Case 586H 588H Tier 4B (final) Rough Terrain Forklift Operator's Manual 47780077 - PDF DOWNLOAD

586H 588H Tier 4B (final) Rough Terrain Forklift

OPERATOR’S MANUAL

Part number 47780077 1st edition English October 2014

Contents 1 GENERAL INFORMATION Note to the owner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Product Identification Number (PIN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Machine orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 CNH Industrial America LLC technical manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Read the Operator's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Manual storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Emissions overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

2 SAFETY INFORMATION Safety rules and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 California proposition 65 warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Fuel handling precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Specific precautions to this machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Utility safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Safety signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Hand signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

3 CONTROLS AND 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 Configure the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Change the display's temperature setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 View or reset Job Timer (JTIME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Regeneration inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Oil life reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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) machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

7 MAINTENANCE GENERAL INFORMATION General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General safety before you service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Hour meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Engine side panel latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Battery disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Definition of fuse, relay, and diode icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Diagnostic/Service tool port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid capacities and lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General specification - Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General specification - Biodiesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil viscosity - Recommended operating temperature range . . . . . . . . . . . . . . . . . .

Organic Acid Technology (OAT) coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-16 7-17 7-18 7-19 7-20 7-22 7-23

MAINTENANCE CHART Maintenance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

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

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

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

Engine - Low Oil Pressure (LOP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto-regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-27 7-30 7-32 7-34 7-35 7-36

Initial 10 hours Wheel nut and bolt torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Every 10 hours of operation or daily Engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

Initial 20 hours Transmission oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Rear steer axle oil level - Four-Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43 Front drive axle fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-45 7-47 7-49 7-50 7-51 7-51 7-52

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

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

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

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

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

7-53 7-55 7-57 7-59 7-60

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

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

Rear steer axle oil 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-61 7-62 7-63 7-64 7-65 7-66 7-66 7-67 7-68 7-70 7-72 7-74 7-75 7-76 7-77 7-78

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

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

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

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

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

7-79 7-81 7-83 7-85 7-86

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

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

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

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

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

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

7-87 7-89 7-90 7-91 7-93 7-95

Every 1500 hours Engine Crankcase Ventilation (CCV) filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98

Every 2000 hours of operation or annually Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-98 Load rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99

Every 4000 hours or every four years Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-100

As required Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-105 Tire pressure and condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-106

Engine air pre-cleaner (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-107 Bleed air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-108 Fan belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-110 Disable parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112

STORAGE Forklift storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-114 Forklift removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-115

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

9 ACCESSORIES Vandal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Auxiliary power outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Telematics - Overview with Case SiteWatch™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION###_1_### Note to the owner

RAPH12FRK1112FA

1

H Series Rough Terrain Forklift 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 Association 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

Intended use 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 that 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.

Use only approved accessories and attachments designed for your machine. Consult your dealer on changes, additions, or modifications that may be required for your machine. Do not make any unauthorized modifications to your machine.

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. Go to www.casece.com.

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

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

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

RAPH12FRK0130AA

1

RAIL14FRK0018BA

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

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

RAIL12FRK1131GA

Top view of the machine 1. Front of the machine 2. Right-hand side of the machine 3. Rear of the machine 4. Left-hand side of the machine

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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.

Rain cap or air pre-cleaner (optional equipment)

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

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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

CNH Industrial 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.

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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 Industrial America LLC instructions on machine operation and maintenance.

Manual storage Keep the Operator's Manual and the Association 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

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1 - GENERAL INFORMATION

Emissions 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 engine exhaust gasses back into the engine combustion chamber to lower combustion temperatures.

The main components of the Exhaust Gas Recirculation (EGR) system include: • Exhaust Gas Recirculation (EGR) valve • Diesel Oxidation Catalyst (DOC) • Particulate Matter (PM) Catalyst • Exhaust gas temperature sensors • Throttle valve actuator

What is a Particulate Matter (PM) Catalyst?

A Particulate Matter (PM) Catalyst is a high efficiency flow through filter that works based on an open flow design to allow exhaust gases to pass through. It is made up of alternating layers of corrugated metal foil on a porous metal fleece. The filter captures particulate matter long enough for catalytic oxidation. By design, a PM Catalyst will not clog, creating no risk of an uncontrolled regeneration.

How does it work?

When exhaust enters the Diesel Oxidation Catalyst (DOC), many chemical reactions occur. Nitric Oxide (NO) gas enters the DOC to be oxidized to nitrogen dioxide (NO2). When it enters the particulate matter catalyst, NO2 oxidizes the particulate matter, creating a continuous, efficient, passive (automatic) regeneration. This reaction occurs best between 220 - 480 °C (428 - 896 °F).

What if the exhaust isn’t warm enough?

A special engine management system has been designed for off road applications to maintain the efficiency of the particulate matter catalyst, even in situations such as prolonged idling, or low-load applications. During these scenarios, the engine management software will activate an exhaust temperature management mode to maintain the efficiency of particulate matter reduction. In this mode, the exhaust gas temperature is controlled via management of multiple injections and control of the air system. This design enhances passive regeneration in low load conditions, and reduces the need for an incinerating (manual) regeneration.

Manual regeneration If the thermal management system is disabled for prolonged periods of time, depending on exhaust temperatures, particulate matter may build up within the Particulate Matter (PM) Catalyst. If the particulate matter build-up reaches extreme levels, a manual regeneration initiated by the operator may be necessary. This is enabled through the instrument cluster, and takes about 20 min. For these reasons, it is recommended to have the thermal management system remain enabled unless the machine is in high fire-risk conditions. Follow the manual regeneration procedure in this manual.

US Environmental Protection Agency (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 US 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: • 2 years or 1,500 hours of operation, whichever occurs first, for engines less than 19 kW (25 Hp).

• 5 years or 3,000 hours of operation, whichever occurs first, for engines greater than or equal to 19 kW (25 Hp).

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

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1 - GENERAL INFORMATION

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

• Catalytic converter (DOC)

• Fuel injectors

• Diesel particulate filter (DPF)

• Fuel injection lines

• Selective catalytic reduction (SCR)

Air induction system

• Diesel Exhaust Fluid (DEF) tank and dispensing systems

• Intake manifold • Turbocharger system (includes exhaust manifold) • Charge air cooler Positive crankcase ventilation system (if applicable) • PCV valve • Oil fill cap

• Particulate Matter Catalyst (PM Cat) Exhaust Gas Recirculation Systems (EGR) • EGR valve assembly • EGR cooler Cold Start Enrichment Systems Electronic Control Units, Sensors, Solenoids, and Wiring harnesses used in above systems

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, warmup, 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).

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1 - GENERAL INFORMATION

• 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.

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2 - SAFETY INFORMATION

2 - SAFETY INFORMATION###_2_### Safety rules 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 safety signs, 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 damage 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 damage 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 General safety rules Use caution when you operate the machine on slopes.

Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces.

Never permit anyone other than the operator to ride on the machine.

chine. Never operate the machine with shields removed.

Always close access doors or panels before you operate the machine.

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

Never operate the machine under the influence of alcohol or drugs, or while you are otherwise impaired.

A person or pet 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.

When digging or using ground-engaging attachments, be aware of buried cables. Contact local utilities to determine the locations of services.

Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation.

Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety.

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

Before you start the machine, be sure that all controls are in neutral or park lock position.

Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.

• Stop the engine, remove the key, and relieve the pressure before you connect or disconnect fluid lines.

• Make sure that all components are in good condition.

Tighten all connections before you start the engine or pressurize the system.

• If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.

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

Start the engine only from the operator’s seat. If you bypass the safety start switch, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury.

Always keep windows, mirrors, all lighting, and Slow-Moving Vehicle (SMV) emblem clean to provide the best possible visibility while you operate the machine.

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

Before you leave the machine:

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

1. Park the machine on a firm, level surface.

Wear protective equipment when appropriate.

3. Engage the parking brake. Use wheel chocks if required.

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

4. Lower all hydraulic equipment — Implements, header, etc.

2. Put all controls in neutral or park lock position.

5. Turn off the engine and remove the key.

Make sure that all guards and shields are in good condition and properly installed before you operate the ma-

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2 - SAFETY INFORMATION

If you would decide to keep the engine running and leave the operator’s station, then you must follow these precautions:

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.

1. Bring the engine to low idle speed.

2. Disengage all drive systems.

W0113A

3. Lower all hydraulic equipment.

4.

Shift the transmission into neutral.

WARNING

5. Apply the parking brake.

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

Stop the engine, remove the key, and relieve pressure before you connect or disconnect fluid lines.

Service the machine on a firm, level surface.

Stop the engine and remove the key before you connect or disconnect electrical connections.

Install guards and shields after you service the machine.

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

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

Scalding can result from incorrect removal of coolant caps. Cooling systems operate under pressure. Hot coolant can spray out if you remove a cap while the system is hot. Allow the system to cool before you remove the cap. When you remove the cap, turn it slowly to allow pressure to escape before you completely remove the cap.

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

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

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 the equipment is securely supported.

The engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when you service such components. Allow surfaces to cool before you handle or disconnect hot components.

Wear protective equipment when appropriate.

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

Incorrect towing procedures can cause accidents. When you tow a disabled machine follow the procedure in this manual. Use only rigid tow bars.

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

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2 - SAFETY INFORMATION

Wheels and tires Make sure that tires are correctly inflated. Do not exceed any recommended load or pressure. Follow the instructions in the manual for proper tire inflation.

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

Never weld on a wheel with a tire installed. Always remove the tire completely from the wheel prior to welding.

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.

DO NOT weld to a wheel or rim until the tire is completely removed. Inflated tires can generate a gas mixture with the air that can be ignited by high temperatures from welding procedures performed on the wheel or rim. Removing the air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. This condition can exist whether tires are inflated or deflated. The tire MUST be completely removed from the wheel or rim prior to welding the wheel or rim.

Driving on public roads and general transportation safety Use safety chains for trailed equipment when safety chains are provided with machine or equipment.

Comply with local laws and regulations.

Use appropriate lighting to meet local regulations.

