FLT12 Operator’s ManualTRANSMISSION OIL; 1. Let the engine run at idle speed. 2. Be sure that the transmission temperature is 80ºC to 90ºC. 3. Open the engine cover/shield. 4. Check, that oil is between the marks in the oil dipstick and top up if required. 1 01 Transmission Oil DipstickCargotec India Pvt. Ltd. Page | 49
FLT12 Operator’s ManualHYDRAULIC OIL:The hydraulic oil level gauge is on the right side of the machine. Before checking the hydraulic oil levelall large cylinders must be retracted; the mast to be downward to lowest position as much as possible.When the oil level line is clear and seen in the gauge, the maximum oil level should be approximately inthe middle of the gauge as per the markings.Fill the hydraulic tank through the filling cap (1) if less. 1 Cargotec India Pvt. Ltd. 2 01 Hydraulic Oil Cap 02 Level GaugePage | 50
FLT12 Operator’s ManualFUEL SYSTEM: 1. Always refuel with low Sulphur diesel oil. 2. Never use any additives for diesel oil 12 3 01 Fuel Cap Page | 51 02 Bleed Screws (Fuel Pipes) 03 Priming Pump WARNING Fire Hazard! Always refuel the machine at designated areas only.Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualCOOLING SYSTEM:The coolant is topped up via the radiator filling cap accessible through an aperture in the engine hood 1 2 01 Radiator Tank 02 Radiator Filling CapWARNING Do not open the cap when the engine is hot, since steam or hot water may spray out.Page | 52 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualAIR FILTER:The filter elements of the air filter must be changed immediately, when the “clogging indicator” is red. 1 2 01 Clog Indicator Page | 53 02 Filter Elements ChangeCargotec India Pvt. Ltd.
FLT12 Operator’s ManualENGINE FAN BELT:Visually check the function of the fan belt. If there are cracks or peel offs, the belt must be changedimmediately.Check also the tightness of the belt by pressing it with finger in the middle of the supporting points. If thebelt is stretching more than 15…20 mm it must be tightened. max. 15 - 20 mmPage | 54 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualBATTERY & MAIN SWITCH:The electrical system operates with a system voltage of 24 VDC. The power source consists of twoseries-connected 12 VDC batteries that are charged by an alternator. The negative terminal isconnected to the frame. The positive terminal is connected to main switch. 2 1 01 Batteries 02 Main Switch CAUTION When working with the electrical system, when carrying out welding on the machine orat long time parking, always isolate the battery.Checking electrolyte level in batteryThe batteries are located inside of a cover behind the steps on the machine's left-hand side. Theelectrolyte level should be about 10mm above the cells. Top up with deionized water as necessary.Batteries contain substances hazardous to health and the environment. Therefore, discarded batteriesmust be handled in accordance with current local/national regulations. WARNING Battery electrolyte contains corrosive sulphuric acid. Use protective glasses andprotective gloves when working with the batteries. Immediately remove any electrolyte on bare skin.Wash with soap and plenty of water. If the electrolyte gets into the eyes, rinse immediately with lots ofwater and contact a doctor immediately. 1. Risk of explosion! Fire hazard! Risk of personal injury! 2. Do not short-circuit the battery. 3. The battery's terminals must not be connected to each other or to common grounding point (chassis).Cargotec India Pvt. Ltd. Page | 55
FLT12 Operator’s ManualStarting from another battery 1. Check that auxiliary batteries are connected in series so that 24V will be supplied. Do not disconnect existing truck battery cables. 2. Connect the jumper cables in the following order: a. Red cable (+) to the auxiliary battery positive terminal. b. Red cable (+) to the truck battery positive terminal. c. Black cable (-) to the auxiliary battery negative terminal. d. Black cable (-) to a point some distance from the truck battery, such as. the negative cable connection to the frame. 3. Start the engine and then run the engine at increased idle for approx. 10 minutes to charge the batteries. Do not disturb the jumper cables while starting as there is a risk of sparks. Do not lean over any of the batteries. 4. Disconnect the jumper cables in the reverse order, one cable at a time. WARNING Batteries emit oxyhydrogen which is an explosive gas. A spark, for example fromincorrectly connected starting cables, could cause a battery to explode and result in serious injury anddamage.Page | 56 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualLIGHTING SYSTEM:It's important to replace the light bulbs with appropriate ratings for respective lighting point. Please seethe below table for correct ratings and bases. Description Rating Watts Model BaseCanopy light 10 R10W BA15sBrake light 21 P21W BA15sParking light, rear 10 R10W BA15sIndicator light, rear 21 P21W BA15sReverse light 21 P21W BA15sHeadlight 100 P45tWork lamp 70 H4 PK22sRevolving beacon 10 H3 LED LEDCargotec India Pvt. Ltd. Page | 57
