Page 1 OPERATOR MANUAL For the Princeton Truck Mounted NICAL DATA Forklift Equipped with Reach Mast Publication Part Number: 091.290.0000 Revision: PB2-1803...
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Page 3: Table Of Contents
A3. CENTER OF GRAVITY Machine Models Basic Principles Using This Operator Manual Sample Load Chart Using the Machine Comparison between a Conventional The Truck Mounted Forklift Forklift and a Truck Machine Description Mounted Forklift Concept Conventional Forklift Major Components Truck Mounted Forklift...
Page 4 TABLE OF CONTENTS Starting the Engine Lifting a Cubed Load from Ground Level Start Safely Traveling With a Cubed Load After Start-Up Placing a Cubed Load at Ground Level Tier 4 Checks Wide Loads Battery Isolator Switch Lifting a Wide Load Driving Techniques Traveling With a Wide Load Driving Forward...
Page 5 TABLE OF CONTENTS A6. MAINTENANCE Air Filter Unit Daily Maintenance Servicing the Filter Daily Pre-Shift Inspection Checklist Cleaning Mast Chains Using Steam Visual Checks Jet Equipment Operational Checks Recommended Jet Equipment Cleaning Transport Checks Method for Leaf Chain Interlocking Seatbelt Chain Lubrication Specification Inspection Grease Specification...
Page 6 TABLE OF CONTENTS PANTOGRAPH LOG BOOK B1. SAFETY CHECKLIST C1. RECORD OF SERVICE INTERVALS Pantograph Safety C2. RECORD OF DAMAGE B2. INTRODUCTION Major Components C3. RECORD OF TRANSFER OF FORKLIFT Safety Decals Hydraulic Levers C4. Notes B3. OPERATING PROCEDURES Operating the Pantograph B4.
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Page 9: A1. Safety Checklist
A1. SAFETY CHECKLIST Safety Notices In this operator manual and on the machine there are safety notices and decals. Each of these has a signal word that indicates the outcome of the hazardous situation if the safety instructions are not followed. The decals on the machine also have a specific color to help identify the hazard level.
Page 10: Introduction To General Safety
All industrial equipment can be hazardous. When a or maintaining the Truck Mounted Forklift. It is also not machine is properly operated and maintained, it is a intended to be used for training purposes.
Page 11: Operational Safety
Truck Mounted Forklift. Be aware of what action machine and be trained and authorized to use it. you MUST take if the machine starts to tip or roll over.
Page 12 Each decal has a part number WARNING: printed beside it. Use this number to order a new decal Engine. Never climb aboard or dismount from the from your Truck Mounted Forklift Distributor. machine with the engine running.
Page 13 Read the safety instructions before operating this machine. If you do not understand WARNING: anything, ask your Truck Mounted Forklift Distributor or supervisor to explain it. Keep this operator manual Seatbelt. The operator’s compartment is designed to clean and in good condition. Do not operate the give you protection in an accident.
Page 14 WARNING: WARNING: Controls. Do not control the machine from outside the Safety. Always wear your seatbelt when driving the operator’s compartment. Operate the control levers Truck Mounted Forklift. The forklift may tip over if only when correctly seated inside operated incorrectly.
Page 15 A1. SAFETY CHECKLIST Operational Safety (continued) WARNING: Loose Articles. Do not leave loose articles in the operator’s compartment. Loose articles can fall and WARNING: strike you, or roll on the floor. You could be knocked Engine Damage. Do not use starting fluid or spray as unconscious, or the controls could get jammed.
Page 16 Warning Lights. If at any point during the operation Safe Operation. If something comes loose, breaks or of the Truck Mounted Forklift one or more of the dash fails to operate: panel warning lights are lit, the forklift must be stopped Stop.
Page 17: Transport Safety
Truck Mounted Forklift specifications. CAUTION: When carrying a Truck Mounted Forklift, make certain that your vehicle complies with the relevant national Rear Bumper. The rear bumper must be folded back and local laws and regulations regarding maximum...
Page 18: Maintenance Safety
WARNING: Any time the Truck Mounted Forklift is being operated and is involved in an accident, the whole seatbelt Procedure. If you are unsure how to follow any assembly must be replaced.
Page 19 A1. SAFETY CHECKLIST Maintenance Safety (continued) WARNING: Hydraulic Fluid. Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your WARNING: fingers to check for hydraulic fluid leaks. Do not put Raised Machine. NEVER position yourself or any part your face close to suspected leaks.
Page 20 A1. SAFETY CHECKLIST Maintenance Safety (continued) WARNING: Electrical Circuits. Understand the electrical circuit before connecting disconnecting electrical WARNING: component. A wrong connection can cause injury Hydraulic Hoses. Damaged hydraulic hoses can cause and/or damage. accidents. Inspect the hoses regularly for: Do not disconnect the battery when the machine is Damaged end fittings running...
Page 21 CAUTION: authorized experienced personnel should allowed to operate the Truck Mounted Forklift. Service Machine Modifications. This machine is manufactured personnel should read and study this manual, the in compliance with legislative and other requirements. service manual, the preventative maintenance manual...
Page 22 A1. SAFETY CHECKLIST Maintenance Safety (continued) CAUTION: Welding. Before carrying out any welding on the machine, disconnect the battery, alternator and ECU to protect the circuits and components. The battery must still be disconnected even if a battery isolator is fitted. Make sure the welding path is kept as short as possible.
