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a WARNING

1. Throttle Position Sensor SysteM Accelerator Pedal Position Sensor gt 4 a a h gt 4d a A n gt u y y n 2 gt E h F b a K gt b a aa Bo u m a3 B 4 9 B3 93 8 W B 9 s a 6 9 nm a a4 3 nmn 5 9 o n m n G gt 4 a G y y e a A o b 9 o amp om a3 w R a 5 a a 5 a b a u g sto 59 9 9 K 089 n 9 9 4 9 Gl 9 a 5 E a a n a u y 4 a 9 58 9 o h gt 9 9 aa 9 a a Adjusting the Clutch Brake Pedal Manual Transmission lille Measuring Brake Stopping Distance Braking Effect oo Adjusting the Stop Lamp Switch ee Adjusting the Inching Brake Pedal TorqFlow Transmission 0 00000 eee Checking Torqflow Clutch Actuation Pressure Checking Torque Converter Stall Speed Testing Specific Gravity of Battery Electrolyte Checking Tires and Adjusting Pneumatic Tire Pressure leen Measuring Minimum Left and Right Turning Radius 0 0 0 0 cee ooo Measure Hydraulic Control Valve Relief Pressure es 8 23 9 W 9 9 9 9 9 5 A 4 4 4 9 a 343 5 5 s K a 3 3 01 01 01 02 01 07 01 15 01 22 01 24 01 32 01 35 02 01 02 02 02 04 02 06 02 08 02 09 02 10 03 01 03 02 03 04 04 01 04 02 04 02 04 02 04 03 04 04 04 04 0
2. e Intake manifold e Exhaust manifold EMISSION CONTROL WARRANTY 60 MONTHS OR 3 500 HOURS FOR GENERAL PARTS e ECM e Catalytic converter e Vaporizer NOTICE Follow the instructions in the Operations Manual concerning any other maintenance programs not required for EPA compliance For questions and additional information contact Kalmar AC Inc 14481 Lochridge Blvd Bldg 2 Covington GA 30014 4908 Voice phone 770 385 4815 Fax phone 770 385 4838 13 01 SAFETY SECTION 1 SAFETY MANAGEMENT A WARNING OPERATION MANUAL AND SAFETY LABELS e Read the instructions in this Manual and the Safety Labels attached to the various parts of the lift truck and make sure that you understand and follow them If you do not understand or do not fol low the instructions this will lead to improper operation which may lead to damage personal injury or death e Be sure that you understand the proper method of using the lift truck and the procedure for carry ing out an inspection and ensure that they are carried out safely e Read this Manual and the Safety Labels again from time to time If the Operation and Maintenance Manual or Safety Labels have been lost or become dirty and cannot be read obtain replacements from your Kalmar AC distributor dealer and attach the Safety Labels in the specified positions WARNING OPERATING QUALIFICATIONS gt This lift truck should be operated only by qualified personnel Be sure
3. FUEL SYSTEM SAFETY Accidents involving fuel systems are always dangerous and can cause fire and explosion serious injury death and property damage Keep the following points in mind when working with fuel systems Read understand and remember relevant information in the NATIONAL FIRE PROTECTION AGENCY NFPA standard for fuel in use Do this BEFORE working on any fuel system Ensure you are wearing proper personal protective equipment Check for fuel leaks before you begin work on any fuel system On LPG systems DO NOT work on the system if the fuel storage container is filled with fuel past the 80 liquid level Ensure there are NO SOURCES OF IGNITION nearby before beginning work Be sure your work area is adequately ventilated Disconnect the battery before working on the fuel system LPG is heavier than air and will sink to the lowest area possible Avoid areas near floor drains or lubrication pits where escaped fuel may collect LPG is stored under high pressure Ensure the LPG fuel storage container valve is turned OFF closed and pressure is released from the lines before working on system Store all LPG cylinders OUTDOORS is a secured area and safe from any vehicle traffic NEVER WELD ON AN LPG PRESSURE VESSEL STORAGE TANK OR CYLINDER LPG fuel tanks mounted horizontally MUST BE positioned properly See MAINTENANCE Section Always utilize a UL listed LPG tank 01 6 01 SAFETY SECTION 2 SAFE TRAVEL A WARNING PR
4. When traveling on slopes or in confined areas unloaded lift trucks should always give the right of way to loaded trucks 01 13 01 SAFETY SECTION A WARNING HEIGHT OR WIDTH LIMITS When going in or out of places with height or width limits AK WARNING PRECAUTIONS WHEN TURNING Ensure that there is ample height and width for the lift truck to pass Do not extend your hands or legs outside the lift truck Check that the surrounding area is safe Be careful of electric wires and other obstacles inside and outside the building When turning while traveling forward the counterweight will swing far out Keep an ample clearance from walls and other objects to ensure safety When turning travel slowly and be careful that the front or rear wheels do not come off the ground When turning on soft road shoulders there is danger that the rear wheels may come off the road shoulder and cause the lift truck to tip A WARNING STOPPING DISTANCE When traveling downhill it requires a longer distance for the lift truck to stop then when traveling on level ground AB801290 When traveling downhill reduce the speed and make sure that you have ample room at the bot tom of the slope to stop When traveling on wet surfaces it requires a longer distance to stop then when traveling on nor mal road surfaces Always have ample room to stop A WARNING NO TOWING If there is any problem with the brakes or steering sys
5. b v O b gt gt gt gt o 5 b nun an o3 s s e 5 E OA an 5 7 7 9 CHAPTER 02 GENERAL INFORMATION AND SPECIFICATIONS l l eese Specifications Mast Data amp Features Indoor amp Outdoor TruckS Truck Data Tables Pneumatic Tire Trucks Truck Data Tables Cushion Tire Trucks Periodic Replacement of Consumable Parts Standard Tightening Torque for Pipe Joints Standard Tightening Torque for Bolts CHAPTER 03 SERVICE DATA Ga G m o a n n m a 4 y gt 343 gt gt gt a sy 49 3 5 Ww n Ww x b a n m an gt h o 5 gt 4 9 4 K 9 4 4 4 3 NB 3 n o e 9 a n n B NW y y 5 9 9 9 4 Rh 9 a b e 5 3 NM 3 WM 4 3 aln on 9 a 5 gt gt mn n n gt 0 9 4 C y 4 9 4 eR sK 4 5 5 a n m 5 Service Data Gasoline Engines Pneumatic Trucks 0 020000 momo Service Data Gasoline Engines Cushion Trucks eee CHAPTER 04 TESTING ADJUSTING AND MEASURING Ll eese Adjusting Ignition TiMiNg Adjusting Spark Plug Gap Adjusting Valve Clearance Adjustment of Fan Belt Measuring Engine Cylinder Compression Measuring Hydraulic Drift on Lift amp Tilt Cylinders Adjusting the Parking Brake Lever Adjusting the Accelerator Pedal
6. 2 690 154 0 3 910 26 5 670 116 0 2 945 164 0 4 165 31 5 800 128 0 3 250 176 0 4 470 37 5 950 3 Stage Full Free View TFV 685 4035 275 700 170 5 4 330 79 5 2 020 31 5 775 1885 4700 S75 650 198 5 5 040 246 5 6 260 41 5 1 055 nn mar 216 5 5 500 97 5 2 475 264 5 6 720 49 5 1 255 235 5 5 980 106 5 2 705 283 5 7 200 58 5 1 485 NOTE Specifications for 4 Stage Full Free View QFV masts are not indicated Please consult your authorized dealer for information and availability Cushion Trucks Only 02 3 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA PNEUMATIC TIRE LIFT TRUCKS OUTDOOR PROAXGC P30AX G PS P35AX G PS GENERAL Operation Type StDown SitDown Sit Down Capacity 24 in 600 mm Load Center Ibs kg 3 500 1 580 Load Distance from Center Axle 2 Stage in mm 15 8 400 Load Distance from Center Axle 3 Stage in mm 15 9 405 Wheelbase in mm 54 1 1 375 WEIGHT Service Weight inc 2 Stage STD Mast Forks tbs kg 5 860 2 660 5 930 2 690 6 380 2 895 TIRES Tire Size Front 6 50 10 10PR Il 6 50 10 10PR I 6 50 10 10PR I Tire Size Rear 5 00 8 8PR I 5 00 8 8PR 1 5 00 8 8PR I Number of Wheels Front Rear x Driven 2x 2 Tread Center of Tires Front Rear in mm 35 0 890 35 0 890 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 6 8 Tilting
7. 2 Stage STD Mast in mm 5 5 140 Height Overhead Guard in mm 77 6 1 970 Length to Fork Face 2 Stage Mast in mm 80 9 2 055 Length to Fork Face 3 Stage Mast in mm 80 9 2 055 Overall Width at Drive Tires in mm 38 0 965 Forks Thickness x Width x Length in mm 1 6 x 4 0 x 42 0 40 x 100 x 1 070 Carriage Width ITA Class in mm 37 0 940 II Ground Clearance under Mast in mm 3 5 90 Ground Clearance Center of Wheelbase in mm 4 0 100 Right Angle Stacking Aisle 2 Stage Mast tf in mm 85 1 2 160 Right Angle Stacking Aisle 3 Stage Mast tt Xin mm 85 1 2 160 Turning Radius Outside in mm 69 7 1 770 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 10 3 16 5 10 3 16 5 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 123 625 126 640 Lifting Speed Loaded Unloaded 3 Stage fpm mm s 116 590 120 610 Lowering Speed Loaded Unloaded 2 Stg fpm mm s 97 490 89 450 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 98 500 69 350 Maximum Drawbar Pull Loaded Ibs kN 4 610 20 5 Maximum Gradeability Loaded 37118 Service Brake Operation Control Foot Hydraulic Parking Brake Operation Control Hand Mechanical Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 6 02 GENERAL INFORMATION amp SPECIFICATIONS DRIVE Battery Voltage Capacity 20 hour rating V Ah 12 41 Engine Model K21 K21 Rated Ou
8. 5 6 GMGINS serrara OL D BL So a te Eas Dave OWE we Data 2 42 APPENDIX 1 ELECTRICAL SCHEMATICS 17 x 11 Fold outs 0oooooooooo ooo CODIeHIS tio di Pel H ee dedecus E Ete LE Eid Oe ea AX20 BX20 EPA T C GASOLINE SHEET 1 cece cece ee hh A 1 AX20 BX20 EPA T C GASOLINE SHEET2 llle lees A 2 AX20 BX20 EPA T C GASOLINE SHEET 3 ulleeee eee es A 3 AX2U0 BX20 ERA HO UP SHEET 1 4 5 orb el ts o Bolte epos A 4 AX20 BX20 EPA T C LP SHEEN TTT A 5 AX20 BX20 EPA C D SHEET 3d ui oro add Ii ESSs A 6 AX20 BX20 EPA T C DUAL FUEL SHEET T A 7 AX20 BX20 EPA T C DUAL FUEL SHEET 2 0 0 ccc es A 8 AX20 BX20 EPA T C DUAL FUEL SHEET 3 eaaa A 9 AX20 BX20 EPA T C LP UL LPS SHEET 1 0 0 0 0 0 2 cee nee A 10 AX20 BX20 EPA T C LP UL LPS SHEET 2 00 leere A 11 AX20 BX20 EPA T C LP UL LPS SHEET 2 0 0 0 0 annann A 12 APPENDIX 2 TORQFLOW TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM FOLDOUT APPLICABLE AX20 EPA LIFT TRUCK MODELS P30AX GC 3 000 Ib capacity K21 Engine Clutch Spec Pneumatic Tire C35AX LS PS 3 500 Ib capacity K21 Engine Torqflow Spec LP Special Cushion Tire FEDERAL EPA EMISSION CONTROL STATEMENT FOR OFF ROAD LSI NON DIESEL ENGINES K21 AND K25 ENGINES This section presents information concerning the correct labeling warranty parts and maintenance of
9. DISaSsembly uou e ER mu pe XU Eat Red xo ORA Sav DR RD e qo UR Ted 07 71 Tilt Cylinder Parts Inspection xs bcos Re Dae ea CORR ne We KARATE EORR ER S 07 71 Tilt Cylinder Reassembly 0 0 0 0 ccc ccc eee cette hr 07 72 Clutch Transmission Clutch Transmission Disassembly After Removal from Truck 07 73 Clutch Transmission Testing a os io Cte eR ER GR CR awd CCS aod bee ee aw aS 07 77 Clutch Transmission Assembly 0 0 0 2 a 07 79 Clutch Transmission Cross Sectional View llle eee 07 82 Drive Axle Drive Axle Disassembly and Assembly Exploded View Pneumatic Trucks 07 83 Drive Axle Assembly Torque Chart Pneumatic Trucks 0 0 0 0 0 0020s cee eee 07 84 Drive Axle Disassembly and Assembly Exploded View Cushion Trucks 07 85 Drive Axle Assembly Torque Chart Cushion Trucks 0 0 0000 cece eee eee 07 86 Differential Differential Direct Drive Transmission Disassenmbly 0 0 0 2 eee ee ees 07 87 Differential Direct Drive Testing o oooooonearo a 07 88 Differential Direct Drive Adjusting oo 07 89 Differential Direct Drive Assembly Drawing 0 0 cece ee eee 07 92 Differential TorqFlow Transmission Disassembly and Assembly Exploded View 07 93 Differential TorgFlow Transmission Disassembly Procedure o oo 07 94 Differential
10. Angle 3 Stage TFV Masts Forward Backward 6 6 Mast Height Lowered 2 Stage Mast in mm 85 5 2 170 Mast Height Extended 2 Stage Mast T in mm 176 0 4 470 Maximum Fork Height 2 Stage STD Mast in mm 128 0 3 250 Free Lift Height 2 Stage STD Mast in mm 5 5 140 Height Overhead Guard in mm 79 7 2 025 Length to Fork Face 2 Stage Mast in mm 89 0 2 260 Length to Fork Face 3 Stage Mast in mm 89 1 2 265 Overall Width at Drive Tires in mm 42 1 1 070 Forks Thickness x Width x Length in mm 1 6 x 4 0 x 42 0 40 x 100 x 1 070 Carriage Width ITA Class in mm 41 0 1 040 li Ground Clearance under Mast in mm 55040 5504 5 5 140 Ground Clearance Center of Wheelbase in mm 5 3 135 Right Angle Stacking Aisle 2 Stage Mast tt in mm 93 8 2 380 Right Angle Stacking Aisle 3 Stage Mast TT in mm 93 9 2 385 Turning Radius Outside in mm 78 0 1 980 PERFORMANCE Travel Speed Forward Loaded Unloaded mph k hr 11 8 19 0 12 4 20 0 Lifting Speed Loaded Unloaded 2 Stage fpm mm s 123 625 126 640 Lifting Speed Loaded Untoaded 3 Stage fpm mm s 116 590 120 610 Lowering Speed Loaded Untoaded 2 Stg fpm mm s 96 490 89 450 Lowering Speed Loaded Unloaded 3 Stg fpm mm s 98 500 69 350 Maximum Drawbar Pull Loaded Ibs KN 3 210 15 4 3 730 16 6 3 730 16 6 39 23 35 21 Foot Hydraulic Foot H
