Terex Handlers TH528C Operator's Manual 236499 - PDF DOWNLOAD

236499

OPERATOR'S MANUAL

TH528C ~ TEREX HANDLERS 455 N. Superior Ave. Baraga, MI 49908-0790 Ph. (906) 353-6675 Fax (906) 353-7543 http://www.terexlift.com 09/15/02

TABLE OF CONTENTS SECTION 1

ROUGH TERRAIN FORKLIFTSAFETY Introduction Standards And Symbols Safety TrainingAnd Knowledge Operator's Responsibilities Management's Responsibilities Maintenance And Repair Operation Safety

1-1 1-3 1-4 1-5 1-5 1-6 1-7 1-8 1-9

SECTION 2

GENERAL SAFETY General Safety Procedures Jump Starting Proper Load Chart Use

2-1 2-3 2-8 2-9

SECTION 3

CONTROLSAND INSTRUMENTS Operator's Compartment Joystick Control Functions Joystick Control Functions (Button Pushed) Service Brakes Parking Brake Frame Sway Control Gauges Hydraulic Pump Destroke Button Steering Transmission

3-1 3-3 3-4 3-5 3-6 3-6 3-7 3-8 3-8 3-9 3-9

SECTION 4

OPERATION Operation And Safety Guidelines Before Starting The Engine Starting The Engine Before Operating The Forklift TransportingALoad Placing A Load

4-1 4-3 4-4 4-9 4-11 4-15 4-17

SECTION 5

MAINTENANCE PROCEDURES General Safety Practices Service Intervals Required Grease Intervals Grease Fitting Locations Daily Maintenance Procedures 50 Hour Maintenance Procedures 100 Hour Maintenance Procedures 250 Hour Maintenance Procedures 500 Hour Maintenance Procedures 750 Hour Maintenance Procedures 1000 Hour Maintenance Procedures 2000 Hour Maintenance Procedures Filter Guide Recommended FluidsAnd Capacities Hydraulic Pressure Settings

5-1 5-3 5-5 5-6 5-7 5-8 5-12 5-18 5-20 5-22 5-23 5-24 5-25 5-26 5-26 5-27

SECTION 6

MATERIAL SAFETYDATASHEETS

6-1

SECTION 1

ROVel! TERRAIN FORK LIFT SAFETY

1- 1

TABLE OF CONTENTS

SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY

mtroduction

1-3

StandardsAnd Symbols

1-4

Safety

1-5

TrainingAnd Knowledge

1-5

Operator's Responsibilities

1-6

Management's Responsibilities

1

Maintenance And Repair

1-8

Operation Safety

1-9

1-2

(ffiROUGH TERRAIN FORK LIFT SAFETY ~ ~

INTRODUCTION

Owners, Users, and Operators: (Handlers) appreciates your choice ofour machine for your application. Our number one priority is user safety, which is best achieved by ourjoint efforts. We feel that you make a major contribution to safety ifyou, as the equipment users and operators:

1. Comply with OSHA, Federal, State, and Local Regulations.

2. Read, Understand, and Follow the instructions in this and other manuals supplied withthis machine.

3. Use Good Safe Work Practices in a common sense way.

4. Only have trained/certified operators - directed by informed and knowledgeable supervision- running the machine.

NOTE: OSHAprohibits the alteration ormodification ofthis machine without written manufacturer's approval. Use only factory approved parts to service or repair this machine.

Ifthere is anything in this manual that is not clear or which you believe should be added, please send your comments to the Manager ofPublications, Terex Handlers, P.O. Box 790, Baraga, Michigan 49908. Telephone number 906-353-6675.

Thank you!

THIS SYMBOL ANS YOUR SAF TY IS INVOLVED I RE , U ERSTAND AND FOLLOW L DAN R, WARNING AND CAUTION DECALS ON YOUR ROUGH TERRAIN FORKLIFT.

1 3

n

TERRAIN FORK LI ST)~NI_AEtDS AND SY

SAFETYLt

OLS

I STANDARDS I Many aspects ofrough terrain forklift operation and testing are discussed in standards published by the American National Standards Institute. These Standards are updated on a regular basis with addendas. recommends that you purchase and refer to the following standards.

ANSI B56.6 - Rough Terrain Fork Lifts This Standard can be purchased from: American National Standards Institute 25 West 43nd'Street, 4thFI. New York, New York, 10036 Tel. 212.642.4900 Fax. 212.398.0023

I

SYMBOLS

I

The symbols below are used to inform the operator ofimportant information concerning the operation ofthis machine.

DANGER

DANGER- Indicates an imminentlyhazardous situation which, ifnot avoided, will result in death or serious injury.

WARNING

WARNING - Indicates a potentially hazardous situation which, ifnot avoided, could result in death or serious mJ~

CAUTION

CAUTION- Indicates a potentiallyhazardous situation which, ifnot avoided, may result in minor or moderate 111J~

ATTENTION

ATTENTION - Indicates a situation which, ifnot avoided, may result in property or equipment damage.

1-4

& ROUGH

RRAIN

I''-1I

1FT SAFETY &

SAFETY

m

lliiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiil These are general safety rules, which must be followed. You are also required to read and understand the Operator's Manual as there are instructions, which are more detailed specific to this machine.

TRAINING AND KN()WLEDGE

1. Safety must always be the operator's most important concern.

This machine must onlybe operated by trained personnel, who have demonstrated their ability to do so safely.

3. Complywith the requirements ofcurrent Occupational Safety and Health Administration (OSHA) standards, including29CFR1910.178; and the American National Standards Institute (ANSI) latest edition.

4. Read and Understand all Decals and Warnings.

5. Read and Understand the Rating Chart.

6. Know that the machine can safety lift each load before attempting to lift.

1-5

ifsRO

TERRAIN FORK LIFT SAF OPEKA.J..uR'S RESPONSIBILITIES

1. Read and understand the Operator's Manual.

2. Know the location and the purpose ofthe controls, instruments and indicator lights.

3. Make sure the machine is in proper order and all operational aids and warning signals are functional before operating.

4. Keep the machine clean, including all instrumentation, windows, lights and other glazed surfaces.

5. Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, hard hats, safety glasses and ear protection where necessary.

6. Wear protective clothing that is snug and belted where required.

7. Store tools and other necessary items in the toolbox.

8.

lift a load without a Load Rating Chart in the cab.

9. Know the load to be lifted.

10. Be alert, physically fit and free from the influences ofalcohol, drugs or medications that might affect the operator's eyesight, hearing, or reactions.

11. Keep people, equipment and material out ofthe work area.

12.

a fully charged fire extinguisher and first aid kit in the cab at all times, and be familiar with how to use these items.

13. Know about movements ofother machinery, trucks and personnel at the j obsite.

14. Make sure is in a safe place outriggers (ifso equipped.)

moving the boom, forks, load or

15. Start and stop movements smoothly and swing at speeds that will keep the load under control.

1-6

ffi ROUGH

U

RRAIN FORK LIFT SAETY ffi MANAGEMENT'S RESPONSIBILITIES

1. Ensure operators are competent, physically fit, trained and ifrequired licensed.

2. Have a supervisor at the job site to be responsible for job safety.

3. Crew members given specific safetyresponsibilities and instructed to report any unsafe conditions to the supervisor.

4. Supply the weight on the load to be lifted to the operator.

5. Verify that all crewmembers are familiar with OSHA,ANSIB56.6 requirements as well as instructions in the manuals.

1-7

D

GH TERRAIN FORK LI

SAFETYLt

MAINTENANCE AND REPAIR

1. Practice safe maintenance procedures. Perform all maintenance and repairs in accordance with instructions provided by the manufacturer in the manuals. Also heed the warnings on the placards and decals on the machine.

Always use supports and braces when working on, under or around the machine or forks.

Shut 0 the and lockout the machine while working on the machine unless instructions specificallyrequire the engine to be running.

4. Always make sure the machine is stationaryprior to performing adjustments or lubrication.

5. Replace all shields and guards after performing service.

6.

use a piece ofcardboard or paper to search for leaks.

7. When performing work on the hydraulic system: Lower the boom to horizontal. n. Support the boom with supports or braces. m. Shut down the engine.

Relieve all pressure before disconnecting lines. v. all connections are tight before applying pressure.

VI. Repair or replace any damaged line, hose or fitting before applying pressure.

1

8.

C"t:)o-rl[T"Ii"";:::.n

and mounted by a qualified person with the proper

tools and guards.