Page 23: A2. Introduction
A2. INTRODUCTION If there is anything you are unsure about ask your About this Operator Manual supervisor or Truck Mounted Forklift Distributor. Do not guess, you or others could be killed or seriously Machine Models injured. This operator manual provides information for the moving mast range of Truck Mounted Forklifts.
Page 24: The Truck Mounted Forklift
Concept Machine Description Unlike a conventional forklift the Truck Mounted Forklift The Truck Mounted Forklift is a three wheeled, non- does not have a counterweight at the rear; instead it counterbalanced forklift capable of being transported on uses its own weight to counter the load. Normally the the rear of a truck or trailer.
Page 25: Major Components
A2. INTRODUCTION Major Components 1. Forks 2. Stabilizers 3. Fork Face 4. Fork Carriage 5. Lift Chains 6. Mast 7. Hood 8. Hydraulic Controls 9. Steering Wheel 10. Beacon 11. Overhead Guard 12. Operator’s Compartment 13. Seat 14. Work Lights x2 15.
Page 26: Identifying Your Machine
A2. INTRODUCTION Identifying Your Machine Serial Plate: This located operator’s compartment and it gives the following information: Type: This is the machine model Serial No: This is a unique number given to all machines. P 24 054-8C Year of manufacture. Week number.
Page 27: Safety Decals
The decals and their attachment points are shown in this manual. Each decal has a part number printed beside it. Use this number to order a new decal from your Truck Mounted Forklift Distributor. DANGER: Forks. Do not permit personnel to stand on or ride on...
Page 28 A2. INTRODUCTION Safety Decals (continued) The machine is fitted with an interlocking Note: seatbelt. The machine will not drive unless the seatbelt is engaged. Part Number 517. 230.0005 Part Number 517. 055.0006 (Seat Presence Optional 517.055.0060)
Page 29 A2. INTRODUCTION Safety Decals (continued) Part Number 517.280.0007 Lower N’ Go only works when ignition key is in Note: the off position.
Page 30 A2. INTRODUCTION Safety Decals (continued) Part Number 517.230.0003...
Page 31 A2. INTRODUCTION Safety Decals (continued) Part Number 517.130.0003...
Page 32 A2. INTRODUCTION Safety Decals (continued) Part Number ENG003 WARNING: The hydraulic tank is pressurized Hydraulic Pressure. and hydraulic oil may be hot. To avoid injury and spillage when removing the cap, stop the engine and remove the cap very slowly.
Page 33 A2. INTRODUCTION Safety Decals (continued) Part Number 517.100.0141 Part Number 517.100.0086...
Page 34 A2. INTRODUCTION Safety Decals (continued) Part N umber E NG 004 CAUTION WARNING WARNING Do not use Pressurized reservoir. Keep away from starting fluid. Turn off engine. Allow moving parts. Engine damage coolant temperature will occur to fall. Remove radiator cap slowly. ENG004 WARNING: Vapors .
Page 35 A2. INTRODUCTION Safety Decals (continued) Part N o. 517. 230.0008 Part N o. USA018...
Page 36 A2. INTRODUCTION Safety Decals (continued) Part N o. 517.999.0296 Part Number 517.999.0842 IMPORTANT OVERFILLING ENGINE OIL WILL Engine oil capacity: 9.2 QTS RESULT IN ENGINE DAMAGE Fully Synthetic Check engine oil level cold, at least = -13°F Use 5W-40, API CJ4 5 minutes after shutdown = -13°F Use 0W-30, API CJ4 517.999.0842...
Page 37 A2. INTRODUCTION Safety Decals (continued) Part N umber 517.999.0254 Part N umber ENG019...
Page 38 A2. INTRODUCTION Safety Decals (continued) Part Number ENG011 WARNING Keep away from pinch points, masts, lift chains, cylinders, etc. Keep all shields and guards in place. ENG011 Note: Location of pinch point decals; part number ENG011 on stabilizers and tilt cylinders.
Page 39 A2. INTRODUCTION Safety Decals (continued) Part N umber 517.130.0038 The valve bank and load chart decals in this Note: section are only examples and may differ from those found on your machine. Please check your machine for the correct part number.
Page 40 A2. INTRODUCTION Safety Decals (continued) When replacing decals always ensure the correct Note: part number is supplied. The decal part number can be found on the machine.
Page 41 A2. INTRODUCTION Safety Decals (continued)
Page 42 A2. INTRODUCTION Safety Decals (Continued) Part Number 517.999.0300 WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Always start and operate the engine in a well ventilated area.
Page 43: Instruments And Controls
A2. INTRODUCTION Instruments and Controls The Truck Mounted Forklift is provided with a set of controls to enable operate machine safely and efficiently. The instruments and controls are in the following groups: Forward/Reverse Pedal Throttle Steering Wheel Dash Panel Hydraulic Controls...
Page 44 A2. INTRODUCTION Instruments and Controls (continued)
Page 45: Ignition Switch/Pre Heater
Flashing Beacon The Truck Mounted Forklift is fitted with a flashing beacon. The beacon is activated when the ignition is turned to the ON position. If the beacon fails to work, do not operate the machine. Contact your supervisor.
Page 46: Air Filter Blockage Light
Warning Lights. If at any point during the operation switched off. The engine oil level should be checked as of the Truck Mounted Forklift one or more of the dash per the maintenance section of this manual and refilled panel warning lights or the red MIL are lit, the forklift if necessary.
