Sellick SD-80 Operators Manual Nov 1998

Operator’s
Manual
SD-50, SD-60, SD-80, SD-100
Please have your dealer record
the information in the spaces
Issued to:
provided. Read this Operator’s Owner’s name: ___________________________________________
Manual carefully before operat-
______________________________________________________
ing your Sellick forklift and keep
it in a convenient location for Address:________________________________________________
future reference. If at any time
______________________________________________________
you have a service problem with
this machine, remember that City:___________________________________________________
your Sellick Equipment dealer
Province/State: ___________________________________________
has factory-trained service per-
sonnel, genuine Sellick parts Postal/Zip code:___________________________________________
and the necessary tools and
equipment to best satisfy your
service needs. Issued by:
Sellick dealer: ____________________________________________
______________________________________________________
Address:________________________________________________
______________________________________________________
City:___________________________________________________
Province/State: ___________________________________________
Postal/Zip code:___________________________________________
Telephone number: ________________________________________

Fax number: _____________________________________________
Delivery date: ____________________________________________
For extra copies of this manual, please order part #272252.

Printed in Canada.
1
to our
customers
We at Sellick Equipment Limited, in the long-standing tradition of quality the

Sellick name represents, take great pride in providing you with your new
SD series forklift. A great deal of time and care has been devoted to the proper
design, manufacturing and preparation of this machine for delivery into your
hands. This truck is designed as an all-purpose forklift and there are a range of
attachments, including forks and buckets, that will enable you to keep your
machine at work all year long.
This manual is directed to you, the operator, to assist in the safe operation and
proper break-in and servicing intervals of your new Sellick SD forklift.
We share your pride in its character and its ability to perform the tasks for
which it has been designed. Our sincere hope is that you derive from its oper-
ation the full measure of value and utility which you anticipated when pur-
chasing it.
The forklift will respond best when given considerate treatment and care. For
maximum operational life, we recommend that you carefully follow the pre-
ventive maintenance and service schedules set out in this manual. Planned
maintenance will ensure that your machine remains in good working order
with minimum down-time and expense. The illustrated step-by-step instruc-
tions included in this publication will guide you through the correct proce-
dures.
Sellick Equipment Limited
358 Erie Street North
Continuing improvement and advancement of product design may cause Harrow, Ontario, Canada
changes to your machine which may not be included in this publication. Each Telephone: (519) 738-2255
Fax: (519) 738-3477
publication is reviewed and revised as required and the revisions are included
E-mail: sellick@mnsi.net
in later editions of the Operator’s Manual. Website: www.sellickequipment.com
Sellick Equipment Limited November, 1998 SD Operator’s Manual

2
serial SD model and serial numbers

numbers
Forklift model number: _____________________________________
Forklift serial number: ______________________________________

It is our aim to provide you with
the best service in the shortest
possible time. Please record the
Engine model number: _____________________________________
serial and model numbers of
your machine and major com- Engine serial number: ______________________________________
ponents in the spaces provided.
Transmission serial number:__________________________________
Please quote these numbers
when ordering parts. Front axle serial number: ____________________________________
Rear axle serial number: ____________________________________
Door key number: _________________________________________
Ignition key number: _______________________________________
Attachments:_____________________________________________
Sellick dealer: ____________________________________________
______________________________________________________
______________________________________________________
Contact: ________________________________________________
Dealer address: ___________________________________________
______________________________________________________
______________________________________________________
Telephone number: ( ) ________________________________
Fax number: ( ) _____________________________________
E-mail address: ___________________________________________
Website: ________________________________________________
SD Operator’s Manual November, 1998 Sellick Equipment Limited

3
Serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
table
Safety requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 of contents
Walk-around inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-51
Operation safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Break-in procedure and seat adjustment . . . . . . . . . . . . . . . . . . . . . . .29
Cab features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-32
Start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-36
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37-40
Travel procedure—no load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4WD option operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Lifting safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-46
Travelling with loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Placing loads, shut-down and parking procedures . . . . . . . . . . . . .48-49
Transporting and towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-51
Preventive maintenance and service . . . . . . . . . . . . . . . . . . . . . . .52-83
Maintenance and service safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Regularly scheduled maintenance chart . . . . . . . . . . . . . . . . . . . . . . . .53
Tool box/storage compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Fuel systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54-61
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62-63
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64-65
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66-67
Transmission and brake system fluids . . . . . . . . . . . . . . . . . . . . . .68-69
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Mast lubrication and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Belts and fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Front (drive) axle - CD60 & PD70 . . . . . . . . . . . . . . . . . . . . . . . . . .74-75
Rear (steer) axle - S50 & SD50 . . . . . . . . . . . . . . . . . . . . . . . . . . . .76-78
Rear (steer) axle - S55 & SD55 . . . . . . . . . . . . . . . . . . . . . . . . . . . .79-81
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82-83
Grease points - 10 and 50 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84-85
Maintenance chart decals - 2WD and 4WD . . . . . . . . . . . . . . . . . . . . . . . .86-89
International symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
SD operator’s checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Fluids types and capacities chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Sellick warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94-95

4
foreword
Right Rear
Left
Front
Throughout this manual, references will be made to left, right, front, and rear.
While seated and facing the forks, the operator is facing the front of the forklift.
Therefore the rear is behind you and left and right are the corresponding sides.
Caution The controls on your new forklift are designed for efficient operation and are
This safety symbol indicates located within comfortable reach, thereby reducing operator fatigue. All instru-
important safety messages in ments are centrally located so you can tell at a glance if the unit is operating
this manual. When you see this properly. The instruments also warn you of possible trouble before it becomes
symbol, be alert to the serious.
possibility of personal injury
and carefully read the message It is the operator’s responsibility to completely read and understand the
that follows. It basically means: Operator’s Manual before attempting to start or operate the forklift. Be sure you
Attention! Become alert! Your are familiar with the location and function of all controls and instruments as
safety is involved! described on pages 16-20.
Know your controls and instruments to ensure safe operation!

5
A careful, skilled operator is the best operator. Most accidents can be avoided.
Lack of operating knowledge can lead to mishaps. Equipment should be oper-
safety
ated only by those who are trained and instructed to do so. Read the following requirements
safety precautions before operating your forklift to help prevent accidents.
• Know the rated capacity and operating characteristics of your machine, see
the nameplate inside the operator’s compartment. Ground and wind con-
Read this Operator’s Manual
ditions may affect stability of the machine, please refer to page 37-40 for
and the E.M.I. Safety Manual
more information on forklift stability.
(part #272052) carefully before
• Always make sure the forklift is adequately counterweighted. using your new forklift. If there
is anything in these manuals
• Always obtain advice on the use of unfamiliar material-handling vehicles
that you do not understand, ask
and attachments before operating with a load.
your supervisor to explain it
• Always buckle your seat belt before starting the machine. to you.
• The forklift could tip over if operated incorrectly. If the forklift tips, do not
jump! Stay in the operator’s compartment, hold on to the steering wheel
and lean away from the direction of the fall.
• Never use the forklift as a personnel lift. Unauthorized personnel should not
be permitted to ride anywhere on the forklift.
• Never leave your forklift unattended in areas open to the public.
• Carry all loads low at the minimum ground clearance.
• Know the rules and regulations required at your job site.

• Do not put any part of your body between the uprights of the mast and the Caution
outside of the operator’s compartment of your forklift. Never service this machine with
the engine running.
• Always walk completely around the forklift, making sure everyone and
everything is clear before starting the engine.
• Always apply the parking brake and place the transmission in NEUTRAL
before starting the engine.
• Never start the engine or operate controls while standing beside or behind
the forklift. Always sit in the seat when starting the engine or when operat-
ing the controls.
• Never drive up to anyone standing in front of a bench or other fixed object.
• Never disconnect safety devices installed on your forklift.
For your safety, always keep your forklift in good operating condition. An
improperly maintained machine can be hazardous.

6
safety Operator safety

requirements Be a skilled and safe operator. The following guidelines will help you protect
yourself and your colleagues.
• Because of the
danger of be-
coming entangled
in moving parts,
clothing worn by
the operator should
be relatively tight
and belted. The
operator
should not wear
loose or untucked items,
such as jackets,
shirts, sleeves, or
jewelry, while operating
the forklift.
• An operator should not use drugs, alcohol or medications—prescription or

over-the-counter—which can affect alertness. When taking medication,
expert advice should be sought before operating any machinery.
• Provide a first-aid kit for use in case of an

accident. Use proper first aid supplies on
scratches, cuts, and other minor injuries
immediately. Know where fire extinguish-
ers and other safety equipment are kept
and learn how to use them.
• Wear all the protective clothing needed

for the work conditions, such as hard
hat, safety shoes, safety glasses, goggles
or face shield, heavy gloves, respirator or filter mask.
• If exposed to noise which is objectionable or uncomfortable, wear a suitable

protective hearing device.
• Keep the operator’s compartment and stepping points are free of grease,
mud, snow or ice to ensure non-slip control. Slippery surfaces can be haz-
ardous.

7
Front walk-around
inspection
Left Right
Caution
Do not make any adjustments
to the forklift, only trained and
authorized personnel should
Rear service and repair this forklift.
Figure 1: For your own safety and maximum life of your forklift, always make a
thorough walk-around inspection each day before operating with your forklift.
Pre-operation, visual checks

For your own safety and maximum service life of your forklift, make a thorough
walk-around inspection, each day, before getting on your forklift. A daily check
is required by the Occupational Safety and Health Act (OSHA) and it is each
operator’s responsibility to check the machine before using it. The operator’s
checklist on page 92 can be photocopied and used as a permanent record. This
checklist is a guide only and it is the responsibility of the owner or operator to
ensure that the forklift is in good working order.
Before the walk-around inspection, make sure the parking brake is applied, all
controls are in neutral, the engine is off and the forks are lowered. To engage
the parking brake, pull the lever all the way back to the vertical position (fig-
ure 2). To disengage the parking brake, push the lever fully forward into the
horizontal position. During an emergency, the parking brake can be applied to
stop the forklift while it is in motion.
The operator should wear clothing that is relatively tight and belted. You should Figure 2: Before the walk-around
never wear loose or untucked clothes. Refer to the safety requirements on inspection always make sure the
parking brake is applied.
page 6 for more information.

8
walk-around
inspection
Figure 3: Check the overhead guard lights for damaged, loose or missing parts.
1. Chassis and overhead guard

Inspect the overall condition of the chassis and the overhead guard of the fork-
lift. If your forklift is equipped with a cab, refer to page 21 for information.
Check for cracked or broken welds and cracked or broken frame members.
Check all exposed nuts and bolts for damage or tightness. Check the lights on
Caution the overhead guard or cab for damaged, loose or missing parts (figure 3).
There are several safety decals
Always check that all nameplates and decals are in place and legible. Replace
on your forklift; make sure you
safety and warning decals when they become illegible (figures 4-10).
read and understand them
before operating the forklift.
Figure 4: Use the 4WD in the

appropriate surface conditions only Figure 5: Always follow the steps on this decal before leaving the operator’s
(part #700641). compartment (part #251691).

9
walk-around
inspection
Read the Operator’s Manual. It is important the operator

understand all the decals on the
Learn to operate this machine SAFELY. forklift. Always replace any
Be Alert. Observe ALL Safety Practices. illegible decals. When ordering,
Machines can be hazardous in the hands of use the part numbers provided.
an UNFAMILIAR, UNTRAINED, or
COMPLACENT operator.
Don’t risk INJURY or DEATH.
Figure 6: For your own safety, read the Operator’s Manual and understand it. This
machine can be hazardous if handled improperly (part #253270).
WARNING
PRESSURIZED FAILURE TO FOLLOW THIS
COOLING SYSTEM WARNING CAN RESULT IN
INJURY OR DEATH
REMOVE CAP
SLOWLY
Figure 7: Radiator cap warning—this machine
has a pressurized cooling system, remove the
cap slowly and carefully (part #901209).
WARNING
WARNING Keep hands
and clothing
away from
rotating fan
and belts to
prevent serious
Figure 8: Always wear your seat belt when
operating the forklift. The forklift could tip if injury. 751681
operated incorrectly (part #901210).
Figure 9: Never stand on Figure 10: Always keep hands and
the forks or on a load; clothing away from rotating fan and
never stand under the belts (part #751681).
forks. This can cause
serious injury or death
(part #751636).

10
walk-around
inspection
Front
After circling the machine once,
be sure to check the different
components in more detail. At
the front, check the mast, mast
chains, carriage, cylinders and
tires.
Figure 11: Inspect mast rails, rollers and mast chains thoroughly for damage.
2. Mast
Check the mast rails, rollers, and mast chains for loose, damaged, or missing
parts and fittings. Check all welds for cracks or breaks. Check the roller path-
ways for metal flakes, dirt or any other obstruction that will interfere with the
safe operation of the mast (figure 11).
3. Mast chains
Inspect the mast chains for missing or broken
links, pins or cotter pins; check especially for
parts that are turned or seized (figure 12). If the
mast chain is damaged in any way, do not
repair, it must be replaced in its entirety. Check
the mast chain for rust or corrosion, if rust is
Figure 12: Inspect the mast chains
for missing or broken links, pins or found lubricate as required, refer to page 72 for
cotter pins; check especially for proper procedure. Check the chain anchors for
parts that are turned or seized. wear and missing or loose parts.
4. Carriage
Inspect the whole carriage for damage or
excessive dirt. If the forklift has hook
A
forks, check for missing or damaged fork
lock pins (A) (figure 13). Check shaft
forks for missing or damaged bolts. Always
make sure the forks are not damaged, Figure 13: Check the fork lock pins
bent or misaligned in any way. (A) for missing or damaged parts.

11
walk-around
inspection
C
A
B
D
Figure 14: Check all cylinders for damaged, loose, or leaking parts:
tilt cylinders (A), steer cylinder (B) and lift cylinder (C).
5. Cylinders
Figure 15: Location of
Using figures 14 and 15 as guides to all cylinder locations, make sure all cylin- sideshift cylinder (D).
der pins and snap rings are tight and secure. Inspect cylinder rods for scratch-
es, grooves or leaking seals. Check all hydraulic fittings and hoses for damaged,
loose or missing parts.
6. Tires
Inspect the drive and steer
tires for wear, cracks, cuts,
gouges, foreign objects, or
leaks. Check all valve stems
for leakage. Check all the
wheel nuts and bolts for
tightness. For safety rea-
sons, always check tire
Caution
pressure from the tread
Inflation of tires should be
side, never the tire side (fig- Figure 16: Check tires for cuts, gouges and cracks.
done by trained and
ure 16). Check tire inflation
authorized personnel only.
only when tires are cold and
always use a long-handled pressure gauge. All tires should be inflated accord-
ing to the manufacturer’s specifications on the tire. The operator should only
check tire pressure; inflation of tires should be done by trained and authorized
personnel only. If the tire pressure is low, refer to page 71 in the maintenance
section for the correct inflation techniques.

12
walk-around
inspection F D
E A
G
Right side
On the right side of the forklift C
check the seat belt, hydraulic oil
level, transmission fluid level,
B
air cleaner, coolant level, trans-
mission oil cooler and battery.
Figure 17: Before operating the forklift always check the seat belt (A), hydraulic
oil (B), transmission fluid level (C), air cleaner (D), engine coolant level (E),
transmission oil cooler (F), battery (G).
7. Seat belt
Check the seat belt for wear or damage. Make
Caution sure the brackets, nuts and bolts are secure.
WARNING
Do not operate this forklift if
Never operate the forklift if the seat belt is
the seat belt is damaged in any
damaged.
way. For your own safety,
always wear your seat belt. 8. Hydraulic oil
Before checking the hydraulic oil level (figure 17) be
sure the forklift is on level ground, the engine is off,
the forward/reverse selector is in NEUTRAL, the park-
ing brake is applied, the mast vertical, and all cylin-
ders in their natural positions. Be sure to cycle the
hydraulic control levers to release pressure from the
system. Check the level using the dipstick inside the
cap—the correct oil level (figure 18) is important Figure 18: The
because low fluid levels can cause pump damage. If hydraulic oil level
should register to the
the hydraulic oil level is low, refer to page 64 in the mark on the dipstick.
maintenance section for correct refilling techniques.
Do not overfill. Check the fluid chart on page 92 for the correct type of hydraulic
oil. Check the rest of the hydraulic lines, tank and fittings for leaks, damage,
cuts, and tightness.
Under the hood

Undo the hood latches and tilt the hood back.