11. CONSUMABLE PARTS For operational safety always perform specified periodic maintenance and be sure to replace all consum able parts listed in the table below following the recommended schedule These parts may deteriorate in time and are susceptible to wear It is difficult to estimate the degree of wear at the time of your periodic maintenance therefore even if no wear is apparent always replace the items with new parts within the scheduled period Consumable parts must certainly be replaced sooner than the recommended intervals if wear damage or malfunction occurs earlier An effective and timely inspection and maintenance program will reveal such conditions before more serious damage occurs to the truck ice and dust seals 02 GENERAL INFORMATION amp SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows nipples and unions Nm kgfm 29 4 39 2 3 4 78 5 103 8 10 5 Tightening Torque Nm 50 6 54 3 57 9 61 4 kgfm 68 6 73 6 7 7 5 78 5 83 3 8 8 5 36 30 86 8 119 3 117 7 161 8 12 16 5 High pressure rubber hoses pipes and sleeve nuts Tightening Torque ft lbs 14 5 21 7 17 3 50 6 43 4 72 4 79 7 1232 108 4 151 9 Nm kgfm 19 6 29 4 23 5 68 6 58 8 98 1 108 167 147 206 2 3 3 7 6 10 11 17 15 21 02 9 02 GENERAL INFORMATION amp SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR BOLTS For unspecified bolts and nut
12. GOnenG ouai RERUM os dus Veet ee Gime esas pud a ved 07 10 Clutch Disassembly Manual Transmission Exploded View lusus 07 14 Clutch Specifications Manual Transmission Checking o o o 07 15 Clutch Assembly Manual Transmission Diagram llli ees 07 17 Clutch Installation Manual Transmission ness 07 18 Clutch Piping Bleeding Air from Lines cee eee eens 07 18 Torque Converter Installation llle In 07 18 Transmission and Drive Axle Installation lll 07 18 Pedal Assembly Brake Piping Installation llle 07 18 Brake System Bleeding Air From Lines 0 0c cee eee eee nee 07 19 Mast Installation Generic ee IR I nh 07 20 Steering Axle Steering Axle Removal from Chassis lille 07 21 Steering Axle Disassembly Exploded View Pneumatic Trucks 2000 07 22 Steering Axle Disassembly Exploded View Cushion Trucks nnna 07 23 Steering Axle Specifications Checking eres 07 24 Steering Axle Lubrication and Adjustments eese 07 24 Steering Axle Assembly Pneumatic Trucks llle 07 26 Steering Axle Assembly Cushion Trucks lees 07 27 Steering Axle Installation vxo ete rai e 07 28 Wheel Brake Wheel Brake Removal REL Exp RUE RR E e Ya RIEN CE EUR MARCAR 07 30 Wheel Brake Disassembly llle hh hh 07 31 Wheel Brake
13. Gauges and Warning Devices 0 00 ccc eee eee ees 05 11 Inspect Rear View Mirror and Reflectors 000 ce eee ees 05 11 Inspect Speed and Forward Reverse Levers Manual Shift Transmission 05 12 CHAPTER 06 MAINTENANCE OPERATIONS eee nnn 06 01 Lubricant List K21 Engines ehm C deals vere eked odes ce dea ate es 06 02 Oil and Greasing Chant x aon ode Reed aC CaS on acte OR EORR do 06 03 Changing Engine Oil and Filter Gasoline LP Engines 2 2 00 0005 06 04 Changing Gear Oil in Differential Case llle 06 05 Changing Transmission Fluid in TorgFlow Transmission Case ooooooc 06 06 Changing Oil in Hydraulic Tank RII 06 07 Is placinig The Fuel Elec ne Yd QUE UN Y COS Oe DOR Ewan EC ec 06 08 Cleaning and or Replacing Air Cleaner Element eee 06 08 CHAPTER 07 REMOVAL DISASSEMBLY ASSEMBLY INSTALLATION 07 01 Overall Disassembly and Assembly Drawing 2 00 ce eee ee eee 07 02 Weight Table Component Assemblies and Parts llli ellen 07 04 Engine Engine Removal rom CnassiS miu due obe eq e b INE dubias tere datus 07 05 Engine Disassembly and Assembly eee en 07 07 Epgine Installaloni iaa ria Efe er hes pd dtum ie deo ds Sah aenea d a Gan c f et 07 07 Transmission and Drive Axle Clutch Torque Converter Transmission Drive Axle Removal from Chassis 07 09 Mast Removal
14. HANDLING LONG OR WIDE LOADS i Be extremely careful when carrying long or wide loads Raise the load slowly and be careful not to touch anything in the surrounding area Keep the load as low as possible and be sure to maintain the balance When turning operate slowly and be careful not to let the load move AB801440 01 20 01 SAFETY SECTION A WARNING OVERHEAD OBJECTS Be careful not to let the mast overhead guard or load contact electrical wiring pipes sprinklers or roof beams If the truck hits such objects there is a risk that the load will fall or the lift truck will tip When the forks are raised the mast height increases so be particularly careful when the forks are raised AB801450 A WARNING NO PUSHING e Do not use the forks to push or pull loads There is a risk that the load will be damaged or fall ABB01460 AX WARNING PRECAUTIONS WHEN LOADING UNLOADING e Do not let anyone place a load on the forks Do not let anyone remove a load directly from the forks e Standing on the forks is dangerous because the forks are slippery and the load may move Do not use anyone to keep the load stable The lift truck may move unexpectedly causing the load to fall and crush the person 01 21 01 SAFETY SECTION 4 STOPPING AND PARKING A WARNING PRECAUTIONS WHEN STOPPING OR PARKING Observe the following procedure when stopping or parking the lift truck 1 2 stop the
15. Inspection amp Adjustments ehh 9o 7 2 9 Internal Reeving InslallatlOnz aie de rane AA emer em ewes Re Roca doe BAN 9 3 1 Feriodic Maintenance 0 0 4c o A A ENG ERE SIE EEE NE RENS 224 14 4 0 TrOUDIESNODUNO edente am o e ad Seo pedes TE et IAS eur eil 5 14 MASLISSITIOV S si ti o ce ox duce ur Ge CR o Ud Runde duo ewe date ree ee tto cap Re aU 22576 52 GVIndets 3 dco A RC d abe Gade Wie aod EA b Re die a boue YA 5 3 Lowering Control Valve aaa EE apre Pee er Rene vaa ps ere S4 Gal AGS E Temp PL 3 90 Mast Belen prada Pa URS RE dcus ei edit edited eo df SIH E Lugd 30D 35D 40D 50D 55D 60D MT 3 Stage Masts CONnICNIS oed is sats qe e Oh e BUR Bot dk Bars PEE RS EE SUAE I BERG 3 Iaeiei ne atts 33 9 6 cei A EAS ole RES EORR ORO Ree 4 1 2 special Definitions uu 24 9 o RO A 8S ne OE PRG bE PRAMAS ERO di ws 4 2 1 Truck System RequiremMentS o ooo 5 2 2 Mounting Bracket Installation roo o 5 2 5 Mast INstallatio aa ara ii T RH SN E eee Sane 6 2 4 Inspection amp Adjustments dada Ada ax ck aas 7 2 5 Internal Reeving Installation sw boda iia educ oie obese aa Sh eee ee Pe 9 3 1 Periodic Maintenaricg erratas irradia A ew heen syaa 16 40 Ireubleshoollfig surcoreano iue Mf S T MaSEROEImoOVOSLE oasis ra a eee eee eee eie Dur CA eee Ge ates Aun 18 A A O ele kas 19 5 3 LOWwerng Control Va TTT a AS S amadas cao RL a a inre ot e ae s sadaa 6 5 Mast UDriOMS anche cst tu oer hose 6 oka 34
16. K21 and K25 engines in order to comply with the EPA off road large spark ignition LSI engine regulations 1 LABELS REQUIRED AND LABEL LOCATIONS All K series engines will display the required identification label as follows Location on K21 K25 Series engines EPA LABEL LOCATION TOP VIEW OF ENGINE the F 1 El i G I LL ie ur gt SSS K21 K25 EPA Emission compliance label SAMPLE shown below 4 375 inch 111 125 mm EMISSION CONTROL INFORMATION 2003 ENGINE FAMILY 4NSXB02 147C ENGINE DISPLACEMENT 2 1 LITER ENGINE MAXIMUM POWER 55 7 HP THIS ENGINE IS CERTIFIED TO OPERATE ON LPG ENGINE S USEFUL LIFE IS 5000 HOURS OF OPERATION OR SEVEN YEARS EXHAUST EMISSION CONTROL TYPE TBI TWC HO2S TEST MODE VARIABLE SPEED ONLY 0 38 MM HOT E E uM T M t o uw N N THIS ENGINE MEETS CALIFORNIA AND U S EPA REGULATIONS FOR 2004 LARGE NONROAD ENGINES NISSAN MOTOR CO LTD K21L 11 2 WARRANTY The following statement is hereby provided as required by regulations of the United States Environmental Protec tion Agency EPA YOUR WARRANTY RIGHTS AND OBLIGATIONS All off road large spark ignition LSI engines must be designed built and equipped to meet the Federal EPA s stringent anti smog standards Kalmar AC Inc KAC must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse damage neglect or improp
17. Oil Pump TorqFlow Transmission Oil PUMP llle RR e 07 124 QI Pump DBisassembly iSo ES dE RR I A BRAS E RR PEE AES 07 124 OIL P rfip ASSembIy vase a d saca doe a dn acie o a RE Rcs Grd a 07 124 TorqFlow Transmission Disassembly Cont ee 07 125 TorqFlow Transmission Input Shaft Exploded View eene 07 126 TorqFlow Transmission Main Shaft and Clutch Drum elles 07 127 TorqFlow Transmission Forward and Reverse Gear 0 0 eee teens 07 128 Measuring Clutch Pack End Gap sanana nnan eee eee ete so 07 129 TorqFlow Transmission Clutch Return SpriNQ ccc ee teens 07 130 TorqFlow Transmission Output Gear 2 eee 07 130 TorqFlow Transmission Oil Filter 0 ee ee tee tenes 07 133 TorgFlow Transmission Case Magnets 0 2 0 cee ee ee ees 07 133 TorqFlow Transmission Gear Backlash Specifications o ooooooooo 07 134 TorqFlow Transmission Control Valve Spring Fatigue Chart o oo 07 135 TorqFlow Transmission Control Valve Assembly Exploded VieW 07 137 TorqFlow Transmission Control Valve DiISassermbliy oo 07 140 TorqFlow Transmission Control Valve Assembly ooooooocooronooo 07 140 CHAPTER 08 MASTS casi rr aia 08 01 Masts 35D 40D 50D 55D 60D MD Series 2 Stage Masts COMES ose asi tus oi ded o ee ese c S D E EM EU A oe dt ae ALME ee de 3 TL WIMOOUCION s ois eee eos eons b
18. WHEN CHARGING When the battery is charged hydrogen gas is generated and the battery is heated by the chemical change To prevent the danger of gas explosion always do as follows e Carry out the charging operation in a well ventilated place Do not smoke or allow any flame Start the charging operation when the temperature of the battery electrolyte is below 95 F 35 C If the electrolyte temperature goes above 122 F 50 C during the charging operation wait for it to go down below 95 F 35 C before starting charging operation again When using a battery charger to charge the battery take the battery caps off WARNING STARTING WITH BOOSTER CABLES e ALWAYS wear safety glasses or goggles when starting the lift truck with booster jumper cables When starting using the battery of another lift truck do not allow the two lift trucks to touch Stop the engine before connecting the cables e Be extremely careful not to let the cables get caught in the fan or fan belt Connect the batteries in parallel positive to positive and negative to negative NEVER connect positive to negative e DO NOT short circuit the starter terminals to start a forklift truck WARNING DO NOT PUSH START i e Do not push the lift truck to start the engine There is danger that the lift truck may suddenly start and operate unexpectedly WARNING HANDLING BRAKE FLUID i It is dangerous if the brakes do not work because in th
19. eee eeel 05 07 Inspect Brake Master and Wheel Cylinders 0 cece ee ee ees 05 07 Inspect Brake Shoes and Associated Parts lille eee 05 07 Inspect Brake DRUMS cir wad aan eeu RES Pun Rc mea AA UAI ADR RR debe qn 05 08 Inspect Brake Backing Plates rhe 05 08 Inspecb Load N e asis dada ERE REED Ipae IR AE ae ced d dre 05 08 IisSDe ct Mas d uere tradu des rette but deu etd NH e pai er 05 08 INSDECLFOIK Garage aod en SR io RR PEE Ret alae ke Ee RUP ee alee 05 09 InSpect LIE GhalfiS ed serm de uiu e able Roe dede S AC MEI ura En bred abi 05 09 Inspect Chain Wee Socia od AAA b o Dd ACA A SUR 05 10 InspactATachmellls zione cu ten rd Gee bee ek C e edet at oU aei dun LA RR 05 10 Inspect Hydraulic Tank a IA eds edo REGN S e a ate Od 05 10 Inspect Chassis and Attachment Piping llle 05 10 Inspect Hydraulic PUMP soe ia hex co abad 05 10 inspect Ree le T 2 6 vox Sacs sce Moved ar of adco a qon ara eis SE o heen 05 10 Inspect Till CVIIde Som A ee eee ae D Bee AA qs fa 05 10 Inspect Attachment CylinderS e rn 05 10 Inspect Lift Truck Chassis and Frame llle 05 10 Inspect Cab If EQuipped s iva Sau AAA a pa RS ar R er pd 05 10 Inspect the Operators Seat 0 0 ee e rs 05 11 Inspect Equipment Used for Accessing the Lift Truck llli eee 05 11 Inspect Display PANOR goa ind 05 11 Inspect Overhead Guard ee Rr 05 11 Inspect Lights
