Case 586G 588G Series 3 Tier 3 Forklift Operator's Manual

OPERATOR’S MANUAL FORKLIFT

586G 588G SERIES 3 TIER 3

READ, UNDERSTAND, AND FOLLOW ALL SAFETY PRECAUTIONS AND INSTRUCTIONS FOUND IN THIS MANUAL BEFORE OPERATING THE MACHINE. Bur • Issued 01April 08 Printed in U.S.A. • Book/Form Number 87657901 NA Copyright © 2007. CNH America, LLC. All Rights Reserved.

CNH America, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

All data given in this publication is subject to production variations. Dimensions and weights are only approximate. Illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your Dealer This unit first became available 04-2008 REVISION HISTORY

Issue

Issue Date

Applicable Machines

Remarks

First Edition

01April 08

586G & 588G Series 3 Tier 3 Forklift

87657901 NA

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO THE POSSIBILITY OF DEATH OR SERIOUS INJURY. Safety Decals on this machine use the words Danger, Warning, or Caution, which are defined as follows: ● DANGER: Indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury.

The color associated with Danger is RED. ● WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. ● CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. If Safety Decals on this machine are ISO two panel Pictorial, decals are defined as follows: ● The first panel indicates the nature of the hazard. ● The second panel indicates the appropriate avoidance of the hazard. ● Background color is YELLOW ● Prohibition symbols such as and STOP if used, are RED.

IMPROPER OPERATION OF THIS MACHINE CAN CAUSE DEATH OR SERIOUS INJURY. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR: ❷ Is instructed in safe and proper use of the machine. ❷ Reads and understands the Manual(s) pertaining to the machine. ❷ Reads and understands ALL Safety Decals on the machine. ❷ Clears the area of other persons. ❷ Learns and practices safe use of machine controls in a safe, clear area before operating this machine on a job site.

It is your responsibility to observe pertinent laws and regulations and follow instructions on machine operation and maintenance.

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery post, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

TECHNICAL MANUALS Manuals are available from your Dealer for the operation, service, and repair of your machine.

Contact your Dealer for assistance in obtaining the manuals for your machine. Your Dealer can expedite your order for Operator’s Manuals, Parts Catalogs, Service Manuals, and maintenance records.

Always give the Machine Name, Model, and P. I.N. (Product Identification Number) or S. N. (Serial Number) of your machine so your Dealer can provide the correct manuals for your machine.

Any use of editorial or pictorial content is strictly prohibited without express written permission from CNH America, LLC. Racine, WI 53403 U.S.A..

TABLE OF CONTENTS CHAPTER 1 GENERAL INFORMATION TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-2 1-3 1-5

CHAPTER 2 SAFETY AND SAFETY DECALS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 CHAPTER 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 OPERATORS SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 CHAPTER 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 MACHINE STABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 CHAPTER 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 LUBRICATION, FILTERS, AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 EVERY 10 HOURS (DAILY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 EVER 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 CHAPTER 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 MAINTENANCE AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 LOAD CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 SEAT BELT INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 87657901NA

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ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 CHAPTER 7 ELECTRICAL TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 CHAPTER 8 SPECIFICATIONS TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1 8-3 8-3 8-3 8-3 8-3 8-4 8-4 8-5 8-6

CHAPTER 9 INDEX CHAPTER 10 AFTER DELIVERY CHECK - DEALER COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 AFTER DELIVERY CHECK - OWNERS COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

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CHAPTER 1 - GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION TO THE OWNER

Figure 1

BD08C179-02

G SERIES FORKLIFT

This manual contains important information about the safe operation, adjustment and maintenance of your Case Forklift. Refer to the Detail Index at the end of this manual for locating specific items about your machine. The Forklift conforms to current safety regulations.

Use this manual as a guide. Your Forklift will remain a reliable working tool as long as it is kept in good working condition and serviced properly.

Do not operate or permit anyone to operate or service this machine until you or the other persons have read and understand the safety, operation and maintenance instructions in this manual. Use only trained operators who have demonstrated the ability to operate and service this machine correctly and safely.

This Forklift, with standard equipment and authorized attachments, is intended to be used for above ground material handling. This machine is not intended to be used for towing other equipment or transporting loads at high speeds.

Do Not use this machine for any application or purpose other than those described in this manual. Consult an authorized dealer of the Case Corporation on changes, additions or modifications that can be required for this machine to comply with various country regulations and safety requirements. Unauthorized modifications will cause serious injury or death. Anyone making such unauthorized modifications is responsible for the consequences.

This Operator’s Manual is to be stored in the manual compartment equipped on this machine. Make sure this manual is complete and in good condition. Contact your Dealer to obtain additional manuals. Contact your Dealer for any further information or assistance about your machine. Your dealer has Case Corporation approved service parts. Your Dealer has technicians with special training that know the best methods of repair and maintenance for your Forklift.

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BD08C215-01

Figure 2

OPERATOR’S MANUAL LOCATED IN THE LOCKING BOX LEFT OF SEAT

RIGHT, LEFT, FRONT, AND REAR OF THE MACHINE The terms Right-hand, Left-hand, Front, and Rear are used in this manual to indicate the sides as they are seen from the operator's seat.

Machine Right-Hand Side

Machine Front

BD08C178-01

Figure 3

Machine Left-Hand Side

Machine Rear

BD08C184-01

1-2

Figure 5

BD08C180-01

Figure 4

Figure 6

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CHAPTER 1 - GENERAL INFORMATION

IDENTIFICATION NUMBERS Write your machine model number, Product Identification Number (P.I.N.) and serial numbers on the lines provided below. Always give these numbers to your dealer when you need parts or information for your machine.

Make a record of the numbers. Keep the record and your Manufacturer’s Statement of Origin in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

Machine ➤ Machine Model and Type

➤ Product Identification Number: P.I.N.

➤ Year of Build

Component Serial Numbers ➤

Figure 8

BD08D010-01

Engine serial number ENGINE SERIAL NUMBER

➤ ROPS Canopy serial number

➤ Transmission serial number

➤ Drive Axle serial number

➤ Steer Axle serial number

➤ Forklift Mast serial number Figure 9

BD08C219-01

ROPS CANOPY PLATE

Figure 7

BD08C190-01

PRODUCT IDENTIFICATION NUMBER (P.I.N.)

Figure 10

BD08C180-01

FORKLIFT MAST

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Figure 11

BD08C252-01

TRANSMISSION

Figure 12

BD08C246-01

DRIVE AXLE

Figure 13

BD08C244-01

STEER AXLE

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MACHINE COMPONENTS 10 1

2

9

3

5 4

6

8 7 Figure 14

BD08C179-02

1.

2.

3.

4.

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Front Work Lamps Rear Work Lamps Operator’s Seat Grab Handles

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6.

7.

8.

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Engine Compartment Steps Drive Axle Lifting Forks

9. Standard Mast 10. ROPS Canopy 11.

12.

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5

6 8 4 7

1

3

2

Figure 15

BD08C185-02

1. Operator’s Steps 2. Steering Axle

1-6

3. Rear Counterweight 4. Grille / Radiator

5. Exhaust 6. Steering Wheel

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7. Lift controls 8. Switches

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4

1

2

5

3

6

Figure 16

BD08C220-02

1. Forward / Reverse Lever 2. Four Speed Shift Lever

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3. Brake Pedals 4. Forklift Controls

5. Key Start Switch 6. Foot Throttle

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CHAPTER 2 - SAFETY AND SAFETY DECALS

Chapter 2 SAFETY AND SAFETY DECALS TABLE OF CONTENTS SAFETY AND SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 GENERAL AND SPECIFIC SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 OPERATOR PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Personnel Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Operator - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Proper Entry And Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting And Stopping Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Fuel Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Burn Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Hazardous Chemical Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Transporting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Wheel And Tire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Roll-over Protective Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Seat Belt Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 To Fasten The Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 To Unfasten The Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Specific Precautions To This Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 READ REPAIR MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

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SAFETY AND SAFETY DECALS GENERAL AND SPECIFIC SAFETY INFORMATION WARNING: This safety alert symbol indicates important safety messages in this manual. When you see this symbol, carefully read the message that follows and be alert to the possibility of death or serious injury.

Figure 1

Most accidents involving machine operation and maintenance can be avoided by following basic safety rules and precautions. Read and understand all the safety messages in this manual, the safety manual, and the safety decals on the machine before you operate or service the machine. See your Dealer if you have any questions.

Safety Decals on this machine use the words, Danger, Warning or Caution, which are defined as follows:

• DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

• WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. Figure 2

BD08C215-01

OPERATOR’S MANUAL LOCATION AND STORAGE

READ THIS MANUAL COMPLETELY and make sure you understand the controls. All equipment has a limit. Make sure you understand the speed, brakes, steering, stability and load characteristics of this machine before you start to operate.

DO NOT remove this manual or the safety manual from the machine. See your Dealer for additional manuals. Also see the manual information on the Title pages (first and second pages in front of the Table of Contents) of this manual.

The safety information given in this manual does not replace safety codes, insurance needs or, federal, state, and local laws. Make sure your machine has the correct equipment according to these rules or laws.

• CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW. ISO two panel pictorial symbol decals are defined as follows:

• The first panel indicates the nature of the hazard.

• The second panel indicates the appropriate avoidance of the hazard.

• Background color is YELLOW. • Prohibition symbols such as

and

STOP

if

used, are RED.

Additional safety messages are used in the text of the manual to show specific safety hazards.

IMPORTANT: Safety messages in this section point out situations which can be encountered during the normal operation and maintenance of your machine.

These safety messages also give possible ways of dealing with these conditions.

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CHAPTER 2 - SAFETY AND SAFETY DECALS UTILITY SAFETY Safety precaution MUST be followed when working near buried and overhead Utility Lines.

During operation it is likely that you will be working around or near buried or overhead utility lines which may include, but are not limited to:

• • • •

Electrical Power Line Gas Line Water Line Communication Line - Telephone or Cable Television

• Sewer Line IMPORTANT: Before beginning any machine operation, it is your responsibility to be aware of all such utility lines buried and overhead in the area of your project and to avoid them.

ALWAYS have all local utility companies mark the location of their lines.

In U.S.A. and Canada call one of many “One Call System Director” services. If you do not know the local number, call the national number (U.S.A. and Canada only): 1-888-258-0808.

IMPORTANT: Check with local authorities for laws, regulations and/or strict penalties requiring you to locate and avoid existing utilities.

Figure 3

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU PERFORM ANY MACHINE OPERATION.

Know the utility color code (U.S.A. and Canada): Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Red Gas, Oil, or Petroleum. . . . . . . . . . . . . . . . Yellow Communication, Telephone, Television. . Orange Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blue Sewer . . . . . . . . . . . . . . . . . . . . . . .Green/Brown Proposed Excavation . . . . . . . . . . . . . . . . .White Surveying . . . . . . . . . . . . . . . . . . . . . . . . . . . Pink Reclaimed Water and Slurry . . . . . . . . . . . Purple After locating any buried utility lines, carefully dig a hole by hand and/or automatic vacuum equipment to the utility line to verify the location and depth of the line.

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CHAPTER 2 - SAFETY AND SAFETY DECALS OPERATOR PRECAUTIONS PROPER ENTRY AND EXIT

PERSONNEL PRECAUTIONS

• Be prepared for emergencies. Always have a first-aid kit and a working fire extinguisher with you and know how to use each.

• Avoid loose fitting clothing, loose or uncovered long hair, jewelry and loose personal articles.

• Know and use the protective equipment that is to be worn when operating this machine. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators and ear protection are examples of equipment that may be required.

• Certain protective equipment should be replaced and renewed upon age and wear. Old hard hats may not afford the original users intention. Faded and soiled vest are no longer as highly visible as original intent.

See the manufacture’s recommendation.

• Do not rush. Walk, do not run.

• Know and use the hand signals required for particular jobs and know responsibility for signaling.

who

has

the

BD08C232-01

Figure 4

• Always face the machine and use the hand holds when getting on and off. Do not rush.

• Exit the machine slowly and use the hand holds.

Do not jump down.

WARNING: Never exit the machine with the engine operating.

Figure 5

OPERATOR - GENERAL

• It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided and use the correct operating procedure. Machines should be operated only by qualified operators.

• Do not operate this machine or perform maintenance work if you have not had appropriate training and read and fully understand the instructions and warnings in this manual.

• Wear the seat belt to maximize the protection capability of the ROPS (Roll Over Protective Structure).

• Inspect the ROPS and seat belt mounting bolts on a daily basis to ensure their integrity.

• Do not permit riders on the machine if there is no manufacturer’s designated place for a rider.

• Make sure that all protective guards, canopies,

WARNING: Never exit the machine without first confirming the parking brake is set.

Figure 6

WARNING: Never exit the machine unless the forks or tools are down resting on the ground.

Figure 7

• Use the recommended hand holds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean.

• Do not jump off the machine.

• Do not dismount while the machine is in motion.

• Foreign material or grease on the steps and hand holds can cause an accident. Keep the steps and hand holds clean.

doors, etc. are in place and secure before starting and operating the machine.

• Remove all loose objects stored in the machine.

Remove all objects which do not belong in or on the machine and its equipment.

• After service has been performed, make certain all tools, parts and equipment have been cleared from the machine area.

• Do not lift personnel or allow personnel to work while standing on the forks or on other attachments. This machine is not a man-lift.

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CHAPTER 2 - SAFETY AND SAFETY DECALS Starting And Stopping Precautions

• Walk around the machine and warn all personnel who may be servicing the machine or are in the machine path prior to starting. Do not start until all personnel are clearly away from the machine.

Sound the horn, if equipped, before starting.

• Walk around the machines tool, attachment, or furthermost contact point to view operation danger area from the work site personnel view and angle.

• Check that the parking device is applied, place the transmission in neutral or park as specified by the manufacturer, before starting the machine.

• Adjust, secure and latch the seat and fasten the seat belt before starting the machine.

• Start and operate the machine only from the operator’s station.

• Use jumper cables only in the recommended manner. Improper use can result in battery explosion or unexpected machine motion.

Ventilate the battery area before using jumper cables. Make sure that using jumper cables will not interfere or harm electronic processing or computer devices.

• Do not operate the engine in an enclosed area without adequate ventilation.

• Park the machine on level ground whenever possible and apply the parking brake. On grades, park the machine with the wheels securely blocked.

• Before leaving the operator station lower the equipment to the ground and shut off the engine.

• Remove the starter key when leaving the machine parked or unattended.

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• Use the recommended transport devices when

Operating Precautions

• Check brakes, steering and other machine control devices in accordance with the manufacturer’s instructions prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to insure proper operation. If any malfunctions are found, remove the starter key. Place a DO NOT OPERATE TAG on the machine until the malfunction is corrected.

• If a failure that causes loss of control such as steering, service brakes or engine occurs, stop the machine motion as quickly as possible, remove the starter key or disconnect switch key. Place a DO NOT OPERATE TAG on the machine and keep it securely parked until the malfunction is corrected or the machine can be safely moved.

• Understand the machine limitations and keep the machine under control.

• Never transport a loaded bucket at full height.

Operate the machine with the load as low as possible until it becomes necessary to raise the boom to discharge the load into a truck, container, etc.

roading the machine.

• Before you operate at night, check that all lamps illuminate.

• If your machine has a cab make sure that all windows are clean and that the windshield wipers work correctly.

• Engine exhaust fumes can cause death. If you operate this machine in an enclosed area, make sure there is ventilation to replace the exhaust fumes with fresh air.

• Check all controls in a clear area and make sure the machine is operating correctly.

• Confirm that the attachment is properly mounted to the mounting mechanism as specified by the manufacturer.

• Dust, fog, smoke, etc., can decrease your vision and cause an accident. Stop the machine or decrease the speed until you can see.

• Contact

with high voltage power lines, underground cables, etc., can cause serious injury or death from electrocution.

• Operate and drive the machine with care and at

• Before you drive or operate in an area with high

speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

voltage lines, cables, or a power station, tell the power or utility company what you are going to do.

You MUST HAVE THE POWER DISCONNECTED OR KEEP A SAFE WORKING DISTANCE from the lines, cables, or power station. Keep all parts of the machine a safe distance away from the power source. You must also know any federal, state/provincial, or local safety codes or regulations that apply to the job site.

• Note and avoid all hazards and obstructions such as ditches, underground lines, trees, cliffs, overhead electrical wires or areas where there is danger of a slide.

• Carry loads in recommended positions for maximum stability.

• Never lift loads in excess of capacity.

• Use the recommended machine ballast and counterweighting.

• Know and understand the job site traffic flow patterns and obey signalmen, road signs and flagmen.

• Know and understand that job site conditions may change on an hourly basis. Hills of dirt, debris or obstructions may grow and change from the time you began the day. It is your responsibility to monitor the changes and keep the machine, tools and attachments, etc. a safe distance.

If a part of the machine touches high voltage power: 1. Warn other workers NOT TO TOUCH THE MACHINE and to stay away from the machine.

2. If you can break contact, reverse the operation that caused contact with the high voltage power, and move the machine away from the danger area. If you cannot break contact stay in the machine until the utility company de-energizes the line and tells you that the power is off.

• If you have extreme conditions, such as a fire, or

be under or to reach through the machine and its equipment while operating.

contact with power lines, etc. and you are forced to leave the machine, do not step off the machine.

Jump as far from the machine as possible with your feet together and do not touch the ground with your hands.

• Select a gear that will prevent excessive speed

• Do not operate the machine if you do not feel well.

• Watch for bystanders and never allow anyone to

when going downhill. Do not coast downhill.

• When roading a machine, know and use the signaling devices required on the machine.

Provide an escort for roading where required.

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This can be dangerous for you and for the people around you.

• You must make a judgment if weather, road, or earth conditions will permit safe operation on a hill, ramp, or rough ground.

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CHAPTER 2 - SAFETY AND SAFETY DECALS

• Stay away from hazardous areas such as ditches, overhangs, etc. Walk around the work area before you start and look for hazards.

• Be alert and always know the location of all workers in your area. Keep all other persons completely away from your machine. Injury or death can result if you do not follow these instructions.

• Develop fluid and smooth operating techniques and maintain the surface condition where the machine travels in order to control vibration transfer to the operator.

Maintenance Precautions

• Do not attempt repairs unless trained. Refer to manuals and experienced repair personnel for help.