Page 47: Transmission Controls
Hydraulic Foot-Pedal Control machine will travel. When traveling on gradients or on With foot-pedal control, the Truck Mounted Forklift is rough terrain, forward/reverse pedal movement should equipped with two foot pedals. The right pedal is the be reduced and engine RPM increased.
Page 48: Hydraulic Levers
Backward The Truck Mounted Forklift is equipped with hydraulic movement of the lever shifts the mast to the right. levers to control movement of the mast, forks and stabilizers. Study the valve bank decal for your Truck D.
Page 49 A2. INTRODUCTION Hydraulic Levers (continued) Note: When the ground is not firm enough to support the stabilizers extra support plates must be used of sufficient size and strength to ensure they do not sink, bend or buckle during operation. A second person may be required to check the support plates.
Page 50: A3. Center Of Gravity
It is common for a large capacity conventional forklift to be used when loading trucks or trailers in a yard. Do not expect the Truck Mounted Forklift to lift the load just because 24" a conventional yard forklift initially loaded it.
Page 51: Sample Load Chart
1. The load capacity may vary depending on the The following sample load capacity chart illustrates the attachments used. Consult the load chart on your rated stacking capacity of a Truck Mounted Forklift machine for the actual rated capacity. equipped with standard forks.
Page 52: Comparison Between A Conventional Forklift And A Truck Mounted Forklift
The mast does not move forward and backward like a Truck Mounted Forklift. The front wheels of a conventional counterbalanced forklift are the points of pivot known as the fulcrum point.
Page 53: Truck Mounted Forklift
(continued) This action increases the counterbalance effect and enables the Truck Mounted Forklift to lift the rated Truck Mounted Forklift capacity with the mast in the forward position without An important feature of the Truck Mounted Forklift is the need for a large counterweight.
Page 54: A4. Operating Procedures
A4. OPERATING PROCEDURES Using the Machine WARNING: Before Using the Machine Never climb aboard or dismount from the Engine. Before you begin to operate the Truck Mounted Forklift machine with the engine running. must read, understand follow information in this manual, be familiar with the machine and be trained and authorized to use it.
Page 55 If you do not understand to lose control or cause the forklift to tip over. anything, ask your Truck Mounted Forklift Distributor or supervisor to explain it. Keep this operator manual clean and in good condition. Do not operate the WARNING: machine without an operator manual in the operator’s...
Page 56 WARNING: before using the machine. Passengers. Passengers in or on the machine can cause accidents. The Truck Mounted Forklift is a one person machine. Do not carry passengers. WARNING: Visibility. Accidents can be caused by working in poor visibility.
Page 57: Clothing
A4. OPERATING PROCEDURES Using the Machine (continued) CAUTION: Obey all laws, work site and local Regulations. regulations which affect you and your machine. WARNING: Loose clothing can get caught in the Clothing machinery. Wear protective clothing to suit the job. CAUTION Examples of protective clothing are;...
Page 58: Overhead Guard
A4. OPERATING PROCEDURES Location of Overhead Guard Conformity Plate Overhead Guard The overhead guard is designed to give you protection Part Number 517.056.0001 in an accident. You must always wear your seatbelt or you could be thrown about inside the operator’s compartment, or thrown out of the machine and This Overhead Guard Conforms crushed.
Page 59: Rollover
Always be aware of the potential danger involved when using the Truck Mounted Forklift. Be aware of what action you MUST take if the machine starts to tip or roll over.
Page 60: Operating The Machine
Safety. Always wear your seatbelt when driving the Truck Mounted Forklift. The forklift may tip over if Seatbelt is not connected when the operator is operated incorrectly. In the event of a tip over, it is sitting in the seat.
Page 61 A4. OPERATING PROCEDURES Operating the Machine (continued) The forklift will not drive unless the seatbelt is Note: connected across the operator’s hips. WARNING: Seatbelt. If the seatbelt does not ‘lock’ when fastened do not drive the machine. The seatbelt assembly must be replaced immediately.
Page 62: Starting The Engine
A 4 . OPERATING PROCEDURES Do not attempt to operate the Truck Mounted Forklift Starting the Engine with a warning light on as serious damage could occur to the engine. Start Safely Adjust the seat and fasten the seatbelt. Ensure all...
Page 63: Tier 4 Checks
A4. OPERATING PROCEDURES There are a number of operator messages displayed on Engine Checks the gauge as follows: The Temperature Gauge also has a MIL (Malfunction PAUSE – Engine temperature is to low and engine Indicator Lamp). This will activate if faults are found revs restricted until...
Page 64: Battery Isolator Switch
Truck Mounted Forklift; the engine will not start if the battery isolator switch is active. If your Truck Mounted Forklift is to be left for a period of one week or more the battery isolator switch should be switched off.
Page 65: Driving Techniques
The Truck Mounted Forklift steers from the rear and can accelerate smoothly and slowly. If you accelerate turn on a very tight radius. Tail swing and fork swing quickly or with jerky movements the load could fall or must be considered when turning.
Page 66: Parking
A4. OPERATING PROCEDURES Operating On Inclines Driving Techniques (continued) The Truck Mounted Forklift is intended for use on firm, flat and stable surfaces. AVOID slopes and uneven or Parking unstable surfaces where possible. However, when a job Always park the Truck Mounted Forklift in a designated site conditions involve slopes, inclines or rough terrain, safe area.
Page 67: Inclines
A4. OPERATING PROCEDURES Driving Techniques (continued) DANGER: Inclines. Never travel across inclines. Traveling across an incline with or without a load greatly increases the possibility of a tip over. Do not travel across an incline. ALWAYS APPROACH AN INCLINE STRAIGHT ON AND TRAVEL UP AND DOWN THE INCLINE.
