Forklift-12 Maintenance Manual

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com
FLT 12 FORKLIFT TRUCK
MAINTENANCE MANUAL
A Foreword
B Safety
1 Engine
MAINTENANCE 2 Transmission
MANUAL
3 Power transmission
4 Brakes
5 Steering
FLT 12
6 Suspension
7 Common hydraulics
8 Common electrics
FLT 12 Maintenance Manual

FLT 12 Maintenance Manual 01
02 FLT 12 Maintenance Manual
Reading instructions
Warning information
Warnings inform on potential dangers which can, if the warnings are
not heeded, result in personal injury or product damage.
D A N GE R
Situation that may result in serious personal injury,
possible death, if the instruction is not followed.
WA R N IN G
Situation that may result in serious personal injury
if the instruction is not followed.
CAUTION
Situation that may result in damage to the product
if the instruction is not followed.

Foreword
Foreword About the Operators & Maintenance Manual
General
Thank you for choosing Cargotec Indital Industries as your
machine supplier. We hope that we'll meet your expectations.
This maintenance manual contains information about how the
machine should be maintained for maximal operating reliability
and service life as well as troubleshooting information for fast
correction of any malfunctions.
Conditions
The instructions are based on the use of generally available
standard tools. All lifting devices must meet governing national
standards and regulations for lifting devices.
Cargotec Indital Industries will not accept any responsibility for
modifications performed without permission from Cargotec
Indital Industries or if other lifting devices, tools or work methods
are used other than those described in this manual.
Storage
NOTE
The operators & maintenance manual shall be accessible to
service personnel.
About the machine version

The information in this publication corresponds to the machine's
design and appearance at the time of delivery from Cargotec
Indital Industries. Due to customizations, there may be variations
and/or deviations.
Cargotec Indital Industries reserves the right to modify
specifications and equipment without prior notice. All information
and data in this manual are valid at the time of publication.
Copyright
Duplication of the content in this manual, in whole or in part, is
strictly prohibited without written permission from Cargotec Indital
Industries . Duplication by any means such as copying, printing,
etc., is prohibited.

Safety
Safety General safety information
Safety concerns everyone!

The safety information concerns everyone who works with the
machine! Persons who do not follow the safety instructions given
in this manual must make absolutely sure that the work is
performed without risks of personal injury and without risk of
damage to machine or machine property!
Remember to:
• follow the instructions in this manual
• be trained for the work in question
• follow local laws, safety rules and regulations
• use the correct equipment and tools for the job
• wear the correct clothes
• use common sense and work carefully, do not take any risks!
Cargotec Indital Industries has in this publication documented
and warned for situations and risks that may occur in connection
with using as well as service/repairs of the machine during normal
circumstances. That' s why it's important that all who work with the
machine, or repair/ service the machine read and follow the
information in the operators & maintenance manual.
INSTRUCTIONS FOR SAFE USE :

The machine should be used only by skilled and properly trained personnel. The responsibility to
choose a suitable person for the work and to acquaint him with the machine and its safe use is with the
owner.
If Machine is used incorrectly, it may be dangerous to the operator and the environment.
The operator should have full control of the machine in various operating conditions. Therefore it is
important that the operator acquaints himself with the systems of the machine and its operations. This
enables him to prepare himself in advance for safe use of the machine in performing different tasks.
“When problems arise, always remember to stay calm.

Think first and then act accordingly”

