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TE

REACH TRUCK

Type: __________________________________
Manufacturing year and number: _____________________

NB:

Please read this manual before operating or performing maintenance on the forklift truck.
Following the instructions will improve safety and enable unnecessary danger situations
and accidents to be avoided.
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Table of contents
FOREWORD ............................................................................................................................................ 3
1. INSTRUCTIONS ON OPERATING THE TRUCK ............................................................................ 3
2. OCCUPATIONAL SAFETY .................................................................................................................. 5
3. LOAD HANDLING .............................................................................................................................. 6
4. DRIVING .............................................................................................................................................. 7
5. PARKING ............................................................................................................................................. 7
6. OTHER WORKING INSTRUCTIONS............................................................................................... 8
7. RECHARGING AND REPLACING THE BATTERY ........................................................................ 8
8. HAZARDOUS WASTE AND DISPOSAL .......................................................................................... 10
9. ORDERING SPARE PARTS .............................................................................................................. 10
10. USE OF THE TRUCK ...................................................................................................................... 11
11. THE OPERATOR’S NORMAL DRIVING POSITION .................................................................. 11
12. NOISE ............................................................................................................................................... 11
13. CONTROLS AND THEIR DISPLAYS ............................................................................................ 12
14. ADJUSTING THE DRIVING POSITION ....................................................................................... 16
15. OPERATION .................................................................................................................................... 17
16. “FLY BY WIRE” ELECTRONIC STEERING ................................................................................ 17
17. HANDLING THE LOAD ................................................................................................................. 19
18. EMERGENCY PROCEDURE ......................................................................................................... 19
19. INSPECTIONS, MAINTENANCE AND REPAIR ......................................................................... 20
20. ADDITIONAL INSTRUCTIONS FOR THE COLD STORAGE TRUCKS .................................. 23
21. TROUBLESHOOTING .................................................................................................................... 24
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FOREWORD

Warehouse trucks are designed for the varying needs of customers to lift and transport objects in indoor
premises. Familiarise yourself with this manual carefully in order to be able to use all the features offered
by the truck for efficient working.

Important:

! After reading this manual, store it in a safe place for later use.
! Do not use the truck before you have read this manual.

The truck conforms to the EN 1726 standard, ensuring its safety according to the EU machine directive.
The most important regulations and guidelines are mentioned in these instructions. As regulations vary
from country to country, we expect users to be aware of the regulations and standards valid in their local
area.

In order to use the truck safely, users should find out about safety risks in advance. All the safety regulations
in the manual must be followed. The truck operator should acquaint himself with the instructions of a
new truck carefully, and practice driving and controlling the truck in a protected area.

We hope that you will put your truck to continuous economical and efficient use. In order to remain fully
operational, the truck must be maintained competently, according to the maintenance instructions and
schedule supplied by us. We offer to you economical and efficient maintenance and spare part service.
The most advantageous arrangement to ensure that the truck is operational at all times is to sign a
maintenance agreement with your dealer.

For further information or training on trucks, please contact our sales organisation.

WARNING!

A truck is a moving machine, which may cause serious accidents, unless its operator is sufficiently
familiar with its operation and unless he knows its operating and maintenance instructions. To order
more copies of instruction books, contact your dealer.

1. INSTRUCTIONS ON OPERATING THE TRUCK

INSTRUCTIONS FOR SITE SUPERVISION

The operator must be trained with the use, maintenance and safety aspects of the truck. The site supervision
must control that the operator and maintenance instructions as well as safety regulations are observed. It
is in everybody’s interest that the truck remains continuously operational and in productive use.

! It is the site supervision’s duty to advise the operator and control that the operator and maintenance
instructions are observed.
! The site supervision must familiarise themselves with the operator instructions and their contents.
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RECEIPT OF THE TRUCK

Before shipping, each truck is inspected carefully to make sure that the truck you receive is in impeccable
condition and equipped as per your order. We request, however, that immediately after receiving the
truck you inspect it for any damages during shipping. This way your truck can be put to productive work
without undue delay.

TRUCK STORAGE

If the truck is not used for a lengthy period, it should be stored in a cool (above 0 C) and dry place on an
even surface. Before storage, complete the following:

BATTERY

Charge the battery well, and while stored recharge it every 2 or 3 months to prevent damage. At the same
time, check the fluid level and add if necessary.

HYDRAULIC SYSTEM

If the machine is out of use for more than a year, change the hydraulic oil.

DRIVE UNIT

If the machine is out of use for more than a week, support the truck in such a way that the load exerted on
the drive wheel becomes lighter.

Returning the Truck to Operation

If the truck has been stored for several months, it must undergo maintenance as per 600 operation hours.
Otherwise normal daily maintenance and inspection are sufficient.

MAINTENANCE AND REPAIR

The operation of the truck requires that it is maintained regularly and competently. Daily and weekly
maintenance is the work of the operator or an appointed individual, who must be supplied with adequate
training and instruction for the task. It should also be borne in mind that the terms of the warranty
prescribe appropriate maintenance of the truck. All spare parts must be original spare parts.