Page 68: Operating With A Load
A4. OPERATING PROCEDURES Driving Techniques (continued) Operating Without a Load Operating With a Load Extend the mast fully and point the forks uphill on Travel with the load and forks facing uphill. an incline. Never travel across a slope. Keep the forks as low as possible. Make allowances for a reduction in both stability and Remember that your safety is most important and lift capacity when operating on inclines.
Page 69: Rules For Driving On Public Roads
Safety. Always wear your seatbelt when driving the and visible. Make sure that any slow moving vehicle Truck Mounted Forklift. The forklift may tip over if sign is visible to any vehicles approaching from the rear operated incorrectly. In the event of a tip over, it is if the law requires such a sign.
Page 70: Warning Triangle
Once the delivery is complete and the Truck Mounted Forklift is again mounted on the rear of the truck/trailer the warning triangle must be...
Page 71: Diff-Lock
A4. OPERATING PROCEDURES How to Activate the Diff-Lock Diff-Lock 1. Foot-Pedal Control Operation of Diff-Lock a) Return the forward/reverse pedal to the neutral Under normal driving conditions the Truck Mounted position to stop the machine. Forklift operates in all-wheel drive. However, in the b) Check to see that the rear wheel is in the straight- event of one or more wheels losing grip the machine ahead position.
Page 72: Stopping Procedure
A4. OPERATING PROCEDURES Stopping Procedure Loose Articles When stopping the machine follow the sequence below: Remove or secure all loose articles in the operator’s Lower the forks to the ground. Tilt the fork carriage compartment such as lunch boxes, tools etc. so the tips of the forks touch the ground.
Page 73: Basic Load Techniques
A4. OPERATING PROCEDURES Using Stabilizers Basic Load Techniques Traveling Without a Load WARNING: Always extend the mast fully forward. Keep the forks as low as possible. . When placing a load, always place the load Stabilizers Never travel with mast back and no load. on a firm and level surface.
Page 74: Lifting And Placing Loads
A4. OPERATING PROCEDURES Lifting and Placing Loads Cubed Loads A cubed load is one that fits between the front wheels and the frame of the machine. To achieve maximum machine and load stability, the load should be carried with the mast retracted and as low as possible between the frame of the machine at all times.
Page 75: Lifting A Cubed Load From Ground Level
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Lifting a Cubed Load from Ground Level 1. Align the forks to suit the load. 2. Approach the load squarely and drive slowly forward until the forks are fully engaged. 3. Check that the surface is strong enough to support the stabilizers. If not, place a metal or wooden support underneath which is strong enough to support the stabilizers.
Page 76: Traveling With A Cubed Load
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Traveling With a Cubed Load 1. Carry the load as low as possible between the frame of the machine. 2. Keep the mast retracted fully. 3. Tilt the mast back. 4. Do not side-shift the load while traveling or turning. 5.
Page 77: Placing A Cubed Load At Ground Level
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Placing a Cubed Load at Ground Level 1. Check the area and be certain that the load can be safely placed. 2. Approach the placement area squarely. 3. Check that the surface is strong enough to support the stabilizers. If not, place a metal or wooden support underneath which is strong enough to support the stabilizers.
Page 78: Wide Loads
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Wide Loads A wide load is a load that will not fit between front wheels and frame of the forklift. Common types of wide load are piping or lumber products. Note: Make sure the load to be lifted is stable and secure.
Page 79: Lifting A Wide Load
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Lifting a Wide Load 1. Align the forks to suit the load. 2. Approach the load squarely and drive slowly forward until the forks are fully engaged. 3. Check that the surface is strong enough to support the stabilizers. If not, place a metal or wooden support underneath which is strong enough to support the stabilizers.
Page 80: Traveling With A Wide Load
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Traveling With a Wide Load 1. Carry the load as low as possible above the frame of the machine. 2. Keep the mast retracted fully. 3. Tilt the mast back. 4. Do not side-shift the load while traveling or turning. 5.
Page 81: Placing A Wide Load
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Placing a Wide Load 1. Check that the area is clear of debris. 2. Approach the placement area squarely. 3. Stop and side-shift the load if necessary to align it with the final resting position.
Page 82: Non Palletized Or Loose Loads
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Non Palletized or Loose Loads Use skids when necessary to allow insertion of the forks beneath the load. Do not allow the skids to interfere with the fork placement. Secure loose loads to prevent them from falling or shifting.
Page 83: Loads Above Ground Level
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Loads above Ground Level These techniques apply to: Stacking one load on top of another. Loading a truck or trailer. Unloading a truck or trailer. Picking Up a Load above Ground Level 1.
Page 84 A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) 6. Check that the surface is strong enough to support the stabilizers. If not, place a metal or wooden support underneath, strong enough to support them. 7. Lower the stabilizers fully. 8. If it is not possible to engage the forks fully, follow the procedure outlined in the section titled Double Forking until the forks are fully engaged.
Page 85 A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) 13. Raise the stabilizers fully. 14. Check behind and back up slightly to clear the pick-up area. 15. Never maneuver or turn with a raised load. 16. Lower the load as close to the ground as possible. 17.
Page 86: Double Forking
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Double Forking If it is not possible to engage the forks fully when lifting the load from a truck or trailer, it will be necessary to move the load to the edge of the body of the vehicle before picking it up. This is known as double forking. Remember that the lift capacity of the machine is reduced if the forks are not fully engaged.