9. Always use an inflation cage during tire inflation.

10. Onlyperform welding on the machine with approval from the manufacturer.

1-8

ffS ROUGH Tl:V···l>l>

ORKLIFTSA

OPERATION SAFETY

1. Always inspect the machine daily. Check for leaks, worn hoses, loose belts, broken structures, and loose or missing bolts. Repair and/replace any worn, damaged or leaking parts prior to operation ofthe machine.

2. Only inspect the coolant level when the engine and coolant are cool.

Be sure that all guards and screens are secure and in the proper place.

4. Inspect for and clear the work area ofany obstructions that could interfere with proper machine operation. Any obstructions that cannot be cleared should be clearly marked and avoided during operation.

5. Refueling: Always stop the engine before refueling the machine.

11. Fill the fuel tank outdoors.

Handle fuel with care, as it is highly flammable. Do not refuel the machine while smoking or near open flames. l~ Always cleanup spilled fuel.

L

6. Make sure the machine and access system is clean and free ofdirt, oil, grease or debris.

7. When getting on and offthe machine, face the machine, use the steps and handrails provided, and always maintain a three point contact.

8. Always remain completelyinside the cab enclosure while operating the machine.

9. Always wear the seat belt while operating the machine.

10. Always completely lower the boom with the forks resting on the ground before any work is performed on or around the machine.

11. Do not operate the while people are under or near an elevated boom whether the boom is loaded or unloaded. Falling objects from the forks or attachment may cause serious injury or death.

1-9

D

~ROUGH TERRAIN FO

IFTSAF

OPERATION SAFETY

12. Maintain an appropriate clearance from electrical power lines. See the chart below for minimum safe approach distances.

Minimum Safe Approach Distance Required Clearance 10 ft. (3.00 m) o to 50 kV 15 ft. (4.60 m) 50 to 200 kV 20 ft. (6.10 m) 200 to 350 kV 25 ft. (7.62 m) 350 to 500 kV 35 ft. (10.67 m) 500 to 750 kV 45 ft. (13.72 m) OOkV 750 t '·T_14._~_ v """!!..-o-

13. Lifting Loads: Using the load chart, confirm that the load is within the rated capacityofthe machine for the required configuration. n. the machine using the level lifting loads. Use the sway control to level the machine only when the boom is at horizontal or lower. Using the sway control with the boom above horizontal may cause the machine to overturn. m. Verify that the load is secured on the forks before perfonning a lift.

Rearrange the load ifnecessary.

1~ Before lowering a maximum load, always retract the boom completely. v. Use proper attachments, such as a truss boom, to lift suspended loads.

L

14. Ifthe load to be lifted the capacity ofthe configuration: i Move the machine closer to the load so that the weight ofthe load will be within the allowable load chart specifications. n. Divide the load into smallerpieces. m. Get a larger machine capable ofhandling the load. "t'rll::llf""t"\'1l"O

15. Always move a load so that you have maximum machine stability and visibility is not obstructed. the boom at or below horizontal, with the load close to the ground.

16. Tilt the forks back towards the machine slightly during travel to ensure stability of load.

1-10

OUG

IN FORK LI T SAFETY Lt OPERATION SAFETY

17. Inspect the path oftravel before beginning movement. Avoid holes and dropoffs.

18. Traveling on slopes/grades. i Ascend and descend slowly and with caution. ii When loaded, always travel with the load uphill. iii When unloaded,travel with the attachment downhill.

IV: Avoid turning, travel straight up and down.

19. Always position all wheels in line with the machine before switching the steering mode.

20. Always position the machine and set the park brake before lifting a load.

21. Do not allow riders on the machine or forks.

22. Do not transport or lift personnel into positionwith this forklift.

23. When leaving the operators station: i ace the directional controls in neutral. ii Apply the parking brake. iii Lower the attachment to the ground.

1-11

SECTION 2 G NERALSAFETY

2-1

TABLE OF CONTENTS

SECTION 2 - GENERAL SAFETY

General Safety Procedures

2-3

Jump Starting

2-8

u .............. _,O......

Load Chart Use

2-9

-2

it GENERAL SAFETY it GEN__ ~"_SAFETYPRDC~EDIURES

SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all messages to avoid and/or death.

& WARNING ALWAYS wear eye protection and personal safety equipment.

THE OPERATOR The operator must be fully trained and qualified to operate this machine.

Before or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. and instruction labels

ACCIDENT PREVENTION _ ...."+,a"'11-1-.:r,a

clo'thlIlg and use equipment such as: boots, and ear protection when necessary.

Wear _.. .,,+~1""'1h-.:T~ CIO"thUlg that is snug and belted where

FIRE PREVENTION/FIRST AID Install a first-aid kit and fITe extinguisher in the operator's cab.

KEEP THE FIRST-AID KIT andFIREEXTINGUISHER maintained. Follow instructions first-aid kit and fITe extmgulsJtler.

_vo,,_ovol-.:r

with the

2-3

GENERAL SAFETY GENERA~LS~AFET'YPR()UEDlJRES

WELDING PRECAUTIONS

~UAUTI()N unauthorized welding can cause structural failure or POS,Slllle personal injury. DO NOT weld on any structural un2Lutl1l0rtZea weJLd.lfLQ will void the warranty.

HAND HOLDS AND STEPS

~W.ARNIN"G and falls can cause serious injury. maintain a three When on and off the maChIne" contact with and hand rails while the machine.

DO NOT use the

ClTJ:lIt::lY1'1'11l'1"

wheel or any other controls as handrails.

NEVERjump on or offthe machine. conditions on platforms, steps and on and off the machine.

ALWAYS shut off the

before

the operator's station.

REFUELING

& WARNING Fires can cause death or severe personal injury.

Handle fuel with care. It is flammable. DO NOT refuel the machine while or when near open flames or sparks. the fuel tank outdoors.

ALWAYS

before retuel:mg the machine. Fill the

Prevent fires by the machine clean of trash, grease and debris. ALWAYS clean up spilled fuel.

2-4

~ GENERAL SAFETY ~ GE

RALSAFETYPROCEDURES

HYDRAULICSAFETY

~WA.RNING Hot hydraulic oil can cause severe bums. DO NOT work on the hydraulic if the oil temperature exceeds 120 F. (49 C).

Before ANYONE works on the hydraulic system: 1.

2.

3.

4.

5.

Lower the boom to the horizontal position. the boom to avoid unintentional lowering.

Shutdown the R.emove the from the ignition.

Clean the area around the oil reservoir cap (A).

A FLUIDS UNDER PRESSURE

~WA.RNING

bS(;apmg fluid under pressure can penetrate the skin and can cause serious injury. of cardboard or paper to search for leaks.

Use a DO NOT use hands! Before hydraulic be sure to relieve all line pressure. Before pressure to the be sure that all connections are DO NOT apply pressure to a hose or by fluid, see a doctor at once. Proper medical administered immediately. A serious infection or reaction can result without proper medical treatment.

SERVICE TIRES SAFELY

~WA.RNING An ImlJrOloerJLV mounted tire can result in tire An inflation cage possible personal device must be used during tire inflation. or other DO NOT eCllllPlm.eltlt and have the proper dealer or

to mount a tire unless you have the proper to perform the job. If you do not to the job have your 1rho¥o~""lll¥ service

\.IAL.I\.I.L.1.V.L.L""'V

""'a..'·...n-r""'l"Vl

2-5

G NERALSA

TY

GENERALSAFETYPROCE

RES

ffi CAUTION USE SEATBELT Always wear the seat belt while OP(~ratlng the machine to reduce the risk injury.

ffi CAUTION PRACTICE SAFE MAINTENANCE Unauthorized modifications to the machine machine function and!or affect machine life.

the

ALWAYS use a or brace when working on, under, or around the machine or forks.

DO NOT

or lubricate the machine while it is in motion.

SHUT OFF the and LOCKOUT the ignition while on the machine unless the maintenance instructions the to be . . . . .

..... r"'11"'Irll ...... rr

'1"1•..." ........ lT

REPLACE all the shields and

after

ClA'l"'tnI"'11'lT

NEVER use the machine as a platform for lifting personal.

ffi CAUTION BOOM SAFETY DO NOT enter the DANGER AREA under or around the boom when the forks are off the ground or while the engine is running.

(See diagram at right for DANGERAREA).

oersonal injury could result if the boom should une'xnt~cteC11V drop.