GENERAL SAFETY PRECAUTIONS :
Thoroughly acquaint yourself with the machine's structure, manuals and its proper use.
Observe the instructions and warnings.
Try to determine the hazards, and avoid them. Report any faults that you have noticed to your
superior or to the person in charge of repairs.
Wear required protective clothing and helmets.
Always observe sufficient caution and care when climbing into or coming down from the
machine. Remove all foreign materials which can affect safety. Wipe away all oil leakages at
once to prevent slipping.
Do not allow any unauthorized persons to operate the machine entrusted in your use. The
operator of the machine is responsible for any damage caused by the machine.
Acquaint yourself in advance with the use of emergency exits.
Do not stand under a hanging container or load.
Before starting the Machine movement, make sure that nobody is standing in front or behind
the machine.
Avoid sudden stops and starts
Observe the condition of your working environment. Note the obstacles restricting your work,
and the slippery areas, Heaps of sand, and oily surfaces also cause increased risks in your work.
Report any sources of danger at once to your superior or to the person in charge of the safety of
your working area.
Limit your driving speeds to ensure safe working conditions.
Always drive far enough from any vehicles ahead. Never drive side by side with other vehicles.
Observe the signs and instructions indicating free height. You should know the exact total
height of your machine before driving into places with restricted free height. Be especially
careful with temporary structures, hanging overhead power lines, etc.
Do not drive in the dark without lights. Report any poorly lighted passages.
When changing driving direction, stop the machine completely with the service brake before
moving the direction selector lever.
Watch out for the edges of driveways where the surface may be loose / yielding and can cause
overturning.
Remember that the machine is not intended for carrying / lifting persons.
Always stop the engines whenever you leave the machine even for a short while. Lower any load
to the ground before you leave the machine.
Always remember to engage the parking brake before leaving the cabin.
Make a detailed report on any collisions, including the damage caused. This could prevent
accidents from being repeated.
Observe the weight of your machine, and its total weight loaded. Do not drive on surfaces with
insufficient load capacity.
Follow the periodic maintenance schedule. This ensures that the controls and the whole
machine operate reliably and safely.
The engine must always be stopped when service or inspections are being carried out.
Stop the engine always for filling the fuel tank!

The use of open flame is absolutely forbidden when checking fuel or battery electrolyte levels.
The radiator is pressurized when the coolant is hot – open the radiator cap slowly and cautiously
to avoid injury.
Do not switch off the main switch when the engines are running.
Only a person who is well acquainted with the machine's control and the cabin controls is
allowed to be in the cabin during service and repairs.
Driving is forbidden without fastening seatbelts.
Never park the machine on an inclined plane.
HAZARDS AND PREVENTING DANGEROUS SITUATIONS
OVERTURNING :
Avoid sudden braking especially when the load is high up; high tipping force may cause
overturning. The load should not be carried higher than 3000 mm from the ground. This keeps
tipping forces to the minimum.
Avoid sudden turns on inclined or bumpy surfaces. Powerful braking causes great danger of
overturning, especially during turning.
Observe the changes in the working environment and limit your driving speed so that you can
safely observe possible obstacles and hazards well in time to avoid accidents. Pay special
attention to slippery conditions, snow, ice, or possible oil spills. The slippery surface constitutes
unpredictable risks with the danger of collision and overturning.
Beware of the holes and other damages in the yard surface. These can cause flat tyres suddenly
and, thus risk overturning.
COLLISIONS :
Be always alert when coming across crates, undulations and also when another vehicle is
approaching you. Adjust your driving speed so that you can stop the vehicle within the visible
free path ahead.
When approaching another container, remember that the machine's springing yields in sudden
braking and the containers may collide (fork Lift).
DAMAGED MACHINE :
If the machine is damaged it must not be used until the damages have been checked and
repaired. Damaged safety system will cause unpredictable results; personal safety is
compromised and the machine and its load will suffer unnecessary technical and financial
damage.
Report any noticed damages at once to your superior or to the person in charge of repairs.
SYSTEM ALTERATIONS :
No alterations to the structures and the system of the machine are allowed without the
manufacturer's written consent. Alternations may lower the level of the machine's safety (by
causing unexpected functions) and thus lead to serious accidents and even loss of life.

Engine
Engine The engine provides power for propulsion and working hydraulics.It is a
low-emission engine and meet emission standards. With the new
engine, a significant improvement is obtained not only of exhaust
emissions but also the power curve and torque curve.
Engine H6ETIC3U/4 is a straight 6-cylinder, 4-stroke turbo charged low-
emission diesel engine .

