SUBJECT/PICTORIAL INDEX

CONTENTS

1 TRUCK MODEL ILLUSTRATIONS 2 SUBJECT/PICTORIAL INDEX 4 SAFETY INFORMATION 5 FOREWORD 6 PM- PLANNED MAINTENANCE PROGRAM

GROUP SECT. 01 1 02 1 06 1 06 2 12 1 12 2 16 1 16 2 16 3 19 3 19 4 20 1 22 1 23 1 23 3 26 2 26 3 29 1 30 1 31 1 32 1 32 2 34 1 34 3 34 4 34 7

PMA - PLANNED MAINTENANCE ADJUSTMENT PROCEDURES PM REPORT FORM LUBRICATION CHARTS SEAT CONTROL ROD ADJUSTMENT DIRECTIONAL CONTROL LEVER ADJUSTMENT HORN AND STEERING HANDWHEEL ADJUSTMENT ELECTRIC TRUCK BATTERY MAINTENANCE ELECTRIC TRUCK BATTERY STANDARD U.L. 583 ELECTRIC MOTOR MAINTENANCE DRIVE MOTOR BRUSH REPLACEMENT - GE DRIVE MOTOR BRUSH REPLACEMENT - PRESTOLITE EV-1 #l CARD INITIAL ADJUSTMENT SETTINGS PUMP AND TRACTION CONTROL LED CHECK DRIVE UNIT MAINTENANCE PNEUMATIC TIRE AND WHEEL MAINTENANCE PARKING BRAKE RELEASE BRAKE BLEEDING PROCEDURE STEER WHEEL BEARING MAINTENANCE POWER STEERING RELIEF PRESSURE CHECK HYDRAULIC SUMP FLUID AND FILTER CHANGE HYDRAULIC SYSTEM RELIEF PRESSURE CHECK AND ADJUSTMENT HYDRAULIC SYSTEM SCHEMATIC DIAGRAM TILT CYLINDER ADJUSTMENT TILT CYLINDER DRIFT TEST UPRIGHT LIFT CHAIN CHECK AND ADJUSTMENT UPRIGHT DOWNDRIFT TEST FORK WEAR INSPECTION LIFT CHAIN MAINTENANCE

-REFERENCE INFORMATION

40 1 TRUCK DATA PLATES AND DECALS 40 2 SUGGESTED EQUIPMENT FOR ELECTRIC TRUCK P.M. 40 3 FIRE EXTINGUISHER RECOMMENDATIONS 40 4 LUBRICANT SPECIFICATIONS AND RECOMMENDATIONS 40 5 TRUCK SPECIFICATIONS 40 17 MEASURING VOLTAGES WITH THE V-O-M 40 18 MEASURING RESISTANCE WITH THE V-O-M WIRING DIAGRAM - TRUCK ELECTRICAL SYSTEM

OWNER SAFE MAINTENANCE PRACTICES

Powered industrial trucks may become hazardous if adequate maintenance is not done. Therefore, maintenance facilities, personnel and procedures must be provided.

Maintenance and inspection of all powered industrial trucks should be done in agreement with the recommenda- tion in this manual and the following practices.

1. A scheduled preventive maintenance, lubrication, and inspection system must be followed.

2. Only qualified and authorized personnel should be permitted to maintain, repair, adjust, and inspect industrial trucks.

3. Before Leaving The Truck:

A. Stop Truck.

B. Fully lower the load engaging means.

C. Put directional controls in neutral.

D. Apply the parking brake.

E. Stop the engine or turn off power.

F. Lock the control or ignition circuit.

G. Put blocks at the wheels if truck is on a ramp, or being worked on.

4. Before Working On Truck:

A. Raise wheels free of floor or disconnect power source. B. Use blocks or other positive truck positioning devices.

C. Put blocks under the load engaging means, inner-mast(s), or chassis before working under them.

Before working on engine fuel system of gasoline powered trucks with gravity feed fuel systems, make sure fuel shutoff valve is closed.

Before working on engine fuel system of LP gas powered trucks, close LP gas cylinder valve and run engine until there is no more fuel in the system and engine stops running.

Operation to check performance of the truck or attachments must be done in a clear, authorized, safe area.

5. Before Starting To Operate The Truck:

A. Be in operating position.

B. Push clutch (or brake pedal on automatic transmission and electric trucks).

C. Put the directional controls in neutral.

D. Start engine or turn on power.

E. Before operating truck, check functioning of lift and tilt systems, directional and speed controls, steering, warning devices, brakes, and any attachment. (If used)

F. Release parking brake.