Monitoring the maintenance instructions is easier if maintenance dates are entered in the maintenance
record located on the last page of the Manual.

The most advantageous arrangement is to sign a maintenance agreement with your dealer, who can also
supply you with any supplies and spare parts you may need. Contact our maintenance department or your
truck dealer for good and efficient maintenance service for your truck.

! If maintenance is neglected, the truck may cause damage to property, and even personal injuries.
! Proper maintenance and care ensure that the truck can be used efficiently and without errors.
! Truck inspections, lubrication and maintenance must be made according to the maintenance schedule.
! Only a specially appointed and trained individual is allowed to repair and adjust the truck.
! If you are not sure of the symptom or the error, do not take any corrective action but contact your
dealer.
! For troubleshooting chart, see Appendix.
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TRUCK OPERATOR

The truck operator must be at least 18 years of age, and he must have the physical (e.g. good hearing and
sight) and psychological properties required for operating the truck without risks. Only an individual
trained for the truck may operate it. In addition, he must have permission from the site supervision to
operate the truck.

The operator must know and master the drive and operational properties of the truck as well as all the
relevant safety and other regulations. He must be able to control the truck also in a situations of sudden
danger. Familiarisation and drive practice with a new truck should be arranged in a protected area.

The operator is responsible to the site supervision for observing all the instructions and regulations in his
daily work and for taking care of the truck. The operator must check the condition of the truck at the start
of each work shift. In particular, he must check the operation of steering and brakes, the condition of the
batteries, parking brake and signal horn.

The operator must familiarise himself carefully with the truck and its operator and maintenance instructions
as well as safety regulations.

LIFTING THE TRUCK

The truck may only be lifted from a marked position.

Make sure that the capacity of the lifting device is sufficient.

TOWING THE TRUCK

The truck may only be towed with its drive wheel raised free of the floor.

ELECTROMAGNETIC COMPATIBILITY

The truck conforms to the prEN... (Proposal 09.95) standard, ensuring its safety according to the EMC
directive.

The truck is designed for use on premises of light and heavy industry (EN 50081-1 and prEN 50082-2).

WARNING

Modifications to electric devices may affect the electromagnetic compatibility and, therefore, the safety
of the truck.

No modifications may be made to the electric devices in the truck without permission from the
manufacturer, as such modifications may put safety at risk.

2. OCCUPATIONAL SAFETY

The truck must be kept clean and in good working order. The daily and weekly checks in accordance with
the maintenance instruction must be carried out on time in order to avoid faults and operational errors.

If any faults or deficiencies risking safety are observed in the truck, the truck must be taken out of
operation until the faults or deficiencies have been remedied.
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! The operator may not make any repairs without permission from the site supervision.
! In case of malfunction disconnect the battery connector.

The operator must always promptly notify the site supervision of any accidents or injuries. In such a case
the operator must leave the truck at the place of the accident.

! When using the truck, the operator is responsible for both his own and his environment’s safety.
! The truck may only be used for purposes corresponding to its outfit.

REPAIRS AND STRUCTURAL MODIFICATIONS

The truck may not be modified without manufacturers permission: no parts may be added or removed, as
the modifications could affect the operation of the truck and might weaken its construction.

! Do not weld or bend the truck’s forks.

WORK ON DANGEROUS PREMISES

Trucks used for working on premises susceptible to fire or explosion or other hazards must be specially
equipped. A standard truck is not suitable for such work.

OVERHEAD GUARD AND LOAD SUPPORT

Trucks driven sitting or standing that are capable of lifting the load more than 1.8 m must be equipped
with an overhead guard. No modifications to the overhead guard that weaken its structure are allowed. If
it is possible that objects might fall through the slots in the overhead guard, the slots must be reduced.

Trucks used for transporting small objects or unstable loads must be equipped with a load support.

3. LOAD HANDLING

The load must be handled without causing any risk of accident or damage to the load. The load can only
be transported when it has been loaded safely.

! The truck must always be driven with its forks lowered.

! If the truck has side supports, use them when you fetch or leave a load. Raise them when driving.
! Do not let anyone, under any circumstances, walk or stand under the forks.
! Never place any part of your body between the mast structures or any moving parts of the truck.
! If driving a load that is larger than the outlines of the truck, take into account the extra space it requires.

LIFTING CAPACITY

The operator must know the truck’s maximum lifting capacity and never exceed it under any circumstances.
Likewise, he must abide by the maximum values for load weight and load centre information printed on
the capacity plate in the different loading situations.

Take into account the effect of any attachments to the lifting capacity.
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4. DRIVING

The truck must always be driven from the actual operator’s seat. Keep your body completely within the
outlines of the truck. Anticipate any dangers so that you can avoid all risks of accident or injury.