20. extra counterweight AD817960A AB801850 WARNING DRIVING IN REVERSE i e When driving in REVERSE turn to face the rear and check the area directly behind the lift truck AB801200 AX WARNING OBSTRUCTION OF REAR VIEW WHEN USING LP GAS FUEL The LP gas cylinder may partially block the view to the rear so extra care is required to minimize the potential danger of hitting personnel products or buildings in the surrounding area Always turn to face the rear to check directly behind the lift truck when dirivng in reverse direction If appropriate for your environmentm you should consider installing backup warning devices backup buzzer rotating backup lamp etc or backup confirmation devices rear view mirror etc to warn personnel in the surrounding area and to confirm that the area to the rear is safe LP GAS CYLINDER AREA THAT CAN BE SEEN WHEN CYLINDER IS INSTALLED AS l i AREA THAT CAN BE SEEN WHEN CYLINDER IS NOT INSTALLED Jit MA AB80121D 01 10 01 SAFETY SECTION Ah WARNING WHEN FRONT VIEW Is POOR If the view to the front is obstructed by the load turn to the rear and drive the forklift truck in reverse When driving in reverse with a high load use a signal person to ensure the safety of the load and the safety in the surrounding area AB301220 WARNING CHECK BEFORE STARTING i When checking the lift truck before starting follow the procedure given in this Ma
21. lift truck do not loosen the rim nuts and bolts The tire is under high pressure and there is a significant risk that the rim nuts and bolts may fly off Relieve tire inflation pressure before removing When the tires have been replaced carry out a test drive and check again for any loose mounting bolts If the tightening torque is low tighten to the specified torque A WARNING JACKING UP LIFT TRUCK when checking or replacing tires Do not go under the fork lift truck when it is jacked up uu mm Check the following before jacking up the lift truck E u5 1 Check that there is no one on the lift truck 2 Check that there is no load on the forks When jacking up stop when the tires come off the ground sur face Put blocks under both sides of the frame to prevent the lift truck from coming down uu Put blocks under any tires contacting the ground to prevent the eee AB801530 lift truck from moving A WARNING LIFTING LIFT TRUCK when checking tires Lift truck slinging work should be carried out by a qualified person who has completed a course in correct lifting meth ods Fit wire ropes to the specified lifting points When lifting the lift truck check that the wire ropes have ample strength and are not damaged Block the tires contacting the ground to prevent the lift truck from moving Insert blocks to prevent the lift truck from coming down Do not go under the lift truck during the lifting operation If the spe
22. lift truck on level ground Apply the parking brake securely to make sure that the lift truck cannot move set the directional lever and the speed lever to neutral Lower the forks to the ground Turn the key switch OFF to stop the engine Remove the key from the key switch Then get off the lift truck AB801480 A WARNING PARKING Park the lift truck in the specified place Park the lift truck on a firm surface Do not park near any emergency exit stairway fire extinguisher or other safety equipment Park the lift truck in a place where it will not obstruct pedestrians or other vehicles Never park the lift truck near any flammable object When parking the lift truck on a slope park as specified above PRECAUTIONS WHEN STOP PING OR PARKING then put blocks under the tires to prevent the lift truck from moving Do not park near any holes for construction or elevator shafts If LPG leaks it can accumulate and cause fire or explosion 01 22 01 SAFETY SECTION A WARNING PARKING MACHINE AFTER FAILURE lf the lift truck has suffered a failure and the lift truck must be parked without lowering the forks put markers on the tips of the forks and take steps to prevent pedestrians or other vehi cles from hitting the forks Select a parking place where people or vehicles do not pass and stop the lift truck so that it is difficult for anyone to go under the forks The area under the forks is a DANGER zone Place a
23. or lowering himself Part No 3EB 96 25770 A WARNING Never enter the area under the forks Part No 3EB 96 25840 7 3EB 96 257 0 5 No one is permitted to ride the lift truck together with the operator Part No 3EB 96 25740 2 Do not put your hand on the mast Warning to avoid getting hand caught Part No 3EB 96 25850 A WARNING 3EB 96 2585 3 Caution before operating machine Part No 3EB 96 25760 Before starting engine Put gearshift lever in neutral Pull parking lever ly de AA 3EB 95 25760 01 36 Warning for operation Decal Part No 3EB 96 25720 01 SAFETY SECTION 4h WARNING SERIOUS INJURY OR DEATH MAY RESULT IF YOU FAIL TO FOLLOW THESE PRECAUTIONS Befor ratin Do not operate or repair truck unless trained and authorized Read and understand all warnings and instructions in manuals and on truck before operating Contact torklift dealer for replacement manuals Check truck before use If truck is in need of repair do not operate until restored to sate condition Do not start truck if fuel is leaking or has leaked While Operati Operate truck only trom operator s seat Keep truck under control at all times Do not overload truck Check capacity plate for load weight and load center Avoid any sudden starts stops turn or change of direction Obey traffic safety rules Yield right of way to pedestrians Keep clear view of travel path If l
24. stand or something similar under the inner mast rail or forks to prevent unexpected drop of the forks Remove the key from the faulty lift truck and hang signs in the operator s compartment to prevent its use AB80149B A WARNING ABRUPT LOWERING OF STUCK FORK Because a stuck fork may drop down unexpectedly do not go under the fork when it is in this con dition Be very careful when dealing with this problem to prevent damage or injury and warn those in the work area 01 23 01 SAFETY SECTION 9 i P INSPECTION AND MAINTENANCE WARNING USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE Only persons authorized by the owner or operator of the equipment and having proper certification local or national may carry out inspection maintenance and repairs of the lift truck If inspection maintenance or repair work is carried out incorrectly it is very dangerous WARNING MAINTENANCE LOCATION When carrying out inspection and maintenance use a level dry dust free area If the work is carried out inside a building make sure that there is ample ventilation WARNING PRECAUTIONS FOR INSPECTION AND MAINTENANCE i i To be prepared in the event of a fire have a fire extinguisher nearby and make sure that you know how to use it Before carrying out inspection lower the forks to the ground and stop the machine Do not run the engine unless it is necessary Place the directional lever speed l
25. you have proper qualifica tions before operating the lift truck When operating this lift truck even if you have experience in operating other lift trucks obtain instructions from an authorized person who has experience in operating this lift truck or the same type of lift truck WARNING CLOTHING AND PERSONAL PROTECTIVE ITEMS e Avoid loose clothing jewelry and loose long hair They can catch on controls or in moving parts and cause E i serious injury or death YT A i3 Always wear a hard hat and safety boots A amp A0055010 Depending on the working conditions wear other safety EB equipment in addition to the hard hat and safety boots co A WARNING OVERHEAD GUARD LOAD BACKREST Do not use this lift truck unless it is equipped with the overhead guard and load backrest shipped with the lift truck from the factory by Kalmar AC 01 2 01 SAFETY SECTION A WARNING UNAUTHORIZED MODIFICATION s Any modification made without authorization from Kalmar AC can create hazards e Before making any modification whatsoever consult your Kalmar AC distributor dealer Kalmar AC will not be responsible for any damage injury or death caused by any unauthorized modification e Do not install any equipment or parts which obstruct or limit the operator s view WARNING EXHAUST GAS Do not leave the engine running where there is poor ventiliation The engine exhaust gas contains carbon monoxide There is a
26. 18 HYDRAULIC l SYSTEM Oil Capacity gal L 9 25 35 03 3 03 SERVICE DATA SERVICE DATA GASOLINE ENGINE LIFT TRUCKS CUSHION Component Check Item Unit C30AX ENGINE Iu Idling Speed 700 Maximum Speed PO No Load 3 600 Instantaneous ENGINE P p Continuous Load 3 000 Torque Converter Stall Speed 2 100 100 rpm Compression psi rpm 178 250 MPa rpm 1 2 250 Engine Oil Capacity qts L 3 91 3 7 w Filter 3 59 3 4 w o Filter l i A i Idle 14 22 98 LUBRICATING Engine Oil Pressure 178 F 80 C psi kPa At 2 000 rpm 39 8 45 5 274 313 COOLING SYS TEMS 2 4 9 1 12 8 psi 0 9 kgf cm 0 47 0 55 12 14 Finger Pressure 98N Fuel Tye fl Unleaded Regular Gasoline 89 Octane Variable Controlled by ECU 56 es INTAKE in mm 015 0 38 w Engine Warm EXHAUST SYS Valve Clearance TEMS in mm 015 0 38 w Engine Warm 509 meda NEN Misa 1240 POWER TRAIN ij aor CONVERTER 27 8 177 0 0 88 4 22 2 000 15874 108 91 4 156 6 1 000 TORQFLOW Clutch Actuation Pressure in ak a eO a l ja oe TRANSMISSION 0 88 1 22 2 000 12 68 12 Including Torque Converter Teo EE TORQFLOW qts L DIFFERENTIAL Oil Capacity CLUTCH TYPE qts L Continued 13 74 13 Inc Direct Drive Trans 03 4 03 SERVICE DATA Component Check Item Unit C30AX C35AX TRAVEL SYSTEM Front tires psi MPa N A Inflation Pressu
27. 4 05 04 06 04 07 04 08 04 09 04 10 04 11 04 11 04 13 04 13 04 14 04 15 04 15 04 16 CHAPTER 05 INSPECTION orcas das Ea AO 05 01 Inspect Engine Starting Operation llle 05 02 Inspect Engine Running Condition llle elles 05 02 Inspect Air Cleaner Assembly eee hen 05 02 Inspecting for Loose Cylinder Head Mounting Bolts 4 Re Torquing 05 02 Iisbect Erigine MOUNIS s i2 ars ia do is arb aus 05 03 Inspect the Engine Lubricating System lees 05 03 Inspect Engine Fuel Velen ss ode etc eR 4h eck h Dee ind enn ver dies 05 03 Inspect LPG Vaporizer for Tar Buildup 2 0 02 eee ee es 05 03 Inspect the Blow by Gas Recirculation System 0 0 0 0 0 ens 05 04 Inspect Cooling System and Radiator leen 05 05 Inspect Charging System Wiring 00 2 eee ren 05 05 Inspect Front Axle and Re Torque Mounting Bolts 0 0 0 cee eee nee 05 05 Inspect Rear Axle and Re Torque Mounting Bolts o o o ooooooooooo 05 05 INSDECE WHEE oues dos te iy Send d AAA RO abd enne Te nee Gk ad teda 05 06 Inspect Steering Knuckles celle mh 05 06 Inspect Steering Wheel 0 0 0 0 ee eee nen een ees 05 06 Inspect the Power Steering System 0 0 0 eee eee eee eens 05 06 Inspect Brake System Rods Cables and Links 0 cece eee ee 05 07 Inspect Brake Piping amp Connections 0
28. AS R veu at hana Mu A WARNING TRAINED PERSONNEL ONLY 10 NO JUMP START Decal Part No 09842 A0481 Located top center of starter solenoid 01 38 01 SAFETY SECTION 11 LPG TANK CHANGE INSTRUCTIONS DECAL On LPG Tank Bracket Base Plate LPG FUEL CYLINDER REPLACEMENT PROCEDURE 1 NO SMOKING DO MOT REPLACE FUEL CYLINDERS IN AREAS THAT HAVE A SOURCE OF FUEL IGNITION 2 CLOSE CYLINDER VALVE AXD RUN ENGINE UNTIL IT STOPS PRIOR TO DISCONNECTING THE FUEL HOSE FROM THE TANK 1 REPLACE FUEL CONTAINER BE SURE TO USE THE CORRECT SIZE AND TYPE PER THE CYLINDER DESCRIPTION PLATE SECURELY MOUNT AND POSITION AS FOLLOWS s WITH LOCATING PIM THROUGH POSITIONING HOLE IN COLLAR b WITH SLOT IN FOOTRING OVER LOCATING KEYWAY 4 CONNECT FUEL HOSE OPEN VALVE SLOWLY 0 THE HOSE AND TANK PRESSURE CAN EQUALIZE OR THE VALVE MAY SLUG SHOULD LEAKAGE OCCUR CLOSE VALVE AND NAVE QUALIFIED PERSONNEL MAKE REPAIRS 5 USE FUEL MANUFACTURED TO NATIONAL GAS PROCESSORS ASSOCIATION HD 5 SPECIFICATION NOTE THE ABOVE I3 PROVIDED AS A GUIDE FOR ADDITIONAL INFORMATION CONSULT THE NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 58 FOR THE SAFE STORAGE AND HANDLING OF LIQUIFIED PETROLEUM GASES Em SS KFOMO0003 12 LPG SAFETY MAINTENANCE DECAL Right side of seat on hood upper surface RECOMMENDED SAFETY MAINTENANCE PROCEDURE FOR LP GAS FUELED FORKLIFT TRUCKS WARNING LP GAS is s combustible fuel that la heavier than air Esc