Before ANY work is performed in the DANGER AREA the boommust be COMPLETELY lowered and the forks must be on the

2-6

LL GEN RAL SAFETY Lts SAFETY

GE

AVOID ELECTRICAL POWER LINES

~DA.NGER

L~'~~JLL~~CLEARANCEFORNORMALVOLTAGEm

OPERATIONNEARIDGH VOLTAGE POWERLINESAND OPERATION m TRANSIT WITH NO LOAD AND BOOM OR MAST LOWERED. Minimum Required Clearance, ft. (m) 10(3.05) 15(4.60) 20(6.10) 25(7.62) 35(10.67) 45(13.72)

to 50 Over 50 to 200 Over 200 to 350 Over 350 to 500 Over 500 to 750 Over 750 to 1000 Transit With No Load and Boom Lowered

Operation

to 0.75 Over 0.75 to 50 Over 50 to 345 Over 345 to 750 Over 750 to 1000

6«(1.83) 10(3.05) 16(4.87) 20(6.10)

~WARNING

remain ,.......... "':.......... +,......... the machine.

inside the cab enclosure while

rr

WARNING Never this machine under the influence of drugs, alcohol and/or medication which can cause drowsiness.

~ WARNING Never transport or lift personnel into position with this forklift. It is not as a personnel device.

2-7

()CEDURES

GENERAL SAFETY JUMP STARTING

Location: The battery is located behind the battery box compartment cover (A).

JUMP STARTING Jump starting at the battery or battery replacement is required when the battery is to the point where the battery will not crank the starter.

& WARNING Never jump start the machine directly to the starter or the starter solenoid. Serious injury or death could result from the machine forward or backward.

L:LWARNING To avoid with another maChIne., be certain that the machines are not touching. Never start a as it will explode. Keep and flames away from the Lead acid batteries ('T~n~'1"-::""~ ~V'1",lnC'1""~ gases when Wear glasses when near batteries. ,{"I:Trt.11"'1r'1'1"lcr

The booster battery must be a 12 volt type. The machine used for jump must have a ground electrical system. start the proceed as follows: cable to the nn'~11'1"TA

2. Connect the other end of the same of the booster 3. Connect one end of the post of the booster

cable to the

cable to the

4. Make the final cable connection to the block or the furthest away from the battery.

5. Start the 6. Remove the jumper cables in the reverse order oftheir connection cable connection etc.)

2-8

A

Lt GENERAL SAFE P

R LOAD CHART USE

LtWARNING NEVER raise a load and drive to position it. This can cause the machine to turnover. When a load, always move a loaded machine with the boom angle indicator (B) at +2 1/2 or less. When the machine is as close as possible to where the load needs to be set the parking brake, raise the then the load into position.

The load chart shows the limits of a properly maintained and machine. To use the load chart the ooe,ratCJr must know the of the load and how far "out" and "up" it is to be placed. If the load is heavier than stated on the load three options can be used: 1. Move the machine closer to the load so that the the load will fall within the load chart specifications.

2. Divide the load into smaller into load chart soe,cI1JLcal10ElS. 3.

so that each

of

falls

machine capable of handling the load within

TEREX HANDLERS

2-9

B

SECTION 3 CQNTROLSAND INSTRUMENTS

3-1

TABLE OF CONTENTS

SECTION 3 - CONTROLS AND INSTRUMENTS

Compartment

3-3

Joystick Control Functions

3-4

Control Functions (Button Pushed)

3-5 3-6 3-6 3-7 3-8

YUJ..u,u...l..l.V

Pump Destroke Button

3-8 3-9 3-9

3-2

CONTROLS AND INSTR MENTS OPE

R'S COMPART

T

1. Accelerator Pedal

7.

Load Chart

13. Frame Level Switch

19. Auxiliary Hydraulics

2. Joystick 4-way Controller

8.

Hourmeter

14.

20.

Steering Wheel

3. Transmission Control Lever

9.

Gauges

15. Parking Brake Handle

21.

Headlight Switch

10. Machine Level Gauge

16. Pump OffButton

22.

Heater Switch

11. Plug / 12 Volt Access.

17. Windshield Wiper

23. Plug / Tum Signal Wires

12.

18.

24.

Selector

4.

5. Service Brake Pedal Brake Warning Light

6.

Seat

Seat Belt

Ignition Switch

20

4

6

20

Interior Rear View Mirror

2

9

16

7

14

13

3

23

21

22

17

19

18

11

3-3

co

S AND INSTRUMENTS JOYSTICK CONTROL FUNCTIONS

A - BoomDown

A

B - BoomUp

t ~~(L""~~~"",

C

B

~

B

A

Boom Out

D - BoomIn

D-

... c

c-

E H,t/ A

E

Boom Down and Out

F -. BoomUpandIn

D-

G - Boom Up and Out

-C

t----W! I'" F

H - Boom Down and In

,

I----........---j

B 3-4

G

CONTROLS

INSTRUMENTS

JOYSTICK CONTROL FUNCTIONS (BUT170N PUSHED)

A - TiltDown

A

B - TiltBack

t

\,'~~~'L'r~

~~,(

-

~

B

3-5

CONTROLSANDINSTR-··-~~~ TS SE

ICE BRAKES

The brake pedal is the operator's control for the service brakes.

I-'l1<::lh11110 the service brake pedal (A) activates the service brakes for all four wheels.

The brakes should be applied during normal operation to stop machine movement.

A

PARKING BRAKE

~WARNING Failure to set the brake before the machine may result in unintended machine movement and possible injury or death and/or to the machine or _.. . __ 0 ......h 7

brake should be enE~agt~<1 ~lrlvt1I1m~ the operator off the machine. To engage the brake, move handle to the "BRAKE ON" oosilt1on.

The

B

3-6

CONTROLS AND INS FRAME SWAY CONT~ROL

~WARNING ensure that the machine level indicator (D) is at zero (0) Ue!;~let;~ before the boom. the boom with an unlevel machine may cause the machine to overturn, resulting in injury or death.

& WARNING Use the frame sway control to level the machine only when the boom indicator is at +2 1/2 or less. the frame sway control when the indicator is more than +2 1/2 may cause the machine to overturn, in or death.

The frame sway control (C) is located on the dash panel. The frame sway control is used in conjunction with the machine level indicator (D) located in the center ofthe cross support that the interior rear view mirror is mounted on. The sway control switch is either to the left or depending on the oaltlclUlaJr reOUJlfelneIlt.

c

3-7

CONTROLSANDINSTRUME GAUGES

The following gauges are used to monitor the machine:

1 - Fuel Level 2 - Oil I

'01"\"'l1"\O'1"'t:llll'l'1"'O

Powershift Transmission

3 - Oill.J't"tJo C'C'111t"tJo Powershift Transmission 1

4 - Voltmeter 5 - Water Temperature, 6 - Oill.J't"tJoC'C'll'rtJo

HYDKAULIC PUMP D STROKE BUTTON

~ DANG R

VelprelsslrLg the pump destroke button while the machine will cause an immediate loss power, nnQQ1hll"l' a very situation. Hydraulic functions that will be affected are: FORK TILT, L BOOM EXTEND and RETRACT, PARKING BRAKE and SWAY. None of these functions will as as the button is depressed. The Service Brakes will continue to function if the accumulator backup has a sufficient gas .... '1"'O,I:lf".. '1"'lcr

The pump destroke button switch located on the dash

is the black push button

the machine for the first time on a 30 the pump destroke button while Continue to the button for 15 to 20 seconds after the starts. Once the is smoothly, release the button and the pump will engage.

UelDre~)Sll1lg the pump destroke button will not be for all other starts of the unless the has been allowed to cool cornplieteJlv,

3-8

A

S

CONTR

ANDINSTR ST

ENTS

RING

In addition to the C'T~,3r.. -rH"r wheel, the machine has another u'"'''''',''''.. . . . . control, the selector switch. .L.I..

B The selector switch (B) is a three-position switch.

The three positions are: 4-wheel, 2-wheel , and oblique.

Switch are selected and function as follows: 4-WHEEL

Handle

2-WHEEL

Handle

OBLIQUE (CRAB)

Handle left ofcenter

centered

& CAUTION Before selections, make sure all four wheels are in line. Failure to align the wheels to the proper before may cause hal)ha,Zal~d u'"'''''''''''......

This may result in injury to personnel and/or to the machine or _r£,_~.rn7

I..L.LJM,..

TRANSMISSION The transmission control (C) has one lever that controls both directional and It is located on the left side of the column.

To shift into Forward gear move the lever upward.

the

toward you and

To shift into Neutral move the lever to the center DO:Sltlon.