Page 87: Placing Or Stacking A Load Above Ground Level
A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) Placing or Stacking a Load above Ground Level 1. Approach the landing area squarely and with care. 2. Side-shift the load if necessary. 3. Raise the load above the level of the landing area or trailer. 4.
Page 88 A4. OPERATING PROCEDURES Lifting and Placing Loads (continued) 7. Extend the mast fully until the load is directly above the landing area or trailer. 8. Lower the load carefully. 9. Tilt the mast forward to position the load and place it on the resting area. 10.
Page 89: Additional Precautions When Placing A Load Above Ground Level
Never side-shift with a raised load. The stability of attempting to pick-up a load from a truck or trailer. the Truck Mounted Forklift will be compromised and the machine may tip over. Always move controls in a smooth, steady manner.
Page 90: A5. Mounting Procedures
Truck Mounted Forklift is carried If your Truck Mounted forklift is being mounted using a by the transport chains or hooks and not the mast, by mounting kit other than the two shown here, please holding the bottom of the Lower N’...
Page 91: Easy Hitch Mounting Kit
Forklift designed transported on the rear of a truck or trailer. Note: When the Truck Mounted Forklift is not on the This section of the manual explains the mounting mounting kit, the D.O.T bumper MUST be folded out procedures for an Easy Hitch Mounting Kit.
Page 92: Mounting Procedure
4. Raise the forks to align them for entry between the fork guides or below the fork bar. 5. Drive the Truck Mounted Forklift forward slowly until the forks are in the fork supports, tilting the mast forward as you drive in.
Page 93 Mounting Procedure – Easy Hitch (continued) 7. Raise the Truck Mounted Forklift until the hooks are above the pins and then retract the horizontal carriage to pull the Truck Mounted Forklift toward the transport vehicle. 8. When the hooks are over the pins, lower the Truck Mounted Forklift until...
Page 94 A5. MOUNTING PROCEDURES Mounting Procedure – Easy Hitch Note: Always ensure the park brake is off when mounting or dismounting the machine. Always wear (continued) your seatbelt, failure to do so will cause the park brake to automatically engage and make mounting difficult. CAUTION: Note: Always remember: Electrical Connector.
Page 95: Dismount Procedure
– Easy Hitch 1. Release both the left and right hand stabilizing chains. If the chains are to stay with the Truck Mounted Forklift, attach the loose ends of the chains to the hooks provided. 2. Remove both “hitch pins”.
Page 96 (continued) 10. Tilt the top of the mast forward to lower the rear tire. 11. Check for pedestrians then drive the Truck Mounted Forklift straight back to pull the forks from the fork supports. 12. Lower the forks to just above ground level and drive away, looking in the direction of travel.
Page 97 A5. MOUNTING PROCEDURES Dismounting Procedure – Easy Hitch (continued) Note: Ensure that your vehicle complies with relevant federal, state and local laws and regulations at all times. Make sure all operating and directional signal lights are functioning and visible. The rear bumper must be locked at full length when the forklift is not being transported.
Page 98: Smooth Ride Mounting Kit
Forklift designed transported on the rear of a truck or trailer. Note: When the Truck Mounted Forklift is not on the This section of the manual explains the mounting mounting kit, the D.O.T bumper MUST be folded out procedures for a Smooth Ride Mounting Kit.
Page 99: Mounting Procedure
A5. MOUNTING PROCEDURES Mounting Procedure – Smooth Ride 1. On trailers, the folding ICC bumper should be folded in and pinned on both sides. 2. Approach the rear of the truck or trailer slowly and squarely. Extend the mast fully and center the side-shift. 3.
Page 100 A5. MOUNTING PROCEDURES Mounting Procedure – Smooth Ride (continued) 7. Lower the forks using the lift lever until the bottom of the front wheel of the forklift is slightly higher than the wheel rests of the mounting kit. 8. Retract the mast fully to move the forklift forward “into” the mounting kit until the front wheels contact the wheel stops.
Page 101 A5. MOUNTING PROCEDURES Mounting Procedure – Smooth Ride Note: Always ensure the park brake is off when mounting or dismounting the machine. Always wear (continued) your seatbelt, failure to do so will cause the park brake to automatically engage and make mounting difficult. CAUTION: Note: Always remember: Electrical Connector.
Page 102: Dismounting Procedure
9. Dismount using the three point contact method. 10. Remove both slackened transport chains from the rear of the truck or trailer. If the chains are to stay with the Truck Mounted Forklift, attach the loose ends of the chains to the hooks provided.
Page 103 A5. MOUNTING PROCEDURES Dismounting Procedure – Smooth Ride (continued) 12. Climb aboard the forklift using the 3-point contact method. 13. Fasten the seatbelt. 14. Start the engine. 15. Extend the mast slowly forward to move the forklift backward out of the mounting kit.
Page 104 A5. MOUNTING PROCEDURES Dismounting Procedure – Smooth Ride Kit (continued) 22. If the chains are to be kept with the truck/trailer, once the forklift is clear of the truck/trailer, connect both chain ends “A” through hitch pin “B” 23. On trailers, the folding D.O.T bumper should be extended and pinned on both sides.
Page 105: Rules For Safe Transportation
Note: Always ensure the park brake is off when Truck Mounted Forklift specifications. mounting or dismounting the machine. Always wear When carrying a Truck Mounted Forklift, make certain your seatbelt, failure to do so will cause the park brake that your vehicle complies with the relevant national to automatically engage.