29. ECAUTIONS WHEN STARTING ENGINE e Before starting the engine always check that the parking brake is applied and that the directional and speed levers are in neutral P Depress the clutch pedal for clutch type trucks or the brake pedal for TORQFLOW transmission trucks firmly and then start the engine e Adjust the operator s seat and the steering wheel before starting the engine Always lock them in position after adjusting Adjusting the seat or steering wheel during operation is dangerous and it may cause you to lose your balance or to operate the lift truck improperly e Before starting the engine check that the surrounding area is safe ALWAYS SIT IN THE OPERATOR S SEAT when starting the engine Before starting the engine sound the horn to warn people in the area e With large sized lift trucks get off the lift truck and walk around it to check that no one is near the engine compartment tires or counterweight then get on the lift truck sit in the operator s seat and start the engine Do not attempt to start the engine by short circuiting the engine starting circuit Such an act may cause a serious bodily injury or fire A WARNING PRECAUTIONS WHEN OPERATING DIRECTIONAL OR SPEED LEVERS e When switching between FORWARD and REVERSE always stop the lift truck It is dangerous to change the direction of travel suddenly e When operating the directional lever or speed lever always depress the clutch pedal before mov i
30. N DATA PLATE Example A120 9Y2195 Transmission Transmission Part No Serial No 00 0002 Location on transmission On top of the torque converter bell housing Transmission Serial No Example 9Y2195 1st character Year of manufacture 2nd character Month of manufacture 1 January 2 February 3 March etc x Octo ber Y November Z December 3rd character Monthly serial number S N 9Y2195 was manufactuered in November 1999 and was transmission no 2 195 for that month NOTICE For EPA engine related troubleshooting refer to the following manuals e TM100 KAC EPA Engine Training Manual separate from this book TM5789 K21 K25 Engine Service Manual follows the chassis mast section of this book CONTENTS CHAPTER 01 SAFETY SECTION Safety Management anana aaa annann A E E aE Z pev a Ue TA Loading Operations 05s Stopping and Parking senan Inspection and Maintenance Structure and Stability of the Lift Truck Safety Label Locations P 8 9 B B A B B B P W 8H 9 B B B B a R K gt K w n gx B o9 uu dmP 4 9 u 4 blo 9 5 4d 9 9 4 b a an Ga u c 99 an Rs amp y 9 4 9 e 5 9 a 9 amp 3 a4 a 9 o a B a a u i3 G3 a 4 u 4 9 4 6 e G amp 9 a Ks a 4 a 9 4 s R C K gt 34 k b a n B a a 93 y gt 4 B 9 4 9 42 5
31. OR S COMPARTMENT Always operate the mast and forks from the operator s compartment A WARNING NO UNSTABLE LOADS Make sure that the center of gravity of the load is in line with the center of the lift truck Do not carry loads off center There is danger that unbalanced loads may cause the lift truck to tip e Place the load so that it contacts the load backrest e Do not handle unstable loads If there is danger that the load may fall off secure it in position and take steps to prevent the load from collapsing or falling e When carrying stacked loads tie with rope to prevent the load from falling AB801340 01 16 01 SAFETY SECTION AX WARNING PO NOT LOAD ABOVE HEIGHT OF LOAD BACKREST Keep the height of the load within the height of the load back rest Do not carry any load that is higher than the load back rest If the load is higher than the load backrest there is danger that it will fall back on top of the operator This may lead to serious injury or death AB801350 A WARNING DO NOT TILT MAST FORWARD WHEN LOADED Do not tilt the mast forward when the forks are loaded and Q raised There is danger that the load may fall and that the lift d truck may tip Do not travel with the mast tilted forward Do not load and unload on slopes AB801360 A WARNING KEEP TENSION ON CHAIN If there is any slack in the chain the mast rail or forks may catch in the load or a shelf and there is d
32. SHOP MANUAL C P30 35AX20 SERIES FORKLIFT TRUCKS Federal Environmental Protection Agency EPA Emission Control Compliant S N 670001A Gasoline LPG Dual Fuel C P30 35AX G C P30 35AX LS A WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place C Kalmar Ac Kalmar AC Inc ISSUED DECEMBER 2004 Ref SM123 INTRODUCTION This Service Manual has been developed as an information resource to help the reader learn about understand repair and maintain the AX20 Series forklift trucks and the vari ous equipment systems inspections sensors diagnostic procedures and diagnostic equipment utilized to maintain adjust and troubleshoot these systems Although refer ence is made to maintenance procedures necessary to perform servicing of this vehicle you should refer to the applicable Operation and Maintenance Manual for these lift trucks for more complete maintenance information Kalmar AC is involved in a concentrated and highly technical program of designing and developing cleaner burning more efficient and more powerful engines for use in the industrial truck market As a result new computerized sensors systems and diagnostic monitors have been created to make the job of maintaining and repairing these systems simple and easy Read this manual carefully refer to it often and learn the rep
33. Structure o ve AE ete RERO RC ARIES ES 07 32 Wheel Brake Specifications Checking llle 07 33 Wheel Brake ASSGmbly SEXE ERR AUR ORO RECS Be UR GENE RCRCR ER RC 07 33 Power Steering Valve OSPC Power Steering Valve Exploded View llle tees 07 36 Power Steering Valve Troubleshooting Chart else 07 37 Power Steering Valve Disassembly Photo Sequence llle eese 07 40 Power Steering Valve Cleaning llle ras 07 47 Power Steering Valve Assembly eee 07 47 Power Steering Valve Installation llle 07 59 Brake Master Cylinder Brake Master Cynder v sur tien boa Pop Enos ep dao sro decus do AR 07 60 Brake Master Cylinder Disassembly 0 00 cece eee eee eee eens 07 61 Brake Master Cylinder Testing rasero 07 62 Brake Master Cylinder Assembly ees 07 63 Clutch Master Cylinder Clutch Master Cylinder Manual Shift Trucks Exploded View oo 07 64 Clutch Release Cylinder Clutch Release Cylinder Exploded View 0 ee eee eee eens 07 65 Clutch Release Cylinder Disassembly 00002 ees 07 66 Clutch Release Cylinder Specifications llle 07 67 Clutch Release Cylinder Assembly n 07 67 Power Steering Cylinder Power Steering Cylinder Disassembly and Assembly 2 0 66 ees 07 69 Tilt Cylinders TIL CVIBde Sa S L oda ew loud E a eee ee AR ee ne ae ae n te ee M 07 70 Tilt Cylinder
34. T SYS Valve Clearance Smkm Ue uu anas Baten Ra Specie Gy POWER TRAIN o S ERST AA Clutch Actuation Pressure MS pum psi MPa qts L qts L ats L Lubricating Oil Pressure TORQFLOW Clutch Type Continued Oil Capacity DIFFERENTIAL Oil Capacity P35AX 700 No Load 3 600 Instantaneous Continuous Load 3 000 2 100 100 rpm 178 250 1 2 250 3 91 3 7 w Filter 3 59 3 4 w o Filter Idle 14 22 98 At 2 000 rpm 39 8 45 5 274 313 2 4 9 1 12 8 psi 0 9 kg cm 0 47 0 55 12 14 Finger Pressure 98N Unleaded Regular Gasoline 89 Octane Variable Controlled by ECU 4 2 1 3 50 8 PSI 350 KPa 9 8 37 015 0 38 w Engine Warm 015 0 38 w Engine Warm 035 0 9 P N 22401 FU412 0 700 1 3 4 2 Minimum 1 240 2 100 100 rpm 91 4 156 6 0 63 1 08 1 000 127 6 177 0 0 88 1 22 2 000 35 5 63 8 0 245 0 440 153 74 1 06 91 4 156 6 1 000 0 63 1 08 1 000 127 6 176 9 2 000 0 88 1 22 2 000 14 5 56 6 0 1 0 39 12 68 12 Including Torque Converter 6 34 6 13 74 13 inc Direct Drive Trans 03 2 03 SERVICE DATA Front tires psi MPa 98 6 0 68 Inflation Pressure TIRES Rear tire s psi MPa 98 6 0 68 Tread Depth Minimum 063 1 6 at tread width 1 4 Front Wheels Ib ft Nm 113 6 180 1 154 245 HUB NUT Ti
35. TION USE SUITABLE TOOLS Always use tools that are suited for inspection and mainte nance It is extremely dangerous to use broken tools or tools E designed for another purpose y y A0055120 WARNING REPLACE SAFETY CRITICAL PARTS PERIODICALLY Even if no abnormality is found always replace safety critical parts periodically As time passes these parts deteriorate and may cause fire or failure in the work equipment system e However if these parts show any abnormality before the replacement interval has passed they should be repaired or replaced immediately A WARNING PRECAUTIONS WITH HIGH TEMPERATURE COOLANT Immediately after using the lift truck the engine coolant is at high temperature HOT and high pressure Do not remove the radiator cap under these conditions Hot water may spurt out and cause burns When removing the radiator cap use a rag and turn it slowly to release the internal pressure When checking the coolant level stop the engine and wait for oi jj MIT the engine to cool down before checking For lift trucks p equipped with a sub tank or reservoir check the level in the sub tank e When adding water on lift trucks equipped with a sub tank add the water to the sub tank A0055050 01 25 01 SAFETY SECTION PRECAUTIONS WITH HIGH PRESSURE HIGH A WARNING TEMPERATURE OIL Immediately after using the lift truck the oil is at high temper ature Do not drain the oil or rep
36. TorqFlow Transmission Assembly Procedure annan 07 94 Pinion Assembly Exploded View he 07 97 Pinion Assembly Disassembly Procedure es 07 98 Pinion Assembly Assembly Procedure eren 07 98 Adjusting Ring Gear Backlash 0 00 ccc eet eee ees 07 102 Differential Pinion Shaft Lock Nut Special Tool 0 0 0 0 020 07 103 Differential Adjustment Nut Special Tool 1 2 0 ee ee ees 07 104 Hydraulic Control Valve Hydraulic Control Valve 3 Spool Type Exploded View oooooooo eee 07 106 Hydraulic Pump Hydraulic Pump 21 0cc Aluminum 0 ee RR ers 07 107 Hydraulic Pump Disassembly ee ee eee teen ran 07 107 Hydraulic Pump Replacement of Seals 0 0 0 0 0c eee eens 07 109 Hydraulic Pump Assembly 4 332 ies AA AAA 07 110 TorqFlow Transmission TorqFlow Transmission w Torque Converter 2 0 0 0 cc eee eens 07 111 TorqFlow Transmission Main Specifications llle leen 07 112 TorqFiow Transmission Disassembly Exploded View o ooooooooo ooo 07 113 TorqFlow Transmission Hydraulic Circuit Diagram ee 07 117 TorqFlow Transmission Explanation of Operation of Hydraulic Circuit 07 118 TorqFlow Transmission Dimensional Diagram moro 07 122 TorqFlow Transmission Torque Converter TorqFlow Transmission Torque Converter non 07 123 TorqFlow Transmission
37. URETOR FLOAT SYSTEM 1 SHUT OFF BOTH FUEL LINES COMPLETELY BY PLACING SWITCH IN THE OFF POSITION 2 START ENGINE AND RUN UNTIL SYSTEM IS PURGED OF ALL FUEL AND STOPS 3 TURN SWITCH TO DESIRED FUEL SELECTION LPG OR GASOLINE 4 START ENGINE AS USUAL KFOMOO007 14 FUEL LEVEL REQUIREMENTS GASOLINE AND LPG On dashboard over Fuel Gauge Dual Fuel applications only THIS GAGE GASOLINE TANK MUST BE AT LEAST 1 4 FULL WHEN OPERATING ON LPG KFOM0008 NOT IN USE USE TANK GAGE DO NOT REMOVE KFOMO0009 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA amp FEATURES INDOOR amp OUTDOOR TRUCKS P35AX GC P35AX G LS PS P35AX G LS PS C35AX G LS PS C30AX G LS PS PNEUMATIC TRUCK SHOWN DRIVE TIRES OVERALL WIDTH a a lt 2 O Q lt W a f gt O a I o m I MAST HEIGHT EXTENDED MAXIMUM FORK HEIGHT MAST HEIGHT LOWERED l JE FREE LIFT a eS mem WHEEL BASE FORK LENGTH LENGTH TO FORK FACE 02 0001KAC 02 2 02 GENERAL INFORMATION amp SPECIFICATIONS SPECIFICATIONS MAST DATA 8 FEATURES CON T MAST HEIGHT in mm MAXIMUM FORK FREE LIFT HEIGHT Lowered Extended in mm in mm in mm in mm Free View C P30 35AX 2 Stage Free View FV 106 0 2 690 154 0 3 910 5 5 140 116 0 2 945 164 0 4 165 5 5 140 128 0 3 250 176 0 4 470 5 5 140 2 Stage Full Free View FFV 106 0
38. a a force is applied towards the rear when the lift truck starts to move and is applied towards the front when the lift truck stops If the brakes are applied suddenly there is danger of a large force being applied towards the front which may make the lift truck tip or the load come off the forks When the lift truck is turned a centrifugal force is applied to the outside from the center of the turn This force pushes the lift truck to the outside and makes it tip The range of stability to the left and right is particularly small so it is necessary to reduce speed when turning in order to prevent the lift truck from tipping If the lift truck is traveling with a raised load the position of the overall center of gravity is high so the danger of tipping to the front left or right becomes greater 01 34 01 SAFETY SECTION SAFETY LABEL LOCATIONS Keep these labels clean If a label decal comes off stick it on again in the same location or replace with a new one Treat all labels decals in the same way whether they are safety related or not 1 a SHROUD INSIDE OF ENGINE HOOD OUTSIDE OF LEFT AND RIGHT OUTER MASTS EN 9 LEFT AND RIGHT OUTER RIMS OF LEFT AND FRONT WHEELS RIGHT REAR WHEELS AWB2296B See following pages for labels corresponding to numbered locations in Figure above 01 35 01 SAFETY SECTION 1 Prohibit the operator from riding on the 4 Never touch fan when rotating forks and lifting
