3 Safety instructions

WARNING

The correct and safe maintenance of these lift trucks as recommended by the manufacturer is given in this document. Read this manual before you do any maintenance on these trucks. Incorrect performance of maintenance operations is dangerous and can cause injury or death.

After making this product available for the market, the manufacturer cannot be held responsible for modifications made by the customer or user and the consequences thereof, which may alter the conformity of the product with the CE marking.

Do not make changes or repairs that can weaken the structure of the truck or put safety at risk.

Do not operate the truck unless you have read and understood the instructions in the operation manual. Incorrect truck operation is dangerous and can cause injury or death.

Knowledge of the system and/or its components is important before you remove or disassemble the components.

The following sections list some basic precautions that should always be observed.

3.1 Safety requirements for industrial trucks

The truck meets the essential requirements of Machinery Directive 2006/42/EC and EMC Directive 2014/30/EU. The truck is designed and constructed according to European safety standards EN ISO 3691-1, EN 16307-1, EN 1175-1 and EN 12895.

The most important regulations and guidelines are given in these instructions. As regulations can vary from country to country, familiarize yourself with the regulations and standards applicable to your country.

Copyright © 2018 by MCFE. All rights reserved. Revision: C

Document ID: 622075-EN 16 (782)

3.2 Repairs and structural modifications

WARNING

After making this product available for the market, the manufacturer cannot be held responsible for modifications made by the end user and the consequences thereof, which may alter the conformity of the product with the CE marking.

To keep the EC Declaration Of Conformity issued by the original truck manufacturer, no modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, must be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This includes the changes affecting, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or his successor must also make and approve the appropriate changes to the capacity plate, decals, tags and operation and maintenance manuals.

If the end user arranges a modification or alteration without the prior written approval of the original truck manufacturer, its authorized representative, or a successor, the end user must:

• arrange for the modification or alteration to be designed, tested and done by an engineer(s) expert in industrial trucks and their safety • maintain a permanent record of the risk assessment, design, test(s) and implementation of the modification or alteration • approve and make appropriate changes to the capacity plate(s), decals, tags and operation and maintenance manuals • put a permanent and readily visible label to the truck stating how the truck has been modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks, and • where appropriate, create a new EC Declaration Of Conformity and sign it.

3.3 Service area safety

• Keep the service area clean. Oil, grease, and water make the floor slippery. • If possible, make all repairs with the truck parked on a level, hard surface. • Before you start to work on the truck, hang a Do not Operate sign in the operator compartment. • The truck must always be supported on jacks, if someone works under it. • Do not work on any truck that is supported only by lift jacks or a hoist. Always use jack stands or other supports to support the truck before doing any disassembly.

Copyright © 2018 by MCFE. All rights reserved. Revision: C

Document ID: 622075-EN 17 (782)

• Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to make sure that they do not fall unexpectedly. • Use steps and grab handles (if applicable) when you mount or dismount a truck.

Clean mud or debris from the steps, walkways or work platforms before use. Always face the truck when you use steps, ladders and walkways. When it is not possible to use the designed access system, use ladders, scaffolds, or work platforms to perform safe repair operations. • To avoid back injury, use a hoist when you lift components that weigh 23 kg (51 lb) or more. Make sure that all chains, hooks, slings, etc., are in good condition and of the correct capacity. Make sure that all hooks are positioned correctly. Lifting eyes are not to be side-loaded during a lifting operation. • Make sure that all protective devices including guards and shields are properly installed and functioning correctly before you start a repair. If a guard or shield must be removed to perform the repair work, be even more careful than usually. • Always support the mast and carriage to keep the carriage or attachments raised when you perform maintenance or repair work that requires the mast to be in the lifted position.

3.4 Personal safety

DANGER

Do not lift or transport anyone on the forks or a load pallet that is on the forks. There is a risk of falling, danger to life!

Do not let anyone, under any circumstances, walk or stand under the forks.

Do not place any part of your body between the mast structures or any moving parts of the truck.

• Remove all rings, watches and other pieces of metal jewellery before you start to work on the truck. If a metal object touches an electrically conductive part, it can cause a short circuit or a serious burn.

• Always, wear protective glasses and protective shoes when you work around trucks. In particular, wear protective glasses when you use a hammer or sledge on any part of the truck or its attachments. Use welding gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing.