Page 106: A6. Maintenance
A6. MAINTENANCE Stroke all cylinders fully in and out and check for Daily Maintenance leaks. If the machine is parked up for a long period of time, ensure all cylinders are fully stroked on a Before you begin your work-day, take time to check regular basis.
Page 107 A6. MAINTENANCE Daily Maintenance (continued) WARNING: Hydraulic Pressure. The hydraulic tank is pressurized and hydraulic oil may be hot. To avoid injury and spillage when removing the cap, stop the engine and remove the cap very slowly.
Page 108: Daily Pre-Shift Inspection Checklist
Visual Checks The Truck Mounted Forklift must be parked on a firm level surface in a SAFE ZONE with the keys removed and the park brake engaged. Starting at the operator’s station, walk around the forklift and complete the following visual checks.
Page 109 A6. MAINTENANCE Daily Pre-Shift Inspection Checklist (continued) 10. Left Carriage Cylinder - Check for leaks at the fittings and gland (where the cylinder rod extends and retracts). Check for scratches and nicks on the cylinder rod. Check the mounts for cracks on either end of the cylinder. Check for missing or loose bolts on the cylinder retaining pins at either end of the cylinder.
Page 110 A6. MAINTENANCE Daily Pre-Shift Inspection Checklist (continued) 20. Mast Lift Cylinder and Mounts – Check for leaks at the fittings and gland (where the cylinder rod extends and retracts). Check for scratches and nicks on the cylinder rod. Check the mounts for cracks on either end of the cylinder.
Page 111 A6. MAINTENANCE Daily Pre-Shift Inspection Checklist (continued) 30. Coolant – The coolant should be no more than 4” below the neck of the radiator. Do not attempt to remove the radiator cap if the engine is hot. 31. Rear Steering Cylinder – Check for leaks at the fittings and gland (where the cylinder rod extends and retracts). Check for scratches and nicks on the cylinder rod.
Page 112: Operational Checks
If the operating temperature reaches the upper end of the gauge, this indicates a problem and the forklift must be shut down. If the Truck Mounted Forklift is difficult to start, have your supervisor arrange for an inspection of the glow plugs and starting system. If the lights do not go out after start up, or illuminate during the operation of the Truck Mounted Forklift, immediately shut down the forklift and report the situation to your supervisor.
Page 113 The pedal should return to neutral and the forklift should come to an immediate stop. Seatbelt – With the parking brake in the OFF position and the seatbelt unfastened the Truck Mounted Forklift should not be able to drive in either the forward or reverse direction. With the parking brake in the OFF position and the seatbelt fastened ensure the machine will drive in both the forward and rearward direction.
Page 114 Park Brake – Switch on the parking brake and attempt to drive forward and reverse. If the parking brake is functioning properly the Truck Mounted Forklift should not move. It is also necessary to carry out a park brake test.
Page 115: Transport Checks
Transport Chains – Check for damaged or dislodged pins on the end shackles at either end of both chains. The bolts and lock nuts that retain the transport chains on either side of the Truck Mounted Forklift should be in place.
Page 116: Interlocking Seatbelt
Any time the Truck Mounted Forklift is being operated and is involved in an accident, the whole seatbelt 2. Buckle Operation – Check the buckle for damage assembly must be replaced.
Page 117 The seatbelt fitted has been designed and tested specifically for the Truck Mounted Forklift. Care must be taken when replacing parts to ensure that they are fitted correctly to maintain the integrity and function of the seatbelt system.
Page 118: Service
Take care when washing close electrical allowed to operate the Truck Mounted Forklift. Service connections. personnel should read and study this manual, the service manual, the preventative maintenance manual and parts manual in order to gain a thorough WARNING: understanding of the unit prior to making any repairs.
Page 119 Service (continued) In order to attain full benefit and service from your Truck Mounted Forklift, it is important that the following service information & guidelines are fully adhered to at all times. We recommend servicing take place at the following intervals: 1.
Page 120: Maintenance Check Sheet
A6. MAINTENANCE Maintenance Check Sheet Table 1 Codes Change Check Grease Clean Adjust Table 2 Additional Every First 300hr 500hr 1000hr Service Every VISUAL INSPECTION Intervals Intervals Intervals Quarter or Every or Every or Every 50hrs Year Year 2 Year Driver Consultation/ Debrief Oil / Fluid Leaks CK/A...
Page 121 A6. MAINTENANCE First Additional Every Service 300hr 500hr 1000hr Every VISUAL INSPECTION - Continued Intervals Intervals Intervals Quarter 50hrs or Every or Every or Every Year Year 2 Year Engine Guards In Place Steering Wheel Condition Accelerator / Directional Pedals Covers / Locks / Hinges CK/A CK/A...
Page 122 A6. MAINTENANCE Additional Every First 300hr 500hr 1000hr Service Every ELECTRICAL - CONTINUED Intervals Intervals Intervals Quarter or Every or Every or Every 50hrs Year Year 2 Year Battery Hold Down STEERING SYSTEM Hoses and Fittings Leaks Steering Linkage Steer Bearing Adjustment Steer Motor Mounting Secure Cylinder Condition and Leaks CK/A...
Page 123 A6. MAINTENANCE Additional Every First 300hr 500hr 1000hr Service Every MAST ASSEMBLY- Continued Intervals Intervals Intervals Quarter or Every or Every or Every 50hrs Year Year 2 Year - Stabilizer Cylinders Mast Cylinder Hose Condition Mast Bearings Condition and Tightness CK/A CK/A Carriage Bearings Condition and Tightness...
