FORKLIFT FLT12 Publ. No. IN4453.0002-01/02-2018 OPERATOR’S MANUAL
FLT12 Operator’s Manual ABOUT USwww.cargotec.com Cargotec is a leading provider of cargo and load handling solutions with the goal of becoming the leader in intelligent cargo handling. Cargotec's business areas Kalmar, Hiab and MacGregor offer products and services that ensure our customers a continuous, reliable and sustainable performance. Cargotec is determined to grow its business through strong customer focus. We do not simply offer products, but provide integrated solutions and services designed to meet customers’ specific needs. Our customers include leading global and local players within their industries.www.kalmarglobal.com Kalmar provides cargo handling solutions and services to ports, terminals, distribution centres and heavy industry. We are the industry forerunner in terminal automation and energy-efficient container handling, with one in four container moves around the globe being handled by a Kalmar solution. We improve the efficiency of your every move through our extensive product portfolio, global service network and solutions for seamless integration of terminal processes. Our offering consists of cargo handling equipment, automation, software and services. The Kalmar equipment portfolio includes straddle and shuttle carriers, terminal tractors, yard cranes, ship-to-shore cranes, reachstackers, empty container handlers and forklift trucks. Navis terminal operating systems (TOS), Bromma spreaders and Siwertell bulk handling systems are provided as part of the Kalmar business area.www.indital.in INDITAL, a brand owned by Cargotec India private limited, is engaged in design, manufacture and sales of reliable, simple and economical material handling equipment for ports and various industries. Cargotec is proud to ‘Make in India’ heavy equipment at Multi Assembly Unit in Bangalore. We have manufactured over 800 heavy equipments under the Indital brand since 1989 at our Bangalore facility. Indital offers an array of products like 45 ton loaded container handling reach stacker, empty container handlers, medium & heavy forklift trucks from 10 ton to 32 ton capacity. Our equipment are well known for simplicity in operation, economical in maintenance and offer value for money with lowest overall owning and operation cost. We have a wide service network of dedicated engineers & technicians spread across India with service offices at Chennai, Cochin, Tuticorin, Mumbai, Mundra, Delhi & Kolkata. Apart from service offices, to support customer operations, we have on site placement of engineers / technicians at many customer sites.Cargotec India Pvt. Ltd. Page | 1
FLT12 Operator’s Manual FOREWORD Thank you for purchasing an Indital product. Your product has been designed to provide years of safe and dependable service, as long as it is used and maintained in accordance with the instructions provided in this manual. Carefully read, understand and follow the instructions provided in this manual, refer it as and when required. This is a permanent part of your product and should be kept in product at all the time. It covers important information of product for Operation, Safety, Driving and Maintenance purpose. This Operator’s Manual shows you how to use your Indital product with utmost care for the environment while driving economically at the same time. The noise and the wear of the product depend on the way how you deal with your product. Some photographs or illustrations in this publication show details or attachments that can be different from your product. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your product which is not included in this publication. NOTE WARNING SIGNS Indicates important information relevant to the product, the product’s use or to sections of this manual to which particular attention must be paid. Indicates a potentially hazardous situation which, if not avoided, CAUTION may result in, minor or moderate injury. Indicates a potentially hazardous situation which, if not avoided, WARNING can result in death or serious injury.Page | 2 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual CONTENTSGENERAL INFORMATION ...................................................................... 5GENERAL SAFETY PRECAUTIONS ...................................................... 7PRODUCT SPECIFICATION.................................................................. 15PRODUCT OVERVIEW .......................................................................... 21INSTRUMENTS AND CONTROLS ........................................................ 25PRODUCT OPERATION ........................................................................ 35INSPECTION AND MAINTENANCE ...................................................... 43PRODUCT TRANSPORTATION ............................................................ 63PRODUCT STORAGE............................................................................ 69APPENDIX .............................................................................................. 71WORK SAFETY...................................................................................... 72NOTES .................................................................................................... 73Cargotec India Pvt. Ltd. Page | 3
FLT12 Operator’s Manual GENERAL INFORMATIONPage | 4 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual GENERAL INFORMATIONWelcome to Cargotec India family.The Operator Manual makes you familiar with the Technology, Operation, Routine Inspection &Maintenance of the machine along with safe operation techniques have been explained in detail. Youare advised to strictly adhere to these Techniques and Instructions. The “Professional Product Support”from Cargotec India is just a call away to give you further onsite instructions & training on “Operation &Maintenance” of your machine. This will enable you to get safe, trouble free and efficient operatingperformance of the machine during the operating life of the machine. Once again, thank you forchoosing Cargotec India product.Cargotec India Pvt. Ltd. Page | 5