Make sure that the Slow-Moving Vehicle (SMV) emblem (A) is visible.

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

When you transport equipment or a machine on a transport trailer, make sure that it is properly secured. Be sure the Slow-Moving Vehicle (SMV) on the equipment or machine is covered while being transported on a trailer.

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

Travel speed should be such that you maintain complete control and machine stability at all times.

Slow down and signal before turning.

RAPH12FRK1118AA

1

Pull over to allow faster traffic to pass.

Make sure that the brake pedal latch is engaged. You must lock brake pedals together for road travel.

Follow correct towing procedure for equipment with or without brakes.

Fire and explosion prevention Fuel or oil that is leaked or spilled on hot surfaces or electrical components can cause a fire.

Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.

Always have a fire extinguisher on or near the machine.

Make sure that the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.

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 the engine, transmission, ex-

haust, battery, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts, gears, cleaning fans, etc. More frequent cleaning of your machine may be necessary depending on the operating environment and conditions.

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

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2 - SAFETY INFORMATION

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

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

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

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

General battery safety Always wear eye protection when you work with batteries.

Follow the manufacturer’s instructions when you store and handle batteries.

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

Ventilate the area when you charge a battery or use a battery in an enclosed area.

Disconnect the negative (-) terminal first and reconnect the negative (-) terminal last.

When you weld on the machine, disconnect both terminals of the battery.

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

When you use auxiliary batteries or connect jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.

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

This is a California Proposition 65 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.

Keep out of reach of children and other unauthorized persons.

Reflectors and warning lights You must use flashing amber warning lights when you operate equipment on public roads.

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2 - SAFETY INFORMATION

Seat belts Seat belts must be worn at all times.

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

Seat belt inspection and maintenance: • Keep seat belts in good condition.

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

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

• Keep seat belts clean and dry.

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

• 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.

• Replace all parts that have damage or wear.

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

RCPH10TLB155AAF

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

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2 - SAFETY INFORMATION

Operator protective structure Your machine is equipped with an operator protective structure, such as: a Roll Over Protective Structure (ROPS), Falling Objects Protective Structure (FOPS), or a cab with a ROPS. A ROPS may be a can frame or a two-posted or four-posted structure used for the protection of the operator to minimize the possibility of serious injury. The mounting structure and fasteners forming the mounting connection with the machine are part of the ROPS. 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 to the protective structure.

The protective structure and interconnecting components are a certified system. Any damage, fire, corrosion, or modification will weaken the structure and reduce your protection. If this occurs, THE PROTECTIVE STRUCTURE MUST BE REPLACED so that it will provide the same protection as a new protective structure. Contact your dealer for protective structure inspection and replacement.

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-site operations: • The protective structure MUST BE REPLACED. • The mounting or suspension for the protective structure, operator’s seat and suspension, seat belts and mounting components, and wiring within the operator’s protective system MUST be carefully inspected for damage.

• All damaged parts MUST BE REPLACED. DO NOT WELD, DRILL HOLES, ATTEMPT TO STRAIGHTEN, OR REPAIR THE PROTECTIVE STRUCTURE. MODIFICATION IN ANY WAY CAN REDUCE THE STRUCTURAL INTEGRITY OF THE STRUCTURE, WHICH COULD CAUSE DEATH OR SERIOUS INJURY IN THE EVENT OF FIRE, TIP OVER, ROLL OVER, COLLISION, OR ACCIDENT. Seat belts are part of your 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.

Backup alarm system The audible backup alarm system notifies others in the area that the machine will be or is moving in reverse

Place the directional lever in the reverse travel position and an audible alarm will sound repeatedly until the operator moves the directional lever into the neutral position or the forward travel position.

Personal Protective Equipment (PPE) Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.

DCAPLT5NE020S2A

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2 - SAFETY INFORMATION

Do Not Operate tag Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be visible.

RH99E029

5

Hazardous chemicals If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants, paints, adhesives, coolant, etc. required for the function of your 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 the chemical substances within a product, safe handling and storage procedures, first aid measures, and procedures to take in the event of a spill or accidental release. MSDS are available from your dealer.

Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, and on manufacturer containers, as well as the information in this manual, when you service 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 filters in accordance with local laws and regulations. Use only appropriate containers for the storage of chemicals or petrochemical substances.

Keep out of reach or children or other unauthorized persons.

Applied chemicals require additional precautions. Obtain complete information from the manufacturer or distributor of the chemicals before you use them.

Utility safety 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.

Make sure that 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 a contact between the machine and an electric

power source occur, the following precautions must be taken: • Stop the machine movement immediately.

• Apply the parking brake, stop 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 that you do not make contact with the ground and the machine at the same time.

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

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2 - SAFETY INFORMATION

Electrical storm safety Do not 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.

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

Mounting and dismounting Mount and dismount the machine only at designated locations that have handholds, steps, and/or or ladders.

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

Do not jump off of the machine.

Never mount or dismount from a moving machine.

Make sure that steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result from slippery surfaces.

Do not use the steering wheel or other controls or accessories as handholds when you enter or exit the cab or operator’s platform.

Face the machine when you mount and dismount the machine.

Working at heights When the normal use and maintenance of the machine requires you to work at heights:

• Do not stand on surfaces that are not designated as steps or platforms.

• Correctly use installed steps, ladders, and railings.

• Never use ladders, steps, or railings while the machine is moving.

Do not use the machine as a lift, ladder, or platform for working at heights.

Lifting and overhead loads

Do not use raised equipment as a work platform.

Loader 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.

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.

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

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 lift load higher than necessary. Lower loads to transport. Remember to leave appropriate clearance to the ground and other obstacles.

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.

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

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

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2 - SAFETY INFORMATION

California proposition 65 warning

RCIL08CCH001EAA

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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.

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2 - SAFETY INFORMATION

Fuel handling precautions

turer's approved cap. Use of a non-approved cap without proper venting may result in pressurization of the tank.

• 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.

• Never use fuel for cleaning purposes.

• Use the correct fuel grade for the operating season.

Use ultra-low sulfur diesel fuel only.

• Tighten the fuel tank cap securely. Should the fuel cap be lost, replace it only with the original manufac-

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2 - SAFETY INFORMATION

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.

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2 - SAFETY INFORMATION

Utility safety

Water 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.

• Make sure that 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:

• 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

Blue Green/Brown White Pink Purple

Red Yellow Orange

• 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 that 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.

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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.

RAIL12FRK1095GA

(1) No riders on the forks. Do not stand under the forks.

(2) Warning. Load carrying precautions.

(3) Warning. Operating the machine precautions (operator platform).

(4) Explosion hazard. Do not use ether.

(5) Warning. Hot liquid under pressure.

1

(6) Warning. Entanglement hazard.

(7) Warning. Fuel under pressure.

(8) Danger. Only start machine in neutral and from the operator’s seat.

(9) Warning. Jump start hazards.

(10) Warning. Pressurized system. (under the machine on the left-hand side)

NOTE: Load control only.

NOTE: Open the left-hand side engine panel to view safety signs (5) through (9).

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2 - SAFETY INFORMATION

RAIL12FRK1096GA

2

(1) No riders on the forks. Do not stand under the forks. (11) Warning. Do not jump from the machine. Use the seat belt.

(5) Warning. Hot liquid under pressure.

(12) Important. Use parking brake.

(13) Warning. Excessive speed or loss of control.

(6) Warning. Entanglement hazard.

(7) Warning. Fuel under pressure.

NOTE: Open the right-hand side engine panel to view safety signs (5) through (7).

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

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2 - SAFETY INFORMATION

(1) No riders on the forks. Do not stand under the 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. Failure to comply could result in death or serious injury.

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

102929A1

3

(1) Location: On the back side of the forklift mast cylinder and one on each side of the mast.

RAPH12FRK0225AA

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2 - SAFETY INFORMATION

(2) Warning. Load carrying precautions.

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. Failure to comply could result in death or serious injury.

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

D-87486

5

(2) Location: On the back of the forklift support bar.

RAPH12FRK0136AA

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2 - SAFETY INFORMATION

(3) Warning. Operating the machine precautions (operator platform).

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.

Failure to comply could result in death or serious injury.

359942A1

7

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

(3) Location: Front left-hand side of the steering column.

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2 - SAFETY INFORMATION

(4) Explosion hazard. Do not use 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

9

(4) Location On the top left-hand side of the fixed engine hood.

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(5) Warning. 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

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(5) Location: On inside of the right-hand side engine panel and the left-hand side engine panel.

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2 - SAFETY INFORMATION

(6) Warning. 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

NOTE: Open both of the engine side panels.

(6) Location: On top of the frame rail.

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2 - SAFETY INFORMATION

(7) Warning. 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

NOTE: Open both of the engine side panels.

(7) Location: On top of the frame rail.

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2 - SAFETY INFORMATION

(8) Danger. Only start machine in neutral and from the operator’s seat.

DANGER Starting in gear can cause death. Start engine only from operator’s seat with 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

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NOTE: Open the left-hand side engine panel.

(8) Location: On top of the frame rail.

RAPH12FRK0152AA

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2 - SAFETY INFORMATION

(9) Warning. Jump start hazards.

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

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NOTE: Open the left-hand side engine panel.

(9) Location: On top of the frame rail.

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(9) Location: On the battery cover plate on the left-hand side of the machine.

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2 - SAFETY INFORMATION

(10) Warning. Pressurized system. (Load Control only) WARNING Pressurized System Hazard.

Relieve pressure before maintenance. Precharge only with dry inert gas such as high purity nitrogen.

Failure to comply could result in death or serious injury.

Quantity: 1 English 384260A1 Spanish 398572A1 French Canadian 398573A1 384260A1

24

(10)Location: On the load control mounting bracket underneath the machine on the left-hand inside frame.

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(11) Warning. Do not jump from the machine. Use the seat belt.

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

Quantity: 1 English 321–7030 Spanish 398672A1 French Canadian 398673A1

321-7030

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(11)Location: Above the instrument cluster on the right-hand post.

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2 - SAFETY INFORMATION

(12) Important. Use 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

87702297A

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(12) Location: On the top right-hand side of the steering column.

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(13) Warning. Excessive speed or loss of control.