13
8A. Transmission fluid (SS600 Series) walk-around

The transmission fluid level
should be checked cold
inspection
with the engine shut off.
Pull out the dipstick located
under the hood. The fluid
level should be between the
two marks (figure 18b). If
transmission fluid needs to Full
Figure 18a
be added, refer to page 68
Low
for the proper procedure.
Figure 18b: The transmission fluid
9. Air cleaner level must be between the marks.
The SD model forklift is equipped with a dual

element air cleaner. Make sure all latches, nuts
and bolts are tight (figure 19). Make sure the air A
cleaner inlet is free from debris. Check the rub-
ber elbow for cracks or cuts and elbow clamps
for tightness. Check the air cleaner service indi-
cator—if the indicator is red—there is an air
restriction or the filter needs to be replaced (see
pages 82-83 for the correct procedure). Figure 19: If the service
indicator (A) is red, replace
the outer element.
10. Engine coolant level

Check the coolant level. On older-style units, Caution
check the level using the rad cap. Remove the Never remove the radiator cap
radiator pressure cap slowly and maintain while the system is hot. Always
the coolant 1 inch below the filler tube. turn the cap slowly to the
first stop and allow the
If your forklift is equipped with a overflow pressure to escape before
Figure 20: Older-style
bottle, always check the level here. If the removing it completely.
engine is cold, ensure the fluid comes up to
the lowest mark; if the engine is hot, ensure
PRESSURIZED
the level reaches the higher line (figure 20a). COOLING SYSTEM
REMOVE CAP
SLOWLY
Refer to page 66 in the maintenance chapter FULL WHEN HOT
for more information about adding coolant.
Also, check the radiator for damage or leaks, FULL WHEN COLD
and remove any debris that may block
air flow.
Figure 20a: Newer-style

14
walk-around 11. Transmission oil cooler

inspection Check the transmission oil cooler and its fittings and hoses for damage, block-
age or leaks.
Rear 12. Battery

At the rear of the forklift check Make sure the positive and negative posts are clean
the rear lights and the grille. and secure (figure 21). If the battery needs cleaning,
refer to page 70 in the maintenance section for cor-
rect cleaning procedures.
Figure 21
13. Rear lights

Check the rear lights for damaged, loose or
missing parts (figure 22). Always make sure
the lights and rear grille are clean.
Figure 22: Always make sure the
rear lights and grille are clean.
14. LPG tanks - if applicable

When trucks using LPG fuel are
D F B
parked overnight or stored
Caution indoors for protracted periods C
Never operate a forklift with a with the LPG tank in place, the A
damaged LPG tank. service valve (see G in figure 23)
of the container should be
E
closed.
Make sure the clamps (A) and

H G
the locking pins (B) are secure
and undamaged. Make sure the Figure 23: Make sure LPG tank is free of
coupling (C) and fill valve (D) dents or gouges. Check clamps (A), locking
are gas tight and show no signs of pins (B), coupling (C), fill valve (D), fuel
gauge (E), pressure relief valve (F) and
leakage. Check service gauge (E), service valve (G) fuel hose (H) for damage.
pressure relief valve (F) and ser-
vice valve (G) for damage or
debris. Make sure fuel lines (H) are securely fastened and protected against
rubbing, chafing or exposure to heat such as the exhaust manifold. If frayed or

15
worn, report this immediately to your supervisor or service department.

walk-around
Ensure the pressure relief valve (F) and the fill valve (D) have protective caps.
inspection
Always make sure the LPG tank is free of sharp dents and gouges. Physical dam-
age such as dents, scrapes, or gouges will materially weaken the structure of the
LPG tank and render it unsafe for use. Never operate a forklift with a damaged
LPG tank, report this to your supervisor or the service technician immediately.
Mounting the forklift

Always safely mount or dismount.
Never get on or off when the
engine is running or the forklift is
moving.
When mounting or dismounting, Caution

it is important to maintain three- Never get on or off the forklift
point contact with the when the engine is running or
machine—always have 3 out of 4 the machine is moving.
limbs in contact with the forklift
at all times (figure 25). Always
face the machine. To prevent
falls, always use the stepping Figure 25: To prevent accidents, always have
three-point contact with the machine when
points and grab handles, never mounting or dismounting.
the steering wheel, when getting
into the operator’s compart-
ment. Keep stepping points and platform clear of mud, debris, and in the win-
ter, snow and ice.

16
walk-around
inspection A
I G
H
C
For the safe and efficient opera-
tion of this forklift, always know
B
where your controls are and E
what they do before you start the D
engine.
F
Figure 26: Check the following controls: instrument panel (A), parking brake (B),
hydraulic control levers (C), accelerator pedal (D), brake pedal (E), gear shifter (F),
J forward/reverse selector (G), horn button (H) and light switch (I).
16. Operator’s compartment

Make sure the operator’s compartment (figure 26) is clean and all loose items
are removed or secured. Loose items will become dangerous once you start
moving the machine. There is a tool box under the seat for your convenience.
Various international symbols have been used on the controls and instruments
Figure 26a: old-style 4WD of the forklift, please refer to page 90 for explanations.
switch (J).
Inspect the top of the dash for any damaged parts, especially broken or missing
lights or gauges on the instrument panel (A). Make sure the parking brake (B)
moves freely and check for any loose or missing nuts or bolts. Make sure the
J hydraulic control levers (C) all move back and forth freely and return to their
neutral positions. Make sure the accelerator (D) and brake pedals (E) move
freely and return to their neutral positions. Fully depress the brake pedal while
checking that the gear shifter (F) and the forward/reverse selector (G) move
Figure 27: new-style 4WD freely. Make sure the horn (H) and the light switch (I) work properly.
switch (J).
If the forklift is equipped with four-wheel drive check that the 4WD lever or
switch (J) (figures 26a or 27) is not damaged or loose. If the forklift is powered
with gasoline or LPG, ensure the choke (K) (figure 28) is not broken and moves
freely.
Ignition
K
Now turn the ignition key to the Figure 29: To check
ON position (A). The ON posi- the instrument
Figure 28: Location of choke (K). tion activates most indicator panel lights, turn
the ignition key to
lights and gauges (figure 29). the ON position.
A

17
D
walk-around
B
C
inspection
A
Re-check all the instrument

panel lights and gauges to make
sure all are in working order.
G
F
E
Figure 30: Ensure all lights and gauges are in working order.
(Instrument gauges serial number 11948021032-2257412832.)
17. Instrument panel (installed on trucks build

from 11948021032 - 2257412832)
A Engine coolant temperature gauge
The engine coolant temperature gauge responds to the temperature of the
circulating coolant. The gauge has increments of 10°C and 20°F. The normal
operating temperature is 82°C (180°F). If the gauge registers over
93°C (200°F), shut off the engine immediately and let the engine cool before
investigating.
B Engine oil pressure gauge
This gauge indicates oil pressure only. It does not indicate low engine oil level.
Normal operation of a four cylinder engine is 138 kPa (20 psi). If the needle
registers below this pressure, shut the engine off immediately and contact
your Sellick dealer.
C Ammeter
The ammeter register the charging current which is being passed to the
battery by the alternator. It also registers a discharge equivalent to the amount
of the current being used by the electrical equipment when the alternator is
not charging. The ammeter is normal when the indicator is at or on the
negative (–) side of zero with the engine running.
D Light switch
The light switch is a two-position pull switch. The first position activates the
rear flasher light; the second position activates the headlights, tail lights,
instrument gauges and flashing rear light.

18
walk-around E Transmission oil temperature gauge

The transmission oil temperature gauge measures the temperature of the
inspection transmission oil. The gauge has increments of 10°C and 25°F. The normal
operating temperature is between 82°C (180°F) and 93°C (200°F). If the oil
temperature rises to 121°C (250°F) stop the forklift immediately. Shift the
transmission to NEUTRAL and run the engine at approximately half throttle.
The temperature should drop rapidly. If the temperature does not drop,
trouble is indicated. The trouble should be determined before the forklift is
operated again. Overheating generally occurs due to working in too high of a
gear ration. Do not shut off the engine when the unit is overheating, if the
cooling system is known to be in working order.
F Hour meter
The hour meter records the running time of the engine. It is also used to
determine when periodic servicing is required.
G Fuel gauge
The fuel gauge measures the amount of fuel in the tank at quarter tank
increments. Refuel the forklift when the needle approaches the quarter tank
mark. The gauge registers only when the key switch is in the ON position.

19
A B C D
walk-around
J
inspection
I
K Trans
Oil
Pressure
Re-check all the instrument

panel lights and gauges to make
sure all are in working order.
E F G H
Figure 30: Ensure all the lights and gauges are in working order.
(Instrument cluster serial number cutoff 22594121032-xxxx.)
17. Instrument panel

(installed on trucks build after 22594121032)
A. Parking brake indicator light
This light illuminates when the parking brake is engaged.
B. Charge indicator light
If light fails to go out after engine is started or comes on during operation, shut
down machine immediately and notify your supervisor or service technician.
C. Engine coolant temperature gauge
This gauge will respond to the temperature of the circulating coolant. The gauge
has increments of 10°F. The normal operating temperature is 180°F (82°C). If
the gauge registers over 200°F (93°C), turn the engine off immediately and
notify your supervisor or service technician.
D. Fuel level gauge
The fuel gauge indicates the amount of fuel in the tank at quarter tank incre-
ments. The gauge registers only when the key is in the ON position. Refuel when
the needle approaches the quarter tank mark. Always make sure the fuel tank
is full after each shift. See page 54 for proper refuelling procedures. For trucks
equipped with LPG, use the indicator on the tank, not the instrument panel.
E. Engine oil pressure warning light
This light will illuminate when the oil pressure is low. If the light comes on while
forklift is in use, turn the engine off immediately and notify your supervisor or
service technician.

20
walk-around F. Transmission temperature warning light
inspection This light will illuminate only when the transmission fluid temperature
becomes too hot. If the light comes on while the forklift is in use, turn the
engine off immediately and notify your supervisor or service technician.
G. Engine oil pressure gauge
This gauge indicates oil pressure only. It does not indicate low engine oil level.
The minimum pressure at maximum engine speed and normal engine tem-
perature is 30 lbf/in² (207 kPa). If the needle registers below this, shut the
machine down immediately and notify your supervisor or service technician.
H. Voltmeter
When the ignition key is in the ON position (and the engine OFF), the voltmeter
needle should be at 12V DC (battery voltage). When the engine is running, the
needle should be between 13.4V and 15.5V (alternator charging voltage). If the
needle does not register these numbers, shut the machine down immediately
and notify your supervisor or service technician.
I. Light switch
The light switch is a two-position pull switch. The first position activates the rear
flasher light; the second position activates the headlights, tail lights, instrument
gauges and flashing rear light. Make sure the light switch and all forklift lights
work. The rear work light has a manual switch.
J. Engine coolant warning light
If light fails to go out after engine is started or comes on during operation, shut
down machine immediately and notify your supervisor or service technician.
K. Transmission low pressure warning light
This will illuminate only when there is a problem. If it comes on during opera-
tion, shut down the machine and notify your supervisor or service technician.
4WD option
The light switch (figure 27) will illuminate when the 4WD is engaged. Push
switch to engage the 4WD option, check the light and push again to disengage.
If the light fails to illuminate notify your supervisor or service technician. Refer
to page 20 for proper operation procedures.

21
B
walk-around
A inspection
D
Figure 31
18. Cab - if applicable

Check the domelight, windshield wiper, windows, fan and the heater before
operating your forklift. Refer to figure 31 for approximate locations.
A. Domelight
The domelight switch is on the domelight itself. Make sure the domelight func-
tions properly and all bolts are secure.
B. Windshield wipers
The front electric windshield wiper switch is located on the right side cab
post (A) (figure 32). The rear wiper has its switch mounted on the motor. Make
sure the wiper functions properly. Check for damaged, loose or missing parts.
C. Windows
The cab has flat safety glass on the front, rear and doors. Ensure the glass is not
damaged in any way.
D. Fan
The fan has two speeds. Adjust for maximum cooling comfort or window defog- B
ging. To turn the fan ON, push the button once (B) (figure 32). For high speed
operation, push the button a second time. Push again to turn it off. Make sure A
the fan is working properly. Check for any loose, damaged or missing parts.
C
E. Heater
The cab has a engine-coolant type heater with a two-speed switch (C) (figure
Figure 32: The wiper switch (A), fan
32) located under the wiper switch. Ensure fan is functioning properly. Check button (B) and heater switch (C)
for loose, damaged or missing parts. Check the heater grille for obstructions. are on the right side cab post.

22
walk-around Operational check

inspection A starter safety switch permits current to flow to the starting motor only when
the forward/reverse selector is in NEUTRAL position.
Warm weather starting procedure

The following checks must be 1. Mount the forklift using the three-point mounting method (see page 15).
made while the engine is run-
2. Adjust the seat (see page 30) and securely fasten the seat belt.
ning. Do not attempt to start or
operate the forklift unless you 3. Alert others around that you will be starting the machine.
have carefully read and under-
4. Make sure the parking brake is applied. Move the forward/reverse selector
stand this entire Operator’s
to the NEUTRAL position.
Manual.
5. Be sure all the hydraulic control levers are in the neutral position.
6. Diesel and gasoline engines: depress accelerator pedal slightly.
LPG engines: check the fuel gauge on the propane tank. Turn fuel on by
Caution
turning valve counter-clockwise slowly.
Do not start or run the engine
in a closed area or poorly 7. Fully depress brake pedal.
ventilated building where
8. Turn ignition key to START position. When engine starts, release key.
exhaust gases can accumulate.
All internal combustion engines 9. Check all gauges and lights, if engine warning lights stay on—turn off the
give off various fumes and engine—do not continue to operate the machine. Notify your supervisor or
gases while running. Avoid service technician.
breathing these gases as they
may contain poisonous carbon Cold weather starting procedure - diesel engines
monoxide which can endanger When starting the forklift in temperatures near or below the freezing point, use
your health or life if inhaled the thermostart feature. The thermostart aids starting by introducing and ignit-
steadily for even a few minutes. ing a small quantity of diesel fuel into the cylinders or intake manifold.
1. Mount the forklift using the three-point mounting method (see page 15).
Caution 3. Alert others around that you will be starting the machine.
Do not use ether or any other
starting aids with the 4. Make sure the parking brake is applied. Move the forward/reverse selector
thermostart (engine preheat), to the NEUTRAL position.
this combination will result in 5. Be sure all the hydraulic control levers are in the neutral position.
a manifold explosion.
6. Depress accelerator pedal slightly.
7. Turn the key to full counter-clockwise position and hold for 30 seconds.

23
8. Release the key and turn to the START position.

walk-around
9. If the engine fails to start, wait approximately 1 minute and beginning at
step 6. inspection
10. Release accelerator pedal slowly to allow engine idle.
11. Check all gauges and lights, if engine warning lights stay on—turn off
engine—do not continue to operate the machine. Notify your supervisor or
service technician.
Cold weather starting procedure - gasoline engines

When starting the forklift in temperatures near or below the freezing point, pro-
ceed as follows:
3. Alert others around that you will be starting the machine.
lever to the NEUTRAL position.
6. Depress accelerator pedal slightly and pull the choke half way out.
Caution
7. Turn the key clockwise to the START position. Release the key when the Push the choke in as soon as
engine starts and push the choke partially in. possible. Prolonged operation
8. If difficulty is encountered, pull the choke control all the way out. Turn the with the choke out will cause
ignition starter switch to START and release when the engine starts. high fuel consumption and
possible engine wear due to oil
9. Release accelerator pedal slowly to allow engine idle. Do not use the forklift dilution.
until the engine has been running for at least 2 minutes.
service technician.
Note: Push the choke in as soon as possible.
Engine block heater (optional)

During extremely cold weather conditions (below -4°F/-20°C), the use of an
engine block heater is recommended if the forklift has not been used for a pro-
longed period of time. A 120V power supply is required. Before starting the
engine, make sure the power cord is unplugged and safely stored.