! The truck must at all times be under the operator’s control, and it must be handled responsibly.
! Sudden starts and stops should be avoided.
! Steering and braking movements should be made smoothly.
! Decrease the speed if the floor is slippery, e.g. because of humidity.
! Take great care when driving on a slanted surface.
! Do not drive over any loose objects on the floor.

When driving, the load must be kept down and, if possible, tilted backwards. The load must not be lifted
except when stacking. This does not apply to trucks designed to be driven with the load raised.

Be especially careful:
! when there are other people, or moving or fixed objects in the working area.
! when the load reduces visibility. When driving in narrow aisles, make sure that there is enough space
for the truck and the load.

SPEED

Speed must be chosen according to the situation. Things to take into consideration include load, visibility,
people in the working area, as well as moving and fixed objects. Speed must be reduced at cross aisles
and whenever vision is obstructed. If the visibility is inadequate, the operator should use an assistant.

Careless driving leads to risk situations: for example, uncontrolled acceleration or braking, excessive
speed at turning points, as well as fast and sudden turning may overturn the load and cause an accident.
In all conditions, drive the truck at a speed which makes it possible to stop it safely. Keep sufficient
distance to a preceding vehicle.

TRAFFIC RULES

The general rule is that the truck should be driven on the right-hand side of the driving lane. The operator
should keep good visibility in the direction of driving and mind the traffic and other people by keeping
sufficient safety distances. It is not allowed to drive the truck outside a private area without an order or
permission by the site supervision. Outside a private area, the truck is subject to general traffic rules and
regulations. Traffic regulations and speed limits should also be observed in a private area.

If a door opening is so narrow that two vehicles cannot pass each other, drive in the middle. When two
trucks meet in a narrow or cross aisle, the loaded truck has the right of way.

! When driving, the horn should sounded when necessary to warn others in the same area.

5. PARKING

The truck can be parked without supervision only in a specially reserved parking place. When parking
the truck, the forks must be lowered to the down position and the parking brake must be on. It must be
ensured that the truck under no circumstances can move by itself or that an inexperienced person can
start driving it.
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! Never park or stack goods in front of fire doors, fire extinguishers, emergency exits and the like.
! Never park the truck on a slanted surface.

6. OTHER WORKING INSTRUCTIONS

FREE SPACE

! The operator must make sure that the truck has sufficient moving space with respect to overhead
structures. Before driving to aisles or door openings, it must be ensured that there is enough space for the
truck, the load and the operator.
! Always drive at a safe distance from the edge of loading platforms or bridges.

BEARING CAPACITY OF THE FLOOR

The operator must make sure that the combined weight of the truck and the load does not exceed the
bearing capacity of the floor.

USE IN ELEVATORS

An elevator can only be used to transport the truck between floors by permission of the site supervision.
When using an elevator, it must be ensured that the combined weight of the truck, the load and the
operator does not exceed the maximum load capacity of the elevator. The truck should always be driven
with the load in front to elevators, as well as any other narrow premises.

! Do not let any other people be in an elevator when driving the truck in or out.
! The parking brake of the truck must be on before the elevator starts.

WORKING ON RAMPS

The operator must get permission from the site supervision to drive on a slope or ramp. When the truck
is loaded, travel with the load uphill. Without a load, you can also travel with the forks downhill.

! Do not turn the steering wheel abruptly on a ramp. The truck might overturn.

WORKING ON LOADING BRIDGES

Before starting with loading or unloading, always check the bearing capacity and the fastening of the
bridge. If the truck is to be driven into another vehicle, it must be ensured that the vehicle cannot move
during the work. Do not drive to the edges of a loading bridge, because there is always the risk of
overturning.

7. RECHARGING AND REPLACING THE BATTERY

Only appointed and trained personnel may replace and recharge batteries. Individuals maintaining batteries
must have sufficient protective clothing.

! Do not handle naked flame in the vicinity of batteries because of a risk of explosion.
! Do not smoke when working with batteries.
! Do not leave tools or other metal implements on top of the battery. Sparking or a short circuit may
cause the battery to explode.
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! When the batteries are recharged, the cell plugs must be screwed tight to prevent battery fluid splashing.
! Battery fluid is a corrosive acid solution, so caution should be exercised to avoid it getting on the skin
or in the eyes. Battery fluid develops an explosive gas at the end phase of recharging. Therefore, make
sure that the battery has sufficient ventilation.
! A low battery charge status may damage the battery during long-time use.

RECHARGING THE BATTERY

! Make sure that the charger is the appropriate model for recharging the battery.
! Park the truck in a specially reserved recharging place.
! Make sure that the battery has sufficient ventilation.

Connecting the battery to a charger:

1. Switch off the truck current

2. Make sure that the charger has been switched off.
3. Disconnect the battery connector and connect it to the charger.
4. Connect the current to the charger.

After charging, when beginning the work:

1. Switch off the charger.

2. Disconnect the battery connector from the charger. Grab the plugs. Do not pull the cables.
3. Check the battery according to the manufacturer’s and maintenance instructions.

