Case 586H 588H Tier 4 Rough Terrain Forklift (RTFL) Operators Manual - PDF DOWNLOAD

586H 588H Tier 4 Rough Terrain Forklift (RTFL) from PIN NCC570000

OPERATOR’S MANUAL

Part number 84587658 1st edition English July 2012

Contents 1 GENERAL INFORMATION Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 CNH America LLC technical manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Note to the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Read the Operator's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Manual storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Right, left, front, and rear of the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Product Identification Number (PIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Exhaust Gas Recirculation (EGR) exhaust treatment - Product overview . . . . . . . . . . . . . . . . 1-11

2 SAFETY INFORMATION Safety rules and signal word definitions and signal word definitions . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules - California Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Do Not Operate hang tag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety rules - Basic operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Safety rules - Electrical storm safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety rules - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Safety rules - Fire or explosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Safety rules - Fuel handling precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Safety rules - Hazardous chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Safety rules - Lifting and overhead loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Safety rules - General maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Safety rules - Mounting and dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety rules - Operator precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Safety rules - Specific precautions to this machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Safety rules - Transporting precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Safety rules - Utility precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Safety rules - Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Safety rules - Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Safety rules - Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

3 CONTROLS/INSTRUMENTS ACCESS TO OPERATOR'S PLATFORM Proper entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

OPERATOR'S SEAT Operator seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

FORWARD CONTROLS

Console controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Instrument control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Menu screen display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

4 OPERATING INSTRUCTIONS COMMISSIONING THE UNIT Run in period of a new machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

STARTING THE UNIT Before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold temperature operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot temperature operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Booster battery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-3 4-4 4-6 4-7

STOPPING THE UNIT Shutting down the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

MOVING THE UNIT Uniform braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling on a hill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before operating the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Wheel Drive (4WD) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10 4-11 4-12 4-12 4-13 4-14 4-15

5 TRANSPORT OPERATIONS SHIPPING TRANSPORT Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

RECOVERY TRANSPORT Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

6 WORKING OPERATIONS GENERAL INFORMATION Machine stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Adjusting the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

7 MAINTENANCE GENERAL INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General safety before you service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Oil life reset - manually - Resetting the oil life monitoring system . . . . . . . . . . . . . . . . . . . . . 7-3 Engine side panel latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Battery disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Definition of fuse, relay, and diode icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Diagnostic/service tool port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Fluid capacities and lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

MAINTENANCE CHART Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

At warning message display Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel Particulate Filter (DPF) regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-22 7-25 7-26 7-28

Initial 10 hours Wheel nut and bolt torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Every 10 hours of operation or daily Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Initial 20 hours Transmission oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Rear steer axle fluid level - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Every 50 hours Fuel system water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant reservoir (de-aeration reservoir) fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle grease fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast pivot grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast carriage roller grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast chain roller grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-38 7-40 7-42 7-43 7-44 7-44 7-44

Initial 100 hours Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-46 7-48 7-50 7-52 7-53

Every 250 hours Seat slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle fluid level - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle breather valve - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle drive shaft - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle breather valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant reservoir (de-aeration reservoir) fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tire pressure and condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt cylinder - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side-shift cylinder bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-54 7-55 7-56 7-57 7-58 7-59 7-60 7-61 7-62 7-64 7-66 7-68 7-69 7-70 7-71 7-72

Every 500 hours Roll Over Protective Structure (ROPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carriage thrust rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-73 7-75 7-77 7-79 7-80

Every 1000 hours Hydraulic fluid and filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission fluid and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle fluid - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-81 7-83 7-84 7-85 7-87 7-89

Every 2000 hours of operation or annually Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92 Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Load rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98

Every 3000 hours Diesel Particulate Filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

Every 4000 hours Engine Crankcase Ventilation (CCV) Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

As required Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Tire pressure and condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101 Engine air precleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103 Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105 Disable parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107

STORAGE Forklift storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Forklift removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110

8 SPECIFICATIONS Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Electrical systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Dimension — 586H Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Dimension — 588H Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

9 ACCESSORIES Vandal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Auxiliary power outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION Intended use

RAPH12FRK1112FA

1

H Series Rough Terrain Forklift The rough terrain 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. Make sure the machine is suitably equipped for the type of work to be performed.

All persons who will be operating this machine shall posses a valid local vehicle operating permit and/or other applicable local age work permits.

Do not use this machine for any purpose or in any manner other than as described in the manual, safety signs, or other product safety information provided with the machine. These materials define the machine's intended use.

Consult an authorized dealer 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.

ATTENTION: The fuel system and engine on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators, and users is strictly prohibited by law. Failure to comply could result in government fines, rework charges, invalid warranty, legal action, and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be done by a certified technician only!

Your CASE CONSTRUCTION dealer is available for any further information. They will also provide any after-sales service you may need, and genuine spare parts, your guarantee of quality and match. CASE CONSTRUCTION customer assistance is also available. Call 1-866-54-CASE6 (1-866-542-2736) or email casecustomerassistance.na@cnh.com.

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1 - GENERAL INFORMATION

CNH America LLC technical manuals Manuals are available from your dealer for the operation, service, and repair of your machine. For prompt convenient service, 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. This Operator's Manual does not include instructions for attachments. Read the manual(s) provided with the authorized attachment to learn safe maintenance and operation.

Always give the machine name, model, and Product Identification Number (PIN) of your machine so your dealer can provide the correct manuals for your machine.

The company is continually striving to improve its products and therefore reserves the right to make improvements and changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.

All data given in this manual is subject to production variations.

NOTICE: Operating and service messages displayed on the instrument control panel may vary from what is shown in the Operator's Manual. Should this occur, adhere to the latest instruction on the electronic operating panel.

Dimensions and weights are approximate only and the illustrations do not necessarily show the machine in standard condition. For exact information about any particular machine, consult your dealer.

Note to the Owner This manual contains important information about the safe operation, adjustment, and maintenance of your forklift.

This manual is divided into chapters as outlined in the table of contents. Refer to the 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 machine will remain a reliable working tool as long as it is kept in 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.

The information in this manual is provided on the basis of information that was available at the time that the manual was written. Settings, procedures, part numbers, software, and other items can change. These changes can affect the service that is given to the machine. Ensure that you have the complete and most current information from your dealer before you start any machine operation.

The 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. Consult your dealer to obtain additional manuals or manuals in other languages.

An Associates of Equipment Manufacturers (AEM) safety booklet is included with each machine. Take the time to read the booklet and understand its content.

Contact your dealer for any further information or assistance about your machine. Your dealer has manufacturer approved service parts. Your dealer has technicians with special training that know the best methods of repair and maintenance for your machine.

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1 - GENERAL INFORMATION

Read the Operator's Manual Improper operation of this machine can cause death or serious injury. Before using the machine, make certain that every operator: •

is instructed in safe and proper use of the machine.

•

reads and understands the manual(s) pertaining to the machine.

•

reads and understands all safety signs on the machine.

•

clears the area of other persons and domestic animals.

•

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 CNH America LLC instructions on machine operation and maintenance.

Manual storage Keep the Operator's Manual and the Associates of Equipment Manufacturers (AEM) safety booklet in the storage compartment located on the left side of the operator seat.

The Operator's Manual and the AEM safety booklet must be available for use by all operators.

RAPH12FRK0145AA

1

Electro-Magnetic Compatibility (EMC) Interference may arise as a result of add‐on equipment which may not necessarily meet the required standards. As such interference can result in serious malfunction of the unit and/or create unsafe situations, you must observe the following: •

The maximum power of emission equipment (radio, telephones, etc.) must not exceed the limits imposed by the national authorities of the country where you use the machine.

•

The electro‐magnetic field generated by the add‐on system should not exceed 24 V/m at any time and at any location in the proximity of electronic components.

•

The add‐on equipment must not interfere with the functioning of the onboard electronics. Failure to comply with these rules will render the warranty null and void.

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1 - GENERAL INFORMATION

Right, left, front, and rear of the machine The terms right hand and left hand, when used in this manual, indicate the right and left sides of the machine as seen from the operator's seat.

RAIL12FRK1131GA

Top view of machine 1.

Front of machine

2.

Right side of machine

3.

Rear of machine

4.

Left side of machine

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1

1 - GENERAL INFORMATION

Component identification

RAIL12FRK1095GA

1.

Forklift mast (standard mast or optional Freelift mast)

2.

Roll Over Protective Structure (ROPS)

3.

Exhaust stack

4.

Air pre-cleaner

5.

Rear counterweight

6.

Rear steer axle

7.

Hydraulic reservoir

8.

Manual and tool storage compartment

9.

Battery compartment

10.

Front drive axle

11.

Lifting forks

1-5

1

1 - GENERAL INFORMATION

RAIL12FRK1096GA

2

1.

Rear work lights

2.

Operator’s seat

3.

Steering column

4.

Front work lights

5.

Grab handles

6.

Transport tie down — four locations (both sides of forklift mast and counterweight)

7.

Fuse and relay location

8.

Entry steps (both sides of machine)

9.

Fuel reservoir

10.

Side engine panels (both sides of machine)

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1 - GENERAL INFORMATION

RAPH12FRK1111FA

3

1.

Forward Neutral Reverse (F-N-R) lever

2.

Steering wheel and column

3.

Forklift controls levers— lift, tilt, side shift, and optional auxiliary (not shown)

4.

Right side control panel switches — differential lock, 4WD (optional), parking brake, clutch cutout, and key ignition switch

5.

Foot throttle

6.

Right and left brake pedal with locking device

7.

Four speed shift lever with clutch cutout button

8.

Left side control panel switches — horn, rear lights, front lights, hazard \ flashers, and turn signal

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1 - GENERAL INFORMATION

Product Identification Number (PIN) Record the machine and Product Identification Numbers (PIN). If needed, provide these numbers to your dealer when you require parts or information for your machine. Keep a record of these numbers 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 identification Model name PIN Model year

Locate the PIN plate on the upper right-hand side of the Roll-Over Protective Structure (ROPS).

RAPH12FRK0130AA

1

RAPH12FRK0178AA

2

RAPH12FRK0127AA

3

NOTE: The PIN is also stamped on the right hand side of the frame.

Roll-Over Protective Structure (ROPS) PIN Locate the PIN plate on the upper left-hand side of the ROPS.

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1 - GENERAL INFORMATION

Engine PIN Locate the PIN plate on the left-hand side of the oil pan near the fuel water separator.

RAPH12FRK0250AA

4

RAPH12FRK0257AA

5

RAPH12FRK0252AA

6

RCPH10TLB394AAF

7

Transmission PIN Locate the PIN plate on the left-hand side of the transmission housing.

Rear steer axle — Two wheel drive (2WD) PIN Locate the PIN plate on the left-hand front side of the rear steer axle.

Rear steer axle — Four wheel drive (4WD) PIN Locate the PIN on the left-hand front side of the rear steer axle.

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1 - GENERAL INFORMATION

Front drive axle PIN

RAPH12FRK0276AA

8

RAPH12FRK0225AA

9

Forklift mast PIN

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1 - GENERAL INFORMATION

Exhaust Gas Recirculation (EGR) exhaust treatment - Product overview What is Exhaust Gas Recirculation (EGR)?

Your CASE CONSTRUCTION machine is equipped with additional components to comply with national and local exhaust emissions requirements. EGR works by recirculating a portion of the engines exhaust gasses back into the engine’s combustion chamber to lower combustion temperatures.

The main components of the EGR system include: •

EGR valve

•

Diesel Particulate Filter (DPF)

•

Diesel Oxidation Catalyst (DOC)

•

Exhaust gas temperature sensors

•

Differential pressure sensor

•

Throttle valve actuator

What is a Diesel Particulate Filter (DPF)?

A Diesel Particulate Filter (DPF) is a filter mounted in the exhaust stream. During normal operating conditions, the exhaust gasses pass through the porous walls of the DPF and trap Particulate Matter (PM) generated by the combustion process of the engine. When channels inside the DPF fill up with PM, the system must be cleaned. The cleaning process is called Regeneration.

How does the regeneration process work?

When the DPF becomes restricted, the system will need to be cleaned or regenerated by raising exhaust temperatures to burn off the trapped Particulate Matter (PM). This process is usually done automatically, but may require a manual regeneration sequence to be activated depending on operating conditions. Burned PM will leave behind traces of ash within the DPF. The ash must be cleaned out by a CASE CONSTRUCTION dealer outfitted with machines specifically designed to clean o DPF systems. In severe cases the DPF may need to be replaced. Refer to the 7-20 for service intervals.

Automatic regeneration When the DPF enters automatic regeneration mode, the display will indicate “DPF ON”, several conditions need to be followed to properly let the machine perform this function.

•

During this mode do not idle or shut the machine down.

•

Hot exhaust gasses will be generated, use in well ventilated area away from combustible materials.

•

Use the machine under normal work scenarios until the automatic regeneration process has completed.

•

If the machine will be idled during this time, shut the machine down and perform a manual regeneration upon resume of operation.

Manual regeneration When automatic regeneration of the DPF is inhibited, unsuccessful or the machine had to be shutdown during the automatic regeneration process, manual regeneration is used. During the manual regeneration mode, the display will indicate “DPF ON”, several conditions need to be followed to properly let the machine perform this function.

•

During this mode, the machine will be unusable

•

Move the machine to a safe place away from combustible materials.

•

Hot exhaust gasses will be generated, use in well ventilated area away from combustible materials.

•

Let the regeneration finish before shutting the machine off.

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1 - GENERAL INFORMATION

Finding a Diesel Particulate Filter (DPF) cleaning facility To find a CASE CONSTRUCTION dealer that is fully equipped to service your DPF system, please call the number below.

CASE CONSTRUCTION Customer Assistance: 1-866-542-2736 casecustomerassistance.na@cnh.com

U.S. EPA and California Emissions Control Warranty Statement CASE CONSTRUCTION warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built and equipped so as to conform with U.S. Environmental Protection Agency regulations applicable at the time of manufacture and that it is free from defects in workmanship or material which would cause it not to meet these regulations for a period of: •

5 years or 3,000 hours of operation, whichever occurs first.

NOTE: This warranty applies to all units operated in the United States or Canada.

Coverage The model year, class of diesel engine, and emission application determination for your engine are identified on the Emission Control Information Label. This label is affixed to one of the following areas of the engine: the top of engine's rocker arm cover, the right-hand side of the oil pan, and the right-hand side of the engine front gear cover.

The warranty period begins on the date the new equipment is sold to the first retail purchaser. The presence of the emission control label is the indication that the engine conforms to the applicable standards. Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period.

The engine owner has responsibility to perform all the required maintenance listed in the Owner's Manual. CASE CONSTRUCTION will not deny an emission warranty claim solely because no record of maintenance exists; however, a claim may be denied if failure to perform maintenance resulted in the failure of a warranted part.

It is recommended that replacement parts used for maintenance or repairs be CASE CONSTRUCTION Service Parts to maintain the quality originally designed into your emission certified engine. The use of non- CASE CONSTRUCTION parts does not invalidate the warranty on other components unless the use of such parts causes damage to warranted parts.

The manufacturer is liable for damages to other engine components caused by the failure of any warranted emission control system part. CASE CONSTRUCTION is not responsible for failures resulting from improper repair or the use of parts that are not genuine CASE CONSTRUCTION or CASE CONSTRUCTION approved parts.

Component coverage New engines certified for sale and registered will have the following items covered by the emission warranty, depending on the emission level of the engine, if the items were first installed on the new engine as original equipment: Fuel injection system

Exhaust after treatment Devices (if applicable)

•

Fuel injection pump

•

Diesel Oxidation Catalytic (DOC)

•

Fuel injectors

•

Diesel particulate filter (DPF)

•

Fuel injection lines

Exhaust Gas Recirculation Systems (EGR)

Air induction system

•

EGR valve assembly EGR cooler

•

Intake manifold

•

•

Turbocharger system (includes exhaust manifold)

Cold Start Enrichment Systems

•

Charge air cooler

Positive Crankcase Ventilation (PCV) system or Crankcase Ventilation (CCV) (if applicable) •

PCV or CCV valve

•

Oil fill cap

Electronic Control Units, Sensors, Solenoids, and Wiring harnesses used in above systems

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1 - GENERAL INFORMATION

Emissions warranty does not cover •

Repairs arising from storage deterioration, failure to maintain the equipment, negligence, alteration, improper use of the equipment, collision or other accident, vandalism, or other casualty, or operation beyond rated capacity or specification.

•

Repairs arising from abuse or neglect, including but not limited to: operation without adequate coolant or lubricants, adjustments to the fuel system outside equipment specifications, over-speeding, improper storage, starting, warm-up, or shutdown practices, incorrect fuel or contaminated fuel, oil or other fluids.

•

Normal maintenance services, such as engine tune-ups, engine fuel system cleaning, checks, adjustments, shimming, etc.

•

Items replaced due to customer demand.

•

Labor charges performed by anyone except a dealer authorized by contract to repair the equipment, unless they qualify under special provisions (i.e. outside labor).

•

Any and all travel costs for items such as towing, service calls, or transporting a unit to and from the place where the warranty service is performed.

•

Normal maintenance costs, including but not limited to: lubricants, coolants, fluids, fuel, filters, and associated labor. Lubricants, filters, and coolants may qualify for warranty reimbursement if they require replacement as a DIRECT RESULT of a defect in material or workmanship.

•

Claims involving the inspection or reconditioning of units after storage or prior use.

•

Repairs arising from service performed by agents not approved by CASE CONSTRUCTION.

•

Repairs arising from any unauthorized modification to the product or the use of non- CASE CONSTRUCTION parts, implements or attachments.

•

Removal, replacement, or installation of non- CASE CONSTRUCTION optional equipment, attachments or components.

•

Premiums charged for overtime labor costs or out of shop expenses.

•

Economic loss including lost profits, crop loss, equipment rental, or other expense.

•

Unauthorized modification or updating machines without a warrantable failure.

•

Any and all costs of dealer shop supplies incurred with repairs, including but not limited to: solvents, cleaners, anti-seize lubricants, loctite, sealant, adhesive, oil-dry, shop towels, etc.

•

Failure of the machine, its implements or attachments caused by improper field application or loading.

•

Any and all costs for coolant, fuel, or lube (oil) analysis including supplies and lab recommendations.

•

Cost associated with cleaning of machine in preparation for servicing.

Glossary Acronym EGR DPD DPF DOC ISO MSDS NOx PPE ULSD PM

Definition Exhaust Gas Recirculation Diesel Particulate Diffuser Diesel Particulate Filter Diesel Oxidation Catalyst International Organization for Standardization Material Safety Data Sheet Nitrogen Oxide Personal Protective Equipment Ultra Low Sulfur Diesel Particulate Matter

Units of measure Symbol C F ° %

Definition Centigrade Fahrenheit Degree Percent 1-13

1 - GENERAL INFORMATION

Symbol < > mg/kg

Definition Less than Greater than Milligrams per kilogram

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2 - SAFETY INFORMATION

2 - SAFETY INFORMATION Safety rules and signal word definitions and signal word definitions Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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2 - SAFETY INFORMATION

Safety rules - California Proposition 65 Warning

RCIL08CCH001EAA

1

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

Do Not Operate hang tag Before you start servicing the machine, attach a 'Do Not Operate' warning tag to the machine. Attach the tag in an area that is easily visible.

RH99E029

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1

2 - SAFETY INFORMATION

Safety rules - General

Understand that your safety and the safety of other workers or bystanders is measured by how you service and operate this machine. Know the positions and operation of all controls before you try to operate. CHECK ALL CONTROLS IN A SAFE AREA BEFORE STARTING YOUR WORK. 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.

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 signs on the machine before you operate or service the machine. See your dealer if you have any questions.

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.

CNH America LLC is continuing to work for your safety by making forklifts with better protection and by providing rules for safe operation.

•

Do not rush. Walk, do not run.

•

Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris.

•

Wear protective equipment when appropriate. 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 user's intention. Faded and soiled vest are no longer as highly visible as original intent. See the manufacture’s recommendation.

•

Wear the seat belt to maximize the protection capability of the cab or Roll Over Protective Structure (ROPS). Inspect the mounting bolts for the seat belt and the ROPS on a daily basis to ensure their integrity.

•

Do not permit riders on the machine or attachments.

•

Remove all loose objects stored in the machine.

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

•

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.

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2 - SAFETY INFORMATION

Safety rules - Basic operating

WARNING Escaping fluid!

Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately.

Failure to comply could result in death or serious injury.

W0178A

WARNING Some components may continue to run down after disengaging drive systems.

Make sure all drive systems are fully disengaged.

Failure to comply could result in death or serious injury.

W0113A

•

Always check the operating and the road safety of the machine before starting.

•

Always make sure the working area is clear of other persons, domestic animals, tools, etc. before you start operating the machine.

•

Another worker or bystander within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area.

•

Always sound horn before starting the machine.

•

Never operate the engine in enclosed spaces as harmful exhaust gases may build up.

•

Check brakes, steering, and other machine control devices in accordance with maintenance instructions, prior to starting operation. Observe all gauges or warning instruments for proper operation. Operate all controls to ensure proper operation. If any malfunctions are found, remove the key and attach 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. Make sure the machine is securely parked. Remove the key and attach a 'Do Not Operate' tag on the machine until the malfunction is corrected or the machine can be safely towed.

Make sure all components are in good condition and tighten all connections before starting the engine or pressurizing the system.

chine. Never operate the machine with the shields removed. Always close access doors or panel before operating the machine.

•

Before starting the engine, be sure all operating controls are in the neutral or park lock position.

•

Start the engine only from the operator’s seat.

•

Operate controls only when seated in the operator's seat, except for those controls expressly intended for use from other locations.

•

Do not allow other persons to ride on the machine or on an attachment/implement.

•

Operate and drive the machine with care and at speed compatible with conditions. Use extra caution when operating over rough ground, on slopes, and when turning.

•

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

•

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

•

Understand the machine limitations and keep the machine under control.

•

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

•

Select a gear that will prevent excessive speed when going downhill. Do not coast downhill.

•

DO NOT attempt to remove material from any part of the machine while it is being operated or components are in motion.

Make sure all guards and shields are in good condition and properly installed before operating ma-

2-4

2 - SAFETY INFORMATION

•

Before leaving the vehicle:

•

•

Park the vehicle on a hard, level surface.

•

Put all controls in neutral or park lock position.

•

Engage the parking brake; use wheel chocks if required.

•

Lower all hydraulic equipment, attachments/ implements or tools, to the ground.

•

In a rare circumstance when the engine must be running without an operator at the controls, take these precautions: •

Reduce engine speed to low idle.

•

Disengage all drive systems.

•

Put the transmission in neutral.

•

Apply the parking brake.

Shut down the engine and remove the key.

Safety rules - Electrical storm safety

•

Do no operate machine during an electrical storm.

•

If you are on the ground during an electrical storm, stay away from machinery and equipment. Seek shelter in a permanent, protected structure.

•

2-5

If an electrical storm should strike during operation, remain in the cab. Do not leave cab or operator's platform. Do not make contact with the ground or objects outside the machine.

2 - SAFETY INFORMATION

Safety rules - Battery

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

•

When using auxiliary batteries or connecting booster cables to start the engine, use the procedure shown in this manual. DO NOT short across terminals.

•

Ventilate when charging or using a battery in an enclosed area.

When working around storage batteries, remember that all of the exposed metal parts are “live”. Never lay a metal object across the terminals because a spark, short circuit, explosion, or personal injury may result.

•

When disconnecting the battery terminals, remove the negative (-) cable first; then remove the positive (+) cable. When connecting the battery terminals, connect the positive (+) cable first; then connect the negative (-) cable.

Frozen electrolyte can cause the battery to explode.

Do not charge a frozen battery or use a frozen battery to booster start the machine. Always keep the battery at full charge to prevent the electrolyte from freezing.

