Rico HSD-EX-60 User manual

OPERATING MANUAL
HSD-EX-60
DO NOT REMOVE THIS MANUAL FROM THIS UNIT
Part Number: OIM-HSDEX60-2019

Operating Manual: HSD-EX-60
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Contents
Forward.......................................................................................... 3
To OWNERS, USERS, and OPERATORS: ............................... 3
Safety Symbols ..........................................................................4
Know the Equipment ..................................................................5
Look Where You are Going........................................................5
Know Your Loads.......................................................................5
Protect Yourself, Fasten Your Seat Belt!.................................... 6
Hazardous Locations ................................................................. 6
Model Description ..........................................................................7
General ......................................................................................8
Operator Protection Equipment................................................ 12
Protection Against Mechanical Sparks..................................... 13
Nameplate................................................................................15
Safety Labels ........................................................................... 16
Operator Controls ........................................................................19
Display Panel Features ............................................................21
Display Panel – Screen and Warning and Indicator Lights ....... 25
Operating Procedures.................................................................. 31
Know Your Lift Truck................................................................ 31
Stability and Center of Gravity ................................................. 32
Capacity (Weight and Load Center)......................................... 34
Inspection Before Operation .................................................... 34
Startup Procedure ....................................................................37
Lift Truck Interlocks ..................................................................38
Basic Operating Procedures .................................................... 38
Drive and Direction Changes ................................................... 40

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Steering....................................................................................41
Auto Power Off......................................................................... 42
Operator Presence System (OPS) ........................................... 42
Load Handling, General ...........................................................43
Load Handling Controls............................................................44
Load Handling, Engaging and Disengaging a Load ................. 45
Load Handling, Traveling ......................................................... 48
Highway Truck, Railroad Cars, and Docks............................... 51
Attachments .............................................................................53
Stopping ...................................................................................53
Parking .....................................................................................54
Maintenance ................................................................................55
How to Move a Disabled Lift Truck........................................... 56
How to Put a Lift Truck on Blocks ............................................ 57
How to Raise the Drive Tires.................................................... 57
How to Raise the Steering Tires............................................... 58
Maintenance Schedule............................................................. 59
Maintenance Procedures .........................................................61

Operating Manual: HSD-EX-60
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Forward
To OWNERS, USERS, and OPERATORS:
The safe and efficient operation of a lift truck requires skill and
alertness on the part of the operator. To develop the skill required,
the operator must:
•Receive training, pursuant to OSHA 1910.178(l), in the
proper operation of THIS truck.
•Understand the capabilities and limitations of the truck.
•Become familiar with the construction of the truck and see
that it is maintained in good condition.
•Read and properly understand the warnings, instructions,
and operating procedures in this manual.
In addition, a qualified person, experienced in lift truck operation,
must guide a new operator through several driving and load
handling operations before the new operator attempts to operate
the truck alone.
It is the responsibility of the employer to ensure that the operator
can see, hear, and has the physical and mental ability to operate
the equipment safely.
Various laws and regulations require the employer to train lift truck
operators. These laws and regulations include:
•Occupational Safety and Health Act (OSHA) (USA)
•Canada Material Handling Regulations
This Operating Manual is the original instruction and contains
information necessary for the operation and maintenance of a
basic fork truck. Optional equipment is sometimes installed that
can change some operating characteristics described in this
manual. Ensure the necessary instructions are available and
understood before operating the truck.

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Safety Symbols
The following symbols and words indicate safety information in
this manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury and property damage.
Indicates safety information regarding operating in a hazardous
environment.