• Before you service the machine, put a DO NOT OPERATE TAG on the key switch. Make sure that the machine is clearly “tagged out”.

• Never make repairs on pressurized components, fluid, gas or mechanical until the pressure has been relieved according to proper service procedures in the Repair Manual.

• Wear protective glasses and other required safety equipment machine.

when

servicing

or

repairing

the

• Wear gloves to protect hands when handling cable.

• Disconnect the battery before working on the electrical system. Know the consequences of disconnecting any electronic or computer devices.

• Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking device, place the equipment in a safe position, securely block the wheels and use extreme caution.

• Securely block the machine or any component that may fall before working on the machine or component. If possible, use a back up or secondary blocking device as well.

• To prevent unexpected movement, securely block working elements when repairing or changing working tool parts such as cutting edges.

• Use extreme caution when removing radiator caps, drain plugs, grease fittings or pressure caps.

Park the machine and let it cool down before opening a pressurized tank.

• Release all pressure before working on systems which have an accumulator.

• Use a piece of cardboard, newspaper, or wood to check for pressurized leaks to prevent fluid penetrating the skin. Pressurize accumulators with the proper gas according to manufacturer’s recommendations.

WARNING: In order to reduce the risk of fires due to the build-up of debris in the engine compartment and elsewhere on your Case Forklift. It is recommended that you clean all radiators, coolers and engine compartments daily. Failure to comply could result in serious injury or death.

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• When inflating tires, use a self-attaching inflation chuck with remote shutoff and stand clear of the tire. Position yourself beside the tire and not beside the rim.

• When absolutely necessary to tow the machine, do not exceed the recommended towing speed. Be sure the towing machine has sufficient braking capacity to stop the towed machine. If the towed machine cannot be braked, a towbar must be used or two towing machines must be used. One in front pulling and one in the rear to act as a brake. Avoid towing over long distances. It is not recommended to tow this machine.

• Observe proper maintenance procedures.

• Whenever servicing or replacing hardened pins, etc., use a brass drift or other suitable material between the hammer and pin. Alternative: Use a brass hammer, drift or suitable material on the pin, etc..

• Keep the brakes and steering systems in good

BURN PREVENTION WARNING: BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote: EXTERNAL - Flush with water.

Antidote: INTERNAL - Drink large quantities of water or milk.

DO NOT induce vomiting. Seek medical attention immediately.

EYES - Flush with water for 15 minutes and seek medical attention immediately.

WARNING: BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame, cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries. Wash hands after handling. KEEP OUT OF REACH OF CHILDREN.

operating condition.

Figure 8

• Replace all missing, illegible or damaged safety signs. Keep all safety signs clean.

FUEL HANDLING PRECAUTIONS

• Do not smoke or permit open flames while fueling or near fueling operations.

• Never remove the fuel cap or refuel gasoline engine powered machines with the engine running or hot. Never allow fuel to spill on hot machine components. Never allow fuel to spill on the environment.

• To avoid spilling fuel maintain control of the fuel filler nozzle when filling the tank.

• Do not fill the fuel tank completely to the top. Allow room for expansion.

• When the battery electrolyte is frozen, the battery can explode if, you try to charge the battery, or you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

• Hot coolant can spray out if the radiator cap is removed. To remove the radiator cap, let the cooling system cool, turn to the first notch, wait until the pressure is released, then remove the radiator cap.

• Confirm that all components, hydraulic, engine, etc., are cool procedures.

before

attempting

service

• Clean up spilled fuel immediately and dispose of contaminated material in an environmentally correct manner.

• Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufacturer’s approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

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CHAPTER 2 - SAFETY AND SAFETY DECALS SEAT BELT PRECAUTIONS

Hazardous Chemical Precautions

• If you are exposed to or come in contact with hazardous chemicals you can be seriously injured.

The fluids, lubricants, paints, adhesives, coolants, etc., used with your machine can be hazardous.

• Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling procedures, first aid measures and procedures to be taken when the product is accidentally spilled or released. MSDS are available from your Dealer.

• Before you service this machine and before you dispose of the old fluids and lubricants, always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

WARNING: Before starting the engine ensure the seat belt is securely fastened. The seat belt can help insure your safety if it is used and properly maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members. Failure to follow these instructions may result in death or serious injury.

Figure 10

TO FASTEN THE SEAT BELT

• Check with your local environmental or recycling center or your Dealer for correct disposal information.

TRANSPORTING PRECAUTIONS

• Know the rules, laws, and safety equipment necessary for transporting this machine on a road or highway.

WHEEL AND TIRE SAFETY

1

IMPORTANT: DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire must be completely removed from the rim prior to welding.

2 Figure 11

BD99J183-01

1. RETRACTABLE HALF OF THE SEAT BELT 2. BUCKLE HALF OF THE SEAT BELT

Pull the seat belt retractable half (1) across the operator and buckle securely with the buckle half (2).

TO UNFASTEN THE SEAT BELT

WARNING: Explosive seperation of the tire/rim parts can cause injury or death.

To release the seat belt, push the red bar or button on the buckle, while holding the retractable end.

Figure 9

• When tire service is necessary, have a qualified tire mechanic service the tire.

ROLL-OVER PROTECTIVE STRUCTURE

• DO NOT modify the ROPS in any manner.

Unauthorized modifications such as welding, drilling, cutting, or adding attachments can weaken the structure and reduce your protection. Replace ROPS if it is subjected to roll-over or damage. Do not attempt to repair.

WARNING: Securely fasten your seat belt.

Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Failure to follow these instructions may result in death or serious injury.

Figure 12

SPECIFIC PRECAUTIONS TO THIS MACHINE

FIRE EXTINGUISHER

• Keep the forks at ground level when moving

It is recommended that you have a fire extinguisher on your machine. Contact your Dealer for the type and location of a fire extinguisher on this machine.

• Be careful when you raise the load.

• Welding in certain areas of the forklift may require

around the work site.

the controller be disconnected and grounded.

Contact your Dealer before you weld.

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CHAPTER 2 - SAFETY AND SAFETY DECALS

SAFETY DECALS READ REPAIR MANUAL WARNING: Replace any missing or damaged safety decals and keep all safety decals clean. See your Case Dealer for new safety decals. If you can not read a decal or if a decal is missing, the result can be serious injury or death.

SC002

When a decal displays the Read Repair Manual symbol, refer to the Repair Manual for fur ther infor mation concer ning the ser vice operation, maintenance or adjustment about to be performed.

Specific information concerning this procedure will be detailed in the Repair Manual.

Make sure that you read all the safety decals and all instructional decals. Check these decals every day before you start. Clean these decals if they are not legible.

NOTE: When you clean the decals, use only a cloth, water, and soap. Do not use solvent, gasoline, etc.

You must replace a decal if the decal is damaged, missing, or can not be read. If a decal is on a part that is replaced, make sure the decal is on the new part. See your Case Dealer for new decals. Part numbers are on the decal.

READ OPERATOR’S MANUAL Decals which display the Read Operator’s Manual symbol are intended to direct the operator to the Operator’s Manual for further information regarding safety, maintenance, adjustments and/or procedures for specific areas of the machine. When a decal displays the following symbol refer to the Operator’s Manual.

BC00G075

One or both of these symbols may appear on a decal relating to safety, machine operation or servicing.

Below is a sample decal that directs the Machine Operator or Repair Technician to the Operator’s Manual for additional information concerning this procedure.

329044A1

Figure 15

Figure 13

384270A1A

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CHAPTER 2 - SAFETY AND SAFETY DECALS

1

1

2

1

2

Figure 16

BD08C213-01/BD08D011-01/384269A1/321-7040

1. 384269A1 (2) ONE LOCATED ON THE LEFT SIDE ON THE BATTERY COVER AND ONE LOCATED INSIDE THE LEFT SIDE ENGINE ACCESS DOOR ON FRAME. 2. 321_7040 (1) LEFT SIDE ENGINE COMPARTMENT ON FRAME.

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3 3

Figure 17

BD01G065/384258A1

3. 329044A1

4

4

Figure 18

BD01G066/384267A1

4. 384267A1 (2) ONE EACH SIDE FRAME RAIL AT REAR OF ENGINE COMPARTMENT.

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CHAPTER 2 - SAFETY AND SAFETY DECALS

5 5

Figure 19

BD08C206-01/321_7030

5. 321-7030 (2) ONE EACH SIDE.

This decal is located on the front, upper ROPS posts.

6

6

6

Figure 20

BK99A021/102929A1

6. 383971A1 (3)

This decal is located on the rear and both sides of the forklift mast.

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7

7

Figure 21

BD08C212-00/D87486

7. D87486

.

8

8

Figure 22

BD08C209-01/347909A1

8. 347909A1

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CHAPTER 2 - SAFETY AND SAFETY DECALS

9 9

Figure 23

BD08C211-01/D150900

9. D150900

12 12

Figure 24

BD08C202-01/8603092

10. 8603092 (1) TOP, FRONT OF RIGHT SIDE ENGINE ACCESS PANEL.

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Figure 25

328904A1

1. ACCUMULATOR WARNING DECAL

(1) Located under left side frame near batter y compartment (if equipped).

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CHAPTER 2 - SAFETY AND SAFETY DECALS

HAND SIGNALS It is recommended that you, and the flagman on the job use hand signals for commumication. Before you start, make sure that you both understand the signals that will be used.

Figure 29

BP97D040

TILT FORKS UP

BI97D045

Figure 26

STOP

Figure 30

BP97D039

TILT FORKS DOWN

BI97D035

Figure 27

RAISE LOAD

Figure 31

BI97D043

MOVE LOAD BACKWARD

BI97D044

Figure 28

LOWER LOAD

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Figure 32

BI97D036

MOVE LOAD FORWARD

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

Chapter 3 INSTRUMENTS AND CONTROLS TABLE OF CONTENTS INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Brake Pedal Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Forklift Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Auxiliary Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Seat Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 OPERATORS SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Fasten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storage Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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INSTRUMENT PANEL

3

2

1 4

Figure 1

BD08C223-01

NOTE: When the key switch is turned to the ON position, all warning lamps should illuminate momentarily and then go off except for the engine oil pressure warning lamp and the alternator warning lamp.

1. Systems Normal Indicator (Green) When the machine is in operating condition and all systems are in working condition this lamp will be illuminated.

3. Hydraulic Filter Warning Lamp (Yellow): If the hydraulic filter becomes restricted, this lamp will illuminate. Service immediately. During cold temperature start up, the warning lamp will stay lit until the hydraulic system reaches operating temperature. If the warning lamp remains illuminated after operating temperature is achieved, check the hydraulic filter for restriction. The systems normal indicator lamp will go out but the warning alarm will not sound.

Figure 2

2. Fuel Level Gauge: This symbol indicates the fuel level gauge, which is located to the left of the symbol.

The gauge consists of a series of lamps that indicate the level of fuel in the fuel tank. When all of the lamps are illuminated the fuel tank is full. When four (4) of the lamps are illuminated the fuel tank is half full. When the bottom lamp flashes, the fuel tank is empty.

Figure 3

BS98M034

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BS98M025

Figure 4

4. Air Filter Warning Lamp (Yellow): This warning lamp illuminates when the engine air filter becomes restricted and requires service. Service immediately. The systems normal indicator lamp will go out but the warning alarm will not sound.

BS98M026

Figure 5

3-3

CHAPTER 3 - INSTRUMENTS AND CONTROLS

5

7

6

8

Figure 6

BD08C223-01

5. Engine Oil Pressure Warning Lamp (Red): This lamp illuminates when the engine is running and the engine oil pressure is too low. The warning alarm will sound and the systems normal indicator lamp will go out.

Stop the engine and check for the problem.

BS98M030

3-4

NOTE: This lamp illuminates when the

engine is running and the engine temperature is too high. The warning alarm will sound and the systems normal indicator lamp will go out. Stop the engine and check for the problem.

Figure 7

6. Alternator Warning Lamp (Red): This lamp illuminates when the engine is running and there is a problem with the alternator. Make sure the engine speed is at full throttle to check this warning lamp.

The systems normal indicator lamp will go out but the warning alarm will not sound.

Stop the machine and check the alternator charging system.

BS98M031

7. Engine Coolant Temperature Warning Lamp (Red):

Figure 9

BS98M027

8. Converter Oil Temperature (Red): NOTE: This lamp illuminates when the

transmission oil temperature raises above 107° C (225° F). The warning alarm will sound and the systems normal indicator lamp will go out. Stop the engine and check for the problem.

Figure 10

BS98M028

Figure 8

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

9

11 10

Figure 11

BK99A029

9. Battery Warning Lamp (Red): This lamp illuminates when the battery voltage falls below 10 volts. The systems normal indicator lamp will go out but the warning alarm will not sound.

Figure 12

BS98M032

10. Park Brake Engaged (Red): This lamp is illuminated when the direction control lever is moved from the “NEUTRAL” position and the parking brake is engaged. The systems normal indicator lamp will go out. The warning alarm will sound and will continue until the direction control lever is placed back to the “NEUTRAL” position or the parking brake is released. DO NOT drive the machine with the parking brake applied.

Figure 13

BS98M029

11. Hourmeter: The hourmeter shows the total hours of engine operation in hours and tenths of an hour. Use the hourmeter to measure the time between the maintenance intervals. Hourmeter is activated by engine oil pressure.

Figure 14

BS98M027

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

1 2

3

4

5 6 Figure 15

BD08C188-02

1. Horn Switch: Push the rocker switch icon to sound the horn.

Figure 16

BS98M064

4. Driving Lamp Switch: Push the rocker switch icon to turn the driving lamps on. push the opposite end of the rocker switch to turn the driving lamps off.

2. BLANK

BC02N191

Figure 19

BS98M062

5. Flasher Lamp Switch: Push the rocker switch icon to turn the flashers on. Push the opposite end of the rocker switch to turn the flashers off.

Figure 17 Figure 20

BS98M063

3. Rear Work Lamp Switch: Push the rocker switch icon to turn the rear work lamps on. Push the opposite end of the rocker switch to turn the rear work lamps off.

BS98M061

3-6

Figure 18

6. Turn Signal Switch: Push the left side of the rocker switch icon to signal a left turn. Push the right side of the rocker switch to signal a right turn.

Move the rocker switch to the center after the turn has been made to stop the signal.

Figure 21

BS98M065

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

7

8

Figure 22

BD08C186-02

7. Differential Lock Switch: To engage, press and hold the differential lock switch. To disengage, release the differential lock switch.

Figure 23

BS98M066

8. 4wd Steer Axle Switch Equipped): To engage, the steer axle, push rocker switch icon. To disengage steer axle, push the opposite end of rocker switch.

(If the the the

NOTE: When the steer axle is engaged, operate the machine only in first or second gear. It is recommended that you disengage the steer axle before you operate on a hard surface or in third or fourth gear.

Figure 24

BC02N191

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

9

10 Figure 25

BD08C186-02

9. CLUTCH CUTOUT SWITCH: RIGHT SIDE OF ROCKER SWITCH DEPRESSED: When you push the brake p e d a l s, t h e t r a n s m i s s i o n r e m a i n s engaged. Use this position when moving a load slowly into a tight place.

LEFT SIDE OF RO CKER SWITCH DEPRESSED: When the switch is in this position and you push the brake pedals, the transmission is disconnected from t h e e n g i n e . U s e t h i s p o s i t i o n fo r maximum hydraulic power.

BS98M061

10. ENGINE PRE-HEAT INDICATOR LAMP Turn the key switch to ON. When the incoming air needs to be preheated, due to cold temperatures, The lamp will illuminate. Wait until the lamp goes off before turning the key switch to the start position.

Figure 28

BC02N191

Figure 26

The clutch cutout control can affect braking of this machine as follows: Left side of clutch cutout switch depressed: When you depress the brake pedal, the transmission is disconnected from the engine. Thus “engine braking� is not available to assist in stopping the machine.

Right side of clutch cutout switch depressed: The engine and transmission remain connected even if you depress the brake pedals. At high engine speeds, the brakes may not be able to stop the machine.

WARNING: Do not work this machine or drive on roads until you are completely familiar with the operation of the clutch cutout control.

Figure 27

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CHAPTER 3 - INSTRUMENTS AND CONTROLS 11. KEY SWITCH: The key switch has four positions: ACCESSORY POSITION This position energizes the accessory switches and instrument cluster.

ENGINE STOP (OFF POSITION) To stop the engine, turn the key to STOP. After the engine has stopped, remove the key.

ENGINE ON (ON POSITION) Turn the key clockwise to ON and check the warning lamps. This is the normal position of the key switch when the engine is running.

ENGINE START (START POSITION) Turn the key completely clockwise to the START position to actuate the starter motor. After the engine starts, release the key. The key will return automatically to ON.

11

Figure 29

BS98M031/BS99J175/BS99J178/BS99J176

BD08C186-01 / BS98N062

Figure 30

INSTRUCTIONAL DECAL FOR KEY SWITCH

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

2 1

3 BD08C214-01

Figure 31

1. DIRECTION CONTROL LEVER: This lever controls the travel direction of the machine. The c e n t e r p o s i t i o n i s N E U T R A L . To t r a ve l FORWARD, lift the lever and push completely forward. To travel in REVERSE, lift the lever and pull completely rearward. Make sure the direction control lever is in NEUTRAL before you start the engine. Before shifting into or out of a position, make sure to stop the machine completely with the brakes.

The direction control system has an impor tant feature. When a fault signal is sensed in the direction control electrical circuits, the transmission will shift into NEUTRAL.

Figure 32

BK99A033

2. TRANSMISSION SHIFT LEVER: The transmission has synchromesh in all four gears.

You can shift to any gear without stopping the machine. Push the clutch cutout button on the transmission shift lever before you shift. Release the button to engage the clutch after the shift.

NOTE: When shifting to a lower gear, reduce the travel speed before you shift.

3. CLUTCH CUTOUT BUTTON: Push this button before you shift the transmission gears. The transmission is in NEUTRAL when this button is pushed.

If the direction control lever is in the NEUTRAL position when the fault is sensed, the transmission will remain in NEUTRAL. If the lever is in FORWARD or REVERSE travel positions when a fault is sensed, t h e t r a n s m i s s i o n w i l l r e m a i n e n g a g e d fo r approximately five seconds before shifting into NEUTRAL. NOTE: By moving the direction control lever to the position of travel opposite that which is desired, and then to the position of the desired direction, the transmission will again engage for approximately five seconds. This procedure is to be used ONLY in the event of an emergency when the machine must be moved to a safe location. Have the machine repaired immediately.