24
walk-around
inspection
A
B
C
Figure 33: Always operate all hydraulic control levers to insure proper functioning
before lifting a load. Make sure the following levers move smoothly and return to
their neutral positions: lift control (A), tilt control (B) and sideshift control (C).
19. Hydraulic control levers

The control levers are locat-
Caution ed on the right side of the
If any of the hydraulics or instrument panel. Make
controls are not working sure the hydraulic lever
properly in any way, do not decal (part #300525) is A B C D
operate the forklift until they legible and that you under- Lift Tilt Sideshift Extra
control control control function
have been serviced. stand it before operating the
forklift (figure 34). Figure 34: Make sure you read this decal.
Always operate all the levers to insure proper functioning before lifting a load.
Make sure the control levers function smoothly and always return to their neu-
tral positions (figure 33). While moving the following controls, from your seat,
watch for jerking movements, excessive vibration and listen for unusual noises.
Caution
If the control levers, mast, forks or hydraulics are not working properly in any
This unit is equipped with 45°
way, do not operate the forklift until they have been serviced. Make sure you
lay down tilt cylinders that are
understand what each lever does before operating the forklift.
used for transporting only.
DO NOT attempt to pick up a A. Lift control
load in the forward tilt
Pulling back on this lever lifts the forks and carriage. Pushing the lever forward
position.
will lower the forks and carriage. Visually inspect roller pathways between the
rails while raising the mast.

25
B. Tilt control
walk-around
Pulling back on this control will tilt the mast back and pushing the lever for-
ward will tilt the mast forward. inspection
C. Sideshift control
Pulling back on this control will move the mast to the right and pushing the
lever forward will move the mast to the left.
Note: While in your seat, visually inspect the cylinders for oil streaks on
the rods, or leaking fittings. This indicates service is required.
20. Moving the machine

While still in NEUTRAL, make sure the accelerator and brake pedals and the
steering wheel move freely. If the steering wheel or pedals stick or make unusu- Caution
al noises do not continue with this check. Do not operate the forklift until it has Do not use the forklift if any
been repaired. pedal, hydraulic control lever,
Release the parking gauge, light or safety device is
brake. The brake pedal is not in working order. Notify
on the left side and oper- your supervisor or service
ates like an automotive technician of any problems.
brake pedal—depress
fully for braking and
release slowly for inching
control. Remember not to
ride the brakes or activate
them unnecessarily, this
Figure 35: The accelerator pedal should always be
will cause premature operated in a smooth manner to avoid jerking the
wear and damage to the forklift. Move the machine slowly while testing the
brake system. Now, the steering and braking systems.
depress the brake pedal
and slowly move the forward/reverse selector into FORWARD. For on-the-go
shifting, press and hold shifter button located on gear shifter, move the shifter
to the appropriate gear and release button to complete the shifting sequence.
Release the brake and move the forklift slowly with the accelerator pedal. This
pedal also operates like an automobile accelerator (figure 35)—pressing the
pedal downward increases engine speed; releasing it returns the engine to an
idle speed. The accelerator pedal should always be operated in a smooth man-
ner to avoid jerking the machine. Slowly move the forklift while testing the
steering, braking, and accelerator pedals. Make sure you have full operating
control before handling a load with the forklift.

26
walk-around Shut-down procedure

inspection The hydraulic system should also be checked after it has been under pressure.
First, turn off the engine using the proper shut-down procedures.
A. Move forward/reverse selector to the NEUTRAL position and apply the park-
ing brake.
B. Lower the forks fully to the ground and keep the mast vertical.
C. Turn the ignition off and remove the key.
LPG engines: close the fuel valve on the tank and run the engine until the
Caution fuel in the lines is used up and the engine stops.
Never use your hands to check
the hydraulic system under D. Release your seat belt and dismount using the three-point method
pressure! Always use a small (see page 15).
piece of cardboard or wood. 21. Hydraulic system
Check the hydraulic system using a
small piece of cardboard or wood,
check for leaks in the tank, fittings
and lines (figure 36). Never
use your hands! Hydraulic oil escap-
ing under pressure can have enough
force to penetrate the skin.
Hydraulic oil may also infect a minor
cut or opening in the skin. If some-
one is injured by escaping oil see a
Figure 36: Always use a piece of
doctor at once. Serious infection or cardboard or wood to check hydraulic
reaction can result if medical treat- fittings and lines while system is under
pressure.
ment is not given immediately.

27
22. Engine oil (Perkins 1000 Series - AA build) walk-around

Check the engine oil level using the dip-
stick (A) (figure 37) located under the hood
inspection
of the forklift. The level should be between A
the two marks on the dipstick (figure 38).
Check for leaking oil in the engine compart-
ment and under the forklift. Also check for
restricted air flow in the engine compartment
that could cause engine overheating. Refer to
page 62 in the maintenance chapter for more
information on topping up the engine oil.
Figure 37: Engine oil dipstick
location - diesel (A).
Figure 38: The engine oil level must
be the two marks on the dipstick.
23. Brake system fluid
The master cylinder is located behind the front
cover. Remove the plastic plug (figure 39) to
gain access to the master cylinder filler cap. A
Clean the surrounding area first and remove
the filler cap. The level should be just beneath
the top the master cylinder neck.
If fluid needs to be added, refer to page 69 for

correct procedure.
Figure 39: Remove the plastic

plug (A) to check the brake
system fluid level.
Your forklift inspection is complete. If the forklift needs

repair, tag the machines steering wheel Do not operate and
report any damaged, loose, or missing parts to the service
department for service and repair. Proper preventive mainte-
nance is essential for operator safety and vehicle perfor-
mance. Remember, a walk-around inspection is required by
OSHA and must be part of every operator’s daily routine.

28
operation Once the walk-around checklist is complete and you are familiar with the loca-
tion and function of all controls, study this section carefully before operating
the forklift. You must read and follow the instructions in this section and the
maintenance section before operating the forklift. To obtain the most from your
new forklift, give special attention to the correct break-in procedures and follow
the inspection, operation and maintenance instructions provided. This will help
you get the job done safely and efficiently, while providing longer vehicle life.
Caution Operation safety

A careful operator is the best
insurance against accidents. • Study and understand the DANGER, WARNING and CAUTION decals on your
new forklift. Any missing or illegible decals should be replaced as soon as
possible (see pages 8-9 for details). If your forklift is equipped with attach-
ments or options that you are unfamiliar with, ask your supervisor to
explain them to you.
• Know the rated load capacity, speed range, braking and steering character-
istics, turning radius and operating clearances of your forklift.
• Keep in mind that weather, soil conditions and type of load can change the
operating capabilities of your machine.
• Never allow anyone to ride on the operator’s platform, forks, counterweight

or hitch a ride in any other manner. It is distracting and dangerous.
• Never start the engine or operate any of the controls unless you are seated
Caution
on the seat with the seat belt properly secured.
When at a standstill the mast
should be lowered to the • Never get off a moving forklift or leave the forklift unattended while the
ground. When raising the mast engine is running.
the vehicle should be stationery.
• Stop the forklift immediately if the steering or engine ceases operating and
notify your supervisor or service technician.
• If the level of oil, coolant, or fuel becomes critically low, bring them to the
vehicle. Never drive the vehicle to them.
• Never attach chains, ropes, cables, etc., to the overhead guard for pulling or
towing purposes. The forklift is not intended for use as a tow vehicle. If the
forklift needs to be towed, refer to the towing instructions on page 51.
• Always use head lights and work lamps for night work and be sure the lights
are adjusted to prevent blinding an oncoming vehicle operator.
• When leaving the operator’s seat, place the forks on the ground, apply the
parking brake and turn off the ignition.

29
Break-in procedure operation

Your new forklift will provide long and dependable service if given proper care,
particularly during the first 50 hours of operation. During his period, follow the
regularly scheduled maintenance chart on page 53 and the following steps:
1. Avoid lugging the engine. Operating in too high a gear under a heavy load
may cause excessive engine/transmission damage. Lugging occurs when
the engine will not respond to a throttle increase. Caution
2. Avoid continuous operation at a constant engine speed. Use a lower gear During the break-in period, it is
when moving a heavy load; a higher gear when moving a light load. Selecting important to avoid continuous
the correct gear ratio will save fuel and prolong engine life. operation at a constant engine
speed. Check the instruments
3. Check the instruments frequently and be prepared to stop and shut down frequently and be prepared to
the forklift if a problem exists. Keep the radiator and oil reservoirs filled to stop and shut down the forklift
the recommended level but do not overfill. It is important to follow the oper- if a problem exists.
ator’s daily checklist found on page 92.
After the first 50 hours of operation, follow the regularly scheduled mainte-
nance chart on page 53. If the forklift is not in proper operating condition, noti-
fy your supervisor or service technician as soon as possible to prevent further
damage from occurring.
Mounting the forklift

To safely mount or dismount your forklift, it is important that you always face
the machine and use the three-point method described on page 15. To prevent
falls, always use the steps and grab handles, never the steering wheel or
hydraulic controls. Never step on the foot controls when mounting or dis-
mounting. Keep stepping points and platform area clear of mud, snow, ice, and
other debris.

30
operation Seat adjustment

(new-style seat)
When operating the forklift, adjust the seat
to provide maximum comfort and safety.
Always adjust the seat before driving. The
forward and backward seat adjustment
A
lever (A) is located just below the front of
the seat (figure 42). Pull the lever left to
Figure 42: Adjust the seat using the
unlock the mechanism, then adjust the seat adjustment lever (A).
seat to suit and release the lever. Ensure
the lever clicks into the locked position.
Seat adjustments (old-style seat)

When operating the most frequently used controls, adjust the seat to provide
Figure 42a: Forward/backward maximum comfort. There are three different adjustments to the seat.
adjustment.
For forward and backward seat adjustment, pull the lever outward to unlock the
mechanism (figure 42a). Then adjust the seat forward or back to suit and
release the lever. Be sure to check that the lever clicks into the locked position.
This knob is for adjusting the seat back angle (figure 42b). Turn the know clock-
wise (positive) to increase the angle of the seat back. Turning the knob counter-
clockwise (negative) decreases the angle of the seat back.
Figure 42b: Seat back angle The lever in figure 42c is used to adjust the seat according to the operator’s
adjustment. weight. Pulling up on the lever decreases the tension. To increase the tension
push down on the lever.
Tilt steering wheel

To tilt the steering wheel grasp the steering
wheel with one hand and move the tilt lock
upwards with the other hand. Adjust to a
Figure 42c: Seat weight tension
lever.
comfortable position and then release the
lever.
Figure 42d: Tilt steering adjustment

lever (A).

31
operation
Figure 43: The optional cab offers full protection from the outside weather.
Cab features - if applicable

The cab (figure 43), if equipped, includes safety glass in the windows and doors
for full protection from the outside weather. Standard equipment features in
the cab consist of: convenient handles for assistance in entry and exit; a dome-
light; electrically operated front and rear wipers; two speed defrosting fan and
an engine-coolant type heater. For maximum comfort and safety, make adjust-
ments to these features before operation.
A. Domelight
The domelight switch (figure 44) is on the domelight (A) itself. The domelight
provides ample lighting for the operator’s platform.
A
B. Windshield wiper Figure 44: Domelight switch (A).
The cab is equipped with a front A

electric windshield wiper which
has its switch (A) located on the B
right side cab post (figure 45).
The rear electric wiper has its Figure 45: Wiper switch (A) and heater switch
switch mounted on the motor. (B) are located on the right side cab post.

32
operation C. Windows
The cab has flat safety glass on

the front, rear and doors. For
extra ventilation, the door win-
dows can be opened by unlock-
ing the window and sliding it
open (figure 46).
Figure 46: Unlock window and slide open.
D. Fan
The fan (figure 47) has two

speeds. Adjust for maximum
cooling comfort or window
defogging. To turn the fan on,
push the fan button once (A).
For high speed operation, push A
the button a second time. Push
Figure 47: Adjust fan for maximum comfort.
again to turn it off.
E. Heater
The optional cab has an engine-

coolant type heater which uses hot
water from the engine cooling sys-
tem. The heater switch is a two-
speed switch located under the wiper A
switch (B) in figure 45. The first
indent is low speed. The second
Figure 48: The heater shut-off valve (A)
indent is high speed. The heater is must be in this position to be fully closed.
located conveniently and out of the Turn valve counter-clockwise to fully open
way under the operator’s seat. There the valve so heater functions properly.
is a shut-off valve (A) on the left side
of the engine (see figure 48 for exact location), which must be fully open for the
heater to function properly. The same shut-off valve must be closed during
summer operation. If the valve remains open, the hot water continues to cir-
culate through the heater producing radiant heat.
F. Accessories
The Sellick SD series forklifts are offered with a wide variety of accessories. For
full information on these accessories, contact your nearest Sellick dealer.

33
operation
Caution
Never start or run any engine
in a closed or poorly ventilated
building where exhaust gases
can accumulate; breathing
these gases may endanger your
health or life if inhaled steadily
for even a few minutes.
Figure 49: Always fasten your seat belt before starting the forklift.
Starting the engine

A starter safety switch permits current to flow to the starting motor only when
the forward/reverse selector, mounted to the steering column, is in NEUTRAL
position (figure 50). It is recommended to always start the forklift with the Caution
parking brake applied and the brake pedal fully depressed. Always adjust and Do not use ether or any other
securely fasten the seat belt before operating the forklift (figure 49). Never start starting aids with the glow plug
the engine unless it is safe to do so. (engine preheat), this
Never start or run any engine in combination will result in a
a closed or poorly ventilated manifold explosion.
building where exhaust gases
can accumulate. All internal
combustion engines give off
fumes and gases while running.
Avoid breathing these gases as
they may contain carbon
monoxide which can endanger Figure 50: Always start the forklift with the
your health or life if inhaled forward/reverse selector in the NEUTRAL
position and the parking brake applied.
steadily for even a few minutes.

34
operation Warm weather starting procedure

6. Diesel and gasoline engines: depress accelerator pedal slightly.
LPG engines: check

the fuel gauge on
the propane tank.
Turn fuel on by
turning the service
valve counter-
clockwise slowly
(figure 51).
7. Fully depress brake

pedal. Figure 51: Turn the service valve counter-clockwise
slowly before starting the engine.
8. Turn ignition key to
START position.
When engine starts, release key.
9. Check all gauges and lights, if engine warning lights stay on—turn off the
service technician.
Cold weather starting procedure - diesel engines

When starting the forklift in temperatures near or below the freezing point, use
the thermostart feature. The thermostart aids starting by introducing and ignit-
ing a small quantity of diesel fuel into the cylinders or intake manifold.

35
operation
6. Depress accelerator pedal slightly.
7. Turn the key to full counter-clockwise position and hold for 30 seconds.
8. Release the key and turn to the START position.
9. If the engine fails to start, wait approximately 1 minute and repeat step 1.
10. Release accelerator pedal slowly to allow engine idle.
service technician.
Cold weather starting procedure - gasoline engines

When starting the forklift in temperatures near or below the freezing point, pro-
ceed as follows:
1. Mount the forklift using the three-point mounting method (see page 15). Caution
Push the choke in as soon
as possible. Prolonged
3. Alert others around that you will be starting the machine. operation with the choke out
will cause high fuel
consumption and possible
engine wear due to oil dilution.
6. Depress accelerator pedal slightly and pull the choke (A) half way out (fig-
ure 52).
7. Turn the key clockwise to the START position. Release the key when the
engine starts and push the choke partially in.
8. If difficulty is encountered, pull the choke control all the way out. Turn the
A
ignition starter switch to START and release when the engine starts.
9. Release accelerator pedal slowly to allow engine idle. Do not use the forklift
until the engine has been running for at least 2 minutes.
Figure 52: Before starting a
10. Check all gauges and lights, if engine warning lights stay on—turn off gasoline engine in cold weather,
pull the choke (A) half way out.
service technician.
Important: Push the choke in as soon as possible. Prolonged operation

with the choke out will cause high fuel consumption and possible engine
wear due to oil dilution.