To shift into Reverse gear move the lever downward.

pull the lever toward you and

To shift into a lower

rotate the lever clockwise.

To shift into

rotate the lever counter-clockwise.

When the transmission from forward to reverse while the machine is in motion the transmission control (C) must be in 1st or 2nd gear only.

Forward Itst Forward 12nd Forward 13rd

c 3-9

SECTION 4 OPERATION

TABLE OF CONTEN S SECTION 4 - OPERATION

Operation And SafetyGuidelines

4-3

Starting The Hncn'nA

4-4

......,_.L'-'..... _

4-9 .......

~ ,,"r~ II

Operating The Forklift

4-11 4-15 4-17

o ERATION OPE.&~TIONA

lD ~SA]~ElrY ~GUIDELINES

LLWARNING Your and the of those around you depends upon you using care and judgement in the operation of this equipment.

Know the positions and functions of all controls before attempting to operate this machine. All equipment has limitations.

Understand the braking, stability, and load chart characteristics of this machine before operating. Read the Manual and ask of your supervisor until you know the machine's limitations. It is very important to fully and follow these operation and safety guidelines. , ..... "'"'....,.. ............... l"I

1. DO NOT this machine while are under or near an elevated boom whether the boom is loaded or unloaded. objects from the forks or attachment may cause serious injury or death. debris can cause serious

2. ALWAYS remain cornplieteJlvwithin the cab enclosure while operating this machine. injury or death. _ o....C"n_t:'Il

3. NEVER extend a load beyond the load chart band. Machine turn over, component damage, injury or death could occur.

4. ABSOLUTELY NO RIDERS SHOULD BE ALLOWED ON TIllS MACHINE OR ATTACHMENTS. 5. NEVER lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur.

6. INSPECT and clear the working area obstructions fence, wire, that could cause machine If obstructions cannot be cleared, mark the obstructions with a stake or other marker that will be clearly visible to the operator.

7. DO NOT check the coolant.

coolant level if the

has recently been run. Injury could occur from esc:ap:mg hot

n"t"t:l>Cl Clll"t"""'7Arf

8. ALWAYS wear the seat belt when operating this machine. the machine daily. Check for leaks, worn loose belts, or anything out of the ordinary. Repair any worn, or parts l11lIne(llate lY. Failure to do so can cause injury or death.

10. CHECK to be sure that all guards and screens are secure and in their proper place.

11. CHECK to be sure that all devices such as parking brake, service level gauge, neutral start and hom are functioning properly. Always make sure the mirrors are adjusted properly.

switch,

12. DO NOT travel on terrain or in dangerous areas that could cause the machine to tip over.

13. DO NOT

to start the

towing or _1'1£~ h'1 ......'n ,l.Jw.........w-.'" to the powershift transmission could result.

14. CARRY A LOAD so that you have maximum machine stability and visibility is not obstructed.

15. ALWAYS level the machine as indicated on the machine level indicator before unlevel machine may cause the machine to overturn injury or death.

the boom. ---'----"l""'l the boom with an

16. USE the frame sway control to level the machine only when the boom position is horizontal or lower. the frame sway control when the boom is higher than a horizontal position may cause the machine to overturn causing injury or death. the pump destroke button while operating the machine. This button should be used only during cold start ups. the button while the machine will cause an immediate loss of hydraulic power that will affect fork tilt, lift, boom extend and retract, sway and all other hydraulic functions. The brakes will continue to function if the accumulator backup has a sufficient gas

4-3

OPERATION BEF()RE STARTING TH

NGINE

& WARNING DO NOT in this "BEFORE STARTING ENGINE", unless the machine's is turned off and the brake is and the is cool. Failure to do so may result in serious injury, death or damage to the equipment.

Walk around the machine and check for any parts that are worn, or Repair and/or replace any worn, damaged, or leaking parts.

.L.L.LI.o..:.U.L.L.L.F-."

CHECK ENGINE OIL LEVEL

Location: To Check:

The machine must be level.

Check when the

A

is cold.

Remove the dipstick from the Oil should read between the add and the full marks. .1.'\..vIJJc.U.,1V

NOTE:

the dipstick.

Refer to page 5-26 of this manual for proper oil specification and capacities.

4-4

OPERA

ON

BEFORE STA TING THE EN

~WARNING

B

DO NOT check the coolant level if the has been run Injury may occur from hot esc~an:me: pressurized coolant.

-rt:l>I"",l'3nf"II'fT

CHECKENGINE COOLANTLEVEL Location:

Tank cap (B).

To Check:

Coolant should be visible in the top of the tank.

NOTE:

If coolant needs to be added fill with a 50/50 mixture of water and ethylene-glycol based antifree~~e. (-34 F)

DRAIN FUEL-WATER SEPARATOR Location:

Fuel-Water seUlaraLtor filter (C).

To Open:

Shut off the

c

Use your hand to open the drain valve on the bottom of the filter.

Tum the valve counterclockwise 4 complete turns until the valve drops down 1 inch.

Drain until clear fuel is visible.

Push the valve up and tum the valve clockwise to close the drain valve.

~CAUTION

Do not "'T,.",.~t'"'rh+L"'_ the valve. threads.

NOTE:

~VeJrt12:hte:nmlg can damage the

If more than 2 offuel are drained, refilling of the filter required to prevent hard starting. Refer to filter replacement on page 5-22 of this manual.

4-5

•··••·.. . ERATION INE

BEFORE ST

CHECKHYDRAULIC OIL LEVEL Location:

Sight (A).On the right hand side of the frame behind the right front tire.

To Check:

Move the machine to level ground.

Level the frame.

Comttletelv' re1tra<:t tJle boom.

Position the forks level.

Lower the boom to the ground.

Oil should be visible 1/2 way in the sight glass.

NOTE:

A

Refer to page 5-26 of this manual for proper oil specification capacities.

INSPECT AIR CLEANER Location:

Air cleaner assembly (B). Located in the air cleaner compartment on hand side ofthe machine behind the air cleaner cover (C).

To Check:

Remove the rear ofthe ............. the filter element.

Guideline:

the filter element for contamination. the to the filter body from the for cracks or leaks. the air cleaner body and for cracks or leaks.

1C'1+.3....

remove

c

& WARNING Due to various the air cleaner's element should be changed as often as the environment reCIUll~es.

4-6

B

OPERATION

CHECK TRANSMISSION OIL LEVEL Location:

Dipstick (D).

D

machine.

To Check:

the transmission control in neutral. parking brake. must be running to check. trallsIIllsslon oil temperature to a

. . . ····_···,--<L?F. nA't1('iTA&:lln

dipstick. The oil level should be the add and full marks.

this manual for proper oil

& WARNING can result from a loose or damaged fan. and/or

be(~aUf)e this may cause

CHECK ENGINE FAN To Check:

E

4-7

OERATION

CHECK TIRE FOR PROPER INFLATION

Location:

Wheel ends.

To Check:

Check pre,SSUlre with the tire cold and a properly tunctl()mru!: pressure gauge. Position the to the top of the tire just in case the tire been filled with an optional

Setting:

50 PSI.

A

4-8

OPERATION STARTING T'RE ENGINE

& DANGER problems discovered in the steps prior to "BEFORE STARTING ENGINE" should be corrected before the machine is started.

& DANGER NEVER to start the machine without being seated in the r._ck....ni-,n....'CI ror."Mn_n~IO......i- the brake (B) in the on POS.lUCln and the transmission control (C) in the neutral position. to start the machine from outside the may result in property damage, serious operator's injury or death.

& DANGER If the machine should start with the transmission control lever operation at once or damage, serious (C) in gear, injury or death may occur. Have a qualified service technician machine.

...L:lt_,n ...... 1- ..... L:lt

Insert the . . ~ . . r,...... clockwise until the starts.

1-...

in the ignition switch (D). Rotate the starts. Release the key when the

D 4-9

OPERATION STARTI

THE ENGINE

ffiCAUTION If the fails to start within 30 seconds release the wait at least 2 minutes to allow the starter motor to cool before If the fails to start after four attempts, troubleshoot and correct the problem. DO NOT turn the key if the is This may cause to the starter motor.

ffiCAUTION Att emlDtlIlg to start the

by towing or pushing the machine will result in (1atna~~e to the powershift transmission and will not start the It also is an unsafe that could cause personal injury.

1

4-10

o

TION

BEFORE OPERATING THE FORKLIFT LtCAUTION gauge does not fall within the set tolerances the machine must be repaired before operation.