3-10

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

5

4

3

2

1

Figure 33

BD08C220-02/BD08C217-01/BD08C218-01

1. FOOT THROTTLE: Push down on the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed.

2. RIGHT BRAKE PEDAL: (With Brake Pedal Lock Disengaged) Push this pedal to help turn the machine to the right.

3. LEFT BRAKE PEDAL: (With Brake Pedal Lock Disengaged) Push this pedal to help turn the machine to the left.

BRAKE PEDAL LOCK 4. Brake Pedals Disengaged: Slide the brake pedal lock to the left to operate the brake pedals separately.

5. Brake Pedals Engaged: Slide the brake pedal lock rod to the right, locking both brake pedals together.

WARNING: Always lock the brake pedals together before you travel on roads or when you operate the machine in 3rd or 4th gear. See the instructions in this manual for brake pedals.

If these procedures are not followed, serious injury or death can occur.

SB05

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Figure 34

3-11

CHAPTER 3 - INSTRUMENTS AND CONTROLS PARKING BRAKE

BD08C201-01

Figure 35

Pull the control lever UP to engage the parking brake.

BD08C200-01

Figure 36

Push the control lever DOWN to disengage the parking brake.

WARNING: The parking brake will not hold this machine from moving if one drive wheel is raised above the ground. Before raising one drive wheel above the ground, always block the front and rear of the other three wheels.

50-02

Figure 37

NOTE: A warning alarm will sound if you shift the direction control lever into FORWARD or REVERSE while the parking brake is engaged.

For adjustment of the Parking Brake see PARK BRAKE ADJUSTMENT in Chapter-Page 6-6 in this manual.

IMPORTANT: You can damage the parking brake, which is also the service brake, if you move the machine and the parking brake is applied.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS FORKLIFT CONTROLS

1

1

5

3

3 5

2 2

4

6

Figure 38 LEVERS SHOWN IN HOLD POSITION (RIGHT). THE FORKS AND MAST WILL STOP MOVING WHEN THE CONTROL LEVER IS IN “HOLD”. WHEN RELEASED, THE CONTROL LEVER WILL RETURN TO “HOLD” AUTOMATICALLY.

6

321_3902

Figure 39

BS98N153

4

BD08C208-01

Figure 42

BS98N156

Figure 43

4. TILT MAST REARWARD

1. LOWER FORKS (DOWN)

Figure 40

BS98N154

2. RAISE FORKS (UP)

BS98N157

Figure 44

5. SIDE SHIFT LEFT

Figure 41

BS98N155

3. TILT MAST FORWARD

BS98N179

Figure 45

6. SIDE SHIFT RIGHT 87657901NA

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3-13

CHAPTER 3 - INSTRUMENTS AND CONTROLS AUXILIARY CONTROLS

1

BK99A038

Figure 46

1. AUXILIARY CONTROL LEVER

This option allows the operator to install hydraulically actuated attachments. Actuate the attachment by moving the control lever. Follow the instructions given by the manufacturer of the attachment.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATOR’S SEAT SEAT CONTROLS WARNING: An accident or sudden machine movement can cause serious injury or death.

Always fasten the seat belt and adjust the seat before you start this machine.

2 1

3 4 Figure 47

BK99A039

The standard operator’s seat can be moved forward or rearward.

The deluxe suspension operators seat can be raised, lowered, moved forward and rearward. You can also adjust the seat backrest. For added operator comfort there is a weight adjustment for ride firmness.

1. WEIGHT ADJUSTMENT CONTROL: Turn the weight adjustment control knob either clockwise (increase) or counterclockwise (decrease) to set the arrow on the graduated scale at your weight.

2. BACKREST TILT ADJUSTMENT CONTROL: Raise the lever and tilt the seat backrest until it is comfortable for you. Releasing the lever will lock it in place.

3. FORWARD/REARWARD CONTROL: Raise the lever to move the seat forward or rearward.

Release the control lever and make sure the seat is locked in position 4. HEIGHT ADJUSTMENT CONTROL: Pull the height control lever up and adjust the height of the seat. Release the control lever and make sure the seat is locked in position.

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

OPERATORS SEAT BELT The illustrations that follow show the correct procedure to fasten and release the belt.

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine. Failure to follow these instructions may result in death or serious injury.

SA080

TO FASTEN Pull the right-hand belt from holder. Fasten the belt end into the left-hand buckle.

Figure 50

BD02M168-01

RELEASE BAR

STORAGE BOX

1

2

Figure 48

BD02M167-01

Make sure the belt end and buckle are securely fastened. The left-hand receiving end of the belt (buckle) will not pull out.

Figure 51

BK99A040

1. STORAGE BOX 2. LOCKING LATCH

TO RELEASE There are two releases on the belt. To release the seat belt, push the red button or the red bar on the buckle.

Figure 49

BD02M169-01

RELEASE BUTTON

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CHAPTER 3 - INSTRUMENTS AND CONTROLS

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CHAPTER 4 - OPERATING INSTRUCTIONS

Chapter 4 OPERATING INSTRUCTIONS TABLE OF CONTENTS RUN-IN PERIOD OF A NEW MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking Brake Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking the Machine and Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 4-3 4-3 4-4 4-4 4-4

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before You Start Each Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Transmission Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Machine Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating On A Hill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Moving A Disabled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5 4-5 4-6 4-6 4-7 4-8 4-9

TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 OPERATING IN COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 BOOSTER BATTERY CONNECTION TO MACHINE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 MACHINE STABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 LIFTING CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Limit Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Certification Label On Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting The Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vandal Lockup Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Control System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4-14 4-16 4-17 4-17 4-18 4-18

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CHAPTER 4 - OPERATING INSTRUCTIONS

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CHAPTER 4 - OPERATING INSTRUCTIONS

RUN-IN PERIOD OF A NEW MACHINE ENGINE OPERATION During the first 20 hours of operation, or if you rebuild the engine, make sure you do the following: 1. Operate the machine with normal loads for the first eight hours.

2. Keep the engine at normal operating temperature.

3. Do not run the engine at idle speeds for long periods of time.

BRAKE PEDAL Check the operation of the brake on a hard level surface when the machine is new.

WARNING: Before starting engine, study Operator’s manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operation. It is your responsibility to understand and follow the manufacturer’s instructions on machine operation, service, and to observe pertinent laws and regulation. Operator’s and Repair manuals can be obtained from your Dealer.

SB055

ENGINE OPERATION WALK-AROUND INSPECTION Do the following items each day before you start the engine.

1. Check for leaks under the machine.

2. Check the tires for damage.

3. Check the forks and mast for wear, damage or missing parts.

4. Check the machine for debris, especially around the engine area and radiator. Make sure these areas are clean.

5. Clean or replace any safety or instructional decals that cannot be read.

6. Clean the steps, hand rails, and operator’s compartment. Remove any loose items in the operator’s compartment.

7. See the Lubrication/Maintenance Chart in this manual and do the items under 10 Hours.

NOTE: If this is a new machine, or a machine with a newly rebuilt engine, See the Run-in Period section in this manual for additional information.

STARTING THE ENGINE NOTE: If the weather is cold, if the machine has not been run for several weeks, or if the engine oil filter has been replaced, see Priming the Turbocharger Lines with Oil in this manual.

3. Make sure the lift control levers are in NEUTRAL with the equipment on the ground.

4. Sound the horn to alert those around the machine that you intend to start.

NOTE: See Operating in Cold Weather in this manual for starting the engine during cold weather.

5. Turn the key switch to the ON position. Wait for approximately 2 seconds while the cluster goes through self test.

6. Turn the key switch to the START position. If the engine star ts and stops, do not engage the starter motor again until the starter motor stops turning.

NOTE: Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for three minutes before you engage the starter motor again. While the starter motor is engaged, white or black smoke must be seen at the exhaust pipe. If no smoke is seen, check the fuel supply.

7. After the engine starts, check the instruments to make sure the gauge indications are correct.

Run the engine at 1000 rpm until the coolant temperature is warm.

1. Adjust the seat and fasten your seat belt. Make sure you can push the brake pedal completely down with your back against the seat cushion.

2. Make sure the parking brake is engaged, the transmission shuttle control and the transaxle control levers are in the neutral position.

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4-3

CHAPTER 4 - OPERATING INSTRUCTIONS ENGINE SPEED WARNING: Raised equipment on the machine without an operator can cause injury or death. Before you leave the operator’s compartment, always support or lower the equipment (backhoe, blade, boom, bucket, etc.) to the ground and stop the engine.

Failure to follow these instructions may result in death or serious injury.

Do not run the engine at idle speed for long periods.

This can cause a low operating temperature, which can cause acids and deposits in the engine oil. It is recommended that you run the engine at full throttle when operating conditions permit and when safe.

IMPORTANT: Turbocharged Engines: If the engine stalls during normal operation, start the engine immediately. This will prevent damage to the turbocharger.

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

PARKING BRAKE CHECK Check the operation of the parking brake after the first 100 hours of operation. Make sure the area is clear of other persons. Apply the parking brake and shift the transmission to third gear. Shift the transmission direction control to FORWARD and increase the engine speed to 1500 r pm. The machine must not move.

Figure 2

SA044

Figure 3

SA038

IMPORTANT: If the machine moves, adjust the parking brake. See the Maintenance and Adjustments chapter.

PARKING THE MACHINE AND STOPPING THE ENGINE 1. When the work day is finished, make sure the machine is parked on level ground.

IMPORTANT: If you must temporarily park the machine on a hillside, put the front of the machine toward the bottom of the hill. Make sure the machine is behind an object that will not move.

2. Lower the forks to the ground.

3. Apply the parking brake and shift the transmission shuttle control lever to NEUTRAL. 4. Run the engine at an idle speed for a few minutes if the engine has been working with a heavy load. This decreases the temperature of the engine parts evenly.

IMPORTANT: The turbocharger may be damaged if the engine is not properly shut down.

5. Make sure the engine is at lowest idle.

6. Turn the key switch to OFF to stop the engine.

WARNING: Movement of the machine without an operator can cause serious injury or death. To prevent machine movement, park the machine properly.

Figure 1

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CHAPTER 4 - OPERATING INSTRUCTIONS

MACHINE OPERATION Be a careful operator, you can prevent accidents.

Read the following information.

WARNING: Always know the location of all workers in your area. Warn them before you start working the machine. Always keep all other persons away from your area. Serious injury or death can result if you do not follow these instructions.

Figure 4

SA015

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

WARNING: Hillside operations can be dangerous. Rain, snow, ice, loose gravel, soft ground, etc., change the ground conditions.

You must make a judgment if your machine can be safely operated on any hillside or ramp.

SB013

The operating tips given in this section do not include all possible conditions. This is basic information that can help you move more material in less time.

If you are a new operator, always operate the machine in an open area at decreased speed until you know the function of each control.

Figure 5

SA080

WARNING: DO NOT operate the machine while under the influence of alcohol or drugs.

Figure 6

CM112

WARNING: This machine is designed and intended for handling materials. A forklift is not designed to lift people. DO NOT use a forklift to lift people.

Figure 7

BEFORE YOU START EACH DAY

Figure 8

BD99J183-01

1. Adjust the seat and fasten your seat belt. Make sure you can push the brake pedal completely down with your back against the seat cushion.

2. Turn the ignition switch to ON and monitor the display gauges.

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4-5

CHAPTER 4 - OPERATING INSTRUCTIONS SELECTING TRANSMISSION GEARS

SELECTING MACHINE DIRECTION

Transmission

Machine Direction

The transmission is synchronized in all gears. You can shift to any gear without stopping the machine.

Before you shift gears, push the clutch cutout button.

1 1

2 Figure 10

BD08C214-01

1. DIRECTION CONTROL LEVER BD08C209-01

Figure 9

1. TRANSMISSION SHIFT LEVER 2. CLUTCH CUTOUT BUTTON

To move forward: Lift the direction control lever and push completely forward (up).

To move in reverse: Lift the direction control lever and pull completely rearward (down).

WARNING: The clutch cutout control can affect braking of this machine as follows:

The center position is NEUTRAL. The direction control lever must be in the NEUTRAL position before you can start the engine.

WARNING: Clutch cutout control in OFF position: When you depress the brake pedal, the transmission is disconnected from the engine. Thus “engine braking” is not available to assist in stopping the machine.

NOTE: For smooth operation before you change directions, reduce the engine speed.

WARNING: Clutch cutout control in ON position: The engine and transmission remain connected even if you depress the brake pedals. At high engine speeds, the brakes may not be able to stop the machine.

WARNING: Do not work this machine or drive on roads until you are completely familiar with the operation of the clutch cutout control.

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CHAPTER 4 - OPERATING INSTRUCTIONS Operating The Machine

DIFFERENTIAL LOCK When conditions are encountered where one drive wheel is spinning, stop the wheels and engage the differential lock to obtain traction from both front wheels.

NOTE: You can engage the differential lock when the machine is moving in a straight line forward or reverse.

IMPORTANT: You can cause damage to the transmission if you try to engage the differential lock when the machine is turning or if one front wheel is rotating faster than the other front wheel.

When the Machine is Stuck 1. Reduce the engine speed and stop the wheels from rotating.

WARNING: Tip over Hazard - The forklift will tipover if the counterweight is removed from the machine before the lift mast is removed. To avoid tipover remove the lift mast first.

Figure 12

WARNING: Know the rules, laws and safety equipment necessary for transporting or operating this machine on a road or highway.

Rotating beacon, backup alarm, slow moving vehicle emblem and other safety equipment items are available from your Dealer.

Figure 13

WARNING: Prevent accidents when you move the machine around the job site. Know the rules for movement of people and machines on the job site. Follow the instructions of the flagman, signals and signs.

1

Figure 14

When driving for any distance around the job site or when dr iving on the highway, raise the for ks approximately 152 mm (6 inches) from the ground and tilt the mast back. Your travel speed must be slow enough to maintain complete control of your machine at all times.

Figure 11

BD08C186-01

1. DIFFERENTIAL LOCK SWITCH

2. Push and hold down on the differential lock switch.(1) 3. Release the differential lock switch once traction has been regained.

If the load has to be raised above the height of the main mast, make sure load is secured by tying, banding, etc. If load is loose, do not have load higher than the fork backing plate.

NOTE: Avoid prolonged converter to hydraulic stall (avoid exceeding 10 seconds of stall). Overheating of the converter and hydraulic oil could cause damage.

NOTE: The differential lock will release automatically when the load is removed or when the clutch cutout button is pushed.

Before You Operate Through a Soft or Muddy Area 1. Before you move the machine through an area that is soft or muddy, make sure that one of the front wheels is not rotating faster than the other front wheel.

2. Push down the differential lock switch. Keep this switch pushed down while you move the machine through the soft or muddy area.

3. After you have moved through the area, release the differential lock switch.

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CHAPTER 4 - OPERATING INSTRUCTIONS OPERATING ON A HILL WARNING: Hillside operation can be dangerous. Rain, snow, loose gravel, soft ground etc., change the ground conditions.

You must make a judgement if your machine can be safely operated on any hillside or ramp.

WARNING: Before you operate on any hillside or ramp, always select low gear and never coast down the hill with the transmission in the NEUTRAL position. The machine can go out of control and roll over if you do not follow these instructions.

Figure 15

Before you operate the machine on a hill, always put the transmission in a lower gear and test your brakes.

DO NOT let the machine move down the hill with the transmission in NEUTRAL. When driving down a hill put the clutch cutout lever in the DRIVE position.

Side shifting the Forks The side shift option is used to move the load from s i d e t o s i d e . A l w ay s c e n t e r t h e l o a d w h e n transporting.

WARNING Secure the load to prevent shifting or other uncontrolled load movement.

Clear the area of all personnel.

Be sure to fasten the seat belt.

If conditions permit, consider backing down the hill for improved load and machine control.

Figure 16

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CHAPTER 4 - OPERATING INSTRUCTIONS MOVING A DISABLED MACHINE

8. Release the parking brake.

If your machine is disabled, you must make a judgement if the machine can be moved without more damage. If possible, repair the machine at the job site.

9. No riders - keep all other persons completely out of the area.

The towing machine must have power, steering and braking ability to stop both machines. The speed at which the disabled machine is moved must not exceed 1/2 mile per hour (2.4 km/h).

The machines must be attached as closely as possible.

10. Tow the disabled machine at a maximum speed of 1/2 mph (2.4km/h). DO NOT exceed this speed.

Engine Stopped (2WD and 4WD) 1. Apply the parking brake.

2. Block the wheels with wheel chocks.

The disabled machine must be moved only far enough to reach a safe repair location or onto a trailer.

3. Shift the direction control lever and transmission control to NEUTRAL.

Before moving a disabled machine you must be able to answer the following questions:

5. Raise the forks as required. Use a hoist to raise the carriage and actuate the control for the forks to the RAISE position as you lift the carriage.

Attach an acceptable chain around the carriage and the tie bar at the top of the mast that will hold the carriage in position.

• Does the towing machine have braking and steering capacity for both machines?

• Does the towing hardware, chains, cables have the proper capacity to move the machine safely?

• Will the disabled machine have steering and braking capability?

• Will moving the machine cause damage to the drivetrain or any other moving parts that lack lubrication?

4. Place the 4WD switch in NEUTRAL, if equipped.

6. Attach a rigid drawbar to the machine. Make sure the towing machine has enough power and braking ability to move and stop both machines.

7. Disconnect the front driveshaft on 2WD machines and both front and rear driveshafts on 4WD models.

Additional considerations:

8. Remove the wheel chocks.

• Be certain that all personnel involved are shielded

9. Release the parking brake.

in the event that the towing apparatus may break.

• An operator may only be allowed on the disabled machine if it has steering and braking capability.

• Always block the disabled machine’s wheels before releasing component.

the

brakes

or

10. No riders - keep all other persons completely out of the area.

IMPORTANT: If you must tow the machine DO NOT exceed 2.4 km/h (1/2 mph).

drivetrain

IMPORTANT: The forklift engine may not be started by towing the machine. The drivetrain components will be damaged!

Engine Running (2WD and 4WD) 1. Apply the parking brake and raise the forks.