FLT12 Operator’s ManualCONTROL PANEL:Below figure shows the relay functions and fuse ratings X632 X633 X634 X635 X722 X159 X160 X156 NEUTRAL LLOP, HWT WI PER HI GH BEAM LOW BEAM FRONT WL REVERSE STOP START ALARM, LI GHT SOLENOI D F1 F2 F3 F4 F5 F6 F8 F10 F11 F12 F13 F14 F15 F16 F17 F19 F20 F21 10A 10A 10A 35A 10A 10A 15A 15A 15A 10A 10A 15A 15A 10A 10A 10A 5A 5A MAI N RELAY NEUTRAL & REVERSE SWI TCH REVERSE ALARM, L I GHT STOP SOLENOI D IW PER, WASHER CANOPY LI GHT GAUGES SUPPLY FRONT WL REAR WL PARKI NG LI GHT HORN HI GH BEAM LOW BEAM BRAKE LI GHT F LASHER BEACON OVER LOAD PROTECTI ON TRANSMI SSI ON SUPPLY X157 X595 X627 DI ODES REAR WL BRAKE HORN D1 D2 D3 D4 D5 D6 LI GHT X717 X527 BEACON MAI N X762 X663 X716 RELAY DECLUTCH OVERLOAD PARKI NG X178 PROTECTI ON FLASHER LI GHTWARNING Never use fuses of higher amperage than stated on the lid decal. Risk of damage or fire.Page | 58 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualSERVICE POINTS:SL CHECKS OPERATING HOURS REMARKSNo. 200 500 1000 2000 Y - Change every 250hrs or 500hrs using Gulf1 Engine fuel filter YY Y Y LEYPOWER LL Diesel Engine Oil2 Engine oil Ck Y Y Y Change every 1000hrs3 Engine oil filter YY Y4 Transmission oil Ck Cg Cg5 Transmission oil filter YY Y Y Y - Change every 250hrs6 Drive axle oil Ck Cg Change every 2000hrs7 Propeller shaft Lb8 Hydraulic oil Ck Cg Change every 2000hrs9 Hydraulic oil filter Ck Cg Cg Change every 1000hrs10 Hydraulic tank strainer Ck Ck Cg11 Air Filter - Primary Element Ck Cg12 Air Filter - Secondary Element Ck Cg13 Cylinder bearing, tilt cylinders Lb14 Hose Roller √ √ - Dismantle, clean, lubricate & reassemble15 Chain Wheels Lb16 Lifting Chains Dismantle, clean with degreaser and lubricate17 Support rollers, forks √ every 3000hrs √ - Brush & spray with18 Cylinder bearing recommended oil Lb Lb19 Support wheels and support Lb rollers, mast20 Mast suspension √ √ - Relieve the mast of load when lubricating21 Steered wheel bearings Dismantle, clean, inspect and pack with grease every22 King pin bearing 4000 Hours23 Linkage Lb24 Hinges, doors Lb25 Brake pedals Ck LbLEGENDCg - ChangeCk - CheckLb – LubricateCargotec India Pvt. Ltd. Page | 59
FLT12 Operator’s ManualOIL RECOMMENDATIONS:1 ENGINE OIL 9ltr API CI4 15W 40 GULF LEYPOWER XLL DIESEL ENGINE OIL ALLISON C4 SAE 30 TOTAL RUBIA TIR 7400 15W 40 API GL5 PETRONAS URANIA SUPREMO CI-4 15W 40 PREMIXED LEYPOWER COOLANT 50002 COOLANT 20ltr 50/50 FLEETGUARD FLEETCOOL HD Top (1:1) PREMIXED CC8950 Up PETRONAS PROFAR3 TRANSMISSION 32ltr C4 SAE 30 TOTAL DYNATRANS AC30 OIL – TRT2221-3 SAE 85W 140 PETRONAS AKROS MATIC TO4 AXLE/GEAR 16ltr 4, 30 OIL TOTAL TRANSMISSION TM 85W- 140 PETRONAS TUTELA TRANSMISSION W140/M-DA TOTAL ACANTIS HM685 HYDRAULIC OIL 180ltr ISO 6743/4 HM VG68 TOTAL EQUIVIS ZS 68 PETRONAS HIDROBAK HV68Page | 60 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual SERVICEIt’s very important that inspections and service are performed at the recommended intervals.Service should be performed by Cargotec India, or by service technicians authorized by Cargotec India. CAUTION1. Service interval must be followed.2. This is to maintain the machine's safety as well as to meet warranty and service agreements!3. Use spare parts and fluids approved by Cargotec India to fulfill warranty terms. NOTE Service intervals and actions are described in the maintenance manual. CAUTION1. Undo the connectors from the control units. Risk of damage to the control units!2. When welding on the machine, all control units shall be disconnected to prevent damage. WARNING For safety reasons, the spare parts should only be replaced with genuine spare parts:Cargotec India Pvt. Ltd. Page | 61