FLT12 Operator’s Manual GENERAL SAFETY PRECAUTIONSWARNINGS TO OPERATOR..................................................................................7WORKING HAZARDS.............................................................................................9 OVERTURNING:....................................................................................................................... 9 COLLISIONS:............................................................................................................................ 9 DAMAGED MACHINE:............................................................................................................ 10 SYSTEM ALTERATIONS:....................................................................................................... 10WARNING SIGNS .................................................................................................11Page | 6 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualGENERAL SAFETY PRECAUTIONS WARNINGS TO OPERATOR WARNING Only trained and authorized personnel may operate this machine. For safe operation,read and follow the Operator and Maintenance Manual furnished with this lift truck and observe thefollowing warnings. 1. Observe the condition of your working 12. Driving is forbidden without fastening environment. Note the obstacles seatbelts. restricting your work. The slippery areas, heaps of sand, and oily surfaces 13. Do not allow anyone to stand or pass will cause increased risks in your work. under the elevated portion of machine. Report any sources of danger at once to your superior or to the person in charge 14. Operate machine and attachments only of the safety of your working area. from operator's position. 2. Report any faults that you have noticed 15. Do not handle unstable or loosely to your superior or to the person in stacked loads. charge of repairs. 16. Use minimum forward tilt when picking 3. Acquaint yourself in advance with the up or placing a load. use of emergency exits. 17. Take extreme care when handling long, 4. Do not allow any unauthorized persons high, or wide loads. to operate the machine entrusted in your use. The operator of the machine 18. Forks should be completely under load is responsible for any damage caused and spread apart as far as load permits. by the machine. 19. Operating continuously pushing work or 5. Before starting machine. Check all both brake pedal and accelerator pedal controls and warning devices for proper using at the same time may result in operation. damage of main parts. Do not stand under a hanging container or load. 6. Before starting the machine movement, make sure that nobody is standing in 20. Limit your driving speeds to ensure safe front or behind the machine. working conditions. 7. Wear required protective clothing and 21. Avoid sudden stops and starts. Always helmets. drive far enough from any other vehicles ahead. Never drive side by side to other 8. Refer to machine identification plate for vehicles. allowable machine capacity. Do not overload. Operate machines equipped 22. Observe the signs and instructions with extra attachments as partially indicating free height. You should know loaded machines even when not the exact total height of your machine handling any load. before driving into places with restricted free height. Be careful with temporary 9. Thoroughly acquaint yourself with the structures, hanging overhead power machine's structure, manuals and its lines, etc. proper use. Observe the instructions and warnings. 23. Do not drive in the dark without lights. Report any poorly lighted passages. 10. Remember that the machine is not intended for carrying or lifting persons. 24. Watch out for the edges of driveways where the surface may be loose / 11. Always observe sufficient caution and yielding and can cause overturning. care when climbing into or coming down from the machine. Remove all foreign 25. When changing driving direction, stop materials which can affect safety. Wipe the machine completely with the service away all oil leakages at once to prevent brake before changing the direction slipping. selector lever.Cargotec India Pvt. Ltd. Page | 7
FLT12 Operator’s Manual26. Observe the weight of your machine, 32. Only a person who is well acquainted and its total weight loaded. with the machine's control and the cabin controls is allowed to be in the cabin27. Always stop the engine whenever you during service and repairs. leave the machine even for a short while. Lower any load to the ground 33. The engine must always be stopped before you leave the machine. when service or inspections are being carried out.28. Never park the machine on an inclined plane. 34. The use of open flame is absolutely forbidden when checking fuel or battery29. Always remember to engage the electrolyte levels. parking brake before leaving the canopy/cabin. 35. Always– open the radiator cap slowly and cautiously to avoid injury. The30. Always stop the engine for filling the fuel radiator is pressurized when the coolant tank. is hot.31. Follow the periodic maintenance 36. Do not switch off the main switch when schedule. This ensures that the controls the engine is running. Make a detailed and the whole machine operate reliably report on any collisions, including the and safely. damage caused. This could prevent accidents from being repeated.Page | 8 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual WORKING HAZARDSOVERTURNING:Avoid sudden braking especially when the loadis high up; high tipping force may causeoverturning. The load should not be carriedvery high from the ground. This keeps tippingforces to the minimum. Avoid sudden turns oninclined or bumpy surfaces. Powerful brakingcauses great danger of overturning, especiallyduring turning.Observe the changes in the workingenvironment and limit your driving speed sothat you can safely observe possible obstaclesand hazards well in time to avoid accidents.Pay special attention to slippery conditions,snow, ice, or possible oil spills. The slipperysurface constitutes unpredictable risks with thedanger of collision and overturning.Beware of the holes and other damages in theyard surface. These can cause flat tyressuddenly and, thus risk overturning.COLLISIONS:Be always alert when coming across crates, undulations and also when another vehicle is approachingyou. Adjust your driving speed so that you can stop the vehicle within the visible free path ahead.When approaching another container, remember that the machine's springing yields in sudden brakingand the containers may collide (Fork Lift).Cargotec India Pvt. Ltd. Page | 9