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

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(13) Location: On the lower right-hand side of the operator’s platform.

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2 - SAFETY INFORMATION

Hand signals When operating the machine, always get the assistance of a signalman when carrying out tasks calling for fine control or when working in areas with poor visibility. 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

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Go this far

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All stop and hold

Come to me Wave hands forward and rearward with palms in

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2 - SAFETY INFORMATION

Stop

Emergency stop

Wave one hand back and forth

Wave both hands back and forth

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Raise load

RCIL09TLB024BAF

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Raise load slowly

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Lower load

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Lower load slowly

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RCIL09TLB022BAF

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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

RCIL09TLB015BAF

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RCIL09TLB016BAF

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3 - CONTROLS AND INSTRUMENTS

3 - CONTROLS AND INSTRUMENTS###_3_### 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

WARNING 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 death or serious injury.

W1340B

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.

RAPH12FRK1118AA

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3 - CONTROLS AND 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 and 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 AND 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.

RAPH12FRK0138AA

(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.

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3 - CONTROLS AND 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.

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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 AND 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.

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3 - CONTROLS AND 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 AND INSTRUMENTS

Indicators (1) Particulate Matter (PM) Catalyst regeneration This PM-Catalyst lamp illuminates when a regeneration of the After Treatment System (ATS) is active or required. Refer to the maintenance section in this manual for the regeneration procedure. Failure to perform a manual generation will eventually result in a loss of engine power (de-rate).

(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.

NOTE: A flashing park symbol with an audible alert indicates the machine’s transmission directional (FNR) lever is not in neutral.

You will not be able to start the engine until the lever is in the neutral position.

(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)

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• 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 AND 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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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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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.

NOTE: 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 and hold any button for 1 s and the current engine work hours will appear in the display.

The ignition key is in the OFF position (after engine operation) You have 30 s to press any key and activate the SETUP menu. The SETUP menu allows the operator to configure the display.

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: RAIL12FRK1123CA

• HOUR engine work hours • RPM engine revolutions per minute • COOLT engine coolant temperature • TRANT transmission oil temperature • CYCLE scrolls through all available options If the enter button is not pressed for 5 seconds the display defaults to the original selection defined in the SETUP menu.

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Access and navigate the SETUP menu When the ignition key is placed in the OFF position the instrument panel will go into Sleep mode and allow for display configuration.

1. Park the machine.

2. Turn the ignition key to the OFF position.

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

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

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

6. 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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Overview of the SETUP menu

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

3-13

(2) Second level menu Engine work hours Engine RPM Engine coolant temperature Transmission oil temperature 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 Allow the auto-regeneration process

3 - CONTROLS AND INSTRUMENTS

Configure the display 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 appears 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” for selection options.

7. Press the escape button (5) twice. EXIT appears 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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Change the display's temperature setting 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 appears 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 appears 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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View or reset Job Timer (JTIME) 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) to display the the current job timer hours (1). To reset the hours continue to Step 5 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 appears 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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Regeneration inhibit 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.

To inhibit the auto regeneration 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 INHIB. ALLOW — Allow the auto regeneration process.

INHIB — Do not allow the auto generation process.

6. Press the escape button (5) twice to save the current selection on the display. EXIT appears 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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Oil life reset 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 appears 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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4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS###_4_### COMMISSIONING THE UNIT

Run in period of a new machine NOTE: During the run in period you will need to check some fluids and torque settings. You will find the procedures in the maintenance section of this manual.

During the first 20 hours of operation During the first 20 hours of operation (new machine or after an engine rebuild), make sure you: • Operate the engine at intermittent heavy loads and engine speeds for this period to ensure proper engine break-in.

• 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.

• It is recommended that the operator run the engine at full throttle when operating conditions permit.

• Monitor the instrument cluster for warnings.

• Check the oil level at 10 h intervals. Oil consumption may be higher during the initial break-in period.

• Check and tighten the wheel bolts and nuts at 10 h intervals.

After the run in period is complete After the first 20 hours of operation (new machine or after an engine rebuild), make sure you: • Check the oil level.

• Check and tighten the wheel bolts and nuts.

• Check the transmission fluid level.

• Check the rear steer axle fluid level on Four-Wheel Drive (4WD) machines.

• Check the fluid level on each rear wheel hub on Four-Wheel Drive (4WD) machines.

• Check the front drive axle fluid level.

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

NOTICE: Prevent damage to the turbocharger. If the engine stalls during normal operation, immediately return the throttle to idle before restarting.

NOTICE: DO NOT run the engine at idle speed for more than 3 h. This can cause a low operating temperature, which 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.

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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.

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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.

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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.

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Normal engine starting DANGER Avoid injury!

Starting in gear can cause death. Start the engine only from the operator's seat with the transmission control(s) in neutral.

Failure to comply will result in death or serious injury.

D0114A

NOTICE: If the engine does not start within 30 s, allow the starter to cool for 2 min and then begin the procedure again.

NOTICE: ALWAYS allow the engine and hydraulic system to warm up before applying a load.

1. Adjust the seat.

2. Fasten the seat belt.

3. Confirm the direction control lever is in neutral.

4. Turn the key switch to the ON position and wait two to three seconds for the instrument control panel to self-check and power up.

5. Wait for the engine preheat lamp to turn off.

6. Sound the horn.

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

NOTICE: If the engine starts and then stops, do not actuate the starter motor again until the starter motor stops turning.

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. Press the ENTER button to cycle through the display until the RPM value appears on the display.

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4 - OPERATING INSTRUCTIONS

Cold temperature operation NOTE: At cold ambient temperatures the engine speed will be automatically limited by the electronic engine control system until the engine has reached a warm operating

temperature. This is to protect the engine system. During this time, the engine throttle controls will be unresponsive.

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 2 h 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 - 5 min 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 h 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 CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT premix (50% CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT concentrate and 50% distilled water). This mixture protects the engine cooling system to -35 °C (-31 °F).

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

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4 - OPERATING INSTRUCTIONS

• Do not wait longer than 30 s after the engine preheat lamp is not lit before cranking the engine. If the delay is longer, the start up cycle is aborted and the process must be restarted.

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.

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

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

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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.

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4 - OPERATING INSTRUCTIONS

Booster battery procedure DANGER Explosion hazard and/or run over hazard!

Read the procedure in the operator's manual before jump-start or service to avoid injury.

Failure to comply will result in death or serious injury.

D0149A

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 that 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 that the booster batteries are 12 V. 3. If using another machine for power, make sure that 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 - 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 - 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.

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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.

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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.

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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 2330 RPM 6.1 km/h (3.8 mph) 9.8 km/h (6.1 mph) 20.6 km/h (12.8 mph) 38.6 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 5925 kg (13062 lb).

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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. 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.

2. 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) machine 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 engaged.

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

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4 - OPERATING INSTRUCTIONS

4-16

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS###_5_### 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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• 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 that 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. Make sure that 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, and 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 that 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 7-112.

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 that 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 (4WD 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###_6_### 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

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(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 its 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 ground 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 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

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.

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6 - WORKING OPERATIONS

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

RAIL12FRK1105CA

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.

6-4

2

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, and smooth ground conditions. Reduce the load to maintain stability.

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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)

6-5

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, and 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)

6-6

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.

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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.

6-7

6 - WORKING OPERATIONS

6-8

7 - MAINTENANCE

7 - MAINTENANCE###_7_### 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.

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7-2

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7 - MAINTENANCE

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

2. Locate the latch on the lower left-hand or right-hand 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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Close the engine side panel: 1. Push the side panel until the latch engages.

7-3

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 National Fire Protection Association (NFPA) Standard NFPA-10-1992.

• Every 6 years - Have the dry chemical removed and refilled by a fire equipment representative. Reference National Fire Protection Association (NFPA) Standard NFPA-10-1992.

• Every 12 years - Have the fire equipment representative hydrostatically test the fire extinguisher. Reference National Fire Protection Association (NFPA) Standard NFPA-10-1992.

7-4

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. Make sure that the battery vents are not restricted.

Disconnect battery 1. Remove the battery cover hardware.

2. Remove the battery cover.

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7-5

1

7 - MAINTENANCE

3. Disconnect the negative battery cable from the negative battery terminal.

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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 s 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.

7-6

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.

1. Remove the battery cover and disconnect the batteries.

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3

2. Disconnect the alternator terminal wires.

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

7-7

7 - MAINTENANCE

4. Disconnect both connectors.

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5

5. Remove the instrument control panel.

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

7-8

7 - MAINTENANCE

Fuses and relays The machine has four fuse and relay locations: • The main fuse and relay location is under the operator seat on the right hand side • The Glow-plug 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 • The Telematics system in-line fuse is located near the starter on the left-hand side of the engine.

Main fuse and relays 1. Locate the main fuse and relay panel on the right hand side below the operator seat.

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RAPH12FRK0209AA

2

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3

2. 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

7-9

7 - MAINTENANCE

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

RAIL13FRK0001AA

4

RAPH12FRK0189AA

5

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 Particulate Matter (PM) Catalyst and in front of the engine lift hooks (2).

7-10

7 - MAINTENANCE

Engine Control Unit (ECU) fuse and relay 1. Remove the four bolts and the ECU cover panel from the right-side of the operator seat.

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

3. 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

7-11

7 - MAINTENANCE

Telematics system fuse 1. Park the machine and turn off the engine.

2. Open the left-hand side engine panel.

3. Locate the wire harness with the in-line 5 A fuse.

A. Machines equipped with the Battery Power Junction Stud (1).

B. Machines equipped with a Master Disconnect Switch (2).

RAIL13TLB0207BA

RAIL14FRK0040BA

7-12

9

10

7 - MAINTENANCE

Definition of fuse, relay, and diode icons

47511944_A

1

Fuse icon definitions Function

Symbol ECU B+

Instrument cluster key ON

Instrument cluster B+

Rear lights

Tail lights

Power 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)

Telematics NOTE: The Telematics system has an additional external fuse location. Refer to “Fuses and relays” starting on page 7-9.