Measuring the Cell Density of the Battery

Measure the acid density of the battery fluid according to the

manufacturer’s instructions. The acid density of a fully charged battery
is 1.28 to 1.30 at + 30 °C.

1.24 3/4 charged

1.20 1/2 charged
1.16 1/4 charged
1.15 Empty. The battery must be charged immediately.

REPLACING THE BATTERY

The battery must be replaced according to the manufacturer’s instructions. When reinstalling batteries,
use the appropriate tools for moving, connecting and fastening the battery solidly. Tools and other metal
implements must not be kept on top of uncovered batteries.

When replacing the battery for an electric truck, use a battery with dimensions and weight that fit the
truck so that the stability or braking properties of the truck are not weakened. The minimum weight of the
battery is indicated on the identification plate of the truck.

When a lifting device is used for lifting the battery, place a non-conductive plate on top of the battery to
avoid the risk of a short circuit. This is not necessary if the lifting device has sufficient insulation and is
equipped with a distributor or if the pole shoes and cell combinations are fully protected.
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ACQUIRING A NEW BATTERY

When acquiring a battery for the truck, pay attention to the standard prEN 1175-1, section “Traction
batteries”, which lays down the requirements on the protective cover of the battery case, ventilation and
interior surface treatment, and section “Minimum markings”, which lays down the requirements on the
truck battery plate.

The battery plate should give at least the following information:

• manufacturer
• type
• serial number
• rated voltage
• capacity (Ah/5h)
• service weight

8. HAZARDOUS WASTE AND DISPOSAL

Hydraulic and gear oils as well as batteries are hazardous waste, which must be disposed of accordingly.
The truck itself is not hazardous waste, and can be recycled.

9. ORDERING SPARE PARTS

When ordering spare parts, always turn to your dealer or maintenance centre. Use only original spare
parts.

To make sure you receive the correct parts, include the following information in the order:
• TYPE OF TRUCK
• SERIAL NUMBER OF TRUCK
• ORDER NUMBER OF PART
• NAME OF PART
• NUMBER OF PARTS ORDERED

Of the above information, items 3 and 4 are listed on the spare part pages of the manual supplied with the
truck, and items 1 and 2 on the front page of the manual or on the identification plate of the truck.
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10. USE OF THE TRUCK

This product is designed for handling pallets and other similar picking units in pallet transfer and stacking
tasks.

The truck is intended to be used on dry indoor premises, on even and straight floors. A standard truck can
work continuously at a working temperature from + 25 to +5 ° C, with occasional variation from + 45 to
0 °C. If your working environment has a different temperature range, contact Rocla, because cold and
freezer premises require a specially constructed machine. A special frost machine can be used down to
- 35 °C.

The truck meets all the relevant requirements of the EU directive on machine safety, indicated by a CE
label.

FORBIDDEN USES OF THE TRUCK

Never use the truck:

• to transport and lift people
• on premises with fire risk
• on premises with explosion risk
• on premises with insufficient floor bearing capacity
• if damaged
• as a mounting surface
• to tow another truck
• under the influence of intoxicating substances.

11. THE OPERATOR’S NORMAL DRIVING POSITION

The driver’s normal position while driving is sitting with the left hand on the steering wheel and the right
on the valve levers. The left foot should always be on the chosen drive direction switch or on the brake
pedal.

NOTE ! When driving, no part of the body must be outside the operator’s cab.

12. NOISE
The maximum noise level the driver may be subjected to is 70 dB (A). This noise level can be reached
when raising classified load.
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13. CONTROLS AND THEIR DISPLAYS

TRUCK PLATES (1)

Identification plate

The identification plate gives the following information:

• manufacturer
• truck type
• serial number
• unloaded mass of the truck in working order without a battery and
removable attachments
• permitted maximum and minimum battery weight
• terminal voltage
• rated load capacity
• CE- label

Capacity plate

On the high-lifting trucks, there is a capacity plate that tells the maximum
lifting capacity with maximum lifting height and the lifting height with
a nominal lifting ability. Only one lifting ability is announced, when
needed, between these two heights. In addition, the plate tells the
center of gravity distances with these lifting abilities.

WARNING !

Recognize and know in every situation the load’s weight and center of gravity. Overloading
the truck is a safety hazard and thus forbidden.

The capacity plate for accessories

If the truck uses detachable accessories, the corresponding plates are fastened to the truck and the lifting
capacity changes are mentioned on the capacity plate where the type of accessory is marked.
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Speed Control and Direction Switches (2), (4), (5)

Press the speed control pedal (2) gently with your right foot. The
lower you press the pedal, the greater the speed. The pedal returns to
the upper position when released.

In a truck equipped with a hand reverser, select the desired direction

of travel by using the hand lever (5). When driving, press the safety
press key (4) with your left foot and adjust the speed with the speed
control pedal.

• Use the speed control gently !

• The security switch connected to the manual direction change is a
safety measure that insures that the driver is completely in the truck.

Option: Foot reverser

As an option, the truck can be equipped with a foot reverser.