•

Keep batteries out of reach of children and other unauthorized persons.

•

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

•

Follow manufacturer's instructions when storing and handling batteries.

•

Always wear eye protection when working with a battery.

•

Do not create sparks or have open flame near the battery.

•

Do not weld, grind, or smoke near a battery.

• •

•

Disconnect the battery (both terminals) before welding on any part of the machine. Failure to do so may cause damage to sensitive electrical components. For additional welding precautions, refer to page 7-8.

2-6

2 - SAFETY INFORMATION

Safety rules - Fire or explosion prevention

•

Leaked or spilled fuel/oil on hot surfaces or electrical components can cause a fire.

•

Sparks from the electrical system or engine exhaust can cause an explosion and fire. Before you operate the machine in an area with flammable dust or vapors, use good ventilation to remove the flammable dust or vapors.

•

•

•

Engine fuel can cause an explosion or fire. Do not fill the fuel tank with the engine running, if you are near an open fire, or if you are welding, smoking, etc.

Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable solvent before welding or flame cutting.

Always have a fire extinguisher near or on the machine. Make sure the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

•

If a fire extinguisher has been used, always recharge or replace the fire extinguisher before operating the machine.

•

Do not expose the machine to flames, burning brush, or explosives.

•

At least once each day, and at the end of the day, remove all trash and debris from the machine especially around hot components such as engine, transmission, exhaust, battery, etc. More frequent cleaning of the machine may be necessary depending on the operating environment and conditions.

•

cleaning of the machine may be necessary depending on the operating environment and conditions.

•

If the machine has an oil, fuel, or hydraulic fluid leak, always repair the leak and clean the area before operating.

•

Keep the cooling system clean and maintain the correct coolant level.

•

Do not store oily rags or other flammable materials on the machine.

•

Inspect the electrical system for loose connections or frayed insulation. Repair or replace loose or damaged parts.

•

Promptly investigate any unusual smells or odors that may occur during operation of the machine.

•

If you weld, grind, or use a cutting torch on the machine:

•

At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fan, etc. More frequent

2-7

•

Clean the area to be repaired.

•

Disconnect or isolate the drive train controller.

•

Keep the ground cable from the welder as near to the work area as possible.

Sparks or flame can cause the hydrogen gas in a battery to explode. To prevent an explosion: •

Connect the negative (-) cable last.

•

When connecting booster cables to start the engine, use the procedure shown in this manual.

•

Do not short circuit the battery posts with metal items.

•

Do not weld, grind, or smoke near the battery.

2 - SAFETY INFORMATION

Safety rules - Fuel handling precautions

•

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

•

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

•

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.

Use ultra-low sulfur diesel fuel only.

Safety rules - Hazardous chemicals

•

•

•

If you are exposed to, or come in contact with, hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolants, etc. required for the function of the machine can be hazardous. They may be attractive and harmful to domestic animals as well as humans.

Material Safety Data Sheets (MSDS) provide information about chemical substances within a product, safe handling procedures, first aid measures, and procedures to be taken in the event of a spill or accidental release. MSDS are available from your dealer.

Before you service the machine, check the MSDS for each lubricant, fluid, etc. used in the machine.

This information indicates the associated risks and will help you service the machine safely. Follow the

information in the MSDS, on manufacturer's containers, as well as the information in this manual when servicing the machine.

•

Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations. Check with local environmental and recycling centers or your dealer for correct disposal information.

•

Store fluids and filter in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

•

Keep out of reach of children or other unauthorized persons.

2-8

2 - SAFETY INFORMATION

Safety rules - Lifting and overhead loads

•

Never lift loads in excess of capacity.

•

Carry loads in recommended positions for maximum stability.

•

Never use buckets, forks, etc. or other lifting, handling, or digging equipment to lift persons.

•

Do not use raised equipment as a work platform.

•

Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area of movement while the machine is in operation.

•

Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unexpectedly and crush persons underneath it.

•

Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylinders must be mechanically

locked or supported if they are left in a raised position for service or access.

•

Buckets, forks, etc. or other lifting, handling, or digging equipment and its load will change the center of gravity of the machine. This can cause the machine to tip on slopes or uneven ground.

•

Load items can fall off the bucket or lifting equipment and crush the operator. Care must be taken when lifting a load. Use proper lifting equipment.

•

Use the recommended machine ballast and counterweighting.

•

Do not lift load higher than necessary. Lower loads to transport. Remember to leave appropriate clearance to the ground or other obstacles.

•

Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.

2-9

2 - SAFETY INFORMATION

Safety rules - General maintenance safety

•

Keep area used for servicing the machine clean and dry. Clean up spilled fluids.

•

Service machine on firm level surface.

•

Do not attempt service unless trained. Refer to manuals and experienced service personnel for help.

•

Wear protective glasses and other required safety equipment when servicing the machine.

• •

•

•

•

•

while the system is hot. Allow the system to cool before removing cap. When removing a cap, turn it slowly to allow pressure to escape before completely removing the cap.

•

Wear gloves to protect hands when handling cables.

Engine, transmission, exhaust components, and hydraulic lines may become hot during operation.

Take care when servicing such components. Allow surfaces to cool before handling or disconnecting hot components. Wear protective equipment where appropriate.

•

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

Continuous long term contact with hydraulic fluid may case skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

•

Do not attempt to clean, lubricate, clear obstructions, or make adjustments to the machine while it is in motion or while engine is running.

When replacing hardened pins, use a brass drift or other suitable material between the hammer and pin.

•

When welding, follow the instructions in this manual. Always disconnect battery before welding on machine. Always wash your hands after handling battery components.

•

Keep the brakes and steering systems in good operating condition.

Unsupported hydraulic cylinders can lose pressure and drop the equipment causing a crushing hazard. Do not leave equipment in a raised position while parked or during service, unless securely supported.

•

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

•

Install guards and shields after servicing the machine.

Shut down the engine, remove the key, and relieve the pressure before disconnecting or connecting fluid lines.

•

Close all access doors and install all panels after servicing the machine.

•

Always make sure working area is clear of tools, parts, other persons, and domestic animals before you start operating the machine.

If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the parking brake, place the equipment in a safe position, securely block the wheels, and use extreme caution.

•

Shut down the engine and remove the key before disconnecting or connecting electrical components.

•

Replace damaged or worn tubes, hoses, electrical wiring, etc.

•

Jack or lift the machine only at jack or lift points indicated in this manual.

•

Scalding can result from incorrect removal of coolant caps. Cooling system operates under pressure. Hot coolant can spray out if a cap is removed

•

Incorrect towing procedures can cause accidents.

When towing a disabled machine follow the procedure in this manual. Use only rigid tow bars.

2-10

2 - SAFETY INFORMATION

Safety rules - Mounting and dismounting

•

Face the machine when mounting and dismounting.

•

Never mount or dismount from a moving machine.

•

Mount and dismount the machine only at designated locations that have hand holds, steps, or ladders.

•

Do not use the steering wheel or other controls or accessories as hand holds when entering or exiting the cab or operator's platform.

•

Maintain a three-point contact with steps, ladders, and hand holds.

•

•

Do not jump off the machine.

Make sure steps, ladders, and platforms remain clean and clear of debris and foreign substances.

Injury may result from slippery surfaces.

2-11

2 - SAFETY INFORMATION

Safety rules - Operator precautions

•

Walk around the work area before you start and look for hazards. 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.

Know and use the hand signals required for particular jobs, and know who has the responsibility for signaling. Refer to page 2-32.

•

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

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

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/implements, etc. a safe distance.

•

Do not operate the machine while under the influence of alcohol, drugs, or while otherwise impaired.

•

Occupational Safety and Health Administration (OSHA) requirements make it the employer’s responsibility to fully instruct each operator in the proper and safe operation of all operative equipment. Both employer and employee should thoroughly familiarize themselves with this manual and the Associates of Equipment Manufacturers (AEM) safety booklet.

•

Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water.

•

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

•

•

•

Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts.

•

Wear protective equipment when appropriate. Hard hats, protective glasses, protective shoes, gloves, reflector type vests, respirators, and ear protection are examples of equipment that may be required.

2-12

2 - SAFETY INFORMATION

Safety rules - Specific precautions to this machine

•

Keep the load or tool as low as possible while moving the machine around the work site.

•

Do not lift loads close to the machine’s lifting capacity high in the air and then tilting the load forward.

•

Know the lifting capacity of your machine and the material you are lifting.

•

Release all hydraulic pressure before servicing the machine.

•

Know the load center of the material you are lifting and keep the material load center as close to the front of the forks as possible.

•

You must know which circuits have accumulators and how to release pressure properly.

2-13

2 - SAFETY INFORMATION

Safety rules - Transporting precautions

•

Comply with local laws and regulations.

•

•

Use appropriate lighting as defined by local regulations. A rotating beacon is recommended.

Lock the brake pedals together when roading to provide equalized brake application.

•

Lift implements and attachments high enough above ground to prevent accidental contact with road.

•

Make sure the Slow Moving Vehicle (SMV) and/or Speed Indicator Symbol (SIS) is visible.

•

Only transport machine on trailers certified to carry the machine. Follow the procedure 5-1 in this manual.

•

Be aware of overhead structures or power lines and make sure the machine and/or attachments can pass safely under.

•

Incorrect towing procedures can cause accidents.

When towing a disabled machine, follow the procedure in this manual. Use only rigid tow bars.

•

Travel speed should be such that complete control and machine stability is maintained at all times.

•

Slow down and signal before turning.

•

Pull over to allow faster traffic to pass.

•

Use approved drawbar and/or attachment point, (if equipped), if using your machine to tow another machine. If a cable or chain is used, keep people away from the tow line.

•

Follow correct towing procedure for equipment with or without brakes.

•

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 load. 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.

2-14

2 - SAFETY INFORMATION

Safety rules - Utility precautions

•

•

Sewer Proposed excavation Surveying Reclaimed water and slurry

During operation it is likely that you will be working around or near buried 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

When digging or using ground-engaging equipment, be aware of buried cables and other services.

Contact your local utilities or authorities, as appropriate, to determine the locations of services. In the United States and Canada call one of many One Call System Director services. If you do not know the local number, call the national number (United States and Canada only): 1-888-258-0808. This number will direct you to the state or regional utility that assists with excavation activity.

•

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.

•

Where applicable, know the utility color code.

Electric Gas, oil, or petroleum Communication, telephone, television Water

Green/Brown White Pink Purple

•

Make sure the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities or utilities to obtain safe clearance distances from high voltage power lines.

•

Retract raised or extended components, if necessary. Remove or lower radio antennas or other accessories. Should contact occur between the machine and an electric power source, the following precautions must be taken:

Red Yellow Orange Blue

2-15

•

Stop the machine movement immediately.

•

Apply the parking brake, shut down the engine, and remove the key.

•

Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your position and call for help. If you can leave your position without touching lines, jump clear of the machine to make sure you do not make contact with the ground and machine at the same time.

•

Do not permit anyone to touch the machine until power has been shut off to the power lines.

2 - SAFETY INFORMATION

Safety rules - Wheels and tires

DANGER Explosion hazard!

Welding to a wheel can create an explosive air and gas mixture. Removing air from the tire or loosening the tire on the wheel (breaking the bead) will NOT eliminate the hazard. ALWAYS remove the tire completely from the wheel before welding.

Failure to comply will result in death or serious injury.

D0033A

•

Tires are heavy. Handling tires without the proper equipment could cause death or serious injury.

•

Make sure tires are correctly inflated. Do not exceed recommended load or pressure. Follow instructions in this manual for proper tire inflation.

•

2-16

Always have a qualified tire technician service the tires and wheels. If a tire has lost all pressure, take the tire and wheel to a tire shop or your dealer for service. Explosive separation of the tire can cause serious injury.

2 - SAFETY INFORMATION

Safety rules - Roll Over Protective Structure (ROPS)

DANGER Crushing hazard!

DO NOT operate the machine with the Roll-Over Protective Structure (ROPS) removed. Remove the ROPS only for service or replacement.

Failure to comply will result in death or serious injury.

D0032A

Your machine is equipped with a ROPS (cab or canopy) protective structure.

A ROPS label is fastened to the protective structure and shows the ROPS PIN, the gross weight, approval, regulation, and model numbers of the machine.

The protective structure is a special safety component of your machine.

DO NOT attach any device to the protective structure for pulling purposes. DO NOT drill holes into the protective structure.

After an accident, fire, tip over, or roll over, the following MUST be performed by a qualified technician before returning the machine to field or job side operation: •

The protective structure MUST be replaced.

•

The mounting or suspension for the protective structure, operator's seat and suspension, seat belt and mounting components, and wiring within the protective structure 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 OVER, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of the protective system and must be worn at all times. The operator must be held to the seat inside the frame in order for the protective system to work.

2-17

2 - SAFETY INFORMATION

Safety rules - Seat belt

WARNING Roll-over hazard!

Securely fasten the seat belt. Your machine is equipped with a Roll-Over Protective Structure (ROPS) cab, ROPS canopy, or ROPS frame for your protection. The seat belt can help ensure your safety if it is properly used and maintained. Never wear a seat belt loosely or with slack in the belt system.

Failure to comply could result in death or serious injury.

W0143A

Seat belts must be worn at all times.

•

Keep seat belts in good condition.

•

Keep sharp edges and items that can cause damage away from the belts.

•

Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage.

•

Replace all parts that have damage or wear.

•

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

•

Check that bolts are tight on the seat bracket or mounting.

•

If belt is attached to seat, make sure seat or seat brackets are mounted securely.

•

Keep seat belts clean and dry.

•

Clean belts only with soap solution and warm water.

•

Do not use bleach or dye on the belts, because this can make the belts weak.

Fasten/release 1.

Pull the right-hand belt strap from the retractor.

2.

Insert the metal end into the latch mechanism of the left-hand side of the seat.

3.

RCPH10TLB155AAF

1

RCPH10TLB156AAF

2

To release, press the red button on the latch mechanism. The seat belt will automatically retract.

2-18

2 - SAFETY INFORMATION

Safety signs The following safety signs are placed on your machine as a guide for your safety and for those working with you. Walk around the machine and note the content and location of these safety signs before operating your machine.

Keep safety signs clean and legible. Clean safety signs with a soft cloth, water, and a gentle detergent. Do not use solvent, gasoline, or other harsh chemicals. Solvents, gasoline, and other harsh chemicals may damage or remove safety signs.

Replace all safety signs that are damaged, missing, painted over, or illegible. If a safety sign is on a part that is replaced, make sure the safety sign is installed on the new part. See your dealer for replacement safety signs.

Safety signs that display the “Read Operator’s Manual” symbol are intended to direct the operator to the Operator’s manual for further information regarding maintenance, adjustments, or procedures for particular areas of the machine. When a safety sign displays this symbol, refer to the appropriate page of the Operator’s manual.

Right side view

Left side view

RAPH12FRK0706EA

1

Top view

RAIL12FRK1096GA

2

RAPH12FRK0288AA

4

Front fork view

RAPH12FRK0705AA

3

2-19

2 - SAFETY INFORMATION

Cab inside view

Cab inside view

RAPH12FRK0707AA

5

RAPH12FRK0711AA

6

RAPH12FRK0712AA

8

Frame view

Cab inside view

RAPH12FRK0708AA

7

Safety sign legend 1.

2.

3.

4.

5.

6.

7.

8.

9.

Seat belt, no jumping Ether Jump start Booster start Neutral start Entanglement hazard Entanglement hazard Liquid under pressure Fuel under pressure

10. Fuel under pressure 11. Seat belt, no jumping 12. Downhill, excessive speed 13. General Instructions 14. Certification plate 15. Parking brake 16. Operator manual 17. Rider on forks 18.Moving load

Following is a listing of all Safety Signs and locations. Read and understand them before operating the machine.

2-20

2 - SAFETY INFORMATION

Do not jump/use seat belt WARNING Avoid Crushing. Do not jump if machine tips. Use seat belt.

Quantity: 2 English 321–7030 Spanish 398672A1 French Canadian 398673A1

321-7030

9

(1) Located in cab front left and right side posts. Right side post shown.

RAPH12FRK0128AA

10

Explosion hazard, ether WARNING Explosion hazard. Do not use ether. Failure to comply could result in death or serious injury.

Quantity: 1 English 8603092 Spanish 8603094 French Canadian 8603093

8603092

11

(2) Located on left hand side of hood.

RAPH12FRK0149AA

2-21

12

2 - SAFETY INFORMATION

Explosion and run over hazard, jump start DANGER Explosion hazard. Run over hazard. Read procedure in Operator’s Manual before jump start or service to avoid injury. Failure to comply will result in death or serious injury.

Quantity: 2 English 384269A1 Spanish 398582A1 French Canadian 398583A1 384269A1

13

(3) Located on left hand side of frame.

RAPH12FRK0152AA

14

RAPH12FRK0216AA

15

(4) Located on the battery cover.

2-22

2 - SAFETY INFORMATION

Do not start in gear. Start only from the Operator’s seat DANGER Starting in gear can cause death. Start engine only from operator seat with the transmission in neutral.

Failure to comply will result in death or serious injury.

Quantity: 1 English 321–7040 Spanish 398674A1 French Canadian 398676A1 321-7040

16

(5) Located on left hand side of frame.

RAPH12FRK0152AA

2-23

17

2 - SAFETY INFORMATION

Entanglement hazard WARNING Entanglement hazard. Keep clear or stop engine before servicing. Failure to comply could result in death or serious injury.

Quantity: 2 English 384267A1 Spanish 398580A1 French Canadian 398581A1 384267A1

18

(6) Located on right hand side of frame.

RAPH12FRK0174AA

19

RAPH12FRK0155AA

20

(7) Located on left hand side of frame.

2-24

2 - SAFETY INFORMATION

Hot liquid under pressure WARNING Hot liquid under pressure hazard. Service when cool. Failure to comply could result in death or serious injury.

Quantity: 1 English 384258A1 Spanish 398570A1 French Canadian 398571A1

384258A1

21

(8) Located on inside of the right side engine panel.

RAPH12FRK0175AA

22

Fuel under pressure WARNING Pressurized System hazard. Do not open high pressure fuel system with engine running. Engine operation causes high fuel pressure. Failure to comply could result in death or serious injury.

Quantity: 2 English 87581010 Spanish 87622505 French Canadian 87622506

87581010

23

(9) Located on right hand side of frame.

RAPH12FRK0174AA

2-25

24

2 - SAFETY INFORMATION

Fuel under pressure WARNING Pressurized System hazard. Do not open high pressure fuel system with engine running. Engine operation causes high fuel pressure. Failure to comply could result in death or serious injury.

Quantity: 2 English 87581010 Spanish 87622505 French Canadian 87622506

87581010

25

(10) Located on left hand side of frame.

RAPH12FRK0154AA

26

Do not jump/use seat belt WARNING Avoid crushing. Do not jump if machine tips Failure to comply could result in death or serious injury.

Quantity: 2 English 321–7030 Spanish 398672A1 French Canadian 398673A1

321-7030

27

(11) Located in cab, left and right side posts. Right side post shown.

RAPH12FRK0128AA

2-26

28

2 - SAFETY INFORMATION

Excessive speed or downhill travel.

WARNING Excessive speed can cause loss of machine control or machine damage. Do not coast down a hill with the transmission in neutral or do not exceed 2500 RPM when driving down a hill. Before driving down a hill, shift to a lower gear and drive slowly. You or others around you can be injured if the machine is out of control.

Quantity: 1 English D150900 Spanish 359937A1 French Canadian 359938A1 D150900C

29

(12) Located in cab on right side of wheel panel cover.

RAPH12FRK0131AA

2-27

30

2 - SAFETY INFORMATION

General warning instructions WARNING Before starting engine study operators manual.

Walk around and check your machine before starting.

Check that all controls are in neutral before starting.

Learn and practice safe use of controls before operating.

Fasten seat belt before starting.

Operate from seat position only.

Stop engine before dismounting.

Clear the area of all persons. Know their locations.

Do not permit riders on any part of the machine.

Lock brake pedals together for road travel.

Be aware of surrounding, persons, obstructions and overhead wires.

Keep forks or attachments as low as possible. On hills or uneven terrain use lower gears and drive slowly.

Lower forks to ground or support them before leaving machine.

Park on level ground, apply parking brake, stop engine, remove key.

Face the machine, use grab handles, supports and steps entering and exiting.

Make sure the operators area is clean and free of loose items.

Check instrument warning lights and buzzers before and after starting.

Incorrect operation of this machine can cause injury or death.

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Quantity: 1 English 347909A1 Spanish 359942A1 French Canadian 359943A1

(13) Located in cab, front and left of console.

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2 - SAFETY INFORMATION

Certification plate Certification plate This forklift conforms to ASME B56.6 1992 safety standards for Rough Terrain Fork Trucks.

Quantity: 2 English 384265A1 Spanish 398578A1 French Canadian 398579A1

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(14) Located in the cab on left and right side posts.

Parking brake IMPORTANT Always set parking brake before leaving seat. After startup, cycle park brake switch ON/OFF to release parking brake.

Quantity: 1 English 87702297 Spanish 87708227 French Canadian 87708242

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(15) Located in cab on right side

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2 - SAFETY INFORMATION

16. Operator’s manual is located the storage compartment left of the seat.

Quantity: 1 English 87702297 Spanish 87708227 French Canadian 87708242

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Riders on forks WARNING Failure to follow this warning can result in injury or death.

Do not permit personnel to ride or be elevated on forks, load or work platform. Do not stand under forks or any part of the lift mechanism.

Quantity: 3 English 102929A1 Spanish 359921A1 French Canadian 359922A1

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(17). Warning is located on the rear and both sides of the forklift mast.

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2 - SAFETY INFORMATION

Use extreme caution when moving lifted loads WARNING Move truck with extreme caution when load is elevated. Extended forward tilt is possible. Tilt forward with extreme caution. Always carry load in down position when in transit.

Quantity: 1 English D87486 Spanish 359927A1 French Canadian 359928A1

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(18) Located across rear fork support bar.

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41

2 - SAFETY INFORMATION

Hand signals When operating the machine, never attempt to carry out tasks calling for fine control or work in areas where visibility is poor without seeking the assistance of a signalman. Make sure that both you and the signalman understand the signals that will be used.

Start the engine

Move away from me Wave hands forward and rearward with palms out

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Stop the engine

RCIL09TLB006BAF

2

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Go this far

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3

All stop and hold

Come to me Wave hands forward and rearward with palms in

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6

2 - SAFETY INFORMATION

Stop

Emergency stop

Wave one hand back and forth

Wave both hands back and forth

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Raise load

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8

Raise load slowly

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Lower load

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10

Lower load slowly

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2 - SAFETY INFORMATION

Turn machine left

Turn machine right

To stop machine movement, stop moving hand and make a fist

To stop machine movement, stop moving hand and make a fist

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3 - CONTROLS/INSTRUMENTS

3 - CONTROLS/INSTRUMENTS ACCESS TO OPERATOR'S PLATFORM

Proper entry and exit WARNING Fall hazard!

Jumping on or off the machine could cause an injury. Always face the machine, use the handrails and steps, and get on or off slowly. Maintain a three-point contact to avoid falling: both hands on the handrails and one foot on the step, or one hand on the handrail and both feet on the steps.

Failure to comply could result in death or serious injury.

W0141A

WARNING Fall hazard!

Clean the steps and access handles to remove all traces of grease, oil, mud, and ice (in winter).

Failure to comply could result in death or serious injury.

W0139A

WARNING Unexpected movement!

Always engage the parking brake and switch off the engine before exiting the machine.

Failure to comply could result in death or serious injury.

W0209A

CAUTION Fall hazard!

When entering or exiting the cab, never use the control levers as handholds. Always mount and dismount the machine in a safe way. Maintain a three-point contact with steps, ladders, and/or handholds.

Failure to comply could result in minor or moderate injury.

C0075B

Access the platform from either side of the machine.

1.

Face the machine.