Relay icon definitions Function

Symbol Power relay #1

Power relay #2

7-14

7 - MAINTENANCE

Symbol

Function Spring-Applied Hydraulic-Released (SAHR) park brake relay 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. Locate the main fuse and relay panel on the right-hand side below the operator seat.

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2. 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 “Engine oil viscosity” 7-22 for recommendations on the oil types designed for your operating environment.

Fuel tank Specification: Capacity:

ASTM D975 GRADE NO. 2-D S15 117 L (31 US gal)

Cooling system Specification: Capacity:

CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT 17.4 L (18.4 US qt)

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

CASE AKCELA HY-TRAN® ULTRACTION 70.0 L (74.0 US qt) 54.5 L (57.6 US qt) 52.6 L (55.6 US qt)

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

CASE AKCELA HY-TRAN® ULTRACTION

Two-Wheel Drive (2WD) 17.0 L (18.0 US qt) 10.5 L (11.1 US qt)

Four-Wheel Drive (4WD) 19.4 L (20.5 US qt) 13.0 L (13.7 US qt)

Front drive axle Specification: Capacity: Differential and planetaries

TUTELA TRANSAXLE FLUID SAE 80W-140 13.6 L (14.4 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.

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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

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1

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General specification - Diesel fuel Only use diesel fuel that conforms to North American standard ASTM D975 Grade No. 2-D S15 or equivalent in your engine. Do not use any other low grade diesel fuel.

NOTE: When operating the machine in very cold climates, the use of winter blended fuel is permitted for a short period of time. See your fuel supplier for winter fuel requirements in your area.

NOTICE: Use of other low grade diesel fuels will result in loss of engine power, high fuel consumption, and damage to the exhaust aftertreatment system (if equipped).

Fuel conditioner Diesel fuel conditioner is available from your CASE CONSTRUCTION dealer. Instructions for the use of the fuel conditioner is on the container.

The use of diesel fuel conditioner will: • Clean fuel injectors, valves, and manifolds for increased service life

• Separate moisture from the fuel • Stabilize fuel in storage NOTICE: Use only CASE CONSTRUCTION approved biocide additives to prevent damage to the exhaust aftertreatment system (if equipped).

• Disperse insoluble gummy deposits that form in the fuel system

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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.

NOTICE: Your emissions control system is compatible with up to 20 % biodiesel fuel (B20). Be aware that the use of biodiesel fuel that does not comply with the standards mentioned in this section could lead to severe damage to the engine, fuel system or aftertreatment system of your machine. The use of non-approved fuels may void CASE CONSTRUCTION Warranty coverage.

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 blends are covered by: • 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.

• 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

• Biodiesel is fully biodegradable and non-toxic.

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.

Diesel and biodiesel fuel specifications Tier 4a diesel fuel specifications are covered by the following: • ASTM D975-10, Standard Specification for Diesel Fuel Oils. (15 ppm sulfur maximum.)

The main concerns related to operation with biodiesel fuels are:

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• Filters and injector blockage caused by poor fuel quality.

• Wear and corrosion of internal components due to water content, which affects lubricity.

• 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. 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.

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: 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.

NOTICE: For machines using Tier 4a engines with an exhaust aftertreatment system in regions where the biodiesel blend stock is supplied to the ASTM D6751-09A standard, it is essential that evidence of compliance to the special limits for Group I Metals, Group II Metals and the reduced phosphorus content specified above be obtained on every delivery of fuel from the fuel supplier. Failure to comply with this requirement can result in damage to the catalyst of the aftertreatment system which will not be covered under warranty.

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 to 250 h 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.

For machines using Tier 4a engines with an exhaust aftertreatment system:

NOTE: Oil sampling kits are available from your authorized CASE CONSTRUCTION dealer.

1. If the biodiesel blend stock to ASTM D6751-09A is used, special precautions need to be taken to insure that it fully complies with the following special requirements:

When switching back from biodiesel to regular #2 diesel, all fuel filter, oil and oil filter should be changed even if this falls between routine service intervals.

• Group I Metals content (Sodium + Potassium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.

• Group II Metals content (Calcium + Magnesium) is ≤ 5 mg/kg per EN14538 as specified in the biodiesel spec.

• Phosphorus content lower than specified is a mandatory requirement. Phosphorus must not exceed 4 mg/kg per ASTM D4951.

2. The resulting greater than B5 through B20 blend must not exceed 1 mg/kg for Group I Metals (Sodium + Potassium) and for Group II Metals (Calcium + Magnesium).

Storage 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 diesel fuel is used.

NOTE: If storage for longer than 3 months is necessary, the engine must be run on regular #2 diesel for a minimum of 20 h to flush the biodiesel fuel out of the fuel system prior to 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.

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Engine oil viscosity - Recommended operating temperature range For machines using Tier 4B (Final) engines

(H) (H)

0W-40 CJ-4 UNITEK to CNH MAT3521 API CJ-4 0W-40* (H)

5W-30 ACEA E6 (H) (H)

10W-40 CJ-4 UNITEK to CNH MAT3521 API CJ-4 10W-40* (H) (H)

-40 °C -40 °F

-30 °C -22 °F

-20 °C -4 °F

-10 °C 14 °F

15W-40 CJ-4 to CNH MAT3522* 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 * Requires a 50 % reduction in oil change interval

7-22

20 °C 68 °F

30 °C 86 °F

40 °C 104 °F

50 °C 122 °F

7 - MAINTENANCE

Organic Acid Technology (OAT) coolant Depending on the date of manufacture, your cooling system may be equipped with conventional ethylene glycol coolant such as CNH XHD HEAVY DUTY COOLANT / ANTI-FREEZE or an Organic Acid Technology (OAT) coolant solution such as CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. You can easily identify CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT by its yellow color. You should never mix the coolant types.

The coolant solution used must meet the following CNH Industrial material specifications for either coolant type: • MAT3624 for OAT coolant • MAT3620 for conventional coolant The decal shown is located near the fill point of the cooling system whenever the factory fill is CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. This decal is available in three different sizes. See the table below for the associated part numbers.

CNH Industrial part number 47757330 47757331 47757332

Size 50 mm x 50 mm 75 mm x 75 mm 100 mm x 100 mm

47757330

1

NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling system with only water. You can use a refractometer to check the concentration level. You should not use Supplemental Coolant Additives (SCA) when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the coolant solution at the recommended change interval.

If you need to change a machine from conventional coolant to OAT coolant or vice versa, you should follow the “Changing coolant types” procedure below to attain the full benefit of the coolant.

Changing coolant types To change coolant from OAT coolant to conventional coolant (or vice versa): 1. Empty the engine cooling system by draining the coolant into a suitable container.

2. Fill the system with clean water.

3. Start the engine and run the engine for at least 30 min.

NOTE: Make sure that you activate the heating system (if equipped) to circulate fluid through the heater core.

4. Repeat Steps 1 to 3 for a total of two washes.

5. Fill the system with conventional coolant (or OAT coolant).

6. Operate the engine until it is warm. Inspect the machine for leaks.

7. If you are changing to OAT coolant, then attach the decal (CNH Industrial part number 47757330) to indicate the use of OAT coolant in the cooling system.

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You may notice the older version of the OAT decal (CNH Industrial part number 47488993) on some applications.

Definitions Conventional coolant: A coolant that relies on inorganic inhibitors such as silicates, nitrites, and phosphates for corrosion and cavitation protection.

Organic Acid Technology (OAT) coolant: A coolant that relies on inhibitors such as organic acid salts for corrosion and cavitation protection.

47488993

7-24

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MAINTENANCE CHART

Maintenance chart Cleaning Check Change fluid Replace

Grease Lubricate Adjust Bleed

Maintenance action

Page no.

At warning message display 7-27 7-30 7-32 7-34 7-35 7-36

Engine air filters Hydraulic filter Engine oil and filter Engine - Low Oil Pressure (LOP) Auto-regeneration Manual regeneration Initial 10 hours Wheel nut and bolt torque

7-38 Every 10 hours of operation or daily

Engine oil level

7-39 Initial 20 hours

Transmission oil level Rear steer axle oil level - Four-Wheel Drive (4WD) Front drive axle fluid level 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 Initial 100 hours Hydraulic filter Transmission filter Fuel filters Service brakes Parking brake Every 250 hours Seat slides Battery Rear steer axle oil 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 Every 500 hours 7-25

7-41 7-43 7-44 7-45 7-47 7-49 7-50 7-51 7-51 7-52 7-53 7-55 7-57 7-59 7-60 7-61 7-62 7-63 7-64 7-65 7-66 7-66 7-67 7-68 7-70 7-72 7-74 7-75 7-76 7-77 7-78

7 - MAINTENANCE

Cleaning Check Change fluid Replace

Grease Lubricate Adjust Bleed

Maintenance action Roll Over Protective Structure (ROPS) Fuel filters Engine oil and filter Carriage thrust rollers Forklift mast chains

Page no.

7-79 7-81 7-83 7-85 7-86 Every 1000 hours 7-87 7-89 7-90 7-91 7-93 7-95

Hydraulic fluid and filter Battery fluid level Front drive axle Transmission fluid and filters Rear steer axle oil - Four-Wheel Drive (4WD) Engine air filters Every 1500 hours Engine Crankcase Ventilation (CCV) filter Every 2000 hours of operation or annually Chain rollers Load rollers Every 4000 hours or every four years Engine cooling system As required Fork inspection Tire pressure and condition Engine air pre-cleaner (if equipped) Bleed air from the fuel system Fan belt Disable parking brake

7-26

7-98 7-98 7-99 7-100 7-105 7-106 7-107 7-108 7-110 7-112

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.

and engine malfunction lamp

remains illuminated

1. Clean the air pre-cleaner (if equipped): 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.

2. Open the right-hand side engine panel.

RAPH12FRK0030BA

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RAIL14FRK0020BA

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

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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 then continue.

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

D. Shine a light inside the filter, if you see light spots or deteriorated areas, then replace the filter. If no damage is apparent, then 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.

RAPH12FRK0194AA

3

RAPH12FRK0196AA

4

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7. 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.

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8. Do not remove the inner filter unless the outside of the inner filter is dirty. Do not clean the inner filter. Replace the inner filter. 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. Make sure that you create a tight seal.