ENGINE
PRE-OPERATION CHECKS:
Following are the pre-operation checks to be carried out before starting the Fork
Lift.
Engine:
Check water level in the radiator. If level is not enough, fill with clean soft water as
required.
Check for fan belt tension and whether it is seated properly in the grooves. If not,
adjust the tension and put back the belt on the grooves. Refer engine manual
supplied for details.
Remove dipstick, clean the end and dip again to check the oil level in the sump. If
level is low, fill as required with recommended engine oil.
Ensure filter element is present in the filter assembly. Check Air filter for clogging.
Indicator provided gives details on the condition of the filter. Refer engine manual
for further details.

Transmission
Transmission The transmission converts the engine power to the drive
wheels(drive axle) via the propeller shaft and also power to
drive the hydraulic oil pumps for hydraulics.
Transmission has 2 Forward and 2 Reverse Gears to deliver

4 forward and 4 reverse speed ranges.
The torque converter and the transmission work together via
a common hydraulic system. The torque converter is a
hydraulic clutch placed between the engine's output shaft
and the transmission's input shaft. The hydraulic oil pumps
as well as the oil pump for the transmission's control and
lubrication are connected to the torque converter via power
take-offs on the transmission.

Power Power Transmission
Driveline/axle
Transmission The machine's power transmission consists of propeller shaft and
drive axle with differential and hub reduction.

POWER UNIT
ENGINE, TRANSMISSION AND DRIVE AXLE DRAWING
1 ENGINE
2 TRANSMISSION
3 PROPELLER SHAFT
4 DRIVE AXLE

DRIVE AXLE
Check for oil in the differential casing up to the over flow plug. If not fill with
the recommended Grade oil up to the level. (Ref. Lubrication chart in part
’C’).
Check and tighten Drive axle bolts in the wheel hub to the torque of 50
Kgm.
General
Check Diesel level in LH tank from Diesel Level Indicator.
Check Hydraulic Oil level in RH tank behind cabin from Hydraulic Level
indicator. Oil should never be low. Top up with the recommended oil as
required. While in mast extended/ raised condition oil level would fall. This
is natural. Level should always be checked in the mast fully retracted and
in the lower most position.
Check for electrolyte level in the battery. If level is not OK top with distilled
water. Protect the terminals from corrosion.
Grease mast slides on both the sides and in the bottom. Adjust side
screws of the boom to have correct sliding fit of the mast. Over tightening
would damage the slides. Under tightening would not provide proper
guide while telescoping.
Check for proper tyre inflation. Pressure should be minimum 9.0 bar and
maximum 10 bar .
Check and tighten all Hydraulic joints for leaks.
Check and tighten all bolts and nuts.
Check for Hydraulic oil return line filter for clogging when there is a drop in
pump output.
Check and apply grease for all lubrication points.
Check for general cleanliness.
:
GENERAL MAINTENANCE GUIDELINES
There are some maintenance duties that a stacker operator should usually
perform during his daily routine.
The following paragraphs are meant to guide the operator in knowing just
what those duties are.
For the components such as: Engine and power shift transmission consult
the relevant operator’s manual drawn up by the manufacturer and
supplied along with the FORK LIFT.
Air cleaner filters

The air filter should be inspected periodically. A dirty air filter can seriously affect
the performance and life of the engine. The following simple service steps are
easily made while the engine is being serviced in the field:
a) Check all connections for tightness.
b) Clean and if necessary replace the filter element.

TYPE
MAINTENANCE, REPAIR AND SERVICE MANUAL

PROPELLER SHAFT
Check and tighten all bolts if necessary.

Grease the cross and ‘U’ Joints.
Check for smooth rotation while operation.

Brakes Brakes
Brakes
There are brakes to stop the machine. The brakes act on the drive axle.

Brakes
Brakes, general
There are brakes to stop the machine. The brakes act on the drive axle(steering axle does not have brakes).
The brake system is divided into three functions:
• Power-assisted brake system, function description
• Parking brake system, function description
Controls and instruments
Brake pedal
Brake pedal, checking and adjusting
1. Clean the floor around the brake pedal and check that nothing blocks movement of the brake pedal.
2. Check that the brake pedal returns all the way and that the clearance between the brake pedal and brake valve
is 1–1.5 mm. If needed, adjust the brake pedal's stop bolt so that the clearance becomes correct.
3. Check that the pedal's travel is smooth.
4. Grease the pedal hinges with EP2 universal grease.