Check the dash mounted gauges for logical (1)

Fuel

1/2 to Full

(2)

Transmission Oil Temp.

180°F to 200°F

(3)

Transmission Oil PSI.

240 to 280 PSI

(4)

Volt

12 to 14

(5)

Engine Water Temp.

180°F to 200°F

(6)

Engine Oil PSI

40 to 80 PSI

-) a

E H,t/

STANDARD JOYSTICK FUNCTIONS

controller momentarily in all directions.

A

.. c

o ..

~E~I'" j1

A Boom Down B - Boom Up C - Boom Out D -Boom In E - Boom Down and Out F - Boom Up and In G Boom Up and Out H Boom Down and In

G

BUTTON DEPRESSED FUNCTIONS

A

t [

B - Tilt Back

I I I I

I I

B

4-11

A - Tilt Forward

BEFORE OP

Operate the

TING THE FORKLIFT

sway control (A) momentarily right and left.

A

c

the wheel (B) dlflectl.on. Ifthe front and rear '1"'\'f"nnPo'f"lu stral~~htf~n the rear wheels with

B -12

OPERATION BEF()

()PEM

G THE F()RKLIFT

LLDANGER problems with the service brakes or the parking brake found while conducting the daily inspection should be corrected Failure to do so could result in injury or death.

Activate the transmission the transmission control lever (D). As soon as the machine starts to move, apply the service brake peda1. The machine should stop immediately.

D

the brake (E). The machine should not be able to be driven. Release the parking brake.

E

4-13

o

RATION

BEFORE OPERATING THE F()RlCLIFT

& DANGER Never operate the machine with a faulty backup alarm. Doing so may result in serious injury or death.

Place the transmission control lever (A) in reverse. The backup alarm should sound. If it does not sound, have the backup

A

B

Check and adjust both the interior rear view mirror (B) and the

c

4-14

o

TION

TRANSI'()~f{TING A LOAD

ffiWARNING a load with the boom extended and the boom indicator arrow (D) more than +2 1/2 could cause a roll over hazard.

I 'ro"nCt_,n'.."·1'.... nrr

& WARNING At no time should any load be suspended from the forks by use of ropes, etc. If a load must be suspended the use of a truss (jib) boom is mandatory. Proper procedures should always be followed.

The forks should always be tilted back slightly during transportation to ensure stability of the load.

D

The load should be as low to the as possible while Always move a loaded machine with the boom indicator arrow (D) at +2 1/2 or less.

4-15

OPERATION TRANSPORTING A LOAD

& WARNING Slower

should be used whenever a load. bring the machine to a complete stop before reversing the transmission control lever (A). Failure to do so can result in to the load, the machine and/or bystanders.

A

Always

the boom retracted to ensure

stability.

the load in the center and completely the back ofthe fork frame. so stability will result.

IMPORTANT: Never attempt to use the forks and/or attachments for or frozen loads free. to the load, pallet and/or machine could result.

4-16

PLi\.C][NG A LOAD

~ WARNING

B

Do not sway the machine with the boom angle indicator arrow (B) at more than +2 1/2 By so you could cause a roll over hazard which may result in injury or death.

~ DANGER Always apply the brake (C) before lifting and/or a load. Failure to do so could allow the machine to roll over which may result in injury or death.

~ CAUTION the machine to a complete stop before applying (C). Failure to do so will damage the parking which may void the axle warranty.

Before placing a load, the frame should be leveled. This can be done by the use of the switch labeled sway control (D) located on the lower hand side of the dash panel in front of the

E

Adjust the sway control (D) until the indicator ball on the level gauge is on the 0 mark.

4-17

OPERATION PLACING A OAD A

& DANGER ItavellnQwith a ofmore than +2 1/2 on the indicator arrow (A) may cause a rollover hazard.

A

Gradually move the 4-way controller towards the letter (B) to lift the load Hold the controller back until the has been achieved.

H

,/

the controller towards the letter (E) to the load DOWN and OUT into final position. Lower the load until the is completely off the forks.

o ..

]

4-18

... C

~~X G ~F:

Gradually move the controller towards the letter (F) to the boom UP and IN. This will the forks out ofthe load. Once the forks are clear of load the boom can be lowered.

E

B

OPERATION NOTES

4-19

SECTION 5 MAINTENANCE PROCEDURES

5-

TABL OF CONTENTS SECTION 5 - MAINTENANCE PROCEDURES

General Safety Practices

5-3

Service Intervals

5-5

Required

'-II'" '"',_..... _

Intervals

5-6

~ . . _'--""_ Fitting Locations

5-7

DailyMaintenance Procedures

5-8

50 Hour Maintenance Procedures

5-12

100 Hour Maintenance Procedures

5-18

250 Hour Maintenance Procedures

5-20

500 Hour Maintenance Procedures

5-22

750 Hour Maintenance Procedures 1000 Hour Maintenance Procedures

5-24

2000 Hour Maintenance Procedures

5-25

Filter Guide

5-26

Recommended FluidsAnd Capacities

5-26

Hydraulic Pressure Settings 5-2

MAINTENANCE PROCE GENERAL Si\FE'TYPRXCTICES

BEFORE SERVICING Read the entire Maintenance Procedure Section.

Familiarize yourself with all the safety precautions listed in Sections 1 & 2.

Pay close attention to all the safety alert symbols.

Be sure you understand the procedures detailed in this section.

Wear personal protective equipment.

Remove rings and jewelry.

Move the machine to a safe level work place.

Lower the boom and support all raised equipment.

Shut down the machine.

Remove the

from the ignition.

Be careful not to spill fuels and lubricants.

Do not fill or refuel the fuel tank while the is running or hot. so could cause a fire and/or an explosion.

Do not smoke while refueling or working with fuel to avoid a fire and/or l3"'V1"'l In£"1 n n

IMPORTANT! clean up spilled fuel and/or lubricants to avoid polluting the earth.

5-3

s

MAINTENANCE PROCEDURES GENERAL SAFETY PRACTICES

HYDRAULIC SAFETY

LfbWARNING Hot hydraulic oil can cause severe burns. DO NOT work on the hydraulic if the oil temperature exceeds 120 F. Before ANYONE works on the hydraulic 1.

2.

3.

4.

5.

Lower the boom to the horizontal position.

Support the boom to avoid unintentional lowering.

Shutdown the Remove the from the 1In_1I1"1II"',_ Clean the area around the oil reservoir cap (A).

A

FLUID UNDER PRESSURE

LfbWARNING bs,:aplng fluid under pressure can _011"01"'11'·1'11"0 the skin and can cauSe serious _OTClAI_.t'.l.1

Use a of cardboard or paper to search for leaks.

DO NOT use hands! Before hydraulic lines, be sure to relieve all line pressure. Before applying pressure to the be sure that all connections are DO NOT apply pressure to a hose or If injured by fluid, see a doctor at once. Proper medical treatment must be administered A serious infection or reaction can result without proper medical treatment.

WELDING PRECAUTIONS

WARNING DO NOT weld on any structural member. unauthorized can cause structural failure or nOSlSlble p~~rS(.nal injury. All unauthorized or repair procedures will void the machine

'l'lTolrI'll1l"\n

'l:'lTt'.lTTt'.l·n+u

Before any authorized be sure to disconnect the lead from the Properly attach the cable ofthe welder to the frame member that is being welded. Failure to do so can cause electrical system damage.

5-4

MAINT NANCE PROCEDURES SR1~VlrCF~ Tl'rTF~RVALS

DAILY CHECK ENGINE OIL CHECK COOLANT LEVEL CHANGE HYDRAULIC RETURN FILTER ELEMENT

50Hrs.

• •

lOOHrs.

250Hrs.

500 Hrs.

750 Hrs.

• •

.*

CHANGE ENGINE OIL & FILTER

•

INSPECT FAN BELT

.***

ENGINE VALVE ADJUSTMENT CHANGE DIFFERENTIAL OIL (AXLE)

• •

REPLACE FUEL FILTER COOLANT CONCENTRATION CHECK ENGINE FAN DRAIN FUEL-WATER SEPARATOR INSPECT BOOM WEAR PADS CHECK TIRE INFLATION FLUSH AND PRESSURE TEST COOLING SYSTEM CHECK TRANSMISSION OIL REPLACE TRANSMISSION OIL & FILTER

• • • •

CHANGE PLANETARY REDUCTION OIL (AXLE) INSPECT AIR CLEANER AND AIR CLEANER SYSTEM CHECK HYDRAULIC OIL LEVEL CHECK HYDRAULIC RETURN FILTER ELEMENT

•

2000 Hrs.

•

• • .*

•

CHECK AXLE OIL LEVELS

lOOOHrs.