36
operation Engine block heater (optional)

During extremely cold weather conditions (below -4°F/-20°C), the use of an
engine block heater is recommended if the forklift has not been used for a pro-
longed period of time. A 120V power supply is required. Before starting the
engine, make sure the power cord is unplugged and safely stored.
Moving off
With the forward/reverse selector in the NEUTRAL position and the parking
brake applied, put the gear shifter into the desired gear. Release the parking
brake and select either a FORWARD or REVERSE mode. Slightly depress the
accelerator pedal and move off.
Shifting on-the-go
For shifting on-the-go in FORWARD
or REVERSE, simply press and hold
the button on the gear shifter (fig-
ures 53), move the gear shifter to
the desired gear and release the but-
ton to complete the shifting
sequence.
Figure 53: Press and hold button on

shifter.

37
Stability COMBINED
CENTRE OF GRAVITY operation
The goal of every opera-
tor and employer should
be the safe and efficient
operation of the forklift. G
To achieve this, a safe Definitions:
working load must be
FULCRUM POINT • combined centre of gravity
transported with stabili-
the centre of gravity of the
ty, by a skilled operator, Figure 54: The weight of the truck and the
counterweight and the weight of the load pivot on a forklift and the load.
using a well-serviced fulcrum point on the forklift.
forklift. The following • stability triangle
information about safe the imaginary area on any
loads and stability must be read and understood STABILITY forklift where the centre of
by both the operator and the employer. TRIANGLE
gravity must be so the
machine is stable.
When working with loads it is important to
understand how the forklift remains stable. The
SD forklift is called a counterbalanced forklift.
This means that the forklift has been designed G
to carry the load in front of the front wheels and
the counterweight at the rear of the truck acts as
a counterbalance to the weight of the load.
These two forces create a see-saw effect in the Caution
forklift with the front wheels acting as the the The forklift’s rated capacity
fulcrum point (figure 54). If the load exceeds COMBINED must be adjusted to account
TOP VIEW CENTRE OF GRAVITY
the rated capacity of the forklift, the weight of for different load and
the load will overcome the counterbalance Figure 55: The stability triangle terrain conditions.
consists of three points—the
effect and cause the forklift to tip over. two front wheels and the
centre pin of the steer axle.
Counterbalanced forklifts are a rigid construc-
tion. The front (drive) axle is directly attached to the truck frame without using
suspension springs. This rigid assembly allows the truck to lift the loads
required. The rear (steer) axle is generally attached to the frame using a centre
pin to allow for the sharp turning radius necessary for operating in aisles and
tight areas. The engineering principle used on counterbalanced trucks is called
the stability triangle The triangle shape consists of three points, the two front
wheels and the center pin of the steer axle (figure 55). Within the stability tri-
angle is the centre of gravity of the truck. Should the centre of gravity ever move
outside of the stability triangle, the truck will tip over.
When operating the forklift, it is important to know where the centre of gravity
is at all times.

38
operation
Figure 57: For maximum stability, the mast and forks must always be at the lowest
height that provides adequate ground clearance.
A safe working load is the maximum weight that can be transported at each lift.
Even though the rated capacity of the forklift is 6,000-10,000 lbs @ 24" load
centre (depending on your model), the capacity must be adjusted to account
for different types and sizes of loads and different terrain conditions. In order
to keep the forklift stable, a safe operator must understand how the centre of
gravity changes with different weights and sizes of loads, positions of the mast
and terrain conditions.
1. Position of the mast and load
Loads can range from cubed to oversized and consist of different materials and
weights. A common type of cubed load would be bricks, blocks or turf grass and
an oversized load would include lumber or timber products. A cubed load car-
ried low, is more stable than a cubed load carried high because the centre of
gravity will be near the centre of the forklift.
All loads should be carried as low as possible because stability decreases as

loads are raised. The load should only be raised or sideshifted when the forklift
is at a complete stop on level ground. Never sideshift a fully raised load. This
may cause the forklift to tip over because the centre of gravity may not be inside
the stability triangle as previously described.

39
Loose or untied loads should be properly secured before lifting them. For max-
imum stability while travelling, the forks must be at the lowest height that pro-
operation
vides adequate ground clearance at all times (figure 57).
Always properly balance a

load on the forks. This
means the forks should be
equally spaced from the
center of the carriage and
set at the maximum width
Caution
apart that the load or pallet
Always transport a load with a
will allow (figure 58). This
forks as low as possible for
is done by raising the forks
maximum stability ad visibility.
4-6 inches above the Figure 59: Always adjust the forks for maximum
ground, pulling the fork stability of the load.
lock pins up and sliding the
forks to the desired posi-
tion. Release the fork lock Caution
pins so they drop into the Never sideshift a fully raised
nearest slot on the carriage. load! This can make the forklift
Make sure both pins are unstable and could cause the
locked to keep the forks forklift to tip over!
from moving (figure 59).
Figure 58: To balance a load, make sure the forks

are equally spaced from the center and set at the
maximum width apart that the load will allow.
2. Weight of load
The weight of the load will effect the stability of the forklift as described above.
The weight of any attachments that are added to the carriage must also be con-
sidered because they decrease the maximum load capacity of the forklift. Always
obtain advice on the use of unfamiliar attachments before operating them with
a load. Only Sellick approved attachments or options should be mounted to
the forklift.

40
operation 3. Terrain
The stability of the

forklift will vary
when travelling on
different terrain—
which can vary
from gravel to
sand to mud and
flat to bumpy to Figure 60: Inclines should be avoided if possible, but if you
must travel on an incline always drive up and reverse down
inclined (sloping). when the forklift loaded so the combined centre of gravity
These conditions stays inside the imaginary stability triangle.
must be taken into
consideration when operating the forklift. For example, an oversized load car-
ried across muddy terrain can decrease the forklift’s stability, obstruct vision,
Figure 61: Never travel with a load
pointing down—the centre of and change the speed and steering characteristics. A skilled operator considers
gravity is outside the stability these factors when working with the forklift.
triangle and the forklift will tip over.
Always obtain advice or check the conditions of the site over which the load will
be carried. Know that the surface is clear of debris and will support your vehi-
cle and its load. Know that your mast will pass under any overhead wires or
cables and through any doorways.
Caution
Never turn the forklift on an Travelling on an
incline—doing so may cause incline should
the forklift to tip over! always be avoided.
Remember that
the centre of gravi-
ty moves as you
drive up or down
Caution hill. If you must Figure 62: Always drive down and reverse up without a load.
Sudden stops should be avoided travel on an incline
when carrying a load, be sure to drive up and reverse down the incline when loaded (figure 60).
especially in a forward
direction—the vehicle will stop Never travel with the load pointing down because the centre of gravity may
but the load may not. move outside the stability triangle and tip the forklift forward (figure 61). For
maximum stability drive down and reverse up an incline when unloaded (fig-
ure 62). Do not turn on an incline, this may cause the forklift to tip. Proceed to
the top or bottom of the incline and turn safely on a level surface.
Caution Changes of direction must be made slowly with due regard for the surface, the
Never drive sideways across a type of load and the rear end swing of the vehicle. Sudden stops should be
slope with the forklift. avoided when carrying a load, especially in a forward direction when the vehi-
cle will stop but the load may not.

41
Travel procedures—no load operation

• Do not make quick or sudden turns or movements when operating the fork-
lift with or without a load.
• Always slow down and sound horn at cross aisles and other locations where
vision is obstructed.
• Always check overhead clearance of the forklift, especially indoors.
• When operating the forklift on public roads, comply with your provincial,
state or local laws governing highway safety by using approved warning
devices and accessory lights (i.e. flags, slow-moving vehicle emblem, lights,
etc.). Keep these devices clean and in good working order.
• Be courteous and have consideration for other traffic on the road.
• Yield the right of way to ambulances, fire trucks and other emergency vehi-
cles.
• Always keep forklift in the travel position, described below, when moving.
Travel position
1. Lower forks for minimum ground clearance, about 6" above the ground.
2. Be aware of surroundings—objects and people—including overhead

objects.
3. With the forward/reverse selector in the NEUTRAL position and the parking
brake applied, put the gear shifter into the desired gear.
4. Depress brake pedal fully.

5. Release the parking brake.
6. Move forward/reverse selector into desired position (D or R).
7. Always look in the direction of travel.
8. Slowly release the brake pedal.
9. Slowly depress accelerator pedal to move at desired speed (safe speed for
terrain).
10. Use brake as required for stopping and inching the machine.

42
operation 4WD option

The 4WD option should only be used when the forklift is used on unimproved
surface conditions or has become immobile due to severe terrain conditions.
Engage the 4WD when the forklift is at a complete stop. Disengage the 4WD
when conditions allow for 2WD operation. Depending on the serial number of
forklift, a lever or a switch may be installed.
The lever is located on the left side of the seatbox (figure 62a). The 4WD but-
ton is conveniently located on the top of the left side of the seat box (figure 63).
Caution
The 4WD option should only be 1. Depress the brake pedal
used when poor surface and make sure the fork-
conditions are encountered; lift is at a complete stop.
engagement on improved 2. If necessary, shift to a
surfaces over extended low gear.
distances may result in damage
to the powertrain. 3. To engage the 4WD,
push the 4WD lever or
switch.
Figure 62a: Older-style four-wheel drive lever.
4. To disengage the 4WD
when conditions allow
for 2WD operation, pull
the lever or push the
4WD switch.
Figure 63: Newer-style four-wheel drive switch.

43
Lifting loads operation

Lifting safety
• Do not attempt to
lift loads in excess
of the forklift’s
rated capacity
(refer to the serial
number plate A
inside the opera-

tor’s compartment,
see (A) in figure 64 Caution
for the exact loca- Lifting an excessive load will
tion). Lifting an make the forklift dangerously
excessive load will Figure 64: Always make sure you know the rated unstable and will cause
make the forklift capacity of the forklift found on the serial number damage to its components.
dangerously unsta- plate (A) located inside the operator’s compartment.
ble and will cause
damage to machine components.
• Double-tiered or stacked loads should not be lifted because they are unsta-
ble and difficult to control. Instead, break the load into two or more lifts.
Always remember that an overhead guard is intended to offer protection
from the impact of small packages, bagged material, boxes, etc. but it is not
intended to withstand the impact of a falling capacity load. Caution
• Before lifting a load, check to be sure it is stable and secure. Check the The mast should always be
weight and load centre of the load—if the weight is not marked, check the tilted backward when lifting
weight of the load with your supervisor or have it weighed. If there is any or travelling with a load.
indication or feeling of instability while lifting a load, stop immediately, Tilting the mast forward with a
lower the load, and restack or break it down into two or more lifts. load in a raised position can
result in the loss of the load.
• The mast should be tilted backwards when lifting and travelling with a load.
Tilting the mast completely forward with a load in a raised position can
result in the loss of the load.
• Never walk under a raised load or allow anyone to do the same. Everyone,
including the signal person, should remain at a safe distance from the fork-
lift and its load at all times. The forks must always be fully engaged when Caution
lifting, lowering, or travelling with a load. Never walk under a raised load
or allow anyone to do the same.

44
operation Lifting loads

The following techniques apply
to stable loads on the ground.
1. Move the forklift slowly and

carefully into position and
engage the load squarely—
Caution forks spaced as far apart as
Never lift a load in excess of the the load permits (figure 65).
forklift’s rated capacity. Doing Figure 65: Engage the load squarely.
so will make your machine
unstable and risk damage to 2. Ensure forks pass cleanly
the components. under the load, then move
forward until the load
touches the carriage
(figure 66).
Figure 66: Move forward slowly until the

carriage touches the load.
3. Tilt the mast back—then lift

the load smoothly (fig-
ure 67). The lifting speed
and tilt cylinder speeds are
controlled by the engine
speed. The higher the rpm
of the engine, the faster the
mast will lift and tilt.
Figure 67: Tilt the mast back then lift the load.
4. Carry the load as low as pos-

sible while still maintaining
ground clearance (fig-
ure 68).
Figure 68: Carry the load as low as possible.

45
Loads above ground level operation

The following techniques apply to stacked loads or unloading and loading a
truck or trailer.
1. Raise carriage to appropriate height to the load.
2. Approach the load squarely When unloading a truck or trail-

ensuring the forks are cen- er, first check the weight and
tered until forks fully engage center of the load to be lifted. If
the load (figure 69). the weight is unknown or not
3. Do not allow the mast to marked, check with your super-
contact the truck or the trail- visor for the correct weight.
er in any way.
4. Sideshift the mast to center Figure 69: Make sure the forks are horizontal
the load on the forks. to the truck or trailer.
5. Raise forks to lift the load

clear of the area.
6. Tilt the mast back to stabi-

lize load (figure 70).
7. Back away slowly, looking in

direction of travel, to clear
area.
8. Never turn the forklift with a

raised load.
9. Lower the load as close to Figure 70: Tilt the mast back to stabilize load.
the ground as possible.
10. Back away and drive slowly,

looking in the direction of
travel (figure 71).
Figure 71: Back away slowly, looking in the

direction of travel.

46
operation Double forking

When it is not possible to fully engage the forks when lifting a load, it will be
necessary to position the load closer before picking it up. This is known as
double forking.
1. Raise carriage to appropriate height to the load.
2. Approach the load squarely ensuring the forks are centred until the forks
Caution engage the load as much as possible.
Remember that the lift capacity
of the machine is reduced if the 3. Sideshift the mast to center the load on the forks.
forks are not fully engaged. 4. Tilt the forks back and raise the load slightly.
5. Back up slowly to position the load closer.
6. Lower the load and tilt the forks back to the horizontal position.
7. Fully engage the forks by moving the forklift forward again.
8. The load can now be lifted.
If the load is located on a truck or trailer, do not allow the mast to contact the
truck or trailer at any time.
Lifting drums or round objects

When lifting block drums or
round objects special care must
Caution
be taken to avoid losing or
Use special care when handling
spilling the load. It is important
drums or round objects to avoid
to have the forks spaced accu-
spilling the load.
rately. Use wood or metal block-
ing to ensure the barrel will not
move (figure 72). Tilt the mast Figure 72: Always block a barrel before lifting.
forward and slide fork tips along
floor or ground to get under the
drum. Tilt mast back slightly
until drum is cradled before lift-
ing.
Drums with large ribs may be
lifted in upright position
(figure 73). Forks must be
spaced accurately for a safe grip Figure 73: Forks must be accurately spaced if
under the drum ribs. picking up a drum in the upright position.

47
Travelling with loads operation

When transporting a load
over rough or uneven
ground, keep the travel
speed within the limits nec-
essary for safe operation.
Always use extreme caution
to maintain proper stability
on steep grades. Do not
coast or free wheel down
Caution
hills. Always drive at speeds Figure 74: When reversing with a load look behind
Make turns slowly and always
compatible with safety you for maximum visibility and safety.
look in the direction of travel.
especially when turning or
operating in rough or muddy conditions. Make turns slowly and always look in
the direction of travel (figure 74).
• Carry loads with the mast tilted back to cradle load and to prevent your load
from sliding off the forks.
• Use extreme caution when operating the forklift with a raised load. The fork-
lift becomes less stable as a load is elevated.
• Check overhead clearance carefully before driving under electrical lines, Caution
bridges, or entering buildings. Check load and machine clearance, front and Use extreme caution when
rear when turning corners. Do not sideshift while travelling or turning with operating the forklift with a
a load. Always transport a load with the forks as low as possible for maxi- raised load, the forklift will
mum stability and visibility. become less stable.
• Check ground surface and site conditions to be sure they will support your
vehicle and its load.
• Travel in reverse when carrying oversized loads for improved visibility.

Remember a load may be wider than the forklift.
• When turning sharp corners,

keep close to the inside corner
and begin turn when the inside
drive wheel meets the corner
(figure 75).
• When turning in narrow aisles,

Figure 76: Keep as far as possible
keep as far from the stockpile as from the stockpile when turning a
Figure 75: Keep close to the inside
possible when turning into it corners when turning a sharp corner. narrow corner.
(figure 76).