RCPH11TLB056BAD

6

RAIL14FRK0019BA

7

RAIL14FRK0018BA

8

11. Install the primary air filter (1). Make sure that you create a tight seal.

12. Position the filter cover (2) over the housing (3), hold the cover in place, and fasten the clips that secure the air filter cover in place.

13. Start up the engine.

14. Make sure that the warning lamps do not illuminate.

If the warning lamps illuminate, then replace the outer filter if it was cleaned instead of replaced. If the problem continues, then replace the inner filter.

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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.

remains illuminated while the engine is running at

Hydraulic oil specification – CASE AKCELA HY-TRAN® ULTRACTION 1. The hydraulic filter is located under the right-hand front portion of the machine, just behind the front axle.

RCPH10TLB045AAF

1

RAPH12FRK0219AA

2

2. Slowly open the hydraulic reservoir cap to help relieve pressure.

3. Clean the area around the filter head before removing the old filter.

4. Use a filter wrench to 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. Make sure that the warning lamp does not illuminate.

12. After running for three or four minutes, shut down the engine.

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7 - MAINTENANCE

13. Inspect for leaks.

14. Check the hydraulic oil level.

15. Add hydraulic fluid if necessary.

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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 s with a single audible alert.

appears on the display. The message will appear

Change the engine oil and replace the filter after every 500 h of operation or when the Engine Control Unit (ECU) prompts the operator.

Engine oil specification – 8.00 L (8.45 US qt) of TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40 or refer to the “Engine oil viscosity” chart 7-22.

1. Start the engine and run until the engine is warm. A warm engine allows a more complete removal of foreign material.

2. Turn the engine off and open the right-hand 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).

RAIL14FRK0018BA

1

RAPH12FRK0250AA

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4. Slowly open the drain plug for the engine oil pan and drain the oil into a suitable container.

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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.

RAPH12FRK0182AA

3

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: Clear the active warning 3-18.

,

, and

from the display screen. Follow the “Oil life reset” procedure

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Engine - Low Oil Pressure (LOP) NOTICE: Do not operate the machine with an active Low Oil Pressure

warning on the instrument cluster.

1. When the engine is running and the Engine Control Unit (ECU) detects a low engine oil pressure the operator is notified with: • A constant audible alarm.

• The emergency stop • The engine malfunction • The Low Oil Pressure (3).

symbol (1) illuminates. symbol (2) illuminates. appears on the display

2. Find a clear area on the job site to park the machine.

3. Turn of the engine.

4. Check the engine oil level.

A. If the engine oil level is sufficient contact your authorized dealer for service.

B. If the engine oil level is low add oil ( TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40).

C. Start the machine.

D. If the warnings continue contact your authorized dealer for service.

7-34

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1

7 - MAINTENANCE

Auto-regeneration CAUTION Burn hazard!

During the particulate matter catalyst 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.

C0164A

Avoid prolonged idle time - Idling reduces operating temperatures which increases particulate matter (PM) build-up in the after treatment system.

Operating the machine at low engine speeds will increase the frequency of the regeneration process.

Auto-regeneration NOTE: The operator may continue to operate the machine normally during the auto-regeneration process.

1. The operator is notified with a single audible beep, and will alternate on the display screen.

The 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 s.

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1

NOTE: The operator may choose to prevent the auto-regeneration procedure, but will eventually force the engine to de-rate significantly affecting machine performance. To bypass the procedure refer to 3-17

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7 - MAINTENANCE

Manual regeneration CAUTION Burn hazard!

During the particulate matter catalyst 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.

C0164A

WARNING Fire hazard!

During the particulate matter catalyst 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.

W1346A

Avoid prolonged idle time - Idling reduces operating temperatures which increases particulate matter (PM) build-up in the after treatment system.

Operating the machine at low engine speeds will increase the frequency of the regeneration process.

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 regeneration symbol will flash, and will alternate on the display screen. A high level of particulate matter is present in the Particulate Matter (PM) Catalyst system.

• Constant audible alert, red emergency stop symbol , the regeneration symbol will flash, and will alternate on the display screen. An extremely high level of particulate matter is present in the Particulate Matter (PM) Catalyst 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.

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1

7 - MAINTENANCE

3. Wait for to appear on the display (1). The system is checking that the machine is in an idle state with the park brake is on.

4. The sequence message appears on the display screen when the system is ready to start the regeneration process.

5. Press the start button (2).

6.

message alternates on the display screen while the system validates all conditions are met.

7. 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 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

2

After Treatment System (ATS) regeneration failure NOTE: There are two levels of warning if the operator does not perform the manual regeneration or a system malfunction occurs. Level 1 warning is provided when the Particulate Matter (PM) Catalyst reaches maximum load at which time the engine power is reduced by 25 %. Level 2 warning is provided when the PM Catalyst 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..

• Level 1 — A single audible alert, an illuminated operator alert symbol , and alternate on the display screen.

• Level 2 — A constant audible alert, an illuminated emergency stop symbol , and alternate on the display screen.

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Initial 10 hours

Wheel nut and bolt torque Check the torque of the wheel nuts and bolts at the first 10 h 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 h of operation. Repeat until the nuts and bolts remain tight.

Front drive wheels NOTICE: Tighten nuts in a crossing pattern (sequence), as shown.

Front drive wheel: 1.

Tighten the five mounting nuts in sequence until the wheel is snug against 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.

Tighten the nuts in sequence an additional 30 ° to set the preload.

5.

Repeat the procedure on the remaining five mounting nuts.

RAIL14FRK0031BA

1

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2

Rear steer wheels NOTICE: Tighten bolts and washers in a crossing pattern (sequence), as shown.

Rear steer wheel (2WD): 1. Tighten the eight mounting bolts with washers in sequence until the wheel is snug against the axle hub.

2. Tighten the bolts in sequence to: ○ For tire size 12 x 16.5 – 119 - 125 N·m (88 - 92 lb ft) ○ For tire size 11 x 16 - 156 - 203 N·m (115 - 150 lb ft) 3. For tire size 12 x 16.5. Tighten the bolts in sequence an additional 30 ° to set the preload.

Rear steer wheel (4WD): 1.

Tighten the eight mounting bolts in sequence until the wheel is snug again the axle hub.

2.

Tighten the bolts in sequence to a torque of 119 125 N·m (88 - 92 lb ft).

3.

Tighten the bolts in sequence an additional 43 ° to set the preload.

7-38

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 h 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.

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5. Inspect the dipstick. The oil level should be between the minimum mark and the maximum mark on the dipstick.

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7 - MAINTENANCE

6. Add TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40 oil as needed at the fill location on the machine.

NOTE: Refer to the “Engine viscosity chart” 7-22 if necessary.

RAPH12FRK0179AA

7-40

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 h of operation on a new machine or after a component rebuild. Then check the fluid level every 250 h of operation.

Transmission oil specification – CASE AKCELA HY-TRAN® ULTRACTION 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-hand side engine panel.

5. Turn the dipstick handle counter-clockwise and pull out the dipstick.

RAIL14FRK0020BA

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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.

7. Add fluid as needed. Do not fill above the high mark.

RCPH10TLB054AAF

7-42

2

7 - MAINTENANCE

Rear steer axle oil level - Four-Wheel Drive (4WD) Check the oil level of the Four-Wheel Drive (4WD) rear steer axle after the first 20 h of operation with a new machine or after a component rebuild. Then check the oil level every 250 h 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 TUTELA TRANSAXLE FLUID SAE 80W-140 as needed.

4. Install the plug.

5. Repeat the procedure for the other wheel.

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Axle oil level 1. Slowly remove the plug from the center bowl. should be even with the orifice.

Oil

2. Add oil TUTELA TRANSAXLE FLUID SAE 80W-140 as needed.

3. Install the plug.

7-43

7 - MAINTENANCE

Front drive axle fluid level Check the oil level of the front drive axle after the first 20 h of operation with a new machine or after a component rebuild. Then check the oil level every 250 h of operation.

Axle oil level 1. Slowly remove the plug. Oil should be even with the orifice.

2. Add oil TUTELA TRANSAXLE FLUID SAE 80W-140 as needed.

3. Install the plug.

RAPH12FRK0276AA

7-44

1

7 - MAINTENANCE

Every 50 hours

Fuel system water separator Drain the water separator and check the fuel for water or sediment every 50 h.

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.

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2. 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.

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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.

7-46

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

NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives (SCA) should not be used when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the coolant solution at the change interval recommended.

Check the de-aeration reservoir fluid level every 50 h of operation.

Coolant fluid specification – CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT 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.

RAPH12FRK0034BA

7-47

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7 - MAINTENANCE

4. Loosen both bolts on the coolant cover plate, but only remove one of the bolts.

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2

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3

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 CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT.

7-48

7 - MAINTENANCE

Hydraulic reservoir fluid level Check the fluid level of the hydraulic system every 50 h of operation.

Hydraulic oil specification – CASE AKCELA HY-TRAN® ULTRACTION 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

7-49

1

7 - MAINTENANCE

Rear steer axle grease fittings Grease the king pins and the rear axle pivot every 50 h of operation, or more frequently, if the machine has been working in water or extremely muddy conditions.

Grease specification – TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9

• King pins, Two-Wheel Drive (2WD) - Four total, two on each side

RCPH10TLB063AAF

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RAPH12FRK0171AA

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• King pins, Four-Wheel drive (4WD) - Four total, two on each side

• Front axle pivot, remote fitting - One

7-50

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 h of operation, or more frequently, if the machine has been working in severe conditions.

Grease each side of the mast pivot with TUTELA MULTI EP GREASE 251H, GR-9.

PURPOSE

RAPH12FRK0136AA

1

Mast carriage roller grease fittings Grease the mast carriage rollers every 50 h of operation, or more frequently, if the machine has been working in severe conditions.

Grease the four mast carriage rollers with TUTELA MULTI EP GREASE 251H, GR-9.

PURPOSE

RAIL14FRK0005AA

7-51

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7 - MAINTENANCE

Mast chain roller grease fittings Grease the mast chain rollers every 50 h of operation, or more frequently, if the machine has been working in severe conditions.

Grease the mast chain rollers with TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9.