FLT12 Operator’s ManualDAMAGED MACHINE:If the machine is damaged it must not be useduntil the damages have been checked andrepaired. Damaged safety system will causeunpredictable results; personal safety iscompromised and the machine and its load willsuffer unnecessary technical and financialdamage.Report any noticed damages at once to yoursuperior or to the person in charge of repairs.SYSTEM ALTERATIONS:No alterations to the structures and the systemof the machine are allowed without themanufacturer's written consent. Alternationsmay lower the level of the machine's safety (bycausing unexpected functions) and thus leadto serious accidents and even loss of life.Page | 10 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual WARNING SIGNS 13 14 14 14 9 6 7 12 11 10 13 8 13 1 13 14 146 2 45 3 13 13 Page | 11Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual 6 18 15 6 16 17Page | 12 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual1 IN2757.0100 - STICKER INDITAL 10 A30534.0100 - BATTERY ON/OFF Brand Battery disconnector2 IN2759.0100 - STICKER FLT12 location point Product Logo 11 IN2411.0100 - SIGN, BATTERY VOLTAGE Refer manual for battery voltage3 IN2419.0200 - WARNING STICKER- 12 450202.0100 - SIGN, DIESEL RH Refer manual for Do not walk under fuel grade the load 13 IN2418.0100 - SIGN, PLATE TIE4 IN2414.0100 - SIGN, HYDRAULIC DOWN OIL Tie down point Hydraulic fluid5 IN2415.0100 - SIGN, WARNING 14 IN2416.0100 - SIGN, HOOK READ INSTR BOOK Fixing point for lift Read the equipment when Instruction Manual lifting the truck6 IN2420.0100 - SIGN, AIR PRESSURE, TYRE 15 A30530.0100 - SIGN WARNING, ROT FAN Tyre pressure Front - Rotating fan. Rear - Fitted on radiator7 IN2419.0100 - WARNING STICKER- 16 A57775.0100 - SIGN LH INFORMATION, COOLANT Do not walk under Refer Manual for the load coolant filling8 IN2421.0000 - Type PLATE, 17 IN2760.0100 - SAFETY STRIPES MACHINE Reflector reflects the light whichCARGOTEC I NDI A PVT L TD. falls on it BANGALORE, I NDI A. 18 IN2991.0100 - STICKER INDITAL MODEL: Type, machine TYPE: Brand bar SL. NO: kg YEAR OF MFG:TYRE PRESSURE P- R: SWL mm VEHI CLE WEI GHT: mm kg kg ENGI NE NO: CHASSI S NO: I N2421. 0000 HD mm Q mm Q C9 A30532.0100 - SIGN PLATE, HOT SURFACE Hot surface warningCargotec India Pvt. Ltd. Page | 13
FLT12 Operator’s Manual PRODUCT SPECIFICATIONPRODUCT DRAWING ..........................................................................................15PRODUCT SPECIFICATIONS..............................................................................16PRODUCT LOAD CAPACITY AND LIFT HEIGHT ...............................................18Page | 14 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT SPECIFICATION PRODUCT DRAWINGB V2 V1 b 100 R2 R1 αß A1 100H5 H4 H3 H6 H8 a L4 Q L2 L3 L5 L Page | 15 L1Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT SPECIFICATIONSGeneral Manufacturer Lifting load Q Kg Cargotec India Pvt LTD. Model Distance L4 mm FLT12 Capacity 12000 Load Centre Capacity ltr Power Unit Capacity ltr 900 (1200)* Diesel Tank Diesel Hydraulic Tank 180 Tyres 180 Pneumatic/SolidDimensions Lift Height Maximum fork height H4 mm 4000 (6500) Fork Carriage ISO class/Type Bar Type Length L1 mm 1800/2200 Fork Width b 200 Thickness a mm 80 Fork Spread Minimum/Maximum Standard V1/V2 100/1880 Tilt Angle Forward α 0 05 Backward β 10 Over all Length to face of forks L Mm 5300 Dimensions Overall Width B mm 2480 with Standard Height with collapsed Mast H3 mm Mast Height with fully extended mm 3520 (4840) Mast H5 mm Turning Radius Overall Height mm 5520 (8090) Seat Height H6 mm Overhang Outer H8 mm 2900 Aisle width Inner R1 mm 1680 Front R2 mm 5000 Rear L2 550 Min. aisle width for 90° L5 800 stacking with forks 990 A1 8550Performance Speed with Travel – Laden/ Unladen Km/hr 26/28 Standard Mast Lifting - Laden m/s 0.28 Lowering - Laden m/s 0.32 Gradability Laden % 34Page | 16 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT SPECIFICATIONS CONTINUED Weight with Laden / Unladen Kg 30215/18215 Standard Mast Front Axle – Laden / Unladen Kg 27535 / 9005 Rear Axle – Laden / Unladen Kg 2680 / 9210 Axle Load with Standard Mast Numbers – Front / Rear 04 / 02Frame and Tyres Tyres Size - Front 11.0 X 20, 18 PR Size - Rear 11.0 X 20, 18 PR Wheelbase L3 mm 3500 Track Front/Rear mm 1815/1985 Under Mast mm 250 Ground Under Frame / Engine mm 285 clearance Brake Service Brake Pneumatic Drum Brakes Parking Brake Mechanical Air Released Manufacturer/ Model Ashok Leyland/ H6ETIC3U23 Rated Power @ Speed hp/kW Rpm 133/99 @ 2300 Engine Max.Torque @ Speed Nm Rpm 475@1900 rpm No.of Cylinders/Displacement cm3 6/5760 Emmission Standard CEV BSIIIDrive Manufacturer/ Model AVTEC/ TRT2221-3 Transmission Speed – Forward / Reverse 2F/2R Effective 4/4 Gear Shift Hydraulic (Electric) Type Power shift with Torque Drive axle Manufacturer/Model Converter Type Meritor MS1497 Heavy Starting Battery Voltage/capacity V/Ah Duty Single Reduction Axle 2 x 12/100 (150)Cargotec India Pvt. Ltd. Page | 17
8090 mm (Max.) FLT12 Operator’s Manual LH 6500 mm (Max.) PRODUCT LOAD CAPACITY AND LIFT HEIGHT 12,000kg 900mm FLT12 CAPACITY WITH MAST IN VERTICAL POSITION ON LEVEL GROUND.Page | 18 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualCargotec India Pvt. Ltd. Page | 19
FLT12 Operator’s Manual PRODUCT OVERVIEWMAIN PARTS OF MACHINE .................................................................................21POWERTRAIN ......................................................................................................22OTHER PARTS .....................................................................................................23Page | 20 Cargotec India Pvt. Ltd.