48
operation Placing loads

1. Check the landing point and sur-
rounding area to be sure it is
clear of debris and can properly
support the load (figure 77).
2. Move forklift into unloading

Figure 77: Be sure landing point is clear
position. of debris and can support the load.
Caution 3. Tilt load forward until horizontal

Always be sure the landing (but only directly over the land-
point will support the load. ing point) and lower the load to
the ground (figure 78).
4. Tilt the forks slightly forward to

deposit the load.
5. Reverse machine carefully to dis- Figure 78: Tilt mast forward over the
landing point and lower the load.
engage the forks from the load.
6. Back away from load carefully,

always looking in the direction of
travel (figure 79).
Figure 79: Back away from load carefully,

always looking in the direction of travel.
Unloading above ground level

1. Check the landing point to be sure it will support the load.
2. Approach the landing point as squarely and as closely as possible.
3. Tilt forks until the load is horizontal but only directly over the landing point.
4. Lower load.
5. Move the forward/reverse selector to the REVERSE position.
6. Tilt the forks slightly forward to clear the load and carefully back away,
always looking in the direction of travel.
7. When load is clear stop the forklift and lower forks to travelling height.
8. Drive away slowly, always looking in the direction of travel.

49
Shut-down procedure operation

For people’s safety and longer machine life it is important to shut down the
forklift properly.
1. Always move the

forward/reverse selector to
the NEUTRAL position and
apply the parking brake.
2. Lower the forks fully

(figure 80).
3. Turn the ignition OFF and

remove the key.
4. Cycle through all hydraulic Figure 80: Always lower the forks fully before
removing the ignition key from the forklift.
control levers to release the
hydraulic pressure.
5. Release the seat belt and dismount the forklift using the three-point method
(see page 15).
Parking procedures
Always park the forklift on level ground where possible. If it is to be parked on
an incline, always lower the forks to the ground, move the forward/reverse
selector to NEUTRAL, apply the parking brake, and chock the wheels securely
(figure 81).
1. Park in safe and authorized areas only.
2. Move the forward/reverse selector to the NEUTRAL position and apply the
parking brake.
3. Lower the forks to the ground. Figure 81: On an incline, always

make sure the front wheels are
4. Turn the ignition OFF and remove the key. chocked.
5. Cycle through all the hydraulic control levers to release hydraulic pressure.
6. Release seat belt and dismount forklift using the three-point method
(see page 15).
7. Securely chock all wheels on uneven or inclined ground.
Note: On forklifts equipped with LPG, close the fuel valve on the tank and
run the engine until the fuel in the lines is used up and the engine stops.

50
operation Transporting the forklift

Transporting safety
• When transporting the forklift,
be sure the mast is fully lowered
and the parking brake is applied
(figure 82).
This unit is equipped with special
45 degree laydown tilt cylinders.
The full 45 degree tilt feature is to
• Comply with your provincial,
be used for TRANSPORTING on
truck or trailer only and not on the
state or local laws governing
jobsite. DO NOT tow the forklift
with the mast tilted forward.
highway safety by using approved
warning devices and accessory Figure 82: When transporting the forklift,
make sure the mast is fully lowered and
lights (i.e. flags, slow-moving the parking brake is applied.
vehicle emblem, lights, etc.)
when transporting forklift. Keep these devices clean and in good working
order.
• Check and comply with local

laws governing maximum
Caution heights of trucks and trailers.
Always check the
• Never move or drive a trailer with
overhead clearance when
a forklift on the back until the
transporting the forklift.
tie-down chains are in place and
correctly secured (figure 83).
Figure 83: Check tightness of tie-down
• Always yield the right of way to chains before moving trailer.
ambulances, fire trucks and
other emergency vehicles.
Overhead clearance
Always check overhead clearance
when transporting your forklift. Overall
Overhead clearance is the total lowered
height of the trailer or truck and height
the forklift (figure 84)—the total
height depends on the height of + Distance of
your truck or trailer and the mast forklift from ground
on your SD. = Overhead clearance
Always make sure overhead Figure 84: Overhead clearance means
clearance is less than provin- the total height of the forklift and the trailer.
cial or state maximum.

51
Towing the forklift operation

The forklift must only be towed short
distances, at very low speeds, in an
emergency situation. The forklift
should never be pushed. Pushing
will cause damage to the frame,
drive components, and fuel or
hydraulic tanks. If the engine oil,
coolant or fuel levels become criti- Figure 84a: Only tow a forklift with the
appropriate capacity tow vehicle, such as
cally low, bring them to the vehi- an Autohauler.
cle—never drive vehicle to them.
When towing, use proper signs conforming to To tow vehicle

all highway regulations. Before attempting to
tow the forklift, have a trained and authorized
repair technician determine if it can be towed
without causing more damage to the
machine.
The forklift should be towed in its forward

facing position, if possible, with the for-
ward/reverse selector in NEUTRAL and the
driveshafts disconnected. A chain can only be
attached to the front axle. (Attach a chain to
the rear axle only if absolutely necessary). Figure 85: Two chains are
required to tow the forklift and
Damage to the machine may result if a chain should be attached as shown.
is attached to other locations on the truck.
Two chains are required for towing and should be attached as shown in fig-
ure 85.

52
preventive Preventive maintenance and service

maintenance Always service your forklift before the service is overdue. A well-serviced forklift
is a matter of cooperation between the skilled operator, the service department
and the employer. They should all know that the service intervals (refer to the
decal located inside the operator’s compartment) are the maximum allowable
and in extreme conditions of dust, heat and cold, the service intervals should
be scheduled accordingly.
The service department depends on the operator for advanced warnings of ser-
vice requirements and should advise the operator on any point of service or dri-
ving that is incorrect. The employer must be aware of the need for adequate ser-
vice time and not expect either the operator or the service department to do
without it.
A well-maintained forklift is safer for the operator and others in the area and
will operate more efficiently. Preventive maintenance is also less expensive; for
example, filters and lubricants are less expensive to replace than hydraulic and
mechanical components. Always observe proper maintenance and repair of all
pivot pins, hydraulic cylinders, hoses, snap rings, and main attaching bolts
prior to each day’s operation.
By performing regularly scheduled maintenance and pre-operational inspec-

Caution
tions, you are increasing the life of your forklift while providing a safe working
Always use brass drift and
environment.
hammer when servicing or
replacing pins in cylinder ends, Preventive maintenance and service safety
buckets, etc. Failure to do so
• Always wear safety goggles when servicing or repairing the forklift. Before
could result in injury from
doing any service on this machine, park the unit on level ground, apply the
flying metal fragments.
parking brake, place the forward/reverse selector in NEUTRAL, lower the
forks to the ground and turn off the ignition. Always stop the engine before
performing any service on the forklift.
• Do not make any attempt to straighten, weld, or otherwise repair the over-
Caution
head guard, mast structure or forks if damage has occurred. These parts
Always, for safe operation,
must be replaced in their entirety.
observe proper maintenance
and repair of all pivot pins, • If it is necessary to raise the mast to work on the side or front end of the
hydraulic cylinders, hoses, snap forklift, be sure that it is fully supported and blocked by means of an over-
rings and main attaching bolts head crane. Do not allow anyone to walk or stand under a raised mast.
prior to each day’s operation.
• Never lubricate or make mechanical adjustments while the unit is in
motion or when the engine is running. Never make repairs or tighten
hydraulic hoses or fittings when the system is under pressure, when the
engine is running or when hydraulic cylinders are under load.

53
First Every Every Every Every Every Every Every Every

50 50 150 300 400 500 600 800 2
preventive
No. Description
1 Adjust and lubricate mast
hrs hrs hrs hrs hrs hrs hrs hrs yrs
• •
maintenance
chains and load roller thrust buttons.
2 Check all wheel nuts for • •
tightness. Retighten if necessary.
3 Check all hydraulic fittings & hoses for • • The service intervals in this
leaks or damage. Replace req’d parts. chart are the maximum allow-
4 Check front hub oil level. • able and in extreme conditions
5 Check rear hub oil level. • of dust, heat and cold, the ser-
6 Adjust carriage side thrust rollers. • vice intervals for the forklift
7 Check fuel lines and clamp. • should be scheduled accordingly.
8 Check front axle oil level. •
9 Check battery electrolyte level. •
10 Check rear axle oil level. • After each regularly scheduled
11 Change engine oil. • • maintenance interval has been
12 Change engine oil filter. • • completed, the daily checklist
13 Check and adjust fan belt. • (see page 92) must be per-
14 Check rad hoses and clamp bands. • formed .
15 Change hydraulic oil filter. • •
17 Clean sediment bowl (gas only). •
18 Change engine fuel filter. • All grease points must be ser-
19 Check all electrical components • viced every 10 and 50 hours,
for malfunction or corrosion. refer to pages 84-85 for forklift
Clean or replace if necessary.
grease point locations.
20 Replace transmission filter. •
21 Change air cleaner element. •
22 Change front axle & hub oil (PD70). •
23 Change rear hub oil (S55/SD55). •
24 Change rear axle oil (SD55) •
25 Change hydraulic oil. •
26 Change transmission fluid. •
27 Check rear hub oil & re-pack
bearings (S50). •
28 Change front axle oil (CD60). •
29 Change rear axle & hub oil (SD50). •
30 Replace battery. •
31 Replace rad hoses and clamp bands. •
32 Replace fuel lines and clamps. •

54
preventive Preventive maintenance procedures

maintenance Minor preventive maintenance outlined in the following section may be done
by the operator unless otherwise noted. Any other maintenance or major ser-
vice must be performed by a trained service technician.
Keep all equipment free of dirt and oil. Be sure to clean any oil, grease, mud,
ice or snow from the floor of the operator’s compartment and stepping points.
Keeping your machine clean will make it safer to use and make leaks or dam-
age easier to detect. Keep a soft cloth handy to wipe the work lights and rear
tail/brake lights of any excess dirt. Always keep the brakes and hydraulic steer-
ing system in good working order.
Tool box/storage compartment

The tool box/storage compartment is located under the seat and can be opened
by lifting the hold downs and lifting the cover toward the front of the forklift.
(figure 86).
Fuel systems
Forklifts using liquid fuels should be refueled only at locations designated for
that purpose. Safe outdoor locations are preferable to those indoors. Never
smoke or keep any type of open flame near the forklift while servicing fluids.
Refer to fluid capacity chart on page 92 for the correct quantities and types
Figure 86: The tool box/storage
compartment is under the seat. of fluids.
The basic purpose of the fuel system is to store, convey, mix fuel with air, then
vapourize and introduce the mixture into the engine.
Fuel
Caution The fuel tank is located on the left
Never refill the fuel tank when side of the machine, see figure 87.
the engine is running. The fuel level is checked by the fuel
gauge on the instrument panel
when the key is in the ON position. If
the level is low, clean the filler cap
and surrounding area before open-
ing the cap. Ground the nozzle Figure 87: To minimize condensation,
always fill it up at the end of the day.
Caution against the filler neck to prevent
Never smoke while refuelling. sparks. Open the filler cap, insert the nozzle and fill the tank. Do not overfill
Keep all open flames away. the tank. If the fuel overflows or spills, wipe it all up. To minimize condensa-
tion on the walls of the tank, always fill it up at the end of the day. Refer to fluid
capacity chart on page 92 for the correct quantity and type of fuel.

55
Diesel fuel (Perkins 1000 Series - AA build) preventive

The fuel transfer pump draws the fuel from the supply tank, forces it through
the filters and delivers it to the injection pump. The fuel injection pump places
maintenance
it under the high pressure required for mechanical atomization, meters it with
great accuracy, distributes it in the proper sequence to the various cylinders,
commences the individual injections with fine precision in timing and pro-
For more information
duces uniformly through the nozzles the correct pattern of spray for the com-
bustion chamber.
about your Perkins
diesel engine,
Careless or too frequent removal of elements of the fuel injection system for
please refer to the
inspection or cleaning is generally far more harmful than beneficial, due to the
danger that dirt will enter the exposed connections and the possibility of mis- manufacturer’s
handling the equipment through lack of knowledge of its design and construc- User’s Handbook
tion. Various components are made with the utmost precision and may be eas- supplied with your
ily damaged when removed. forklift.
All injection pumps should be calibrated and repaired at authorized service sta-
tions, unless factory trained personnel are available with the proper tools and
test equipment.
Priming the fuel system

Priming is necessary on initial installation of the fuel injection system, after any
subsequent removal and if the system should be drained by running out of fuel.
Before priming, ensure that the surrounding area is thoroughly clean to pre-
vent dirt and foreign matter from entering the system.
Note: Electrical equipment such as starters should be shielded during prim-

ing to prevent fuel entry.
This method is used on the CAV and Stanadyne fuel injection pumps. Vent
screws are not fitted to these pumps.
If the engine has stopped because of air in the fuel system ensure that fuel has
been added to the tank or that the leakage has been corrected.
Although some fuel injection pumps will eliminate air automatically, use the
procedure that follows to remove air from the fuel system to ensure that the
battery will not discharge excessively:
1. Release the vent plug (figure 88) on the fuel filter head. Operate the

56
preventive priming lever of the fuel lift pump

(figure 89) until fuel, free of air,
A
maintenance comes from the vent plug. Tighten

the vent plug. If the drive cam of
the fuel lift pump is at the point of
maximum lift, it will not be possi-
ble to operate the priming lever. In
this situation, the crankshaft must Figure 88: Loosen bolt on filter (A).
be turned one revolution.
2. Loosen the high-pressure connec-

tions (figure 90) at the atomizers.
Ensure that the manual stop con-
trol, if one is fitted, is in the run
position. Operate the starter motor
until fuel, free of air, comes from
the pipe connections. Tighten the Figure 89: Location of priming lever.
connections to 16 lbf·ft (22 N·m)
Note: Do not tighten the nuts of

the high pressure pipes more than A
the recommended torque tension.
If there is a leakage from the
union nut, ensure that the pipe is
correctly aligned with the atomiz-
er inlet. Do not tighten the atom-
izer union nut more, as this can
cause a restriction at the end of
the pipe and this can affect the
fuel delivery. Figure 90: Loosen the high pressure
Caution connection (A).
Damage to the fuel 3. The engine is now ready to start.
injection pump, battery and
If the engine runs correctly for a short time and then stops or runs roughly,
starter motor can occur if the
check for air in the fuel system. If there is air in the fuel system, there is prob-
starter motor is used excessively
ably a leakage in the low pressure system.
to eliminate air from the
fuel system. Fuel filter
Clean fuel is a must in diesel operation. Extreme conditions may require addi-
tional filters to provide longer filter changed periods—when clean fuel is not
available. The fuel filter is of the paper element type and no attempt should be
made to clean the element. It should be replaced when periodic maintenance
is being carried out.

57
The period for changing the element will largely depend upon the quality and
condition of the fuel available. Under normal conditions the element should be
preventive
renewed every 300 hours. This period should be decreased if unavoidable con- maintenance
tamination of the fuel is experienced.
Replacing fuel filters

Note: Electrical equipment such as
starters should be shielded during filter
element replacement. Caution
1. Unscrew the centre fuel filter bolt on A There should be no tampering
the right side of the unit (figure 91). with the injection pump
Remove the filter base and filter. assembly or removal of it for
inspection unless engine
2. Discard the dirty element. Remove and operation is seriously impaired
discard the element seal. Figure 91: Fuel filter location (A). and the cause of the difficulty is
3. Fit the new seals. Place the new filter directly traceable to the pump
element in position and tighten the centre fuel filter bolt unit.
4. Vent the fuel system.
Injectors
Injectors should not be disassembled unless testing shows that cleaning or
other service is needed.
Gasoline fuel
Gasoline is stored in the tank; it is filtered through the sediment bowl and flows
through the fuel supply line to the carburetor under pressure of a fuel pump.
The carburetor mixes the fuel with proper proportions of air and at the same
time breaks it into very fine spray particles. This atomized spray changes to
vapor, by absorbing heat as it travels through the intake manifold to the com-
bustion chamber. Fuel must be vapourized since it will not burn as a liquid.