2.

Grab both hand holds.

3.

Use the steps to climb onto the operator platform.

Exit the platform from either side of the machine.

1.

Face the machine.

2.

Grab both hand holds.

3.

Use the steps to climb down from the operator platform.

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3 - CONTROLS/INSTRUMENTS

OPERATOR'S SEAT

Operator seat adjustments WARNING Loss of control hazard!

DO NOT make seat adjustments while the machine is in motion. All seat adjustment should be made with the machine stationary and the parking brake applied.

Failure to comply could result in death or serious injury.

W0293A

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

1.

Push the lever inward, slide the seat forward or rearward.

2.

Release the lever and confirm the seat position locks in place.

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Adjusting the deluxe suspension operator’s seat 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 and 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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3 - CONTROLS/INSTRUMENTS

FORWARD CONTROLS

Console controls Function switches (left side) (1) Horn switch Push the horn symbol on the rocker switch to sound the horn.

(2) Blank

(3) Rear work lamp switch Push the rear work lamp symbol on the switch to turn on the rear work lamps. Push the other side to turn off the rear work lamps.

(4) Driving lamp switch Push the driving lamp symbol on the switch to turn on the driving lamps. Push the other side to turn off the driving lamps.

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(5) Flasher switch Push the flasher symbol switch and the front and rear signal lamps flash simultaneously.

Push the other side of the flasher switch to turn off the signal lamps.

(6) Turn signal switch (three position switch) Push the left side of the switch to signal a left turn. Push the right side of the switch to signal a right turn. Place the switch in the center position to turn off the turn signal.

3-3

1

3 - CONTROLS/INSTRUMENTS

Function switches (right side) (1) Differential lock switch The differential lock switch engages the differential lock. To engage the differential lock, ensure that neither drive wheel is spinning freely, press and hold the differential lock switch. Release the switch to disengage the differential lock.

(2) Four wheel drive (4WD) switch (optional) Push the 4WD symbol on the switch to engage the 4WD option on the steer axle.

Push other side of the switch to disengage 4WD. NOTICE: When the 4WD steer axle is engaged, operate the machine only in first or second gear. Disengage the 4WD before operating on a hard surface or in 3rd or 4th gear.

(3) Clutch cutout switch The clutch cutout switch lets the engine increase speed and supplies the forklift hydraulic system with more oil for more power and faster control function. Push and hold the clutch cutout switch, the transmission disengages from the drive wheels. Release the clutch cutout switch to engage the transmission power. The machine can move freely when the clutch cutout button is pushed. If required, use the service brake to stop the machine.

(4) Park brake switch Press the park brake symbol on the rocker switch to set the park brake. Press the O symbol on the switch to release the park brake.

The park brake is a Spring Applied Hydraulic Released (SAHR) brake. The park brake should be applied if the engine is stopped. The park brake is always engaged on startup. At start up, cycle the switch from the park symbol to the O symbol. Cycle the switch, regardless of the position the switch was in at startup.

3-4

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3 - CONTROLS/INSTRUMENTS

Ignition key switch The ignition key switch has four positions: (1) ST — 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 the ON position.

(2) RUN — Turn the key clockwise to the RUN position. There will be a momentary delay as the system powers up. For example, in cold weather starts turn the key to the RUN position and allow the engine to preheat before cranking the engine. The preheat symbol will illuminate on the instrument control panel and the machine is ready to start when the preheat symbol is not illuminated.

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(3) OFF — Turn the key to the OFF position to stop the engine. After the engine has stopped, remove the key.

(4) ACC - Turn the key counterclockwise from the OFF position to ACC, provides power to the accessories.

Transmission controls (1) Directional lever — The Forward Neutral Reverse (FNR) control lever is on the left-hand side of the steering column and controls the direction of travel for the machine.

(F) is forward travel, lift the lever and push completely forward.

The center position (N) is neutral. Make sure the direction control lever is in Neutral before you start the engine.

(R) is reverse travel, lift the lever and pull completely rearward.

(2) Gear shift lever The transmission has four fully synchronized gears.

Use the clutch cutout button (3) when changing gears. Reduce travel speeds before shifting into a lower gear.

(3) Clutch cutout button located on the right hand side of the gear shift lever Press and hold the clutch cutout button and shift the gear lever (2) . Release the clutch cutout button to engage the clutch after shifting.

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3 - CONTROLS/INSTRUMENTS

Foot brake and throttle pedals (1) Left brake pedal — When the service brake pedals are unlocked, as shown, press the left pedal to help turn the machine to the left.

(2) Brake pedal lock — Lock the service brake pedals for uniform braking and maximum stopping ability.

(3) Right brake pedal — When the service brake pedals are unlocked, as shown, press the right pedal to help turn the machine to the right.

(4) Foot throttle — Push down on the foot throttle to increase the engine speed. Release the foot throttle to decrease the engine speed.

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Forklift control levers Standard forklift control levers (1) LIFT control — Push lever forward lowers the forks or load. Pull lever backward raises the forks or load.

(2) TILT control — Push lever forward tilts the forklift mast forward. Pull lever backward tilts the forklift mast backwards.

(3) SIDE SHIFT control — Push lever forward shifts the forklift mast to the left. Pull lever backward shifts the forklift mast to the right.

Standard forklift control levers with auxiliary control If equipped, the auxiliary control lever (2) allows the operator to actuate a hydraulically controlled attachment. Follow the instructions provided by the manufacturer for the attachment. The three control levers (1) function the same way as the standard forklift control levers previously mentioned.

3-6

3 - CONTROLS/INSTRUMENTS

Instrument control panel The instrument control panel is located on the right hand canopy post and will provide information on the machine performance, required maintenance, and allow the operator to select a few optional display features from the setup menu.

NOTE: The maintenance section in this manual will help you resolve some of the warnings that may appear during operation of the machine. However, some warnings will require the assistance from an authorized dealer or information from the service manual.

Warnings (1) Emergency stop This red lamp illuminates along with a continuous alarm and a fault code will appear in the display. Shut down the machine immediately, and contact an authorized dealer or the service manual for details.

(2) Hydraulic system malfunction This yellow lamp will flash when a Hydraulic fault is detected. Refer to the maintenance section in this manual and replace the hydraulic filter.

(3) Warning This amber lamp will flash, and an intermittent alarm will sound. Check the bar graph gauges as well as the other indicator icons for possible indications of the error.

Refer to the maintenance section in this manual for possible solutions.

(4) Engine malfunction This yellow lamp will flash when an engine fault is detected. Check the other gauges and lamps for possible indications of the error.

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3 - CONTROLS/INSTRUMENTS

Indicators (1) Diesel Particulate Filter (DPF) regeneration This DPF lamp illuminates when a forced regeneration of the after treatment system is required. Failure to perform a forced generation will eventually de-rate the engine.

Refer to the maintenance section in this manual for the regeneration procedure.

(2) Park brake This red lamp illuminates to indicate the park brake is engaged.

Under normal conditions the Park Brake will be set when: •

The Park Brake Switch is activated.

•

The engine is shut off.

(3) Display The operator may choose to leave one of the following options continuously on or select to the cycle option to continuously cycle through each option: •

HOUR — Displays engine work hours (default setting)

•

TRANT — Transmission coolant temperature (degrees F or C)

•

COOLT — Engine coolant temperature (degrees F or C)

RPM — Engine RPM • The display screen is also used to help the operator select functions in the SETUP menu, provide information to the operator during machine operation, as well as display fault codes that may be present.

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3 - CONTROLS/INSTRUMENTS

(4) Fuel gauge (bar graph) The fuel gauge consists of a series of bars that indicate the level of fuel in the fuel tank.

When all 8 bars are visible the fuel tank is full. Bottom bar flashing with an audible alert indicates refueling is necessary.

(5) Engine coolant temperature gauge (bar graph) The engine coolant temperature gauge indicates the relative temperature of the engine coolant from 65 - 112 °C (149 - 234 °F). If the temperature exceeds 112 °C (234 °F), all 8 graph segments will display, backlighting will flash, and an audible alarm will sound.

(6) Transmission oil temperature gauge (bar graph) The transmission oil temperature gauge indicates the relative temperature of the transmission oil from 70 - 116 °C (158 241 °F). If the oil temperature exceeds 116 °C (241 °F), all 8 bars will display, the backlighting will flash, and an audible alarm will sound.

(7) Engine preheat If the Engine Preheat lamp illuminates after an attempt to start the engine, the operator must wait until the lamp is not illuminated before another attempt to start the engine.

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3 - CONTROLS/INSTRUMENTS

Menu buttons Menu buttons allow the user to select between display features as well as select a few machine functions listed in the SETUP menu. The SETUP menu selections are described in more detail in this manual, refer to page 3-11.

(1) Up arrow Press the UP arrow button to scroll through menu screens.

(2) Down arrow Press the DOWN arrow button to scroll through menu screens.

(3) Enter Press the ENTER button to enter menus in the display or acknowledge a question on the display.

(4) Escape Press the ESCAPE button to move up to the next level of screens.

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3 - CONTROLS/INSTRUMENTS

Menu screen display Menu navigation controls An operator may retrieve information from the instrument control panel when the machine is in operation, when the ignition key is in the OFF position, or the ignition key is not available.

The operator may only configure and save desired settings, when the instrument control panel is in Sleep mode. The instrument control panel is in Sleep mode, when the ignition key is in the OFF position.

Use the four menu buttons to navigate through the setup menu functions.

(1) DISPLAY Displays the menu text.

(2) UP ARROW Use to navigate through menu selections.

(3) DOWN ARROW Use to navigate through menu selections.

(4) ENTER Use to select the top level menu and access the second level menu . Use to save the second level menu selection that appears on the display.

(5) ESCAPE Use to escape to the top level menu or escape the setup menu entirely.

The ignition key is not available Press any button and the current engine work hours will appear in the display.

The ignition key is in the OFF position The SETUP menu is accessible for operator display preferences.

The machine is in operation Press and hold the enter button (4) for two seconds, each additional press of the enter button will scroll the various options: •

HOURS engine work hours

•

TRANT transmission oil temperature

•

COOLT engine coolant temperature

•

RPM engine RPM

RAIL12FRK1123CA

If the enter button is not pressed for 5 seconds the display defaults to the original selection defined in the SETUP menu.

3-11

1

3 - CONTROLS/INSTRUMENTS

Access and navigate the SETUP menu If the ignition key is placed in the ON position the instrument panel will automatically go into Sleep mode.

1.

Park the machine and place the ignition key in the OFF position.

2.

Simultaneously press and hold the enter button (4) and the down arrow button (3) until the word SETUP appears in the display (1).

3.

Press the down arrow button (3) or the up arrow button (2) to scroll through the top level menus.

4.

Press the enter button (4) to select the option that is in the display (1).

5.

Press the down arrow button (3) or the up arrow button (2) to scroll through the second level menu.

NOTE: Pressing the escape button (5) will bring you directly to the top level menu.

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2

3 - CONTROLS/INSTRUMENTS

Overview of the SETUP menu

RAIL12FRK1124GA

SETUP EXIT DSPLY UNITS JTIME DPF OIL

(1) Top level menu Setup the start of the top level menus Exit the setup menu Alternate between desired display options Alternate between desired temperature units (degrees F or C) Job timer (track hours for a specific job) Diesel Particulate Filter (inhibit auto regeneration) Oil life reset

3

HOUR TRANT COOLT RPM CYCLE FAHR CELC (3) RESET INHIB

3-13

(2) Second level menu Engine work hours Transmission oil temperature Engine coolant temperature Engine RPM Cycle through each option listed under the DSPLY menu Display temperatures in degrees Fahrenheit Display temperatures in degrees Celsius Total work hours appear for the current job timer Reset the job timer work hours or oil life Inhibit the auto regeneration process

3 - CONTROLS/INSTRUMENTS

Change or select what appears in the display 1.

Park the machine and place the ignition key in the OFF position.

2.

Simultaneously press and hold the enter button (4) and the down arrow button (3) until the word SETUP appears in the display (1).

3.

Press the down button (3) until DSPLY appears in the display (1).

4.

Press the enter button (4), HOUR will appear in the display.

5.

Press the up arrow (2) or down arrow (3) to scroll through the selections.

6.

Press the enter button (4) to select the desired option that appears in the display (1) NOTE: Use the “Overview of the SETUP menu” 3 for selection options.

7.

Press the escape button (5) twice, EXIT will appear in the display (1).

8.

Press the enter button (4) to exit the menu. The instrument control panel is now in Sleep mode.

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4

3 - CONTROLS/INSTRUMENTS

Select Celsius or Fahrenheit temperature scales 1.

Park the machine and place the ignition key in the OFF position.

2.

Simultaneously press and hold the enter button (4) and the down arrow button (3) until the word SETUP appears in the display (1).

3.

Press the down button (3) until UNITS appears in the display (1).

4.

Press the enter button (4), FAHR will appear in the display.

5.

Press the up arrow (2) or down arrow (3) to switch to CELC .

6.

Press the enter button (4) to select the desired option that appears in the display (1)

7.

Press the escape button (5) twice, EXIT will appear in the display (1).

8.

Press the enter button (4) to exit the menu. The instrument control panel is now in Sleep mode.

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3 - CONTROLS/INSTRUMENTS

View or reset the job timer (JTIME) The operator may choose to set a timer that will run independent from the machine hours. To view or reset the timer: 1.

Park the machine and place the ignition key in the OFF position.

2.

Simultaneously press and hold the enter button (4) and the down arrow button (3) until the word SETUP appears in the display (1).

3.

Press the down button (3) until JTIME appears in the display (1).

4.

Press the enter button (4) the current job timer hours will appear in the display (1). To reset the hours continue otherwise proceed to step 7

5.

Press the up arrow (2) or down arrow (3) to switch to RESET .

6.

Press the enter button (4) to reset the current job timer to zero.

7.

Press the escape button (5) twice, EXIT will appear in the display (1).

8.

Press the enter button (4) to exit the menu. The instrument control panel is now in Sleep mode.

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3 - CONTROLS/INSTRUMENTS

Inhibit auto regeneration The regeneration inhibit selection display allows the operator to turn off the auto regeneration process during the current key cycle.

NOTE: The regeneration inhibit feature returns to the enable setting by default at the next key cycle.

NOTE: Operators that continue to disable the regeneration process will eventually de-rate the engine’s performance.

1.

Park the machine and place the ignition key in the OFF position.

2.

Simultaneously press and hold the enter button (4) and the down arrow button (3) until the word SETUP appears in the display (1).

3.

Press the up button (3) until DPF appears in the display (1).

4.

Press the enter button (4), ALLOW appears in the display (1).

5.

Press the enter button (4) to toggle between the two choices ALLOW and OFF. ALLOW — Allow the auto regeneration process.

OFF — Do not allow the auto generation process.

6.

Press the escape button (5) twice will save the current selection on the display and EXIT will appear in the display (1).

7.

Press the enter button (4) to exit the menu. The instrument control panel is now in Sleep mode.

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3-17

7

3 - CONTROLS/INSTRUMENTS

Reset oil life The Engine Control Unit (ECU) tracks engine oil life and will notify the operator in the display when an oil change is required. After the oil change service is complete the technician must reset the oil life from the SETUP menu, otherwise the oil change notification will continue.

1.

Park the machine and place the ignition key in the OFF position.

2.

Simultaneously press and hold the enter button (4) and the down arrow button (3) until the word SETUP appears in the display (1).

3.

Press the up button (3) until OIL appears in the display (1).

4.

Press the enter button (4), RESET appears in the display (1).

5.

Press the enter button (4) again to reset the oil life.

6.

Press the escape button (5) twice, EXIT will appear in the display (1).

7.

Press the enter button (4) to exit the menu. The instrument control panel is now in Sleep mode.

NOTE: You may also reset the oil life using the foot throttle, refer to the procedure in the manual 7-3.

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4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS COMMISSIONING THE UNIT

Run in period of a new machine During the first 20 hours of operation (new machine or after an engine rebuild), make sure you: •

Operate the machine with normal loads for the first 8 hours.

•

Do not work the engine hard at stall speeds (wheels slowly turning or stopped and the engine running at full throttle).

•

Keep the engine at normal operating temperature.

•

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

•

Operating the machine at low idle for prolonged periods, increases the frequency of the regeneration process and shortens the life of the diesel particulate filter.

Engine speed It is recommended that you run the engine at full throttle when operating conditions permit and when safe.

NOTICE: Do not run the engine at idle speed for long periods. This can cause a low operating temperature. Low operating temperature can cause acids and deposits in the engine oil.

NOTICE: Operating the machine at low idle for prolonged periods, increases the frequency of the regeneration process and shortens the life of the diesel particulate filter.

4-1

4 - OPERATING INSTRUCTIONS

STARTING THE UNIT

Before starting the engine WARNING Inhalation/asphyxiation hazard!

Make sure there is proper ventilation before starting the engine.

Failure to comply could result in death or serious injury.

W0091A

WARNING Unexpected machine movement!

Before starting the engine, make sure all controls are in the neutral position.

Failure to comply could result in death or serious injury.

W0311A

Walk around inspection: •

Check for leaks under the machine

•

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

•

Confirm the machine is properly lubricated and greased. Refer to the maintenance section of this manual.

•

Check the engine oil level, engine coolant level, and transmission oil. Refer to the maintenance section of this manual.

•

Check that the machine fuel tank is filled with clean fuel that meets the specifications provided in this manual.

•

Remove any water or sediment from the water separator.

•

Check the tires for correct air pressure, wheel bolt torque, and for any visible damage.

Before you start the engine: •

Adjust the position of the seat so that all controls may be moved through their entire range of motion.

•

Fasten your seat belt.

•

Confirm that you are able to push the brake pedals all the way to the end of pedal action, while sitting with the seat belt fastened.

4-2

4 - OPERATING INSTRUCTIONS

Normal engine starting 1.

Adjust the seat and fasten the seat belt.

2.

Confirm the direction control lever is in neutral.

3.

Turn the key switch to the ON position and wait two to three seconds for the instrument control panel to selfcheck and power up.

4.

Wait for the engine preheat lamp to turn off.

5.

Sound the horn.

6.

Push the foot throttle 1/4 down and turn the key switch to the START position to actuate the starter motor.

7.

If the engine starts and stops, do not actuate 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 two minutes before you actuate the starter motor again.

8.

After the engine starts: A.

Check the instrument control panel to make sure no warning indicators are present. Resolve any emergency stop or malfunction issues before machine operation.

B.

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

NOTE: If the RPM value is not shown in the display, press and hold the ENTER button for two seconds. Now you may press the ENTER button to cycle through the display until the RPM value appears on the display.

4-3

4 - OPERATING INSTRUCTIONS

Cold temperature operation 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.

To start and operate your machine during cold ambient temperatures, observe the following recommendation/instructions.

Battery and electrical components: •

Ensure the batteries are at full charge.

•

If you add water to the batteries, charge the batteries or run the engine for approximately two hours to prevent battery freezing in ambient temperatures below 0 °C (32 °F).

•

Inspect the battery cables and terminals. Clean and coat each terminal with a corrosion prevention product.

Engine: •

Use engine oil with the correct viscosity for the ambient temperature range.

•

Allow longer warm up periods to bring the machine and components up to operating temperature.

•

WARNING Explosion hazard!

DO NOT use ether starting fluid. Explosion, death, serious personal injury, or serious engine damage could occur.

Failure to comply could result in death or serious injury.

W0148B

Preheat system, engine glow plugs are standard. Turn the key switch to the ON position, the engine preheat lamp illuminates as the heater conditions indrawn air. Wait for the lamp to stop illuminating before starting the engine. If the engine fails to start after two attempts, allow the battery to recover for 4 to 5 minutes before repeating the procedure.

•

WARNING Electrical shock hazard!

NEVER use an ungrounded or inadequate extension cord. Always use a functional (three-wire), grounded extension cord rated for the appropriate voltage and current (15 A), with circuit protection of either a standard circuit breaker or a Ground Fault Circuit Interrupter (GFCI).

Failure to comply could result in death or serious injury.

W0400A

If equipped, plug the engine block heater into 110 V outlet for up to four hours before starting the engine. Unplug the block heater before continuing with the cold weather start procedure.

Fuel system: •

Check with your dealer for the correct cold weather fuel.

•

Check for water in the fuel system. Inspect the water separator every 50 hours of operation. If water is found, check the fuel tank.

•

Fill the fuel tank after each operating day to prevent condensation in the fuel tank and water entering the fuel system.

•

Use ultra-low sulfur diesel fuel only.

Cooling system •

Use a mixture of 50 % ethylene glycol and 50 % water. This mixture protects the engine cooling system to -34 °C (-29 °F).

Machine start up in cold weather Machines at temperatures of -15 °C (5 °F) or lower: •

Do not wait longer than 30 seconds after the engine preheat lamp is not illuminated before cranking the engine.

If the delay is longer, the start up cycle is aborted and the process must be restarted.

4-4

4 - OPERATING INSTRUCTIONS

Warm up the hydraulic system When the temperature is below 4 °C (40 °F) and the engine has been warmed up: 1.

Raise the engine throttle between 1600 - 1800 RPM.

2.

Drive the machine slowly in a low gear.

3.

Actuate each of the hydraulic forklift controls.

NOTE: Watch the hydraulic malfunction indicator lamp. If the oil is too cold the lamp will illuminate while the operator cycles the functions.

4.

Cycle the functions for approximately 10 min.

7.

Release the controls and leave the machine throttle set for approximately 15 seconds.

NOTE: Immediately after the warm up procedure, the machine may operate a bit slower than normal, but will quickly warm to normal operating speeds.

4-5

4 - OPERATING INSTRUCTIONS

Hot temperature operation Hot weather conditions cause special problems. During these conditions, your machine will require special attention to prevent serious damage. Hot weather maintenance will extend the service life of your machine.

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

NOTICE: Prevent damage to the machine: 1.

Keep the coolant at the correct level in the coolant de-aeration reservoir and in the radiator.

2.

See your dealer and have the de-aeration cap tested before hot weather starts. Replace the cap as required.

3.

Clean all dirt and debris from the radiator, coolers, and engine area.

4.

Check the condition of the fan drive belt.

5.

Use lubricants of the correct viscosity.

4-6

4 - OPERATING INSTRUCTIONS

Booster battery procedure WARNING Explosion hazard!

If battery electrolyte is frozen, attempting to charge the battery or jump-start the engine can cause the battery to explode. Always keep batteries at full charge to prevent frozen battery electrolyte. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0203A

WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

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

Booster battery procedure 1.

Release the left hand side engine panel latch and swing the panel open.

2.

Sit in the operator's seat and have the other person make the connections. Make sure the booster batteries are 12 V.

3.

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

4.

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

5.

Connect the negative (-) jumper cable to the frame, as far away as possible from the positive (+) cable.

6.

Start the engine and have the other person disconnect the negative (-) jumper cable first and the positive (+) jumper cable last.

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4-7

1

4 - OPERATING INSTRUCTIONS

Booster battery procedure with optional jump post 1.

Release the left hand side engine panel latch and swing the panel open.

2.

Sit in the operator's seat and have the other person make the connections. Make sure the booster batteries are 12 V.

3.

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

4.

Remove the red rubber boot from the terminal post.

5.

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

6.

Connect the negative (-) jumper cable to the frame, as far away as possible from the positive (+) cable.

7.

Start the engine and have the other person disconnect the negative (-) jumper cable first and the positive (+) jumper cable last.

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4-8

2

4 - OPERATING INSTRUCTIONS

STOPPING THE UNIT

Shutting down the engine 1.

Before you leave the machine, make sure the machine is parked on a level surface. The machine must be on level ground before you do scheduled maintenance.

2.

Lower the forks to the ground.

3.

Apply the parking brake and place the direction control lever in the Neutral position.

4.

Run the engine at idle speed for two minutes (or more if the engine has been working at full load) to cool the engine parts evenly.