Press the reverser of the desired direction of travel with your left foot.
The truck cannot be driven if the reverser is not pressed.

BRAKES

Operating and parking brake (3), (6)

The left pedal is the brake pedal (3). The deceleration force is adjusted
by the movement of the pedal.

The operating and parking brake affect the drive wheel. When the
truck is equipped with load wheel brakes (TES, TEH), they can be
operated only with pedals.

The operating brake is a magnetic brake that is always switched on

(6) when the driver leaves the truck. The magnetic brake is also
switched on with the operating brake pedal if pressed hard enough
(“panic braking”).

Recharging (regenerating) braking

The truck is equipped with a recharging motor brake system. This enables conserving the energy generated
by braking, which otherwise would be wasted. This increases the life expectancy of the battery and
spares the driving motor.

Motor braking recharges the battery and decelerates the truck in the following cases:
1. When the brake pedal is pressed
2. When the direction is reversed
3. When the truck rolls freely

• Practice using the brake both with and without a load before starting work.
• The parking brake is always used when the truck is not in use.
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Charging Plug (7)

The charging plug of the truck is equipped with a handle and it is detachable.
On using the charging plug for recharging the battery, see the section “Recharging the
Battery”.

Opening of the panel:

NOTE !
When welding with electrical welding equipment,
the battery must be disconnected.

CONTROL PANEL

Key switch (8)

The key switch connects the electrical devices of the

truck to the battery circuit.

0 = Power off (power remains on for certain electronic

devices)
1 = Power on

Valve Levers (9)

A reach truck usually has four levers. From left to right:

1. Lifting and lowering the forks

2. Pushing the mast forward and backward
3. Tilting the mast
4. Side-shifting the carriage

If the truck is equipped with a fork adjustment device, there is a rocking-

switch instead of a covering plate.

• Familiarize yourself with the operation of the levers

Steering wheel (10)

The steering wheel turns the drive unit by ±100° or without limits. For the adjustment of the steering
wheel, see “Adjusting the position of the boomerang.”

• See Section “Fly by Wire ”Electronic Steering for more details.

The emergency stop button(11)

Press this button to disconnect the truck current circuit from the battery. Use this button:
• in case of a short circuit or other electrical malfunction, for example, if the pump motor is on continuously
• in case of an accident.
The switch is released by rotating the button clockwise.

Horn Signal Button (12)

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Display

(1) Power-on LED

• The green LED is lit when the power is on.

(2) Problem monitoring of the speed control

• The red LED flashes if the speed control has a fault. The truck cannot be driven before the fault has
been corrected.
• When the LED flashes, switch off the power with the ignition key, wait for about 5 seconds, then switch
on the power again (do not touch any drive or load management controls). The controller gives also a fault
message if the start order is wrong. Correct order: push first the safety controller or direction switch
down and then the speed control pedal. The fault is fixed by taking the feet of the pedals, waiting ca. 2 s
and trying to start again in the right order.
If the fault is not removed, contact your maintenance centre.

(3) Problem monitoring of the pump control

• The red LED flashes when the pump speed control has a fault. The truck cannot be driven before the
fault has been corrected. When the LED flashes, switch off the power from the ignition key, wait for
about 5 seconds, then switch on the power again (do not touch any drive or load management controls).
If the fault is not removed, contact your maintenance centre.

(4) Travel direction arrows

• The blue LED arrow indicates the direction of travel.

(5) Liquid crystal display

• In connection with the powering-on, the LCD displays the operating hours of the truck for about 5
seconds, after which the LCD shows the charge status of the battery.
• The hour meter calculates the active working time of the truck. It is always on when the electronic
devices are operating. If the charge status of the battery is too low, the charge indicator / hour meter
combination stops lifting.

(6) Seat heating (optional)

• As an option, the truck can be equipped with seat heating, in which case the green LED is lit when seat
heating is on.

(7) Problem monitoring of control electronics

• A red LED warns you about a steering disturbance. When the indicator is lit, immediately stop the
truck using the foot brake ! See Section “Fly by Wire” Electronic Steering for more details.

(8) Monitoring of carbon brushes (optional)

• A red LED is lit when the carbon brushes of the driving motor or the pump motor have worn too short.
The carbon brushes of the motor in question must then be replaced immediately.
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(9) Magnetic brake (parking brake) LED

• A red LED is lit when the magnetic brake is switched on.

(10) Thermal monitoring (optional)

• As an option, the truck can be equipped with thermal monitoring of drive and pump speed controls. In
this case the red LED indicates that the control has overheated. If this happens, drive the truck slowly to
to a place where it is not in anybody’s way and does not pose a danger to anybody. Let the truck cool
down. The reason for overheating must be found out, before the truck is driven again.

14. ADJUSTING THE DRIVING POSITION

SEAT

The springs of the seat are adjusted according to the driver’s weight. Then the tilt of the
backrest and the distance from the seat to the pedals are adjusted.