58
preventive Mechanical fuel pump

maintenance The mechanical fuel pump (figure 92) is generally used when the fuel supply
is below the level of the carburetor. This mechanical fuel pump mounts on the
cylinder block pad and is driven by an eccentric on the engine camshaft con-
tacting the fuel pump rocker arm. Constant fuel pressure is maintained by an
air dome and a pulsating diaphragm operated and controlled by linkage which
adjusts itself to pressure demands.
Fuel pump tests

The fuel pressure may be measured by installing a pressure gauge between the
fuel pump and carburetor. When pressures are below the range, the pump
should be disassembled and re-conditioned with the special overhaul kits avail-
Figure 92: Fuel pump. able.
Fuel pump trouble is only of two kinds—either the pump is supplying too lit-
tle gas or, in rare cases, too much.
If the pump is supplying too little gas, the engine either will not run or it will
cough and falter. If too much gas—it will not idle smoothly or you will see
gasoline dripping from the carburetor.
If there is little or no flow—check the following:
1. Look for leaky diaphragm cover gasket or line connections—tighten them.
2. Look for clogged fuel line—blow out with compressed air.
3. Make sure that all pump cover screws and external plugs are tight.
4. Inspect flexible fuel line for deterioration, leaks, chafing, kinks, or cracks.
If none of these items restore proper flow—remove the pump for replace-
ment or overhaul.
If getting too much gas—an oversupply of gasoline is generally caused by trou-

ble other than the fuel pump, so check the following:
1. Excessive use of hand choke.
2. Loosely connected fuel line or loose carburetor assembly screws.
3. Punctured carburetor float.
4. Defective carburetor needle valve.
5. Improper carburetor adjustment.
If none of these items corrects the flooding, remove the fuel pump for replace-
ment or overhaul.

59
Carburetor choke preventive

The manually operated choke
(figure 93) is operated by a flex-
maintenance
ible cable control from the
instrument panel. While this is
the most simple type, it is most
important that the operator
A
have the choke valve in wide
open position when engine
operating temperature is
reached. Figure 93: Location of choke (A).
Carburetor
The carburetor mixes fuel with air and meters the mixture into the engine as
the power is demanded. Dirt is the main enemy of good carburetion because
it fills up the tiny air and gasoline passages and accelerates the wear of delicate
parts.
Never use a wire to clean out restriction in jets as this will destroy the accurate
calibrations of these parts. Always use compressed air. The jets are made of
brass to prevent rust and corrosion and a wire would cut or ream the hole in
the jet and ruin it.
After a carburetor has been in service for some time, the holes in the jet and
the float valve and seat become worn from the constant flow of fuel through
them and should be overhauled by a competent carburetor service station.
Do not experiment with other size jets or any so-called fuel-saving gadgets as
your arrangement has been thoroughly tested on a dynamometer program.
Clean the sediment bowl every 300 hours. The sediment bowl is located on the
right side of the unit beside the fuel pump on the gas engine.
Draining the fuel tank

To drain the fuel tank, unscrew
the plug at the bottom of the
fuel tank (figure 94).
Figure 94: Fuel tank drain plug (A).

60
preventive Liquid propane gas - if applicable

maintenance LPG safety
• Only trained and authorized personnel should change or fill LPG tanks.
• Smoking is not permitted in the refuelling area.
• Engine shall be stopped and the operator off the forklift before refuelling.
• Protective clothing and safety equipment should be worn when changing or

Caution refilling cylinders or servicing any propane equipment.
Do not overfill LPG tanks. Use
the fuel level indicator on the • Check the date on the collar to ensure the tank has been inspected and
tank—do not use the fuel level stamped. If a tank is out of date, do not use the tank. The tank should be
gauge on the instrument panel. tagged and returned to the supplier for certification.
Use face shield and protective • Never use a damaged or leaking LPG tank. All defective or damaged LPG
clothing when refilling tanks. tanks must be removed from service.
• All valves on empty tank must be closed.
• Check for any leaks using a soap/water solution or leak detector, smell for
any leaks, look and listen.
• The careless handling of LPG tanks can result in a serious accident. Extreme
care should be exercised when transporting containers so they are not phys-
ically damaged. Do not drop, throw, roll or drag tanks or fuel systems.
• Do not leave the forklift for even short periods of time in the vicinity of
objects with high temperatures such as ovens and furnaces. The heat may
raise the pressure of the fuel to point at which the relief valve will open.
• Whenever trucks using LPG fuel are parked overnight or stored indoors for
protracted periods with the fuel tank in place, the service valve on the tank
should be closed.
• Do not refuel or store LPG-powered forklifts near any underground

entrances, elevator shafts or any other place where the gas could collect in
a pocket, causing a potentially dangerous condition.
Changing LPG tanks

1. Park the forklift on level ground with the parking brake applied, the for-
ward/reverse selector in NEUTRAL, forks lowered and the engine running in
low idle.
2. Close the service valve at the LPG tank by turning clockwise (figure 95) and
run the engine until the fuel in the line is consumed and the engine stops.

61
Then turn off the ignition switch.

preventive
3. Disconnect the fuel supply (fig-
ure 96). maintenance
4. Loosen retaining clamps. Clamp
lifts up to release. Carefully
remove the tank from the
Figure 95: Close the service valve.
mounting bracket (figure 97).
5. Check that the mounting brack-

ets are secure (figure 98).
6. Check to be sure the replace-

ment tank is of the same type of
withdrawal system.
7. Inspect the replacement tank for

physical damage such as dents, Figure 96: Disconnect fuel supply line.
scrapes or gouges and for indica-
tions of leakage.
8. Check for debris in the pressure

relief valve and for damage to
any valve and the fuel gauge.
9. Inspect the quick-disconnect

couplings for damage, deteriora-
Figure 97: Lift clamps and remove tank Figure 98: Check that the mounting
tion or missing flexible seals. from mounting bracket. brackets are secure.
10. Clamp the tank securely to the
truck making sure the pressure relief valve is in the 12 o’clock position.
11. Connect the fuel supply.
12. Turn the service valve on by turning the valve slowly counterclockwise (fig-
ure 99).
13. Check the LPG fuel lines and coupling for odour of leakage.
14. Turn the ignition switch to the start position. Do not depress the accelera-
tor pedal while starting. Release the ignition switch when the engine starts.
Note: if the service valve is opened too quickly the pressure relief valve
will shut-off the fuel supply. If this happens, close the service valve com-
pletely, wait about 5 seconds, and open the service valve very slowly.
Figure 99: Open the service valve.

62
preventive B
maintenance
A
For more information

about your Perkins
diesel engine, B
please refer to the
manufacturer’s A
User’s Handbook
supplied with your
forklift. Figure 100: Location of dipstick (A) and Figure 101: Location of dipstick (A) and
oil filler cap (B) - Perkins diesel engine. oil filler cap (B) - Perkins gas and LPG.
Engine oil
Check the engine oil level daily. Wait until the engine has
been turned off for a minimum of 5 minutes. The
engine oil dipstick is located under the hood. The engine
oil dipstick is on the right side of the engine on the
diesel (figure 100), gas and LPG engines (figure 101). Full
Always check the level using the dipstick (A). The level Low
must be between the lower and upper marking (fig-
ure 102). To add oil, remove the oil cap (B) on top of the Figure 102: The level
engine and fill as required. Do not overfill—this will must be between
cause engine damage. Replace the engine oil cap and these two lines.
clean any spilled oil. Refer to the fluid capacity chart on
page 92 for the correct quantity and type of engine oil required.

63
Changing engine oil and filter preventive

The engine oil and filter should be changed every 150 hours.
maintenance
1. The unit should be on level
ground, the parking brake
applied, the forward/reverse
B
selector in NEUTRAL and the Discard used filters and oil in a
ignition off. safe place and in accordance
with local regulations.
2. The oil should be at normal
operating temperature when A
foreign material is in sus-

pension. Drain the oil by
removing the drain plug (A) Figure 103: Location of oil pan drain plug (A)
and o-ring at the bottom of and oil filter (B) - Perkins diesel.
the oil pan (figure 103 and
figure 104). Ensure o-ring is
not damaged. Re-install the
plug and o-ring when the oil
finishes draining and tighten
the plug to 34 N·m
(25 lbf lb).
3. Unscrew the oil filter (B),

A
catching the oil in a suitable B
container below the filter.
Figure 104: Location of oil pan drain plug (A);
Discard the filter. oil filter (B) is on the other side - Perkins
gas and LPG.
4. Clean the filter head.
5. Coat the gasket on the new

filter with a film of oil (fig-
ure 105). Screw the filter
into place until the gasket
contacts its mating surface,
then turn the filter approxi-
mately 3/4 of a turn by
hand. Do not over-tighten.
6. Fill the engine with oil

Figure 105: Make sure to coat the new filter
through the filler neck (refer seal with a film of oil.
to figures 100 and fig-
ure 101). After adding the oil, start the engine and check the filter and drain
plug for leaks. Refer to page 92 for correct type and quantity of engine oil.

64
preventive Hydraulic oil

maintenance The hydraulic tank is located
on the right side of the forklift.
Check hydraulic oil at operat-
ing temperature, with all cylin-
ders in their natural positions
and the engine turned off. Be
Caution
sure to cycle the control levers
Be sure to cycle the hydraulic
to release the pressure. Clean
controls to release pressure.
around the filler cap area first,
before removing the cap, to
Figure 106: The hydraulic oil filler cap is on the
prevent any loose dirt from right side of the forklift.
entering the tank. To avoid
injury from hot hydraulic
fluid, remove the filler cap in figure 106 slowly.
F mark
Check using the dipstick. The hydraulic oil level
should register to the F mark (figure 107). If not,
Caution fill to the required level and replace the cap Figure 107: The hydraulic oil
Never make repairs or tighten securely. Clean any spilled oil. Never reuse level should register to the
hydraulic hoses when the hydraulic fluid! Refer to the fluid capacity chart F mark on the dipstick.
system is under pressure, when on page 92 for quantity and type of hydraulic oil.
the engine is running or when
the hydraulic Changing hydraulic oil
cylinders are under Change the hydraulic oil
load. every 600 hours.
1. Be sure the machine is A

on level ground with the
parking brake applied,
the forward/reverse
selector in NEUTRAL
and the ignition off.
2. Place a large suitable Figure 108: The hydraulic tank oil plug (A).
container under the
hydraulic tank and
remove the filler cap.
3. Remove the drain plug (A) from under the tank and let the oil drain (figure
108).
4. Replace the drain plug and fill with the correct grade of hydraulic oil as
specified on page 92.

65
preventive
maintenance
Figure 109: The hydraulic oil filter (A) is on the right side of the forklift.
Changing hydraulic oil filter

Replace the hydraulic oil filter every 300 hours. It is located on the right side
of the unit in the engine compartment (figure 109).
1. Be sure the machine is on level ground with the parking brake applied, the
forward/reverse selector in NEUTRAL and the ignition off.
2. Unscrew the filter element from the filter head and discard.
3. Lightly coat the gasket on the new filter with a film of oil. Screw the filter into
place until the gasket contacts its mating surface, then turn the filter
approximately 3/4 of a turn by hand. Do not over-tighten.
4. Start the engine and cycle the hydraulics. Check for leaks and top up the
hydraulic oil level to its full mark on the dipstick.

66
preventive
maintenance
PRESSURIZED A
COOLING SYSTEM
REMOVE CAP
SLOWLY
Figure 110: If your truck is equipped with a radiator overflow bottle (A), check and
fill the coolant level using the bottle.
Cooling system
To obtain maximum efficiency and service life from the engine, it must operate
at the correct temperature. This is dependent on the cooling system. The sys-
Caution tem should be kept filled with a rust inhibitor or anti-freeze solution. If the anti-
The cooling system operates freeze does not contain a rust inhibitor, then one should be added.
under pressure due to the
sealed radiator cap. It is If the coolant is low, add clean water or anti-freeze solution as necessary. If the
dangerous to remove the cap cooling system already contains anti-freeze solution, add only anti-freeze solu-
while the system is hot. Always tion of the correct water/anti-freeze mixture. Plain water will dilute the solution
turn the cap slowly to the first and weaken its protection. When adding fluid use a funnel to prevent spillage.
stop and allow the pressure to Replace cap securely and clean any spilled fluid. Refer to the fluid capacity chart
escape before removing the on page 92 for quantity and type of coolant.
radiator cap completely. If the truck is equipped with a radiator over-
flow bottle (figure 110), fill the bottle with
fluid as required. If the engine is cold, ensure
the fluid comes up to the lowest mark; if the
FULL WHEN HOT
engine is hot, ensure the level reaches the
higher line (figure 110a).
FULL WHEN COLD
Keep the radiator fins clean of dirt to allow

free passage of air. If the oil is spilled on the Figure 110a: Radiator overflow
radiator fins, clean immediately with a suit- bottle.
able solvent. Oil will allow dirt to accumu-
late, restricting the cooling passages.

67
Draining and flushing the cooling system preventive

(Perkins diesel 1000 Series - AA build)
maintenance
Drain and flush the radiator and engine block every 24 months.
1. Be sure the machine is on level ground with the parking brake applied, the
forward/reverse selector in NEUTRAL and the ignition off.
2. Remove the radiator cap and

Caution
open the drain valve at the radi-
Do not operate the forklift if the
ator.
engine temperature exceeds
3. Remove the drain plug (A) from 38°F (100°C).
the right side of the cylinder
block (figure 111) and drain the A
engine. Make sure the hole is not
blocked.
Figure 111: Location of drain plug (A)
4. Remove the drain plug at the - Perkins diesel.
bottom of the radiator to drain
the radiator.
5. After the coolant has drained, run water through the system by placing a
water hose in the radiator filler neck. When the water flowing from the
drain valve is free of discoloration and sediment, remove the hose and
allow the system to drain.
6. Close the drain valve and slowly refill the system with an anti-freeze solu-
tion until the coolant level is at the appropriate level on the overflow bottle
(see figure 110a).
7. Clean the radiator cap and cap seal and install the radiator cap.
8. Run the engine until normal operating temperature is reached, then stop
the engine and re-check the coolant level. Add coolant as required.
Thermostat
A
The thermostat is located in the coolant outlet connection (figure 112).
When the engine is cold, the thermostat, which is a temperature sensitive valve,
shuts off the flow of coolant to the radiator, allowing rapid engine warm-up. A
re-circulating bypass allows the coolant to circulate within the engine whenev-
er the thermostat shuts off flow to the radiator. If it ever becomes necessary to
install a new thermostat, because the old one is damaged by corrosion, it must Figure 112: The thermostat is
be positioned in the recess of the water outlet connection, so the head element located in the thermostat
(spring end) will be in the water header. housing (A).

68
preventive Transmission fluid

maintenance Check the transmission fluid
level daily when the oil is cold
(before starting the forklift) with
the parking brake applied, the
forward/reverse selector in A
NEUTRAL and the engine off.
The transmission fluid dipstick
Caution is located on the right side of the
Figure 113: Check the transmission fluid
Be sure to apply the parking forklift (figure 113). The trans- level (A) using the dipstick.
brake before checking the mission fluid level (A) must be
transmission fluid level or between the lower and upper markings on the dipstick
changing the filter. (figure 114). If low, place a funnel in the dipstick tube
and fill to required level. Do not overfill—this will dam-
age the transmission. Replace the dipstick. Clean any
spilled fluid. Refer to the fluid capacity chart on page 92 Full
for correct quantity and type of transmission fluid Low
required.
Figure 114: The level
Changing the transmission filter must be between
these two lines.
Change the transmission filter every 300 hours. The fil-
ter is located under the seat (figure 115).
1. The unit should be parked on level ground, forward/reverse selector in

NEUTRAL and the parking brake applied.
Figure 115: To gain access to the 2. Clean around the filter area with a clean rag to remove any dirt build-up.
transmission filter lift the seat.
3. Position a pan under the filter area and then proceed to remove the filter
and allow it to drain. Discard the oil filter.
4. Coat the gasket on the new filter with a

coat of transmission oil (figure 116).
Screw the filter into place until the gas-
ket contacts the filter head, then turn
the filter approximately 3/4 of a turn by
hand. Do not over-tighten.
5. Re-check the transmission oil level

Figure 116: Coat new filter seal
and top up as necessary.
with a film of oil.
6. Start the engine and check for leaks.
7. Re-check the transmission fluid level.