FLT12 Operator’s Manual PRODUCT TRANSPORTATIONMACHINE LIFTING AND TIEDOWN INFORMATION...........................................63SHIPPING .............................................................................................................64TOWING ................................................................................................................ 66MECHANICAL DISENGAGEMENT OF PARKING BRAKE ..................................67Page | 62 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT TRANSPORTATION MACHINE LIFTING AND TIEDOWN INFORMATION 1. Weight and instructions given herein apply to lift trucks as manufactured by Cargotec India. 2. Use properly rated cables and slings for lifting. Position the crane for level lift truck lift. 3. Spreader bar widths should be sufficient to prevent contact with the lift truck. 4. Use the tiedown locations provided for lift truck tiedown. NOTE Improper lifting or tiedowns can allow load to shift and cause injury and/or damage.Contact Cargotec India Service for more lifting & shipping instructions for your lift truck. A 1 1 A 22 01 Lifting Points Page | 63 02 Tie Down PointsCargotec India Pvt. Ltd.
FLT12 Operator’s Manual SHIPPINGCheck travel route for overpass clearances. Make sure there is adequate clearance if the lift truck beingtransported is equipped with a high mast, overhead guard or cab.To prevent the lift truck from slipping while loading, or shifting in transit, remove ice, snow or otherslippery material from the loading dock and the truck bed before loading. NOTE Obey all state and local laws governing the weight, width and length of a load. Observe allregulations governing wide loads. Remove ice, snow or other slippery material from the shipping vehicleand the loading dock. 1. Always block the trailer or the rail car wheels before loading the lift truck. 2. Position the lift truck on the trailer or the rail car. 3. Apply the parking brake and place the transmission control in NEUTRAL. 4. Tilt the mast forward and lower forks to the floor. 5. Turn key to switch OFF position and remove the key. 6. Disconnect the battery. 7. Block the tires and secure the lift truck with tiedowns.Page | 64 Cargotec India Pvt. Ltd.
FLT12 Operator’s ManualCargotec India Pvt. Ltd. Page | 65
FLT12 Operator’s Manual TOWINGIf possible, the engine should be running during towing in order to retain braking and steering functions.When the engine is not running, there is no hydraulic pressure for the steering of the truck which is thenextremely limited. Furthermore, the gearbox will be insufficiently lubricated. 1. Towing may only take place over very short distances. 2. The brakes function as long as there is pressure in the accumulator, thereafter the operating brakes cease to function and the parking brake is automatically applied. If, thereafter, it is necessary to move or tow the truck, the parking brake must be released mechanically. (Refer below instructions for how to mechanically disengagement of the parking brake) 3. The vehicle or machine use to for towing must be at least as heavy as the machine to be towed and have sufficient engine and brake capacity. 4. For towing over longer distances or at speeds higher than 10km/h, the propeller shaft must be disconnected. 5. Before taking actions and after finished towing, the parking brake must be applied and the wheels blocked to prevent the machine from starting to roll. 6. Extreme care must be observed during towing work to avoid personal injuries. WARNING The machine may not roll on a downhill grade if the engine is off. If possible, tow withmaintained hydraulic pressure. If it’s not possible to have the engine running when towing, a tow barmust be used! Only tow for short distances!Before preparations for towing begin and after towing have been completed, the parking brake must beapplied and the wheels chocked to prevent the machine rolling. The greatest possible care must beexercised during towing operations to prevent personal injury. CAUTION Do not try to start the machine by towing it causes serious damage to engine and powertransmission. Start the engine according to instructions in the operator's manual.Page | 66 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual MECHANICAL DISENGAGEMENT OF PARKING BRAKEThe parking brake is automatically applied by powerful springs in the brake cylinders if the pressure ofthe air system accumulator drops below a certain level.If the machine has to be moved (towed) without sufficient pressure in the air system accumulator, theparking brake must be released mechanically (manually).The parking brake is a spring brake chamber on the drive axle as shown. 1. Note the nut's position on the bolt and remove the split pin that secures the nut. 2. Loosen the nut until the brake is free. 3. Restore the parking brake function by screwing the nut to the same position acc. to item 1. 4. Install new split pin. NOTE If the parking brake has been mechanically disengaged it must always be reset in order torestore the parking brake function 1 2 01 Nut 02 Split Pin WARNING1. Before starting to work with the parking brake, make sure that the machine cannot move when the braking action is released. Chock the wheels on sloping ground.2. The parking brake has high spring force. If the brakes are opened incorrectly, parts may detach and fly off with great force. Risk of personal injury! Follow the above instructions.Cargotec India Pvt. Ltd. Page | 67