NOTICE: Shutting down the engine when at a higher RPM than idle will damage the turbocharger.

5.

Turn the key switch to the OFF position to shut down the engine. Remove the key.

Parking on a hill WARNING Roll-over hazard!

Always try to park the machine on firm level ground. Avoid parking on slopes. Block the wheels in both directions.

Failure to comply could result in death or serious injury.

W0242A

NOTE: 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.

4-9

4 - OPERATING INSTRUCTIONS

MOVING THE UNIT

Uniform braking WARNING Loss of control hazard!

Uneven brake force exists on left-hand and right-hand brakes. To ensure uniform brake application and maximum stopping ability, always lock the service brake pedals together when operating the machine in 3rd or 4th gear or before road travel.

Failure to comply could result in death or serious injury.

W0146A

The lock lever locks the two service brakes for uniform braking.

Engage pedal lock: 1.

Rotate the pedal lock lever upward.

2.

Slide the lock lever all the way to the right into the right brake service pedal.

3.

Rotate the lock lever downward to engage the pedal lock position.

RAPH12FRK0284AA

Disengage pedal lock: 1.

Rotate the lock lever upward.

2.

Slide the lock lever all the way to the left completely out of the right brake service pedal.

3.

Rotate the lock lever downward behind the pedal.

4-10

1

4 - OPERATING INSTRUCTIONS

Traveling on a hill WARNING Driving hazard!

Hillside operations can be dangerous. Rain, snow, ice, loose gravel, or soft ground, etc. can change the ground conditions. You must make a judgment if it is safe to operate your machine on any hillside or ramp.

Failure to comply could result in death or serious injury.

W0144A

WARNING Loss of control hazard!

Travel speed should be such that complete control and machine stability is maintained at all times.

Where possible, avoid operating near ditches, embankments and holes. Reduce speed when turning, crossing slopes, and on rough, slick, or muddy surfaces.

Failure to comply could result in death or serious injury.

W0233A

WARNING Overturning hazard!

Four-wheel drive (4WD) greatly increases traction. Extra caution is needed on slopes. Compared to two-wheel drive, a 4WD machine maintains traction on steeper slopes, increasing the possibility of overturning.

Failure to comply could result in death or serious injury.

W0453A

Before you operate the machine on a hill: •

Always put the transmission in a lower gear and test the service brakes.

•

Keep engine speed below 2500 RPM

•

Keep the machine in gear when traveling down a hill.

•

Use caution if you must use the clutch cutout when you are maneuvering the forklift mast.

•

Keep loads centered in front of the machine.

4-11

4 - OPERATING INSTRUCTIONS

Machine direction The transmission direction control lever must be in the neutral (center) position (2) before you can start the engine.

•

Travel forward, lift up the direction control lever and push completely into the forward position (1).

•

Travel in reverse, lift up the direction control lever and pull completely into the rearward position (3).

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

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Transmission gears NOTICE: Transmission is de-clutched when the parking brake is engaged.

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

For smooth transitions release the foot throttle when down shifting into the next lower gear.

Choose the appropriate transmission gear for the type of work the machine will be operated for.

Shifting gears 1.

Press and hold the clutch cutout button (2) on the gear shift lever (1) before you shift gears.

2.

Move the gear shift lever into the desired gear.

3.

Release the clutch cutout button.

Gear 1st 2nd 3rd 4th

Direction Forward and reverse Forward and reverse Forward and reverse Forward and reverse

Travel speed at 2300 RPM 6.2 km/h (3.9 mph) 11.0 km/h (6.8 mph) 20.7 km/h (12.9 mph) 38.7 km/h (24.0 mph)

NOTE: Speeds are to be used as a reference only, the speeds were recorded based on a total machine weight of 7405 kg (16325 lb).

RAIL12FRK1125BA

4-12

1

4 - OPERATING INSTRUCTIONS

Before operating the machine WARNING Equipment failure could cause accident or injury!

Before operating the machine, check for correct operation of steering, brakes, hydraulic controls, instruments, and safety equipment. Make sure the transmission control lever is in the neutral position.

Make all adjustments before operating the machine.

Failure to comply could result in death or serious injury.

W0204A

Check the instrument control panel Turn the key switch to the on position and verify that warning/indicator lights illuminate and turn off as designed.

Test the parking and service brakes NOTE: Review the procedures in their entirety before proceeding. Ensure that you allow surplus room for machine travel.

1.

2.

To test the parking brake: A.

Sit in the operator's seat and fasten the seat belt.

B.

Engage the parking brake.

C.

Disengage four wheel drive, if equipped.

D.

Place the direction control lever in neutral and the transmission in 2nd gear.

E.

Start up the engine.

F.

Ensure the forks are raised in preparation of forward travel.

G.

Press and hold the service brakes and release the parking brake.

H.

Place the direction control lever in forward.

I.

Release the service brakes.

J.

Increase the engine speed to full throttle.

K.

Travel forward approximately 8 m (26 ft).

L.

Engage the parking brake. The machine should come to a stop within 2 m (6.5 ft) of engaging the parking brake and the transmission should declutch. Contact your dealer for service as needed.

To test the service brakes: A.

Lock the right and left service brakes together.

B.

Sit in the operator's seat and fasten the seat belt.

C.

Engage the parking brake.

D.

Disengage four wheel drive, if equipped.

E.

Place the direction control lever in neutral and the transmission in 2nd gear.

F.

Start up the engine.

G.

Ensure the forks are raised in preparation of forward travel.

H.

Press and hold the service brakes and release the parking brake.

I.

Place the direction control lever in forward.

J.

Release the service brakes.

K.

Increase the engine speed to full throttle.

L.

When the machine is moving at full speed in 2nd gear, push the brake pedals and stop the machine. The machine must stop smoothly and the brake pedal effort must feel firm. Contact your dealer for service as needed.

4-13

4 - OPERATING INSTRUCTIONS

Differential lock system The differential lock provides equal power to both front wheels and is used in conditions where traction is poor.

NOTICE: You can cause damage to the front axle or 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.

If operating through a soft or muddy area: 1.

Confirm that the machine is moving in a straight direction and that one of the front wheels is not rotating faster than the other front wheel.

2.

Push and hold the differential lock switch.

3.

After you have moved through the area, release the switch.

If the machine is stuck: 1.

Reduce the engine speed and confirm that the front wheels are not rotating.

2.

Push and hold the differential lock switch.

3.

Release the switch once traction is regained.

4-14

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4 - OPERATING INSTRUCTIONS

Four Wheel Drive (4WD) control If equipped, Four Wheel Drive (4WD) significantly improves traction in rough conditions. When the rear steer axle is engaged, operate the machine only in 1st or 2nd gear. Disengage the rear steer axle before operating on the hard surface or in 3rd or 4th gear.

NOTICE: The use of 4WD when it is not required will increase the wear on machine components and affect the machines mobility in certain driving situations.

NOTE: 4WD can be engaged when the machine is on the move or at a stop.

Engage or Disengage 4WD: 1.

Press the 4WD symbol end of the rocker switch to engage 4WD system. The 4WD symbol illuminates when 4WD is enganged.

2.

Press the other side of the 4WD switch to disengage.

RAPH12FRK0139AA

4-15

1

4 - OPERATING INSTRUCTIONS

4-16

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS SHIPPING TRANSPORT

Transporting on a trailer WARNING Transport hazard!

The machine can slip or fall from a ramp or trailer. Make sure the ramp and trailer are not slippery.

Remove all oil, grease, ice, etc. Move the machine on or off the trailer with machine centered on the trailer or ramp.

Failure to comply could result in death or serious injury.

W0152A

NOTE: The trailer shown may be different from your trailer. The procedure is the same.

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

Load the machine onto a trailer: 1.

Park the truck and trailer on a level surface.

2.

Put a block at the front and rear of the trailer wheels.

RCPH10TLB056AAF

3.

Sit in the operator’s seat and start the engine.

4.

Raise the forks enough to clear the ramp of the trailer.

5.

Shift the transmission into 1st gear, and slowly drive the machine onto the trailer.

6.

Confirm the machine is evenly centered and fully on the trailer.

7.

Lower the forks onto the trailer, shift the direction control lever to neutral, and apply the parking brake.

8.

Place the transmission in neutral.

9.

Shut down the engine and remove the key.

10.

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

5-1

1

5 - TRANSPORT OPERATIONS

11.

Use chains and binders to fasten the machine to the trailer. Use the machine’s tie down locations.

•

•

Rear lower frame (both sides)

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3

Front forklift mast (both sides)

12.

Measure the distance from the ground to the highest point of the machine. You must know the clearance height of the machine.

13.

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

Unload the machine from a trailer: 1.

Park the trailer on a level surface.

2.

Remove the chains and blocks from the machine.

3.

Sit in the operator’s seat and fasten the seat belt.

4.

Start the engine.

5.

Raise the forks off of the trailer floor. Confirm you have enough clearance between the bottom of the forks and the ground when traveling down the trailer ramp.

6.

Shift the transmission to 1st gear, release the parking brake, and drive slowly off the trailer.

5-2

5 - TRANSPORT OPERATIONS

RECOVERY TRANSPORT

Towing the machine WARNING Loss of control!

Only tow at safe speeds. Use caution when making corners or meeting traffic.

Failure to comply could result in death or serious injury.

W0126A

WARNING Avoid injury!

DO NOT allow riders. A rider may fall off the machine and be run over.

Failure to comply could result in death or serious injury.

W0970A

WARNING Roll-over hazard!

Attempting to free a stuck machine can involve safety hazards: the stuck machine or the towing vehicle may tip or overturn, or the tow bar may fail. Always use the proper towing equipment to free a stuck machine.

Failure to comply could result in death or serious injury.

W0327A

NOTICE: Towing the machine is not recommended.

NOTICE: Do not attempt to start the engine while towing the machine. The drive train components will be damaged!

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

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 2.4 km/h (1.5 mph).

The machines must be attached as closely as possible.

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

Before moving a disabled machine you must be able to answer these questions: •

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 drivetrain or moving parts that lack lubrication?

Additional considerations: •

Be certain that all personnel involved are shielded in the event that the towing apparatus might break.

•

An operator may only be allowed on the towed vehicle if it has steering and braking capability.

•

Always block the disabled machines wheels before releasing the brakes or drive train component.

5-3

5 - TRANSPORT OPERATIONS

Tow procedure - engine runs 1.

Engage the parking brake.

2.

Block the wheels with wheel chocks.

3.

Place the transmission in neutral.

4.

Place the direction control lever in neutral.

5.

Place the 4WD switch in the disengaged position, if equipped.

6.

Raise the forks off the ground.

7.

Attach a rigid drawbar to the disabled machine.

8.

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

9.

Remove the wheel chocks.

10.

Release the parking brake. If the parking brake will not disengage (for any reason), manually disengage the parking brake. Refer to page 7-107.

11.

Tow the disabled machine, the maximum tow speed is 2.4 km/h (1.5 mph).

Tow procedure - engine does not run 1.

Block the wheels with wheel chocks.

2.

Place the transmission in neutral.

3.

Place the direction control lever in neutral.

4.

Place the 4WD switch in the disengaged position, if equipped.

5.

Attach a rigid drawbar to the disabled machine.

6.

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

7.

Disconnect the front drive shaft (two wheel drive machines) or both the front and rear drive shafts (four wheel drive machines).

NOTE: The forklift is equipped with Spring Applied Hydraulic Released (SAHR) parking brake integrated in the transmission. The parking brake remains engaged if the engine is disabled. Manual disengagement of the parking brake is not required for towing with the drive shafts removed.

8.

Remove the wheel chocks.

9.

Tow the disabled machine, the maximum tow speed is 2.4 km/h (1.5 mph).

5-4

6 - WORKING OPERATIONS

6 - WORKING OPERATIONS GENERAL INFORMATION

Machine stability WARNING Hazard to bystanders!

Always know the location of all workers in your area. Warn them before you start operating the machine. Always keep all unauthorized bystanders clear of the work area.

Failure to comply could result in death or serious injury.

W0206A

WARNING Loss of control hazard!

To maintain machine stability and reduce the risk of tip-over, only lift loads that are within the lift capacity of the machine. An overload on the forks makes the machine unstable and hard to handle.

Failure to comply could result in death or serious injury.

W1215A

WARNING Tip-over hazard!

When there is an elevated load, move the machine with extreme caution. Extended forward tilt is possible. Tilt the load forward with extreme caution. During transport, always carry the load in a down position.

Failure to comply could result in death or serious injury.

W1214A

6-1

6 - WORKING OPERATIONS

RAIL12FRK1126FA

1

(1) Fulcrum point of the machine (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 mast and its load.

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

6-2

6 - WORKING OPERATIONS

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.

Load center The load center is the center of gravity of the load. The height and weight limits of a forklift are determined by the distance of the load center (2) from the face of the forks (1).

NOTE: The lifting height and weight limits of the machine, are based on loads that have their weight centered or less from the 610 mm (24 in) face of the forks.

RAIL12FRK1102BA

1

RAIL12FRK1105CA

2

Machines with a 4.57 m (15.0 ft) mast Load center 610 mm (24 in) face of the forks.

Machine 586H 588H

Maximum height (A) 4.57 m (15.0 ft) 4.57 m (15.0 ft)

Maximum weight (B) 2722 kg (6000 lb) 3629 kg (8000 lb)

Machines with a Freelift mast (586H only) Load center 610 mm (24 in) face of the forks.

Freelift Mast option 4.88 m (16.0 ft) 6.71 m (22.0 ft)

Maximum height (A)

Maximum weight (B)

4.88 m (16.0 ft)

2722 kg (6000 lb)

4.88 m (16.0 ft) 6.71 m (22.0 ft)

2722 kg (6000 lb) 1361 kg (3000 lb)

Machines with a 6.71 m (22.0 ft) mast Load center 610 mm (24 in) face of the forks.

Machine 586H 588H

Maximum height (A) 4.57 m (15.0 ft) 6.71 m (22.0 ft) 4.57 m (15.0 ft) 6.71 m (22.0 ft)

Maximum weight (B) 2722 kg (6000 lb) 1361 kg (3000 lb) 3629 kg (8000 lb) 1814 kg (4000 lb)

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

6-3

6 - WORKING OPERATIONS

586H Load limit chart The lift capacity decreases as the load center distance to the front of the fork face increases.

NOTE: Machine capacity is less when operating on uneven, unstable or soft ground conditions. Lift capacities are based on solid, level, smooth ground conditions. Reduce the load to maintain stability.

RAIL12FRK1107GA

3

Lift capacity chart as load center distance increase (1) (2) (3) (4) (5)

The load center distance (B) from the fork face 0 - 610 mm (0 - 24 in) 711 mm (28 in) 813 mm (32 in) 914 mm (36 in) 1016 mm (40 in)

6-4

Approximate maximum load limit (A) 2722 kg (6000 lb) 2359 kg (5200 lb) 2041 kg (4500 lb) 1769 kg (3900 lb) 1633 kg (3600 lb)

6 - WORKING OPERATIONS

588H Load limit chart The lift capacity decreases as the load center distance to the front of the fork face increases.

NOTE: Machine capacity is less when operating on uneven, unstable or soft ground conditions. Lift capacities are based on solid, level, smooth ground conditions. Reduce the load to maintain stability.

RAIL12FRK1108GA

4

Lift capacity chart as load center distance increase (1) (2) (3) (4) (5)

The load center distance (B) from the fork face 0 - 610 mm (0 - 24 in) 711 mm (28 in) 813 mm (32 in) 914 mm (36 in) 1016 mm (40 in)

6-5

Approximate maximum load limit (A) 3629 kg (8000 lb) 3175 kg (7000 lb) 2722 kg (6000 lb) 2449 kg (5400 lb) 2268 kg (5000 lb)

6 - WORKING OPERATIONS

Adjusting the forks Adjust the forks to suit the appropriate material handling.

Hook style fork adjustment 1.

Park the machine on level ground with the forks just off the ground.

2.

Turn off the engine.

3.

Locate the fork lock lever.

4.

Pull up on the fork lock lever and turn it 180 ° until it locks into an upward position.

5.

Slide the forks to the desired location.

6.

Pull up on the fork lock lever, turn it 180 °, and release the lever into the lock position.

7.

Confirm that the fork lock lever is firmly seated in one of the slots on the fork back support (A).

8.

Move the forks left to right firmly to confirm that the forks are locked into position.

Shaft style fork adjustment 1.

Park the machine on level ground with the forks just off the ground.

2.

Turn off the engine.

3.

Lift the front of the fork and slide the fork into the desired location on the carriage.

4.

Repeat previous step on the other fork.

6-6

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7 - MAINTENANCE

7 - MAINTENANCE GENERAL INFORMATION

General Information DANGER Improper operation or service of this machine can result in an accident.

Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information.

Failure to comply will result in death or serious injury.

D0010A

WARNING Maintenance hazard!

Always perform all service procedures punctually at the intervals stated in this manual. This ensures optimum performance levels and maximum safety during machine operation.

Failure to comply could result in death or serious injury.

W0132A

WARNING Pressurized system!

Before attempting any service procedure, it is your responsibility to know the number of accumulators on the machine, and the correct procedure for releasing the pressure of each accumulator.

Failure to comply could result in death or serious injury.

W0136A

NOTICE: Extreme working and environmental conditions require maintenance intervals to be shortened.

Use CASE CONSTRUCTION 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.

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

Read the safety decals and information decals on the machine. Read the Operator’s Manual and safety manual.

Understand the operation of the machine before you start any service.

Before you service the machine, put a 'Do Not Operate' tag on the steering wheel or over the key switch. Ensure the tag is at a location where everyone who might operate or service the machine may see clearly. One tag is included with your new machine. Additional tags are available from your dealer.

Plastic and resin parts •

Avoid using gasoline, paint thinner, etc. when cleaning plastic parts, console, instrument cluster, etc.

•

Use only water, mild soap, and a soft cloth when you clean these parts.

•

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

7-1

7 - MAINTENANCE

General safety before you service Unless otherwise instructed, always perform these steps before you service the machine: 1.

Park the machine on a flat, level surface.

2.

Place the forks on the ground, with the bottom of the forks parallel to the surface.

3.

Place the direction control lever and the transmission in neutral.

4.

Engage the park brake.

5.

Shut down the engine.

6.

Place a 'Do Not Operate' tag on the key switch so that it is visible to other workers or remove the key.

Hour meter The engine hour meter displays the amount of actual hours the engine has run. Use the engine hour meter along with the Maintenance Chart in this manual to service your machine at the correct time periods.

RAPH12FRK0137AA

7-2

1

7 - MAINTENANCE

Oil life reset - manually - Resetting the oil life monitoring system Regenerating the Diesel Particulate Filter (DPF) system at high temperatures will cause accelerated deterioration of the engine oil due to fuel injection events during the exhaust stroke. The engine controller can estimate oil life based on the number of regeneration events and engine operating conditions since the last oil change. Therefore, the oil life monitoring system must be reset every time the engine oil is changed. Follow one of the procedures below.

Reset oil life with the foot throttle 1.

Turn the key switch to the ON position but do not start the engine.

2.

Press the foot throttle greater than 90 % of its travel and hold for 15 s.

3.

Fully release the foot throttle for 15 s.

4.

Press the foot throttle greater than 90 % of its travel and hold for 15 s.

5.

Fully release the foot throttle for 15 s.

6.

Press the foot throttle between 10 - 90 % and hold for 15 s.

7.

Turn the key switch to the OFF position.

Reset oil life with the instrument control panel 1.

The system must be reset using the instrument control panel. Refer to the Reset oil life procedure listed in the 3-11 Section 3 of this manual.

7-3

7 - MAINTENANCE

Engine side panel latch Open the engine side panel: 1.

Shut down the engine.

2.

Locate the latch on the lower left or right side of the operator platform.

3.

Push the side panel latch to release the side panel.

4.

Swing open the side panel.

NOTE: A gas strut assists in opening the side panel and hold the side panel in an open position.

5.

If applicable, repeat on the other side.

NOTICE: To avoid damage to the side panels parts, always close the side panels before moving the machine.

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1

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3

Close the engine side panel: 1.

Push the side panel until the latch engages.

7-4

7 - MAINTENANCE

Fire extinguisher It is recommended that you have a fire extinguisher on your machine. A fire extinguisher is available from your dealer and can be installed on the machine.

This dry chemical fire extinguisher has a 2 kg (5 lb) capacity and is approved for class A, B, and C type fires. The operating temperature is from -54 - 49 °C (-65 - 120 °F).

Fire extinguisher care •

Every month - Inspect the fire extinguisher for damage and to ensure that the gauge is working correctly.

•

Once a year - Have the fire equipment representative inspect the fire extinguisher. Reference NFPA Standard No. 10-1992.

•

Every 6 years - Have the dry chemical removed and refilled by a fire equipment representative. Reference NFPA Standard No. 10-1992.

•

Every 12 years - Have the fire equipment representative hydrostatically test the fire extinguisher. Reference NFPA Standard No. 10-1992.

7-5

7 - MAINTENANCE

Battery disconnect WARNING Explosive gas!

Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.

Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen battery.

Failure to comply could result in death or serious injury.

W0005A

WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

•

Do not run the engine with the alternator wires disconnected.

•

Before using an electric welder, disconnect the alternator wires, instrument cluster and batteries. Disconnect the ECU connectors.

•

Do not use a steam cleaner or a cleaning solvent to clean the alternator.

•

Keep the battery vents clean. Ensure the battery vents are not restricted.

Disconnect battery 1.

Remove the battery cover hardware.

2.

Remove the battery cover.

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7-6

1

7 - MAINTENANCE

3.

Disconnect the negative battery cable from the negative battery terminal.

RAPH12FRK0278AA

2

RAPH12FRK0976BA

3

Master disconnect switch (if equipped) Enable or disable electrical power from the machine batteries to the electrical components using the master disconnect switch, located on the left hand side of the engine.

NOTICE: Wait at least 60 seconds after ignition key is placed in the OFF position before turning master disconnect switch to OFF. This allows the machine controllers to shutdown properly.

NOTICE: Some machine service procedures require an actual terminal disconnect of the batteries. Do not use the master disconnect for those types of procedures, such as welding on the machine.

7-7

7 - MAINTENANCE

Welding on the machine Contact your dealer if you have any questions before welding on this machine. The following procedures must be completed before welding.

Remove the battery cover and disconnect the batteries.

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1

RAPH12FRK0163AA

2

RAPH12FRK0242AA

3

Disconnect the alternator terminal wires.

Disconnect the Engine Control Unit (ECU) 1.

Remove the four bolts and the ECU cover panel from the right side of the operator seat.

7-8

7 - MAINTENANCE

2.

Disconnect both connectors.

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4

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5

Disconnect the instrument control panel.

1.

Remove the instrument control panel.

2.

Disconnect the wire connector on the back of the instrument control panel.

7-9

7 - MAINTENANCE

Fuses and relays The machine has three fuse and relay locations: •

The main fuse and relay location is under the operator seat on the right hand side

•

The Glowplug Control Unit (GCU) fuse is accessible from either side of the engine side panels.

•

The Engine Control Unit (ECU) fuse and relay location is behind the ECU cover panel on the right hand side of the operator seat

Main fuse and relays 1.

2.

Locate the main fuse and relay panel on the right hand side below the operator seat.

RAIL12FRK1097BA

1

RAPH12FRK0209AA

2

RAPH12FRK0211AA

3

Remove the four screws and the panel.

(1) Power relay #1 (2) Power relay #2 (3) Flasher relay and Shuttle interlock timing relay

3.

Remove the fuse covers.

(1) Fuse, diodes, and relays (2) Relays (3) Diagnostic port

7-10

7 - MAINTENANCE

4.

Refer to the decal on the interior side of the panel cover for fuse, relay, and/or diode functions.

84543643

4

Glowplug Control Unit (GCU) fuse 1.

Open the right side engine panel.

NOTE: You can access the fuse from the left side as well.

2.