A = Seat spring tension adjustment

B = Seat tilt
C = Seat distance adjustment

CONTROL PANEL

The turning angle of the control panel can be adjusted by rotating the screw behind the
panel.
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15. OPERATION

Before start, make sure that the daily maintenance has been carried out. See ”The Operator’s Daily
Routines before Work”.

Turn on the truck and grab the knob of the steering wheel with your left hand. Release the parking brake
by pushing the brake lever forward.

Hold on to the knob of the steering wheel with your left hand and use the valve levers with your right. The
left foot must always be on either the driving direction switch or the stopping button (manual direction
change). Press the speed control panel with the right foot.
The reach truck is always driven with the mast tilted backwards and pulled in, and the fork and the load
low. The pushing and pulling movement of the mast is only used in stacking and unstacking.

• Practice steering and controlling the truck

• Make the truck’s control movements calmly
• Anticipate the braking situations in plenty of time and brake softly
• Drive slowly in intersections and while turning
• Practice using an unfamiliar truck in a safe area
• Warning ! With sudden movements of the speed control or brake pedal, you may lose control
of the truck or load.

16. “FLY BY WIRE” ELECTRONIC STEERING

The truck is equipped with a new and completely electronic steering system. The steering wheel movement
in electronic steering is transmitted without a mechanical connection to the motor that controls the drive
wheels.

The system consists of three main components, a tachometer located in the steering wheel, a control unit
located in the motor compartment, and a servo motor, which is also in the motor compartment. The control
unit processes the signal coming from the tachometer and controls the servo motor to turn the drive wheel
in the desired direction. In addition, the control unit constantly monitors how the system is functioning and
its status. The control unit reacts immediately whenever something goes wrong.

The drive wheel turns ± 360° or ± 100°.

SAFETY

When the power is turned on by the main switch and the ignition key, the system performs a diagnostic
test which lasts no more than 0.3 seconds. After the test is done, the truck is fully operational and ready
to use.

When the power is turned on, the system constantly performs a diagnostic check by sending a check
signal throughout the system. This signal can be heard as the tapping noise emitting from the truck. In
case something goes wrong, the control unit will react immediately to the situation by turning on the
STEERING STOP indicator and applying the magnetic brake.

The truck immediately stops when a problem appears.

Wait for at least 2 seconds before you turn the power on again after it has switched off.
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OPERATION

Completely acquaint yourself with the truck and please note that when the turning wheel reaches the
turning limit (± 100°), the steering wheel may continue turning as it has no mechanical stops to prevent it
from doing so.

The “STEERING STOP” indicator

The STEERING STOP light is lit when there is a fault in the control system or if the power is switched off
and on too quickly (<2 seconds). The truck cannot be driven if the light is on.

NOTE ! Do not turn the steering wheel unnecessarly, when the truck is not moving!

MAINTENANCE

The system has been designed to be as maintenance free as possible. The user only has a few simple
maintenance tasks to take care of.

Quarterly maintenance check (300 hrs.)

• Fastening of the steering control unit terminals

NOTE:
• DO NOT under any circumstances adjust the control unit as it has been pre-set at the factory.
• DO NOT subject the control unit to running water.

An authorized serviceman can, when needed, tune the steering, e.g. the number of rotations for the steering wheel.
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17. HANDLING THE LOAD

Familiarize yourself with the load handling instructions that are in the general instructions !

Set the load so that its weight is distributed as evenly as possible on both of the lift forks. You can see the
truck’s maximum capacity on the type plate and you may not exceed that capacity.

WARNING: DO NOT TRANSPORT BADLY PILED OR BOUND LOADS. DO NOT EXCEED

THE TRUCK CAPACITY.

STACKING AND UNSTACKING

While stacking and unstacking with the reach truck, you must follow the following guidelines.

Stacking:
1. Drive calmly perpendicular to the front of the stack of shelf with the load low and the mast tilted
backwards.
2. Straighten the mast into an upright position.
3. Lift the load so high that it clearly is higher than the stacking or shelf level.
4. Push the mast forward until the forks and the load are above the shelf level.
5. Lower the fork so they are no longer touching the pallet but at the same time not touching the shelf
level. Make sure that the load is stable.
6. Pull in the mast and carefully drive backwards. Tilt the mast backwards and lower the forks to the
driving position.

Unstacking:
1. Drive calmly perpendicular to front of the stack of shelf with the forks low and the mast tilted backwards.
2. Straighten the mast into an upright position.
3. Raise the forks to the height of the desired pallet and approach the pallet by driving carefully. Make
sure that the forks can freely go underneath the pallet the whole time.
4. Push the mast forward until the pallet is completely on top of the forks.
5. Lift up the forks so that the pallet is no longer on the stacking level. Make sure that the load is stable.
6. Pull in the mast and carefully drive backwards. Lower the load to the lower position and tilt the mast
backwards.