3.5 Work safety

• Unauthorized truck modification is not permitted. Modifications or alterations to a powered industrial truck, which could affect, for example, capacity, stability or safety requirements of the truck, must not be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof.

Copyright © 2018 by MCFE. All rights reserved. Revision: C

Document ID: 622075-EN 18 (782)

This includes changes that have an effect on, for example, braking, steering, visibility and the addition of removable attachments. When the manufacturer or his successor approves a modification or alteration, the manufacturer or successor must also make and approve appropriate changes to the capacity plate, stickers, tags and operation and maintenance manuals.

Only if the truck manufacturer is no longer in business and there is no successor in the interest to the business, can the operator arrange for a modification or alteration to a powered industrial truck, provided that the operator:

a. arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety, b. maintains a permanent record of the design, test(s) and implementation of the modification or alteration, c. approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook, and d. puts a permanent and readily visible sticker to the truck that shows the manner in which the truck was modified or altered, together with the date of the modification or alteration and the name and address of the organization that accomplished those tasks. • Set the power of the truck to OFF and disconnect the battery connector before you open the cover of the motor compartment or the electrical system. • Release all pressure in the air, oil or water systems before you disconnect or remove lines, fittings or related items. Release the residual pressure when you remove a pressurized device. • If it is necessary to work at height during maintenance work, make sure that you use applicable access equipment and follow the safety instructions of the equipment manufacturer. • With sit-on trucks, remove the seat when you do servicing to the truck. • Before you operate, lubricate or repair the truck, read all warning plates and stickers on the truck.

• Do not use your hands to find oil leaks. • To prevent burns, be careful of the hot sections and hot fluids in lines, tubes and compartments, also when the truck is idle or OFF. • Only use clean oil in the hydraulic system. Always fill the oil through the oil filter. • Do not mix different lubricants. It is possible that different brands of lubricants are not be compatible with each other. Only use lubricants recommended by the manufacturer.

• Repairs that need welding must be done only with the applicable reference information and by personnel trained in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. • When you weld, always disconnect the battery and electronic devices. Remove all paint from a 10 cm radius from the welding point to avoid creating toxic gases during welding.

Copyright © 2018 by MCFE. All rights reserved. Revision: C

Document ID: 622075-EN 19 (782)

• Use the correct lifting procedures when you remove components. • Be careful when you remove cover plates. Gradually, remove the last 2 bolts or nuts at the opposite ends of the cover or device. Before you remove the last 2 bolts or nuts, turn the cover loose to release springs or other pressures. • Be careful when you remove filler caps, breathers and plugs on the truck. Put a cloth around the cap or plug to make sure that you do not become sprayed or splashed by liquids under pressure. Be aware that the liquids spray and splash more easily immediately after you have stopped the truck, because the fluids are very hot. • Only use well-maintained tools. Also, make sure that you use the tools in a correct way. • Reinstall all fasteners with the same part number. If a replacement is necessary, do not use a fastener of lesser quality. • Do not cause damage to the wiring during the removal process. Do not use damaged wiring. When you install the wiring back, make sure the wiring does not touch sharp corners or hot parts. Put all wiring away from the oil pipe. • Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or hit high pressure lines or install ones that are bent or damaged. Examine all lines, tubes and hoses carefully. Pin hole (very small) leaks can cause a high velocity oil stream that cannot be seen near the hose. This oil can go through the skin and cause personal injury. Use a cardboard or paper to find pin hole leaks.

• Tighten connections to the correct tightening torque. Make sure that all heat shields, clamps and guards are installed correctly to prevent excessive heat, vibration or rubbing against other parts during operation. Protective shields against oil sprays onto hot exhaust components in the event of a line, tube or seal failure must be installed correctly. • Do not operate the truck, if a rotating part is damaged or touches another part during operation. All high speed rotating components that are damaged or altered must be examined for balance before you use them again.

3.6 Operating temperature

The ambient operating temperature range of the truck is +5...+25°C. The truck can be operated at a temperature of 0...+45°C for short periods. The recommended humidity is 30...95% (noncondensing).

CAUTION

Do not move a damp truck into a freezer storage! Let the truck dry before you do! If you move a damp truck into a freezer storage, there is a risk of malfunction because of ice accumulation!

Copyright © 2018 by MCFE. All rights reserved. Revision: C

Document ID: 622075-EN 20 (782)