2. Block the wheels with wheel chocks.

3. Shift the direction control lever and transmission control to NEUTRAL. 4. Place the 4WD switch in NEUTRAL, if equipped.

5. Raise the forks off the ground.

6. Attach a rigid drawbar to the machine. Make sure the towing machine has enough power and braking ability to move and stop both machines.

7. Remove the wheel chocks.

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CHAPTER 4 - OPERATING INSTRUCTIONS

TRANSPORTING THE MACHINE WARNING: The machine can slip and fall from a trailer or ramp and cause injury or death. Make sure the trailer and ramp is not slippery. Remove all oil, grease, ice, etc.

Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp.

SB042

You must know the rules or laws for safety that are used in each area that you will be in. Make sure that your truck and crawler are equipped with the correct safety equipment.

Figure 18

BD08C204-01

FRONT TIE DOWN (1 EACH SIDE)

1

1

B835873F-01

Figure 17

1. Put a block on both sides of the trailer wheels.

2. Lock brake pedals together, make sure your seat belt is fastened and then carefully move the machine slowly onto the trailer.

3. Lower the forks to the trailer.

4. Shift the direction control lever and the transmission control to NEUTRAL and apply the parking brake.

5. Stop the engine and remove the key.

6. Put a block at the front and rear of each tire.

7. Use chains and binders and fasten the machine to the trailer, using the front and rear tiedowns.

Figure 19

BD08C203-01

REAR TIE DOWN (1 EACH SIDE)

8. If the machine is to be transported for a long distance, it is recommended the forks chains are secured to the mast.

9. Measure the distance from the ground to the highest point of the machine. You must know the clearance height of the machine. Put this dimension into the cab of the truck.

10. After you have driven a few miles, stop the truck and check your load. Make sure the chains are still tight and that the machine has not moved on the trailer.

11. UNLOADING - After the chains and blocks are removed from the machine, fasten your seat belt, star t the engine, raise the for ks, shift the transmission to 1st gear, release the parking brake, and drive slowly off the trailer.

WARNING: When moving the machine on or off of the trailer, drive slowly and keep the machine centered on the trailer and ramp.

Figure 20

CM113

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CHAPTER 4 - OPERATING INSTRUCTIONS

OPERATING IN HOT WEATHER To prevent damage to the machine, do the following: 1. Keep the coolant at the correct level in the coolant reservoir and in the radiator.

2. Test the radiator cap before hot weather starts.

Replace the cap as required.

3. Clean all dirt and debris from the radiator and engine area daily.

4. Check the condition of the fan drive belt.

5. Use lubricants of the correct viscosity.

6. Use the correct solution of ethylene glycol and water in the cooling system.

7. Check the dust valve for the air cleaner more frequently during extreme dust conditions.

8. Check the battery at 250 hours when conditions require.

9. Clean dirt from the precleaner daily.

4. COOLING SYSTEM: Check the coolant mixture before you operate in cold temperatures. A mixture of 50% ethylene glycol and 50% water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37°C (-34°F). If the ambient temperature is lower, adjust the mixture to 60% ethylene glycol and 40% water. It is recommended that ethylene glycol and water be used in your machine all year.

5. COLD TEMPERATURE STARTING AIDS: See your Dealer for extra starting aids such as battery heater, coolant heater, engine oil heaters, etc.

6. GENERAL: Before you operate, move the machine slowly in LOW gear and actuate each hydraulic control for about ten minutes.

WARNING: This machine can be equipped with an engine pre-heating system. DO NOT use ether for cold weather starting.

Figure 21

OPERATING IN COLD WEATHER Cold weather conditions cause special problems.

During these conditions, your machine will require special attention to prevent serious damage. Cold weather maintenance will extend the service life of your machine.

1. BATTERY AND ELECTRICAL SYSTEM: Clean the battery and make sure the battery is at full charge.

NOTE: A fully charged battery at -17°C (0°F) has only 40 percent of the normal starting power.

Then, when the temperature decreases to -29°C (-20°F), the battery has only 18 percent of the power remaining.

If you add water to the battery and the temperature is below 0°C (32°F), make sure you charge the battery or run the engine for approximately two hours. This procedure will prevent battery freezing.

Inspect the battery cables and terminals.

2. LUBRICANTS: Use the correct viscosity oil in each component. As an example: SAE 30 engine oil at 0°C (32°F) increases the starting load by about 250 percent. Make sure you follow the recommended oil and filter service as shown in this manual.

STARTING THE ENGINE 1. See Starting the Engine page 4-3 and use the correct procedure to start the engine.

2. Turn the key switch to ON and watch the right side switch panel, just above the key start switch.

If the temperature is too low, and engine pre-heating is required the engine pre-heating lamp will illuminate. If the lamp does illuminate, wait until it goes out, before cranking the engine.

3. Hold the foot throttle at the 1/2 throttle position and hold until the engine starts.

4. Actuate the starter motor.

NOTE: Do not operate the starter motor more than 30 seconds at one time. Let the starter motor cool for three minutes before you engage the starter motor again. While the starter motor is engaged, white or black smoke must be seen at the exhaust pipe. If no smoke is seen, check the fuel supply.

3. FUEL SYSTEM: Check with your fuel supplier for the correct cold weather fuel. Engine power will be reduced if wax particles are in the fuel filters.

Make sure to check for water in the fuel system. Cold temperatures can cause water to collect in the fuel tank. Check the first stage fuel filter for water. If no water is found, extend the interval.

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CHAPTER 4 - OPERATING INSTRUCTIONS

BOOSTER BATTERY CONNECTION TO MACHINE BATTERY WARNING: Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries.

SA031

Two persons are required for this procedure. Make sure the person making the connection is wearing face protection.

1. Sit in the operators seat and have the other person make the connections. Make sure the booster battery is 12 volts.

2. If using another machine for power, make sure the two machines do not touch.

3. Connect the positive (+) jumper cable to the positive (+) terminal as shown.

4. Connect the negative (-) jumper cable to a good frame ground away from the battery.

5. See Starting the Engine in this manual and use the correct procedure to start the engine. Have the other person disconnect the negative (-) jumper cable first and the positive (+) jumper cable last.

2 1

BD08C239-01

Figure 22

1. POSITIVE (+) JUMPER CABLE 2. NEGATIVE (-) JUMPER CABLE

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MACHINE STABILITY

2

3 1 Figure 23

BS98N054

1. FULCRUM POINT 2. COUNTERWEIGHT AND MACHINE WEIGHT 3. MAST AND LOAD WEIGHT

The drive wheel axle is the fulcrum or pivot point on which the weight of the forklift and its load is balanced against the weight of the machine and its attached counterweight.

For purposes of operating stability, the weight of the machine and counterweight is always kept greater than the weight of the forklift and its load.

WARNING: Always know the location of all workers in your area. Warn them before you start working the machine. Always keep all other persons away from your area. Serious injury or death can result if you do not follow these instructions.

Figure 25

The relation between machine and the load is altered by changes in:

• • • •

Load weight and it’s load center.

Load movement on the forks.

The load height.

Changes in the motion of the machine and the grade on which it is moving.

• Soft areas, holes and other ground hazards.

• Machine stability must be maintained while these factors constantly change during forklift operation.

WARNING: The forklift is less stable as the load is lifted higher.

Figure 24 87657901NA

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CHAPTER 4 - OPERATING INSTRUCTIONS

LIFTING CAPACITIES Machine stability is maintained only when the forklift handles loads within its rated lifting capacity and the conditions listed above.

The lifting capacity of a forklift is determined by the safe height and weight limits of the load. An overload on the forks makes the machine unstable, hard to handle, and in danger of tipping over.

WARNING: Do not try to lift or haul loads that exceed the rated capacities of the forklift.

Figure 26

Load Center The height and weight limits of a forklift are determined by the distance of the load center from the face of the forks. The load center is the center of gravity of the load.

See Load Limit Charts in this Section of the manual.

2 1

BS98N053-01

Figure 27

1. FORK FACE 2. LOAD CENTER

Height and Weight Limits with Load Center 610 mm (24 Inches) or less The height and weight limits of the Forklift, shown on the following pages, are based on loads that have their weight centered 610 mm (24 inches) or less from the face of the forks. See the Lift Capacity decal on the back of the mast.

Height and Weight Limits with Load Center Over 610 mm (24 Inches) The height and weight limits of the Forklift decrease when the load center is greater than 610 mm (24 inches) from the face of the forks.

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CHAPTER 4 - OPERATING INSTRUCTIONS 586G Forklift - Load Limits with 610 mm (24 inch) Load Center Only (Mast Vertical)

588G Forklift - Load Limits with 610 mm (24 inch) Load Center Only (Mast Vertical)

NOTE: For limits with load centers other than 610 mm (24 inches), refer to Load Limit Chart in this Section of the manual.

NOTE: For limits with load centers other than 610 mm (24 inches), refer to Load Limit Chart in this Section of the manual.

4.6 M (15 FT) 2721 KG (6000 LBS)

4.6 M (15 FT) 3630 KG (8000 LBS)

Figure 28

BS98N057

Figure 30

BS98N057

4.6 M (15 FT) MAST

4.6 M (15 FT) MAST

6.7 M (22 FT)

6.7 M (22 FT)

1360 KG (3000 LBS)

1814 KG (4000 LBS)

4.6 M (15 FT)

4.6 M (15 FT)

2721 KG (6000 LBS)

3630 KG (8000 LBS)

Figure 29

BS98N058

6.7 M (22 FT) MAST

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Figure 31

BS98N058

6.7 M (22 FT) MAST

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CHAPTER 4 - OPERATING INSTRUCTIONS LOAD LIMIT CHARTS The following charts show how much your machine can lift as the load center increases out of 1016 mm (40 in.).

Please note how the lift capacity decreases as the load center increases.

586G Forklift

Figure 32

BS08B092

588G Forklift

Figure 33

BS08B093

IMPORTANT: Machine capacity is less when operating on uneven, unstable or soft ground conditions.

IMPORTANT: Lift capacities are based on solid, level, smooth ground conditions.

IMPORTANT: Reduce the load to maintain stability.

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CHAPTER 4 - OPERATING INSTRUCTIONS CERTIFICATION LABEL ON MACHINE

Figure 34

345368A1

IMPORTANT: See the certification label on your machine for the correct information on load and height ratings.

ADJUSTING THE FORKS

3 1

BD08C230-01

Figure 35

BD08C228-01

To adjust the forks, pull up on the lever (1) and turn it until it locks in the upward position, as shown, then slide the forks to the desired location.

Figure 37

Make sure the lock is firmly seated into a slot (3) as shown.

2

Figure 36

BD08C229-01

Pull up on the lever (2) and turn it back to the locked position to hold the forks into the desired location.

Move the forks left to right firmly to ensure they are locked into position.

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CHAPTER 4 - OPERATING INSTRUCTIONS VANDAL LOCKUP KITS

LOAD CONTROL SYSTEM (IF EQUIPPED) The Load Control System has a gas charged accumulator connected directly into the mast lift circuit.

Console Panels

To disconnect this system follow these steps: 1. With the mast in the vertical position, lower the carriage to the ground. Place blocks under the carriage to insure there is slack in the chains and all load is removed from the lift cylinders.

2. Engage the park brake and shut the engine off.

3. Move the lift control lever in both directions to remove any pressure from the hydraulic circuit.

4. Place a container under the mast flow control valve to catch any oil that may spill.

BD08C222-01

Figure 38

With the console lockup kit installed, the control switches are locked out to prevent vandalism.

1 2

Figure 40

BD99B002

BD08D013-01

Figure 39

Install a padlock on both access doors of the engine compartment to prevent vandalism.

1. LOAD CONTROL LINE 2. MAST FLOW CONTROL VALVE

5. Disconnect the load control line at the mast flow control valve.

6. Cap the tee fitting on the mast flow control valve and plug the hose from the accumulator and tie strap this loose hose to the bundle.

To reconnect this system follow these steps.

1. Remove the cap from the tee fitting on the mast flow control valve.

2. Remove the tie strap and plug from the accumulator hose.

3. Reconnect the accumulator hose back to the hydraulic circuit.

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NOTES

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

Chapter 5 LUBRICATION, FILTERS, AND FLUIDS TABLE OF CONTENTS LUBRICATION, FILTERS, AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Safety Before You Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Systemgard Lubrication Analysis Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plastic And Resin Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3 5-3 5-4 5-4 5-4

FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Case Family Lubrication And Service Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Engine Access Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 EVERY 10 HOURS (DAILY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 EVERY 50 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 EVERY 250 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 EVERY 500 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 EVER 1000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 EVERY 2000 HOURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION, FILTERS, AND FLUIDS GENERAL SAFETY BEFORE YOU SERVICE WARNING: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your Dealer or the Repair Manual for this machine.

Figure 1

WARNING: Before attempting any service procedures on the machine, it is your responsibility to know how many accumulators are on the machine and how to properly release the pressure of each. Not releasing the pressure properly can cause death or serious injury.

Figure 2

The following two chapters cover servicing the machine with recommended lubricants and coolants, under normal working conditions. To insure long service and efficient operation, follow the service intervals listed. Extreme working and environmental conditions require that service intervals be shortened.

This chapter is organized by service intervals. Beginning with items that may be As Required service, then followed by 10 hours or Daily, through 2000 hour service points. Initial service checks for new machines or rebuilt components are also included in this chapter.

Use Case fluids, lubricants and filters for the best protection and performance of your machine. All fluids, lubricants and filters must be disposed of in compliance with environmental standards and regulations in your area.

Contact your Dealer with any questions regarding the service and maintenance of this machine.

Read the Safety decals and operational decals on the machine. Read the Operator’s manual and Safety manual.

Understand the operation of the machine before you start servicing.

Before you ser vice the machine, put a Do Not Operate tag on the instrument panel. One Do Not Operate tag is included with your machine. Additional tags are available from your Dealer.

Unless otherwise specified: Use the correct safety clothing and safety equipment.

Understand how to use a fire extinguisher and first aid kit.

Figure 3

321-4614

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS SYSTEMGARD LUBRICATION ANALYSIS PROGRAM

Figure 4

BD97H063-01

Ask your Dealer about our lubr icant analysis program, Systemgard. Through this service, your lubricants are tested in an independent laboratory.

You simply remove a sample of lubricant from your machine and send the sample to the independent S y s t e m g a r d l a b o r a t o r y. A f t e r t h e s a m p l e i s processed, the laboratory will report back to you and g u i d e yo u w i t h m a i n t e n a n c e r e q u i r e m e n t s .

Systemgard can help support your equipment up time and provide you with a service that can pay back dividends when you trade for another piece of Case equipment.

ENGINE HOURMETER Service your machine at the intervals and locations given in the Lubrication/Maintenance Chart. When you service your machine, use only high quality lubricants.

The normal engine oil change interval is every 250 hours of operation. Operating conditions, quality of the engine oil and fuel quality can change this inter val. It is recommended that you use the Systemgard Lubricant Analysis program. See your Dealer.

PLASTIC AND RESIN PARTS Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinners, etc., will cause discoloration, cracking or deformation of the part being cleaned.

5-4

Figure 5

BD08C223-02

The engine hourmeter shows the amount of actual hours the engine has run. The first number to the right displays tenths of an hour and the remaining numbers to the left display hours. Use the engine hourmeter along with the Lubrication/Maintenance Chart to service your machine at the correct time periods.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

FLUIDS AND LUBRICANTS Engine Crankcase Capacity with Filter Change ......................................................................................................... 13.6 qt. (14.4 L) Capacity w/o Filter......................................................................................................................... 10.6 qt. (10.0 L) Specifications .......................................... CASE No. 1 (factory fill is SAE 10W-30) API Service CI-4 (MAT 3520) Fuel Tank Capacity ...........................................................................................................................................31 gal (117 L) Cooling System Capacity ....................................................................................................................................... 16.7 qt. (15.8 L) Specifications ............................................................................................. 50% Water and 50% Ethylene Glycol NOTE: If the ambient temperature is lower than -37°C (-34°F), adjust the mixture according to the coolant manufacturer specifications.

Hydraulic Reservoir Refill Total System Capacity ................................................................................................................... 72.0 qt (68.1 L) Refill Capacity with Filter Change ..................................................................................................... 58 qt (54.5 L) Refill Capacity without Filter Change ................................................................................................ 56 qt (53.0 L) Specification ................................................................................................................... MS-1209, Hy-Tran® Ultra Transmission 2 Wheel Drive Total System Capacity................................................................................................................... 19.0 qt (18.5 L) Refill Capacity with or without Filter Change.................................................................................. 16.9 qt (16.0 L) Specification .................................................................................................................. MS-1209, Hy-Tran® Ultra 4 Wheel Drive Total System Capacity.................................................................................................................... 22.0 qt (20.8 L) Refill Capacity with or without Filter Change.................................................................................. 19.5 qt (18.5 L) Specification .................................................................................................................. MS-1209, Hy-Tran® Ultra Axle Lubricant Front (Drive) Capacity of Center Bowl................................................................................................................. 15.0 qt (14.2 L) Capacity of each Planetary End......................................................................................................... 1.6 qt (1.5 L) Specification ...................................................................................... MS-1209, Hy-Tran® Ultra with AOA additive Rear (Steer) 4WD Capacity of Center Bowl..................................................................................................................... 5.8 qt (5.5 L) Capacity of each Planetary End......................................................................................................... 0.7 qt (0.7 L) Specification ................................................................................................................... MS-1209, Hy-Tran® Ultra Brake Master Cylinder Specification ................................................................................................................... MS-1209, Hy-Tran® Ultra Grease Fittings Quantity ............................................................................................................................................. As Required Specifications ............................................................................................................. Case Molydisulfide Grease

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

LUBRICATION AND MAINTENANCE QUICK REFERENCE CHART

As Required (AR)

Every 10 Hours

Every 50 Hours

Every 250 Hours

Every 500 Hours

Every 1000 Hours

Every 2000 Hours

5-8 5-8 5-8 5-9 5-9 5-10 5-12 5-11 5-11 5-13 5-15 5-15 5-16 5-17 5-17 5-18 5-19 5-21 5-23 5-24 5-25 5-26 5-26 5-26 5-27 5-28 5-28 5-29 5-30 5-30 5-30

Fan Drive Belt Air Filter Dust Valve Air Filter Pre-Cleaner Engine Oil Fuel Tank Safety & Instructional Decals Steer Axle Pivots 2 WD & 4WD Mast Grease Fittings Machine Grease Fittings Hydraulic Fluid Check Clean Battery Steer Axle Oil 4 WD Drive Axle Oil Radiator Fluid Level Transmission Fluid Level Forklift Mast Chain Engine Oil and Filter ROPS Fuel Filters Mast Chain Hydraulic Filter Hydraulic Fluid Battery Fluid Level Drive Axle Oil Change Transmission Fluid, Filter, Breather Steer Axle Oil Change 4 WD Air Filter Elements Engine Valve & CCV Filter Engine Coolant System Cleaning Chain Rollers Load Rollers

REPLACE

LUBRICATE

DRAIN

CHANGE

CLEAN

CHECK

SERVICE POINTS

INITIAL

SERVICE INTERVAL

PAGE NUMBER

FREQUENCY IN HOURS

AR AR AR 10 10 10 50 50 50 50 250 250 250 250 250 250

250 500

500 500 500 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 2000 2000 2000 2000

1000 1000 2000

Figure 6

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS CASE FAMILY LUBRICATION AND SERVICE PRODUCTS

Figure 7

BD08A523

For the very best protection of your investment use the Case Family of Lubrication and Service Products. Contact your Dealer for these products and any questions you may have about your machine’s service and lubrication requirements.