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WARNING
AUTHORIZED, TRAINED OPERATOR ONLY!
Know the Equipment
•KNOW operating, inspection, and maintenance instructions
in Operating Manual.
•DO NOT operate or repair truck unless trained and
authorized.
•INSPECT truck before use.
•DO NOT operate if truck needs repair. Tag truck and
remove key. Repair truck before use. Always use RICO
Approved parts when making repairs. Replacement parts
must meet or exceed the specifications of the original
equipment manufacturer.
•USE attachments for intended purpose only.
•ENSURE truck is equipped with overhead guard and load
backrest adequate for the load.
Look Where You are Going
•IF YOU CAN'T SEE, DON'T GO.
•TRAVEL in reverse if load blocks forward vision.
•ENSURE tail swing area is clear before turning.
•SOUND horn at intersections or whenever vision is
blocked.
•WATCH clearances, especially overhead.
Know Your Loads
•HANDLE only stable loads within specified weight and load
center. See Nameplate on this truck.
•DO NOT handle loose loads higher than load backrest.
•SPACE forks as far apart as load allows and center load
between forks. Keep load against load backrest.

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Protect Yourself, Fasten Your Seat Belt!
•AVOID bumps, holes, loose materials, and slippery areas.
•AVOID sudden movements. Operate all controls smoothly.
•NEVER turn on, or angle across an incline. Travel slowly.
•TRAVEL on inclines with load uphill or unloaded with mast
downhill.
•TILT mast slowly and smoothly.
•LIFT or LOWER with mast vertical or tilted slightly back.
Use minimum tilt when stacking elevated loads.
•TRAVEL with carriage as low as possible and tilted back.
•SLOW DOWN before turning, especially without load.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE
THE TRUCK TO TIP OVER!
DO NOT JUMP off if the truck tips! HOLD steering wheel firmly.
BRACE your feet. LEAN FORWARD and AWAY from point of
impact.
Hazardous Locations
ONLY OPERATE THIS TRUCK IN AREAS APPROVED FOR
USE!
•It is the responsibility of the employer to determine the
hazard classification of any particular atmosphere or
location according to ANSI/NFPA 505.
•No repairs shall be made in Class I, II, and III locations.
•Battery changing and charging shall be performed in
designated, nonhazardous areas.

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Model Description
Figure 1. Diagram of Major Components
1. Overhead Guard
2. Seatbelt
3. Mast
4. Load Backrest Extension
5. Carriage
6. Forks
7. Drive Tires
8. Steer Tires
9. Counterweight
1
2
3
4
5
6
7
8
9

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General
The lift truck covered in this Operating Manual has solid rubber
tires (often called cushion tires) that are pressed onto the rim.
A battery supplies power for the traction motor, hydraulic pump
motor, control panel, and display panel.
The truck covered in this Operating Manual is manufactured with
two motors: a traction motor and a hydraulic pump motor.
Both motors use AC motor and control technology and are housed
within the EX motor enclosure.
See Figure 2 .
The truck described in this manual has regenerative braking. This
is in addition to the regular service brakes at the drive wheels.
Regenerative braking allows the operator to change the direction
of travel without applying the service brakes. When a new
direction of travel is selected, regenerative braking uses the motor
to stop the truck before traveling in the opposite direction.
A brake pedal actuates the hydraulic service brakes at the drive
wheels. A foot-operated parking brake also actuates the same
brakes.

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Figure 2. EX Motor Enclosure
1. EX Motor Enclosure
2. EX Motor Enclosure Lid
3. Traction Motor
4. Hydraulic Pump Motor
5. Hydraulic Pump
1
2
3
4
5

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The truck covered in this Operating Manual is equipped with
manual hydraulic levers to operate load handling functions.
Forward or reverse movements are controlled by a direction
control switch located on the left side of the first lever.
See Figure 3 .
Figure 3. Manual Hydraulic Levers and Directional Control Switch

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Figure 4. Seat Components
1. Seatbelt
2. Weight Adjustment Knob
3. Ride Position Indicator
4. Forward/Backward Adjustment Lever
5. Backrest Angle Adjustment Lever
6. Hip Restraint Bracket
7. Swivel Latch Release Lever
1
2
3
7
4
5
6