• 586H — two grease fittings • 588H — four grease fittings

RAPH12FRK1117AA

7-52

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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 h of operation, whenever the warning lamp remains illuminated while the engine is running at normal operating temperature, and under normal working conditions every 1000 h.

Hydraulic oil specifications – CASE AKCELA HY-TRAN® ULTRACTION 1. The hydraulic filter is located under the right-hand front portion of the machine just behind the front axle.

RCPH10TLB045AAF

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RAPH12FRK0219AA

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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.

7-53

7 - MAINTENANCE

12. After running for three or four minutes, shut down the engine.

13. Inspect for leaks.

14. Check the oil level.

15. Add oil if needed.

7-54

7 - MAINTENANCE

Transmission filter Replace the transmission filter after the first 100 h and every 1000 h on a new machine or if a major component has been rebuilt.

Transmission oil specification – CASE AKCELA HY-TRAN® ULTRACTION 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 right-hand and left-hand engine side panels.

2. Clean the area around the transmission dipstick.

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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.

7-55

7 - MAINTENANCE

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.

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.

7-56

7 - MAINTENANCE

Fuel filters Replace the fuel filters after the first 100 h of operation on a new machine or if a major component has been rebuilt.

Then replace the fuel filters every 500 h 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.

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5. 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.

7-57

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.

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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.

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 7-108.

7-58

7 - MAINTENANCE

Service brakes Check the operation of the service (pedal) brakes on a hard level surface after the first 100 h 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.

7-59

7 - MAINTENANCE

Parking brake Check the operation of the parking brake after the first 100 h of operation. Then check the parking brake as required.

NOTE: Review the procedures in their entirety before proceeding. Make sure that you have a large open area that will allow the machine to travel forward as straight as possible to complete this procedure.

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 de-clutch. Contact your dealer for service as needed.

7-60

7 - MAINTENANCE

Every 250 hours

Seat slides Lubricate the seat slides every 250 h 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.

7-61

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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 h 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.

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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.

7-62

7 - MAINTENANCE

Rear steer axle oil level - Four-Wheel Drive (4WD) Check the oil level of the Four-Wheel Drive (4WD) rear steer axle after the first 20 h of operation with a new machine or after a component rebuild. Then check the oil level every 250 h 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 TUTELA TRANSAXLE FLUID SAE 80W-140 as needed.

4. Install the plug.

5. Repeat the procedure for the other wheel.

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Axle oil level 1. Slowly remove the plug from the center bowl. should be even with the orifice.

Oil

2. Add TUTELA TRANSAXLE FLUID SAE 80W-140 as needed.

3. Install the plug.

7-63

7 - MAINTENANCE

Rear steer axle breather valve - Four-Wheel Drive (4WD) Clean the breather valve on the rear steer axle every 250 h 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.

RAPH12FRK1115AA

4. Spin the top cap on the breather valve to ensue that it turns freely.

7-64

1

7 - MAINTENANCE

Rear steer axle drive shaft - Four-Wheel Drive (4WD) Grease the rear drive shaft every 250 h of operation. Use TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9.

NOTE: Shown with optional Four-Wheel Drive (4WD) drive shaft guard.

RAIL11TLB0010AA

7-65

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7 - MAINTENANCE

Front drive axle fluid level Check the oil level of the front drive axle after the first 20 h of operation with a new machine or after a component rebuild. Then check the oil level every 250 h of operation.

1. Slowly remove the plug. Oil should be even with the orifice.

2. Add TUTELA TRANSAXLE FLUID SAE 80W-140 as needed.

3. Install the plug.

RAPH12FRK0276AA

1

Front drive axle breather valve Clean the breather valve on the front drive axle every 250 h 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. 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 RAIL12FRK1134BA

1

RAIL14FRK0039BA

2

Blow dry the area with compressed air.

4. Spin the top cap on the breather valve to ensue that it turns freely.

7-66

7 - MAINTENANCE

Front drive axle - drive shaft Grease the front drive shaft every 250 h of operation. Use TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9.

RAPH12FRK0258AA

7-67

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7 - MAINTENANCE

Fuel tank drain Inspect the fuel tank for water and sediment every 250 h 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.

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2. 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.

7-68

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.

7-69

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

NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives (SCA) should not be used when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the coolant solution at the change interval recommended.

Check the de-aeration reservoir fluid level every 250 h of operation.

Coolant fluid specification – CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT 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).

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7 - MAINTENANCE

3. Loosen both bolts on the coolant cover plate, but only remove one of the bolts.

RAPH12FRK0215AA

2

RAPH12FRK0213AA

3

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.

7-71

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 h of operation on a new machine or after a component rebuild. Then check the fluid level every 250 h of operation.

Hydraulic oil specification – CASE AKCELA HY-TRAN® ULTRACTION 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-hand side engine panel.

5. Turn the dipstick handle counter-clockwise and pull out the dipstick.

RAIL14FRK0020BA

7-72

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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.

7-73

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 and 588H

Tire size 19.5L x 24 — 12 ply

Recommended tire pressure 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 16.5 — 12 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 7-38 in this manual for the procedure.

• Use an air hose with a remote shutoff and stand behind the tire tread.

7-74

7 - MAINTENANCE

Forklift mast chains Check the chain tension on the forklift mast every 250 h 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.

7-75

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 h 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.

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Tilt cylinder - Grease Grease the tilt cylinders (four locations) every 250 h of operation. Use TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9.

NOTE: All views are from underneath the machine.

7-77

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7 - MAINTENANCE

Side-shift cylinder bearing Grease the side shift cylinder bearings (two locations) every 250 h of operation. Use TUTELA MULTI -PURPOSE EP GREASE 251H, GR-9.

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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 h 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.

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Front ROPS mounting hardware. Check both sides. Torque specification 650 - 730 N·m (479 538 lb ft)

3. Check for cracks, rust, or holes in the ROPS and ROPS parts. Age, weather, and accidents can cause damage to the ROPS and ROPS parts. If you have any doubt about the integrity of the ROPS system, contact your dealer.

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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.

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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.

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Fuel filters Replace the fuel filters after the first 100 h of operation on a new machine or if a major component has been rebuilt.

Then replace the fuel filters every 500 h 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.

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5. 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.

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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.

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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.

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 7-108.

7-82

7 - MAINTENANCE

Engine oil and filter Change the engine oil and replace the filter after every 500 h of operation or once a year, whichever occurs first.

Engine oil specification – 8.00 L (8.45 US qt) of TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40 or refer to the “Engine oil viscosity” chart 7-22.

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-hand 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).

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4. 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.

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11. Install the drain plug for the engine oil tank.

12. Fill the engine with new oil.

Next operation: Clear the active warning 3-18.

,

, and

from the display screen. Follow the “Oil life reset” procedure

7-84

7 - MAINTENANCE

Carriage thrust rollers Inspect the carriage thrust rollers every 500 h 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.

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Forklift mast chains Inspect the mast chains and hardware every 500 h 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.

7-86

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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 h of operation.

Hydraulic oil specification – 54.5 L (57.6 US qt) of CASE AKCELA HY-TRAN® ULTRACTION. 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.

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7. 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.

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7 - MAINTENANCE

NOTICE: Do not use a filter wrench to install the new filter.

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.

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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 h 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) .

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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.

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7 - MAINTENANCE

Front drive axle Change the oil of the front drive axle after 1000 h of operation.

Front drive axle oil specification – 14.2 L (15.0 US qt) of CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL Planetary hub oil specification – 1.5 L (1.6 US qt) of CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL 1. Prepare the machine: A. Start the engine and run the machine until the front drive axle oil 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.

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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.

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7 - MAINTENANCE

Transmission fluid and filters Change the transmission oil and filter every 1000 h.

Transmission oil specification (Two-Wheel Drive) – 10.5 L (11.1 US qt) of CASE AKCELA HY-TRAN® ULTRACTION Transmission oil specification (Four-Wheel Drive) – 13.0 L (13.7 US qt) of CASE AKCELA HY-TRAN® ULTRACTION 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-side and right-side engine panels.

2. Clean the area around the transmission dipstick.

3. Turn dipstick counter-clockwise and remove.

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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. 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.

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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.

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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.

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Rear steer axle oil - Four-Wheel Drive (4WD) Change the oil of the Four-Wheel Drive (4WD) rear steer axle every 1000 h of operation.

Rear steer axle oil (4WD only) specification – 5.5 L (5.8 US qt) of CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL Planetary hub (4WD only) oil specification – 0.7 L (0.7 US qt) of CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL

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.

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6. Rotate the wheel so that the oil level plug is in the fill position.

7. Fill the hub with oil.

8. Install the oil level plug.

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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.

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4. Allow the oil to drain.

5. Install the drain plug.

6. Pour oil into the oil fill orifice until full.

7-94

7 - MAINTENANCE

Engine air filters Replace the engine air filters every 1000 h of operation. Replace more frequently if the machine operates in severe conditions.

1. Clean the air pre-cleaner (if equipped): 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.

2. Open the right-side engine panel.

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

6. Remove the primary filter.

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7. 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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8. Remove the inner filter.

9. 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.

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7 - MAINTENANCE

13. Position the filter cover over the housing, hold the cover in place, and fasten the clips that secure the air filter cover in place.

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7 - MAINTENANCE

Every 1500 hours

Engine Crankcase Ventilation (CCV) filter Replace the Crankcase Ventilation (CCV) filter every 1500 h of operation.

NOTE: Refer to the Engine Service Manual or contact your dealer for service.

Every 2000 hours of operation or annually

Chain rollers Inspect the chain rollers on the mast for wear every 2000 h of operation.

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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Load rollers Inspect the load rollers on the mast for wear every 2000 h of operation.

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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Every 4000 hours or every four years

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

NOTICE: NEVER mix OAT coolant with conventional coolant. Under no circumstances should you top off a cooling system with only water. You can use a refractometer to check the concentration level. Supplemental Coolant Additives (SCA) should not be used when using CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT. Change the coolant solution at the change interval recommended.

Drain, flush, and replace the engine coolant every 4000 hours of operation.