•

.**

•

.*

• • •

For procedures to perform the above listed items turn to the following pages: 5-8 thru 5-25.

For initial break-in period only.

** For initiall 00 hours only.

For initial 250 hours only.

5-5

MA NTENANCE PROCEDURES REQUIRED GREASE INTER.VALS

LOCATION

DAILY

50Hrs.

250Hrs

•

RAS:P PNn BOOM CYLINDER

TILT CYLINDER

HEAD F( I"lK

•

CYLINDER

END

,'IJA

YIN

11-1'

LIFT ('VI JNnPR (2) LIFT CYLINDER (2) CYLINDER CYLINDER

END

BASE END SWAY CYLINDER CYLINDER

END BOOM

(2)

REAR

TRUNIONS (4)

• • • • • • • • •

• • • • •

(4) PIVOT (2) RPAR AXT.P PIVOT (2)

BOOM WEAR

(4)

DRIVESHAFT (3) REAR DRIVESHAFT (3)

5-6

500Hrs.

• •

MAINTENAI'I. E PROCEDURES SE FITTING LOCA.TIONS

TH528C

1 (BEHIND REAR COVER)

212

1

1

1 1 11

1

1

1

5-7

1

1

1

1

MAINTENANCE P OCEDURES DAILY MAIN

ANCE

Perfonn "BEFORE SERVICING PROCEDURES" before attempting any of the following checks.

Perfonn "BEFORE OPERATING CHECKS" before attempting any of the checks.

CHECKENGINE OIL LEVEL

Location:

(A). Left hand side of the (cab side).

To Check:

The machine must be level.

. L J I L ' U L I ..."IlL

Check when the

A

is cold.

Remove the dipstick from the engine.

The oil level should be between the add and full marks. ~'-\,.iIJJ.U\,I\,.i the dipstick.

NOTE:

Refer to page 5-26 of this manual for proper oil specification and capacities.

B

& WARNING Do not check the coolant level if the has been run. Injury may occur from hot eSCiaPlIlg ..,..,""".. . . .'. . . . . . t.J""" ....... coolant.

1"131"",13,"1"11",

CHECKENGINE COOLANTLEVEL

Location:

Radiator cap (B).

To Check:

Coolant should be visible in the top of the tank.

NOTE:

to be added fill with a 50150 and based

5-8

MAINTENANCE PROCEDURES DAILY MAINTENANCE

LLWARNING Serious personal injury can result from a loose or damaged fan.

Never pry on a fan because this may cause fan damage and/or failure.

CHECKENGINE FAN To Check:

Visually inspect the cooling fan (C) for cracks, loose bolts, bent or loose blades, etc.

c

DRAIN FUEL-WATER SEPARATOR Location:

Fuel-Water separator filter (D).

To Open:

Shut off the

D

Use your hand to open the drain valve on the bottom of the filter.

Tum the valve counterclockwise 4 complete turns until the valve drops down 1 inch.

Drain until clear fuel is visible.

Push the valve up and turn the valve clockwise to close the drain valve.

LLCAUTION Do not r1I."Tc..-r+1£'Yhi-t::Ji_ the valve. threads.

NOTE:

)ve:rtl~;hte:nmlg can aaIna~~e the

If more than 2

offuel are drained, refilling of the is required to prevent hard starting. Refer to filter of this manual. replacement on page

5-9

ANCE ROC DURES

CHECK TRANSMISSION OIL LEVEL

Location:

Dipstick (A).

To Check:

Level the machine.

A

Place the transmission control in neutral.

Set the The

'1"'\t:l ...·1T.. -n10

brake.

must be . . .

'1"11'"11 .. ....,10

to check.

the transmission oil temperature to a

nrinllnumof180

R

Remove the dipstick. The oil level should be between the add and full marks.

NOTE:

to 5-26 manual for proper oil specification and capacities.

CHECK HYDRAULIC OIL LEVEL

Location:

To Check:

the

hand side of the front tire.

Move the machine to level Level the frame.

L;o:mp,letlelv rel:ra(;t Ule boom.

Position the forks level.

Lower the boom to the ground.

Oil should be visible 1/2 way in the

NOTE:

B

5-26 of this manual for proper oil spetcifil:ati(Jn and capacities.

5 10

MAINTENANCE PROC DURES DAII.JY ~~A][Nl'ENANCE

CHECK TIRE FOR PROPER INFLATION Location:

Wheel ends.

To Check:

Check the tire pressure with the tire cold and a functioning air pressure gauge. Position the valve stem (C) to the top of the tire just in case the tire has been filled with an optional calcium chloride solution.

Setting:

50 PSI.

c

INSPECTAlR CLEANER Location:

Air cleaner (D). Located in the air cleaner on the hand side ofthe machine behind the air cleaner cover (E).

To Check:

Remove the rear ofthe . . . the filter element.

Guideline:

the filter element for contamination. the to the filter body from the for cracks or leaks. the air cleaner body and for cracks or leaks.

remove

n"l"'l11Cl1".:::Ii....

E

& WARNING Due to various OPt~ratlng COILGUlon.s'l the air cleaner's element as the environment . . ~rt'1'1'1 should be .... j:3C!

5 -11

D

MAINTENANCE PROCED

ES

50 HOUR MAINTENANCE Petform "BEFORE SERVICING PROCEDURES" before attempting any of the following checks.

COJmnJlete all "DAILY MAINTENANCE" checks prior to this time interval.

Petform "BEFORE OPERATING CHECKS" before attempting any of the checks.

CHECK HYDRAULIC RETURNFILTER GAUGE

Location:

Return filter gauge (A). Located under the sliding cover, on top of the oil reservoir and on the rearward side ofthe return filter assembly (B).

To Check:

Retract the boom fully. Raise the boom to a position that will clear the cover when it is slid forward to expose the return filter gauge. Extend the boom fully. Raise the to full RPM. Retract the

E

A

The return filter gauge should not read more than 25 PSI. Ifthe is more than 25 PSI, the filter element must be Ch'ln2;ect.

B

CHANGE HYDRAULIC RETURNFILTER ELEMENT

Location:

D

is located inside the ofthe oil reservoir.

To Change: Raise the boom and remove the sliding engine cover.

Retract the boom and lower the forks to the ground.

Shut off the Release the pressure in the oil reservoir the filler / breather cap (D).

F

~CAUTION The return filter cover is loaded. """'.L..... but do not remove, the four cover bolts (E) on the of the return filter assemlrHy. Ca]~ehll1y down and rotate the cover clockwise to remove.

Remove the cover and pull the filter element out the swivel handle on the element. Make sure both are in inside the new filter elelnerlt'l then transfer the valve into the new filter element. Reinstall the filter cover and cover, sure the is in place between the cover and the return filter assembly.

Raise the boom and the sliding cover.

A-I'V' • ...., .....

NOTE:

change interval only for the first initial 50 hours of initial replacement of the filter see "Service on page 5-5 of this manual for standard change

Hn/Jn1AJ1IVlCT

5 -12

c

MAINTENANCE PROCED

s

HOlJR MAINTENANCE CHANGE TRANSMISSION OIL AND FILTER

Location:

Transmission filter (G).

Drain plug (H) Dipstick (I)

~~G )

To Change:

the transmission oil tenLlPe:rature to a minimum of 180 F. Remove the drain plug.

Allow the oil to drain completely into a proper collection container.

Clean the area around the filter thoroughly.

Remove the transmission filter.

Apply a thin film of clean transmission oil to the new filter surface and install the filter to the manufacturer's

Install the drain plug.

Fill the transmission through the dipstick tube (I) until the oil level is between the add and full marks.

Run the for a minimum of 2 minutes at idle.

Check the oil level at the d.lp:stlC.k.

Raise the transmission oil to a minimum of 180 F. Recheck the oil at the d.lp:stlC.k.

NOTE:

This hours of

is only for the first initial 50 initial replacement of oil and the "Service Intervals" on page 5-5 of this manual interval.

NOTE:

Refer to page 5-26 of this specifications and capacities.

the proper oil

5 -13

H

I

s

NANCE 50 HOUR 1M

E

INSPECT BOOM WEAR PADS

Location:

Bottom front of the large boom section.

Tolerance:

The thickness of the wear pads (A) should be NO LESS THAN 1 INCH. Ifthe thickness is less than 1 the wear pads will need to have shims added.