ENGINE ACCESS DOORS To gain access to the machine fluid check points inside the engine access doors, use the following procedure.

1 Figure 8

BD08C233-01

To Open: 1. Pull the release lever (1), located inside the ROPS, toward you.

2. Pull the door open.

To Close: 1. Push the engine access door closed until it latches.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

AS REQUIRED MAINTENANCE Air Filter Pre-Cleaner

FAN DRIVE BELT Check the condition of the belt as required by machine hours and working conditions. Check for cracking, deterioration and replace as necessary.

1. Park the machine on a level surface and apply the parking brake.

1

2. Lock out and tag out the machine to insure it is not started.

2 3

4 BD08C079-01

Figure 9

3. Install a 1/2 inch breaker bar in the tension pulley bracket.

Push the breaker bar forward just enough to release the tension on the drive belt. Remove the drive belt from the water pump pulley first and then from the other pulleys.

AIR FILTER DUST VALVE

Figure 11

BS08B132

1.

2.

3.

4.

NUT CAP BOWL BASE

Check the pre-cleaner bowl and remove the dust as required.

1. Loosen the nut and remove the cap.

2. Remove the bowl and clean with a damp cloth.

3. Re-assemble bowl and cap to base.

BD08C192-01

Figure 10

Under normal conditions the dust valve will clear itself. Under certain conditions, it may be necessary to remove the valve and wipe it clean.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 10 HOURS (DAILY) Engine Oil Level

Fuel Tank

Check the engine oil level ever y 10 hours of operation or once each day. Always check the oil level with the engine stopped and the machine on level ground.

Specification . . . . . . . . . . . . . Case No. 1 Engine Oil

Fill the fuel tank at the end of each day. A full tank will prevent water condensation. The use of Case Diesel Fuel Conditioner will also help with this problem.

Factory fill is SAE10W-30.

To get an accurate measure of the engine oil level, make sure to push the engine oil level dipstick completely down before removing.

WARNING: Engine fuel is flammable and can cause a fire or explosion. DO NOT fill the fuel tank or service the fuel system near an open flame, welding, or while smoking tobacco.

Figure 14

2 1

Figure 12

BD08D008-01

1. ENGINE OIL DIPSTICK 2. ENGINE OIL FILL TUBE

BD08C181-01

Figure 15

Fuel Conditioner Diesel Fuel Conditioner is available from your Case Dealer. The conditioner will clean the fuel injectors, valves and manifold. It will also disperse insoluble gum deposits that form in the fuel system, separate moisture from the fuel and stabilize fuel in storage.

Coolers And Engine Compartment Clear Of Debris Check the radiator, coolers and engine compartment for a build up of debris, dirt and foreign material that might impede the cooling components. Failure to comply could result in serious injury or death.

Figure 13

BD08A305

Follow the instructions on the dipstick and add oil if necessary. DO NOT OVER FILL.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 10 HOURS (Daily) Safety and Instructional Decals Check the condition of the safety and instruction decals on your machine every 10 hours of operation or each day, whichever occurs first.

Use soap and water to clean any dir ty decals.

Replace any decal that is damaged, missing or installed on a part that is being replaced.

See the Safety Section in this manual for locations of all Safety Decals on your machine.

For decal replacement, see your Parts Catalog and your Dealer for additional information and ordering instructions.

WARNING: Damaged, missing, or dirty safety decals can cause injury or death. Replace any missing or damaged safety decals and keep all safety decals clean. See your dealer for new safety decals.

Figure 16

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 50 HOURS

Draining Water From Fuel Filter

Grease Fittings

Check the fuel system for water or sediment every 50 hours of operation or each week. If, after several checks no water if found, extend the interval.

Lubricate the machine according to the intervals given in the lubrication and maintenance chart unless you operate the machine in severe conditions. If you operate the machine in severe conditions, lubricate the machine more frequently. Remove all dirt from the grease fittings before you lubricate.

1. Hold a small glass container under the first stage filter and loosen the drain valve.

1

WARNING: Never grease, oil or perform any maintenance with the engine running unless so instructed in the Operator’s manual or Repair manual. If the attachment must be raised in order to perform the operation, block up the attachment securely.

2

Figure 17

Mast Grease Fittings BD08C242-01

Figure 19

1. FUEL FILTER 2. DRAIN VALVE (BOTTOM OF FILTER)

1

1

2. Remove a small amount of fuel and tighten the drain valve. Check the container for water and sediment. If you do not find water or sediment, no other service is required.

3. If you find water or sediment, open the drain valve on the bottom of the fuel tank. After the water and sediment are removed, close the drain valve.

Figure 18

BD08C236-01

1. Mast Pivot . . . . . . . . . . . . . . . . . . . .2 (1 ea. side)

Check the fuel tank for water and sediment every 250 hours of operation.

Fuel Conditioner Diesel fuel conditioner will clean the fuel injectors, valves and manifold.The conditioner will also disperse insoluble gum deposits that form in the fuel system, separate moisture from the fuel and stabilize fuel in storage. Diesel fuel conditioner is available from your Case Dealer.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 50 HOURS

Steer Axle- 2WD 1. Tie-Rod End Outer . . . . . . . . . . . . 2 (1 ea. side) 2. Tie-Rod End Inner. . . . . . . . . . . . . . 2(1 ea. side) 3. King Pins Upper and Lower . . . . . . 4 (2 ea. side)

Steer Axle Pivot Pin- 4WD

1

Figure 20

BD08C203-01

1. Steer Axle Pivot . . . . . . . . . . . . . . . . . . . . . . . . .1

2

2 Figure 21

BD08C253-01

2. King Pins Upper and Lower . . . . . . 4 (2 ea. side) Steer Axle Pivot Pin - 2WD

3

BD08C203-01

Figure 22

3. Steer Axle Pivot . . . . . . . . . . . . . . . . . . . . . . . . .1

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 50 HOURS

Hydraulic Fluid Level Check Specification . . . . . . . . . . . . MS-1209 Hy-Tran® Ultra

Mast - Grease Fittings

Check the fluid level of the hydraulic reservoir every 50 hours of operation.

NOTE: Check the oil level of the hydraulic reservoir only when the machine is level, front mounted equipment is on the ground and the engine is stopped.

1

1

2 Figure 23

BD08C235-01

1. Carriage Thrust Rollers. . . . . . . . . . . . . . . . . . . 4

1

BD08C183-01

Figure 25

1. HYDRAULIC OIL RESERVOIR SIGHT GAUGE 2. HYDRAULIC RESERVOIR FILL TUBE

2

The hydraulic oil reservoir sight gauge is located behind the right-rear access door.

The oil level must be up to the FULL COLD mark.

Figure 24

BD08C234-01

2. Chain Rollers on Mast. . . . . . . . . . . . . . . . . . . . 2 NOTE: 588G Forklift with 22 ft (6.7 m) mast only.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 250 HOURS Engine Coolant Reservoir

4WD Drive Shaft - Grease Fittings

Check the coolant reservoir fluid level every 250 hours of operation, when the coolant is cold and the engine is stopped. Do Not remove the coolant bottle cap during this check. The coolant level must be between the FULL and ADD marks on the reservoir.

If the level is below the ADD mark, add 50% Ethylene Glycol and 50% water to raise the level up to the FULL mark.

1

Figure 28

BD08C249-01

1. Rear Axle Slip Spline . . . . . . . . . . . . . . . . . . . . 1 Drive Axle Drive Shaft - Grease Fittings

1 1 BD08C192-01

Figure 26

WARNING: Do not open or service the cooling system when it is HOT. Allow the system and components to cool BEFORE servicing. Serious injury could result if you fail to follow these instructions.

SA023

Figure 27 Figure 29

BD08C248-01

NOTE: After you fill the cooling system, mix the ethylene glycol and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done when the machine is in temperatures below 0 ° C (32 ° F).

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1. Front (Drive) Axle Slip Spline . . . . . . . . . . . . . . 1

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 250 HOURS SUSPENSION SEAT RAILS

1 2

Figure 31

BD08C257-01

1. OIL LEVEL AND DRAIN PLUG 2. LEVEL LINE Figure 30

BK99A039

Apply a small amount of grease to the front 3 in. (76 mm) of slide rail on each side. Move the seat forward and rearward, as needed, to lubricate the rails.

CLEANING THE BATTERIES

3. Rotate the wheel so that the oil level plug is in the position shown.

4. Remove the oil level plug. The oil must level must be at the plug opening. Replace the oil level plug.

5. Repeat steps 3 and 4 for the other side.

Check the batteries every 250 hours of operation for d i r t , c o r r o s i o n a n d d a m a g e. D i r t m i xe d w i t h electrolyte or moisture on the top of the battery, can cause a discharged condition in the battery. Wear face protection and use one of the following methods to clean the battery:

6. Lower the wheels to the ground.

1. Use Case Battery Saver and follow the directions on the container. This cleaner does not require water.

2. Use baking soda or ammonia and flush the outside of the battery with water. If you do not have Case Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

3

BD08C254-01

Figure 32

3. OIL LEVEL PLUG

STEER AXLE OIL LEVEL - 4WD Check the oil level of the steer axle after the first 20 hours of operation with a new machine. Then, check the oil level every 250 hours of operation. You must check the oil level of the center bowl and each planetary end.

7. Remove the plug from the center bowl. The oil level must be even with the bottom of the plug opening. Replace the oil level plug.

1. Park the machine on a level surface. Make sure the direction control lever is in the NEUTRAL position and the gear shift control lever is in the NEUTRAL position.

2. Raise the rear wheels about 1 in. (25 mm) above the ground.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS 4. Remove the oil level plug. The oil level must be even with the plug opening. Replace the oil level plug.

EVERY 250 HOURS STEER AXLE BREATHER - 4WD Clean the breather for the steer axle every 250 hours of operation. If you operate the machine in severe operating conditions, clean the breather more frequently.

5. Repeat steps 3 and 4 for the other side.

6. Lower the wheels to the ground.

3 1

Figure 35

BD08C255-01

Figure 33

BK99A066

3. CENTER BOWL OIL LEVEL PLUG

DRIVE AXLE BREATHER

1. BREATHER

Remove the dirt from the area around the breather and clean the breather with solvent. Wear face protection and blow dry with compressed air.

DRIVE AXLE OIL LEVEL

Clean the breather for the drive axle every 250 hours of operation. If you operate the machine during severe operating conditions, clean the breather more frequently.

Check the oil level of the drive axle after the first 20 hours of operation with a new machine. Check the oil level in the center bowl and each planetary end every 250 hours of operation.

1. Park the machine on a level surface. Make sure the direction control lever is in the NEUTRAL position and the gear shift control levers in the NEUTRAL position.

1

2. Raise the front wheels about 1 in. (25 mm) above the ground.

Figure 36

BD08C247-01

1. BREATHER

2

Remove the dirt from the area around the breather and clean the breather with solvent. Wear face protection and blow dry with compressed air.

1

BD08A455

Figure 34

1. OIL LEVEL AND DRAIN PLUG 2. LEVEL LINE

3. Rotate the wheel so that the oil level plug is in the position shown.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 250 HOURS

Drain Water Or Sediment From The Fuel Tank

Radiator Fluid Level WARNING: Do not open or service the cooling system when it is HOT. Allow the system and components to cool BEFORE servicing. Serious injury could result if you fail to follow these instructions.

Figure 37

Check the radiator coolant level every 250 hours of operation when the coolant is cold and the engine is stopped. The coolant level must be between the FULL and ADD marks on the coolant reservoir.

1

Figure 39

BD08C224-01

1. FUEL TANK DRAIN

Drain water and sediment from the fuel tank every 250 hours of operation.

Transmission Fluid Levels

1

Check the fluid level of the transmission after the first 20 hours of operation with a new machine. Then check the fluid level every 250 hours of operation.

Check the fluid level when the machine is parked on level ground and with the engine running.

Figure 38

BD08C225-01

1. COOLANT RESERVOIR CAP

Coolant Solution

The fluid level must be between the ADD and FULL marks on the dipstick. If the fluid level is at the ADD mark, add fluid as required until the fluid level is at the full mark.

A mixture of 50% Ethylene Glycol and water must be used in this machine. This mixture is used if the lowest ambient temperature is above -37째C (-34째F).

If the ambient temperature is lower, adjust the mixture. It is recommended that Ethylene Glycol and water be used in this machine all year.

1

IMPORTANT: Mix the Ethylene Glycol and water completely by running the engine at operating temperature for approximately five minutes. This procedure must be done before the machine is put outside in temperatures below 0째C (32째F).

BD08D009-01

Figure 40

1. TRANSMISSION DIPSTICK

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 250 HOURS

Forklift Mast Chain

Tire Condition and Air Pressure Check the air pressure and the condition of the tires every 100 hours of operation. See chapter-page 6-11 for the correct tire air pressure.

Cylinders - Grease Fittings

Figure 43

BD08C234-01

1. Lower mast to the ground and wear face protection.

2. Clean mast with a stiff brush or wire brush to clear dust and debris from the space between the plates.

BD08C256-01

Figure 41

Tilt cylinders, rod end . . . . . . . . . . . . . . . . . . . . . . . .2

3. Oil may be applied with a narrow paint brush or directly poured on, but the chain should be well flooded to be sure that the oil penetrates the joint.

4. In locations difficult to reach, it may be necessary to use a good quality oil under pressure, such as an aerosol can or pump pressure spray.

Forklift Mast Chain Adjustment

BD08C250-01

Figure 42

Tilt cylinders, closed end . . . . . . . . (2) one each side 25 mm (1 in)

Figure 44

BD99B006

Check the chain adjustment after the first 20 hours of operation with a new machine. Then check the chain adjustment every 250 hours of operation.

To Adjust: Lower the carriage completely and check the amount of carriage roller exposed from the rail.

Tighten chains until the roller is only exposed 25 mm (1 in).

Check the chain tension on both sides to make sure they pull evenly. Adjust as necessary.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 500 HOURS ENGINE OIL AND FILTER Change the engine oil and engine oil filter every 500 hours of operation. Change the engine oil more frequently than every 500 hours when the engine operating conditions are severe (frequent stopping and starting and high or low engine temperatures).

Specification ................................................................................ Case No. 1 Engine Oil (Factory fill is SAE10W-30) ENGINE LUBRICATION AND ENGINE OIL SELECTION Case No. 1 Engine Oil is recommended for use in your Case Engine. Case Engine Oil will lubricate your engine correctly under all operating conditions.

Chose the proper viscosity for the ambient air temperature in your work environment.

If Case Multi-Viscosity Engine Oil is not available, use only oil meeting API CI-4 engine oil service category.

NOTE: Do not put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with Case lubricants.

NOTE: Use of an engine oil pan heater or an engine coolant heater may be required when operating temperatures are in Winter or Arctic conditions.

NOTE: The use of low viscosity oils, such as 10W-30 can be used to aid in starting the engine and in providing sufficient oil flow at ambient temperatures below - 5°C (23°F). The continuous use of low viscosity oils can decrease engine life due to wear.

See the chart below for recommended viscosity at ambient air temperature ranges.

Figure 45

BP97H064-01

Oil Viscosity/Temperature Ranges

Figure 46

BC07N452

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS IMPORTANT: Do not use a filter strap wrench to install the oil filter. An oil filter strap wrench can cause a leak if the filter is dented.

EVERY 500 HOURS Oil Change and Filter Replacement NOTE: For more complete removal of foreign material, change the engine oil while the engine is still warm from operation.

Park the machine of firm, level ground. The old oil and contaminants will drain better if the engine is slightly warm.

Use a 21 mm wrench and remove the four bolts that secure the engine oil access plate under the engine.

1. Before draining the oil, have a container that will hold the suitable quantity.

IMPORTANT: Clean all dirt and foreign material from the front engine guard a minimum of every thirty days. Dirt will cause rust on the engine oil pan and a loss of engine oil.

7. Install the drain plug. Tighten the drain plug to a t o r q u e o f 6 8 t o 8 2 N m ( 5 0 t o 6 0 l b. f t . ) .

Overtightening can damage the oil pan. Install the guard plate.

8. Put new oil into the engine oil fill tube.

9. Before you start the engine, prime the turbocharger oil lines with oil. See the following topic.

10. Start the engine and run at idle speed. Check the engine oil filter for leaks. After two minutes, stop the engine, wait for 2 or 3 minutes, and check the engine oil level with the dipstick.

1 Priming the Turbocharger Oil Lines with Oil In cold weather, after several weeks of storage, or after the engine oil filter has been replaced, prime the turbocharger oil lines with oil.

Figure 47

BD08C243-01

1. Disconnect the electrical connection (plug) to the injection pump solenoid.

2. Remove the engine oil drain plug (1).

3 Figure 49 ELECTRICAL CONNECTION TO THE INJECTION PUMP SOLENOID

BD08C058-01

BD08C260-01

Figure 48

3. Turn the oil filter (3) counter-clockwise to remove.

Discard the filter.

4. Use a clean cloth and wipe the sealing surface of the oil filter base to remove all dirt or gasket material.

2. Actuate the starter motor for 10 - 20 seconds.

3. Connect the wire to the injection pump solenoid and start the engine.

Run the engine at idle speed for a few minutes.