Cargotec India Pvt. Ltd. TILT CYLINDER OVERHEAD GUARD Hydraulic cylinders that are mounted A metal roof supported by posts at each corner to the truck frame and the mast. Tilt of the cab that helps protect the operator from FLT12 Operator’s Manual cylinders pivot the mast backward or forward to assist in engaging a load. COUNTERWEIGHT PRODUCT OVERVIEW A mass attached to the rear of the forklift truck MAST frame. The purpose of the counterweight is to MAIN PARTS OF MACHINE The vertical assembly that does the counterbalance the load being lifted. work of raising and lowering the load. The mast is driven hydraulically, and ENGINE COMPARTMENT operated by one or more hydraulic It consists of an internal combustion engine that cylinders directly or using chains and is powered by diesel fuel. Engine compartment cylinders. provides access for servicing of machine. CARRIAGE REAR AXLE/ STEER AXLE The component to which the forks or The rear axle has a full time power steering with other attachments mount like the mast, hydrostatic steering system and heavy duty balanced the carriage may have either rollers or cylinder. Steering axle fabricated from high strength bushings to guide it in the interlocking steel and stub axles are made from forged single mastrails. piece alloy steel. FORKS FOOT STEP CANOPY Two cantilevered arms that carry the load. The area that contains a seat for the operator along with the control pedals, steering wheel, levers and switches operator readouts. The cab area may be open air or enclosed but it is covered by the cage like overhead guard assembly. WHEELS AND TYRES Heavy duty wheels with off highway tyres are assembled on the machine.Page | 21
Page | 22 RADIATOR WITH TRANSMISSION OIL COOLER ENGINE The engine is a straight 6-cylinder turbocharged low emission engine. The engine provides the power for propulsion and hydraulics. PROPELLER SHAFT FLT12 Operator’s Manual It transmits power from transmission to drive axle. POWERTRAINCargotec India Pvt. Ltd. DRIVE AXLE TRANSMISSION It is the load carrying member of the forklift. It has planetary reduction system to increase the The Fork Lift is provided with a Power Shift Transmission linked to torque to wheels. Engine through a Torque Converter. Usage of the Torque converter eliminates the need for manual disconnect clutch, and gives Torque multiplication thereby improving the overall driver and equipment efficiency. It also reduces shock and strain on the entire drive line thereby increasing its service life. Speed change is achieved by electrical, or mechanical shifter.
FLT12 Operator’s Manual OTHER PARTS BEACON LIGHT WORKING LIGHTS MAST CANOPY EXHAUST MUFFLER MAIN SWITCHHEAD LIGHTS & INDICATORS CARRIAGE TAIL LIGHTS & INDICATORSFIRE EXTINGUISHER FORK STEPS FUEL TANK REAR AXLE BATTERY BOX RIMS AND TYRES HANDLEDRIVE AXLE FUEL LEVEL INDICATOR TILT CYLINDER WORKING LIGHTS STEERING WHEEL AIR INTAKE LIFT CYIINDER AIR FILTER TAIL LIGHTS & INDICATORS TURNINGCOUNTERWEIGHT INDICATOR HYDRAULIC TANK PARKING LIGHT HEAD LIGHTS & INDICATORS HANDLE STEPS ELECTRICAL CONTROL PANELCargotec India Pvt. Ltd. Page | 23
FLT12 Operator’s Manual INSTRUMENTS AND CONTROLSCABIN INTERIOR .................................................................................................25DASHBOARD INSTRUMENTS:............................................................................26 LEFT DASHBOARD: ............................................................................................................... 26 RIGHT DASHBOARD:............................................................................................................. 27 CENTRE DASHBOARD: ......................................................................................................... 28FORKLIFT CONTROLS ........................................................................................30 FOOT CONTROLS: ................................................................................................................ 30 LEFT HAND CONTROLS:....................................................................................................... 31 RIGHT HAND CONTROLS: .................................................................................................... 32SEAT ADJUSTMENTS..........................................................................................33Page | 24 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual INSTRUMENTS AND CONTROLSThe machine has ergonomically designed canopy with overhead guard provided. CABIN INTERIOR 3 21 6 7 4 501 Left Dashboard02 Right Dashboard03 Centre Dashboard04 Foot Controls05 Left Hand Controls06 Right Hand Controls07 Driver seat with arm rests and seat beltCargotec India Pvt. Ltd. Page | 25
FLT12 Operator’s Manual DASHBOARD INSTRUMENTS:LEFT DASHBOARD: 1 234 8 5 679 10 11 12 13 14 15 INDICATORS (LED) Cargotec India Pvt. Ltd. 01 Left Turn Indicator 02 High Beam 03 Battery Charging Indicator 04 Right Turn Indicator 05 High Water Temp Indicator 06 Low Oil Pressure Indicator 07 Low Air Pressure Indicator OTHERS 08 Warning Buzzer ON/ OFF SWITCHES 09 Beacon Lamp 10 Wiper 11 Cabin Light 12 Head Light 13 Parking Light 14 Front Working Light 15 Rear Working LightPage | 26
FLT12 Operator’s ManualRIGHT DASHBOARD: 1 23 45 6 8 7GAUGES01 Engine Oil Pressure02 Transmission Oil Temperature03 Engine Water Temperature04 Air Pressure05 Transmission Oil Pressure06 RPM + Hour meterKEY SWITCH07 Engine StopPUSH BUTTON SWITCH08 Ignition SwitchCargotec India Pvt. Ltd. Page | 27
FLT12 Operator’s ManualCENTRE DASHBOARD: 2 6 5 1 4 301 Combination Switch for Head Light high/low, Left/Right Indicator, horn02 Steering Wheel with knob03 Steering Column04 Horn05 Turn Indicator06 BeamPage | 28 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualElectrical Gear ShifterThe gear-changing mechanism is electrical, and the gearbox is operated via solenoid valves.F – FORWARDN – NEUTRALR – REVERSEThe engine cannot be started unless the gear lever is in neutral. The truck must be stopped completelybefore changing between forward and reverse, in order to prevent overloading of the gearbox.Run the engine at idle speed, select the forward direction of travel by pushing the gear lever forward andengage first gear, using the rotary control. Never drive away in a higher gear, since this may lead tounnecessary overheating.Release the parking brake, and accelerate carefully.To change up, rotate the gear selector handle to second gear, release the accelerator pedal and thesecond gear will be engaged, accelerate, and so on.Reverse the procedure when changing down. Remember to increase engine speed before engaging alower gear, since the truck will otherwise brake heavily. 2 F N 1 R 01 Gear Shifter 02 F – Forward, N – Neutral, R – ReverseCargotec India Pvt. Ltd. Page | 29