Locate the 60 A fuse (1) for the GCU. Look underneath the Diesel Particulate Filter (DPF) and in front of the engine lift hooks (2).

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7-11

5

7 - MAINTENANCE

Engine Control Unit (ECU) fuse and relay 1.

2.

Remove the four bolts and the ECU cover panel from the right side of the operator seat.

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6

RAPH12FRK0236AA

7

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8

Locate the ECU B+ relay (1) and the ECU fuse (2) location.

Remove the cover from the ECU fuse block.

(1) ECU B+ 20 A fuse (2) ECU B+ 7.5 A fuse (3) LAMBDA SENSOR B+ 7.5 A fuse

7-12

7 - MAINTENANCE

Definition of fuse, relay, and diode icons

1

84543643

Fuse icon definitions Function

Symbol ECU B+

Instrument cluster key ON

Instrument cluster B+

Rear lights

Tail lights

Cigarette lighter plugs

7-13

7 - MAINTENANCE

Function

Symbol Head lights

Transmission de-clutch

Turn signal, Hazards

High beam

Horn

Key switch

SAHR brake

Customer B+

Customer key ON

Starter

Four Wheel Drive (4WD)

Relay icon definitions Function

Symbol Power relay #1

Power relay #2

Spring-Applied Hydraulic-Released (SAHR) park brake relay

7-14

7 - MAINTENANCE

Symbol

Function SAHR park brake transmission cutout relay

Forward relay

Reverse relay

Transmission De-clutch relay

Shuttle interlock relay

Start relay

Neutral relay

Starter interlock relay

Diode icon definitions Function

Symbol Reverse signal diode

Forward signal diode

7-15

7 - MAINTENANCE

Diagnostic/service tool port The diagnostic/service tool port is located in the fuse box at the side console. Connect the Electronic Service Tool (EST) or DATAR to this port to update software and/or perform service and diagnostic tests.

1.

2.

Locate the main fuse and relay panel on the right hand side below the operator seat.

RAIL12FRK1097BA

1

RAPH12FRK0209AA

2

RAPH12FRK0211AA

3

Remove the four screws and the panel.

3.

Remove the diagnostic port cap.

4.

Plug the diagnostic tool into the diagnostic port.

7-16

7 - MAINTENANCE

Fluid capacities and lubricant specifications Engine crank case Specification: Capacity: With filter change

TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40( API CJ-4) 8.00 l (8.45 US qt)

NOTE: Refer to the Recommended operating temperature range chart located in this manual to determine the appropriate oil type for your operating environment.

Fuel tank Specification: Capacity:

No. 2 ultra-low sulfur diesel 119 l (31 US gal)

Cooling system Specification: Capacity:

CNH XHD PREMIX ( 50 % water and 50 % ethylene glycol) 16.1 l (17.0 US qt)

Hydraulic system Specification: Capacity: Total system Reservoir with filter change Reservoir without filter change

CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL 68.1 l (72.0 US qt) 55.0 l (58.1 US qt) 53.0 l (56.0 US qt)

Transmission Specification: Capacity: Manual (Power shuttle) Total system Refill (with or without filter change)

CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL

Two wheel drive 18.5 l (19.5 US qt) 11.9 l (12.6 US qt)

Four wheel drive 20.8 l (22.0 US qt) 14.4 l (15.2 US qt)

Front drive axle Specification: Capacity: Differential Each hub

TUTELA TRANSAXLE FLUID SAE 80W-140 14.2 l (15.0 US qt) 1.5 l (1.6 US qt)

Rear steer axle — Four Wheel Drive (4WD) Specification: Capacity: Differential Each planetary hub

TUTELA TRANSAXLE FLUID SAE 80W-140 5.5 l (5.8 US qt) 0.7 l (0.7 US qt)

Brake master cylinder Brake fluid supplied by the transmission.

7-17

7 - MAINTENANCE

Consumables For the very best protection of your investment, use the recommended lubrication and service products. Contact your dealer for these products and any questions you might have about the machine's service and lubrication requirements.

Always remember the environment before you service the machine and before you dispose of the old fluids and lubricants.

You must follow local, state, and regional regulations when disposing of fluids, filters, fuels, and lubricants.

•

Do not put oil or fluids into the ground or into containers that can leak.

•

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

Systemgard lubrication analysis Ask your dealer about the lubricant 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 Systemgard laboratory. After the sample is processed, the laboratory will report back to you and guide you with maintenance requirements. 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 CONSTRUCTION equipment.

RCPH10TLB297AAF

7-18

1

7 - MAINTENANCE

CJ-4 Oils – Tier 4 F5H emissions equipped machines Recommended operating temperature range

(H)

0W-40 CJ-4 UNITEK to MAT3521

(H)

API CJ–4 0W-40 (H)

10W-40 CJ-4 UNITEK to CNH MAT3521

(H)

API CJ–4 10W-40 (H)

15W-40 CJ-4 UNITEK to CNH MAT3521

(H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

API CJ–4 15W-40

0 °C 32 °F

10 °C 50 °F

(H) Engine oil pan or coolant block heater recommended in this range

7-19

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

7 - MAINTENANCE

MAINTENANCE CHART

Maintenance Chart

Interval

Page Nb.

At warning message display

7-22 7-25 7-26 7-28 Initial 10 hours 7-31 Every 10 hours of 7-32 operation or daily Initial 20 hours 7-34 7-36 7-37 Every 50 hours 7-38 7-40 7-42 7-43 7-44 7-44 7-44 Initial 100 hours 7-46 7-48 7-50 7-52 7-53 Every 250 hours 7-54 7-55 7-56 7-57 7-58 7-59 7-60 7-61 7-62 7-64 7-66 7-68 7-69 7-70 7-71 7-72

Maintenance Action

Engine air filters Hydraulic filter Engine oil and filter Diesel Particulate Filter (DPF) regeneration Wheel nut and bolt torque Engine oil level

Bleed Adjust Lubricate Grease Check Cleaning Change fluid Replace Nb. of pts X X X X X X

Transmission oil level Rear steer axle fluid level - Four Wheel Drive (4WD) Front drive axle fluid level Fuel system water separator Coolant reservoir (de-aeration reservoir) fluid level Hydraulic reservoir fluid level Rear steer axle grease fittings Mast pivot grease fittings Mast carriage roller grease fittings Mast chain roller grease fittings Hydraulic filter Transmission filter Fuel filters Service brakes Parking brake Seat slides Battery Rear steer axle fluid level - Four Wheel Drive (4WD) Rear steer axle breather valve - Four Wheel Drive (4WD) Rear steer axle drive shaft - Four Wheel Drive (4WD) Front drive axle fluid level Front drive axle breather valve Front drive axle - drive shaft Fuel tank drain Coolant reservoir (de-aeration reservoir) fluid level Transmission oil level Tire pressure and condition Forklift mast chains Forklift mast chains Tilt cylinder Side-shift cylinder bearing

7-20

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

7 - MAINTENANCE

Interval

Every 500 hours

Every 1000 hours

Every 2000 hours of operation or annually Every 3000 hours Every 4000 hours As required

Page Nb. 7-73 7-75 7-77 7-79 7-80 7-81 7-83 7-84 7-85 7-87 7-89 7-92 7-97 7-98 7-99 7-99 7-100 7-101 7-102 7-103 7-105 7-107

Maintenance Action

Roll Over Protective Structure (ROPS) Fuel filters Engine oil and filter Carriage thrust rollers Forklift mast chains Hydraulic fluid and filter Battery fluid level Front drive axle Transmission fluid and filters Rear steer axle fluid - Four Wheel Drive (4WD) Engine air filters Engine cooling system Chain rollers Load rollers Diesel Particulate Filter (DPF) Engine Crankcase Ventilation (CCV) Filter Fork inspection Tire pressure and condition Engine air precleaner Bleed air from the fuel system Fan belt Disable parking brake

7-21

Bleed Adjust Lubricate Grease Check Cleaning Change fluid Replace Nb. of pts X X X X X X X X X X X X X X X X X X X X X X

7 - MAINTENANCE

At warning message display

Engine air filters Clean or replace the engine air filter when the warning lamp while the engine is running.

1.

2.

and engine malfunction lamp

remains illuminated

Clean the air pre-cleaner: A.

Remove the wing nut (1).

B.

Remove the cover (2).

C.

Remove the bowl (3).

D.

Clean the bowl with a damp cloth.

E.

Assemble the air pre-cleaner.

Open the right side engine panel.

3.

Clean the area around the outside front cover of the air filter housing.

4.

Inspect the air filter housing and components for damage.

5.

Release three clips that secure the air filter housing cover in place.

7-22

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1

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2

7 - MAINTENANCE

6.

Remove and inspect the primary filter.

A.

If damage is noticed on the sides or edges of the filter, replace the filter. If okay continue.

B.

Examine the inside of the filter. If the filter has dust and debris on the inside, replace the filter.

If clean continue.

C.

Lightly tap the ends of the filter against the palm of your hand. Never against a hard surface.

D.

Shine a light inside the filter, if you see light spots or deteriorated areas, replace the filter.

If no damage is apparent continue.

NOTICE: It is okay to clean the primary filter three or four times but it needs to be replaced if damage to the filter is apparent.

7.

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3

RAPH12FRK0196AA

4

RAPH12FRK0197AA

5

With the primary filter removed, use a lint-free cloth tied to a stiff rod and wipe the inside of the housing clean. Avoid touching the inner filter.

7-23

7 - MAINTENANCE

8.

Do not remove the inner filter unless the outside of the inner filter is dirty, replace the inner filter do not clean. Repeat step 7 if replacing the inner filter.

9.

Dispose of the filters in accordance with local, regional, and federal regulations.

10.

If applicable, install the inner air filter. Ensure that a tight seal is created.

11.

Install the primary air filter. Ensure that a tight seal is created.

12.

Position the filter cover over the housing with the dust valve facing downward, hold the cover in place, and fasten the clips that secure the air filter housing in place.

RCPH11TLB056BAD

6

RAPH12FRK0193AA

7

NOTE: Under normal conditions the dust valve will clear itself. Confirm the valve is clear, wipe clean if necessary.

13.

Start up the engine.

14.

Ensure that the warning lamps do not illuminate. If the warning lamps illuminate replace the outer filter if it was cleaned instead of replaced. If the problem continues replace the inner filter.

7-24

7 - MAINTENANCE

Hydraulic filter WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

Replace the hydraulic oil filter whenever the warning lamp normal operating temperature.

1.

remains illuminated while the engine is running at

The hydraulic filter is located under the right front portion of the machine just behind the front axle.

2.

Slowly open the hydraulic reservoir cap to help relieve pressure.

3.

Clean the area around the filter head area before removing the old filter.

4.

Use a filter wrench and remove the old filter. Have a suitable container ready to capture any fluid that might leak or spill.

5.

Dispose of the filter in accordance with local, regional, and federal regulations.

6.

Lubricate the gasket of the new filter with clean oil.

7.

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

8.

Continue to tighten the filter for 1/3 turn.

9.

Tighten the hydraulic reservoir cap.

10.

Start up the engine.

11.

Ensure the warning lamp does not illuminate.

12.

After running for three or four minutes, shut down the engine.

13.

Inspect for leaks.

7-25

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1

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2

7 - MAINTENANCE

Engine oil and filter The Engine Control Unit (ECU) monitors the oil life of the machine. The ECU will notify the operator through the instrument control panel that engine oil service is required.

Change the engine oil and filter when , , and every five minutes for 30 seconds with a single audible alert.

appears on the display. The message will appear

Change the engine oil and replace the filter after every 500 hours of operation or when the ECU prompts the operator.

1.

Start the engine and run until the engine is warm.

A warm engine allows a more complete removal of foreign material.

2.

Turn engine off and open the right side engine panel.

3.

Clean around the engine fill cap (1), engine oil filter and head (2), engine oil dipstick (3), and oil pan drain plug (not shown).

4.

RAPH12FRK0179AA

1

RAPH12FRK0250AA

2

RAPH12FRK0182AA

3

Slowly open the drain plug for the engine oil pan and drain the oil into a suitable container.

5.

Turn the oil filter counter-clockwise to remove. Use a filter removal tool, if necessary.

6.

Dispose of the filter and collected oil in accordance with local, regional, and federal regulations.

7.

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

8.

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

NOTICE: Do not use a filter wrench to install the oil filter.

The wrench can dent the filter and cause a leak.

9.

Turn the new oil filter onto the base until the gasket makes contact with the base.

7-26

7 - MAINTENANCE

10.

Continue to tighten the filter for 3/4 turn.

11.

Install the drain plug for the engine oil tank.

12.

Fill the engine with new oil.

Next operation: If applicable, clear the Oil life reset active warning symbol for the display screen. Refer to 7-3 for the procedure.

7-27

7 - MAINTENANCE

Diesel Particulate Filter (DPF) regeneration CAUTION Burn hazard!

During the Diesel Particulate Filter (DPF) regeneration process the exhaust stack and fixed hood area becomes extremely hot. Allow area to cool before servicing or working near the exhaust system components.

Failure to comply could result in minor or moderate injury.

C0102B

Automatic DPF regeneration NOTE: The operator may continue to operate the machine normally during the automatic DPF regeneration process.

1.

The operator is notified with a single audible beep, and will alternate on the display screen. The DPF regeneration process has started.

The audible beep and display will reappear occasionally during the process.

2.

Operator is notified the regeneration process is complete and successful with a single audible alert, and will alternate on the display screen. This will appear on the display screen for approximately 30 seconds.

RAPH12FRK0137AA

1

NOTE: The operator may choose to prevent the automatic DPF regeneration procedure, but will eventually force the engine to de-rate significantly affecting machine performance. To bypass the procedure refer to 3-11

7-28

7 - MAINTENANCE

Manual DPF regeneration WARNING Fire hazard!

During the Diesel Particulate Filter (DPF) forced regeneration process the exhaust stack and fixed hood area becomes extremely hot. Park the machine outside and away from combustible or highly flammable material.

Failure to comply could result in death or serious injury.

W1165B

1.

Operator will be notified on the instrument control panel with one of the following: •

A single audible alert, an amber operator alert symbol , the DPF symbol will flash, and will alternate on the display screen. A high level of soot is present in the DPF system.

•

Constant audible alert, red emergency stop symbol , the DPF symbol will flash, and will alternate on the display screen. An extremely high level of soot is present in the DPF system.

RAPH12FRK0137AA

2.

Find a location out of the way on the job site and clear away from any combustible material. Perform the following: A.

Bring machine to operating temperature.

B.

Do not actuate the hydraulic controls or the transmission control levers.

C.

Engage the park brake.

D.

Release all pressure from the foot throttle.

7-29

2

7 - MAINTENANCE

3.

4.

5.

6.

7.

Wait for to appear on the display (1). The system is checking that the machine is an idle state with the park brake on.

The sequence message appears on the display screen when the system is ready to start the regeneration process.

Press the start button (2). message alternates on the display screen while the system validates all conditions are met.

One of the following will occur.

•

will alternate on the display screen, the regeneration process starts.

•

will alternate on the display screen, the machine is not ready. Repeat Step 2.

NOTE: If the DPF regeneration continues to FAIL, contact your authorized dealer for service.

8.

will alternate on the display screen and return to the main screen. The regeneration process is complete and the machine is ready for operation.

RAIL12FRK1123CA

3

After Treatment System (ATS) regeneration failure NOTE: There are two levels of warning if the operator does not perform the manual regeneration when requested.

Level 1 warning is provided when the DPF reaches maximum load at which time the engine power is reduced by 25%.

Level 2 warning is provided when the DPF is overloaded at which time the engine power is reduced by 50%.

When the below messages appear during machine operation the Engine Control Unit (ECU) will begin to de-rate the engine output, contact your dealer for service the DPF may need to be replaced.

•

Level 1 — A single audible alert, an illuminated operator alert symbol , and alternate on the display screen.

•

Level 2 — A constant audible alert, an illumiand nated emergency stop symbol , alternate on the display screen.

7-30

7 - MAINTENANCE

Initial 10 hours

Wheel nut and bolt torque Check the torque of the wheel nuts and bolts at the first 10 hours of operation whenever a wheel is removed or for a new machine. If the nuts and bolts are loose, tighten and check after an additional 10 hours of operation. Repeat until the nuts and bolts remain tight.

Front drive wheels Specification: 305 N·m (225 lb ft) NOTICE: Tighten nuts in a crossing pattern (sequence), as shown.

Front drive wheel: 1.

Tighten the ten mounting nuts in sequence until the wheel is snug again the axle hub.

2.

Tighten the nuts in sequence to a torque of 136 N·m (100 lb ft).

3.

Tighten the nuts a second time, in sequence, to a torque of 271 N·m (200 lb ft).

4.

Turn the nuts in sequence an additional 30 ° to set the preload.

RCPH10TLB075AAF

1

RCPH10TLB074AAF

2

Rear steer wheels Specification: •

Two Wheel Drive (2WD) — 156 - 203 N·m (115 - 150 lb ft)

•

Four Wheel Drive (4WD) — 251 N·m (185 lb ft)

NOTICE: Tighten nuts in a crossing pattern (sequence), as shown.

Rear steer wheel (2WD): 1.

Tighten the eight mounting nuts in sequence until the wheel is snug again the axle hub.

2.

Tighten the nuts in sequence to a torque range of 156 - 203 N·m (115 - 150 lb ft) .

Rear steer wheel (4WD): 1.

Tighten the eight mounting nuts in sequence until the wheel is snug again the axle hub.

2.

Tighten the nuts in sequence to a torque of 122 N·m (90 lb ft).

3.

Turn the nuts in sequence an additional 43 ° to set the preload.

7-31

7 - MAINTENANCE

Every 10 hours of operation or daily

Engine oil level Check the engine oil level before you start the engine each day or before the start of each 10 hour shift.

1.

Ensure an accurate level reading: A.

Park the machine on level ground.

B.

Shut down the engine.

C.

Allow time for the oil to drain down into the pan.

2.

Open the right side engine panel.

3.

Wipe the area clean before you remove the dipstick or the fill cap.

4.

Push the dipstick completely in and then pull the dipstick out.

5.

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1

RCPH10TLB029AAF

2

Inspect the dipstick. The oil level should be between the minimum mark and the maximum mark on the dipstick.

7-32

7 - MAINTENANCE

6.

Add oil as needed at the fill location on the machine.

RAPH12FRK0179AA

7-33

3

7 - MAINTENANCE

Initial 20 hours

Transmission oil level WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

WARNING Unexpected machine movement!

Always engage the parking brake before exiting the machine.

Failure to comply could result in death or serious injury.

W1011B

WARNING Unexpected machine movement!

Before starting the engine, make sure all controls are in the neutral position.

Failure to comply could result in death or serious injury.

W0311A

Check the fluid level of the transmission after the first 20 hours of operation on a new machine or after a component rebuild. Then check the fluid level every 250 hours of operation.

1.

Start the engine. The engine must be running to accurately check the transmission fluid level.

2.

Keep the park brake engaged.

3.

Ensure that the transmission gear shift and the directional control lever are in the neutral position.

4.

Open the right side engine panel.

5.

Turn the dipstick handle counter-clockwise and pull out the dipstick.

RAPH12FRK0178AA

7-34

1

7 - MAINTENANCE

6.

Check the fluid level on the dipstick. The level should be between the high (H) mark and the (L) mark.

7.

Add fluid as needed. Do not fill above the high mark.

RCPH10TLB054AAF

7-35

2

7 - MAINTENANCE

Rear steer axle fluid level - Four Wheel Drive (4WD) Check the oil level of the 4WD rear steer axle after the first 20 hours of operation with a new machine or after a component rebuild. Then check the oil level every 250 hours of operation.

Wheel hub oil level 1.

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

2.

Slowly remove the plug. Oil should be even with the plug orifice.

3.

Add oil as needed.

4.

Install the plug.

5.

Repeat the procedure for the other wheel.

RAIL11TLB0011AA

1

RAPH12FRK1115AA

2

Axle oil level 1.

Slowly remove the plug from the center bowl. Oil should be even with the orifice.

2.

Add oil as needed.

3.

Install the plug.

7-36

7 - MAINTENANCE

Front drive axle fluid level Check the oil level of the front drive axle after the first 20 hours of operation with a new machine or after a component rebuild. Then check the oil level every 250 hours of operation.

Wheel hub oil level 1.

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

2.

Slowly remove the plug. Oil should be even with the plug orifice.

3.

Add oil as needed.

4.

Install the plug.

5.

Repeat the procedure for the other wheel.

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1

RAPH12FRK0276AA

2

Axle oil level 1.

Slowly remove the plug. Oil should be even with the orifice.

2.

Add oil as needed.

3.

Install the plug.

7-37

7 - MAINTENANCE

Every 50 hours

Fuel system water separator Drain the water separator and check the fuel for water or sediment every 50 hours.

1.

Open the right side engine panel.

NOTE: A clear bowl allows a visible check of the fuel for water. If water or sediment are present, drain water out of the filter and the fuel tank.

2.

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1

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2

RCPH10TLB031AAF

3

Remove the wire connector attached to the bottom of the drain valve for the water separator.

NOTE: View is from underneath the machine.

Press on the wire clasp that holds the connector to the drain to remove.

3.

Hold a small container under the water separator and loosen the drain valve.

7-38

7 - MAINTENANCE

4.

Collect a small amount of fluid and inspect for water or sediment.

5.

Drain until water or sediment is no longer present.

6.

Close the drain valve.

7.

If water or sediment was found in the water separator, drain the fuel tank.

A.

Place a collection container under the drain plug and remove the plug .

B.

After water and sediment are removed, install and tighten the plug.

7-39

7 - MAINTENANCE

Coolant reservoir (de-aeration reservoir) fluid level CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

Check the de-aeration reservoir fluid level every 50 hours of operation.

1.

Ensure an accurate level reading: A.

Park the machine on level ground.

B.

Shut down the engine.

C.

Allow time for the coolant to completely cool.

Coolant must be cold before proceeding.

D.

Open the right hand side engine panel.

2.

Check the coolant level on the reservoir. The coolant level should be between the HOT MAX mark (1) and the COLD MIN mark (2).

3.

If coolant is below the COLD MIN mark add coolant.

4.

RAPH12FRK0034BA

1

RAPH12FRK0215AA

2

Loosen both bolts on the coolant cover plate, but only remove one of the bolts.

7-40

7 - MAINTENANCE

5.

Slide the coolant cover plate (1) away from the opening.

6.

Open the filler cap (2), turn slowly counter-clockwise until you can remove the cap. It is not necessary to remove the hoses in order to remove the cap.

7.

Add coolant.

RAPH12FRK0213AA

7-41

3

7 - MAINTENANCE

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

1.

To ensure an accurate level reading: •

Lower the forks to the ground.

•

Tilt the mast fully backward.

•

Allow the hydraulic fluid to cool.

2.

Check the gauge (2) on the hydraulic reservoir. The hydraulic reservoir is full when hydraulic fluid is level with the FULL COLD mark in the gauge.

3.

Slowly turn the reservoir cap (1) to relieve pressure and remove the cap.

4.

Add hydraulic fluid as needed.

RAPH12FRK0219AA

7-42

1

7 - MAINTENANCE

Rear steer axle grease fittings Grease the king pins and the rear axle pivot every 50 hours of operation, or more frequently, if the machine has been working in water or extremely muddy conditions.

•

•

•

King pins, two-wheel drive - Four total, two on each side

RCPH10TLB063AAF

1

RCPH10TLB369AAF

2

RAPH12FRK0171AA

3

King pins, four wheel drive - Four total, two on each side

Front axle pivot, remote fitting - One

7-43

7 - MAINTENANCE

Mast pivot grease fittings DANGER Improper operation or service of this machine can result in an accident.

Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information.

Failure to comply will result in death or serious injury.

D0010A

Grease the mast pivot every 50 hours of operation, or more frequently, if the machine has been working in severe conditions.

1.