5. Apply a thin layer of clean grease or oil to the gasket of the new oil filter.

6. Turn the new oil filter onto the base until the gasket makes contact with the base. Continue to tighten the filter for 1/3 turn with your hand.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS Roll-Over Protective Structure WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine.

1

Figure 52

SA029

WARNING: Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting or adding attachments can weaken the structure and reduce your protection. Replace ROPS if subjected to roll-over or damage. Do not attempt to repair.

Figure 50

BD08C179-01

1. ROPS LABEL

Your machine has a roll-over protective structure (ROPS). A ROPS label is fastened to the structure.

The ROPS label has important information about ROPS.

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

The ROPS label shows the serial number of the ROPS, gross weight approval and regulation numbers and Model Number of the machine.

IMPORTANT: Read the following important information. Do not remove the ROPS label.

Figure 53

SB026

Figure 54

SA027

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

ROPS Label

Figure 55

SA028

WARNING: You are protected by the ROPS system on this machine (Roll-Over Protective Structure). The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

SA080

Figure 56

Figure 51

347809A1

Seat Belt for the ROPS Maintenance and Inspection of the ROPS After the first 20 hours of operation with a new machine and after every 500 hours of operation, do the following:

The seat belt is an important part of your ROPS. You MUST wear the seat belt at all times when you operate the machine.

1. Check the torque of the ROPS mounting bolts.

See chapter-page 5-22 for correct torque specifications. If necessary, tighten the bolts to the correct torque.

2. Check the operator’s seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See chapter-page 6-6 for correct torque specifications. Replace parts that have wear or damage.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS

Torque Specifications for ROPS Canopy Mounting Bolts

Possible Damage to the ROPS If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you MUST replace the damaged ROPS components.

NOTE: After impact or tip over incident if the ROPS has been moved or deformed from it’s original state, regardless of the degree of damage, the welded joints of the structure have absorbed energy in a non-elastic manner. The ROPS will not perform as expected prior to deformation in any future impact.

Therefore, when a ROPS has undergone an impact causing permanent deformation it must be replaced to assure expected performance in any future impact associated with a rollover or tip over.

After an accident, also check for damage to:

1 2

• The operator’s seat.

• The seat belt and the seat belt mountings.

• All accessories, lamps wiring, etc., in the ROPS. IMPORTANT: DO NOT DRILL HOLES, WELD OR TRY TO STRAIGHTEN THE ROPS.

1

Figure 57

BT99A021

1. M12 (GRADE 10.9) 84 TO 151 NM (62 TO 110 LB.FT.) 2. M20 (GRADE 10.9) 405 TO 730 NM (300 TO 540 LB.FT.)

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS

4. Tighten the upper and lower hose clamps on the fuel filter.

Replacing the Fuel Filter

5. Remove the air from the fuel system.

Replace the fuel filters every 500 hours of operation or if you have a loss of engine power.

1. Clean the area around the filter.

2. Use a filter wrench and counterclockwise to remove.

turn

the

filter

3. Remove the rubber seal from the spud on the filter head.

4. Use a cloth and clean the gasket surfaces of the filter body.

5. Apply clean engine oil to the new rubber seal.

Removing air from the Fuel System Air must be removed from the fuel system if one or more of the following conditions occurs:

• • • •

If the engine stops because of no fuel in the tank.

If the fuel filters are replaced.

If the fuel system has been serviced.

If the machine has been in storage for three months or more.

1. Fill the fuel tank.

6. Install the rubber seal on the filter head spud.

7. Apply clean oil to the gasket of the new filter. Do not fill the new filter with fuel before installation.

1

8. Turn the main filter clockwise onto the filter body until the filter gasket makes contact with the filter body. Continue to tighten the filter with your hand for 1/2 to 3/4 turn.

IMPORTANT: Do not use a filter wrench to tighten the filter. You can cause a leak if the filter is dented with the wrench.

9. Remove the in-line fuel filter and discard. Install a new in-line fuel filter. Make sure the hose clamp and nut are tight.

Figure 59

BD08D008-01

1. AIR REMOVAL SCREW

2. Loosen the air removal screw on the filter head two or three turns.

10. Fill the tank with fuel.

11. Remove the air from the fuel system.

Replacing the In-Line Fuel Filter 1. Clean the area around the filter.

1 1

BD08D008-01

Figure 60

2. HAND PRIMER PUMP

Figure 58

BD08C241-01

3. Actuate the hand primer pump. When fuel with no air flows from the air removal screw, tighten the air removal screw.

1. IN-LINE FUEL FILTER

2. Loosen the upper and lower hose clamps for the in-line fuel filter. Prevent the lower hose from falling down and draining the fuel from the tank.

3. Remove the old filter and install a new filter.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 500 HOURS Mast Chain - Wear Or Stretch

BD08C234-01

Figure 61

NOTE: Inspect the mast chain for wear or stretch every 500 hours of operation. See your Repair Manual for this procedure.

Carriage Thrust Rollers - Wear or Damage

BD08C231-01

Figure 62

NOTE: Inspect the carriage thrust rollers for wear or damage every 500 hours of operation. See your Repair Manual for this procedure.

Steer Axle Bearings And Seals - 2 Wheel Drive NOTE: Lubricate the bearings of the steer axle and replace the seals every 500 hours of operation. See your Repair Manual for this procedure.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVER 1000 HOURS Hydraulic Filter

Replacing the Hydraulic Filter

If the machine is new, replace the filter after the first 20 hours of operation. Then, replace the filter after every 1000 hours of operation or if the warning lamp for the hydraulic filter is illuminated.

1. Lower the forks to the ground and apply the parking brake.

2. Stop the engine.

1

BD08C251-01

Figure 63

BD08C223-03

Figure 64

1. HYDRAULIC FILTER

1. HYDRAULIC FILTER WARNING LAMP

Procedure To Check The Condition Of The Hydraulic Filter 1. Start the engine and raise the temperature of the hydraulic fluid to operating temperature (side of the hydraulic reservoir feels very warm). To increase the temperature of the hydraulic fluid, do the following: A. Increase the engine speed to full throttle and tilt back the forklift mast and hold the control lever in this position for 15 seconds.

3. Use a filter wrench and remove the old filter from the machine.

4. Lubricate the gasket on the new filter with clean oil.

5. Install the new filter and turn clockwise until the gasket contacts the head of the filter assembly.

Continue to tighten the filter for 1/3 turn.

6. Start the engine and check for leaks at the hydraulic filter.

B. After 15 seconds, move the control lever to the NEUTRAL position.

C. Repeat steps A and B until the side of the hydraulic reservoir feels very warm.

2. Increase the engine speed to full throttle. If the warning lamp for the hydraulic filter illuminates, replace the filter.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS

Battery Fluid Level

Hydraulic Fluid Change Change the hydraulic fluid every 1000 hours of operation.

1. Make sure the hydraulic fluid is at operating temperature.

2. Apply the park brake.

3. Lower the forks to the ground.

4. Stop the engine and put a Do Not Operate tag on the key switch.

5. Put a container under the drain plug that will hold 57 litres (15 U.S. gallons).

Wear face protection and check the fluid level of the batteries every 1000 hours of operation. If the fluid level is low, add clean or distilled water to each cell until the fluid level is 1/8 inch below the split ring at the bottom of each cell opening.

IMPORTANT: If the temperature is 0° C (32 ° F) or below and you have added water to the batteries, do the following: Connect a battery charger to the batteries or run the engine for approximately two hours. This procedure is necessary to mix the water with the electrolyte.

Drive Axle Oil Change You must change the oil in the drive axle every 1000 hours of operation.

1. Park the machine on a level surface and make sure the oil in the drive axle is at operating temperature.

1

2. Make sure the direction control lever is in the NEUTRAL position and the gear shift control lever is in the NEUTRAL position.

2

3. Raise the front wheels about 25 mm (one inch) above the ground.

BK99A074

Figure 65

1. FILL CAP 2. DRAIN PLUG

6. Remove the fill cap and remove the drain plug.

Drain the hydraulic fluid from the hydraulic reservoir.

4. Rotate the wheels so that the oil level plugs are in the correct position to drain the oil. Lower the wheels to the ground.

5. Stop the engine.

6. Put a pan under each planetary and the drain plug for the center bowl.

7. Replace the hydraulic fluid filter 8. Install the drain plug.

9. Put 55 litres (14.5 U.S. gallons) of Case TCH fluid into the reservoir.

10. Start the engine and operate the forklift controls for three to four minutes. Stop the engine and check for leaks. Check the fluid level.

IMPORTANT: When the hydraulic fluid level is low, a small amount of hydraulic fluid will remain on the lower part of the sight gauge window. This condition does not show a correct fluid level.

Pump Charge Procedure If the hydraulic fluid supply to the pump has been interrupted due to hydraulic fluid change, pump replacement, or a broken line, see the Repair Manual or your Case Dealer for proper start up procedure.

5-26

1 Figure 66

BD08C246-01

1. CENTER BOWL DRAIN PLUG

7. Remove the three drain plugs and remove the oil from each planetary and from the center bowl.

8. Rotate the wheels to the oil level check position and put the specified amount of oil in each planetary end and in the center bowl. See page 5-5.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS

1. Clean the area above the mounting surface for debris and dirt.

Transmission Fluid, Transmission Filter Change, and Breather Cleaning Change the transmission filter after the first 20 hours of operation.

Change the transmission fluid, replace the transmission filter, and clean the breather every 1000 hours of operation.

Transmission Fluid Change 1. Put a container under the drain plug that will hold 20.8 litres (5.5 U.S. gallons).

2. Remove the old filter and discard. Clean the filter mounting surface with a clean cloth.

3. Lubricate the gasket of the new filter with clean oil.

4. Install the new filter and turn clockwise until the gasket contacts the head of the filter assembly.

Continue to tighten the filter for 1/3 turn.

IMPORTANT: Do not use a filter strap wrench to install the filter. A fluid leak can occur if the filter is dented by the filter strap wrench.

5. Install the drain plug and fill with new fluid.

6. Start the engine and check for leaks around the filter.

7. Operate the machine in first and second gear for a few minutes. Park the machine on a level surface. Apply the park brake. With the engine running at idle speed, check the fluid level. Add fluid as required.

1

Transmission Breather Cleaning Figure 67

BD08C252-01

1. DRAIN PLUG

2. Remove the dipstick and drain plug.

Transmission Filter Replacement

1

BK99A079

1

1. Clean the area around the breather.

Figure 68

BK99A078

Figure 69

1. TRANSMISSION BREATHER

2. Remove and clean the breather with solvent ever y 1000 hours of operation. Wear face protection, blow dry with compressed air, and install the breather.

1. STANDARD TRANSMISSION FILTER

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS EVERY 1000 HOURS

Warning Lamp for Air Filter Restriction

Steer Axle Oil Change - 4WD You must change the oil in the steer axle every 1000 hours of operation.

1. Park the machine on a level surface and apply the park brake. Make sure the oil in the steer axle is at operating temperature.

2. Make sure the direction control lever is in the NEUTRAL position and the gear shift control lever is in the NEUTRAL position.

3. Raise the rear wheels about 25 mm (1 in.) above the ground.

1 Figure 71

BD08C223-03

1. AIR FILTER RESTRICTION WARNING LAMP

4. Rotate the wheels so that the oil level plugs are in the correct position to drain the oil. Lower the wheels to the ground.

You must service the air filter if the air filter warning lamp illuminates when the engine is running.

5. Stop the engine.

Primary Element - Outer

6. Put a pan under each planetary and the drain plug for the center bowl.

Replace the primary (outer) element after three washings or after the element has been in the machine for one year.

IMPORTANT: Always use a bright lamp to inspect a cleaned or new primary (outer) filter element before installation into the machine.

To Service: 1. Raise the right engine access door.

1

BK99A065

Figure 70

2

1. CENTER BOWL DRAIN PLUG

1

7. Remove three drain plugs and remove the oil from each planetary and from the center bowl.

8. Install the drain plugs.

Air Filter Elements

• The shelf life of a new air filter element is five years; do not install a new element that is more than five years old. The date of manufacture is on the end cap of the element.

• Replace both filter elements after one year in the

Figure 72

BD08C192-01

1. AIR CLEANER END COVER CLAMP (3) 2. AIR CLEANER END COVER

2. Loosen the clamps on the air cleaner cover and remove the end cover.

machine.

• Do not remove the elements from the machine to check for restrictions; always follow the recommended service instructions in the section.

• Each time you service the air filter system, make sure all hose connections and flanges are air tight.

Replace all damaged parts.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS To Service:

EVERY 1000 HOURS

1. Remove the end cover and remove the primary (outer) element.

1 1 Figure 73

BD08C193-01

1. PRIMARY OUTER ELEMENT

3. Carefully remove the primary (outer) element.

4. Use a clean damp cloth and clean the inside of the filter body.

5. Install a clean or new primary (outer) element.

Make sure the gasket is making full contact.

6. Install the end cover.

BD08C194-01

Figure 74

1. SECONDARY (INNER) ELEMENT

2. Remove and discard the secondary (inner) element.

3. Use a clean damp cloth and clean the inside of the filter body.

4. Install a new secondary (inner) element. Make sure the gasket is making full contact.

7. Apply the park brake.

8. Make sure other persons are clear of the machine. Start the engine and check the air filter warning lamp. If the lamp is still illuminated, replace the secondary (inner) element.

5. Install a clean or new primary (outer) element.

Make sure the element has full gasket contact.

6. Install the end cover.

Secondary Element - Inner

Engine Valve Adjustment

Replace the secondary (inner) element:

NOTE: Check the engine valve adjustment every 1000 hours of operation. See you Repair Manual for this procedure.

A. After the primary (outer) element has been cleaned three times.

B. After one year in the machine.

CCV FILTER

C. After the primary (outer) element has been cleaned or replaced and the air filter warning lamp illuminates with the engine running.

R e p l a c e t h e C C V f i l t e r eve r y 1 0 0 0 h o u r s o f operation.

NOTE: DO NOT clean the secondary element.

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Contact your Dealer for this procedure or see the Repair Manual for this machine.

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CHAPTER 5 - LUBRICATION, FILTERS, AND FLUIDS

EVERY 2000 HOURS Cleaning Cooling System Do not open or service the cooling system when it is HOT. Allow the system and components to cool BEFORE servicing.

Serious injury could result if you fail to follow these instructions. Check and service engine cooling system according to maintenance instructions.

8. Start the engine and increase the temperature of the engine coolant. When the coolant is at operating temperature, stop the engine and allow to cool. Check the coolant level at the coolant reservoir only.

9. Fill the coolant reservoir to the FULL mark as required and install the cap.

Chain Rollers On Mast

Figure 75

SA023

Drain, flush, and replace the engine coolant every 20 00 ho ur s of o pe ratio n o r ever y t wo ye a rs, whichever occurs first. Clean the system and replace the coolant if the coolant becomes dirty or has the color of rust.

DO NOT service if the coolant is hot. Allow the system to cool, then:

Figure 77

BD08C234-01

NOTE: Inspect the chain rollers on the mast for wear every 2000 hours of operation. See your Repair Manual for this procedure.

1

Load Rollers On Mast

BD08C056-01

Figure 76

1. RADIATOR DRAIN VALVE

1. Put a container under the drain valve that will hold 19 litres (5 U.S. gallon).

2. Open the radiator drain valve and remove the coolant reservoir cap.

3. After all coolant is removed, close the drain valve.

4. Add cleaning solution to the cooling system and fill the cooling system with clean water. Follow the directions included with the cleaning solution.

Figure 78

BD08C234-01

NOTE: Inspect the load rollers on the mast for wear every 2000 hours of operation. See your Repair Manual for this procedure.

5. After you drain the cleaning solution, flush with clean water and drain the water.

6. Check the hoses, elbows, and water pump for leaks. Make sure the outside of the engine and radiator are clean.

7. Put a mixture of 50% ethylene glycol and 50% water in the radiator. Completely fill the radiator and coolant reservoir slowly with coolant.

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NOTES

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

Chapter 6 MAINTENANCE AND ADJUSTMENTS TABLE OF CONTENTS MAINTENANCE AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 LOAD CONTROL ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 PARK BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 SEAT BELT INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Torque Specification for Seats and Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance and Inspection of ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Specifications For Rops Canopy Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Damage to the ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7 6-7 6-7 6-7 6-8

MACHINE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Type of Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Inspection and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Wheels And Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Tire Air Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Storage Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Removal From Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

MAINTENANCE AND ADJUSTMENT Steps 4 - 6 apply only to the hook style fork.

Fork Maintenance and Inspection WARNING: Do not drag the forks on the work surface (especially concrete) when operating the vehicle.

Figure 1

SA135

WARNING: Do not interchange forks between lifting devices. Always make sure that forks of the proper capacity are used with the correct mast capacity. Refer to the capacity decal on the forklift mast.

4. Check to see that the lock pin is in position in the top hanger of the fork and is functioning properly as listed in steps 5 and 6.

5. When the pin is in the down position, the fork should not be able to move.

6. When the pin is in the up position, this allows the fork to move freely on the carriage.

Figure 2

SA136

WARNING: Do not grind, weld or modify the forks in any way.

Figure 3

SA137

WARNING: Do not attempt to straighten bent forks.

Figure 4

SA138

Use the illustration on the next page as a guide to inspect the forks. There are two styles of forks, the hook fork and the shaft fork.

The following procedures are for both style forks: 1. Check for visible bent forks. Check for visible wear on bottom side of forks.

2. Inspect the forks for visible cracks along the inside radius of the heel.

3. Inspect the hanger welds on the forks for visible cracks.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

6

4 5

2

3

1

Figure 5

BD08C228-01/BD08C229-01/BS08C255

1.

2.

3.

4.

5.

6.

6-4

VISIBLE WEAR AND BENT FORKS FATIGUE CRACKS AT HEEL VISIBLE WEAR AND CRACKS ON HANGER BLOCK LOCK PIN IN POSITION LOCK PIN IN LOCKED POSITION LOCK PIN IN ADJUSTABLE POSITION

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LOAD CONTROL ACCUMULATOR WARNING: The accumulator on this machine contains highly pressurized nitrogen gas. If the accumulator system does not function correctly, replace the accumulator. DO NOT attempt to repair the accumulator, only install a new one. Injury or death can result if you do not follow these instructions.