Page 124 A6. MAINTENANCE Additional Every First 300hr 500hr 1000hr Service Every ENGINE Intervals Intervals Intervals Quarter or Every or Every or Every 50hrs Year Year 2 Year Hoses and Fittings Leaks Mounting Secure Electrical Connections Radiator Mounts and Hoses Alternator V Belt CK/A CK/A Coolant Level and Condition...
Page 125 A6. MAINTENANCE Additional Every First 300hr 500hr 1000hr Service Every OPERATION AND TEST DRIVE Intervals Intervals Intervals Quarter or Every or Every or Every 50hrs Year Year 2 Year Horn Travel Alarm Strobe and Work Lights Pedals and Cables Operation Return To Neutral Gauges/Hour Meter/Warning Lights Differential Lock (Forward and Reverse)
Page 126: Grease Point Chart
A6. MAINTENANCE Grease Point Chart Note: Before greasing any points on the machine remove any hardened grease that may prevent the flow of lubricant. Each item should be moved after the initial application of grease and greased again to ensure complete lubrication at each point.
Page 127 A6. MAINTENANCE Grease Point Chart (continued)
Page 128: Steering Linkage, Spindle Housing And Steering Cylinder Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Steering Linkage, Spindle Housing and Steering Cylinder Grease Point...
Page 129: Fem 2 Fork Carriage Grease Points
A6. MAINTENANCE Grease Point Chart (continued) FEM 2 Fork Carriage Grease Points...
Page 130: Fem 3 Fork Carriage Grease Points
A6. MAINTENANCE Grease Point Chart (continued) FEM 3 Fork Carriage Grease Points...
Page 131: Chain Rollers Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Chain Rollers Grease Points...
Page 132: Mast Section Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Mast Section Grease Points...
Page 133: Tilt Cylinder Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Tilt Cylinder Grease Points...
Page 134: Side-Shift Cylinder Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Side-Shift Cylinder Grease Points...
Page 135: Mast Carriage Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Mast Carriage Grease Points...
Page 136: Side-Shift Bushing Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Side-Shift Bushing Grease Points...
Page 137: Lift Cylinder Grease Points
A6. MAINTENANCE Grease Point Chart (continued) Lift Cylinder Grease Points...
Page 138: Nylon Wear Pad
Corrosion or a lack of lubrication on the steel channels may cause the nylon blocks to stick or judder when lifting a load or mounting the Truck Mounted Forklift. In situations where this occurs the frequency of lubrication must be increased to prevent damage to the nylon...
Page 139: Engine Oil
A6. MAINTENANCE Engine Oil AMBIENT TEMPERATURE OIL SPECIFICATION The engine oil should be SYNT Above -13°F (-25°C) SAE 5W-40 SAE 5W-40 or 0W-30, LOW SAPS Below -13°F (-25°C) SAE 0W-30 EURO 6 or API-CJ4. Change the type of engine oil according to the Max.
Page 140: Engine Coolant
A6. MAINTENANCE Engine Coolant A mix of 50% permanent type antifreeze and 50% distilled water should be used to fill the cooling system. The coolant mix inhibits corrosion, galvanic currents and calcium deposits. Coolant should comply with one of the following specifications: Technical Specifications: 50% Ethylene Glycol 50% Decalcified Water...
Page 141: Engine Fuel Specification
A6. MAINTENANCE Engine Fuel Specification Use a No.2-D grade of ultra low sulfur diesel fuel oil according to ASTM D975-09B regulation - S 15. This is a distillate fuel oil of lower volatility for engines in industrial and heavy mobile service (SAE J313 Jun87). Be sure to use a strainer when filling the fuel tank, as dirt or sand in the fuel may cause trouble in the fuel injection pump.
Page 142: Fuel Filter Cartridge Replacement Procedure
A6. MAINTENANCE Fuel Filter Cartridge Replacement Procedure a) Disconnect the water presence sensor cable. b) Remove the water presence sensor from its cartridge. c) Loosen the cartridge. d) Lubricate the new cartridge gasket (Not shown). DO NOT FILL THE NEW CARTRIDGE WITH FUEL.
Page 143: Hydraulic Fluid
Mounted Forklift must have the correct temperature range for the ambient temperature in which the machine is being operated. If the operating temperature is outside the range of the oil supplied with the Truck Mounted Forklift, the oil should be replaced with the correct grade. Some examples of commercially available oils are listed below. Make sure the correct type is used in the relevant ambient environment.
Page 144: Air Filter Unit
A6. MAINTENANCE Servicing the Filter. Air Filter Unit Loosen the body clamp to remove the access cover assembly and wipe The Air Filter Unit supplied on clean. your Truck Mounted Forklift Ensure the Vacuator™ Valve is clean and clear. consists of a single stage filter If the ServiSignal™...
Page 145: Cleaning Mast Chains Using Steam Jet Equipment
A6. MAINTENANCE Cleaning Mast Chains Using Steam Jet Equipment Recommended Jet Equipment Cleaning Method for Leaf Chain The following method is recommended for when the use of jet equipment cannot be avoided in leaf chain and forklift chain maintenance: 1. Cleaning - Clean the leaf chain using steam or hot water only. Absolutely no additives should be used. 2.
Page 146: Chain Lubrication Specification
A6. MAINTENANCE Chain Lubricant Specification Grease Specification The lubricant oil’s viscosity should be chosen so that it The recommended grease for all moving parts is will remain fluid at all occurring ambient temperatures. Lithium EP2 or a grease of equivalent specification. This Under normal temperature conditions, lubricating oils is particularly important for all bearings and rollers.