39. adjusting check that the forks are held securely in posi 4 l I L tion by the fork stopper If the forks are not held in position d 7 there is a danger that the forks may move when the lift truck d MY REE N J is traveling and the load may fall off LOCK CK UI lt Q U N 3 WIR UA 3 AE818008 A CAUTION ADJUST CHAIN Be sure the tension of the left and right chains is the same See CHECK BEFORE OPERATION If the tension is not the same the load will be unbalanced even if it is loaded correctly in the center and there is danger that the lift truck may tip 01 19 01 SAFETY SECTION WARNING BE CAREFUL OF FORK TIPS Do not allow the tips of the forks to get close to people A The tips of the forks are pointed so there is a risk that S uh they may cause injury d AM Do not hook the tips of the forks under objects if the LAS forks slip out there is danger that the lift truck or object may move unexpectedly Bo AB801430 WARNING PEOPLE IN WORKING AREA i se Do not allow anyone except the signal person in the working area Do notlet any person or another lift truck come close during operation When working with a signal person always follow their instructions WARNING USE STRONG PALLETS AND SKIDS i Always be sure that the pallets and skids have ample strength If broken or damaged pallets or skids are used there is a risk that the load may fall WARNING
40. air testing and adjustment procedures to the best of your ability Please note that some illustrations are generic and may not look exactly like your unit in every detail Ensure that when you are working on or around industrial trucks Safety is priority Number One Read understand and obey all WARNINGS and CAUTIONS Follow the instructions and procedures presented in this manual when working on these lift trucks and their systems Damage to the equipment and possible injury to yourself or others may result if these procedures are not adhered to carefully Keep this manual nearby and accessible for use when necessary If this book becomes dirty worn or illegible contact Kalmar AC for a replacement The procedures outlined in this manual will be updated periodically Be sure that you have the latest revision in order to learn the newest information available Revision dates will be clearly displayed on the lower left hand corner of the cover page This will aid in maintaining your equipment in excellent condition and in ensuring that these lift trucks will operate safely at maximum efficiency ENGINE SERIAL NUMBER LOCATION The K21 K25 engine serial number is stamped on an angled and machined pad on the right side of the engine block in the center just beneath the valve cover The machined boss is split vertically by a groove The Engine Model number is on the left pad and the Engine Serial number is on the right pad TRANSMISSIO
41. all oil or grease from the ground When working on quays platforms docks or other places where there is a danger of falling set up blocks to prevent the lift truck from going over the edge Put warning signs up in dangerous places to warn the operator not to approach Mark the travel areas clearly and maintain the road surfaces in good condition Put up signs to prevent unauthorized machines from entering areas where trucks are being operated Ensure that there is adequate lighting to enable operations to be carried out safely WARNING CLEAN OPERATOR S COMPARTMENT Keep the operator s compartment clean and tidy Be sure to clean up all oi or mud If the opera tor s hand or foot slips this may lead to a serious accident Do not leave tools or spare parts lying around in the operator s compartment They may damage or obstruct the control levers or pedals Always keep them in the tool box when not being used WARNING SAFE OPERATING PLAN Before operation establish an operating plan and hold a meeting to discuss operating safety In confined areas position a signal person and carry out operations in accordance with his her instructions When carrying out operations on roads put up fences around the working area and carry out oper ations in accordance with instructions from the signal person WARNING REDUCE LOAD FOR LIFT TRUCKS WITH ATTACHMENT L The permissible load for any lift trucks equipped with an attachment is lowe
42. anger that the load may fall and the lift truck tip Always be careful that there is no slack in the chain when pulling the forks out from a pallet or shelf AB801370 01 17 01 SAFETY SECTION A WARNING USE ONLY FOR INTENDED PURPOSES e Do not use the lift truck for anything other than the intended use loading operations using the forks e Do not use the forks to open or close the doors of railroad cars or warehouses e Do not push any other vehicle e Do not hook ropes or cables on the forks and use the forks to lift loads e Do not use the drawbar pin for towing operations AB801380 A WARNING LEVER OPERATION e Be careful not to operate the lever by mistake There is danger that the forks or work equipment may cause serious injury e Do not operate the levers when getting off the lift truck Ah WARNING USING DRAWBAR PIN Do not use the drawbar pin for towing other lift trucks for being towed by other lift trucks or for lifting operations e The drawbar pin installed to the rear of the counterweight is used only to free the truck when the tires have become stuck in mud or in a ditch and the lift truck cannot move or when loading the lift truck on to a trailer or truck DRAWBAR PIN Arg47998 01 18 01 SAFETY SECTION A WARNING FIT FORKS SECURELY IN POSITION When adjusting the position width of the forks be careful not to get your hands caught AE y AB90 1400 Aher
43. aping gas mey accumulate in iow areas The fuel cylinder shouid be mounted so that it does not extend outside the truck and shouid also be property positioned by using the locating pin or key way The fuel valve shouid be turned off when the machine is not in service Cast fittings should not be used In the LP GAS system Uee only Underwriters Laboratories or Factory Mutual listed LP GAS hose assemblies where re fuel lines are required Ai pipe threaded fittings should be installed using an approved seating compound Fuel lines should be supported by clamps to minimize chafing and wear The LP GAS solenoid valve should be wired to en automatic shut off switch otl pressure of vacuum to prevent leekage of gas in the event the ignition is on without the engine running Vaud all abends dint shutoff valve for leakage as toliowa 1 Turn fuel cylinder valve off start and run engine until it stope 2 Install a 0 to 30 PSI pressure gauge per instruction A or B A Primery test port of single units consisting of primary and secondary regulators B Between the primary end secondary stage reguistors when the propane system consists of two seperate regulators 3 Turn cylinder fuel vaive on The on pressure gauge should maintain a zero reading If it does not the solenoid valve or vacuum shutoff valve must be repaired or replaced An odor is added to LP GAS to help detect leaks If gas odor is detected the fuel cylinder supply valve and engine sho
44. cified lifting point is the counterweight check that the counterweight mounting bolts are tightened to the speci fied torque before carrying out the lifting operation Check also that there is no damage to the lifting portion on the coun terweight AB80 1540 01 28 01 SAFETY SECTION Ah WARNING BATTERY HAZARD PREVENTION Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing If you spill electrolyte on yourself immediately flush the area with a large quantity of water Battery electrolyte can cause blindness if splashed into the eyes If electrolyte gets into your eyes flush them immediately with large quantities of water and consult a doctor at once If you accidentally drink electrolyte drink a large quantity of water or milk mixed with beaten egg white or vegetable oil Call a doctor or poison control center immediately When working with batteries ALWAYS wear safety glasses or goggles Batteries generate hydrogen gas Hydrogen gas is highly EXPLOSIVE and is easily ignited with a small spark or flame Do not smoke or create any spark near a battery Before working with batteries stop the engine and turn the starting switch to the OFF position When removing the battery remove the cable from the nega tive terminal first When installing the battery install the cable to the positive terminal first This prevents possible sparks or arcing between the positive terminal and
45. conditions WARNING CHECK WHEN TRAVELING IN REVERSE When reversing depending on the situation an optional alarm reversing lamp or rotary lamp should be used In all cases be sure to face the rear and check around before traveling in reverse WARNING TRAVELING REGULATIONS ON PUBLIC ROADS Always observe all traffic regulations when operating the lift truck Do not drive on public roads with the lift truck loaded Do not tow other machines on public roads Do not tow other machines even when not on public roads Always carry your driver s license when traveling on public roads WARNING SAFETY EQUIPMENT i The overhead guard is installed to protect the operator from falling objects It is designed to with stand the force of light boxes or small packages It is not designed to withstand every possible impact Always be careful to prevent damage or injury from falling objects A WARNING TIRE FENDERS INCORRECT The tire fenders prevent objects from being thrown up by the tires When changing from a single tire to a double tire arrangement on your forklift truck always extend the tire fenders to cover the additional tires If the fenders are not extended small stones and other objects will be thrown up and may injure the operator or other people in the surrounding area CORRECT FENDERS FENDERS AB803110 01 4 01 SAFETY SECTION WARNING SAFE WORKING AREA Always work on level surfaces and wipe up
46. d limit for the gang planks dock boards and do not use them if they do not have ample strength to take the weight of the lift truck when loaded Apply the brakes on the highway truck and block the wheels e With trailers use jacks and take steps to prevent the trailer from sinking when the forklift truck travels on it AB801170 When driving the forklift inside trucks reduce speed when backing out and be sure to check that the gangplanks are safe Be careful of pedestrians e Tell the truck driver not to move the truck until the operation is completed e if there is some system to secure the truck to the dock always use this system Secure the gangplanks so that they do not slip and fall A WARNING ESCAPING FROM A RAILROAD CROSSING e f engine trouble occurs on a railroad crossing and the lift truck cannot move you cannot use the starting motor to move the truck as can be done in automobiles The lift truck s neutral safety switch prevents this action e In such an emergency light a flare or smoke candle to warn approaching trains vehicles and pesons n the area that there is a broken down truck on the tracks e itis critically important to remove the lift truck from the tracks as soon as possible AB801180 01 9 01 SAFETY SECTION WARNING NO RIDERS i FORKLIFT TRUCKS ARE ONE PERSON MACHINES Do not allow any other person to ride on the truck under any circumstances Never allow anyone to act as an
47. damage to the seat belt itself If any abnormality is found repair or replace the seat belt immediately AB801700A WARNING SAFETY WHEN STARTING e Before starting and moving the lift truck check that the surround ing area is safe e Before moving the lift truck raise the forks approx 8 in 20cm from the ground surface and tilt the mast back e Before moving the lift truck release the parking brake Tilt back B80125B WARNING BRAKING WHEN TRAVELING i s Do not stop the engine when traveling If the engine is stopped the power steering for lift trucks with power steering and power brake for trucks with power brakes will not work e Ifthe inching pedal is depressed the braking effect of the engine will be lost e Do not use the brake excessively Do not rest your foot on the brake pedal or inching pedal unless you are operating it If you do the brake will overheat and the braking effect will be lost For TORQFLOW lift trucks if you leave your foot on the inching pedal the multiple disc clutch inside the transmission will overheat In the worst case the clutch discs will be deformed and the clutch will not function normally 01 12 01 SAFETY SECTION Ah WARNING SAFETY DURING TRAVEL Keep a clear view of the path of travel and observe for other traffic personnel and safe clearances Yield the right of way to pedestrians When passing oncoming vehicles reduce speed and keep a safe distance fr