69
Changing the transmission fluid preventive

Change the transmission fluid every 600 hours—change when fluid is cold.
maintenance
1. Park the unit on a level surface. Place the forward/reverse selector in NEU-
TRAL, ensure the engine is off and the parking brake applied. Drain the
transmission fluid by removing the suction strainer (A) (figure 117).
2. Clean the strainer by washing in a suitable solvent and by blowing the

debris with compressed air.
3. Using a new gasket, fit the suction strainer and apply loctite to bolts (B) and A
tighten to 7.4 lbf·ft (10 N·m).
4. Refill the transmission with the correct grade of transmission fluid. Refer
B
to page 92 for the correct quantity and type of transmission fluid required.
Figure 117: Drain the transmission
Brake system fluid fluid by removing suction
strainer (A) and bolts (B).
Check the brake system fluid level with
the engine off. The master cylinder is A
located behind the front cover.
1. Remove the plastic plug on the front

cover to gain access to the master
cylinder filler cap (figure 118).
2. Wipe cap (A) and master cylinder top

clean. Remove cap and check brake
system fluid level (see figure 119
Figure 118: Remove the plug (A) to
below). check the brake system fluid level.
3. Fill to the proper level, just below the

cap. The brake system fluid to use is A
hydraulic oil, see page 92 for the cor-
rect type. Replace the cap securely.
4. There should always be a small

amount of free-play between the
push rod and the master cylinder to
prevent the brakes from riding. Figure 119: Remove the master
cylinder cap (A) to check and to
top up the brake system fluid.

70
preventive Battery
maintenance Batteries contain sulfuric acid and can produce explosive gases. Follow the
instructions below to prevent personal injury.
• Wear eye and skin protection.
• Keep any sparks and all types of open flame away.
• Always have adequate ventilation while charging or using a battery.
• Follow the manufacturer’s instructions which are shown on the battery.
The battery is located at the

rear of the forklift under the
hood. Check the battery every
Caution
50 hours or every week for
The gases given off by a battery
the correct electrolyte level.
are explosive. To avoid injury
or battery damage, always keep 1. Unlatch the hood latches
sparks and open flames away and lift the hood.
from the battery. Always wear
2. Clean the top of the bat-
eye and skin protection!
tery by wiping with a
damp cloth. If corrosion
is present around the ter-
minal connections,
remove the battery cables
and wash the terminals Figure 120: Lift the hood of the forklift to clean
with an ammonia solu- and service the battery. Always make sure the
tion or a solution consist- cables are tight and secure.
ing of 1/4 lb. (113 grams)
of baking soda added to 1 qt (0.9 L) of water. Be sure the vent plugs are
tight to prevent the cleaning solution from entering the cells. After cleaning,
flush the outside of the battery, the battery compartment and surrounding
areas with clean water.
3. Check the electrolyte level (acid and water solution) in the battery by
removing the vent plugs (figure 120). Fill the cells to the bottom of the filler
neck. Use distilled water only.
4. Install the vent plugs after making sure the breathing holes in the plugs are
not blocked.
5. Check to see that the battery cables are tight and secure. Protect the termi-
nals from corrosion with a light application of petroleum jelly.

71
preventive
maintenance
Figure 121: Always check the tire pressure from the tread side, never the tire side.
Tires
Inflating and servicing tires can be dangerous. To avoid possible injury, follow
the safety precautions below. Only trained and authorized personnel should ser-
vice tires and wheels.
• Check tire pressure from the tread side only, never the tire side (figure 121).
• Do not re-inflate a tire that has been run flat or seriously under-inflated
until tire has been inspected for damage by a qualified person.
Caution
Inflating and servicing tires
• Tires should only be inflated in a safety cage or other portable safety device. can be dangerous. Only trained
and authorized personnel
• Do not weld, braze or otherwise repair or use a damaged rim. The rim
should service tires and wheels.
should be replaced in its entirety.
• Do not inflate a tire unless the rim is mounted on the forklift or secured
firmly so it will not move if the tire or rim should suddenly fail.
• Tires must be properly inflated to obtain maximum tire life. Under-inflated

or over-inflated tires cause deterioration, slippage, and failure. Never inflate
tires over the recommended pressure.
Before driving your forklift, check tires for proper inflation and report any cuts,
cracks, gouges or abrasions immediately. For accurate pressure reading, check
tire pressure only when tires are cold. All tires should be inflated to the manu-
facturer’s specifications found on the tire.
Check the wheel nuts daily for tightness.

72
preventive Mast lubrication & maintenance

maintenance Adjust and lubricate the mast chain
and load roller thrust buttons every
50 hours. Check the mast chains
for tightness.
1. Park the forklift on a level sur-

face, with the parking brake
applied, the forward/reverse
selector in NEUTRAL and the Figure 122: The mast mast chains should
be taut, not loose, when the mast is
engine off. vertical and the fork heels touch the
ground.
2. The mast rails should be vertical
and the fork heels touching the
floor, the chains should be evenly taut (figure 122), not loose. Adjust to
comply.
3. Check and lubricate the mast chain rollers.
4. Check the chains for pliability and apply SAE No. 10 oil.
5. Check the carriage and rails for sloppiness and also the tilt cylinder pins and
the retaining rings. Make sure the cylinders are properly adjusted and the
locknut is tight.
6. Check the mast rollers and also the sideshift cylinder for correct adjust-
ment.
Side thrust adjustment

If the mast sections or carriage
become loose from side to side
through normal wear, use a B
socket head wrench to adjust
the side thrust screw. These
A
screws are located in the centre
of each load roller (figure 123)
and can be adjusted without dis- Figure 123: If the mast becomes loose, adjust
assembling the mast. the side thrust screw (A) until the side thrust
plug (B) is snug against the rail.
Tighten the screw (A) until the
side thrust plug (B) is snug against the mast rail, then back the screw off 1/2 a
turn. Operate the mast full lift height with no load. If the mast appears to stick
at any position, back the set screw off another 1/2 turn. Continue this proce-
dure until the mast operates freely. Both sides should be tightened equally.

73
Belts preventive
1. Park the forklift on
C maintenance
level ground with
the forks lowered,
the parking brake
A
applied, the for-
ward/reverse selec-
tor in NEUTRAL and
the engine OFF.
2. Raise the hood. B
3. Check the condi-

tion of the belt (A)
and adjust if neces-
sary (figure 124).
Correct adjustment Figure 124: When checking the belts (A), always make
allows 3/8" sure the engine is off and the parking brake is applied.
(10 mm) deflec- To adjust the belt, loosen the alternator bracket bolt (B).
tion.
4. Loosen the alternator bracket bolts (B) and pivot bolts (C) and pry out to
adjust. Tighten the bolt.
Note: If a new belt is fitted, the belt tension must be checked again after
the first 20 hours of operation.
Fuses
Fuses are located
behind the front cover
A
(figure 125) (A). To
remove the cover,
unscrew all the bolts
and remove the panel.
B
Fuses are also located
under the hood on the
right side of the forklift Figure 125: The fuses are located behind the front
(near the starter) (B). cover (A) and under the hood (B) of the forklift.

74
preventive Front (drive) axle (ITL CD60 axle)

maintenance Used on trucks from S/N 1068611832-4-1502003632
Checking front axle oil level
Check the front axle oil level every 50 hours.
The forklift has to be

parked on level ground to
ensure accurate oil level
checking. Make sure the
forward/reverse selector is
in NEUTRAL and the park-
ing brake is applied.
To check the front axle oil

level, remove the level Figure 125a
plug (figure 125a). Oil level
should be level with the bot-
tom of the level hole. If necessary add oil. Clean and replace the level plug.
Refer to page 92 for the correct quantity and type of oil.
Changing front axle oil

The front axle oil should be changed and refilled every 800 hours.
1. The unit should be

parked on level ground,
transmission controls
in neutral and the park-
ing brake applied.
2. Place a large capacity

container under the
drain plug of the front
axle. Figure 125b
3. Remove the drain plug

located under the front axle (figure 125b).
4. Allow the oil to drain completely. Replace the drain plug and tighten snug-
gly. Do not overtighten.
5. Refill with the correct grade of oil. Refer to page 92 for the correct quantity
and type of oil.

75
Front (drive) axle (ITL PD70 axle) preventive

Used on trucks from S/N 1504003632-xxxx maintenance
Checking front axle oil level
Check the front axle oil level every 50 hours.

checking. Make sure the A
in NEUTRAL and the park-
B
To check the front axle oil
level, remove the level Figure 126
plug (A) (figure 126). Oil
level should be level with
the bottom of the level hole. If necessary add oil. Clean and replace the level
plug. Refer to page 92 for the correct quantity and type of oil.
Changing front axle oil

The front axle oil should be changed and refilled every 500 hours.
1. The machine should be parked on level ground with the machine tires just
clear of the ground, forward/reverse selector in NEUTRAL and the parking
brake applied. Make sure the forklift is properly secured. C
2. Manually rotate both wheels to bring the oil level marks on the hubs to the
vertical with the level plugs (C) at the 6 o’clock position (figure 127).
D
3. Place a large capacity fluid container under the drain plug (B).
4. Remove drain plug (B) from differential case and level plugs (C) from hubs.
5. Allow the oil to drain completely. Clean and replace the drain plug (B) and
tighten snuggly. Do not overtighten.
6. Set both hub oil level marks to the horizontal (D) (figure 127).
7. Fill the axle through the level plug (A) (figure 126). If the machine has been Figure 127: To change the front
axle oil, remove the hub level plugs
set level, oil should just dribble out both hub level points. Refer to page 92 (C); to fill set the oil level marks
for the correct quantity and type of oil. horizontal (D).
8. Clean and replace the fill plug (A) and the hub level plugs (C).

76
preventive Rear (steer) axle - 2WD (ITL S50 axle)

maintenance Used on trucks built before S/N 2287501832
Hubs - 2WD
Check and re-pack the bearings
in the rear steer axle on the two-
wheel drive unit every 600
hours.
Pop off the cap (figure 127a)

and check the condition of the
bearings.
Figure 127a
Rear (steer) axle - 4WD (ITL SD50 axle)

Used on trucks built before S/N 2207409831-4
Checking rear axle oil - 4WD
Check the rear steer axle oil level on the four-wheel drive every 50 hours.
1. The unit should be parked on level ground, transmission in NEUTRAL and

the parking brake applied.
2. To check the oil level, simply remove the level plug (figure 127b). If low, top
up through the same hole until oil flows from the level hole.
Figure 127b

77
Changing the rear axle oil – 4WD (SD50 axle) preventive

The rear axle should be changed and refilled every 800 hours.
maintenance
1. The unit should be parked on level ground, transmission in NEUTRAL and
the parking brake applied.
2. Place a large capacity fluid container under the drain plug of the rear axle.
3. Remove the drain plug located under the

steer axle (figure 127c) and allow to drain
completely.
4. Replace the drain plug and tighten snuggly.

Do NOT overtighten.
5. Refill through the filler hole (figure 127d)

until the oil flows from the level hole. Refer to
page 92 for the the correct fluid type and
capacity of the rear steer axle.
Note: When refilling the rear axle, allow

time for the oil to drain past the axle bear-
Figure 127c
ings into the axle arm before rechecking the
level.
Figure 127d

78
preventive Checking the hub oil - 4WD (SD50 axle)

maintenance Check the oil in the hubs every 50 hours.
1. To check the oil in the hubs,

move the forklift until the level
plug on the rear steer hub in at
the 3 o’clock position (fig-
ure 127e).
2. Remove the level plug. Oil

should flow from the level hole.
Figure 127e
If not, top up the oil flows from
the level hole.
Changing the hub oil – 4WD (SD50 axle)

Change the hub oil every 800 hours.
1. To change the hub oil move the

unit until the drain on the hub
casing is in the 6 o’clock position
(figure 127f).
2. Place a suitable container under

the hub and remove the drain
Figure 127f
plug. Allow to drain completely
before replacing the plug.
3. Fill with the correct grade of oil through the oil level hole until oil flows from
the hole. See page 92 for the correct type of oil to use.

79
Rear (steer) axle - 2WD (ITL S55 axle) preventive

Used on trucks built from S/N 2287501832-xxxx maintenance
Checking rear axle hub oil level
Check the hub oil level every 50 hours. The
forklift has to be parked on level ground to
ensure accurate oil level checking. Make
sure the forward/reverse selector is in
NEUTRAL and the parking brake is applied.
Make sure the oil level mark on the hub is
horizontal (figure 128).
A
To check the hub oil level, remove the level
plug (A) (figure 128). The oil level should
Figure 128: To change the hub oil,
be even with the bottom of the level hole. If remove the hub level plugs (A).
necessary add oil. Clean and replace the
level plug. Refer to page 92 for the correct quantity and type of oil.
Changing rear axle hub oil

The rear axle oil should be changed and refilled every 500 hours.
1. The machine should be parked on level

ground with the machine tires just
clear of the ground, forward/reverse
selector in NEUTRAL and the parking
brake applied. Make sure the forklift is
properly secured.
2. Manually rotate both wheels of the axle

to bring the oil level mark on the hubs B
to the vertical with the level plugs (B) at
Figure 129: To fill the hubs, set the
the 6 o’clock position (figure 129). oil level marks horizontal (B).
3. Remove the level plugs from the hubs.
4. Allow the oil to drain completely.
5. Set both hub oil level marks to the horizontal (A) (figure 128).
6. Fill the hubs with oil through the level holes. Oil should be level with the
bottom of the level hole. Refer to page 92 for the correct quantity and type
of oil.
7. Clean and replace the level plugs.

80
preventive Rear (steer) axle - 4WD (ITL SD55 axle)

maintenance Used on trucks built from S/N 2207409831-4-xxxx
Checking rear axle oil level
Check the rear axle oil level every 50 hours.

checking. Make sure the
in NEUTRAL and the park- A
To check the axle oil level, B

remove the level plug (A)
and its bonded washer (fig- Figure 130: To check the rear axle oil level, remove
ure 130). Oil level should the level plug (A); to drain, remove drain plug (B).
be even with the bottom of
the level hole. If necessary add oil. Clean and replace the level plug with a new
bonded washer. Refer to page 92 for the correct quantity and type of oil.
Changing rear axle oil

1. The machine should be parked on level ground, forward/reverse selector in

NEUTRAL and the parking brake applied.
2. Place a large capacity fluid container under the drain plug (B).
3. Remove the level plug (A) and drain plug (B), together with their bonded
washers. Allow time for the oil to drain out.
4. Allow the oil to drain completely. Clean and replace the drain plug (B) with
a new bonded washer and tighten to 58 lbf·ft (79 N·m). Do not overtighten.
5. Fill the axle with oil through the level plug (A). Oil should be level with the
of oil.
6. Clean and replace the level plug (A) with a new bonded washer.

81
Checking hub oil level (SD55 axle) preventive

Check the hub oil level every 50 hours.
The forklift has to be parked on level
maintenance
A
ground to ensure accurate oil level
checking. Make sure the forward/reverse
selector is in NEUTRAL and the parking
brake is applied. Make sure the oil level
mark on the hub is horizontal (fig-
ure 131).
To check the hub oil level, remove the

level plug (A) (figure 131). Oil level Figure 131: To fill the hubs, set the
oil level marks horizontal (A).
should be even with the bottom of the
level hole. If necessary add oil. Clean and
replace the level plug. Refer to page 92 for the correct quantity and type of oil.
Changing rear axle hub oil (SD55 axle)

1. The machine should be parked on level ground with the machine tires just
clear of the ground, forward/reverse selector is in NEUTRAL and the parking
brake applied. Make sure the forklift is properly secured.
2. Manually rotate both wheels of the

axle to bring the oil level mark on the
hubs to the vertical with the level
plugs (B) at the 6 o’clock position
(figure 132).
3. Remove the level plugs (B) from the

hubs.
B
4. Allow the oil to drain completely.
5. Set both hub oil level marks to the Figure 132: To change the hub oil,
remove the hub level plugs (B).
horizontal (A) (figure 131).
6. Fill the hubs with oil through the level holes. Oil should be level with the
of oil.
7. Clean and replace the level plugs.

82
preventive
maintenance
Figure 133: Location of air cleaner on

forklifts equipped with gasoline
engine.
Air cleaner
Figure 133a: Location of air cleaner on
Caution Your forklift is equipped with a dual forklifts equipped with diesel engine.
The air cleaner elements must element air cleaner (figure 133).
be replaced only. Do not Check the air cleaner service indica-
attempt to clean them with an tor every day before starting the machine. If the indicator is red, or becomes red
airline or by washing. while the engine is running, replace the outer element immediately. Be sure the
engine is shut off before changing the air cleaner element. Replace the air
cleaner outer element every 400 hours or at least once a year if it has not been
indicated earlier. The inner element must be replaced every third time the
outer element is replaced. As a record, mark the inner element with a felt tip
pen each time the outer element is replaced.
1. The machine should be

parked on level ground, for-
ward/reverse selector in
NEUTRAL, the parking brake
applied and the engine OFF.
2. Loosen the retainer clamp

and remove the air cleaner
end cap (figure 134).
Figure 134: Remove end cap.
3. Loosen and remove the wing
nut. Remove the outer filter element (figure 135).