FLT12 Operator’s Manual FORKLIFT CONTROLSFOOT CONTROLS:Accelerator Pedal:Depressing this pedal with right foot will increase engine RPM and vice versa. The linked to the fuelpump through a mechanical cable.Inching Brake Pedal:This brake pedal is located on the left side of the steering column and works as a clutch pedal becauseof the inching valve built in the hydraulic system. When the pedal is depressed slightly, the engine poweris disconnected. When depressed further, brake begins to operate. NOTE Do not overuse the inching brake pedal. it may cause transmission oil to overheat or theclutch to slip if it is used as a footrest or used for a long time.Brake Pedal:The lift truck is equipped with a conventional brake pedal as well as an inching brake pedal. Theconventional pedal is located on the floor to the right. 3 2 1 01 Inching Brake Pedal Cargotec India Pvt. Ltd. 02 Brake Pedal 03 Accelerator PedalPage | 30
FLT12 Operator’s ManualLEFT HAND CONTROLS: 1 2 01 Gear Lever for Forward (F1 & F2), Neutral and Reverse 02 Parking Brake NOTE On the machine fitted with Electrical Gear Shifter on Steering Column, Direction Lever andGear lever will not be present.Cargotec India Pvt. Ltd. Page | 31
FLT12 Operator’s ManualRIGHT HAND CONTROLS:Left lever - Lift LowerLIFT – pull the lever backLOWER – push the lever forwardThe lifting speed can be adjusted by varying the engine speed and the distance the lever is moved. Thelowering speed can be adjusted only by the distance the lever is moved.Right lever - TiltBACKWARD – pull the lever backFORWARD – push the lever forwardThe forward or backward tilting speed can be adjusted by the engine speed and the distance that thelever is moved. 12 01 Left Lever (Mast, Lift and Lower) 02 Right Lever (Mast, Forward and Backward Tilt)Page | 32 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual SEAT ADJUSTMENTS 1 32 01 Inclination Adjustment Page | 33 02 Sliding Adjustment 03 Weight AdjustmentCargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT OPERATIONRUNNING-IN FOR NEW MACHINE .....................................................................35 ENGINE:.................................................................................................................................. 35 TYRES AND RIMS: ................................................................................................................. 36SAFE WORKING PRACTICES .............................................................................36 PHYSICAL CONDITIONS OF OPERATOR; ........................................................................... 36 BEFORE STARTING THE FORKLIFT: ................................................................................... 36 GETTING IN AND OUT OF THE MACHINE: .......................................................................... 37 BEFORE OPERATING THE FORKLIFT: ................................................................................ 37 STARTING ENGINE:............................................................................................................... 37 WARMING-UP: ....................................................................................................................... 37 OPERATING THE FORKLIFT:................................................................................................ 38 LOADING THE FORKLIFT TRUCK: ....................................................................................... 39 DRIVING WITH LOAD:............................................................................................................ 40 DRIVING SPEED: ................................................................................................................... 41 STOPPING THE FORKLIFT: .................................................................................................. 41 ENVIRONMENTAL IMPACT: .................................................................................................. 41Page | 34 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT OPERATION CAUTION User is responsible forensuring that the machine comes in for serviceaccording to prescribed service intervalsThe machine is intended to be used in the waythat is described in the operator's manual. Ifthe machine is used in any other way or inpotentially dangerous environments, e.g. anexplosive environment, then special safetyrules must be followed and the machine mustbe equipped for such an environment. NOTE Procedures are described in themaintenance manual RUNNING-IN FOR NEW MACHINEA new machine should always be treated with care during a certain running-in period. During this period,the surfaces of the bores, gears and bearings will become hard and polished, and this will ensure a longuseful life of the engine.Avoid running the engine at full load during the first 50 hours. The load can then be gradually increased.Try to extend the running-in period to 200 hours. This will pay in the long run – the stoppages andbreakdowns will be fewerENGINE:A new engine should always be handled withgreat care - it must have a running-in period.Avoid running the engine at full load during thefirst 8 hours. Then, loading the engine can beincreased gradually. NOTE Check the oil pressure andtemperature at regular intervals.Engine oil and filters should be changed forthe first time after 50 operating hours.Thereafter oil and filter change take placeaccording to intervals described later.Cargotec India Pvt. Ltd. Page | 35