Steering Steering
steering
.The function steering means to steer the machine while operating

79
Steering
Steering, general
The function steering means to steer the machine while operating. The
machine is steered with the rear wheels by a power-assisted steering
system.
Power assisted system
Power assisted system, function description
The function power assisted system refers to steering the machine.

The machine's steering is power-assisted with pressure from the
hydraulic oil pumps.
Steering consists of steering wheel, steering column, steering

valve, hydraulic oil pumps, steering cylinder, link arms, and wheel
spindles.
The steering wheel acts on (via the steering shaft) the steering valve
which in turn directs oil pressure from the hydraulic oil pumps to the
steering cylinder. The priority valve, located between the hydraulic oil
pumps and the steering valve, gives priority to oil supply of the steering
valve before other functions, e.g., load handling. The steering cylinder
acts on the wheel spindles. The link arms are located between the
steering cylinder and wheel spindles. Valve block servo pressure
handles control signals to the hydraulic oil pumps.

Suspension Suspension
Suspension
.The machine's wheel suspension is made up of its tyres (with
associated rims and bolts), steering axle with hubs, wheel
spindles,
and the steering axle's suspension in the frame.

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81
Suspension
Suspension, description
The machine's wheel suspension is made up of its tyres (with

associated rims and bolts), steering axle with hubs, wheel spindles,
and the steering axle's suspension in the frame. The drive axle belongs
to the power transmission, see section 3 Driveline/Axel group
3.3 Drive axle.
Suspension
Suspension, description
Suspension refers to:
• Steering axle cradle
• Wheel spindle
• Wheel hub
The steering axle cradle is mounted to the frame with shaft and clamp,
one at the leading edge and one at the trailing edge of the steering
axle cradle. In the steering axle cradle there are two wheel spindles
mounted on journaled shafts. The wheel spindle is flexible to enable
steering. On the wheel spindles there are journaled wheel hubs
where the wheels are mounted.

Steering axle cradle
Steering axle cradle, checking
The figure shows rear mounting
1. Check that the Locking plate, Bolts in the suspension are intact.
2. Measure the distance between the frame and the steering axle
cradle. Note the measurement.
3. Lift the machine under the rear counterweight.
Do not lift under the steering axle.
The rear mounting is flexible, make sure that the joint's

movement is blocked when measuring.
4. Again, measure the distance between the frame and the steering
axle cradle. Note the measurement.
Calculate the difference between the two measurements. The difference

may be max. 3 mm. If the difference is greater, the bushing must be
replaced.

Tyres and rims
Tyres and rims, safety
DANGER
Always block wheels on the side of the axle that is
not going to be worked on before placing the jack.
Always secure the jack to prevent it from slipping out
of position.
Deflate the tyres before removing. Otherwise the lock

ring and lock lugs can release and shoot off when the
pressure changes. For twin tyres, both tyres must be
deflated!
The air must always be released through the valve. If

this is not possible — drill holes in the tread to release
the air. Damaged tyres may explode.
Never stand in front of the tyre when deflating or

inflating. Lock ring and lock lugs may release and
shoot off when the pressure changes.
Never install damaged tyres or rims.
It's prohibited to repair rims with welding.
It's prohibited to operate the machine if one of the

tyres is flat.
Wheels, tyres, and rims are dimensioned and selected

for each machine type so that max. wheel loads
and operating speeds are not exceeded. Therefore,
changing of tyre dimension, tyre brand, tyre type, rim
type, or rim brand is not permitted without approval
from Cargotec India.