Note !
• Always compare the load weight to the lifting height and capacity that are on the truck's type plate.
• Always observe the space above the load.
• While the load is up, the steering and braking movements have to be done carefully and softly.
• A broken pallet or an unstable load may not be lifted nor left on a stack or shelf.

18. EMERGENCY PROCEDURE

If the truck overturns, keep hold of the steering wheel and warn others. If the truck behaves strangely,
brake and power off the truck. The truck must not be returned to operation until it has been repaired by an
individual authorised by the site supervision.
 - 20 -

19. INSPECTIONS, MAINTENANCE AND REPAIR

SAFETY INSTRUCTIONS IN MAINTENANCE WORK

• Only individuals trained for maintaining and repairing this type of trucks may repair and maintain the
truck.
• The maintenance site should be kept clean: oil, grease and water make the floor slippery.
• When working with the truck’s electrical system, there is a risk of a short circuit and skin burn if a metal
object touches live connectors. No watches, rings or other metal jewellery should therefore be worn.
• Power off the truck before opening the cover of the drive unit or the electrical system.
• Remove hydraulic pressure before opening the system.
• Do not use your hand when checking possible oil leaks.
• Note that hydraulic system oil or motor surfaces may be hot.
• Use only clean oil for filling the hydraulic system.
• Disconnect the battery when welding. To prevent formation of toxic gases during welding, remove paint
up to 10 cm from the work object.
• Support the truck with jacks when working underneath the truck.

DRIVER’S DAILY ROUTINES BEFORE OPERATION

• As an operator, you are responsible for the daily checking and maintenance of the truck.
• Carry out the daily maintenance according to the list below before the start of a working day or shift,
before the truck is used.
• Neglecting the daily maintenance may decrease the safety and reliability of the truck.
• Notify the site supervision immediately if you notic any error or deficiency during the check.
• Check the truck externally to see that no oil leaks can be observed.
• Check all wheels for damage or outer wear.
• Check the battery fluid in each battery cell. Top up with battery water if needed. The fluid surface
should be about 15 mm above the plates.
• Check the gearbox for leaks. Also check the hydraulic pipes, hoses and connectors. No leaks or damage
should be found.
• Switch on the current and test the operation of the lifting hydraulics by raising and lowering the forks.
• Check the operation of the speed control by driving slowly forward and backward. Also check the
operation of the other electrical functions.
• Make sure that the stopping pedal returns to the upper position and that the parking brake functions
properly.
• Test the sound signal.
• Make sure that the fastenings of the lifting chain have not loosened.
• Make sure that the steering is working
 - 21 -

DRIVER’S WEEKLY MAINTENANCE PROGRAMME

• Check and clean the fastenings of the battery cables.

• Make sure that the air holes of the battery cell plugs are not plugged up.
• Clean the batteries with a dry rag. If necessary, you can wash the batteries with warm water or mild
soda solution, which neutralises the battery acid. Dry the battery carefully after the wash.
• Check the length of the lifting chains. When the mast is upright and the top of the mast bars is on the
same level, all the chains should be somewhat loose. Adjust, when needed, the adjust screws at the end
of the chains.
• Thinly oil the mast’s, push sled’s and lifting sled’s grooves.
• Check the amount of hydraulic oil in the oil container when the forks are down. If necessary, add oil.
See the separate oil recommendation (Section 17.4) for more details.
• Check that the driving wheel’s fastening bolts are tight. The tightening moment is 190 Nm.
• Make sure that screws, nuts and pipe connectors are tight.
• Check that machine plates and labels are fastened securely and fully legible.
• Clean the truck if necessary.

NB: DO NOT LET WATER IN THE ELECTRICAL DEVICES, especially if the power is on !

THE TRUCK’S LUBRICATING POINTS SHOULD BE LUBRICATED ABOUT ONCE A MONTH.

pivoting bearing grease nipples (2 nipples)

Reach carriage grease nipples (4 nipples)

OIL RECOMMENDATIONS

Hydraulic oil: ISO VG 32

In freezer warehouses: ISO VG 15
Gearbox oil: SAE 80W/90, API: GL-4
• Fill to the volume of 4.5 l
Lubricating grease: NLGI No. 2. containing molybdenumdisulfide.
In freezer warehouses: NLGI No. 1 or No. 0.
 - 22 -

QUARTERLY MAINTENANCE INSPECTION (300H)

The most convenient arrangement is to make a maintenance agreement on inspection and scheduled
maintenance with your service centre. Only competent maintenance guarantees a fault-free operation of
your truck.

Following the maintenance programme is easier when you enter the maintenance dates in the maintenance
record.

