbols. . . . . . . . . . . . . . . . . . 13 Central lever operation. . . . . . . . . . . . . 95
Inspection and maintenance data. . . . . . 198 Single lever operation. . . . . . . . . . . . . 100
Insulation testing. . . . . . . . . . . . . . . . . . . . 40 Operating company. . . . . . . . . . . . . . . . . . 24
Drive battery test values. . . . . . . . . . . . 41 Operating optional attachments. . . . . . . . 161
Test values for the truck. . . . . . . . . . . . 41 Operating the clamp
Insurance cover on company premises. . . 27 Central lever operation. . . . . . . . . . . . . 98
Issue date of the operating instructions. . . 13 Single lever operation. . . . . . . . . . . . . 103
Operating the fork positioner
Single lever operation. . . . . . . . . . . . . 102
306 5001 801 1624 EN - 05/2022 - 02

Index
Operating the fork prong positioner Service brake. . . . . . . . . . . . . . . . . . . . . . 104

Central lever operation. . . . . . . . . . . . . 96 Service intervals. . . . . . . . . . . . . . . . . . . 198
Operating the lifting and tilting equipment Service plan
Central lever operation. . . . . . . . . . . . . 94 Regular maintenance. . . . . . . . . . . . . . 57
Single lever operation. . . . . . . . . . . . . . 99 Side window
Operating the rotator Closing. . . . . . . . . . . . . . . . . . . . . . . . . 68
Central lever operation. . . . . . . . . . . . . 97 Opening. . . . . . . . . . . . . . . . . . . . . . . . 68
Single lever operation. . . . . . . . . . . . . 102 Special risks. . . . . . . . . . . . . . . . . . . . . . . . 33
Operating the sideshift Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Central lever operation. . . . . . . . . . . . . 96 Status code. . . . . . . . . . . . . . . . . . . . . . . 121
Single lever operation. . . . . . . . . . . . . 101 Steering. . . . . . . . . . . . . . . . . . . . . . . . . . 103
Override key. . . . . . . . . . . . . . . . . . . . . . 106 Storage unit. . . . . . . . . . . . . . . . . . . . . . . 137
Overview of type sheets - 1200 mm load Switching on the direction indicators. . . . 128
centre. . . . . . . . . . . . . . . . . . . . . . . . . . 297 Switching on the flashing beacon. . . . . . 127
Overview of type sheets - 600 mm Switching on the hazard warning system. 127
load centre. . . . . . . . . . . . . . . . . . . . . . 291 Switching on the rear window heating. . . . 77
P Switching on the rotating beacons. . . . . . 127
Switching on the terminal board and interi-
Packaging. . . . . . . . . . . . . . . . . . . . . . . . . 18
or lighting. . . . . . . . . . . . . . . . . . . . . . . . 126
Parking brake. . . . . . . . . . . . . . . . . . . . . . 105
Switching on the working spotlight. . . . . . 127
Precautions. . . . . . . . . . . . . . . . . . . . . . . . 10 Switch panel. . . . . . . . . . . . . . . . . . . . . . . 53
Prohibition of use by unauthorised persons. 26
Putting the truck back into service. . . . . . 285 T
Tighten the wheel nuts. . . . . . . . . . . . . . . 271
Q
Quarter window
Central lever operation. . . . . . . . . . . . . 95
Opening. . . . . . . . . . . . . . . . . . . . . . . . 69 Single lever operation. . . . . . . . . . . . . 100
R Tilting the lift mast forwards
Regular inspections. . . . . . . . . . . . . . . . . . 40 Central lever operation. . . . . . . . . . . . . 95
Residual dangers. . . . . . . . . . . . . . . . . . . . 32 Single lever operation. . . . . . . . . . . . . 100
Residual risks. . . . . . . . . . . . . . . . . . . . . . 32 Tire pressure monitoring system. . . . . . . 143
Retrofitting. . . . . . . . . . . . . . . . . . . . . . 19, 27 Topicality of the operating instructions. . . 13
Reversing warning system. . . . . . . . . . . . 160 To tow the truck. . . . . . . . . . . . . . . . . . . . 108
Trailer coupling. . . . . . . . . . . . . . . . . . . . 107
S Transmission oil level check. . . . . . . . . . 266
Safety devices and warning labels. . . . . . 51 Travelling with load. . . . . . . . . . . . . . . . . 187
Safety information regarding servicing Troubleshooting guide (Hydraulic sys-
work. . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 tem). . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Safety inspection. . . . . . . . . . . . . . . . . . . . 40 Truck data acquisition using keypad. . . . 115
Safety regulations when driving. . . . . . . . . 43 Truck data acquisition, special setting
Scope of service PIN and status code. . . . . . . . . . . . . . 118
Before initial commissioning. . . . . . . . . 56 Truck data acquisition, standard setting
Scope of the documentation PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CO solutions. . . . . . . . . . . . . . . . . . . . . 12
U
Seat belt
Fastening. . . . . . . . . . . . . . . . . . . . . . . 76 Update of this manual. . . . . . . . . . . . . . . . 15
Unfastening. . . . . . . . . . . . . . . . . . . . . 76 Using working platforms. . . . . . . . . . . . . . 21
5001 801 1624 EN - 05/2022 - 02 307