48. danger that this will cause gas poisoning which may result in serious injury or death 40055060 A WARNING FIRE EXTINGUISHER AND FIRST AID KIT e f any abnormality in the lift truck occurs stop operation immediately park the lift truck in a safe place and safe condition then contact the person in charge Be sure that fire extinguishers have been provided and that you read the labels to ensure that you know how to use them Know what to do in the event of a fire Be sure that you know the phone numbers of persons you should contact in case of an emer gency Provide a first aid kit at the storage point e Do not use the lift truck if it is leaking fuel Inform the person on charge of the nature of the abnor mality and repair the leakage before using the lift truck Do not leave the lift truck with the engine running Always apply the parking brake securely lower the forks to the ground stop the engine and remove the key before leaving the lift truck 01 3 01 SAFETY SECTION WARNING SAFETY RULES Do not operate the lift truck if you are fatigued or when you have been drinking or you have taken any medication which can make you drowsy or sleepy When carrying out operation inspection or maintenance of the lift truck always follow all work shop rules safety regulations and precautions During operation always pay attention to safety and be careful of pedestrians traffic and other surrounding
49. er maintenance of your engine Your emission control system may include parts such as the carburetor regulator or fuel injection system ignition system engine computer unit ECM catalytic converter and air induction system Also included may be sensors hoses belts connectors and other emission related assemblies Where a warrantable condition exists an Authorized Kalmar AC Dealer will repair your LSI engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Beginning January 1 2004 off road large spark ignition EPA engines are warranted for the time periods listed below If any emission related part on your engine is defective the part will be repaired or replaced by an Autho rized Kalmar AC Dealer OWNER S WARRANTY RESPONSIBILITIES As the off road LSI engine owner you are responsible for the performance of the required maintenance listed in your Operation and Maintenance Manual KAC recommends that you retain receipts covering maintenance on your off road engine but KAC cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the off road large spark ignition engine owner you should be aware however that KAC may deny you warranty coverage if your off road large spark ignition engine or a part thereof has failed due to abuse damage neglect improper maintenance or unapproved modifications Your engine
50. eter ee A eed L A aE T M 4 1 2 Special Definitions xus sc ad C nb aia as RTE cori ia hens awa BSR 4 13 TOOL REQUIRGIIEING ar a nde e A cee REOR M i ead ee De EH iia BS de 4 2 1 Truck System Requirements lt ccc ec eee eee eee ee rosa 5 2 2 Mounting Bracket Installation ce RRR ete ee bees 5 2 9 M st Installato sia ri Seed a OG ek aed eek de we ee 6 2 4 Inspection amp Adjustments sud ue ts pad ne han ae tees ae Seats Ro ease a eum We OR E 7 2 5 Internal Reeving Installation llle 9 3A Penodic Maintenall6e o3 0h obici durer Ebo ictor paene dedere COE A ES bts e 4 0 TrOUDIESNOOUNG es do S a tutius Db a ThE EHE RICO edens oh Dani oe ddl icd uot 5 T Mast Removal arises oa ame oerte oi Aere o IP dur ad pv Red Ade OR o 12 Dez NINOS id dota Aaa aia x 9 9 DOUET IDT CONTO VAG sui hts s mir TEES dM RS aedes quii avd D sp i9 u is MC ORTO a a Eaa a a a aa a a a a a a 24 5 5 Mast UDHOBIS so ere oa eae A e dedu da ae A AS 3000 A O O NR TT ues dd Masts 30D 35D 40D 50D 55D 60D MS 2 Stage Masts COnN a O ea nde wd eub utet Sve aie Td aA d eae 3 TL Bian c a er al iSo d aid ANO SUR AE Rol dpi ANA DR Arr Ane side dodrina Ero RECS ded thane acai infe np aho 4 1 2 SpectalDellnillohs iaa pac US r Eee twee 65525244 CER ual id dio deem 4 2 1 Truck System Requirements ee hos 5 2 2 Mounting Bracket Installation llle rn 5 2 3 Mast InstallallOn suc em Ree prox PR Dd REUS binarias bea 6 2 4
51. ever and work equipment control levers in neutral WARNING PRECAUTIONS WHEN CARRYING OUT INSPECTION AND MAINTENENCE Wipe off any oil or grease Immediately wipe up any oil that has leaked If the lift truck is dirty it becomes difficult or impossible to find cracks or other problems Always clean the lift truck before starting inspection Do not smoke or allow any flame to exist under any circumstances Do not use any cloth which is soaked in fuel flammable solvent oil or grease There is danger that it may catch fire Wear suitable clothes for the job Use suitable safety and protective equipment hard hat safety boots safety glasses gloves for the job When working on top of the lift truck be careful not to fall Do not put your feet under the forks When opening or closing the floor plate or engine hood be careful not to get your hands or body caught When carrying out inspection with the forks raised insert a stand under the inner mast to prevent the forks and mast from dropping When carrying out the job with another worker decide who is the leader and carry out the job in accordance with instructions from that person After repairing make sure that the trouble has been corrected by performing a trial run During the trial run start and operate the lift truck carefully because it is possible that the trouble has not been fully corrected or that defective parts have not been removed 01 24 01 SAFETY SECTION A CAU
52. fied place Stop engine when fueling and avoid open flame or sparks and provide adequate ventilation Keep vent caps clear when charging battery Disconnect battery during servicing After Operating Before getting off truck shift F R lever and high low lever ciutch type to neutral position fully lower lifting mechanism and pull parking lever securely Shut off power when leaving truck unattended Block wheels when parking on incline Warning for use of split rim Only pneumatic tires Decal Part No 3EB 96 25750 Deflate tire compietely before removing rim nuts 3EB 96 285750 KFIDI0451 01 37 01 SAFETY SECTION 8 Prevention of tip over Decal Parts No 3EB 96 25730 Tep aver can occur even when unloaded amp Oan t tisk injury or death A Seu dawn betore kaang gons seatbeit man Rese KACO10449 9 Warning for handling LPG FLAMMABLE GAS Decal Part No 3EB 96 25780 Close fuel valve on tank when parking truck Do not store tank or park truck near heat or ignition sources Avoid sparks or open flame e Follow filling and operating instructions in perating manual When checking or filling tank No smoking Stop engine Fill in designated area To prevent damage to hase or fitlings Make sure pin extends through hole Ao in rim of tank Use only tank with part number shown on bracket E Frost or LPG odor Indicates leak Inspect and repair immediately Flammable LP G
53. ghtening Torque Rear Wheels Ib ft Nm 61 2 108 4 83 147 RIM MATING Front Wheels ib ft Nm 64 9 90 7 88 123 Tightening Torque NUT Rear Wheels Ib ft Nm 43 5 54 6 59 74 STEERING BRAKING SYSTEMS POWER STEER utet eZ Z rite ons vn TATUR rn ING RELIEF Relief Pressure psi MPa 1 073 3 7 4 VALVE STEERING 7 WHEEL Play in mm 1 2 2 4 30 60 Minimum Turning Radius in mm 76 6 1 945 78 0 1 980 STEERING AXLE Support Thrust Clearance in mm 0 028 0 7 D to CLUTCH PEDAL Play in mm 0 12 0 2 3 5 y in mm 0 08 0 12 2 3 INCHING PEDAL Interconnected Travel in mm 1 85 2 09 47 53 Play in mm 0 51 0 67 13 17 BRAKE PEDAL Pedal Height when Depressed in mm 3 15 3 54 80 90 Brake Fluid Capacity qts L 158 015 BRAKE Parking Brake Operating Force lof N 55 1 245 Torque for Back Plate Mtg Bolt Ib ft Nm 108 4 144 5 147 196 Unloaded 14 76 4 5 m STOPPING E UD em LOADING SYSTEM sd ULIS TA 1 26 32 Minimum 1 34 34 Minimum Thickness at Fork Root FORK Difference in Height in mm 0 6 15 Maximum Amount of Opening at Tip 1 4 35 Maximum CHAIN Length of 17 Links 13 1 332 Maximum ts TP 20 50 Maximum Hydraulic Drift Lift Cylinder in mm 15 Minutes CYLINDER 18 45 M fief l aximum Hydraulic Drift Tilt Cylinder in mm 15 Minutes MAIN RELIEF l l VALVE Relief Pressure psi MPa 2 610
54. he slope and FORWARD down the slope with the load engaging means downgrade When traveling down slopes use the braking force of the engine together with the foot brake and travel slowly down the slope A WARNING DO NOT JUMP OFF LIFT TRUCK EVEN IF IT TIPS NEVER JUMP OFF the lift truck even if it seems that it will tip Always do as follows e Hold the steering wheel securely Stay in the operator s seat Brace your legs f you jump off the lift truck when it turns over there is danger that you will be fatally crushed under the lift truck Always stay in the operator s compartment if the lift truck turns over then escape from the lift truck after it has stopped Always wear the seat belt correctly Tip over can oreur even when unloaded S Don t risk injury or deat d Slew dawn before turning EY 2 x Demit P lip over Falow these J instructions af KACO10449 01 8 AB801140 ABBO1150 01 SAFETY SECTION A WARNING ROAD SHOULDER e There is danger that soft road shoulders may collapse so do not go near them with the lift truck e Always maintain a safe distance from the edge of road shoulders and platforms AB801160 A WARNING LOADING HIGHWAY TRUCKS OR RAILROAD CARS e Do not travel on the edge of docks There is danger that the lift truck may fall which may result in serious injury or death Before starting operations check the loa
55. is condition the lift truck cannot be stopped Always do the following e Check the level of the brake fluid periodically Always use the specified brake fluid e Check that the breather of the brake fluid reserve tank is not clogged e Be careful not to let dirt or dust get into the brake fluid reserve tank 01 30 01 SAFETY SECTION A WARNING HANDLING ANTIFREEZE Antifreeze can be flammable Keep away from flame when handling Antifreeze is poisonous so do not drink it If you drink it by mistake drink large amounts of water vomit it out and get medical attention immediately Follow safety precautions on container A CAUTION WASTE MATERIALS Obey appropriate laws and regulations when disposing of harmful items and materials such as oil fuel solvent filters and batteries INCORRECT LEE A8801580 01 31 01 SAFETY SECTION 6 STRUCTURE AND STABILITY OF THE LIFT TRUCK TO PREVENT LIFT TRUCK FROM TIPPING To operate the lift truck safely it is important to understand the structure and stability of the lift truck A CAUTION STRUCTURE OF LIFT TRUCK A forklift truck consists basically of the lifting mechanism the forks and mast at the front and the lift truck itself with tires at the rear The front wheels of the lift truck act as the fulcrum and the center of gravity of the lift truck and center of gravity of the load are kept in balance The relationship between the position of the cente
56. is designed to operate on gasoline and or LPG fuel Use of any other fuel may result in your engine no longer operating in compliance with the Federal EPA s emissions requirements You are responsible for initiating the warranty process It is suggested that you present your off road large spark ignition engine to an Authorized Kalmar AC Dealer as soon as you become aware that a problem exists The war ranty repairs should be completed by the dealer as expeditiously as possible If you have any questions regarding your warranty rights and responsibilities you should contact the Kalmar AC Product Support Dept at 1 770 385 4815 In addition to the standard warranty periods the components listed below are covered by the following specific warranty periods 12 EMISSION CONTROL WARRANTY 36 MONTHS OR 2 500 HOURS FOR GENERAL PARTS For the first 2 500 operating hours or for a period of thirty six months from the date of the first use by the original purchaser from an Authorized Kalmar AC Dealer whichever occurs first KAC warrants the following emission related parts e Oxygen sensor e PCV valve Water temperature e Gasoline injector Sensor e LPG injector e LPG pressure sensor e LPG solenoid e LPG switching module s Mass air flow sensor Throttle chamber e Ignition coil e Crankshaft position sensor e Camshaft position sensor e Distributor e Spark plugs EMISSION CONTROL WARRANTY 36 MONTHS OR 4 000 HOURS FOR POWER TRAIN PARTS