FLT12 Operator’s ManualTYRES AND RIMS:For a new machine it is extremely important that the wheel nuts are check tightened during the first weekof operation until they are properly set in. This should be done at intervals of 4-5 operating hours (up toapprox. 40-50 operating hours). SAFE WORKING PRACTICESPHYSICAL CONDITIONS OF OPERATOR;1. Free from any physical or mental 3. Normal hearing, preferably without need condition that would jeopardize the safe of a hearing aid. operation of the truck (dizzy spells, medication, bad back, etc.) 4. Normal reflexes and reaction time.2. Good vision, of at least 20/40, corrected 5. No use of illegal substances; and use of if necessary; depth perception of at alcohol. least 90 percent of normal. Wearing vision protection is recommended at all 6. Ability to understand and read times. instructions, signs, etc.BEFORE STARTING THE FORKLIFT: 9. Make sure the forklift horn, lights, backup alarm (if equipped) and all other 1. Perform a walk-around inspection daily devices are working properly. or at the start of each shift. 10. Check for proper operation of mast and 2. Make a habit of checking whether attachments. Pay particular attention to coolant temperature is within the unusual noises or erratic movement prescribed limit (80-105 °C) and fuel which might indicate a problem. level from fuel level indicator. 11. Make sure service and parking brakes, 3. Adjust the seat in such a way that full and steering, are operational. brake pedal travel should be achieved 12. Forks are not bent; no cracks present; 4. Make sure that the forklift is equipped positioning latches are in good working with proper lighting system based on condition; carriage teeth not broken, working conditions. chipped or worn. 5. Make sure that all the hydraulic controls 13. Battery is fully charged; check cables for are in proper condition. exposed wires; battery plug connections not loose, worn or dirty; vent caps not 6. Make sure the parking brake is clogged; electrolyte levels in cells; hold- engaged. downs or brackets to keep battery securely in place. 7. Make sure no one is standing or working or underneath or close to the 14. Ensure Fire extinguisher is present and forklift before operating. charged 8. Operate the forklift and controls only from the operator's station.Page | 36 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualGETTING IN AND OUT OF THE MACHINE: 5. Do not use any controls as handholds when entering or leaving the operator's 1. Clean your shoes and wipe your hands station before mounting. 6. Never get on or off a moving forklift. 2. Use both hands; face the lift truck when Never jump off the forklift. getting in and out. 7. Keep hands and steering wheel free 3. Use handgrips for getting in and out. from slippery material. 4. Do not try to climb on or off the forklift when carrying tools or supplies.BEFORE OPERATING THE FORKLIFT: attachments work. Before moving the forklift, look around. Start, turn and test 1. Test brakes, steering control, horn and brake smoothly. other devices for proper operation. Report any faulty performance. Do not 3. An operator must constantly observe his operate lift truck until repaired. forklift for proper operation. 2. Learn how your forklift operates. Know its safety devices .Know how theSTARTING ENGINE: WARNING Never use a starting spray to 6. Check that the hour meter is working orfacilitate starting, since this may cause an not.explosion. 7. Now, accelerate the engine to 1000 1. Ensure parking brake is “ON” RPM and check whether oil level in the transmission is within limits. Top up the 2. Ensure that all lights and electrical oil if necessary. devices are OFF 8. Ensure that Transmission Oil pressure 3. Set gear selector lever in NEUTRAL is not in the “RED” Zone. position. 9. Ensure that Transmission Oil 4. Turn the start key to operating position.- temperature is in the green Zone. Power is now supplied to all electrical circuits CAUTION IF THE ENGINE DOES NOT START, try again after 15-20 seconds. Do not 5. Turn the start key to start position. operate the starter motor for more than 10 seconds at each start attempt. a. Starter motor crank’s the engine, release the key when the engine fires. NOTE Battery charging indicator lightshould remain illuminated after start to indicatestate.WARMING-UP:Never race a cold engine. Run the engine at 1400–1500 r/min until it starts to warm up. It is essentialthat the engine oil be warm and that it is circulating correctly before the turbocharger starts running athigh speeds. Nor should the engine be run at critically low speeds. Start using the truck only when theengine has reached normal working temperature, i.e. when the coolant temperature gauge on theinstrument panel reads about 80°C.Cargotec India Pvt. Ltd. Page | 37
FLT12 Operator’s ManualOPERATING THE FORKLIFT: 1. Always wear the seat belt NOTE If the seat belt is torn, if pullingmotion is interrupted during extension of thebelt, or if the belt cannot be inserted into thebuckle properly, replace the seat belt assembly 2. Always keep the lift truck under control. 3. Obey all warning signs. Never leave the forklift in “on” condition, or with the parking brake disengaged. 4. Always observe floor load limits and overhead clearance. 5. Stay in designated travel path, clear of dock edges, ditches, other drop-offs and surfaces which cannot safely support the lift truck. 6. Slow down for turns, grades, slippery or uneven surfaces. 7. A lift truck is designed for only one operator and no co-drivers. 8. Do not stunt ride or indulge in horseplay. 9. Do not overload, or handle offset, unstable, or loosely stacked loads. Refer to load capacity plate on the forklift truck. Use extreme caution when handling suspended, long, high or wide load. 10. When stacking, watch for falling objects. Use load backrest extension and overhead guard. 11. Always look and keep a clear view of the path of travel. Travel in reverse if the load or attachment blocks visibility. In such cases use rear view mirrors. WARNING Do not use machine forpushing the loads.Do not overload the machine.Page | 38 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualLOADING THE FORKLIFT TRUCK: Load Centre Load 1. The most important safety • consideration when operating a forklift is Correct Loading the stability of the forklift when it is loaded. 2. If the load on the forklift causes it to become unstable, it may tip forward or tip sideways. 3. It is essential that the load on the pallet is stable and well stacked before it is lifted and moved. 4. Make sure the pallet is in good condition. 5. Broken pallets should not be used. The load may need to be restacked if the pallet is broken or appears unsafely loaded. 6. The load should have a center of gravity that is: a. Low as possible in the load. b. Towards the back of the load. c. Centered across the load. 7. To make sure that the load is stable, heavy objects should be placed at the bottom of the load and to the rear of the load. 8. Use strapping to secure the load if there is a chance of objects falling off. 9. No part of the load should extend beyond the back rest of the carriage, unless it cannot possible. Slide load back towards the driver. WARNING NO OVERLOADING! Do not Incorrect Loadingexceed the recommended load limit of yourforklift truckCargotec India Pvt. Ltd. Page | 39
