Still RCG40 - Diagrams

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Table of Contents5
Introduction11
Truck Data12
Intended Use13
Impermissible Use14
Description of Use and Climatic Conditions15
Modifications to the Truck15
Symbols Used15
CE Labelling16
EMC - Electromagnetic Compatibility17
EC Declaration of Conformity in Accordance with Machinery Directive18
Safety19
Definition of Terms Used for Responsible Persons20
Operating Company20
Specialist20
Competent Person20
Drivers20
Safety Regulations22
Safety Guidelines22
Exhaust Gases23
Ground Condition for Using the Truck24
Safety Regulations Relative to Forklift Use24
Residual Dangers, Residual Risks25
Safety Regulations When Driving26
Safety Regulations in Case of Accidental Lateral Tipping27
Commissioning of LPG-Fuelled Trucks27
General Safety Rules for Liquid Gas28
Exercise Caution When Handling Gas Springs and Accumulators30
Safety Regulations for Handling Consumables31
Permissible Consumables31
Oils32
Hydraulic Fluid33
Battery Acid34
Disposal of Consumables34
Environmental Considerations35
Disposal of Components and Batteries35
Packaging36
Safety Instructions for the LPG System36
Safety Information on the LPG System37
Emissions37
Safety Tests39
Carrying out Regular Safety Inspections on the LPG System39
Information about the Truck41
General Forklift View42
General Front View42
General Rear View43
Instrumentation and Controls44
Overview of the Driver's Compartment44
Display Unit45
Truck Identification46
Chassis Number46
Production Number46
Nameplate47
Engine Plate48
Location of the Decals50
Use and Operation53
Truck Transport and Lifting54
Use a Truck or Flatbed Trailer to Carry the Forklift Truck54
Environmental Conditions for Transport and Storage54
Loading and Unloading the Truck55
Commissioning the Truck57
Remaining Ready for Operation58
Pre-Shift Checks58
Checking the Cap on the High-Pressure Relief Valve on the Outside of the LPG System58
Daily Checks before Use58
Seat Belt Status and Performance Checks60
Checking the Condition of the Tyres61
Check the Wheel Nuts for Correct Condition62
Check the Condition and Operation of Chain63
Checking the Coolant Level64
Check the Engine Oil Level66
Transmission Oil Level Inspection Procedure67
Checking the Drive Axle Gearbox Oil68
Checking the Hydraulic Oil Level68
Change the LP Gas Tank69
Fill the LPG Tank72
Fuel-Specifications74
Engine Coolant - Specifications74
Using the Truck76
Opening the Tap of the Gas Bottle or Gas Tank76
Opening the Gas Cylinder or LPG Tank* Shutoff Valve76
Climbing On/Off the Forklift77
Adjustment of the Driver's Seat77
Fastening the Seat Belt78
Adjusting the Position of Steering Wheel80
Ignition Device81
Lighting and Turn Indicator Switch82
Warning Horn83
Direction Selection Lever84
Start the Engine84
Driving85
Forward87
Reversing87
Speed Switch88
Changing Direction of Travel88
Driving Brake Pedal and Inching Pedal89
Operating the Service Brake90
Parking Brake91
Closing the Gas Cylinder or LPG Tank* Shutoff Valve92
Lifting System and Attachments93
Operating the Lifting Device93
Operating Attachments94
Handling Loads96
Safety Regulations When Handing Loads96
Load Centre Distance and Load Capacity96
Capacity Plate97
Before Lifting a Load98
Transporting Pallets98
Danger Area98
Transporting Suspended Loads99
Adjusting the Fork Arm Distance101
Picking up a Load102
Transporting Loads106
Driving on Ascending and Descending Gradients107
Driving on Lifts108
Driving on Loading Bridges109
Setting down Loads110
Towed Load112
Forklift Towing113
Leaving the Truck113
Cleaning115
Cleaning the Truck115
Cleaning the Electrical System117
Lubricate the Lift Mast and Chains with Chain Spray118
After Washing119
Decommissioning120
General Information120
Measures to be Implemented When Decommissioning120
Recommissioning after Storage121
Permanent Decommissioning (Scrapping)122
Maintenance123
General Information124
Personnel Qualifications125
Preliminary Maintenance Operations125
Scheduled Truck Maintenance127
Maintenance - 500 Hours127
Maintenance - 1000 Hours/Annually129
Maintenance - 3000 Hours132
Supply Table135
Providing Access to Maintenance Points136
Opening the Bonnet136
Closing the Bonnet137
Installing and Removing the Bottom Plate138
Maintenance Service140
Changing the Engine Oil140
Replacing the Engine Oil Filter143
Replacement of Coolant143
Cleaning the Radiator, Checking for Leaks147
Clean the Air Filter147
Change the Air Filter148
Check the Belt Tension149
Changing the Hydraulic Transmission Crude Oil Filter150
Replacing the Fine Hydraulic Transmission Oil Filter151
Changing the Oil of the Hydraulic Transmission152
Checking the Drive Axle Gearbox Oil153
Wheel Replacement Procedure153
Change Brake System Liquid155
Fill up the Hydraulic Oil155
Checking the Hydraulic Oil Level156
Changing the Suction Filter and Return Filter156
Replacing the Breather Filter157
Technical Datasheet Dimensions160
VDI Datasheet for RCG40161
VDI Datasheet for RCG50163
Mast Specification165
Diagrams175
Electric Schematic Diagram for Doosan P34 Engine-With ISO3691 Function176
Hydraulic Diagram177

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