57. lace the filter when the oil is hot Hot oil may spurt out and cause burns When carrying out inspection and maintenance wait for the oil temperature to go down and carry out the operation in the order given in this manual Do not forget that the work equipment circuits are always under pressure Do not add oil drain oil or carry out mainte nance or inspection before completely releasing the internal pressure If oil is leaking under high pressure from holes it is danger ous if the jet of high pressure oil hits your skin or eyes Always wear safety glasses and thick gloves and use a piece of cardboard or a sheet of plywood to check for oil leakage Release the internal pressure before checking the accumula tor piping If you are hit by a jet of high pressure oil consult a doctor immediately A WARNING ROTATING FAN AND BELT It is extremely dangerous if you or any tool touches or gets caught in the fan or fan belt when the fan is rotating Never touch the fan when it is rotating Always stop the engine before inspecting rotating parts When inspecting the areas around rotating parts do not allow anything to come close which may get caught 01 26 INCORRECT CORRECT A0055190 inn d AB801500A 01 SAFETY SECTION A WARNING BE CAREFUL NOT TO GET CAUGHT OR FALL NEVER put your hands or feet into the mast structure There is danger that you will get caught in moving parts and be seri ou
58. n the nameplate on the lift truck If the load center moves to the front of the forks the overall center of gravity also moves to the front so this means that the load must be reduced A CAUTION ALLOWABLE LOAD The allowable load is stamped on the nameplate to show the relationship regarding the position of the load center A o e al the height of the fork and the maximum load Before load Eer swt ing the forks check that the load and load center are within Arracumenr moon A e e a the permitted range on the stamped allowable load If the shape of the load is complex set it so that the heavi est part of the load is at the center of the forks and set the AB801820 load close to the load backrest p dg TRUCK WEIGHT hs muck A neme anar aan r n NOE vr NNNM If the forks are loaded more than the allowable value the T mm B veo ont TAE drive wheels will float during travel and the steering system sd cS monan wax mam oy S s x B will not work This is very dangerous Furthermore the lift LEE truck will tip over easily under this condition Therefore be sure to keep the load below the allowable value and prop erly balanced A WARNING SPEED AND ACCELERATION If a stationary object is not subjected to external force it will remain stationary In the same way if a moving object is not subjected to external force it will continue to move at the same speed This is called inertia Because of inerti
59. ng the lever for clutch type lift trucks If the lever is moved without disengaging the clutch the lift truck will move suddenly and may cause injury A WARNING TIPPING e f the load engaging means or load is raised the center of gravity of the lift truck will also rise and increase the danger of the lift truck tipping Do not turn the lift truck when the forks are raised high Do not suddenly raise the forks or tilt the mast to the front or rear when the forks are loaded There is danger that the lift truck will tip e Reduce speed before turning the lift truck In particular when traveling unloaded the rear of the lift truck is heavy e If the lift truck is turned at high speed there is a greater chance of tipping than with the forks loaded Always ensure that the hood is properly latched AB801120 AB801130 01 7 01 SAFETY SECTION A WARNING TRAVEL ON SLOPES e Do not turn or travel across or at an angle on slopes There is danger that the lift truck will tip e Before starting to drive up a slope stop the lift truck and adjust the clearance between the ground surface and the bottom of the forks so that the bottom of the forks or pallet do not contact the ground surface or the tip of the fork does not stick into the ground when traveling For safe travel on slopes When loaded Travel FORWARD up the slope and in REVERSE down the slope with the load upgrade When unloaded Travel in REVERSE up t
60. nual and do not start the lift truck until all the checks have been completed If anything abnormal is found inform the person in charge and carry out the necessary repairs WARNING LAMPS Check that the lamps light up correctly Replace any broken or inoperative bulbs WARNING KEEP HANDS FREE FROM OIL AND WATER Do not drive the lift truck if your hands are wet or covered with oil Your hands will slip on the work equipment control levers or directional lever and this may cause a Serious accident WARNING MOUNTING AND DISMOUNTING gt NEVER jump on or off the lift truck When getting on or off the lift truck always stop the lift truck and use the handrails and steps to ensure that you support yourself Never hold any control levers or the steering wheel when getting on or off the lift truck If there is any oil grease or mud on the handrails or steps wipe it off immediately Always keep these parts clean Repair any damage AL187320 01 11 01 SAFETY SECTION WARNING ALWAYS SIT IN OPERATOR S SEAT gt e Never operate the lift truck from outside the operator s compart ment e Always keep your body under the overhead guard e Do not extend your arms and legs outside the operator s com partment AB801240 WARNING SEAT BELT e Always wear your seat belt correctly when on the operator s seat The seat belt will reduce the risk of injury e Always check the seat belt mounts and check for any
61. oad being carried blocks forward view travel with load trailing Slow down and sound horn when vision is blocked Watch clearances especially forks mast overhead guard and tailswing area Slow down tor turns and on uneven or slippery surfaces Avoid running over loose objects Never angie or turn on incline Travel with load uphill when loaded Travel with lifting mechanism downhill when empty Secure dockboard or bridgeplate properly Do not exceed rated capacity Use special care when operating on dockboard or bridgeplate Do not handle unstable loads or loosely stack loads Do not handie loads higher than toad backrest Space forks as far as load permits Be sure load is centered and forks are completely under load Never tilt load with mast tilted forward Do not tilt forward when elevated except to pick up or deposit load Travel load or lifting mechanism low and tilted back Tipover can occur if operated improperly Do not jump if truck begins to tip over Hold on firmly and lean away from point of impact Avoid being trapped between truck and ground General Precautions Allow no one to stand or pass under or near load or lifting mechanism Never place any part of body into mast structure between mast and truck or outside truck Do not carry passengers on any part of truck Lift no one under any circumstances Do not operate without overhead guard and load backrest Fill fuel or charge battery only in speci
62. om the other vehicle In places where there are speed limits observe the speed limit and maintain a safe distance from other vehicles A WARNING CONFIRMING SAFETY When traveling always pay careful attention to the area around your lift truck particularly in the direction of travel or ic ae when turning Do not pass other vehicles on narrow roads or at crossings or other places where the view is poor When traveling through crossings or other places where the view is poor or when entering or leaving narrow roads stop and sound the horn to confirm safety before driving on Even if you sound the horn not everyone in the surround ing area will necessarily hear it Always pay careful atten ABBO1280 tion to the movements of people in the surrounding area When crossing roads or turning corners stop and confirm safety before continuing Always pay careful attention to the movements of people in the surrounding area and take steps to prevent people from entering the working area A WARNING SAFETY DURING TRAVEL Avoid traveling in places which are flooded or where there are holes Do not try to drive the lift truck on soft ground Avoid curbs rails ditches or other obstacles and do not travel directly over them Do not travel on slippery road surfaces When entering buildings check the weight limit of the floor and be careful not to exceed the limit AB801270 A WARNING GIVE PRIORITY TO LOADED LIFT TRUCKS
63. r of gravity of penter of gravity lift truck gravity of load AB80159B Center of aravity of load Combined center of gravity Center of aravity of lift truck It is assumed that the lift truck body is constant 48801606 Ah CAUTION STABLE RANGE OF CENTER OF GRAVITY For the lift truck to be stable the position of the combined center of gravity must be inside the triangle stable range of center of gravity formed by the ground contact points of the left and right front tires and the center of the rear axle If the position of the overall center of gravity is in front of the front axle the front tires will form the fulcrum and the lift truck will tip to the front if the position of the combined center of gravity moves outside the triangle forming the stable area for the center of gravity the lift truck will tip in the direction where the combined center of gravity moves outside of the triangle 01 33 Stable range AB80161B 01 SAFETY SECTION AX CAUTION MAXIMUM LOAD weight and center of gravity of load The horizontal distance between the center of gravity of the load on the forks and the load backrest of the forks or the front face of the forks whichever is shorter is called the load cen e ter The maximum load is the maximum weight of the load that can be loaded at the standard load center The relationship between the maximum load and the load center is given in the load capacity charts o
64. r of gravity of the lift truck and the center of gravity of the load is extremely important for maintaining the safety of the lift truck peavey A CAUTION CENTER OF GRAVITY OF LOAD The loads carried by forklift trucks come in various shapes and weights from boxes to planks and long objects To judge the stability of the lift truck it is important to distinguish the position of the center of gravity for loads of various shapes AB801580 01 32 01 SAFETY SECTION A CAUTION CENTER OF GRAVITY AND STABILITY The stability of the lift truck is determined by the position of the combined center of gravity resulting from the combination of the centers of gravity of the lift truck and the load When the lift truck is carrying no load the center of gravity remains as it is but when the lift truck is loaded the com bined center of gravity becomes the combination of the cen ters of gravity of both the lift truck and the load The position of the center of gravity of the load changes according to whether the mast is tilted forward or back or whether the mast is raised or lowered The position of the combined center of gravity of the lift truck is governed by the following factors e Size weight shape of load e Lifting height e Tilting angle of mast Inflation pressure of tires e Acceleration deceleration turning radius e Condition of road surface angle of road e Type of attachments Center of Combined Cente
65. r than the permissible load for the standard lift truck Reason 1 The permissibie load must be reduced by an amount equivalent to the weight of the attach ment itself 2 Because of the thickness of the attachment the load center moves forward Always observe the permissible load table strictly this table is stuck to the lift truck or the attach ment Never exceed the permissible load WARNING NO JUMP START SAFETY PLATE DECAL DO NOT JUMP START the engine by short circuiting the starting motor terminals This SAFETY PLATE DECAL is located on the top center of the starter s magnet switch If your machine is not equipped with this SAFETY PLATE install a new plate decal in the specified location after cleaning the surface 01 SAFETY SECTION A WARNING FIRE PREVENTION FOR FUEL FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE FIRES AND EXPLOSIONS Carry out refueling away from flames or sparks Stop the engine when refueling After refueling tighten the gas cap securely and wipe up any spilled fuel The specific gravity of LPG is heavier than air so it is easy for the vapors to accumulate in low places holes road surface depressions etc This can create a fire or explosion hazard Be extremely careful A0055020 A0055030 A0055040 Ah WARNING NO STARTING AIDS Engine starting aids are highly flammable and may cause an explosion Do not use starting aids to start the engine 4h WARNING LPS SAFETY