FLT12 Operator’s ManualDRIVING WITH LOAD: Tilt Back 300 mm 1. While driving the forklift with load, the mast should be tilted max backward and the forks should be lifted 300mm from ground for level surfaces. 2. Release park brake and select forward or reverse. 3. Check that the direction of travel is clear. 4. On entering or leaving a confined space, sound horn or warning device to warn any personnel of the machine movement.WARNING Transporting loads isassociated with major risks. Risk of roll-overand tipping over! Chance of damage to loadand property!5. The machine should not be operated on very uneven surfaces.6. Do not transport the load in high position since this may cause the machine to roll or tip over.7. Always operate with the load facing uphill on an uphill (drive forward) and downhill grade (drive backward).8. Never operate or turn across a grade.9. Operate the machine in reverse if the transported load obscures visibility to the front.10. No personnel may encroach or stand under a raised load.11. The operator must avoid forceful acceleration and heavy braking in order to prevent risk of tipping and roll-over.12. The operator must always adjust the speed when turning to prevent skidding and risk of roll-over or tipping over. WARNING Tip over can occur if truck isimproperly operated. Injury or death couldresultIn case of tip over Don’t jump off, Hold on tightto steering wheel, Brace feet and Lean awayfrom impact.Page | 40 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualDRIVING SPEED: 3. Drive always with lower driving speed: maximum 22 Kmph. 1. You can drive with maximum driving speed only by driving direct on level and 4. Avoid sudden and violent braking and well maintained surface. starting. 2. Drive always with lower driving speed 5. Drive in curved roads with low speed during turning or driving on uneven surface and always be very slow when visibility is low.STOPPING THE FORKLIFT: 1. Release the accelerator pedal gradually. 2. When vehicle almost come to stop, apply brakes. 3. Shift the gear lever to neutral position. 4. Apply parking brake. 5. Place the load on desired position. 6. Lower the fork to its normal position without tilting forward or backward. 7. Idle run engine for about 2 minutes and press Engine Stop button, Engine stops.WARNING Never park the machine on slope.ENVIRONMENTAL IMPACT:It is important that the machine is used in a way that results in minimal environmental impact withregards to fuel consumption, exhausts, and noise emissions.Therefore, keep the following in mind:1. Plan the work and optimize machine 4. Optimize operation with regard to use. acceleration and braking.2. Avoid operating with full throttle when 5. Minimize the time the machine runs at transporting. idling speed. Do not allow the machine to idle when there is a break in the work.3. Do not rev the engine unnecessarily when load handling.Cargotec India Pvt. Ltd. Page | 41
FLT12 Operator’s Manual INSPECTION AND MAINTENANCEDAILY INSPECTION .............................................................................................44INSPECTION WORK INSTRUCTIONS ................................................................45 WALK-AROUND INSPECTION:.............................................................................................. 45MAINTENANCE ....................................................................................................46 TYRES AND RIMS: ................................................................................................................. 46 ENGINE OIL:........................................................................................................................... 48 TRANSMISSION OIL; ............................................................................................................. 49 HYDRAULIC OIL: .................................................................................................................... 50 FUEL SYSTEM: ...................................................................................................................... 51 COOLING SYSTEM: ............................................................................................................... 52 AIR FILTER: ............................................................................................................................ 53 ENGINE FAN BELT:................................................................................................................ 54 BATTERY & MAIN SWITCH: .................................................................................................. 55 LIGHTING SYSTEM:............................................................................................................... 57 CONTROL PANEL: ................................................................................................................. 58 SERVICE POINTS: ................................................................................................................. 59 OIL RECOMMENDATIONS: ................................................................................................... 60SERVICE ............................................................................................................... 61Page | 42 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual INSPECTION AND MAINTENANCEThis chapter describes:• DAILY INSPECTION - performed by the operator.Daily inspection describes the running inspection that significantly contributes to making the machine asafe and reliable workplace.• MAINTENANCE - performed by the operator.Maintenance describes some simple maintenance actions.• SERVICE - performed by trained service technician.Advanced maintenance is performed according to a service schedule and by service technicians.Advanced maintenance is described in the maintenance manual.The user is responsible for ensuring that the machine comes in for service according to prescribedservice intervals. NOTE All time information refers to operating time, that is, the time shown by the hour meter on thepanel. CAUTION 1. Only genuine spare parts, coolants, oils and lubricants approved by Cargotec India should be used. 2. This is to maintain the machine's safety as well as to meet warranty and service agreements!Cargotec India Pvt. Ltd. Page | 43