Grease each side of the mast pivot.

RAPH12FRK0136AA

1

Mast carriage roller grease fittings Grease the mast carriage rollers every 50 hours of operation, or more frequently, if the machine has been working in severe conditions.

1.

Grease the four mast carriage rollers.

RAPH12FRK0288AA

1

Mast chain roller grease fittings Grease the mast chain rollers every 50 hours of operation, or more frequently, if the machine has been working in severe conditions.

7-44

7 - MAINTENANCE

1.

Grease the mast chain rollers.

•

586H — two grease fittings

•

588H — four grease fittings

RAPH12FRK1117AA

7-45

1

7 - MAINTENANCE

Initial 100 hours

Hydraulic filter WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

Replace the hydraulic oil filter at the initial 100 hours of operation, whenever the warning lamp remains illuminated while the engine is running at normal operating temperature, and under normal working conditions every 1000 hours.

1.

The hydraulic filter is located under the right front portion of the machine just behind the front axle.

2.

Slowly open the hydraulic reservoir cap to help relieve pressure.

3.

Clean the area around the filter head area before removing the old filter.

4.

Use a filter wrench and remove the old filter. Have a suitable container ready to capture any fluid that might leak or spill.

5.

Dispose of the filter in accordance with local, regional, and federal regulations.

6.

Lubricate the gasket of the new filter with clean oil.

7.

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

8.

Continue to tighten the filter for 1/3 turn.

9.

Tighten the hydraulic reservoir cap.

10.

Start up the engine.

11.

Ensure the warning lamp does not illuminate.

7-46

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7 - MAINTENANCE

12.

After running for three or four minutes, shut down the engine.

13.

Inspect for leaks.

7-47

7 - MAINTENANCE

Transmission filter Replace the transmission filter after the first 100 hours and every 1000 hours on a new machine or if a major component has been rebuilt.

1.

2.

Prepare the machine: A.

Bring transmission fluid to operating temperature.

B.

Park the machine on level ground.

C.

Place both the directional lever and gear shift lever in neutral.

D.

Turn engine off.

E.

Open the right and left side engine panels.

Clean the area around the transmission dipstick.

3.

Turn dipstick counter-clockwise and remove.

4.

Locate the transmission filter (2) on the left hand side below the brake reservoir tank (1).

5.

Clean the area around the transmission filter head and surrounding areas to help eliminate contamination.

6.

Place a suitable container under the transmission filter to capture fluid during the procedure.

7.

Remove the filter. Use a filter removal tool, if necessary.

8.

Dispose of the filter and collected fluid in accordance with local, regional, and federal regulations.

9.

Lubricate the gasket of the new filter with clean oil.

NOTICE: Never use a filter removal tool to install the filter.

10.

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

11.

Continue to tighten the filter another 1/3 turn.

7-48

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7 - MAINTENANCE

12.

Replace the transmission dipstick.

13.

Start up the engine.

14.

Check for leaks around the filter

15.

Operate the machine in 1st and 2nd gear for a few minutes.

16.

Park the machine on a level surface.

17.

Check the fluid level and add if necessary.

7-49

7 - MAINTENANCE

Fuel filters Replace the fuel filters after the first 100 hours of operation on a new machine or if a major component has been rebuilt. Then replace the fuel filters every 500 hours of operation or after a loss of engine power.

1.

Fill the fuel tank before proceeding.

2.

Open the fuel tank cap slightly to release pressure.

3.

Open the right side engine panel.

4.

Clean the area around the water separator of dirt and debris.

5.

RAPH12FRK0180AA

1

RAPH12FRK0249AA

2

RCPH10TLB031AAF

3

Remove the wire connector at the base of the water separator.

•

Press on the wire clasp that holds the connector to the drain to remove.

NOTE: View is from underneath the machine.

7-50

7 - MAINTENANCE

6.

Remove the black collar (1) and the filter (2). Use a filter removal tool, if necessary.

7.

Apply clean engine oil to the new fuel filter seal.

8.

Install the new filter.

9.

Install the black collar and turn until it snaps into place.

NOTICE: Never use a filter removal tool to install a new filter.

10.

Continue to tighten the filter and additional 1/2 to 3/4 turn.

11.

Install the wire connector. You should hear it click into position.

12.

Clean the area around the primary fuel filter of dirt and debris.

13.

Turn the primary filter counter-clockwise to remove.

Use a filter removal tool, if necessary.

14.

Apply clean engine oil to the new primary filter seal.

15.

Turn the new primary filter clockwise onto the filter head until the filter gasket makes contact with the filter body.

16.

Continue to tighten the primary filter and additional 1/2 to 3/4 turn.

17.

Tighten the fuel tank cap.

18.

Dispose of the filters and collected fluid in accordance with local, regional, and federal regulations.

RAIL11TLB0009AA

4

RAPH12FRK0179AA

5

NOTICE: Air in the fuel system causes excessive engine cranking before the engine starts. It is crucial that all air be removed from the system.

19.

WARNING Pressurized system!

Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.

Failure to comply could result in death or serious injury.

W0285A

Bleed air from the system. For detailed instructions, refer to page 7-103.

7-51

7 - MAINTENANCE

Service brakes Check the operation of the service (pedal) brakes on a hard level surface after the first 100 hours of operation.

NOTE: Review the procedures in their entirety before proceeding. Ensure that you allow surplus room for machine travel.

1.

Lock the right and left service brakes together.

2.

Sit in the operator's seat and fasten the seat belt.

3.

Engage the parking brake.

4.

Disengage four wheel drive, if equipped.

5.

Place the direction control lever in neutral and the transmission in 2nd gear.

6.

Start up the engine.

7.

Ensure the forks are raised in preparation of forward travel.

8.

Press and hold the service brakes and release the parking brake.

9.

Place the direction control lever in forward.

10.

Release the service brakes.

11.

Increase the engine speed to full throttle.

12.

When the machine is moving at full speed in 2nd gear, push the brake pedals and stop the machine.

The machine must stop smoothly and the brake pedal effort must feel firm. Contact your dealer for service as needed.

7-52

7 - MAINTENANCE

Parking brake Check the operation of the parking brake after the first 100 hours of operation. Then check the parking brake as required.

NOTE: Review the procedures in their entirety before proceeding. Ensure that you allow surplus room for machine travel.

1.

Sit in the operator's seat and fasten the seat belt.

2.

Engage the parking brake.

3.

Disengage four wheel drive, if equipped.

4.

Place the direction control lever in neutral and the transmission in 2nd gear.

5.

Start up the engine.

6.

Ensure the forks are raised in preparation of forward travel.

7.

Press and hold the service brakes and release the parking brake.

8.

Place the direction control lever in forward.

9.

Release the service brakes.

10.

Increase the engine speed to full throttle.

11.

Travel forward approximately 8 m (26 ft).

12.

Engage the parking brake. The machine should come to a stop within 2 m (6.5 ft) of engaging the parking brake and the transmission should declutch.

Contact your dealer for service as needed.

7-53

7 - MAINTENANCE

Every 250 hours

Seat slides Lubricate the seat slides every 250 hours of machine operation.

1.

Move the seat all the way the back on the seat slides.

2.

Wipe away any debris from the seat slides (1) and underneath the seat area (2).

3.

Apply a small amount of graphite grease to the front of seat slides.

4.

Slide the seat forward and backward to lubricate the seat slides.

7-54

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1

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2

7 - MAINTENANCE

Battery WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

Check the batteries for dirt, corrosion, and damage every 250 hours of operation.

Dirt mixed with electrolyte or moisture on the top of the battery can cause a discharged condition in the battery.

1.

Remove the hardware and battery access door.

2.

Use baking soda or ammonia and flush the outside of the battery with water.

3.

Use the CASE CONSTRUCTION battery saver to prevent corrosion on the battery terminals. Follow the instructions on the bottle. The battery saver does not require water. If the battery saver is not available, use a suitable, special cleaner designed to prevent corrosion.

4.

Keep the battery vents clean. Make sure the vents are not restricted.

7-55

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1

RAPH12FRK0278AA

2

7 - MAINTENANCE

Rear steer axle fluid level - Four Wheel Drive (4WD) Check the oil level of the 4WD rear steer axle after the first 20 hours of operation with a new machine or after a component rebuild. Then check the oil level every 250 hours of operation.

Wheel hub oil level 1.

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

2.

Slowly remove the plug. Oil should be even with the plug orifice.

3.

Add oil as needed.

4.

Install the plug.

5.

Repeat the procedure for the other wheel.

RAIL11TLB0011AA

1

RAPH12FRK1115AA

2

Axle oil level 1.

Slowly remove the plug from the center bowl. Oil should be even with the orifice.

2.

Add oil as needed.

3.

Install the plug.

7-56

7 - MAINTENANCE

Rear steer axle breather valve - Four Wheel Drive (4WD) Clean the breather valve on the rear steer axle every 250 hours of operation. If you operate the machine in severe conditions, clean it more frequently.

1.

Locate the breather valve on the right side of the rear steer axle.

2.

Remove dirt and debris from the area around the breather valve and clean with solvent.

3.

CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Blow dry the area with compressed air.

4.

RAPH12FRK1115AA

Spin the top cap on the breather valve to ensue that it turns freely.

7-57

1

7 - MAINTENANCE

Rear steer axle drive shaft - Four Wheel Drive (4WD) Grease the rear drive shaft every 250 hours of operation.

Use TUTELA MULTI-PURPOSE EP GREASE 251H, GR-9.

RAIL11TLB0010AA

7-58

1

7 - MAINTENANCE

Front drive axle fluid level Check the oil level of the front drive axle after the first 20 hours of operation with a new machine or after a component rebuild. Then check the oil level every 250 hours of operation.

Wheel hub oil level 1.

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

2.

Slowly remove the plug. Oil should be even with the plug orifice.

3.

Add oil as needed.

4.

Install the plug.

5.

Repeat the procedure for the other wheel.

RCPH10TLB075AAF

1

RAPH12FRK0276AA

2

Axle oil level 1.

Slowly remove the plug. Oil should be even with the orifice.

2.

Add oil as needed.

3.

Install the plug.

7-59

7 - MAINTENANCE

Front drive axle breather valve Clean the breather valve on the front drive axle every 250 hours of operation. If you operate the machine in severe conditions, clean it more frequently.

1.

Locate the breather valve (1) just left of the front drive axle center bowl.

NOTE: The arrow in the image is pointing towards the front of the machine.

2.

3.

Remove dirt and debris from the area around the breather valve and clean with solvent.

CAUTION Eye injury hazard!

Wear protective goggles when using compressed air.

Failure to comply could result in minor or moderate injury.

C0035A

Blow dry the area with compressed air.

4.

Spin the top cap on the breather valve to ensue that it turns freely.

7-60

RAIL12FRK1134BA

1

7 - MAINTENANCE

Front drive axle - drive shaft Grease the front drive shaft every 250 hours of operation.

Use TUTELA MULTI-PURPOSE EP GREASE 251H, GR-9.

RAPH12FRK0258AA

7-61

1

7 - MAINTENANCE

Fuel tank drain Inspect the fuel tank for water and sediment every 250 hours of operation.

1.

Open the right side engine panel.

NOTE: A clear bowl allows a visible check of the fuel for water. If water or sediment are present, drain water out of the filter and the fuel tank.

2.

RAPH12FRK0180AA

1

RAPH12FRK0249AA

2

RCPH10TLB031AAF

3

Remove the wire connector attached to the bottom of the drain valve for the water separator.

NOTE: View is from underneath the machine.

Press on the wire clasp that holds the connector to the drain to remove.

3.

Hold a small container under the water separator and loosen the drain valve.

4.

Collect a small amount of fluid and inspect for water or sediment.

5.

Drain until water or sediment is no longer present.

7-62

7 - MAINTENANCE

6.

Close the drain valve.

7.

If water or sediment was found in the water separator, drain the fuel tank.

A.

Place a collection container under the drain plug and remove the plug .

B.

After water and sediment are removed, install and tighten the plug.

7-63

7 - MAINTENANCE

Coolant reservoir (de-aeration reservoir) fluid level CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

Check the deaeration reservoir fluid level every 250 hours of operation.

1.

2.

3.

Ensure an accurate level reading: A.

Park the machine on level ground.

B.

Shut down the engine.

C.

Allow time for the coolant to completely cool.

Coolant must be cold before proceeding.

D.

Open the right hand side engine panel.

Check the coolant level on the reservoir. The coolant level should be between the HOT MAX mark (1) and the COLD MIN mark (2).

RAPH12FRK0034BA

1

RAPH12FRK0215AA

2

Loosen both bolts on the coolant cover plate, but only remove one of the bolts.

7-64

7 - MAINTENANCE

4.

Slide the coolant cover plate (1) away from the opening.

5.

Open the filler cap (2), turn slowly counter-clockwise until you can remove the cap. It is not necessary to remove the hoses in order to remove the cap.

6.

Add coolant.

RAPH12FRK0213AA

7-65

3

7 - MAINTENANCE

Transmission oil level WARNING Rotating parts!

The engine is running. Keep clear of rotating fans and belts.

Failure to comply could result in death or serious injury.

W0275A

WARNING Unexpected machine movement!

Always engage the parking brake before exiting the machine.

Failure to comply could result in death or serious injury.

W1011B

WARNING Unexpected machine movement!

Before starting the engine, make sure all controls are in the neutral position.

Failure to comply could result in death or serious injury.

W0311A

Check the fluid level of the transmission after the first 20 hours of operation on a new machine or after a component rebuild. Then check the fluid level every 250 hours of operation.

1.

Start the engine. The engine must be running to accurately check the transmission fluid level.

2.

Keep the park brake engaged.

3.

Ensure that the transmission gear shift lever and the directional control lever are in the neutral position.

4.

Open the right side engine panel.

5.

Turn the dipstick handle counter-clockwise and pull out the dipstick.

RAPH12FRK0178AA

7-66

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7 - MAINTENANCE

6.

Check the fluid level on the dipstick. The level should be between the high (H) mark and the (L) mark.

RCPH10TLB054AAF

7.

Add fluid as needed. Do not fill above the high mark.

7-67

2

7 - MAINTENANCE

Tire pressure and condition DANGER Explosion hazard!

Welding to a wheel can create an explosive air and gas mixture. Removing air from the tire or loosening the tire on the wheel (breaking the bead) will NOT eliminate the hazard. ALWAYS remove the tire completely from the wheel before welding.

Failure to comply will result in death or serious injury.

D0033A

WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

Check the condition and pressure of the tires as needed. Tires will loose air on a regular basis. Check the tire pressure and condition more often when working in extreme conditions or weather.

Front drive wheel tire pressure Model 586H 586H and 588H

Tire size 17.5L x 24 — 10 ply 19.5L x 24 — 12 ply

Recommended tire pressure 221 kPa (32 psi) 234 kPa (34 psi)

Rear steer wheel tire pressure Model 586H (2WD) 588H (2WD) 586H and 588H (4WD)

Tire size 11L x 16 — 10 ply 12 x 16.5 — 12 ply 12 x 16.8 — 8 ply

Recommended tire pressure 359 kPa (52 psi) 310 kPa (45 psi) 345 kPa (50 psi)

NOTE: Tire inflation pressure affects the amount of weight that a tire may carry.

It is recommended that you have a qualified tire mechanic service the tires and rims on these machines. It is recommended that you have this mechanic inflate the tires.

•

Inspect the tire for damaged tread or side walls.

•

Inspect the rim for damage.

•

Confirm that the wheel is properly mounted to the machine. Refer to 7-31 in this manual for procedure.

•

Use an air hose with a remote shutoff and stand behind the tire tread.

7-68

7 - MAINTENANCE

Forklift mast chains Check the chain tension on the forklift mast every 250 hours of operation.

1.

Lower the carriage to the ground.

2.

Measure the exposed carriage roller (A), 25 mm (1 in) is the recommended exposure.

3.

Tighten the chain until 25 mm (1 in) of the carriage roller is exposed.

4.

Repeat the procedure on the other side.

RAIL12FRK1128BA

NOTICE: Confirm both sides have the same carriage roller exposure for a smooth lift and even chain wear.

7-69

1

7 - MAINTENANCE

Forklift mast chains CAUTION Eye injury hazard!

Always wear eye or full face protection when performing this procedure.

Failure to comply could result in minor or moderate injury.

C0081A

Lubricate the forklift mast chains every 250 hours of operation.

1.

Lower the carriage to the ground.

2.

Use a stiff brush or wire brush to clear the dust and debris from the space between the plates.

3.

Apply oil with a narrow brush or pour oil directly onto the chain. Ensure that the oil penetrates the joints.

NOTE: Locations that are difficult to reach, it may be necessary to use a good quality oil under pressure, such as an aerosol can or pump pressure spray.

RAPH12FRK1117AA

7-70

1

7 - MAINTENANCE

Tilt cylinder - Grease Grease the tilt cylinders (four locations) every 250 hours of operation. Use TUTELA MULTI-PURPOSE EP GREASE 251H, GR-9.

NOTE: All views are from underneath the machine.

7-71

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2

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3

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4

7 - MAINTENANCE

Side-shift cylinder bearing Grease the side shift cylinder bearings (two locations) every 250 hours of operation. Use TUTELA MULTI-PURPOSE EP GREASE 251H, GR-9.

RAPH12FRK0263AA

7-72

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7 - MAINTENANCE

Every 500 hours

Roll Over Protective Structure (ROPS) WARNING Equipment failure could cause accident or injury!

The Roll Over Protective Structure (ROPS) and interconnecting components are a certified system.

Make sure you tighten the ROPS mounting bolts to the required torque specification.

Failure to comply could result in death or serious injury.

W0935A

Check the Roll Over Protective Structure (ROPS) canopy, the lower frame, and the seat mount every 500 hours of operation for damage or wear and for proper hardware torque.

1.

Follow the ROPS canopy posts downward to the mounting hardware location. Check the torque of the ROPS mounting bolts.

Rear ROPS mounting hardware. Check both sides. Torque specifications: (1) — 650 - 730 N·m (479 - 538 lb ft) (2) — 134 - 151 N·m (99 - 111 lb ft)

2.

3.

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1

RAPH12FRK0018BA

2

Front ROPS mounting hardware. Check both sides. Torque specification 650 - 730 N·m (479 - 538 lb ft)

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 integrity of the ROPS system, contact your dealer.

7-73

7 - MAINTENANCE

Inspect operator seat and components WARNING Equipment failure could cause accident or injury!

Always fasten seat belt securely before operating the machine. Inspect seat belt parts for wear and/or damage. To ensure operator safety, replace any and all worn or damaged parts of the seat belt prior to operation.

Failure to comply could result in death or serious injury.

W0046B

1.

Check the seat mounting bolts for damage, wear, or looseness.

RAPH12FRK0927BA

2.

Tighten to standard torque specifications. Change the mounting bolts as needed.

3.

Check the seat belt, buckles, retractors, tethers, and slack take-up system for damage or wear. Keep sharp edges and items that can cause damage away from the belts.

4.

Replace as need. Replace belts that have cuts that make the belt weak.

7-74

3

7 - MAINTENANCE

Fuel filters Replace the fuel filters after the first 100 hours of operation on a new machine or if a major component has been rebuilt. Then replace the fuel filters every 500 hours of operation or after a loss of engine power.

1.

Fill the fuel tank before proceeding.

2.

Open the fuel tank cap slightly to release pressure.

3.

Open the right side engine panel.

4.

Clean the area around the water separator of dirt and debris.

5.

RAPH12FRK0180AA

1

RAPH12FRK0249AA

2

RCPH10TLB031AAF

3

Remove the wire connector at the base of the water separator.

•

Press on the wire clasp that holds the connector to the drain to remove.

NOTE: View is from underneath the machine.

7-75

7 - MAINTENANCE

6.

Remove the black collar (1) and the filter (2). Use a filter removal tool, if necessary.

7.

Apply clean engine oil to the new fuel filter seal.

8.

Install the new filter.

9.

Install the black collar and turn until it snaps into place.

NOTICE: Never use a filter removal tool to install a new filter.

10.

Continue to tighten the filter and additional 1/2 to 3/4 turn.

11.

Install the wire connector. You should hear it click into position.

12.

Clean the area around the primary fuel filter of dirt and debris.

13.

Turn the primary filter counter-clockwise to remove.

Use a filter removal tool, if necessary.

14.

Apply clean engine oil to the new primary filter seal.

15.

Turn the new primary filter clockwise onto the filter head until the filter gasket makes contact with the filter body.

16.

Continue to tighten the primary filter and additional 1/2 to 3/4 turn.

17.

Tighten the fuel tank cap.

18.

Dispose of the filters and collected fluid in accordance with local, regional, and federal regulations.

RAIL11TLB0009AA

4

RAPH12FRK0179AA

5

NOTICE: Air in the fuel system causes excessive engine cranking before the engine starts. It is crucial that all air be removed from the system.

19.

WARNING Pressurized system!

Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.

Failure to comply could result in death or serious injury.

W0285A

Bleed air from the system. For detailed instructions, refer to page 7-103.

7-76

7 - MAINTENANCE

Engine oil and filter Change the engine oil and replace the filter after every 500 hours of operation or once a year, whichever occurs first.

1.

Start the engine and run until the engine is warm.

A warm engine allows a more complete removal of foreign material.

2.

Turn engine off and open the right side engine panel.

3.

Clean around the engine fill cap (1), engine oil filter and head (2), engine oil dipstick (3), and oil pan drain plug (not shown).

4.

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3

Slowly open the drain plug for the engine oil pan and drain the oil into a suitable container.

5.

Turn the oil filter counter-clockwise to remove. Use a filter removal tool, if necessary.

6.

Dispose of the filter and collected oil in accordance with local, regional, and federal regulations.

7.

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

8.

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

NOTICE: Do not use a filter wrench to install the oil filter.

The wrench can dent the filter and cause a leak.

9.

Turn the new oil filter onto the base until the gasket makes contact with the base.

10.

Continue to tighten the filter for 3/4 turn.

11.

Install the drain plug for the engine oil tank.

12.

Fill the engine with new oil.

Next operation: 7-77

7 - MAINTENANCE

If applicable, clear the Oil life reset active warning symbol for the display screen. Refer to 7-3 for the procedure.

7-78

7 - MAINTENANCE

Carriage thrust rollers Inspect the carriage thrust rollers every 500 hours of operation.

1.

Lower the carriage to the ground.

2.

Inspect the carriage thrust rollers for wear or damage.

RAIL12FRK1130AA

3.

Inspect both sides. Contact your dealer for replacement if necessary.

7-79

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7 - MAINTENANCE

Forklift mast chains Inspect the mast chains and hardware every 500 hours of operation.

1.

Lower the carriage to the ground.

2.

Inspect the mast chains and hardware from top to bottom for damage, wear or stretch points. Contact your dealer for replacement if necessary.

7-80

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7 - MAINTENANCE

Every 1000 hours

Hydraulic fluid and filter WARNING Personal Protective Equipment (PPE) required.

When assembling, operating, or servicing the machine, wear protective clothing and PPE necessary for the particular procedure. Some PPE that may be necessary includes protective shoes, eye and/or face protection, hard hat, heavy gloves, filter mask, and hearing protection.

Failure to comply could result in death or serious injury.

W0353A

WARNING Burn hazard!

Before performing any service on the hydraulic system, you must allow it to cool. Hydraulic fluid temperature should not exceed 40 °C (104 °F).

Failure to comply could result in death or serious injury.

W0241A

Replace the hydraulic fluid and oil filter every 1000 hours of operation.

1.

Warm up the hydraulic fluid by operating the forklift controls.

2.

Park the machine on level ground.

3.

Lower the carriage to the ground and turn off the engine.

4.

Place a suitable container underneath the hydraulic reservoir drain plug.

5.

Remove the hydraulic fill cap.

6.

Remove the drain plug.

7.

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2

Remove the hydraulic filter: A.