Index
W Wheels and tyres

Warning regarding non-original parts. . . . 29 Safety principles. . . . . . . . . . . . . . . . . . 30
With cup holder. . . . . . . . . . . . . . . . . . . . 138
308 5001 801 1624 EN - 05/2022 - 02

STILL GmbH
5001 801 1624 EN - 05/2022 - 02

RCD 100-180 Cummins-Eu5 EN Manual

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Original instructions

5410 5411 5412 5413 5414 5415

5001 801 1624 EN - 05/2022 - 02

Address of manufacturer and 

Rules for the operating com-

trial trucks for a particular area of applica-

● Information on transport, initial commission-

ing and storage of industrial trucks

Internet address and QR code 

5001 801 1624 EN - 05/2022 - 02 I

ACM Aftertreatment Control Module

II 5001 801 1624 EN - 05/2022 - 02

5001 801 1624 EN - 05/2022 - 02 III

Warning regarding non-original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

IV 5001 801 1624 EN - 05/2022 - 02

Wheel refitting — drive axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5001 801 1624 EN - 05/2022 - 02 V

4450 005 With cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

VI 5001 801 1624 EN - 05/2022 - 02

5001 801 1624 EN - 05/2022 - 02 VII

Load lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

VIII 5001 801 1624 EN - 05/2022 - 02

2 5001 801 1624 EN - 05/2022 - 02

Your industrial truck

5001 801 1624 EN - 05/2022 - 02 3

4 5001 801 1624 EN - 05/2022 - 02

5001 801 1624 EN - 05/2022 - 02 5

The manufacturer uses the conformity mark-

● UKCA: in the United Kingdom (UK)

● EAC: in the Eurasian Economic Union

The conformity marking is applied to the

6 5001 801 1624 EN - 05/2022 - 02

Declaration that reflects the content of the declaration of conformity

Industrial truck type corresponding to these operating instructions

− "Machinery Directive 2006/42/EC" 1)

Personnel authorised to compile the technical documents:

See declaration of conformity

The declaration of conformity document is The declaration of conformity must be careful-

8 5001 801 1624 EN - 05/2022 - 02

5001 801 1624 EN - 05/2022 - 02 9

Use of the truck

The truck may not be operated in areas where

Description of use and climatic

5001 801 1624 EN - 05/2022 - 02 11

Information about documentation

● A special towing device

When fitted with a CO, the industrial truck is

information in the original operating instruc-

Issue date and topicality of the

Copyright and trademark rights

Explanation of information sym-

5001 801 1624 EN - 05/2022 - 02 13

To prevent environmental damage.

14 5001 801 1624 EN - 05/2022 - 02

Date of edition and latest update

5001 801 1624 EN - 05/2022 - 02 15

Lp Sound pressure level at the workplace

Average continuous sound pressure level

16 5001 801 1624 EN - 05/2022 - 02