In addition to the weekly programme, the Rocla service engineer checks and adjusts, if necessary, the
following:
• operation of the hydraulic valve
• the action of the speed control
• the contactors, microswitches and solenoids
• the condition of the cables
• the amount of brake fluid (TES, TEH)
• If necessary add SAE J 1703 F brake fluid into the tank.
• the brake pipes and tubes
• Press the brake pedal strongly and check that there aren’t any fluid leaks.
• the cylinders’ fastenings and the adjustments’ locking
• the condition of the forks and the connection of the mast to the body
• thinly oiling the lift chain with oil
• horizontal and vertical play of the reach carriage
• If necessary, you can reduce play by loosening up the tension screws and turning the
adjustment screw.
collectors, carbon brushes and guides of the driving, steering and pump motors
• strain percentage of the lifting chains

SEMIANNUAL SCHEDULED MAINTENANCE (600 H)

In addition to the quartely and weekly procedures, the service engineer will
• check the collectors, carbon brushes and wiring of the driving and pump motors and clean the coal dust
off the motors.
• change the hydraulic oil once a year (1200 h)
• change the gearbox oil once a year (1200 h)
• replace the oil filter
• check the operation of the hydraulics and the pressure-limiting valves
• check the fastening of the gearbox
• check the wear on the driving wheel
• The wheels are exchanged at last when there is 10 mm of surfacing left on the wheel
• check, clean and oil the lifting chains
• oil the motors’ bearings once a year (1200 hrs.)
• check the lifting chains’ wheels
• check how the battery locking mechanism works
• check the driver’s cover
 - 23 -

LOCATION OF THE FUSES:

1. Main fuse of the driving and pump motor

2. Steering motor fuse
3. Main fuse

WARNING: DO NOT MAKE ANY CHANGES OR

REPAIRS IN THE TRUCK THAT MAY WEAKEN
ITS CONSTRUCTION OR ENDANGER SAFETY.

20. ADDITIONAL INSTRUCTIONS FOR THE COLD STORAGE TRUCKS

You can use trucks with a cold storage specification for working in temperatures above -35°C. You can
also use them when working in humid or difficult environments, but not in environments that are too warm,
due to limited cooling capacity.

The classification of these machines is Class 3. This classification replaces the old classes (Class 1, Class
2, Class 3).

Whenever the truck is used or left idle for short periods of time (e.g. during a lunch break) in temperatures
below 0°C, the heating must be left on. If the truck is left unused for a longer time, it should be kept in a
warm area.

Grease the truck lubricating points once a month. The lubricating points include the following:
• Swivel bearing grease nipples, 2 pcs
• Grease nipples of speed adjustment and brake pedals, 2 pcs
• Grease nipples of reach carriage, 4 pcs
• Grease nipples of mast tilting bearing, 2 pcs
• Sprocket wheel grease nipples, 4 pcs
• Grease nipples of leaders, 12 pcs

• Lubricate the gear wheel of the swivel ring and steering motor
• Lubricate the lifting chains
• Lubricate the mast leader surfaces
• Lubricate the leader surfaces of the lift carriage
• Lubricate the leader surfaces of the reach carriage

Perform the following maintenance operations every six months or when the red indicator pin of the
moisture trap has risen:
• Change the hydraulic oil
• Replace the oil filter
• Replace the oil tank moisture trap

21. TROUBLESHOOTING
SYMPTOM:
Truck does not move
The lift pump doesn’t run
lifting functions improperly
Battery does not charge
The steering isn’t
working properly
The steering works poorly
- 24 -
FAULT:
• the battery connector is loose
• the battery is empty
• the emergency stop button is
activated
• the key switch is faulty
• the microswitch for the safety pedal is
broken
• the drive motor fuse has blown
• the main power fuse has blown
• the drive motor carbon brushes are
worn out
• the speed control is faulty
• Pump fuse has blown
• Control current fuse has blown
• Pump motor carbon brushes are worn
out
• Drive switch is broken
• Overload
• Battery is empty
• Not enough oil in tank
• Oil leak
• Pump is faulty
• Dirt in valve
• Charger is connected incorrectly
• Charge fuse has blown or mains
voltage is missing
• the battery cells’ water level or
specific gravity is low
• The control motor fuse has blown
• The control power fuse has blown
• A short voltage break (<2 sec.). It
could be caused by switching the
power on too soon.
• faulty steering controller (indicators
are not lit)
• The steering motor carbon brushes
are worn out
• The steering hits an obstacle when
strongly turning to extreme position
PROCEDURE:
• plug in the battery connector
• recharge the battery
• release the emergency stop button
• replace the key switch
• replace the microswitch
• check the connections and cables and
replace the fuse
• check the connections and cables and
replace the fuse
• replace the carbon brushes
• contact your truck dealer
• Replace the fuse
• Replace the fuse and check cables
• Replace the carbon brushes
• Replace the switch
• Decrease the load
• Recharge the battery
• Add oil
• Check joints and seals
• Replace the pump
• Clean the valve, replace if necessary
• Check the connection
• Replace the fuse
• check the cells current and specific
gravity. Add water and / or acid when
necessary. See Section “Recharging the
battery”
• Change the fuse
• Change the fuse
• Switch the power off and wait more
than 2 seconds. Turn the power on.
• Contact your truck dealer
• Replace the carbon brushes
• the end line switches are faulty or
misadjusted. Replace and adjust