Locate the hydraulic filter under the right front portion of the machine just behind the front drive axle.

B.

Clean the area around the filter head area before removing the old filter.

C.

Use a filter wrench and remove the old filter.

Have a suitable container ready to capture any fluid that might leak or spill.

D.

Dispose of the filter in accordance with local, regional, and federal regulations.

NOTICE: Do not use a filter wrench to install the new filter.

7-81

7 - MAINTENANCE

8.

Install a new hydraulic filter: A.

Lubricate the gasket of the new filter with clean oil.

B.

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

C.

Continue to tighten the filter 1/3 turn.

9.

Install the drain plug.

10.

Fill the hydraulic reservoir.

NOTICE: The hydraulic pump must be filled with oil before operating the machine. Contact your dealer for assistance.

11.

Charge the hydraulic pump: A.

Attach a regulated air supply to pressurize the hydraulic reservoir. A pressure of 34.5 - 69.0 kPa (5.0 - 10.0 psi) is all that is required to move the oil.

NOTICE: Pressure above 69.0 kPa (10.0 psi) can damage the hydraulic reservoir.

B.

Have another person start and run the engine at low idle while the air pressure is being applied to the hydraulic reservoir.

C.

After three to four minutes turn off the engine.

D.

Disconnect the regulated air supply.

12.

Tighten the hydraulic reservoir cap.

13.

Start up the engine.

14.

Operate the forklift controls for three to four minutes

15.

Inspect for leaks.

16.

Confirm that the hydraulic fluid level is at the full mark on the gauge.

7-82

7 - MAINTENANCE

Battery fluid level WARNING Hazardous chemicals!

Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling.

Failure to comply could result in death or serious injury.

W0006A

Check the battery fluid level every 1000 hours of operation.

Check the battery fluid level if the machine has not been operated in a long time.

Check the fluid on a monthly basis if the machine is operated in very warm climates.

1.

Shut down the engine.

2.

Clean the area around the battery to prevent external material or contaminants from entering the battery vent wells.

NOTICE: Use caution when working with metallic tools or conductors. Contact can create sparks and short circuits.

3.

Use a flat head screwdriver and remove the cap (2) for the vent well (1) .

4.

Check the fluid level in each vent cell. Specification (2) is 3 - 10 mm (0.12 - 0.39 in) from the base of the vent well (1) to the start of the electrolyte level.

5.

Add distilled water to each cell as needed.

6.

Reinstall the vent cap and tighten the screw. Do not overtighten! Screw torque must not exceed 1 N·m (12 lb in).

7.

In temperatures of 0 °C (32 °F) and below, connect a battery charger to the batteries (or run the engine) for approximately two hours to ensure the electrolyte mixes with the added water.

7-83

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7 - MAINTENANCE

Front drive axle Change the oil of the front drive axle after 1000 hours of operation.

1.

Prepare the machine: A.

Start the engine and run the machine until the front drive axle fluid is at operating temperature.

B.

Park the machine on level ground.

2.

Place a suitable container under each planetary drain plug, one on each side.

3.

Remove each planetary drain plug.

4.

Place a suitable container underneath the front drive axle drain plug (2) .

5.

Clean the area around the drain plug (2) and the fill plug (1).

6.

Allow all the oil to drain out.

7.

Install all three drain plugs.

8.

Remove the fill plug and add oil to the front drive axle.

9.

Install the plug.

7-84

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7 - MAINTENANCE

Transmission fluid and filters Change the transmission oil and filter every 1000 hours.

1.

Prepare the machine: A.

Bring transmission fluid to operating temperature.

B.

Park the machine on level ground.

C.

Place both the directional lever and gear shift lever in neutral.

D.

Turn engine off.

E.

Open the left and right side engine panels.

2.

Clean the area around the transmission dipstick.

3.

Turn dipstick counter-clockwise and remove.

4.

Clean the area around the drain plug.

5.

Place a suitable container underneath the drain plug.

6.

Remove the drain plug and allow the oil to drain out.

7.

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3

After all the fluid has drained from the system, inspect the transmission oil suction filter.

A.

Remove the two cap screws.

B.

Remove the plate and pull out the suction filter.

C.

Inspect the filter for any type of debris.

NOTICE: If suction filter contains debris, contact your authorized dealer before continuing with this procedure.

7-85

7 - MAINTENANCE

8.

Insert the suction filter, secure in place with plate and bolts. Torque bolts to 23 N·m (17 lb ft).

9.

Locate the transmission filter (2) on the left hand side below the brake reservoir tank (1).

10.

Clean the area around the transmission filter head and surrounding areas to help eliminate contamination.

11.

Place a suitable container under the transmission filter to capture fluid during the procedure.

RAPH12FRK0161AA

12.

Remove the filter. Use a filter removal tool, if necessary.

13.

Dispose of the filter and collected fluid in accordance with local, regional, and federal regulations.

14.

Lubricate the gasket of the new filter with clean oil.

NOTICE: Never use a filter removal tool to install the filter.

15.

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

16.

Continue to tighten the filter another 1/3 turn.

17.

Replace the transmission dipstick.

18.

Start up the engine.

19.

Check for leaks around the filter

20.

Operate the machine in 1st and 2nd gear for a few minutes.

21.

Park the machine on a level surface.

22.

Check the fluid level and add if necessary.

7-86

4

7 - MAINTENANCE

Rear steer axle fluid - Four Wheel Drive (4WD) Change the oil of the Four Wheel Drive (4WD) rear steer axle every 1000 hours of operation.

Wheel hub oil level 1.

Prepare the machine: A.

Bring the rear steer axle oil to operating temperature.

B.

Park the machine on level ground.

2.

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

3.

Place a suitable container underneath each wheel hub drain plug.

4.

Slowly remove the drain plug. Repeat on the other side.

5.

Allow the oil to drain out.

6.

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

7.

Fill the hub with oil.

8.

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3

Install the oil level plug.

Axle oil level 1.

Clean the area around the fill plug (1) and the drain plug (2).

2.

Place a suitable container underneath the drain plug.

3.

Remove the fill plug and drain plug.

4.

Allow the oil to drain.

5.

Install the drain plug.

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7 - MAINTENANCE

6.

Pour oil into the oil fill orifice until full.

RAPH12FRK1115AA

7-88

4

7 - MAINTENANCE

Engine air filters Replace the engine air filters every 1000 hours of operation. Replace more frequently if the machine operates in severe conditions.

1.

2.

Clean the air pre-cleaner: A.

Remove the wing nut (1).

B.

Remove the cover (2).

C.

Remove the bowl (3).

D.

Clean the bowl with a damp cloth.

E.

Assemble the air pre-cleaner.

Open the right side engine panel.

3.

Clean the area around the outside front cover of the air filter housing.

4.

Inspect the air filter housing and components for damage.

5.

Release three clips that secure the air filter housing cover in place.

6.

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2

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3

Remove the primary filter.

7-89

7 - MAINTENANCE

7.

8.

9.

With the primary filter removed, use a lint-free cloth tied to a stiff rod and wipe the inside of the housing clean.

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4

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5

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6

Remove the inner filter.

Use a lint-free cloth and wipe the inside of the housing clean.

10.

Dispose of the filters in accordance with local, regional, and federal regulations.

11.

Install the inner air filter. Ensure that a tight seal is created.

12.

Install the primary air filter. Ensure that a tight seal is created.

7-90

7 - MAINTENANCE

13.

Position the filter cover over the housing with the dust valve facing downward, hold the cover in place, and fasten the clips that secure the air filter housing in place.

NOTE: Under normal conditions the dust valve will clear itself. Confirm the valve is clear, wipe clean if necessary.

RAPH12FRK0193AA

7-91

7

7 - MAINTENANCE

Every 2000 hours of operation or annually

Engine cooling system CAUTION Burn hazard!

Hot coolant can spray out if you remove the filler cap while the system is hot. After the system has cooled, turn the filler cap to the first notch and wait for all pressure to release before proceeding.

Failure to comply could result in minor or moderate injury.

C0043A

Drain, flush, and replace the engine coolant every 2000 hours of operation.

Drain the engine coolant system 1.

Open the right and left side engine panels.

2.

Remove the four bolts (1) and remove the radiator grille (2)

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7-92

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7 - MAINTENANCE

3.

WARNING Hot liquid under pressure!

Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool.

Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.

Failure to comply could result in death or serious injury.

W0296A

Remove the de-aeration tank cap

4.

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2

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3

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4

Locate the drain valve for the cooling system near the bottom of the radiator.

5.

Route an appropriate drain hose (1) to the drain valve through the opening between the counterweight (2) and the rear frame (3).

6.

Attach the drain hose to the drain valve and place the opposite end of the hose into an appropriate drain pan.

7.

Open the drain valve slowly and allow the cooling system fluid to drain completely.

7-93

7 - MAINTENANCE

Flush the engine coolant system 1.

Close the drain shut off valve. Do not disconnect the drain hose.

2.

Loosen both bolts from the cover plate on top of the fixed hood and remove one bolt completely.

3.

Slide the cover plate (1) out of the way.

4.

Remove the de-aeration tank cap (2).

5.

Add CASE CONSTRUCTION radiator flush and follow the directions on the container. Install the de-aeration tank cap.

6.

5

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6

WARNING Hot liquid under pressure!

Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool.

Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.

Failure to comply could result in death or serious injury.

W0296A

Open the drain valve and allow contents to drain completely.

7.

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Close the drain valve and detach the drain hose.

7-94

7 - MAINTENANCE

Fill the engine coolant system 1.

Remove the de-aeration tank cap.

2.

Add CNH XHD PREMIX or a mixture of 50 % ethylene glycol and 50 % water into the de-aeration tank until the level reaches between the COLD MIN mark (2) and the HOT MAX mark (1) on the tank.

3.

Install the de-aeration tank cap.

4.

Start the machine and allow the engine coolant to reach normal operating temperature.

5.

Stop engine and inspect for leaks.

6.

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7

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8

WARNING Hot liquid under pressure!

Never remove the filler cap or the recovery tank cap while the engine is running or the coolant is hot. Let the system cool.

Turn the filler cap to the first notch and allow any pressure to escape, and then remove the filler cap. Loosen the recovery tank cap slowly to allow any pressure to escape.

Failure to comply could result in death or serious injury.

W0296A

Check the coolant level. Add if necessary.

7-95

7 - MAINTENANCE

7.

Install the radiator grille (2) using four bolts (1).

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8.

9

Secure the cover plate to the fixed hood.

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7-96

10

7 - MAINTENANCE

Chain rollers Inspect the chain rollers on the mast for wear every 2000 hours of operation.

1.

Inspect the chain rollers for wear. Refer to the service manual for forklift mast disassembly if damage or wear is detected. Contact an authorized dealer for assistance.

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7-97

1

7 - MAINTENANCE

Load rollers Inspect the load rollers on the mast for wear every 2000 hours of operation.

1.

Inspect the load rollers for wear. Refer to the service manual for forklift mast disassembly if damage or wear is detected. Contact an authorized dealer for assistance.

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7-98

1

7 - MAINTENANCE

Every 3000 hours

Diesel Particulate Filter (DPF) Contact your authorized dealer to have the DPF replaced on your machine.

NOTE: Operating a machine with an excessively high ash level in the DPF will de-rate the engine performance significantly and shorten the life of the DPF.

Every 4000 hours

Engine Crankcase Ventilation (CCV) Filter Replace the Crankcase Ventilation (CCV) filter every 4000 hours of operation.

NOTE: Refer to the Engine Service Manual or contact your dealer for service.

7-99

7 - MAINTENANCE

As required

Fork inspection WARNING Misuse hazard!

Only use forks that match the lift capacity of the forklift mast. The interchange of forks from one machine to another may not provide the expected lift capacity of the machine. Refer to the lift capacity sign on the forklift mast for details.

Failure to comply could result in death or serious injury.

W1217A

WARNING Equipment failure could cause accident or injury!

Replace all damaged forks. An attempt to modify forks or an attempt to fix damaged forks will weaken the structure and lower the expected lift capacity.

Failure to comply could result in death or serious injury.

W1216A

WARNING Equipment failure could cause accident or injury!

Provide enough clearance between the ground and the bottom of the forks whenever the machine turns or moves in forward or reverse. This is particularly important on hard surfaces such as concrete.

Forks that drag or scrape the ground may cause excessive wear, which will weaken the structure and lower the expected lift capacity.

Failure to comply could result in death or serious injury.

W1219A

1.

2.

Inspect the forks (hook and shaft styles), replace the forks if anyone of the following are found: •

Forks are visibly bent

•

Cracks along the inside radius (A) of the forks

•

Cracks on the upper and/or lower hanger blocks (B)

•

Bottom of the forks (C) show a considerable amount of wear

Inspect the operation of the fork lock pin (hook style forks only): •

•

Put the lock pin in the down position. Try to move the fork side to side on the carriage, if it moves replace the fork.

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1

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2

Put the lock pin in the up position. Try to move the fork side to side on the carriage it should move freely. If fork movement is difficult inspect the hanger blocks and carriage more closely, excessive wear on components may be present.

7-100

7 - MAINTENANCE

Tire pressure and condition DANGER Explosion hazard!

Welding to a wheel can create an explosive air and gas mixture. Removing air from the tire or loosening the tire on the wheel (breaking the bead) will NOT eliminate the hazard. ALWAYS remove the tire completely from the wheel before welding.

Failure to comply will result in death or serious injury.

D0033A

WARNING Explosion hazard!

When inflating tires, use a clip-on air chuck with a gauge, remote valve, and hose long enough to allow you to stand to one side and NOT in front of or over the wheel assembly. Keep others out of the DANGER AREA. Never inflate a tire beyond the maximum allowable pressure printed on the tire.

Failure to comply could result in death or serious injury.

W0059A

Check the condition and pressure of the tires as needed. Tires will loose air on a regular basis. Check the tire pressure and condition more often when working in extreme conditions or weather.

Front drive wheel tire pressure Model 586H 586H and 588H

Tire size 17.5L x 24 — 10 ply 19.5L x 24 — 12 ply

Recommended tire pressure 221 kPa (32 psi) 234 kPa (34 psi)

Rear steer wheel tire pressure Model 586H (2WD) 588H (2WD) 586H and 588H (4WD)

Tire size 11L x 16 — 10 ply 12 x 16.5 — 12 ply 12 x 16.8 — 8 ply

Recommended tire pressure 359 kPa (52 psi) 310 kPa (45 psi) 345 kPa (50 psi)

NOTE: Tire inflation pressure affects the amount of weight that a tire may carry.

It is recommended that you have a qualified tire mechanic service the tires and rims on these machines. It is recommended that you have this mechanic inflate the tires.

•

Inspect the tire for damaged tread or side walls.

•

Inspect the rim for damage.

•

Confirm that the wheel is properly mounted to the machine. Refer to 7-31 in this manual for procedure.

•

Use an air hose with a remote shutoff and stand behind the tire tread.

7-101

7 - MAINTENANCE

Engine air precleaner Check the air pre-cleaner bowl and remove any debris from the bowl.

1.

Remove the wing nut (1) .

2.

Remove the cover (2) and bowl (3) .

3.

Empty debris from the bowl and wipe with a damp cloth.

4.

Assemble the air pre-cleaner.

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7-102

1

7 - MAINTENANCE

Bleed air from the fuel system WARNING Pressurized system!

Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.

Failure to comply could result in death or serious injury.

W0285A

NOTICE: Air in the fuel system causes excessive engine cranking before the engine starts. It is crucial that all air be removed from the system.

Remove the air from the fuel system if one or more of these conditions have been met: •

The fuel filters are replaced.

•

The components of the fuel system have been replaced or serviced.

•

The machine has been stored for three months or more.

•

The engine has stopped because the fuel tank ran dry.

1.

Open the bleed screw (2) on the head of the water separator.

2.

Activate the hand primer (1) until fuel flows freely from the bleed screw. Approximately 35 to 45 pumps.

3.

Tighten the bleed screw.

4.

Loosen the bleed screw from the primary filter head.

Loosen two or three turns.

5.

Activate the hand primer on the water separator head until fuel flows freely from the bleed screw. Approximately 100 to 125 pumps.

6.

Tighten the bleed screw.

7-103

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2

7 - MAINTENANCE

7.

Start up the engine.

•

DO NOT crank the engine for more than 30 seconds.

•

If the engine will not start, repeat the bleeding process.

NOTE: The engine will start hard the next four or five times.

Generally, the engine will crank for ten seconds the second time it is started and about five seconds the third time it is started.

8.

Run the engine for several minutes and then shut down the engine.

7-104

7 - MAINTENANCE

Fan belt Replace the fan drive belt as needed.

Removal 1.

Loosen the lower alternator bolt (2).

2.

Loosen the pivot bolt (1).

3.

Loosen the adjustment bolt lock nut (1) .

4.

Turn the adjustment bolt (2) counter-clockwise, to loosen the belt tension.

5.

83118121

1

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2

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3

Slide the belt (1) off of the water pump pulley (2) and remove the belt.

7-105

7 - MAINTENANCE

Install 1.

2.

Route the drive belt on the pulleys as shown.

83118087

4

83118121

5

RAIL11TLB0004AA

6

83118121

7

Setting and securing the fan belt tension: A.

Turn the adjustment bolt (1) clockwise, until the pivot bolt (2) is near the end of the tension bracket slot (3).

NOTE: Special belt design will adjust to the proper tension.

B.

3.

Tighten the adjustment bolt lock nut (1) securing the adjustment bolt (2) in position.

Torque to 45 - 55 N·m (33 - 41 lb ft): •

Pivot bolt (1)

•

Lower alternator bolt (2)

7-106

7 - MAINTENANCE

Disable parking brake For disabled forklifts, disable the parking brake whenever the parking brake fails to disengage.

1.

Chock the wheels to prevent movement.

2.

Locate the solenoid block for the parking brake on the transmission.

3.

Clean the area of dirt and debris.

4.

RCPH10TLB064AAF

1

RCPH10TLB065AAF

2

RCPH10TLB070AAF

3

Remove the two bolts that secure the solenoid block.

5.

Carefully lift up and rotate the solenoid block 90 ° (1).

6.

Reinstall the bolts and tighten the bolts to a torque of 20 N·m (15 lb ft).

7.

Attach the grease supply to the fitting (2) and pump approximately 65 pumps.

NOTICE: Extreme pressure is NOT needed to release the parking brake. Over pressurization may damage the seals.

Moderate effort is required on the grease gun.

8.

Carefully remove the wheel chocks, as the machine may now be moved.

NOTICE: The machine should be free to roll. If the machine does not roll, there may be an issue in the parking brake or drivetrain. Contact your dealer.

NOTICE: After grease has been used to release the parking brake it will be necessary to clean and flush the entire system before placing the machine back into operation.

Contact your dealer for this procedure.

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7 - MAINTENANCE

9.

Enable the parking brake: A.

Slowly loosen and remove the two bolts that hold the solenoid block in position. Grease trapped in the parking brake will come out under the block.

B.

Confirm that the three O-rings are in the correct position and that all surfaces are free of contamination.

C.

Return the solenoid block to its original position.

D.

Reinstall the bolts and tighten the bolts to a torque of 20 N·m (15 lb ft).

E.

Test the parking brake to ensure it functions correctly. For example, the transmission is declutched when the parking brake is applied.

7-108

7 - MAINTENANCE

STORAGE

Forklift 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.

Geographic, environmental and actual storage conditions make it difficult to follow a set storage procedure for all areas and conditions. The following procedure is for a storage period of six months or longer. This procedure is a good starting point but may not be all inclusive. If you have questions about storing your machine, contact your dealer.

1.

Inspect the machine for visible signs of wear, breakage or damage. Order any parts required and make the necessary repairs to avoid delays when starting the next operating period.

2.

Wash the machine.

3.

Lubricate the machine at all grease fittings.

4.

Paint any area where the paint has been damaged.

5.

Drain the fuel tank.

6.

Put approximately 8 l (2 US gal) of diesel flushing oil in the fuel tank. Run the engine until the exhaust smoke is blue white.

7.

Drain the flushing oil from the fuel tank.

8.

Fill the fuel tank and add diesel fuel conditioner by following the directions on the container.

9.

Move all hydraulic controls to relieve any pressure in the hydraulic circuits.

10.

Change the engine oil and replace the oil filter.

11.

Drain the cooling system. Leave the drain valves open and do not tighten the radiator cap.

12.

Put a Do Not Operate tag on the instrument panel.

13.

Clean or replace the primary element for the air filter.

14.

Cover the exposed cylinder rods, valve spools, and any other bare metal parts with a rust and corrosion preventive.

15.

Charge the battery. Remove the battery from the machine and store in a cool dry area 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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7 - MAINTENANCE

Forklift removal from storage Do not start the engine until steps 1 through 12 have been done.

1.

Change the fuel filters and fill the fuel take if required.

2.

Tighten the cooling system drain valves.

3.

Fill the engine cooling system.

4.

Check the condition of the engine drive belt. Replace if required.

5.

Check the engine oil level.

6.

Check the hydraulic oil level.

7.

Check the transmission oil level.

8.

Lubricate the machine at all grease fittings.

9.

Use petroleum base solvent and remove the rust and corrosion preventive from the hydraulic cylinder rods, valve spools and any other location the preventative was used.

10.

Install a new battery or confirm the battery is charged.

11.

Bleed the air from the fuel system. Refer to 7-103 in this manual.

12.

Start the engine. It is important that you review the “STARTING THE UNIT” chapter 4-2 in this manual.

7-110

8 - SPECIFICATIONS

8 - SPECIFICATIONS Engine - General specification 586H and 588H Model Type Firing order Bore and stroke Displacement Compression ratio Fuel injection Horsepower - rated at 2200 RPM Gross Net with 39 ° fan Peak torque at 1400 RPM Gross Net with 39 ° fan Maximum torque rise Engine speeds Rated speed, full load Low idle High idle, no load Converter stall Hydraulic stall

Diesel, F5HFL413D*A, emissions compliant Four cylinder, turbocharged 1-3-4-2 99 mm x 110 mm ( 3.90 in x 4.33 in) 3.4 l (207.5 in³) 16.5 to 1 Direct HPCR 63 kW (85 Hp) 58 kW (78 Hp) 374 N·m (276 lb ft) 364 N·m (268 lb ft) 33 % ± 5 RPM 2200 RPM 875 - 1025 RPM 2300 - 2450 RPM 2180 - 2310 RPM 2230 - 2330 RPM

8-1

8 - SPECIFICATIONS

Transmission - General specification Transmission •

Electronic F/R shuttle control

•

On the go electric four wheel drive control

•

Clutch disconnect buttons on the transmission gear shift lever and the steering column console

Four speed, manual gear shift, fully synchronized Toque converter stall ratio: 3.2 Speed selection: 4 forward and 4 reverse Reverse Gear ratios: Forward 1st 5.491 5.491 2nd 3.043 3.043 3rd 1.584 1.584 4th 0.793 0793 Splitter gear ratio for drive to rear steer axle (four wheel drive): 1.222 to 1

Differential lock On the go, push button activation on the steering column console

Axle, differential and planetaries Four wheel drive machines Front drive axle Differential ratio Planetary hub ratio Total reduction ratio Rear steer axle Differential ratio Planetary hub ratio Total reduction ratio

2.0 6.0 12.0 2.333 6.923 16.153

Brakes Service •

Foot pedal operated

•

Boosted hydraulic actuated

•

Self adjusting, maintenance free

•

Outboard mounted

•

Wet disc, two discs per side

Parking •

Electronic console switch NOTICE: Transmission is declutched when the parking brake is engaged.