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Operator Protection Equipment
The OVERHEAD GUARD is intended to offer reasonable
protection to the operator from falling objects but cannot protect
against every impact. Therefore, it must not be considered a
substitute for good judgment and care when handling loads. Do
not remove the overhead guard.
See Figure 1 .
The SEATBELT and HIP RESTRAINT BRACKETS provide
additional means to help the operator keep the head and torso
within the confines of the truck frame and operator compartment if
a tip over occurs. This restraint system is intended to reduce the
risk of the head and torso being trapped between the truck and the
ground, but it cannot protect the operator against every potential
injury in a tip over. The hip restraint bracket will help the operator
resist side movement if the seat belt is not fastened. It is not a
substitute for the seatbelt. Always fasten the seatbelt.
See Figure 4 .
The LOAD BACKREST EXTENSION is installed to keep loose
parts of the load from falling back toward the operator. It must be
high enough, with openings small enough to prevent the parts of
the load from falling backward. If a load backrest extension that is
different from the one installed on your truck is required, contact
RICO Manufacturing or your RICO dealer.
See Figure 1 .

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Protection Against Mechanical Sparks
The periphery of the truck covered in this Operating Manual is
protected from mechanical sparks by means of bumpers or
cladding constructed of non-sparking materials.
See Figure 5 .
DO NOT operate the truck in a hazardous location if the non-
sparking material is missing or worn through to the underlying
ferrous metals.

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Figure 5. Typical Protection Against Mechanical Sparks
1. Truck Body: Aluminum Bumpers on Sides
2. Rear Counterweight: Aluminum Bumper on Back
3. Drive Hub: Aluminum Cap
4. Steer Hub: Aluminum Cap
5. Drive Tire Fender: Brass Cladding on Sides
6. Fork Shank: Brass Cladding on Front and Sides
7. Fork Blade: Brass Cladding on Front, Sides, Top, and Bottom
8. Load Backrest Extension: Brass Cladding on Front and Sides
1
2
3
4
5
6
7
8

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Nameplate
Figure 6. Nameplate
WARNING
Any changes to the truck, its tires, or its equipment can affect its
capacity, stability, or safe operation. If the truck equipment—
including the battery—does not match that shown on the
Nameplate, the truck must not be operated.

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The truck’s nameplate is located on the battery hood to the rear
and right of the seat. The nameplate contains the following
information:
•Truck model
•Truck serial number
•Type designation (EX)
•Nominal truck voltage
•Rated capacity in pounds and kilograms
•Rated load center in inches and millimeters
•MAX lift height at the rated capacity
•Alternate capacities with removable attachments or at various
load centers or lift heights
•Removable attachment information (if applicable)
•MIN and MAX service weight of battery
•Truck weight without battery
•MAX grade percentage which the truck is rated to traverse
Contact RICO Manufacturing for capacities at lift heights or load
centers not given on your truck’s nameplate.
Safety Labels
Safety labels are installed on the truck to provide information
about potential hazards. It is important that all safety labels are
present a legible.
If a label is missing or cannot be read, contact RICO
Manufacturing or your RICO dealer. Replacement part numbers
can be found in your truck’s maintenance manual.
See Figure 7 - Figure 18 .

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Figure 7 Figure 8
Notice of FM approval.
Identification of the hazardous
locations the truck is tested
and approved to operate in per
NFPA Standard 505.
Figure 9 Figure 10
Warning against servicing
electrical equipment in a
hazardous area.
EX marker on both sides and
rear of truck.
Figure 11 Figure 12
Fasten seatbelt notice.
Operator warning.

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Figure 13
Figure 14
Mast warning.
Figure 15
Tip-over warning.
No passengers warning.
Figure 16
Mast crush hazard warning.
Figure 17 Figure 18
MAX capacity warning.
Pinch or crush point hazard.

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Operator Controls
Figure 19. Operator Controls
5
14
1
12
9
11
10
3
4
2
6
7
8
15
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