FLT12 Operator’s Manual PRODUCT STORAGEBEFORE STORAGE: ........................................................................................................ 69DURING STORAGE: ......................................................................................................... 69AFTER STORAGE: ............................................................................................................ 69Page | 68 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual PRODUCT STORAGETo place the machine in storage for an extended period of time, the following measures must be taken toensure that it can be returned to operation with minimal service.BEFORE STORAGE: 1. When storing the fork lift , take care that it will not be in the way of other operations. Make sure that no charged energy source are left on the fork lift . i.e. Pressure vessels, Hyd. Pressure Electric Batteries etc. If left to discharge by themselves these energy sources may cause incontrollable danger situations. 2. Make sure that possible oil leaks from the fork lift cannot harm OR pollute the environment. 3. After every part is washed and dried, the machine should be housed in a dry building. Never leave it outdoors. In case it has to be left outdoors, lay wooden boards on the ground, park the machine on the boards and cover it with canvas, etc. 4. Fuel tank should be emptied completely. 5. Lubricate, grease and replace oil before storage. 6. Apply a thin coat of grease to metal surface (hydraulic cylinder piston rods.) 7. After removing connections, remove the batteries from the machine and cover and store separately. Battery terminals should be covered with petroleum jelly, preferably once every month. Electrolyte level and specific gravity should be checked against the specifications. 8. Water should be drained out from radiator, engine block etc. 9. Cover intake and exhaust openings of engine to prevent moisture entry 10. Bring all control levers to neutral position. 11. The wheels should be jacked up. 12. Lower forks completely. 13. Protect exposed portion of tilt and lift cylinder piston rod with rust preventive oil or apply grease.DURING STORAGE: 1. Carry out regular follow-up inspections on the stored fork lift. 2. Drive the truck for a short period at least once a month. This coats moving part surfaces with a new film of oil and charges the battery at this same time.AFTER STORAGE:After storage (when it is kept without cover or rust preventive oil and once in month operation has notbeen made), you should apply the following treatment before operation. 1. Remove the drain plug on hydraulic tank and drain mixed water. 2. Wipe off grease from hydraulic cylinder piston rod. 3. Measure specific gravity and check that battery is charged. 4. Drive at low speed to make sure inside of engine, transmission is well oiled.Cargotec India Pvt. Ltd. Page | 69
FLT12 Operator’s Manual APPENDIXPage | 70 Cargotec India Pvt. Ltd.
FLT12 Operator’s Manual APPENDIXRefer Supplementary Manual(s) supplied with the product for customized solutions if applicable.Cargotec India Pvt. Ltd. Page | 71
FLT12 Operator’s Manual WORK SAFETYSAFETY IS ALWAYS YOUR FIRST PRIORITYThink of your own and your co-workers safety before you start working!Safety Accessories for operator In Case of Emergency: Cargotec India Pvt. Ltd. 1. Warn others and secure the workplace. 2. Identify & secure entry and exit points. 3. Help others and give necessary first aid 4. Inform management. 5. Call 112 – Emergency 100 – Police 102 – Ambulance 101 – Fire Brigade State your name. Location of accident. Type of accident. Number of casualties, if any.Page | 72
FLT12 Operator’s Manual NOTESCargotec India Pvt. Ltd. Page | 73
FLT12 Operator’s Manual Robust as Cargotec India Pvt. Ltd. Enquires +91-22-67736666 Kesar Solitaire, 3rd Floor Tel +91-22-67736600 Office No. 303 - 306 Fax Plot No. 5, Sector - 19 Offices +91 9718472220 Sanpada, Navi Mumbai Delhi +91 9867529012 400705, India Mumbai +91 9840721119 www.indital.in Chennai +91 8584974633 KolkataPage | 74 Cargotec India Pvt. Ltd.
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