CAUTION
When removing wheels, leave the wheel nuts in place
after they have been loosened. If the wheel nuts are
removed immediately the wheel may release from the
hub.
When removing drive wheels, make sure that the

wheels are secured when removing the spacer rings. If
the wheels move they may move the spacer rings,
which may result in crushing injuries.
When installing drive wheels, ensure that the clamps

clamp straight on the spacer ring.
Wheel nuts should be check-tightened after 4-5

operating hours.
Always follow the tyre manufacturer's or other

approved instructions when changing tyres.
Never use a steel hammer to install or remove rim

components. Instead, use a lead, brass, or plastic
mallet.
Keep tyre pressures at the prescribed level. Loosely

inflated tyres impair stability and reduce the machine's
capacity.
Remove penetrating objects such as crushed glass,

pieces of wood, metal filings, etc.
Check if the tyre wear is abnormal, this may be

indicative of mechanical problems. Take action
immediately to repair any defects and change damaged
tyres.
Tyre and rim system, description
The tires are the points of contact between the machine and the
ground, and the tires absorb unevennesses and provide suspension.
The drive axle is exposed to high forces during operation, if the drive
wheels' rolling circumference is different the stresses increase on the
drive axle. It is important that tyres on the drive axle have uniform wear
and correct air pressure.

Tyres and rims, check
Read the safety instructions before working with tyres and rim, see
Tyres and rims.
DANGER
inflating! Lock ring and lock lugs may release and
The air must always be released through the valve. If

this is not possible — drill holes in the tread to release
the air. Damaged tyres may explode.
Do not exceed prescribed air pressure! When changing

tyre or rim version, another air pressure may apply,
contact Cargotec India.
1. Check the rims.
• Check that the lock ring and lugs are installed correctly.
• Check that there are no cracks in the rims' parts.
In case of damage, the tyre and rim must be removed and

checked.
2. Check the tyres.
• Check for uneven and fast wear, this is caused by mechanical

defects such as, e.g., uneven brake action. Make sure that
such defects are repaired immediately.
• Remove penetrating objects such as crushed glass, pieces of

wood, metal filings, etc.
If the tyre is damaged, the wheel shall be dismantled and the tyre
shall be changed, see Tyre, change.
4. If the tyres and rims have no defects, check-tighten the wheel n

nuts.
Torque-tighten crosswise with 400 Nm (oiled bolt).
Examples:The figure shows inflation of drive wheel.

Tyre and rim system, removing and fitting (drive
axle)
Tyres and rims, safety.
Removing
1 Machine in service position, see section B Safety.
2 Lift the machine under the drive axle by the relevant wheel.
Support under the drive axle in a secure way.
DANGER
With double wheel fitting both tyres must be deflated
otherwise the inner may explode when the outer is
removed.
Risk of tyre explosion! Fatal danger!
Empty both tyres of air.
3 Release the air from the tyres by:
a) Unscrewing the valve and releasing the air.
b) If this does not work, undo the valve in the rim and release the
air.
c) If this does not work, break off, cut or saw off the valve pipe.
d) If it is not possible to release the air via the valve connection, the
tyre must be emptied by drilling a hole in the tyre's tread. Use a
drill with max. Ø 5 mm.

4 Loosen the wheel nuts.
5 Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
6 Remove the nuts, washers and clamps.
7 Remove the spacer ring.
Pull the wheel out a bit so that the spacer ring comes loose.
The spacer ring is heavy.
8 Lift the wheel away and position it safely so that it does not fall or
move.
9 Secure the inner drive wheel with lifting equipment.
10 Remove the spacer ring between the outer and inner wheels.
11 Remove the inner drive wheel and position it safely so that it does
not fall or move.
Installing
12 Fit the inner drive wheel. Turn the wheel so that the guide lug
enters the groove on the hub.
13 Fit the inner spacer ring.
14 Install the outer drive wheel. Turn the wheel so that the guide lug
enters the groove on the hub.