Figure 6

If the load control accumulator (if equipped) must be replaced for any reason, always follow the instruction on the decal located on the accumulator mounting plate.

Never disconnect the hydraulic line between the accumulator and the solenoid valves without first discharging all hydraulic pressure from the hydraulic system. Always refer to the accumulator decal located at the right, in the safety section of this manual or the decal located on the accumulator mounting plate.

328904A1

Figure 7

1. ACCUMULATOR WARNING DECAL

(1) Located under frame rail near batter y compartment (if equipped).

Refer to the Repair Manual for complete instructions on testing the accumulator and solenoid.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

PARK BRAKE ADJUSTMENT

SEAT BELT INSPECTION AND MAINTENANCE

WARNING: The parking brake will not hold this machine from moving if one drive wheel is raised above the ground. Before raising one drive wheel above the ground, always block the front and rear of the other three wheels.

50-02

Figure 8

To adjust parking brake, do the following: 1. Push the parking brake lever down to the DISENGAGED position.

2. Turn the handle of the parking brake lever two or three turns clockwise.

3. Pull the parking brake lever back to the ENGAGED position.

4. Put the control lever for the transaxle in third gear.

5. Start the engine and put the direction control lever in FORWARD. 6. Increase the engine speed to 1500 rpm. The machine must not move.

NOTE: If the machine moves after this adjustment is complete, see the Repair Manual for this machine or see your Dealer.

The following procedure should be followed for care maintenance and inspection of the safety seat belt on your machine: 1. Keep sharp edges and items that can cause damage, away from the belts.

2. From time to time, check belts, buckles, retractors, tethers, slack take-up system and mounting bolts for damage.

3. Replace all parts that have damage or wear.

4. Replace belts that have cuts that can make the belt weak.

5. Check that bolt are tight on the seat bracket or mounting.

6. If belt is attached to seat, make sure seat or seat brackets are mounted securely. See below for torque specifications.

7. Keep seat belts clean and dry 8. .Clean belts only with a soap solution and warm water.

9. DO NOT use bleach or dye on the belts, this can make the belts weak TORQUE SPECIFICATION FOR SEATS AND SEAT BELTS

4 5

BD08C201-01

Figure 9

1

ENGAGED POSITION

3

2 Figure 11

BT99A022

BK99A036

DISENGAGED POSITION

6-6

Figure 10

1. 7/16� NF (GRADE 5) - 45 - 81 NM (33 - 60 LB FT) 2. M8 (CLASS 10) - 24 - 44 NM (18 - 32 LB FT) 3. M10 (CLASS 8.8) - 34 - 61 NM (25 - 45 LB FT) (STANDARD SEAT ONLY) 4. 51 MM (2 INCH) SEAT BELT 5. 76 mm (3 INCH) SEAT BELT Issued 04-08

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS

ROLL-OVER PROTECTIVE STRUCTURE Your machine is equipped with an operator Protective Structure, such as: a Rollover Protective Structure (ROPS) or Falling Object Protective Structure ( F O P S ) . A R O P S m ay b e a c a b f r a m e o r a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injur y. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS.

Before you operate this machine, always make sure that the ROPS and operator’s seat belts are correctly installed.

WARNING: You are protected by the ROPS (Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

T h e P r o t e c t i ve S t r u c t u r e i s a s p e c i a l s a fe t y component of your machine.

DO NOT atta ch any device to th e Prote ctive Structure for pulling purposes. DO NOT drill holes into the Protective Structure.

SA080

TORQUE SPECIFICATIONS FOR ROPS CANOPY MOUNTING BOLTS

The Protective Structure and interconnecting components are a certified system. Any damage, fire, corrosion or modification will weaken the structure and reduce your protection. If this occurs, the Protective Structure MUST be replaced so that it w ill provide the same protection as a new Protective Str ucture. Contact your Dealer for Protective Structure inspection and replacement.

1 2

Figure 12

321-6931

Before you operate this machine, always make sure that the ROPS and operator’s seat belt are correctly installed.

MAINTENANCE AND INSPECTION OF ROPS 1. Check the torque of the ROPS mounting bolts. If necessary, tighten the bolts to the correct torque.

See ROPS Torque Specifications in this manual.

2. Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See “Operator’s Seat” in this manual.

Replace the parts that have wear or damage.

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your Case Dealer.

1

BT99A021

Figure 13

1. M12 (GRADE 10.9) - 84 TO 151 NM (62 TO 110 FOOT POUNDS) 2. M20 (GRADE 10.9) - 405 TO 730 NM (300 TO 540 FOOT POUNDS)

SEAT BELT The seat belt is an important part of your ROPS. You must wear the seat belt at all times when you operate the machine.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS DAMAGE TO THE ROPS WARNING: Before you start the engine, always sit in the operators seat, fasten the seat belt, apply the parking brake, and make sure the transmission and direction control levers are in NEUTRAL. Give a warning to all persons around you that you are starting the engine.

After an accident, fire, tip or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job site.

• The Protective Structure MUST be replaced.

• The mounting or suspension for the Protective Structure, operator seat and suspension, seat belts and mounting components and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST be replaced.

DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP, ROLLOVER, COLLISION OR ACCIDENT. WARNING: Do not modify ROPS in any manner. Unauthorized modifications such as welding, drilling, cutting or adding attachments can weaken the structure and reduce your protection. Replace ROPS if subjected to roll-over or damage. Do not attempt to repair.

SB026

Figure 14

WARNING: If you operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement. Do not operate this machine with the ROPS removed.

SA027

Figure 18

SB037

MACHINE CLEANING It is recommended that the complete machine be kept clean. Machine operation in water, mud, dust, landfill, land clearing or forestry will require complete machine clean up. Cleaning includes periodically removal of inspection covers and guards to gain access for cleaning and removal of dirt or debris.

Clean all dirt and foreign material from all engine compartments. Dirt will cause rust on the engine oil pan and the loss of engine oil.

After cleaning is complete, install ALL covers and guards.

DO NOT operate machine with covers or guards removed.

WARNING: Replace all covers or guards after servicing or cleaning the machine.

NEVER operate the machine with covers or guards removed.

CM115

Figure 15

WARNING: Adding additional weight (attachments, etc.) to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

SA028

Figure 16

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Case parts catalog for this machine.

SA029

6-8

Figure 17

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FIRE EXTINGUISHER MOUNTING (IF EQUIPPED) TYPE OF FIRE EXTINGUISHER It is recommended that you have a fire extinguisher on your machine. The fire extinguisher shown below is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from -54째 to 49째C (-65째 to 120째F).

INSPECTION AND CARE EVERY MONTH - It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

E V E RY 6 M O N T H S - H ave t h e d r y c h e m i c a l removed and refilled by a fire equipment technician.

ONCE EACH YEAR - Have the fire equipment technician inspect the fire extinguisher.

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS or FOPS structure. DO NOT make any modifications to the ROPS or FOPS structure.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS WHEELS AND TIRES

Adding Air to the Tires

WARNING: Exploding tires and/or rim parts can cause injury or death. Keep yourself and others out of the DANGER AREA. Stand on the tread side of the tire. Always use the correct air pressure and follow the instructions in this manual for adding air or servicing the tires.

Figure 19

WARNING: DO NOT weld to wheel or rim when a tire is installed. Welding will cause an explosive air/gas mixture that will be ignited with high temperatures. This can happen to tires inflated or deflated. Removing air or breaking bead is not adequate. Tire MUST be completely removed from the rim prior to welding.

Figure 20

WARNING: Explosive separation of the tire and/or rim parts can cause injury or death.

When tire service is necessary, have a qualified tire mechanic service the tire.

This procedure is only for adding air to the tire. If the tire has lost all the pressure or service to the tire or rim is required, do the following: 1. Before you add air, have the tire correctly installed on the machine or put the tire in a restraining device (tire inflation cage).

2. Wear face protection.

3. Use an air hose with remote shutoff valve and self-locking air chuck.

4. Stand behind the tread of the tire and make sure all persons are away from the side of the tire before you start to add air.

5. Inflate the tire to the recommended air pressure.

D O N OT i n f l a t e t h e t i r e m o r e t h a n t h e recommended pressure (see table, page 6-11).

IMPORTANT: Follow the tire manufacture’s recommended pressure specifications whenever adding air to the tires.

Figure 21

WARNING: Tip over Hazard - Stability of this forklift will be affected by wheel and tire installations used other than those specified in this manual. Use only the wheel and tire combinations referenced in this manual.

Figure 22

IMPORTANT: Check the air pressure and the condition of the tires every 100 hours of operation.

See the tire pressure chart on the following page for the correct air pressures.

Tire or Rim Service/Inflating the Tire Always have a qualified tire mechanic service the tires and rims on this machine. It is recommended that you have this mechanic inflate the tires. To prevent accidents, always use a restraining device (tire inflation cage), correct equipment, and correct procedure. Explosive separation of the tire can cause serious injury.

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CHAPTER 6 - MAINTENANCE AND ADJUSTMENTS TIRE AIR PRESSURES Front (Drive) 2/4 WD

Rear (Steer) 2WD Rear (Steer) 4WD

Model

Size

Ply

Tread

Pressure

586

19.5L x 24

12

(R4) IT525

34 psi / (2.3 bar)

586

17.5L x 24

10

(R4) IT525

32 psi / (2.2 bar)

588

19.5L x 24

12

(R4) IT525

34 psi / (2.3 bar)

586

11L x 16 SL

10

(F3) LAB

52psi / (3.6 bar)

588

12 x 16.5 LT

12

CHM

45 psi / (3.1 bar)

All

12 x 16.5 NHS

8

SGLSS

50 psi / (3.4 bar) Figure 23

WHEEL NUT AND BOLT TORQUES When the machine is new or when a wheel is removed for service, check the wheel nut or bolt torques every 10 hours of operation until the wheel nuts or bolts remain tight.

IMPORTANT: The wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts catalog for this machine.

Procedure: 1. Check torque with a dial or click torque wrench. If the nut does not move on the following torques specification, it is tight and does not need re-torqued.

Front Wheel Mounting Nut .................................................................................................. 325 Nm (240 lb ft) Rear Wheel Mounting Nut - 4wd ......................................................................................... 271 Nm (200 lb ft) Rear Wheel Mounting Nut - 2wd ......................................................................................... 156 Nm (115 lb ft) 2. If any of the nuts are loose, re-torque using the following methods.

Front Wheel Mounting Nut ........................................................................... Torque Turn Method (see below) Back off the torque, re-torque to 271 nm (200 lb ft), then turn and additional 30 degrees (one half the distance on one side of the nut.

Rear Wheel Mounting Nut Four Wheel Drive ............................................................................................. 270 to 352 Nm (200 to 260 lb ft) Two Wheel Drive .............................................................................................. 156 to 203 Nm (115 to 150 lb ft)

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MACHINE STORAGE STORAGE PREPARATION

REMOVAL FROM STORAGE

If the machine is to be in storage for more than 30 days, park the machine inside a building. If a building is not available, park the machine in a dry area on planks and cover the machine with a waterproof covering.

Do not start the engine until steps 1 through 12 have been done.

1. Wash the machine.

2. Lubricate the machine at all grease fittings.

3. Paint any area where the paint has been damaged.

1. Change the fuel filters.

2. Put coolant in the engine cooling system.

3. Check the condition of the drive belt. Replace if required.

4. Check the engine oil level.

5. Check the hydraulic oil level.

4. Drain the fuel tank.

6. Check the transmission oil level.

5. Put approximately 8 litres (2 U.S. gallons) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue white.

7. Lubricate the machine at all grease fittings.

6. Drain the flushing oil from the fuel tank.

7. Put 15 ml (one teaspoon) of Shell Oil Company VPI crystals in the fuel tank.

8. Use petroleum base solvent and remove the Rust and Corrosion Preventive from the hydraulic cylinder rods, equipment valve spools and transmission valve spools.

9. See Battery Service in this manual. Install the battery.

8. Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

10. Fill the fuel tank.

9. Change the engine oil and replace the oil filter.

11. Remove the air from the fuel system. See Removing Air from Fuel system in this manual.

10. Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap. Put a Do Not Operate tag on the instrument panel.

11. Clean the primary element for the air filter.

12. Cover the exposed cylinder rods, equipment valve spools, and transmission valve spools with Rust and Corrosion Preventive.

12. If the machine is equipped with a turbocharger, you must prime the turbocharger oil lines with oil.

See Priming the Turbocharger in this manual.

13. Start the engine. It is important that you refer to the procedure on Starting the Engine in this manual.

13. Charge the battery. Remove the battery from the machine and put the battery on a wooden pallet in a cool dry area. If possible, keep the battery in a building where the temperature is above freezing 0°C (32 F). Make sure the battery is clean.

NOTE: Check the battery periodically for the correct electrolyte level. Test the electrolyte with a hydrometer. When the hydrometer reading is near 1.215, charge the battery.

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CHAPTER 7 - ELECTRICAL

Chapter 7 ELECTRICAL TABLE OF CONTENTS ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One Battery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuses And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHAPTER 7 - ELECTRICAL

ELECTRICAL SYSTEM SPECIFICATIONS Type .....................................................................................................................................12 Volt, Negative Ground Batteries .................................................................................................................................................. One, 12 Volt Optional Cold Start Batteries................................................................................Two, 12 Volt, Connected in Parallel Alternator ................................................................................................................................12 Volt, 90 Amp Output Starter........................................................................................................................12 Volt, 2.7 kW Nominal Output LAMPS AND BULBS APPLICATION Flasher and Turn Signal Lamp Bulb ......................................................................................................... No. 1156 Stop and Tail Lamp Bulb .......................................................................................................................... No. 1157 Front and Rear Flood Lamps ........................................................................................................... No. H3, (55W) ACCESSORY OUTLETS There are two 12 volt (30 amp. max.) accessory outlets located on the right side of the instrument console.

Figure 1 12 VOLT / 30 AMP MAX. ACCESSORY OUTLETS (2) LEFT SIDE OF STEERING CONSOLE.

BD08C189-01

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BATTERY SAFETY WARNING: Batteries give off explosive gases. Keep all open flames, sparks and cigarettes away. Ensure adequate ventilation when charging batteries or when using in a confined place. Always protect your eyes when working near batteries.

2

1

WARNING: Do not reverse battery terminals. Connect positive cable ends to positive (+) terminals and negative cable ends to negative terminals (-).

Figure 2

BK99A045

WARNING: When the battery electrolyte is frozen, the battery can explode if, (1) you try to charge the battery, or (2) you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.

1. POSITIVE BATTERY CABLE 2. NEGATIVE BATTERY CABLE

TWO BATTERY SYSTEM

1

2

SA033

WARNING: Before any operation on the components of the electrical circuit, put the key switch in the shut down position. When disconnecting the battery cables, always disconnect the negative (-) cable first. When reconnecting the battery cables, always connect the negative (-) cable last.

Figure 3

BK99A046

WARNING: Connecting auxiliary cables wrongly or short-circuiting batteries terminals can cause an accident. Connect auxiliary starting cables as per the following instructions.

SB034\

Before you service components of the electrical system, always disconnect the NEGATIVE (-) battery cable. This is the negative post on the battery.

Dirt, moisture, and corrosion on the battery will discharge the battery. Clean the battery with Battery Saver and Cleaner. Follow the instructions on the can.

1. POSITIVE BATTERY CABLES 2. NEGATIVE BATTERY CABLES

NOTE: The electrical system in this machine is 12 volts negative ground. Battery/chassis ground, to the positive post(s) on battery is 12 volts.

For the two battery system the two 12 volt batteries are connected in parallel.

BATTERY VENTS Keep the battery vents clean, make sure the vents are not restricted.

Disconnect the alternator wires if you must run the engine with the battery wires disconnected.

Before you use an electric welder, disconnect the alternator wires and instrument cluster.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

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CHAPTER 7 - ELECTRICAL FUSES AND RELAYS

Figure 4

BD08D052-01

The fuses and relays are located behind the access panel below the seat on the right side.

See the fuse decal located on the back side of the access door.

FUSE AND RELAY IDENTIFICATION

Figure 5

87700807

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CHAPTER 8 - SPECIFICATIONS

Chapter 8 SPECIFICATIONS TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 REPLACEMENT BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 OPERATING DATA AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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CHAPTER 8 - SPECIFICATIONS

SPECIFICATIONS ENGINE Make and Model .............................................................................................. Case 445T/M3 Emissions Compliant Bore and Stroke ...................................................................................................... 104 x 132 mm (4.09 x 5.19 inch) Displacement ...................................................................................................................................... 4.5 L (272 in³) Compression Ratio ...................................................................................................................................... 17.5 to 1 Number of Cylinders (firing order) ..............................................................................................................4 (1-3-4-2) Rated Power: Gross (ISO 14396) .............................................................................. 63 kW at 2200 rpm (85 hp at 2200 rpm) Net ...................................................................................................... 60 kW at 2200 rpm (80 hp at 2200 rpm) Engine Speeds: Full Throttle, No Load ............................................................................................................ 2385 to 2480 rpm Full Throttle, Full Load .........................................................................................................................2200 rpm Hydraulic Stall ........................................................................................................................ 2320 to 2410 rpm Converter Stall ....................................................................................................................... 2190 to 2330 rpm Idle Speed ................................................................................................................................. 900 to 925 rpm Peak Torque: Gross (ISO 14396)......................................................................... 374Nm @ 1400rpm (276 lbf-ft @ 1200rpm) Net .................................................................................................. 366Nm @1400rpm (270 lbf-ft @ 1400rpm) Lubrication Angle: Fore and Aft .................................................................................................................................................. 35° Side to Side................................................................................................................................................... 35°

HYDRAULIC SYSTEM Control Valve (main relief) ............................................................... 214 - 235 bar (3100 - 3400 lbf/in²) @ 2200 rpm

ELECTRICAL SYSTEM Type of System .................................................................................................................... 12 volt, negative ground Battery ....................................................................................................................................................... (1) 12 volt Optional Cold Start Batteries .................................................................................. (2) 12 volt, connected in parallel

REPLACEMENT BULBS Front Flood Lamps ........................................................................................................................ Number H3, (55w) Rear Flood Lamps ........................................................................................................................ Number H3, (55w) Turn Signal and Flasher Lamps ............................................................................................................ Number 1156 Stop and Tail Lamps ............................................................................................................................. Number 1157

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CHAPTER 8 - SPECIFICATIONS

CAPACITIES Cooling System .................................................................................................................................. 16.1 L (17.0 qt) Fuel Tank ............................................................................................................................................117 L (31.0 gal) Hydraulic Reservoir Refill Capacity With Filter Change.............................................................................................................................. 54.5 L (58.0 qt) Without Filter Change......................................................................................................................... 52.6 L (56.0 qt) Total System .......................................................................................................................................... 68.1 L (72 qt) Engine Crankcase Oil With Filter Change.............................................................................................................................. 13.6 L (14.4 qt) Axle Capacity Front - Drive Capacity of Center Bowl (Differential).................................................................................................... 14.2 L (15 qt) Capacity of each Planetary End ............................................................................................................. 1.5 L (1.6 qt) Rear - Steer - 4WD Capacity of Center Bowl (Differential)..................................................................................................... 5.5 L (5.8 qt) Capacity of each Planetary End ............................................................................................................. 0.7 L (0.7 qt) Transmission 2WD With or without Filter Change ................................................................................................................ 16 L (16.9 qt) Total System ............................................................................................................................................. 18 L (19 qt) 4WD With or without Filter Change ............................................................................................................. 18.5 L (19.5 qt) Total System ............................................................................................................................................. 20.8 (22 qt)

TRAVEL SPEEDS 1st

2nd

3rd

4th

km/h

MPH

km/h

MPH

km/h

MPH

km/h

MPH

Forward

6.16

(3.83)

11.12

(6.91)

20.01

(13.05)

40.60

(25.22)

Reverse

6.16

(3.83)

11.12

(6.91)

20.01

(13.05)

40.60

(25.22)

NOTE: Travel speeds taken with 19.5 L x 24 - 12 PR drive tires.