Page 147: Tire Inflation
A6. MAINTENANCE Tire Inflation See the chart for the recommended tire inflation pressures used by the Truck Mounted Forklift. It is recommended that the tread depth should never fall below 20% of the original tread depth. WARNING: Specification Compressed Air.
Page 148: Noise And Vibration Data
A6. MAINTENANCE Noise and Vibration data Noise Data Noise (In accordance with EN12053) The figures below are a combination of the values for the operating modes “DRIVE”, “LIFT” and “IDLE” weighted with a proportion factor and is made in accordance with EN12053, 2001 1.
Page 149: A7. Special Procedures
A7. SPECIAL PROCEDURES Even with the starter switch set to the off position some Jump Starting circuits will still be energized when the external power supply is connected. Ensure all machine switches are Safety set to the off position before connecting the external power supply.
Page 150: Procedure
A7. SPECIAL PROCEDURES Jump Starting (continued) Procedure Your machine has a 12 volt starting system. The Note: negative terminal (-) is connected to the engine cylinder block. A) Make sure that the park brake is engaged and the forward/reverse pedal is in neutral. B) Ensure all switches are set to the off position.
Page 151: Priming The Fuel System
A7. SPECIAL PROCEDURES Priming the Fuel System In the event of the machine running out of Procedure. fuel, or the fuel tank being drained, the fuel system must be primed before the next startup. Fill the tank as normal, you must then press button A repeatedly in order to fill the circuit.
Page 152: A8. Attachments
A8. ATTACHMENTS Using other Attachments The Truck Mounted Forklift is available with a range of attachments fitted from the factory. The general rule is that any attachment used on this forklift must be intended for the function of lifting only. This forklift is not designed to PULL, TOW or DRAG other objects.
Page 153: A9. Certificate Of Conformity
A9. CERTIFICATE OF CONFORMITY Certificate of Conformity MANUFACTURER’S CERTIFICATE OF CONFORMITY IN The Truck Mounted Forklift is supplied with a certificate RESPECT OF SELF-PROPELLED FORKLIFT TRUCKS of conformity. This document certifies the directives that the Truck Mounted Forklift is in compliance with.
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Page 158: Safety Decals
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Page 162: Hydraulic Levers
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Page 170: Daily Pre-Shift Inspection Checklist
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Page 171: Operational Checks
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Page 172: Grease Point Chart
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Page 174: Lift Cylinder Grease Points
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Page 175: Mast Outer Section Grease Points
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Page 176: Mast Inner Section Grease Points
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Page 177: Pantograph Mast Section Grease Points
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Page 178: Pantograph Arm Middle Section Grease Points
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Page 179: Pantograph Arm Rear Section Grease Points
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Page 180: Pantograph Arm Front Section Grease Points
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Page 181: Pantograph Cylinder Grease Points
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Page 183: Log Book
The Princeton Truck LOG BOOK Mounted Forklift This section of the manual Note: allows for the recording of machine services, machine damage machine transfer.
Page 185 Machine Model: Serial Number: Capacity: Customer Name: Customer Address: Date: DEALER’S STAMP...
Page 186: C1. Record Of Service Intervals
C1. RECORD OF SERVICE INTERVALS Service type : ______ Hours :______ Service type : ______ Hours :______ Date: Signature: Date: Signature: Hour Count: Company stamp: Hour Count: Company stamp: Remarks: Remarks: Next service: Related service bulletin: Next service: Related service bulletin: Service type : ______ Hours :______ Service type : ______ Hours :______ Date:...
Page 187 C1. RECORD OF SERVICE INTERVALS Service type : ______ Hours :______ Service type : ______ Hours :______ Date: Signature: Date: Signature: Hour Count: Company stamp: Hour Count: Company stamp: Remarks: Remarks: Next service: Related service bulletin: Next service: Related service bulletin: Service type : ______ Hours :______ Service type : ______ Hours :______ Date:...
Page 188 C1. RECORD OF SERVICE INTERVALS Service type : ______ Hours :______ Service type : ______ Hours :______ Date: Signature: Date: Signature: Hour Count: Company stamp: Hour Count: Company stamp: Remarks: Remarks: Next service: Related service bulletin: Next service: Related service bulletin: Service type : ______ Hours :______ Service type : ______ Hours :______ Date:...
Page 189 C1. RECORD OF SERVICE INTERVALS Service type : ______ Hours :______ Service type : ______ Hours :______ Date: Signature: Date: Signature: Hour Count: Company stamp: Hour Count: Company stamp: Remarks: Remarks: Next service: Related service bulletin: Next service: Related service bulletin: Service type : ______ Hours :______ Service type : ______ Hours :______ Date:...
Page 190: C2. Record Of Damage
C2. RECORD OF DAMAGE Date Name Brief Details of Damage or Accident Job No Reported to...
Page 191: C3. Record Of Transfer Of Forklift
C3. RECORD OF TRANSFER OF FORKLIFT Date Transferred From Comments Transport No. Transferred to:...
Page 192: C4. Notes
C4. Notes...
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Page 194 Cargotec USA Inc. 12233 Williams Rd, Perrysburg, Ohio 43551, United States. Tel: +1 419 482 6000 Fax: + 1 419 482 6001 E-mail: info@piggy-back.com Website: www.piggy-back.com...

Princeton Truck Mounted Forklift Operator's Manual

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