15 Fit the outer spacer ring.
The outer spacer ring is spit. Turn the ring so that the
opening ends up directly opposite the groove on the hub.
16 Install clamps and wheel nuts. Tighten the wheel nuts crosswise
in turn with increasing torque:
• 400 Nm (oiled screw).
Don not forget the bracket for the inner tyre's valve
extender.
17 Inflate the tyres, see Tyres, inflating, page 109.
18 Lower the machine and remove the jack.
19 Test-drive the machine and check that the wheels are secure.
20 Check-tighten the wheel nuts crosswise to a torque of:
• 400 Nm (oiled screw).
Tyre and rim system, removing and fitting

(steering axle)
Removing
1. Machine in service position, see section B Safety.
2. Lift the machine under the steering axle by the relevant wheel.
Support under the steering axle in a secure way.
3. Release the air from the tyres by:
a) Unscrewing the valve and releasing the air.
b) If this does not work, undo the valve in the rim and release the
air.

c) If this does not work, break off, cut or saw off the valve pipe.
d) If it is not possible to release the air via the valve connection,

the tyre must be emptied by drilling a hole in the tyre's tread.
Use a drill with max. Ø 5 mm.
4. Secure the wheel with the lifting equipment, i.e. make sure that
the wheel is positioned safely for lifting in the lifting equipment.
5. Remove wheel nuts and clamps.
6. Remove the wheel and position it safely so that it does not fall
or move.
Installing
7. Fit the wheel.
8. Install clamps and wheel nuts. Tighten the wheel nuts crosswise
successively with increasing torque to 400 Nm oiled screw.
9. Inflate the tyre, see Tyres, inflating.
10. Lower the machine and remove the jack.
11. Test-drive the machine and check that the wheels are secure.
12. Check-tighten the wheel nuts crosswise to a torque of 400 Nm.

Tyres
Tyres, inflating
DANGER
Always follow the instructions for inflating tyres to
avoid risk of accidents.
Only use approved rim components.
If the tyre has been completely deflated, the tyre must

be dismantled and the rim checked for damage.
Never install rim components by striking with a

hammer while inflating. Never strike fully or partly
inflated tyres or rim sets.
Never inflate tyres before all parts are in place.

Wheels shall be inflated on the machine or in a
protective device, designed and dimensioned so that
it can handle or dissipate a shock wave from a tyre
explosion as well as catch the ejected parts.
Do not exceed the prescribed tyre pressures which

must be checked at ambient temperature. When
changing tyre or rim version, another air pressure
may apply, contact Cargotec India. Plate for air
pressure in tyres must be replaced with a plate that
shows applicable pressure.

inflating. Lock ring and lock lugs may release and
Check that all parts are in place when the tyre

pressure is 30 kPa.
An air filter and water trap should be installed on the line
from the compressor that is used to inflate tyres to avoid
rim corrosion.
1. Make sure that the lock ring and lock lugs are in the correct
position before inflating.
2. Connect the compressor with a locking air-chuck to the nipple

on the tyre.
3. Move to the side and stay to the side of the tyre while inflation
is in progress.
4. Inflate the tyre to prescribed pressure, see specifications.
When changing tyre or rim version, another air pressure may

apply, contact Cargotec India.

Tyre, change
DANGER
Changing tyres is complicated and dangerous work.
FATAL DANGER!
Leave tyre work to authorised personnel/tyre company.
The wheel rims must be checked when tyres are changed. See 6
Suspension, group 6.3.2 Rims.
Rim
Rim, check
DANGER
Perform the following checks to minimize risks of
accidents for all split rims.
Always use the right tyre size and a design

corresponding to the manufacturer's rim type and size.
Overdimensioned tyres may not be used.
Replace all damaged, worn or corroded rims or

mounting parts.
1. Dismantle the rim, see Tyre, change.
2. Carefully clean the outside of the rim edge with a steel brush.
3. Measure wear after the lock ring.
The lock ring's wear on the tyre bead often gives a mark, A in
the figure. The mark occurs between the lock ring's ends.
Measure wear depth at point A using a steel ruler and sliding

gauge. If wear exceeds 0.5 mm then the wheel rim, lock ring
and the tapered rim must be discarded and replaced with new
parts.