FLT12 Operator’s Manual DAILY INSPECTIONDaily inspection of the machine is extremely important in order to ensure that it is safe both for theoperator and its surroundings. Every operator should perform checks before a new work shift. In thisway, operators can avoid running defective machines with malfunctions that have been generated orcaused during an earlier work shift. WARNING 1. Never use a machine without first performing the daily inspection. 2. Risk of personal injury and property damage! 3. Report to the foreman/supervisor if defects are found on the machine during daily inspection!Page | 44 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual INSPECTION WORK INSTRUCTIONSWALK-AROUND INSPECTION:For your own safety and maximum service life of the lift truck, make a thorough walk-around inspectionbefore mounting the lift truck or starting to move it.Look for such items as loose bolts, trash build-up, oil leaks, condition of tires, mast, carriage, forks orattachments. 1. Inspect the canopy for loose items and clean any mud or debris from the floor plates for safe footing. 2. Inspect the instrument panel for damage to the indicator display. 3. Inspect the mast and lift chains for wear, broken links, pins and loose rollers. 4. Inspect the carriage, forks or attachments for wear, damage and loose or missing bolts. 5. Inspect the tires and wheels for proper inflation, cuts, foreign objects like glass, metal filings etc. 6. Check for loose wheel nuts and tighten periodically. 7. Inspect the overhead guard for damage, loose or missing mounting bolts. 8. Inspect the hydraulic system for leaks, worn hoses or damaged lines. 9. Inspect the ground for any oil leaks. 10. Inspect the battery compartment for loose connections, frayed cables and loose battery restraint. 11. Ensure that sensors are clean and free from grease. 12. Check Engine lubrication oil/engine oil level in the dipstick. 13. Check Transmission oil level in the dipstick. 14. Check Hydraulic oil level in the hydraulic tank gauge. 15. Check Engine Coolant level in the radiator coolant tank. 16. Check Fuel level in the fuel gauge. 17. Check windscreen cleaner and condition of the wipers. 18. Check the condition and its tightness of the engine fan belt periodically. 19. Drain water from the fuel filter water separator periodically. 20. Inspect for noises & leakage from engine, transmission, drive axle and hydraulic components. 21. Test the service and parking brakes 22. Test the horn and other safety devices for proper operation. 23. Do not forget the necessary maintenance and repair work in order to keep the operational safety and operating performance of the machine on the planned level. Take care to complete all refills. WARNING Residue from fuel, oils, grease or other flammable materials on the engine or in theengine compartment is a fire hazard.Remove residue of flammable materials in the engine compartment as soon as they are detected. Beextra careful on hot surfaces such as exhaust systems, manifolds or turbo chargers. If leakage of oil, fuelor coolant is detected, the reason should be investigated and the fault corrected before starting theengine.Cargotec India Pvt. Ltd. Page | 45
FLT12 Operator’s Manual MAINTENANCETYRES AND RIMS:Checking1. Check the tyres regularly, if possible, daily.2. Remove objects that could penetrate the tyres, such as broken glass, pieces of wood, metal shvings, etc.3. Check for uneven and rapid wear. This is caused by mechanical faults such as unevenly acting brakes. Make sure that such faults are immediately rectified.4. Inspect tyres for wear, cuts, gouges and foreign objects. Look for bent rims and correct seating of locking ring.,5. Changing tyres is high-risk work and WARNING extreme danger!. Let service personnel change tyres, they have the 1. Check-tighten the wheel nuts on a new competence and authority to handle wheel after 4-5 operating hours. tyres! Extreme hazard to personal health and risk of property damage!6. When changing tyres, deflate first. Risk of tyre explosion! Extreme danger! 2. Tighten bolted joints crosswise. Contact Deflate tyres by loosening and removing a service technician if required. the valve. NOTE7. Rim damage makes wheel handling extremely dangerous! Risk of tyre 1. Spare and replacement tyres should be explosion! Extreme danger! Let service of brand names approved by Cargotec personnel change tyres, they have the India. Risk of overloaded tyres! Use competence and authority to handle tyres approved by Cargotec India. tyres! 2. Wheels, tyres, and rims are8. Penetrating objects such as crushed dimensioned and selected for each glass, pieces of wood, metal shavings, machine type so that maximal wheel etc. and mechanical defects, such as loads and speeds are not exceeded. uneven brake wear, can cause tyre For this reason it is not permitted to damage. Risk of tyre explosion! change tyre dimension, tyre make, tyre Extreme danger! Check the tyres at type, rim type, or rim make without regular intervals for external damage approval from Cargotec India. and tyre pressure.Page | 46 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual Tyre inflationInflating tyres Locking ringCare of compressor for inflating tyres: 1. An air filter with water separator should be installed in the line from the compressor used for inflating tyres. The water filter minimizes the risk of corrosion on wheel rims. 2. Drain the water separator regularly.Tyre inflation 1. Before inflating, make sure that the rim's lock ring is in the correct position. NOTE If the tyre has been completelydeflated, the rim must be dismantled andchecked for damage. Let service personnelchange tyres, they have the competence andauthority to handle tyres! 2. Connect the compressor with a locking air-chuck to the nipple on the tyre. 3. Move to the side and stay to the side of the tyre until inflating has been completed. 4. Inflate the tyre to the prescribed pressure. When changing tyre or rim version, another tyre pressure may apply, contact Cargotec India. WARNING Never stand in front of a tyrewhen inflating! Do not exceed prescribed airpressure, which must be checked at ambienttemperature. When changing tyre or rimversion, another tyre pressure may apply,contact Cargotec India. The plate for tyre airpressure must be replaced with a plate withthe applicable tyre pressure!Extreme danger!Always follow instructions for inflating tyres toavoid serious accidents.Cargotec India Pvt. Ltd. Page | 47
FLT12 Operator’s ManualENGINE OIL: 1. If the engine is running already, stop the engine and wait for a minimum of five minutes. 2. Open the engine shield/cover. 3. Check, that oil is between the max – min level marks in the oil dipstick. 4. If oil level is found less than minimum mark, then the engine oil has to be filled to the required level. 1 01 Engine oil filling cap 2 02 Engine oil dipstick Cargotec India Pvt. Ltd.Page | 48
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