Coolant fluid specification – 16.5 L (17.4 US qt) of CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT

Drain the engine coolant system 1. Open the right-side and left-side engine panels.

2. Remove the four bolts (1) and remove the radiator grille (2)

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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

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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.

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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.

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3. Slide the cover plate (1) out of the way.

4. Remove the de-aeration tank cap (2).

5. Fill the system with clean water.

6. Secure the de-aeration tank cap.

7. Start the engine and run for at least 30 min.

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

Open the drain valve slowly and allow the water to drain completely.

9. Repeat Steps 4 – 8. Continue to the Step 10 after the second system flush.

10. Close the drain valve and detach the drain hose.

7-102

7 - MAINTENANCE

Fill the engine coolant system 1. Remove the de-aeration tank cap.

2. Add CASE AKCELA ACTIFULL™ OT EXTENDED LIFE COOLANT into the de-aeration tank until the fluid reaches between the COLD MIN mark (2) and the HOT MAX mark (1) on the tank.

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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.

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.

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7 - MAINTENANCE

7. Install the radiator grille (2) using four bolts (1).

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8. Secure the cover plate to the fixed hood.

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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. 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 2. 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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• 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.

7-105

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 and 588H

Tire size 19.5L x 24 — 12 ply

Recommended tire pressure 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 16.5 — 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 7-38 in this manual for procedure.

• Use an air hose with a remote shutoff and stand behind the tire tread.

7-106

7 - MAINTENANCE

Engine air pre-cleaner (if equipped) 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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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.

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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.

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7 - MAINTENANCE

7. Start up the engine.

• DO NOT crank the engine for more than 30 s.

• 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.

7-109

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).

83118121

1

RAIL11TLB0004AA

2

83118121

3

3. Loosen the adjustment bolt lock nut (1) .

4. Turn the adjustment bolt (2) counter-clockwise, to loosen the belt tension.

5. Slide the belt (1) off of the water pump pulley (2) and remove the belt.

7-110

7 - MAINTENANCE

Install 1. Route the drive belt on the pulleys as shown.

83118087

4

83118121

5

RAIL11TLB0004AA

6

83118121

7

2. Setting and securing the fan belt tension: A. Turn the adjustment bolt (1) clockwise, until the pivot bolt (2) is at the end of the tension bracket slot (3).

NOTE: Special belt design will adjust to the proper tension.

B. Tighten the adjustment bolt lock nut (1) securing the adjustment bolt (2) in position.

3. Torque to 45 - 55 N·m (33 - 41 lb ft): • Pivot bolt (1) • Lower alternator bolt (2)

7-111

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. The parking brake solenoid block (1) is on the transmission housing near the hydraulic filter (2).

NOTE: Image is from underneath the machine.

3. Clean the area of dirt and debris.

RAIL14FRK0041BA

1

RCPH10TLB064AAF

2

RCPH10TLB065AAF

3

4. Remove the two bolts that secure the solenoid block.

7-112

7 - MAINTENANCE

5. Carefully lift up and rotate the solenoid block 90 ° (1).

NOTE: Arrow points towards the front of the machine.

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.

RCPH10TLB070AAF

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.

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.

7-113

4

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.

7-114

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 7-108 in this manual.

12. Start the engine. It is important that you review the “STARTING THE UNIT” chapter 4-2 in this manual.

7-115

7 - MAINTENANCE

7-116

8 - SPECIFICATIONS

8 - SPECIFICATIONS###_9_### Engine - General specification 586H and 588H Model

Diesel, F5HFL463D*F005, TIER 4B Final 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) 17 to 1 Direct High Pressure Common Rail (HPCR)

Type Firing order Bore and stroke Displacement Compression ratio Fuel injection Horsepower - rated at 2200 RPM Gross Net with 33 ° fan Peak torque at 1400 RPM Gross Net with 33 ° fan Maximum torque rise Engine speeds Rated speed, full load Low idle High idle, no load Converter stall Hydraulic stall

55 kW (75 Hp) 51 kW (69 Hp) 316 N·m (233 lb ft) 298 N·m (220 lb ft) 35 % ± 5 RPM 2200 RPM 900 - 1000 RPM 2330 - 2430 RPM 1925 - 2075 RPM 2175 - 2330 RPM

8-1

8 - SPECIFICATIONS

Transmission - General specification Transmission • Electronic F/R shuttle control • On the go electric Four-Wheel drive (4WD) 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: 3.01 Speed selection: 4 forward and 4 reverse Forward Reverse Travel Gear speeds ratios: 1st 5.603 5.603 1st 2nd 3.481 3.481 2nd 3rd 1.584 1.584 3rd 4th 0.793 0793 4th Splitter gear ratio for drive to rear steer axle (four wheel drive):

Forward

Reverse

6.1 km/h (3.8 mph) 9.8 km/h (6.1 mph) 20.6 km/h (12.8 mph) 38.6 km/h (24.0 mph) 1.222 to 1

6.1 km/h (3.8 mph) 9.8 km/h (6.1 mph) 20.6 km/h (12.8 mph) 38.6 km/h (24.0 mph)

Differential lock On the go, push button activation on the steering column console

Axle, differential and planetaries Four-Wheel Drive (4WD) machines Front drive axle Differential ratio Planetary hub ratio Total reduction ratio Rear steer axle Differential ratio Planetary hub ratio Total reduction ratio

2.5 6.4 16.0 2.0 6.0 12.0

Brakes Service • Foot pedal operated (hydraulic) • 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, 3.5 kW nominal output 12 V, group 30H 850 Cold Cranking Amps (CCA) @ -18 °C (0 °F) 150 min recharge @ 27 °C (80 °F) Connected in parallel, 2 x 12 V, group 28 850 Cold Cranking Amps (CCA) @ -18 °C (0 °F) 150 min recharge @ 27 °C (80 °F) each battery Fuses on individual circuits 2 x 12 V 30 A maximum 107 dB(A)

Protection Power plug outlet Backup alarm 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 19.5L x 24 tires 2117 mm (83.3 in) Overall height with mast closed, unloaded 3225.8 mm (127.0 in) Ground clearance 260 mm (10.2 in) (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires 3302 mm (130 in) (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires 5486 mm (216.0 in) (C) Maximum fork height 4572 mm (180 in) (D) Degree tilt, forward 45 ° (E) Degree tilt, rearward 15 ° (F) Overall length with 1219 mm (48.0 in) forks 4928 mm (194 in) Lift capacity to full height at 610 mm (24.0 in) load center 2722 kg (6000 lb) Overall machine weight with 1219 mm (48.0 in) forks with a 1782 kg (3929 lb) counterweight.

2WD 6206 kg (13682 lb) 4WD 6292 kg (13871 lb) NOTE: Weights are approximate and should only be used as a guideline.

8-5

8 - SPECIFICATIONS

586H Forklift with 6.71 m (22.0 ft) mast

RAPH12FRK0722EA

2

Overall width with 19.5L x 24 tires 2117 mm (83.3 in) Overall height with mast closed, unloaded 3225.8 mm (127.0 in) Ground clearance 260 mm (10.2 in) (A) Overall height, forks 152.4 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires 3276.6 mm (129.0 in) (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires 7670.8 mm (302.0 in) (C) Maximum fork height 6705.6 mm (264.0 in) (D) Degree tilt, forward 45 ° (E) Degree tilt, rearward 15 ° (F) Overall length with 1219 mm (48.0 in) forks 4953 mm (195 in) Lift capacity height with a 610 mm (24.0 in) load center Lift height 4.57 m (15.0 ft) 2722 kg (6000 lb) Full lift height 6.71 m (22.0 ft) 1361 kg (3000 lb) Lift height 4.57 m (15.0 ft) 2722 kg (6000 lb) Full lift height 6.71 m (22.0 ft) 1361 kg (3000 lb) Overall machine weight with 1219 mm (48.0 in) forks with a 1782 kg (3929 lb) counterweight.

2WD 6546 kg (14431 lb) 4WD 6632 kg (14621 lb) NOTE: Weights are approximate and should only be used as a guideline.

8-6

8 - SPECIFICATIONS

586H Forklift with 4.88 m (16 ft) Freelift mast

RAPH12FRK0722EA

3

Overall width with 19.5L x 24 tires 2117 mm (83.3 in) Overall height with mast closed, unloaded 2616.2 mm (103.0 in) Ground clearance 260 mm (10.2 in) (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires 2616.2 mm (103.0 in) (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires 5791 mm (228 in) (C) Maximum fork height Maximum fork height 4876.8 mm (192.0 in) Maximum Freelift fork height (fork to ground) 1702 mm (67.0 in) (D) Degree tilt, forward 45 ° (E) Degree tilt, rearward 15 ° (F) Overall length with 1219 mm (48.0 in) forks 4953 mm (195 in) Lift capacity to full height at 610 mm (24.0 in) load center 2722 kg (6000 lb) Overall machine weight with 1219 mm (48.0 in) forks with a 1782 kg (3929 lb) counterweight.

2WD 6220 kg (13713 lb) 4WD 6306 kg (13902 lb) NOTE: Weights are approximate and should only be used as a guideline.

8-7

8 - SPECIFICATIONS

586H Forklift with 4.88 m (16 ft) Freelift mast

RAPH12FRK0722EA

4

Overall width with 19.5L x 24 tires 2117 mm (83.3 in) Overall height with mast closed, unloaded 3225.8 mm (127.0 in) Ground clearance 260 mm (10.2 in) (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires 3225.8 mm (127.0 in) (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires 7620 mm (300 in) (C) Maximum fork height Maximum fork height 6705.6 mm (264.0 in) Maximum Freelift fork height (fork to ground) 2311 mm (91.0 in) (D) Degree tilt, forward 45 ° (E) Degree tilt, rearward 15 ° (F) Overall length with 1219 mm (48.0 in) forks 4953 mm (195 in) Lift capacity height with a 610 mm (24.0 in) load center Lift height 4.57 m (15.0 ft) 2722 kg (6000 lb) Full lift height 6.71 m (22.0 ft) 1361 kg (3000 lb) Overall machine weight with 1219 mm (48.0 in) forks with a 1782 kg (3929 lb) counterweight.