4. Check the rim's diameter.
Measure the rim edge's circumference (O) with a measuring
tape and calculate the diameter (D). [D = Circumference (O) /
3.14]
Compare the value of the diameter with specified min.

measurement. If diameter is smaller, then the wheel rim, lock
ring, and the tapered rim must be discarded and replaced with
new parts.
Information about min. diameter can be obtained from Cargotec

O. Circumference India.
D. Diameter
5. Check for damage in the areas with high stress concentration.
Checking is done in two steps:

1. The magnetic powder method is used to determine if there's
a crack or not, and where it is.
2. Confirmed cracks are investigated further with penetrating
fluid.
Typical rim damages are circumference cracks, corrosive

damage, rust, warping and wear.
Magnetic powder method
1. Blast clean the marked area around the entire rim so that it is
completely clean from all paint.
2. Test using magnetic powder and the following equipment:
• Equipment:Yoke Tiede
• Method:
a. Alternating current AC
b. Contrast colour
• Checking medium:
a. Wet
b. Colour (for example, Tiede Ferrolux)
If no cracks are detected with the magnetic powder method,

checking is finished and the rim is approved.
If cracks are indicated, the crack should be investigated further

with penetrating fluid.
Checking cracks with penetrating fluid
1. Clean the area with cleaning fluid part no. 923626.0668.
2. Spray penetrating fluid part no. 923626.0669 on the cleaned

area and let dry 10 min.
3. Wash off penetrating fluid with cleaning fluid part no.

923626.0668.
Thoroughly wipe off the cleaning fluid with a drying cloth and let
any remaining cleaning fluid evaporate.
4. Spray detection fluid part no. 923626.0670 on the area.
5. Let the sprayed area dry 1-2 hours.

6. Visually inspect the lock ring groove.
If the tested area does not indicate linear or point-shaped

cracks in the lock ring groove the rim is approved.
If the crack check indicates linear or point-shaped cracks the rim

should be discarded.
Examples of cracks
1. Linear crack
2. Pointed crack

Common Hydraulic Common
Common Hydraulic
Hydraulic
.Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics.

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95
Common hydraulics
Common hydraulics, description
Hydraulic functions that are common to several of the machine's
main functions are found under the function common hydraulics. For
example, the hydraulic oil pumps that supply load handling, steering,
and certain cab functions with hydraulic pressure.
The brake system is completely separate, and is found in section 4
Brakes.

Hydraulic oil
Hydraulic oil, level check

The oil level is checked with the mast fully lowered and
fully retracted.
1. Machine in service position, section B Safety.
2. Check the oil level in the hydraulic oil tank with the lift cylinders
completely down and the extension cylinder completely in. The
oil should be in the middle of the level glass. Top up as needed,
for quality see section F Technical data.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the mast

completely lowered and retracted.

Hydraulic oil, changing
Read safety instructions for oil before starting work, see

section B Safety.
IMPORTANT
Ensure cleanliness around the filter and filling point
when working on the hydraulic tank.
Dirt particles may cause machine damage.
1. Machine in service position, see section B Safety.
2. Remove the filler cap and pump out the hydraulic oil in a
collection container.
1. Cover plate for oil filter 3. When most possible oil has been pumped out. Place a
2. Level glass hydraulic oil container under the hydraulic oil tank's drain plug and drain the
3. Filling point hydraulic oil last hydraulic oil.
4. Breather filter hydraulic oil tank
4. Fit the drain plug when the oil has drained.
Make sure that the drain plug's washer seal is also

removed.
5. If the hydraulic oil filters are to be changed, change them before

filling the tank with oil.
Fill oil until the oil level is in the middle of the level glass.
CAUTION
Do not overfill!
Leakage and environmental damage!
The hydraulic oil level is checked with the mast

completely lowered and retracted.

Common Electrics Common
Common Electrics
Electrics
.Electrical functions that are common to several of the machine's main
functions are found under the function common electrics.

7
103
Electrical protection
Electrical protection, components5

6
1. Fuses Indicator Box
2. Battery Disconnector

Batteries
Start battery
Start battery, checking
WARNING
Battery electrolyte contains corrosive sulphuric acid.
Risk of corrosive injuries! Hazardous to health!
Use protective safety goggles and protective work

gloves when working with batteries. Remove
immediately any electrolyte on the skin. Wash with
soap and plenty of water. If electrolyte has splashed in
the eyes, rinse immediately with plenty of water and
contact a doctor immediately.
1 Check the battery voltage from the operating menu for electrical
system.
With the engine off, the battery voltage should be 23–25 V.