WARNING: Changing the components or combination of components on this machine can decrease the stability of the machine and can cause roll over. The correct components or combination of components, such as tires, masts, counterweights, etc., are specified in this manual and parts catalog for this machine. If you have any questions, see your Case dealer.

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CHAPTER 8 - SPECIFICATIONS

WEIGHTS Two Wheel Drive Machines 586G Forklift 4.57 m (15 ft) Standard Mast..................................................................................................... 6,000 kg (13,228 lbs) 6.71 m (22 ft) Standard Mast..................................................................................................... 6,340 kg (13,977 lbs) 588G Forklift *4.57 m (15 ft) Standard Mast ................................................................................................... 7,094 kg (15,639 lbs) *6.71 m (22 ft) Standard Mast ................................................................................................... 7,405 kg (16,325 lbs) NOTE: The above machine shipping weights taken with 19.5 x 24 - 12 PR drive tires, 11 x 16.5 - 10 PR (*12 x 16.5 - 12 PR) steer tires, 1219 mm (48 inch) hook forks, and standard equipment.

Add on Weights 4 Wheel Drive Machines.................................................................................................................... 163 kg (360 lbs) Backrest............................................................................................................................................... 54 kg (120 lbs) Load Control .......................................................................................................................................... 16 kg (35 lbs)

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OPERATING DATA AND DIMENSIONS

Figure 1

BS08C269

586 FORKLIFT WITH 6.71 M (22 FT) MAST Overall Width ....................................................................................................................................2,109 mm (83 in) A. Overall height, forks 152.4 mm (6 in) off ground, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................3,225.8 mm (128 in) with 2WD and 19.5L x 24 tires ...............................................................................................3,302 mm (130 in) B. Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................5,435.6 mm (214 in) with 2WD and 19.5L x 24 tires ............................................................................................5,486.8 mm (216 in) C. Maximum fork height.............................................................................................................4,572.0 mm (180 in) D. Degrees tilt, forward ....................................................................................................................................... 45 ° E. Degrees tilt, rearward...................................................................................................................................... 15° F. Overall length with 1,219 mm (48 in) forks............................................................................4,928.0 mm (194 in) Lift capacity to full height at 610 mm (24 in) load center ............................................................ 1,361.0 kg (3,000 lb)

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Figure 2

BS08C269

586 FORKLIFT WITH 4.57 M (15 FT) MAST Overall Width ....................................................................................................................................2,109 mm (83 in) A. Overall height, forks 152.4 mm (6 in) off ground, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................3,256.2 mm (127 in) with 2WD and 19.5L x 24 tires ............................................................................................3,302.0 mm (129 in) B. Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................5,435.6 mm (300 in) with 2WD and 19.5L x 24 tires ............................................................................................5,486.0 mm (302 in) C. Maximum fork height.............................................................................................................4,572.0 mm (264 in) D. Degrees tilt, forward ....................................................................................................................................... 45 ° E. Degrees tilt, rearward...................................................................................................................................... 15° F. Overall length with 1,219 mm (48 in) forks...............................................................................4,902 mm (193 in) Lift capacity to full height at 610 mm (24 in) load center ............................................................2,722.0 kg (6,000 lb)

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CHAPTER 8 - SPECIFICATIONS

Figure 3

BS08C269

586 FORKLIFT WITH 4.88 M (16 FT) FREE LIFT MAST Overall Width ....................................................................................................................................2,109 mm (83 in) A. Overall height, forks 152.4 mm (6 in) off ground, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................2,565.4 mm (101 in) with 2WD and 19.5L x 24 tires ............................................................................................2,616.2 mm (103 in) B. Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................5,740.4 mm (226 in) with 2WD and 19.5L x 24 tires ............................................................................................5,791.2 mm (228 in) C. Maximum fork height................................................................................................................4,572 mm (180 in) Free Lift with 19.5L x 24 tires...............................................................................................1,701.8 mm (67 in) D. Degrees tilt, forward ....................................................................................................................................... 45 ° E. Degrees tilt, rearward...................................................................................................................................... 15° F. Overall length with 1,219 mm (48 in) forks...............................................................................4,928 mm (194 in) Lift capacity to full height at 610 mm (24 in) load center ............................................................... 1,361 kg (3,000 lb)

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CHAPTER 8 - SPECIFICATIONS

Figure 4

BS08C269

586 FORKLIFT WITH 6.71 M (22 FT) FREE LIFT MAST Overall Width ....................................................................................................................................2,109 mm (83 in) A. Overall height, forks 152.4 mm (6 in) off ground, unloaded: with 2WD and 17.5L x 24 tires ...............................................................................................3,175 mm (125 in) with 2WD and 19.5L x 24 tires ............................................................................................3,225.8 mm (127 in) B. Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires ............................................................................................7,569.2 mm (298 in) with 2WD and 19.5L x 24 tires ...............................................................................................7,620 mm (300 in) C. Maximum fork height.............................................................................................................6,705.6 mm (264 in) Free Lift with 19.5L x 24 tires ................................................................................................2,311.4 mm (91 in) D. Degrees tilt, forward ....................................................................................................................................... 45 ° E. Degrees tilt, rearward...................................................................................................................................... 15° F. Overall length with 1,219 mm (48 in) forks...............................................................................4,902 mm (195 in) Lift capacity to full height at 610 mm (24 in) load center ...............................................................1,361 kg (3,000 lb)

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CHAPTER 8 - SPECIFICATIONS

Figure 5

BS08C269

588 FORKLIFT WITH 4.57 M (15 FT) MAST Overall Width ....................................................................................................................................2,235 mm (88 in) A. Overall height, forks 152.4 mm (6 in) off ground, unloaded: with 2WD and 19.5L x 24 tires ............................................................................................3,251.2 mm (128 in) B. Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires ...............................................................................................5,588 mm (220 in) C. Maximum fork height................................................................................................................4,572 mm (180 in) D. Degrees tilt, forward ....................................................................................................................................... 45 ° E. Degrees tilt, rearward...................................................................................................................................... 15° F. Overall length with 1,219 mm (48 in) forks...............................................................................5,207 mm (205 in) Lift capacity to full height at 610 mm (24 in) load center ............................................................... 3,629 kg (8,000 lb)

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CHAPTER 8 - SPECIFICATIONS

Figure 6

BS08C269

588 FORKLIFT WITH 6.71 M (22 FT) MAST Overall Width ....................................................................................................................................2,235 mm (88 in) A. Overall height, forks 152.4 mm (6 in) off ground, unloaded: with 2WD and 19.5L x 24 tires ............................................................................................3,225.8 mm (127 in) B. Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires ...............................................................................................7,747 mm (305 in) C. Maximum fork height.............................................................................................................6,705.6 mm (264 in) D. Degrees tilt, forward ....................................................................................................................................... 45 ° E. Degrees tilt, rearward...................................................................................................................................... 15° F. Overall length with 1,219 mm (48 in) forks...............................................................................5,232 mm (206 in) Lift capacity to full height at 610 mm (24 in) load center ...............................................................1,814 kg (4,000 lb)

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CHAPTER 9 - INDEX

Chapter 9

INDEX A Access Doors ...................................................... 5-8 Accessory Outlets ................................................ 7-3 After Delivery Check ................................. 10-1, 10-3 Air Pressure, Tire ............................................... 6-11

B Battery Booster Connection to Machine Battery ........ 4-12 Safety .............................................................. 7-4 Service ............................................................ 7-4 Vents ............................................................... 7-4 Battery Fluid Level ............................................. 5-26 Before You Start Each Day ................................. 4-5 Brake Pedal Lock .............................................. 3-11

C Clutch Cutout Button ............................................................ 3-10 Switch .............................................................. 3-8 Cold Start Engine Pre-Heat ............................................ 4-11 Coolant Reservoir .............................................. 5-14 Coolant Solution, Engine ................................... 5-14

D Damage to the ROPS ........................................ 5-22 Decals Instructional ................................................... 5-10 Safety ............................................................ 2-11 Differential Lock Switch ....................................... 3-7 Direction Control Lever ...................................... 3-10 Driving Lamp Switch ............................................ 3-6

E Electrical Service Accessory Outlets ........................................... 7-3 Electrical System ................................................. 7-3 Engine Cooling System ............................................. 5-14 Hourmeter ....................................................... 5-4 Pre-Heat ........................................................ 4-11 Specifications .................................................. 8-3 Engine Lubrication Engine Oil Selection ...................................... 5-19 Engine Oil Level .................................................. 5-9 Engine Operation ................................................. 4-3 Engine Speed .................................................. 4-4 Parking the Machine and Stopping the Engine 4-4 Starting the Engine .......................................... 4-3 87657901NA

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Engine Service Engine Oil Level ...............................................5-9 Oil Change and Filter Replacement ...............5-20 Engine Speed .......................................................4-4 Engine Start Aid Starting the Engine ........................................4-11 Extinguisher Mounting, Fire ..................................6-9

F Filters Engine Oil ......................................................5-20 Fuel ................................................................5-23 Transmission ..................................................5-27 Fire Extinguisher Mounting ...................................6-9 Flasher Lamp Switch ............................................3-6 Fluid and Lubricants .............................................5-5 Fluid Levels Hydraulic ........................................................5-13 Transmission ..................................................5-17 Foot Controls Left Brake Pedal ............................................3-11 Right Brake Pedal ..........................................3-11 Throttle ...........................................................3-11 Front Console Key/Ignition Switch ...........................................3-9 Fuel Filter Replacement .....................................5-23 Fuel Handling Precautions ...................................2-9 Fuses And Relays ................................................7-5

G General Information ..............................................1-1

H Hazardous Chemical Precautions ......................2-10 Height Limits .......................................................4-14 Horn Switch ..........................................................3-6 Hourmeter, Engine ...............................................5-4 Hydraulic Filter Change ......................................5-25 Hydraulic Fluid Change ......................................5-26 Hydraulic Fluid Level Check ...............................5-13

I Identification Numbers Product Identification Number (P.I.N.) .............1-3 ROPS ...............................................................1-3 Inspection of the ROPS ......................................5-21 Instructional Decals ............................................5-10 Instrument Panel ..................................................3-3

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CHAPTER 9 - INDEX Instruments/Controls Operators Seat .............................................. 3-15 Operators Seat Belt ....................................... 3-16

J Jump Start, Battery ............................................ 4-12

K Key Switch, Ignition ............................................. 3-9

L Left Brake Pedal ................................................ 3-11 Lubrication/Filters/Fluids Access Doors .................................................. 5-8 Engine Lubrication ........................................ 5-19 Fluid and Lubricants ........................................ 5-5

M Machine Cleaning ................................................ 6-8 Machine Components .......................................... 1-5 Machine Operation .............................................. 4-5 Machine Storage ............................................... 6-12 Removal From ............................................... 6-12 Storage Preparation ...................................... 6-12 Maintenance of the ROPS ................................. 5-21 Maintenance Precautions .................................... 2-8 Maintenance/Adjustments Machine Cleaning ........................................... 6-8 Roll-Over Protective Structure ........................ 6-7

O Oil Change Engine ........................................................... 5-20 Oil Viscosity/Temperature Ranges .................... 5-19 Operating Data and Dimensions ......................... 8-6 Operating in Cold Weather ................................ 4-11 Operating in Hot Weather .................................. 4-11 Operating Instructions ......................................... 4-3 Booster Battery Connection .......................... 4-12 Operating in Cold Weather ............................ 4-11 Operating in Hot Weather ............................. 4-11 Run-In Period of a New Machine .................... 4-3 Transporting the Machine ............................. 4-10 Operating Precautions ......................................... 2-7 Operation Before You Start Each Day ............................. 4-5 Operators Seat Belt ........................................... 3-16 Owner, To The ..................................................... 1-1

P Parking the Machine and Stopping the Engine ... 4-4 Plastic and Resin Parts ....................................... 5-4

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R Rear Work Lamp Switch .......................................3-6 Relays and Fuses .................................................7-5 Replacing the Fuel Filter ....................................5-23 Right Brake Pedal ..............................................3-11 Roll-Over Protective Structure ..............................6-7 ROPS Damage Information ......................................5-22 Damage To ......................................................6-8 Maintenance and Inspection .................. 5-21, 6-7 Run-In Period of a New Machine .........................4-3

S Safety Decals .....................................................2-11 Safety, Battery ......................................................7-4 Safety/Decals/Hand Signals Safety Decals .................................................2-11 Seat Belt .............................................................3-16 Seat Belt Precautions .........................................2-10 Seat Controls Backrest Tilt Adjustment Control ....................3-15 Forward/Rearward Control .............................3-15 Height Adjustment Control .............................3-15 Weight Adjustment Control ............................3-15 Sides of the Machine Right-Hand, Left-Hand, Front, and Rear ..........1-2 Specific machine precautions .............................2-10 Specifications Engine Specifications .......................................8-3 Operating Data and Dimensions ......................8-6 Starting and Stopping Precautions .......................2-6 Starting the Engine ..................................... 4-3, 4-11 Steer Axle Switch - 4WD ......................................3-7 Storage Machine Storage ............................................6-12 Preparation ....................................................6-12 Removal From ...............................................6-12 Switches Clutch Cutout ...................................................3-8 Differential Lock ...............................................3-7 Driving Lamp ....................................................3-6 Flasher Lamp ...................................................3-6 Horn .................................................................3-6 Key/Ignition ......................................................3-9 Rear Work Lamp ..............................................3-6 Steer Axle - 4WD .............................................3-7 Turn Signal .......................................................3-6

T Tire Air Pressure ...................................................6-11 Condition ........................................................5-18 To the Owner ........................................................1-1 Towing a Disabled Machine .................................4-9 Issued 04-08

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CHAPTER 9 - INDEX Transmission Filter Replacement ........................................ 5-27 Fluid Levels ................................................... 5-17 Shift Lever ..................................................... 3-10 Transmission Controls Clutch Cutout ................................................ 3-10 Direction Control Lever ................................. 3-10 Transmission Shift Lever ............................... 3-10 Transporting the Machine .................................. 4-10 Turn Signal Switch ............................................... 3-6

U Utility Safety ......................................................... 2-4

W Walk-Around Inspection ...................................... 4-3 Weight Limits ..................................................... 4-14

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CHAPTER 10 - AFTER DELIVERY CHECK

Chapter 10 AFTER DELIVERY CHECK - DEALER COPY AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.):

COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Check the pressure setting of the main relief valve.

FUEL SYSTEM GENERAL

Check for leaks.

Look for oil leaks and loose parts.

Drain water and sediment from the fuel tanks.

Tighten all hose clamps.

Check drive chain tension

ELECTRICAL SYSTEM Check battery.

Check track shoe torque.

Check operation of starter, alternator, and instruments.

Check brake operation.

Check operation of all lamps.

Check the control levers for correct operation.

Check the operators seat for correct operation.

LUBRICATION SAFETY

Lubricate all pivot points.

Inspect the ROPS. Check the safety decals and replace if necessary.

ENGINE Check condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Make sure the machine has the operators manual in the manual storage box.

Check engine speed at idle and at full throttle.

Service air cleaner.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature:

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CHAPTER 10 - AFTER DELIVERY CHECK

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CHAPTER 10 - AFTER DELIVERY CHECK

AFTER DELIVERY CHECK - OWNERS COPY AFTER FIRST 100 HOURS OF OPERATION OF NEW MACHINE

Owners Name: Address: Dealers Name: Address: Hourmeter Indication:

Machine Model Number: Machine Product Identification Number (P.I.N.):

COOLING SYSTEM

HYDRAULIC SYSTEM

Check the coolant levels.

Check the oil level.

Check for leaks.

Check the pressure setting of the main relief valve.

FUEL SYSTEM GENERAL

Check for leaks.

Look for oil leaks and loose parts.

Drain water and sediment from the fuel tanks.

Check tire pressure.

Tighten all hose clamps.

ELECTRICAL SYSTEM Check battery.

Check track shoe bolt torque.

Check operation of starter, alternator, and instruments.

Check brake operation.

Check operation of all lamps.

Check the control levers for correct operation.

Check the operators seat for correct operation.

LUBRICATION SAFETY

Lubricate all pivot points.

Inspect the ROPS. Check the safety decals and replace if necessary.

ENGINE Check condition of drive belt.

Check the operator restraint system.

Check engine oil level.

Make sure the machine has the operators manual in the manual storage box.

Check engine speed at idle and at full throttle.

Service air cleaner.

DEALER: Make sure the owner and/or operator understands all the safety and information decals, the service information, and the service procedures in this manual.

Technician Signature: Dealer Signature: Owner Signature:

87657901NA

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