2WD 6626 kg (14608 lb) 4WD 6712 kg (14797 lb) NOTE: Weights are approximate and should only be used as a guideline.

8-8

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 2236 mm (88.0 in) Overall height with mast closed, unloaded 3175 mm (125.0 in) Ground clearance 260 mm (10.2 in) (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires 3251.2 mm (128.0 in) (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires 5588 mm (220.0 in) (C) Maximum fork height 4572 mm (180 in) (D) Degree tilt, forward 45 ° (E) Degree tilt, rearward 15 ° (F) Overall length with 1219 mm (48.0 in) forks 5207 mm (205.0 in) Lift capacity to full height at 610 mm (24.0 in) load center 3629 kg (8000 lb) Overall machine weight with 1219 mm (48.0 in) forks with a 2523 kg (5562 lb) counterweight.

2WD 7304 kg (16103 lb) 4WD 7390 kg (16292 lb) NOTE: Weights are approximate and should only be used as a guideline.

8-9

8 - SPECIFICATIONS

588H Forklift with 6.71 m (22.0 ft) mast

RAPH12FRK0722EA

2

Overall width with 19.5L x 24 tires 2236 mm (88.0 in) Overall height with mast closed, unloaded 3175 mm (125.0 in) Ground clearance 260 mm (10.2 in) (A) Overall height, forks 152 mm (6.0 in) off ground, unloaded: with 2WD and 19.5L x 24 tires 3225.8 mm (127.0 in) (B) Overall height, mast raised, unloaded: with 2WD and 19.5L x 24 tires 7747 mm (305.0 in) (C) Maximum fork height 6705.6 mm (264.0 in) (D) Degree tilt, forward 45 ° (E) Degree tilt, rearward 15 ° (F) Overall length with 1219 mm (48.0 in) forks 5232 mm (206.0 in) Lift capacity height with a 610 mm (24.0 in) load center Lift height 4.57 m (15.0 ft) 3629 kg (8000 lb) Full lift height 6.71 m (22.0 ft) 1814 kg (4000 lb) Overall machine weight with 1219 mm (48.0 in) forks with a 2523 kg (5562 lb) counterweight.

2WD 7615 kg (16788 lb) 4WD 7701 kg (16978 lb) NOTE: Weights are approximate and should only be used as a guideline.

8-10

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

9 - ACCESSORIES

9 - ACCESSORIES###_10_### Vandal protection Use cover plates (if equipped) and padlocks to secure the machine from unauthorized use, deter vandalism and theft.

NOTE: Padlocks are not provided.

Console switch covers (if equipped) 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

9 - ACCESSORIES

Telematics - Overview with Case SiteWatch™ NOTE: The CASE CONSTRUCTION SiteWatch™ website (www.casesitewatch.com) will not be accessible until the CASE CONSTRUCTION SiteWatch™ subscription for this machine is registered by an authorized CASE CONSTRUCTION dealer. Contact an authorized CASE CONSTRUCTION dealer for details.

This machine may be equipped with a Telematics system. This is an asset-monitoring system that combines Internet, cellular, and GPS technologies. A transponder unit is mounted on the equipment that wirelessly communicates with the user interface CASE CONSTRUCTION SiteWatch™ at www.casesitwatch.com. Using cellular technology, the transponder can send equipment data, including location, on/off status, usage and production metrics, diagnostic data, movement alarms, unauthorized usage and monitor machine maintenance to the user interface CASE CONSTRUCTION SiteWatch™. The system will help cut costs and keep accurate records.

9-3

9 - ACCESSORIES

9-4

Index ###_Index_###

A Adjusting the forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Auto-regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Auxiliary power outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . . . . . . .

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B . . . . . . . . . . . . . .

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California proposition 65 warning . . . . . . . .

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

Chain rollers . . . . . . . . . . . . . . . . .

Change the display's temperature setting . . . .

CNH Industrial America LLC technical manuals . .

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

Component identification . . . . . . . . . . .

Configure the display . . . . . . . . . . . . .

Console controls . . . . . . . . . . . . . . .

Consumables . . . . . . . . . . . . . . . .

Coolant reservoir (de-aeration reservoir) fluid level

. . . . . . . . . . .

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C . . . . . . . . . . . . . . . . . . . . . .

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Definition of fuse, relay, and diode icons Diagnostic/Service tool port . . . . .

Differential lock system . . . . . . .

Dimension — 586H Forklift . . . . .

Dimension — 588H Forklift . . . . .

Disable parking brake . . . . . . . .

. . . . . .

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D . . . . . . . . . . . .

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E Electrical systems - General specification . . . . . . . . . . .

Electro-Magnetic Compatibility (EMC) . . . . . . . . . . . . .

Emissions overview . . . . . . . . . . . . . . . . . . . . .

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

Engine air pre-cleaner (if equipped) . . . . . . . . . . . . . .

Engine cooling system . . . . . . . . . . . . . . . . . . .

Engine Crankcase Ventilation (CCV) filter . . . . . . . . . . .

Engine - General specification . . . . . . . . . . . . . . . .

Engine - Low Oil Pressure (LOP) . . . . . . . . . . . . . . .

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

Engine oil level . . . . . . . . . . . . . . . . . . . . . . .

Engine oil viscosity - Recommended operating temperature range Engine side panel latch . . . . . . . . . . . . . . . . . . .

Engine speed . . . . . . . . . . . . . . . . . . . . . . .

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. . . 8-4 . . . 1-2 . . . 1-12 7-27, 7-95 . . 7-107 . . 7-100 . . . 7-98 . . . 8-1 . . . 7-34 7-32, 7-83 . . . 7-39 . . . 7-22 . . . 7-3 . . . 4-1

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. . . . 7-110 . . . . . 7-4 . . . . . 7-17 . . . . 7-105 7-75, 7-76, 7-86

Battery . . . . . . . . . .

Battery disconnect . . . . .

Battery fluid level . . . . . .

Before operating the machine Before starting the engine . .

Bleed air from the fuel system Booster battery procedure . .

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. 7-62 . 7-5 . 7-89 . 4-13 . 4-2 7-108 . 4-7

. . 2-10 . . 7-85 . . 7-98 . . 3-15 . . 1-10 . . 4-4 . . 1-7 . . 3-14 . . 3-3 . . 7-18 7-47, 7-70 . . . . . .

. 7-13 . 7-16 . 4-14 . 8-5 . 8-9 7-112

F Fan belt . . . . . . . . . . . . . . . .

Fire extinguisher . . . . . . . . . . . .

Fluid capacities and lubricant specifications Fork inspection . . . . . . . . . . . . .

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

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Forklift removal from storage . . .

Forklift storage . . . . . . . . .

Four-Wheel Drive (4WD) machine Front drive axle . . . . . . . . .

Front drive axle breather valve . .

Front drive axle - drive shaft . . .

Front drive axle fluid level . . . .

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

Fuel handling precautions . . . .

Fuel system water separator . . .

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

Fuses and relays . . . . . . . .

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Hand signals . . . . . . . . . . . . .

Hot temperature operation . . . . . . .

Hour meter . . . . . . . . . . . . .

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

Hydraulic fluid and filter . . . . . . . .

Hydraulic reservoir fluid level . . . . . .

Hydraulic systems - General specification

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. . . 2-26 . . . 4-6 . . . 7-2 7-30, 7-53 . . . 7-87 . . . 7-49 . . . 8-3

General Information . . . . . . . .

General safety before you service. .

General specification - Biodiesel fuels General specification - Diesel fuel .

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. 7-115 . 7-114 . . 4-15 . . 7-90 . . 7-66 . . 7-67 7-44, 7-66 7-57, 7-81 . . 2-11 . . 7-45 . . 7-68 . . 7-9 . . . .

. 7-1 . 7-2 . 7-20 . 7-19

I Instrument control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7 1-2

L Lifting capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Load rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-99 Machine direction . . . . . . . .

Machine orientation . . . . . . .

Machine stability . . . . . . . .

Maintenance chart . . . . . . .

Manual regeneration . . . . . .

Manual storage . . . . . . . . .

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

Mast pivot grease fittings . . . .

Menu screen display . . . . . .

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4-12 1-6 6-1 7-25 7-36 1-11 7-51 7-52 7-51 3-11

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

Note to the owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 1-1

O Oil life reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Operator seat adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Organic Acid Technology (OAT) coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 P Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60 Product Identification Number (PIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Proper entry and exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 R Read the Operator's Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Rear steer axle breather valve - Four-Wheel Drive (4WD) . . . . . . . . . . . . . . . . . . . . . . . 7-64

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

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

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

Regeneration inhibit . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) . . . . . .

Run in period of a new machine . . . . . . . . .

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. . . 7-65 . . . 7-50 . . . 7-93 7-43, 7-63 . . . 3-17 . . . 7-79 . . . 4-1

Safety rules . . . . . . . . . . . .

Safety rules and signal word definitions Safety signs . . . . . . . . . . . .

Seat slides . . . . . . . . . . . . .

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

Shutting down the engine . . . . . .

Side-shift cylinder bearing . . . . . .

Specific precautions to this machine. .

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. . . 9-3 . . . 7-77 7-74, 7-106 . . . 8-11 . . . 5-3 . . . 7-55 . . . 7-91 . . . 4-12 . . . 8-2 7-41, 7-72 . . . 5-1 . . . 4-11

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Telematics - Overview with Case SiteWatch™ Tilt cylinder - Grease . . . . . . . . . . .

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

Torque . . . . . . . . . . . . . . . . .

Towing the machine . . . . . . . . . . . .

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

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

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

Transmission - General specification . . . .

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

Transporting on a trailer . . . . . . . . . .

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

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2-2 2-1 2-14 7-61 7-59 4-9 7-78 2-12

T . . . . . . . . . . . .

U Uniform braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Utility safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 V Vandal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 View or reset Job Timer (JTIME) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 W Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Wheel nut and bolt torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Dealer’s stamp

CNH Industrial 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.

Copyright © 2014 CNH Industrial America LLC. All Rights Reserved.

Case is a registered trademark of CNH Industrial America LLC. Racine Wisconsin 53404 U.S.A.