With engine at max. engine speed (2,000 rpm), the battery voltage
should be 27–29 V.
2 Turn off the engine and turn off the system voltage.
3 Check that the battery's terminals are free from dirt. If needed,
lube the battery terminals with terminal grease.
4 Check the fluid level in the battery cells. Top up with battery water
If needed.
The electrolyte level should be 10 mm above the cells.
Use only distilled water if topping up is necessary.

Battery cables, checking
DANGER
Check that the battery cables are correctly clamped
and free from damage.
Fire hazard! Risk of personal injury!
Repair or replace damaged clamps and check that no

machine parts wear or chafe against the battery cables.
Change damaged battery cables.
• One battery positive terminal to another battery negative terminal
• Battery positive to battery disconnector (cutoff)

switch
• Battery disconnector (cutoff) to starter motor positive
• Ground cable between starter motor negative and

frame (Body Ground)
• Ground cable between battery negative and frame

(Body Ground)
WARNING
Always stop the engine and break the current using the
main switches before working on the engine.

TM
we keep cargo on the move

Cargotec India Private limited
(Multi Assembly Unit)
10-B, Peenya Industrial Area, 2nd Phase, Bangalore-560 058, India
Tel: 91-80-39225641 (4 Lines) Fax: 91-80-28395702
Website: www.cargotec.com

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FLT 12 FORKLIFT TRUCK

FLT 12 Maintenance Manual

FLT 12 Maintenance Manual 11

About the machine version

FLT 12 Maintenance Manual 13

Safety concerns everyone!

INSTRUCTIONS FOR SAFE USE :

“When problems arise, always remember to stay calm.

FLT 12 Maintenance Manual 15

16 FLT 12 Maintenance Manual

HAZARDS AND PREVENTING DANGEROUS SITUATIONS

FLT 12 Maintenance Manual 17

FLT 12 Maintenance Manual 19

20 FLT 12 Maintenance Manual

Transmission has 2 Forward and 2 Reverse Gears to deliver

FLT 12 Maintenance Manual 25

FLT 12 Maintenance Manual 47

ENGINE, TRANSMISSION AND DRIVE AXLE DRAWING

48 FLT 12 Maintenance Manual

Air cleaner filters

FLT 12 Maintenance Manual 49

MAINTENANCE, REPAIR AND SERVICE MANUAL

50 FLT 12 Maintenance Manual

Check and tighten all bolts if necessary.

FLT 12 Maintenance Manual 75

FLT 12 Maintenance Manual 77

The brake system is divided into three functions:

• Power-assisted brake system, function description

• Parking brake system, function description

Controls and instruments

Brake pedal, checking and adjusting

3. Check that the pedal's travel is smooth.

4. Grease the pedal hinges with EP2 universal grease.

78 FLT 12 Maintenance Manual

FLT 12 Maintenance Manual 7

Power assisted system

Power assisted system, function description

The function power assisted system refers to steering the machine.

Steering consists of steering wheel, steering column, steering

80 FLT 12 Maintenance Manual

FLT 12 Maintenance Manual 1

The machine's wheel suspension is made up of its tyres (with

Suspension refers to:

• Steering axle cradle

82 FLT 12 Maintenance Manual

Steering axle cradle, checking

The figure shows rear mounting

3. Lift the machine under the rear counterweight.

Do not lift under the steering axle.

The rear mounting is flexible, make sure that the joint's

Calculate the difference between the two measurements. The difference

FLT 12 Maintenance Manual 83

Tyres and rims, safety

Deflate the tyres before removing. Otherwise the lock

The air must always be released through the valve. If

Never stand in front of the tyre when deflating or

Never install damaged tyres or rims.

It's prohibited to repair rims with welding.

It's prohibited to operate the machine if one of the

Wheels, tyres, and rims are dimensioned and selected

84 FLT 12 Maintenance Manual

When removing drive wheels, make sure that the

When installing drive wheels, ensure that the clamps