•

Transmission mounted

•

Spring-Applied Hydraulic-Release (SAHR)

•

Electronic forward/reverse neutral interlock

8-2

8 - SPECIFICATIONS

Hydraulic systems - General specification Components Pump Filtration Oil cooler Steering relief valve (in priority valve) Control Valve (main relief) Operation Auxiliary operation Load control (optional equipment)

Single section, gear type pump Seven micron spin on filter; full flow replaceable cartridge on return line Heavy duty Flow as required Three spool for lift, tilt, and side-shift. Optional fourth spool available for auxiliary attachments Mechanical control: Levers Mechanical control: Lever Hydraulic accumulator 276 bar (4000 psi)

Flow 2200 RPM 586H 588H Control valve Steering relief valve

68 l/min (18 US gpm) @ 207 bar (3002 psi) 91 l/min (24 US gpm) @ 207 bar (3002 psi) 214 - 235 bar (3103 - 3408 psi) 141.6 - 148.4 bar (2053 - 2152 psi) @ 900 RPM flow is 14.4 l/min (3.8 US gpm)

8-3

8 - SPECIFICATIONS

Electrical systems - General specification Alternator Starter Battery

Dual battery (optional equipment)

12 V, 120 A @ 6000 revolutions per minute 12 V, 2.7 kW nominal output 12 V, BCI group 30H 685 Cold Cranking Amps (CCA) @ -18 °C (0 °F) 165 min recharge @ 27 °C (80 °F) Connected in parallel, 2 x 12 V, BCI group 28 525 Cold Cranking Amps (CCA) @ -18 °C (0 °F) 110 min recharge @ 27 °C (80 °F) each battery Fuses on individual circuits 2 x 12 V 30 A maximum 107 dB 115 V Nema 5–15P 15 A

Protection Power plug outlet Backup alarm Engine block heater (optional) Lights Flasher and turn signal 12 V bulb (No.1156) Stop and tail lamp 12 V bulb (No.1156) Front and rear work lights (optional) 12 V 55 W (No. H3)

8-4

8 - SPECIFICATIONS

Dimension — 586H Forklift 586H Forklift with 4.57 m (15.0 ft) mast

RAPH12FRK0722EA

1

Overall width with 17.5L x 24 tires Overall width with 19.5L x 24 tires Overall height with mast closed, unloaded Ground clearance (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (B) Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (C) Maximum fork height (D) Degree tilt, forward (E) Degree tilt, rearward (F) Overall length with 1219 mm (48.0 in) forks Lift capacity to full height at 610 mm (24.0 in) load center Overall machine weight with 1219 mm (48.0 in) forks

8-5

2165 mm (85.2 in) 2117 mm (83.3 in) 3225.8 mm (127.0 in) 260 mm (10.2 in) 3257 mm (128.2 in) 3302 mm (130 in) 5441 5486 4572 45 ° 15 ° 4928 2722 6000

mm (214.2 in) mm (216.0 in) mm (180 in)

mm (194 in) kg (6000 lb) kg (13228 lb)

8 - SPECIFICATIONS

586H Forklift with 6.71 m (22.0 ft) mast

RAPH12FRK0722EA

2

Overall width with 17.5L x 24 tires Overall width with 19.5L x 24 tires Overall height with mast closed, unloaded Ground clearance (A) Overall height, forks 152.4 mm (6.0 in) off ground, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (B) Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (C) Maximum fork height (D) Degree tilt, forward (E) Degree tilt, rearward (F) Overall length with 1219 mm (48.0 in) forks Lift capacity height with a 610 mm (24.0 in) load center Lift height 4.57 m (15.0 ft) Full lift height 6.71 m (22.0 ft) Overall machine weight with 1219 mm (48.0 in) forks

8-6

2165 mm (85.2 in) 2117 mm (83.3 in) 3225.8 mm (127.0 in) 260 mm (10.2 in) 3321.6 mm (130.8 in) 3276.6 mm (129.0 in) 7625.8 mm (300.2 in) 7670.8 mm (302.0 in) 6705.6 mm (264.0 in) 45 ° 15 ° 4953 mm (195 in) 2722 kg (6000 lb) 1361 kg (3000 lb) 6340 kg (13977 lb)

8 - SPECIFICATIONS

586H Forklift with 4.88 m (16 ft) Freelift mast

RAPH12FRK0722EA

3

Overall width with 17.5L x 24 tires Overall width with 19.5L x 24 tires Overall height with mast closed, unloaded Ground clearance (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (B) Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (C) Maximum fork height Maximum fork height Maximum Freelift fork height (fork to ground) (D) Degree tilt, forward (E) Degree tilt, rearward (F) Overall length with 1219 mm (48.0 in) forks Lift capacity to full height at 610 mm (24.0 in) load center Overall machine weight with 1219 mm (48.0 in) forks

8-7

2165 mm (85.2 in) 2117 mm (83.3 in) 2616.2 mm (103.0 in) 260 mm (10.2 in) 2616.2 mm (103.0 in) 2661.2 mm (104.8 in) 5791.2 mm (228.0 in) 5836.2 mm (229.8 in) 4876.8 mm (192.0 in) 1702 mm (67.0 in) 45 ° 15 ° 4928 mm (194 in) 2722 kg (6000 lb) 6000 kg (13228 lb)

8 - SPECIFICATIONS

586H Forklift with 4.88 m (16 ft) Freelift mast

RAPH12FRK0722EA

4

Overall width with 17.5L x 24 tires Overall width with 19.5L x 24 tires Overall height with mast closed, unloaded Ground clearance (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (B) Overall height, mast raised, unloaded: with 2WD and 17.5L x 24 tires with 2WD and 19.5L x 24 tires (C) Maximum fork height Maximum fork height Maximum Freelift fork height (fork to ground) (D) Degree tilt, forward (E) Degree tilt, rearward (F) Overall length with 1219 mm (48.0 in) forks Lift capacity height with a 610 mm (24.0 in) load center Lift height 4.57 m (15.0 ft) Full lift height 6.71 m (22.0 ft) Overall machine weight with 1219 mm (48.0 in) forks

8-8

2165 mm (85.2 in) 2117 mm (83.3 in) 3225.8 mm (127.0 in) 260 mm (10.2 in) 3225.8 mm (127.0 in) 3270.8 mm (128.8 in) 7620 mm (300.0 in) 7665 mm (301.8 in) 6705.6 mm (264.0 in) 2311 mm (91.0 in) 45 ° 15 ° 4953 mm (195 in) 2722 kg (6000 lb) 1361 kg (3000 lb) 6340 kg (13977 lb)

8 - SPECIFICATIONS

Dimension — 588H Forklift 588H Forklift with 4.57 m (15.0 ft) mast

RAPH12FRK0722EA

1

Overall width with 19.5L x 24 tires Overall height with mast closed, unloaded Ground clearance (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires (C) Maximum fork height (D) Degree tilt, forward (E) Degree tilt, rearward (F) Overall length with 1219 mm (48.0 in) forks Lift capacity to full height at 610 mm (24.0 in) load center Overall machine weight with 1219 mm (48.0 in) forks

8-9

2236 mm (88.0 in) 3175 mm (125.0 in) 260 mm (10.2 in) 3251.2 mm (128.0 in) 5588 4572 45 ° 15 ° 5207 3629 7094

mm (220.0 in) mm (180 in)

mm (205.0 in) kg (8000 lb) kg (15640 lb)

8 - SPECIFICATIONS

588H Forklift with 6.71 m (22.0 ft) mast

RAPH12FRK0722EA

2

Overall width with 19.5L x 24 tires Overall height with mast closed, unloaded Ground clearance (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires (C) Maximum fork height (D) Degree tilt, forward (E) Degree tilt, rearward (F) Overall length with 1219 mm (48.0 in) forks Lift capacity height with a 610 mm (24.0 in) load center Lift height 4.57 m (15.0 ft) Full lift height 6.71 m (22.0 ft) Overall machine weight with 1219 mm (48.0 in) forks

8-10

2236 mm (88.0 in) 3175 mm (125.0 in) 260 mm (10.2 in) 3225.8 mm (127.0 in) 7747 mm (305.0 in) 6705.6 mm (264.0 in) 45 ° 15 ° 5232 mm (206.0 in) 3629 kg (8000 lb) 1814 kg (4000 lb) 7405 kg (16325 lb)

8 - SPECIFICATIONS

Torque Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubricants, Molydisulfide greases, or other extreme pressure lubricants are used.

Decimal hardware Grade 5 bolts, nuts, and studs Nm

Size

12 - 15 Nm 23 - 28 Nm 48 - 57 Nm 73 - 87 Nm 109 - 130 Nm 149 - 179 Nm 203 - 244 Nm 366 - 439 Nm 542 - 651 Nm 787 - 944 Nm 1085 - 1193 Nm 1519 - 1681 Nm 1980 - 2278 Nm 2631 - 2983 Nm Markings for Grade 5 hardware

1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

lb in/lb ft 108 - 132 lb in 204 - 252 lb in 420 - 504 lb in 54 - 64 lb ft 80 - 96 lb ft 110 - 132 lb ft 150 - 180 lb ft 270 - 324 lb ft 400 - 480 lb ft 580 - 696 lb ft 800 - 880 lb ft 1120 - 1240 lb ft 1460 - 1680 lb ft 1940 - 2200 lb ft

Grade 8 bolts, nuts, and studs Size 1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

Nm 16 - 20 Nm 33 - 39 Nm 61 - 73 Nm 95 - 114 Nm 149 - 179 Nm 217 - 260 Nm 298 - 358 Nm 515 - 618 Nm 814 - 976 Nm 1220 - 1465 Nm 1736 - 1953 Nm 2468 - 2712 Nm 3227 - 3688 Nm 4285 - 4827 Nm Markings for Grade 8 hardware

NOTE: Use thick nuts with Grade 8 bolts.

8-11

lb in/lb ft 144 - 180 lb in 288 - 348 lb in 540 - 648 lb in 70 - 84 lb ft 110 - 132 lb ft 160 - 192 lb ft 220 - 264 lb ft 380 - 456 lb ft 600 - 720 lb ft 900 - 1080 lb ft 1280 - 1440 lb ft 1820 - 2000 lb ft 2380 - 2720 lb ft 3160 - 3560 lb ft

8 - SPECIFICATIONS

Metric hardware Grade 8.8 bolts, nuts, and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

Nm 3 - 4 Nm 7 - 8 Nm 11 - 12 Nm 26 - 31 Nm 52 - 61 Nm 90 - 107 Nm 144 - 172 Nm 217 - 271 Nm 434 - 515 Nm 675 - 815 Nm 1250 - 1500 Nm 2175 - 2600 Nm Markings for Grade 8.8 hardware

lb in/lb ft 24 - 36 lb in 60 - 72 lb in 96 - 108 lb in 228 - 276 lb in 456 - 540 lb in 66 - 79 lb ft 106 - 127 lb ft 160 - 200 lb ft 320 - 380 lb ft 500 - 600 lb ft 920 - 1100 lb ft 1600 - 1950 lb ft

Nm 4 - 5 Nm 9 - 11 Nm 15 - 18 Nm 37 - 43 Nm 73 - 87 Nm 125 - 150 Nm 200 - 245 Nm 310 - 380 Nm 610 - 730 Nm 1050 - 1275 Nm 2000 - 2400 Nm 3500 - 4200 Nm Markings for Grade 10.9 hardware

lb in/lb ft 36 - 48 lb in 84 - 96 lb in 132 - 156 lb in 324 - 384 lb in 54 - 64 lb ft 93 - 112 lb ft 149 - 179 lb ft 230 - 280 lb ft 450 - 540 lb ft 780 - 940 lb ft 1470 - 1770 lb ft 2580 - 3090 lb ft

Grade 10.9 bolts, nuts and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

Grade 12.9 bolts, nuts, and studs Nm Size lb in/lb ft Typically the torque values specified for grade 10.9 hardware can be used satisfactorily on grade 12.9 hardware.

Markings for Grade 12.9 hardware

8-12

8 - SPECIFICATIONS

General specification - Biodiesel fuels Biodiesel usage in CASE CONSTRUCTION products Introduction to Fatty Acid Methyl Ester (FAME) biodiesel FAME biodiesel, called biodiesel fuel in the following section, consists of a family of fuels derived from vegetable oils treated with methyl esters.

There are two main biodiesel fuel types: Rapeseed Methyl Ester (RME) and Soybean Methyl Ester (SME).

RME is a blend of rapeseed and sunflower methyl ester, and is the preferred crop in Europe. SME is the preferred crop in the United States.

Biodiesel fuel is a renewable alternative fuel source. Its use and development is promoted worldwide, especially in Europe and in the United States.

Biodiesel fuel can be used to run diesel engines as pure biodiesel fuel or when blended with standard diesel fuel: •

B5: indicates the blend of 5 % biodiesel and 95 % diesel fuels.

•

B7: indicates the blend of 7 % biodiesel and 93 % diesel fuels.

•

B20: indicates the blend of 20 % biodiesel and 80 % diesel fuels.

•

B100: indicates pure biodiesel, or 100 % biodiesel fuel. Do not use.

Biodiesel fuel has several positive features in comparison with diesel fuel: •

Biodiesel fuel adds lubricity to the fuel, which is beneficial in many circumstances, particularly as sulfur and aromatics are removed from the fuel.

•

Biodiesel has a greater cetane number and burns cleaner.

•

Biodiesel produces less particulate matter and reduces smoke emissions.

•

Biodiesel is fully biodegradable and non-toxic.

Diesel and biodiesel fuel specifications

ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)

Biodiesel blends are covered by: •

United States Biodiesel Fuel Specification ASTM D7467-09A provides specifications for diesel and biodiesel blends from B5 to B20.

Pure biodiesel (B100) specification is covered by the following requirements: •

ASTM D6751-09A - Standard specification for biodiesel fuel blend stock (B100) for middle distillate fuels.

NOTE: ASTM D6751 specification has been updated to improve the quality of biodiesel in the market place.

Before raw oil can be converted into usable biodiesel fuel, it must undergo transesterification to remove glycerides. During the transesterification process, the oil reacts with an alcohol to separate the glycerine from the fat or vegetable oil. This process leaves behind two products: methyl ester (the chemical name for biodiesel) and glycerine (a byproduct usually sold for use in soaps or other products).

NOTICE: Biodiesel fuels approved for use in the CASE CONSTRUCTION equipment must be transesterified and comply with the North America Standard ASTM D6751.

NOTICE: Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel, are fuels that are normally made from Rapeseed oil or similar high oil content crops. These kinds of fuel are not transesterified, so they do not fulfil the ASTM D6751 requirements. There is no recognized quality standard available for these types of fuel. Therefore the use of Cold Pressed Biodiesel, Cold Pressed Oil, Straight Vegetable Oil (SVO), or more generally unrefined vegetable oils used as motor fuel are NOT APPROVED at any blend in any CASE CONSTRUCTION product.

NOTICE: Any engine and fuel injection equipment fitted to a CASE CONSTRUCTION vehicle found to have run with any blend of NON-APPROVED fuel (fuel not fulfilling the specification described in the requirement ASTM D6751) will no longer be covered for Warranty by CASE CONSTRUCTION.

Biodiesel fuel usage conditions

Tier 4a diesel fuel specifications are covered by the following: •

•

United States Diesel Fuel Specification ASTM D6751-09A allows up to 5 % biodiesel since 2009.

United States fuel suppliers are allowed to use up to 5 % biodiesel fuel (B5) to supply the network.

You must stringently follow the biodiesel fuel usage conditions. Incorrect application of the biodiesel fuel usage conditions could lead to severe damage to the engine, fuel injection equipment and aftertreatment system.

The main concerns related to operation with biodiesel fuels are: •

Filters and injector blockage caused by poor fuel quality.

•

Wear and corrosion of internal components due to water content, which affects lubricity.

8-13

8 - SPECIFICATIONS

•

Deterioration of some rubber sealing compounds in the fuel system.

•

Biodiesel oxidation, which can lead to the formation of deposits that can harm the fuel injection system.

NOTICE: Any problem in the engine fuel injection equipment associated with non-compliance to the following conditions for biodiesel fuel handling and maintenance will not be covered for Warranty by CASE CONSTRUCTION.

value when using biodiesel blends greater than B5 up to B20. Please refer to the maintenance intervals specified in the Operator Manual for all engines.

Check all hoses, connections and gaskets to ensure integrity and cleanliness every 3 months or 150 hours of operation, whichever comes first.

Regular oil sampling is highly recommended to monitor for oil and engine deterioration.

Purchase biodiesel fuel from a trusted supplier who understands the product and maintains acceptable fuel quality. It is highly recommended that you use biodiesel from BQ 9000 accredited suppliers to maintain the quality and consistency of the fuel. The BQ 9000 Quality Management Program is accredited by the National Biodiesel Board for producers and marketers of biodiesel fuel. See the National Biodiesel Board website at www.biodiesel.org for more information.

NOTE: Oil sampling kits are available from your authorized CASE CONSTRUCTION dealer.

The use of biodiesel blends above B5 through B20 will not void the CASE CONSTRUCTION warranty as long as the following conditions for biodiesel fuel handling and maintenance are stringently followed:

The machine should not be stored for more than three months with biodiesel in the fuel system. For longer storage time, it is strongly suggested that only regular #2 ultra-low sulfur diesel fuel is used.

Biodiesel fuel must be pre-blended by the supplier. Mixing biodiesel fuels on-site can result in an incorrect mixture that could damage the engine and/or fuel system.

NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 ultra-low sulfur diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to storage.

NOTICE: CASE CONSTRUCTION may void your warranty if the problem is associated with poor fuel quality due to improper blending. It is the responsibility of the fuel supplier and/or yourself to ensure the right type of fuel and blend is delivered and used.

Maintenance intervals For machines using the all electronic engines with a high pressure common rail fuel system, the engine oil and filter change interval is reduced down to 50% of the standard

When switching back from biodiesel to regular #2 ultralow sulfur diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.

Storage

Biodiesel is highly hygroscopic and tends to collect water more than diesel fuel. This increases the risk of algae and bacteria growth which can cause severe damage to the fuel injection system. Keep the machine fuel tanks and on-site storage tanks as full as possible to limit the amount of air and water vapors inside the tank. Drain water from the tanks at least once a week.

NOTICE: Do not use biocide additives on Tier 4a engines with an exhaust aftertreatment system.

8-14

9 - ACCESSORIES

9 - ACCESSORIES Vandal protection Use cover plates and padlocks to secure the machine from unauthorized use, deter vandalism and theft.

NOTE: Padlocks are not provided.

Console switch covers 1.

Insert the bottom of the cover plate (1) and rotate the cover plate over the switches.

2.

Secure the cover plate in place with a padlock (2).

3.

Repeat on the other side.

RAPH12FRK0190AA

1

RAPH12FRK0207AA

2

Engine side panel lock NOTE: Place the master disconnect switch in the off position before locking the left side engine panel.

1.

Close the engine side panel.

2.

Secure with a padlock.

3.

Repeat on the other side.

9-1

9 - ACCESSORIES

Auxiliary power outlet Locate the two 12 V auxiliary power plug outlets on the left side of the steering column.

RAPH12FRK0140AA

9-2

1

Index ACCESS TO OPERATOR'S PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Proper entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Auxiliary power outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Vandal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disable parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine air precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tire pressure and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-103 7-107 7-102 7-105 7-100 7-101

At warning message display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Diesel Particulate Filter (DPF) regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-28 7-22 7-26 7-25

COMMISSIONING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Run in period of a new machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

CONTROLS/INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Console controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Instrument control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Menu screen display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Operator seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Proper entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Every 10 hours of operation or daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Every 1000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81 Battery fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic fluid and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle fluid - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission fluid and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-83 7-89 7-84 7-81 7-87 7-85

Every 2000 hours of operation or annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92 Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92 Load rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98

Every 250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant reservoir (de-aeration reservoir) fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle breather valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle breather valve - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle drive shaft - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-55 7-64 7-69 7-70 7-61 7-60 7-59 7-62 7-57 7-58

Rear steer axle fluid level - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side-shift cylinder bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt cylinder - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tire pressure and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-56 7-54 7-72 7-71 7-68 7-66

Every 3000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 Diesel Particulate Filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

Every 4000 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 Engine Crankcase Ventilation (CCV) Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

Every 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Coolant reservoir (de-aeration reservoir) fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel system water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast carriage roller grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast chain roller grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast pivot grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear steer axle grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-40 7-38 7-42 7-44 7-44 7-44 7-43

Every 500 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Carriage thrust rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-79 7-77 7-80 7-75 7-73

FORWARD CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Console controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Instrument control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Menu screen display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 CNH America LLC technical manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Exhaust Gas Recirculation (EGR) exhaust treatment - Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Manual storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Note to the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Product Identification Number (PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Read the Operator's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Right, left, front, and rear of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Adjusting the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Machine stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Battery disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Definition of fuse, relay, and diode icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Diagnostic/service tool port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Engine side panel latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Fluid capacities and lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General safety before you service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Oil life reset - manually - Resetting the oil life monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Initial 10 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Wheel nut and bolt torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Initial 100 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-50 7-46 7-53 7-52 7-48

Initial 20 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 Rear steer axle fluid level - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-55 Battery disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Battery fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-83 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-103 Carriage thrust rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-79 Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Coolant reservoir (de-aeration reservoir) fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 Coolant reservoir (de-aeration reservoir) fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64 Definition of fuse, relay, and diode icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Diagnostic/service tool port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Diesel Particulate Filter (DPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 Diesel Particulate Filter (DPF) regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Disable parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107 Engine Crankcase Ventilation (CCV) Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Engine air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-89 Engine air precleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-92 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Engine oil and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77 Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Engine side panel latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Fluid capacities and lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100 Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-69 Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70 Forklift mast chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-80 Forklift removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110 Forklift storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Front drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-84 Front drive axle - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61 Front drive axle breather valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59 Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50 Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75 Fuel system water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Fuel tank drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General safety before you service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 Hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Hydraulic fluid and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-81 Hydraulic reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Load rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Mast carriage roller grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Mast chain roller grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Mast pivot grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Oil life reset - manually - Resetting the oil life monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-53 Rear steer axle breather valve - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57 Rear steer axle drive shaft - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58 Rear steer axle fluid - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-87 Rear steer axle fluid level - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Rear steer axle fluid level - Four Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56 Rear steer axle grease fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73 Seat slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54 Service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52 Side-shift cylinder bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-72 Tilt cylinder - Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71 Tire pressure and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68 Tire pressure and condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-101 Transmission filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48 Transmission fluid and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-85 Transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34 Transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66 Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Wheel nut and bolt torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Maintenance Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

MOVING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Before operating the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four Wheel Drive (4WD) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling on a hill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uniform braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13 4-14 4-15 4-12 4-12 4-11 4-10

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before operating the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Before starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Booster battery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Cold temperature operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Differential lock system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Four Wheel Drive (4WD) control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Hot temperature operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Machine direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Normal engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Run in period of a new machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Shutting down the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Transmission gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Traveling on a hill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Uniform braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Operator seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

RECOVERY TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Do Not Operate hang tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Safety rules - Basic operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Safety rules - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Safety rules - California Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Safety rules - Electrical storm safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Safety rules - Fire or explosion prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Safety rules - Fuel handling precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Safety rules - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Safety rules - General maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Safety rules - Hazardous chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Safety rules - Lifting and overhead loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Safety rules - Mounting and dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Safety rules - Operator precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Safety rules - Roll Over Protective Structure (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Safety rules - Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Safety rules - Specific precautions to this machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Safety rules - Transporting precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Safety rules - Utility precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Safety rules - Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Safety rules and signal word definitions and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

SHIPPING TRANSPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Dimension — 586H Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Dimension — 588H Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Electrical systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11 Transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

STARTING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Before starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Booster battery procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold temperature operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot temperature operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2 4-7 4-4 4-6 4-3

STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Shutting down the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109 Forklift removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110 Forklift storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-109

TRANSPORT OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Transporting on a trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

WORKING OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Adjusting the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Machine stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Dealer’s stamp

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

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

Printed in U.S.A. Copyright © 2012 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.