To Shim:

Remove the 5/8 NC x 1 1/2 capscrews and locKwashers from the wear pads. Lift the small boom until the is off the wear pads.

Remove the wear pads and then add a 1/4 inch shim between the boom bottom plate and the wear Install the capscrews and lockwashers. Grease the wear pads the grease located at the bottom of the boom section. Run the boom in and out to test that the boom is smoothly.

INSPECT BOOM WEAR PADS

Location: Tolerance:

front of the

boom section.

The thickness of the wear (B) should be NO LESS THAN 7/16 INCH. Ifthe thickness is less than 7/16 the wear need to be replaced.

To Replace: Remove the 1/2 NC x 1 inch capscrews and lockwashers from the wear pads. Remove the old wear Install the new wear pads, capscrews and Smear grease on the surface of the wear Run the boom in and out to test that the boom is working smoothly.

5-14

A

A

B

B

MAINTENANCE PROCED

ES

TENANCE

INSPECT BOOM WEAR PADS

boom section.

Location:

Front sides of the

Tolerance:

The thickness of the wear pads (C) should be NO LESS THAN 7/8 INCH. Ifthe thickness is less than 7/8 inch, the wear pads will need to have shims added.

To Shim:

Remove the 5/8 NC x 1 1/4 inch long capscrews and lockwashers from the wear pads. Remove the wear pads and then add a 1/4 inch shim between the boom side plates and the wear pads.

Install the capscrews and lockwashers. Smear grease on the surface of the wear pads.

Run the boom in and out to test that the boom is .... T"""',... sIno ()thJlv,

c

c

IT'I1"'I£"l'

NOTE:

pads may be shimmed once. When they a second time, new wear pads must be or damage to the boom may result.

D

INSPECT BOOM WEAR PADS

Location: Tolerance:

rear ofthe small boom section.

The thickness of the wear (D) should be NO LESS THAN 7/16 INCH. Ifthe thickness is less than 7/16 inch, the wear need to be replaced.

To Replace: Remove the 1/2 NC x 1 inch capscrews and lockwashers from the wear Remove the old wear Install the new wear capscrews and lockwashers. Grease the wear pads the grease located on the top of the boom section directly in front of the lift cylinder Run the boom in and out to test that the boom is smoothly.

5 -15

D

M

NTENANCEPROCEDURES 50HOUR~~~[Nl'ENANCE

INSPECT BOOM WEAR PADS

Location:

Bottom rear ofthe small boom section.

Tolerance:

The width of the wear should be NO LESS THAN 3 1/4 INCH. Ifthe width is less than 3 1/4 the wear pads need to be rotated.

To Rotate:

Remove the 1/2 NC x 1 inch capscrews and lockwashers from the Remove the wear and rotate them 180 and re-install the wear capscrews and lockwashers. Smear grease on the bearing surface of the wear pads.

Run the boom in and out to test that the boom is

NOTE:

be once. When they require wear pads must be installed or result.

E

INSPECTBOOM WEAR PADS

Location:

Rear sides of the small boom section.

Tolerance:

The thickness of the wear should be NO LESS THAN 3/4 INCH. Ifthe thickness is less than 3/4 inch the wear need to be reUllac:eQ.

To Replace: Remove the 1/2 NC

1 lockwashers from the wear wear Install the new wear capscrews and lockwashers. Smear grease on the bearing surface of the wear Run the boom in and out to test that the boom is smoothly.

5 -16

E

E

MAINTENANCE PROCE·T"T1RES 50 HOUR MAINTENANCE

CHECKAXLE PLANETARY OIL

Location:

Filler/drain plug (F).

To Check:

check the lubricant level in the wheel end with the filler!drain plug at the 3 or 9 o'clock position.

Remove the filler!drain plug.

Oil should flow freely from the hole.

Replace the filler!drain plug.

NOTE:

Refer to page 5-26 of this manual for the proper oil specifications and capacities.

F

CHECKAXLE DIFFERENTIAL OIL

Location:

Fill plug (G).

(H). . . _.. . . . . . . . . . _,..., (I).

To Check:

Move the machine to level ground.

Remove the . . . . . . "'. . . . 1,.._1",...... Oil should flow freely from the hole.

G to 5-26 of this manual for the proper oil specifications and capacities.

5 -17

I

H

MA

TENANCEPROCEDURES 100

TENANCE

Petfonn "BEFORE SERVICING PROCEDURES" before " ......"".........tJ .......... any of the following checks.

LF,

COll1pJlete all "DAILY MAINTENANCE" checks prior to this time interval.

L:oltl1PJlete all "50 HOUR MAINTENANCE" checks prior to this time interval.

Petfonn "BEFORE OPERATING CHECKS" before atteltl1Pltmg any of the checks.

CHANGE AXLE DIFFERENTIAL OIL

Location:

To Change: Remove the Loosen the fill plug to allow the oil to drain cornplieteJly into a proper collection container.

Remove the check

and the fill plug.

A

and the fill plug.

NOTE:

NOTE:

interval is for initial 100 hours. Refer to 5-5 of this manual for additional intervals.

Refer to page 5-26 of this manual for the proper oil specifi.cations and capacities.

5 -18

B

c

s

MAINTENANCE P 100 H()UR

CHANGEAXLEPLANETARYEND OIL (D).

Location:

To Change: Rotate the wheel end until the filler/drain plug is at the lowest point of the wheel end.

Remove the and allow the oil to drain completely into a proper collection container.

Rotate the wheel end until the filler/drain plug hole is at the 3 or 9 o'clock position.

Fill with oil until it flows freely from the filler/ hole. .J.'-.\.tIJ..lU,\.,I\.t

the filler/drain plug.

D NOTE:

interval is for the first initial 100 hours. Refer to page 5-5 of this manual for additional service intervals.

Refer to page 5-26 of this manual for the proper oil slJecitilr::ations and capacities.

CHANGE TRANSMISSION OIL AND FILTER To Change: Refer to the nrocedlure listed on page 5-13 ofthis manual.

NOTE: 5-5

initial 100 hours. Refer to additional intervals.

5 -19

NTENANCE PROC

M

250 DOUR MAINTENJ\N"(;E

Perfonn "BEFORE SERVICING PROCEDURES" before attempting any of the following checks.

COlnOJlete all "DAILY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

COJffiOJLete all "100 HOUR MAINTENANCE" checks prior to this time interval.

Perfonn "BEFORE OPERATING CHECKS" before attempting any of the following checks.

CHANGEHYDlUULICRETURNFILTER

To Change: Refer to the procedure listed on page 5-12 of this manual.

ADJUSTENGINE VALVES

To Check:

See

manual for procedure.

5-20

URES

MAINTE

NeE

250 HOUR MAINTENANCE

CHANGE ENGINE OIL AND FILTER Location:

Oil filter (A).

(B).

Fill cap (C).

To Change:

the until the tenlPeratlllre has reached 140 ~I.LJl=~ LJ~JL" I

Tum the

off.

c

Remove the drain plug.

Allow the oil to drain completely into a proper collection container.

Clean the area thoroughly around the filter area.

Remove the oil filter. a thin film of clean oil filter surface.

oil to the new

Install the oil filter to the manufacturer's

Clean the surface around the drain plug.

Install the drain plug.

Fill the with the proper oil through the oil fill cap until the oil level is between the add and the full marks on the dipstick.

Run the idle.

for a minimum of 2 minutes at

Tum the

off.

A

has cooled recheck the oil level Once the at the dlp:stlCk.

to page 5-24 this manual for proper oil specifications and capacities.

5 -21

B

MAINT-

CEDU~ "~.L' 500 H()lJR MAI~~TE~N

CE

Perfonn "BEFORE SER.VICINGPR.OCEDURES" before att€~mlJtllJLg any of the following checks.

COltl1pJlete all "DAILY MAINTENANCE" checks prior to this time interval.

COl1rlplete all "50 HOUR. MAINTENANCE" checks prior to this time interval.

COltl1PJlete all "100 HOUR. MAINTENANCE" checks prior to this time interval.

Complete all "250 HOUR. MAINTENANCE" checks prior to this time interval.

Perfonn "BEFORE OPERATING CHECKS" before attempting any of the following checks.

REPLACE FUEL FILTER Location:

Fuel filter (A).

A

To Change: Close any OEM fuel valves (if equipped) to fuel from draining or siphoning.

Clean the area around the fuel filter head.

Remove the fuel filter.