66. re TIRES psi MPa N A Tread Depth N A Ib ft Nm 115 8 180 7 157 245 HUB NUT Tightening Torque Rear Wheels Ib ft Nm NIA ET NA RIM MATING NUT Tightening Torque bt Nm NA STEERING BRAKING SYSTEMS CONOCI d vt mei de POWER STEER ING RELIEF Relief Pressure psi MPa 1 073 3 7 4 VALVE STEERING l Minimum Turning Radius in mm 67 9 1 725 69 7 1 770 STEERING AXLE Support Thrust Clearance in mm 0 028 0 7 CLUTCH PEDAL Play in mm 12 20 3 5mm y in mm 0 08 0 12 2 3 in mm 1 85 2 09 47 53 INCHING PEDAL Y D Interconnected Travel BRAKE PEDAL Pedal Height when Depressed 3 15 3 54 80 90 Brake Fluid Capacity qts L 158 0 15 BRAKE Parking Brake Operating Force Ibf N 55 1 245 Torque for Back Plate Mtg Bolt Ib ft Nm 108 4 144 5 147 196 Unloaded 14 7 4 5 LOADING SYSTEM Um deco E u E Thickness at Fork Root in mm 1 26 32 Minimum 1 34 34 Minimum FORK Difference in Height in mm 0 6 15 Maximum Amount of Opening at Tip 1 4 35 Maximum CHAIN Length of 17 Links 13 1 332 Maximum Hydraulic Drift Lift Cylinder in mm 20 50 Maximum 15 Minutes CYLINDER Hydraulic Drift Tilt Cylinder in mm 1 8 45 Maximum 15 Minutes MAIN RELIEF HYDRAULIC SYSTEM Oil Capacity gal L 9 25 35 03 5
67. s use the torque values specified in this list b Select a proper torque value corresponding to the width across the flats b of the boit or nut When replacing bolts and nuts always use the manufacturer s specified part s of the same size and strength as the original a parts 01 0002 Tightening Torque Thread diameter Width across of bolt in mm flat in mm a b 236 6 315 8 394 10 A72 12 551 14 630 16 709 18 787 20 866 22 945 24 1 06 27 1 18 30 394 10 512 13 669 17 748 19 866 22 945 24 1 06 27 1 18 30 1 26 32 1 42 36 1 61 41 1 81 46 1 97 50 2 16 55 2 36 60 9 73 1 03 23 2 2 10 48 5 5 00 82 6 7 20 131 14 0 206 21 282 29 405 43 549 58 684 72 973 100 1 270 140 1 630 180 2 030 210 2 420 250 02 10 279 29 383 39 549 58 745 78 927 98 1 320 140 1 720 190 2 210 240 2 750 290 3 280 340 1 35 0 15 3 20 0 30 6 70 0 70 11 5 1 00 18 0 2 00 28 5 3 00 39 0 3 00 56 0 6 00 76 0 8 00 94 5 10 0 135 15 175 20 225 25 280 30 335 35 03 SERVICE DATA SERVICE DATA GASOLINE ENGINE TRUCKS PNEUMATIC si e ae ee ENGINE at ete oc 9 o ENGINE Maximum Speed rpm Torque Converter Stall Speed rpm Compression LUBRICATING Engine Oil Pressure 178 F 80 C COOLING SYS fme EXHAUS
68. sly injured Do not use the mast as a ladder If you slip there is danger that you will fall AB801320 AB801330 Ah DANGER CHECKING AND INFLATING TIRES If the tire inflation pressure is low it will affect truck stability However do not inflate the tires immediately The inflation pres sure may have gone down because of damage to the rim If the rim is damaged or cracked and the tires are inflated there is danger that the rim will break when the tire is under high pres sure and this may cause personal injury or death For safety when checking tire pressure place your body in front of the tread face of the tire Do not check from the side face of the tire Suitable qualifications are needed for tire inflation work Always have the work carried out by properly qualified personnel The tire inflation pressure on a forklift truck is several times higher than the pressure on an automobile When the tires are being inflated there is danger that dirt or dust may be thrown up by the compressed air and enter your eyes Always wear safety glasses to protect your eyes 01 27 AB801510 01 SAFETY SECTION A WARNING HANDLING TIRES Disassembly and assembly of tires should be carried out by a tire dealer The tire pressure is extremely high so caution is needed when handling tires The wheel is fitted with mounting lug nuts It also has rim nuts and bolts used to join the rim halves When removing the tire from the
69. tem of your lift truck do not use another lift truck to tow it There is danger that the lift truck may run away 01 14 01 SAFETY SECTION 3 LOADING OPERATIONS A WARNING NO OVERLOADING Do not load the lift truck over the capacity set forth in the load capacity chart If the rear wheels come off the ground because of overloading the lift truck cannot travel or turn There is also danger that it may tip Always check the load capacity chart to confirm the loading capacity AB801190 Ah WARNING DON T GO UNDER FORKS Never allow anyone to go under the load engaging means or load when it is raised The area under the forks is a danger area If the forks B come down the person under the forks may be crushed or seriously injured or killed Never allow anyone to go under the load engaging means or load even if it is elevated or sticked It may fall down suddenly at any moment L O AD817970A AK WARNING PO NOT LIFT PEOPLE ON FORKS Do not use the forks to lift people If the person falls from the forks he she may be seriously injured ADR17980A 01 15 01 SAFETY SECTION A WARNING BE CAREFUL NOT TO GET CAUGHT OR FALL e Never put your hands or feet into the mast structure There is dan ger that you will get caught in moving parts and be seriously injured AB801320 Do not use the mast as a ladder If you slip there is danger that you will fall A WARNING OPERATE FROM OPERAT
70. the positive cable Avoid short circuiting the battery terminals through accidental contact with tools or other metal objects across the terminals Tighten the battery terminals securely Loose terminals can generate sparks and lead to an explosion When removing or installing the battery confirm which is the CHECK BATTERY positive terminal and which is the negative terminal Be TERMINAL careful not to connect the cables to the opposite incorrect ter MARKINGS minals Tighten the battery caps securely When cleaning the battery leave the battery caps tightened A0055100A WARNING DO NOT PUT METAL OBJECTS ON TOP OF BATTERY Never place any metal objects on top of the battery There is danger that they will cause a short cir cuit and start a fire A WARNING CHANGING LPG FUEL TANKS Only trained and certified personnel may change LPG tanks Turn ignition switch to the OFF position Change LPG tanks in designated and well ventilated area approved for this operation Check LPG tank and lines for fuel leaks Ensure no sparks flame or ignition sources are present Once the full tank is in place ensure it is mounted correctly and securely Check all connections Do not attempt to start the truck until all LPG odor is gone If the truck is hard to start contact a certified mechanic to repair the problem Tag the truck Out of Service until properly repaired 01 29 01 SAFETY SECTION WARNING PRECAUTIONS
71. tput SAE Gross HP kW rpm 60 1 45 2 950 Maximum Torque SAE Gross Ib ft Nm rpm 115 156 1 600 No of Cylinders Displacement cu in cm 4 1126 2 065 Cylinder Bore x Stroke in mm 3 5 89 x 3 3 83 Fuel Tank Capacity U S gallons liters 6 6 25 OTHER Relief Pressure Maximum psi bar 2 650 182 7 Hydraulic Tank Capacity U S gallons liters 5 8 22 Clutch Torque Converter Transmission TORQFLOW Air Cleaner Type Cyclone ry NOTE Most values shown in this publication are rounded Therefore direct conversion between metric and English or Impe rial may be slightly different than displayed in this table The performance of the machines is affected by the condition of the vehicle and how it is equipped as well as the nature and condition of the operating area If these specifications are critical or if your needs exceed the specifications shown here discuss the proposed application with your authorized dealer Optional masts attachments longer load dimensions and higher lifting heights may result in derating of the capacity Con tact your authorized dealer Other mast heights available See MAST DATA CHART for other mast heights Contact your authorized dealer t includes 48 in 1 220 mm high Load Backrest Contact your authorized dealer for additional information tt Add load length and clearance Contact your authorized dealer 02 7 02 GENERAL INFORMATION amp SPECIFICATIONS PERIODIC REPLACEMENT OF
72. uld be turned oft Remove all sources of ignition and ventilate the eres Make ali of the necessary repairs before you turn the fuel supply on The complete LP GAS system should be inspected periodically Check ali hoees for weer connections for leaks and ali parte for damage NOTE Fuel hoses have a limited life expectancy They should be checked for crecking and drying due to age Hoses with visibile signs of age should be replaced Use only Underwriters Laboratories or Factory Mutua listed LP GAS parte for replacements NOTE The above Information ts provided as a guide Consult the National Fire Protection Association pamphiet 58 for the safe storage and handling of liquefied petroleum gases Governmental safety reguiations in your locality could vary Check with the authority having jurisdiction to be sure that you meet ali of their requirements Contact the manufacturer for detailed service information SERVICE WORK SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY KFOMO004 01 39 01 SAFETY SECTION 13 LPG FUEL SYSTEM DECALS A LPG LOW FUEL ALARM LIGHT On dashboard to left of steering column OP KFOMOO06 B DUAL FUEL SYSTEM FUEL CHANGE OVER INSTRUCTIONS On Air Cleaner housing Not illustrated in Fig AWB2296B FUEL CHANGEOVER INSTRUCTIONS DUAL FUEL SYSTEM CAUTION FLAMMABLE LIQUIDS WHEN SWITCHING FROM LP GAS TO LIQUID FUEL BE SURE THAT THERE IS NO SPILLAGE OF LIQUID FUEL FROM THE CARB
73. uthorized dealer Optional masts attachments longer load dimensions and higher lifting heights may result in derating of the capacity Con tact your authorized dealer Other mast heights available See MAST DATA CHART for other mast heights Contact your authorized dealer t Includes 48 in 1 220 mm high Load Backrest Contact your authorized dealer for additional information TT Add load length and clearance Contact your authorized dealer 02 5 02 GENERAL INFORMATION amp SPECIFICATIONS TRUCK DATA CUSHION TIRE LIFT TRUCKS GENERAL Power Type Gasoline Operation Type SitDown Sit Down Capacity 24 in 600 mm Load Center ibs kg 3 500 1 580 Load Distance from Center Axle 2 Stage in mm 15 4 390 Load Distance from Center Axle 3 Stage in mm 15 4 390 Wheelbase in mm 47 2 1 200 WEIGHT Service Weight inc 2 Stage STD Mast Forks Ibs kg 6 450 2 925 TIRES Tire Type Cushion Tire Size Front 18 0 x 6 x 12 1 8 Tire Size Rear 14 x4 1 2x8 Number of Wheels Front Rear x Driven 2x 2 Tread Center of Tires Front Rear in mm 32 1 815 32 1 815 DIMENSIONS Tilting Angle 2 Stage FV Masts Forward Backward 717 Tilting Angle 3 Stage TFV Masts Forward Backward 7 5 Mast Height Lowered 2 Stage Mast in mm 83 5 2 120 Mast Height Extended 2 Stage Mast in mm 176 0 4 470 Maximum Fork Height 2 Stage STD Mast in mm 128 0 3 250 Free Lift Height
74. ydraulic a 31 23 Service Brake Operation Control Foot Hydraulic Maximum Gradeability Loaded Unloaded at 1 mph Parking Brake Operation Control Hand Mechanical Hand Mechanical Hand Mechanical Hydrostatic Power Hydrostatic Power Steering Type Hydrostatic Power TABLE CONTINUED ON NEXT PAGE 02 4 02 GENERAL INFORMATION amp SPECIFICATIONS DRIVE Battery Voltage Capacity 20 hour rating V Ah Engine Model Rated Output SAE Gross HP kW rpm Maximum Torque SAE Gross Ib ft Nm rpm No of Cylinders Displacement cu in cm Cylinder Bore x Stroke in mm Fuel Tank Capacity U S gallons liters OTHER Relief Pressure Maximum psi bar Hydraulic Tank Capacity U S gallons liters Clutch Transmission Air Cleaner Type P30AX GPS 4 126 2 065 3 5 89 x 3 3 83 9 8 37 Ez a E P35AX G PS 12 41 K21 65 7 49 2 900 145 197 1 600 2 650 182 7 8 2 31 Torque Converter TOROFLOW Cyclone NOTE Most values shown in this publication are rounded Therefore direct conversion between metric and English or Imperial may be slightly different than displayed in this table The performance of the machines is affected by the condition of the vehicle and how it is equipped as well as the nature and condition of the operating area If these specifications are critical or if your needs exceed the specifications shown here discuss the proposed application with your a

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