Clean the U r .....",I ... " r .

surface of the filter head.

the

Fill the new fuel filter with and lubricate the seal with clean lubricating oil.

Thoroughly clean the after filter removal.

surface

Install the new fuel filter as specified by the filter manufacturer.

~CAlJTI()N Mechanical OVt,rtU~ht(~nIIlg will distort the threads, filter element seal or filter can.

5-22

MAINT NANCE PROCEDURES 500 HOUR MALIN'JrE~(AlSrCE

B

CHECK COOLANT CONCENTRATION Location:

Radiator cap (B).

To Check:

Remove the radiator cap.

Factory recommended coolant concentration is a 50/50 mixture ofwater and ethylene-glycol based antifreeze. (-34 F.) Replace the radiator cap.

750 HOUR M Petfonn "BEFORE SERVICING PROCEDURES" before n++t31"'V1_1f-.. _rr any of the following checks.

LOJlTIPJlete all "DAILY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

LOJlTIpJlete all "100 HOUR MAINTENANCE" checks prior to this time interval.

COJlTIPJlete all "250 HOUR MAINTENANCE" checks prior to this time interval.

COJlTIPJlete all "500 HOUR MAINTENANCE" checks prior to this time interval.

Perfonn "BEFORE OPERATING CHECKS" before attemptany of the checks.

CHANGE AXLE OILS To Change:

to the procedures listed on pages 5-18 & 5-19 ofthis manual.

5-23

NTENANCE

MAINTENANCE 10

IVIAJ[l~TENANCE

Perfonn "BEFORE SERVICING PROCEDURES" before attempting any of the following checks.

COll1oJlete all "DAILY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

CODLlolete all "100 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "250 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "500 HOUR MAINTENANCE" checks prior to this time interval.

CODlolete all "750 this time interval.

MAINTENANCE" checks

to

Perform "BEFORE OPERATING CHECKS" before attemptchecks. any of the

MANUFACTURER ENGINE MANUALS ARE AVAILABLE FROM YOUR LOCAL TEREX HANDLER DEALER.

ADJUSTENGINE VALVES ToAdjust:

See

manual for procedure.

CHECK FAN BELT TENSION To Check:

See

manual for oroced"ure.

CHECK FANBELT CONDITION To Check:

See

OCEDURES

manual for procedure.

CHANGE TRANSMISSION OIL AND FILTER To Change: Refer to oroced.ure listed on page 5-13 of this manual.

5-24

MAINTENANCE PROCEDURES 2000

'U~llVIAINTENANCE

Perfonn "BEFORE SERVICINGPROCEDURES" before t:l+-t~T't"'I1"1h-nrT any of the following checks.

LOlmpJlete all "DAILY MAINTENANCE" checks prior to this time interval.

Complete all "50 HOUR MAINTENANCE" checks prior to this time interval.

COlnpJlete all "100 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "250 HOUR MAINTENANCE" checks prior to this time interval.

LOlnpJlete all "500 HOUR MAINTENANCE" checks prior to this time interval.

LOlnpJlete all "750 HOUR MAINTENANCE" checks prior to this time interval.

Complete all "1000 HOUR MAINTENANCE" checks prior to this time interval.

Perfonn "BEFORE OPERATING CHECKS" before attempting any of the checks.

FLUSHAND PRESSURE TEST COOLING SYSTEM

To Test:

See

manual for procedure.

5-25

MAINTENANC

s

ROCEDU

FILTER GlJIDE

PART NO.

FILTER Oil Filter

7-343-96

Transmission Oil Filter

7-126-349

Hydraulic Oil Reservoir Return Filter Element

7-118-02

Cleaner Element

7-109-04

Fuel Filter

7-343-97

Fuel Filter I In-Line

7-343-80

Filler-Breather (Hydraulic Oil Reservoir)

7-272-11

RECOMMENDED FLlJIDS AND CAPACITIES

DESCRIPTION

CAPACITY

Engine Oil

8.5 Quarts

TYPE SAE 15W-40 H.D.engine oil

with an (API) CH4/SG rating 13.6

Chevron RPM SAE 10W

Differential Planet Ends

9 Quarts 1

Chevron Chevron

Hydraulic Oil Reservoir

36 Gallons

ChevronAW 46

Hydraulic System

51 Gallons

ChevronAW 46

Fuel Tank

30 Gallons

#2 Diesel Fuel

Transmission Oil Axles

NOTE: Fluid levels may vary slightly/rom machine to machine so fluid levels should

5-26

80W90LS 80W90LS

be manually checked.

MAINTENANCE PROCED RAULIC PRESSIJRE SET

ES

GS

GAUGEPORTI (G1) MAIN PUMP PRESSURE Location: Test port 1 (A). Located on the control block, inside the frame near the rear axle cross members.

Hydraulic pump (B). Located on the transmission, under the sliding cover. }-\.IIIIISIt"':1

(C). Located on the hydraulic pump.

To Check: Attach a pressure gauge to test port 1 (A).

Start the Do not operate any controls.

The pressure should be as follows:

I mS28C

3000 PSI

ToAdjust: Remove the acorn nut from the adjuster (C).

Loosen the jam nut and tum the allen head adlustlng screw clockwise to increase the pressure and counter-clockwise to decrease the pressure. Retighten the jam nut. Replace the acorn nut.

A

B

GAUGE PORT 2 (G2) STEERING SYSTEMPRESSURE 2 (D). Located on the control block (E).

Location:

Control block (E). Located inside the frame near the rear axle cross members. ''':l''f'''f-.r1r1r1"O (F). Located on the forward face of the control block.

To Check: Attach a pressure gauge to test port 2 (D).

Start the Do not any controls.

The pressure reading should be as follows:

I

mS28C

2250 PSI

ToAdjust: Loosen the jam nut on the cartridge (F) and tum the allen head adjusting screw clockwise to increase the pressure and counterclockwise to decrease the pressure. Retighten the jam nut.

D 5-27

F

E

c

MAl

s

ENANC PROC ULIC PRESSURE S

INGS

GAUGE PORT 3 (G3) SERVICE BRAKE ACCUMULATOR Located on the control block (B).

Location: Test port 3

Control block (B). Located inside the frame near the rear axle cross members.

To Check: Attach a pressure gauge to test port 3 (A). Start the Do not any controls. Apply and release the service brakes a few times. With the service brakes released, shut down the engine.

The pressure should be as follows:

I

TH528C

3000 PSI

ToAdjust: Not adjustable. If the pressure drops below 2000 PSI after a period of two minutes, troubleshoot the brake circuit.

B

GAUGE PORT 4 (G4) CONTROL (PILOT) PRESSURE (C). Located on the control block (B).

Location:

Located inside the frame near the rear axle cross members.

(D). Located on the forward face ofthe control block. ...............&........., ... to-.""

To Check: Attach a pressure gauge to test port 4 (C).

Start the Do not any controls.

The pressure should be as follows:

I

TH528C

500 PSI

ToAdjust: Loosen the jam nut on the controller cartridge (D) and turn the allen head adjusting screw clockwise to increase the pressure and counterclockwise to decrease the pressure. the jam nut.

5-28

B

D

MAINTENANCE PROC NOTES

5-29

ES

S CTION6

Mi\TERIi\L SAFETY Di\Ti\ SHEETS

6-1

TABLE OF CONTENTS SECTION 6 - MATERIAL SAFETY DATA SHEETS

6-2

AFETY DATA SHEETS

The Federal Occupational, Safety and Health Administration (OSHA) Standard 29 ctr 1910.1200, and in some cases state and local Right-To-Know laws, may require specific MSDS be available to employees prior to operating this equipment. This mayinclude infonnation on substances contained in the equipment such as antifreeze, brake fluid, battery acid and hydraulic fluid.

TEREX HANDLERS will provide, at no cost, Material Safety Data Sheets which are applicable to their product line. Simply request them from your local TEREX HANDLER dealer or contact us at: TEREX HANDLERS P.O. Box 790 Baraga, MI 49908-0790

To ensure a prompt response, please be sure to include your return address and zip code, along with the machine model and serial number.

6-3

MAT/ERIAL SAFE

The following warning is required on all offroad equipment operating in the State ofCalifornia. Ifyou are operating a TEREX HANDLER in the State ofCalifornia and do not see the approved warning label, please contact us for a replacement at no charge. Our address is: TEREX HANDLERS P.O. Box 790 Baraga, MI 49908-0790

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some ofits constituents are known to the State of Califomia to cause cancer, birth defects, and other reproductive harm.

4