83
preventive
maintenance
Figure 135: Loosen wing nut. Figure 136: Remove the outer element.
Figure 137: Loosen wing nut. Figure 138: Remove the inner element.
Figure 139: Clean canister. Figure 140: Reset button on indicator.
4. Loosen and remove the wing nut from the inner filter element (figure 137).
The inner filter element is not serviceable and must be replaced with a new
filter when required.
5. Clean the inside of the canister with a damp, lint free cloth (figure 139).
6. Install a new inner element in the the holder, if necessary. Secure the wing
nut.
7. Install a new outer filter element in holder. Secure the wing nut.
8. Install the end cap and tighten the retainer clamp.
9. Make sure the hose and all retainer clamps are secure.
10. Press the reset button (A) in figure 140 on the service indicator.

84
grease points A
10 hours
For the maximum operational

life of your forklift, we recom- B
mend you grease the following
grease points every 10 hours
using a lithium-based,
No. 2 consistency grease. C
A
Grease point locations Figure 137: Newer-style ITL axle: Trunnion bearings - top and bottom (A), steer
cylinder ends (B) and tie rod ends (C).
Fig. Description
A Trunnion bearings 4
(top and bottom) AA
AA King pins (top and bottom) 4
B Steer cylinder ends 2 B
C Tie rod ends 2
CC Mast pivot bearings 2
AA
Figure 137a: Older-style ITL axle: king pins and steer cylinder ends.
A
CC
Figure 138: Trunnion bearings (A). Figure 138a: Mast pivot bearings (CC).

85
grease points
50 hours
For the maximum operational

life of your forklift, we recom-
mend you grease the following
D
grease points every 50 hours
using a lithium-based,
No. 2 consistency grease.
Figure 139: Tilt cylinder - truck end (D).
Grease point locations

D Fig. Description Qty
D Tilt cylinder ends 4

E Axle pivot bearings 2
E
I Pump drive universals 2
(if applicable)
E
2WD only
D
F Driveshaft universals 2
G Driveshaft slip yoke 1
4WD only
F Driveshaft universals 4
Figure 140: Tilt cylinder - mast end (D). Figure 141: Axle pivot bearings (E). G Driveshaft slip yoke 2
H Axle driveshaft universals 4
I
H
F
G I H
Figure 142: Driveshaft universals (F) Figure 142a: Pump drive (I). Figure 143: Axle driveshaft
and slip yoke (G). universals (H) (4WD only).

86

87

88
PERIODIC MAINTENANCE - SD 2WD

REFER TO OPERATOR’S MANUAL FOR DETAILED INFORMATION
INTERVAL ITEM ITEM DESCRIPTION

HOURS NO.
CHECK AS 2 WHEEL NUT TORQUE CHECK

REQUIRED 13 MASTER CYLINDER CHECK FLUID LEVEL
19 MAST CHAINS CHECK AND OIL
(SEE OPERATOR’S MANUAL)
22 ALTERNATOR & FAN BELTS CHECK
10 HOURS 9 TIE ROD ENDS LUBE
SD Operator’s Manual
OR DAILY 11 STEER CYLINDER ENDS & UNIVERSALS LUBE
15 ENGINE OIL LEVEL CHECK
18 TRUNNION BEARINGS - TOP & BOTTOM LUBE
24 ENGINE COOLANT LEVEL CHECK
25 MAST PIVOT BUSHINGS LUBE
50 HOURS 1 TIRE PRESSURE CHECK

OR WEEKLY 3 FRONT HUB OIL LEVEL CHECK
4 DRIVE SHAFT UNIVERSALS LUBE
6 TRANSMISSION OIL LEVEL CHECK
12 FRONT AXLE OIL LEVEL CHECK
November, 1998
17 REAR HUB OIL LEVEL - 2WD CHECK
20 TILT CYLINDER ENDS LUBE
21 AIR CLEANER CHECK INDICATOR & CLEAN OR
REPLACE OUTER FILTER ELEMENT
24 BATTERY ELECTROLYTE CHECK LEVEL - ADD
DISTILLED WATER ONLY
26 AXLE PIVOT BEARINGS LUBE
27 LOAD ROLLERS & THRUST BUTTONS ADJUST
28 CARRIAGE SIDE THRUST ROLLERS ADJUST
150 HOURS 10 ENGINE OIL FILTER CHANGE

15 ENGINE OIL CHANGE - DRAIN WARM & REFILL
300 HOURS 5 TRANSMISSION OIL FILTER REPLACE

8 HYDRAULIC OIL FILTER REPLACE
14 FUEL FILTER ELEMENTS REPLACE
16 SEDIMENT BOWL (PERKINS GAS ONLY) CLEAN
500 HOURS 12 FRONT AXLE OIL CHANGE - DRAIN WARM & REFILL
3 FRONT HUB OIL CHANGE - DRAIN WARM & REFILL
17 REAR HUB OIL - 2WD CHANGE - DRAIN WARM & REFILL
600 HOURS 5 TRANSMISSION OIL CHANGE - DRAIN & REFILL

7 HYDRAULIC OIL CHANGE - DRAIN & REFILL
EVERY 24 23 PERMANENT ANTI - FREEZE CHANGE (SEE OPERATOR’S MANUAL)

MONTHS

PERIODIC MAINTENANCE - SD 4WD
REFER TO OPERATOR’S MANUAL FOR DETAILED INFORMATION
INTERVAL ITEM ITEM DESCRIPTION
HOURS NO.
CHECK AS 2 WHEEL NUT TORQUE CHECK

REQUIRED 13 MASTER CYLINDER CHECK FLUID LEVEL

20 MAST CHAINS CHECK AND OIL
(SEE OPERATOR’S MANUAL)
23 ALTERNATOR & FAN BELTS CHECK
10 HOURS 9 TIE ROD ENDS LUBE

OR DAILY 11 STEER CYLINDER ENDS & UNIVERSALS LUBE
15 ENGINE OIL LEVEL CHECK
18 TRUNNION BEARING - TOP & BOTTOM LUBE
24 ENGINE COOLANT LEVEL CHECK
26 MAST PIVOT BUSHINGS LUBE
50 HOURS 1 TIRE PRESSURE CHECK

OR WEEKLY 3 FRONT HUB OIL LEVEL CHECK
4 DRIVE SHAFT UNIVERSALS LUBE
6 TRANSMISSION OIL LEVEL CHECK
12 FRONT AXLE OIL LEVEL CHECK
17 REAR HUB OIL LEVEL - 4WD CHECK
19 REAR AXLE OIL LEVEL - 4WD CHECK
21 TILT CYLINDER ENDS LUBE
22 AIR CLEANER CHECK INDICATOR & CLEAN OR
REPLACE OUTER FILTER ELEMENT
25 BATTERY ELECTROLYTE CHECK LEVEL - ADD
DISTILLED WATER ONLY
27 AXLE PIVOT BEARINGS LUBE
28 LOAD ROLLER & THRUST BUTTON ADJUST
29 CARRIAGE SIDE THRUST ROLLERS ADJUST
November, 1998
150 HOURS 10 ENGINE OIL FILTER CHANGE
15 ENGINE OIL CHANGE - DRAIN WARM & REFILL
300 HOURS 5 TRANSMISSION OIL FILTER REPLACE

8 HYDRAULIC OIL FILTER REPLACE
14 FUEL FILTER ELEMENTS REPLACE
16 SEDIMENT BOWL (PERKINS GAS ONLY) CLEAN
500 HOURS 12 FRONT AXLE OIL CHANGE - DRAIN WARM & REFILL
3 FRONT HUB OIL CHANGE - DRAIN WARM & REFILL
17 REAR HUB OIL - 4WD CHANGE - DRAIN WARM & REFILL
19 REAR AXLE OIL - 4WD CHANGE - DRAIN WARM & REFILL
600 HOURS 5 TRANSMISSION OIL CHANGE - DRAIN & REFILL
7 HYDRAULIC OIL CHANGE - DRAIN & REFILL
EVERY 24 24 PERMANENT ANTI - FREEZE CHANGE (SEE OPERATOR’S MANUAL)

MONTHS 254813
89
90
international
symbols
As a guide to the operation of

your forklift forklift, various
international symbols have
been used on the instruments
and controls. The symbols are
shown with their meanings.
Parking brake
Air cleaner
Engine coolant Transmission oil filter
Engine coolant temperature Wiper
Lights Air cleaner

91

92
fluid types For the maximum operational life of your forklift, please use the
& capacities recommended fluid type.
Item Capacity Fluid type/International specification
Perkins Diesel Engine (1000 Series AA build)

(Refer to your Perkins User’s Handbook for important engine maintenance
information)
Engine oil 10.9 L (11.5 US qt) API service

CF4
(The above capacities are approximate. Always use the
maximum and minimum marks on the dipstick when filling.)
Perkins Gasoline Engine (G4.236 Series)

(Refer to your Perkins User’s Handbook for engine maintenance information)
Engine oil 7.9 L (8.3 US qt) API service
SE/CC
(The above capacities are approximate. Always use the maximum and minimum marks on the dipstick when filling.)
Coolant
Engine block 9.4 L (9.9 US qt)
Radiator 20.8 L (21.8 US qt)
Overflow bottle 2.4 L (2.5 US qt) - if applicable
Transmission (SS600 Series)

2WD - approx. system 19.0 L (20.0 US qt) (Mobil ATF210)
2WD - approx. transmission 13.0 L (13.7 US qt)
4WD - approx. system 21.0 L (22.0 US qt)
4WD - approx. transmission 14.0 L (14.8 US qt)
(The above capacities are approximate. Always use the maximum and minimum marks on the dipstick when filling.)
Front (drive) axle (PD70)

25.0 L (26.2 US qt) M2C134D (Mobilfluid 424)
Front (drive) axle (CD60)

28.0 L (29.6 US qt) M2C134D (Mobilfluid 424)
Rear (steer) axle - 4WD (SD50 & SD55)

Differential 13.5 L (14.2 US qt) MIL-L-2105C, API-GL-5 (Mobil HD80W-90)
Hubs 1.5 L (1.6 US qt)
Rear (steer) axle - 2WD (S50 & S55)

Hubs 1.5 L (1.6 US qt) MIL-L-2105C, APL-GL-5 (Mobil HD80W-90)
Hydraulic system
Tank 71.89 L (19.0 US gal) ISO VG 32 (Mobil Hydraulic Oil AW 32)
Fuel system
Tank 71.89 L (19.0 US gal)

Warranty
Sellick Equipment Limited warrants new products sold by it under the 8. Incidental charges such as oil, fuel or anti-freeze.
trademark “Sellick” to be free defects in material and workmanship during
9. Travel, shipping expense, service calls, meals and overtime.
the first twelve (12) months or two thousand (2000) operating hours

(whichever occurs first) after date of delivery of the product to the initial 10. Transportation and trucking charges on replacement material or loaner
user. (Rentals are considered as retail sales). equipment.
This warranty shall be fulfilled by any authorized Sellick dealer to provide, 11. Replacement and rental units.
at his place of business and during normal working hours, a new or repaired 12. Loss of revenue.
part (whichever Sellick elects) along with established labour for the
installation of such parts found upon its inspection to be defective in material 13. The addition of foamed plastic “fill” to tires by the customer changes the
or workmanship. characteristics of our product and voids warranty on wheels and axle
components unless customer has written consent by Sellick to make this
Replacement parts provided under the terms of this warranty are warranted modification.
until the expiry date of the warranty of the product in which they are
installed. THE FOREGOING WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED
Note: Perkins engine warranty and related engine components must be WARRANTY OF MERCHANTABILITY, OR FITNESS FOR A PARTICULAR
carried out by a Perkins distributor and dealers. (Perkins warranty PURPOSE, OR OTHERWISE. NO EMPLOYEE OR REPRESENTATIVE OF
conditions attached.) SELLICK EQUIPMENT LIMITED IS AUTHORIZED TO CHANGE THIS
THIS WARRANTY SHALL NOT APPLY TO: WARRANTY IN ANY WAY OR GRANT ANY OTHER WARRANTY.
1. Any operation which is part of predelivery or 50 hour inspection LIMITATION OF LIABILITY
procedure. (Includes loose hydraulic fittings, bolts, nuts, etc.) In no event shall Sellick Equipment Limited be liable for special or
2. Vendor warranted items such as tires and tubes. consequential damages claimed to arise under this contract, nor shall it be
liable for loss or damage sustained or caused by the operation and use of the
3. Normal maintenance services (such as engine tune up, fuel system
equipment while any of the parts are loose, broken or out of order, nor will
cleaning, lubrication, brake and other adjustments, chain and roller
Sellick Equipment Limited be liable in any manner if the equipment is
adjustment).
improperly operated or its successful operations impaired by the natural
November, 1998
4. Normal replacement of regular maintenance items (such as filters, oils, elements after its delivery to the purchaser. Sellick will in no event be
spark plugs, ignition points and brakes). responsible for any consequential damages including but not limited to lost
profits, lost sales or revenue, increased freight or shipping costs, increased
5. Deterioration of belts and exterior finish due to normal use and
handling costs or lost production time arising from the performance, or
exposure.
failure of performance, of the Sellick product.
6. Any part of the machine that has been subject to negligence, alterations,
(The term “Sellick” as used herein means Sellick Equipment Limited).
accident, or in connection with parts or attachments made or supplied by
someone other than Sellick, if in Sellick’s opinion such use affects its
performance, stability or reliability.
7. Incidental charges such as towing and trucking.
272151-A March, 2001
93
94
index
4WD, operation...................................42 Choke

4WD lever/switch checking .....................................16
checking .....................................16 operation....................................35
light ............................................20 Coolant
Accelerator pedal checking .....................................13
location ......................................16 draining......................................67
operational check.......................25 fluid type/capacity ......................92
using...........................................25 refilling.......................................66
service interval ...........................53
Air cleaner
warning light ........................17, 19
checking .....................................13
clean/replace.........................82-83 Cooling system ..............................66-67
service interval ...........................53 Cylinders
Ammeter warning light.......................17 checking .....................................11
controls .................................24-25
Axle, front (drive)
axle oil level check ................74-75 Decals................................................8-9
axle oil change ......................74-75 Domelight
grease points.........................84-85 checking .....................................21
fluid type/capacity ......................92 operation....................................31
Axle, rear (steer) ...........................76-81 Double forking....................................46
grease points.........................84-85 Driveshaft, grease points ....................85
hub oil level check.........78, 79, 81
Engine
hub oil change`...................77, 80
block heater .........................23, 36
fluid type/capacity ......................92
break-in procedure ....................29
Battery oil level check.............................27
checking .....................................14 shut-down ............................26, 49
maintenance ..............................70 starting-cold weather .22-23, 34-35
warning light ........................17, 19 starting-general ..........................33
Belts, maintenance.............................73 starting-warm weather .........22, 34
Block heater .................................23, 36 Engine oil
Brakes changing.....................................63
fluid level check .........................27 checking .....................................27
operational check.......................25 fluid type/capacity ......................92
pedal location.............................16 refilling.......................................62
refilling.......................................69 warning light ........................17, 19
service interval ...........................53 Fan
Break-in procedure ............................29 checking .....................................21
operation....................................32
Cab
checking................................21-22 Foreword...............................................4
operation...............................31-32 Forks
Charts adjusting.....................................39
checklist .....................................91 lock pins.....................................10
fluid capacity ..............................92 Forward/reverse selector ......................7
grease point...........................84-85 Fuel gauge ....................................18, 19
scheduled maintenance .............53
Fuel systems..................................54-61

95
index
diesel.....................................54-57 placing above ground .................48 Three-point mounting method...........15

fluid type/capacity ......................92 safety ..........................................43 Tires
gasoline.................................57-59 stability of..............................37-40 checking .....................................11
LPG .......................................60-61 travelling with.............................47 maintenance ..............................71
refilling.......................................54 Mast Tool box ..............................................54
Fuses ..................................................73 carriage ......................................10 Towing.................................................51
Gear shifter chains.........................................10
Transmission
checking .....................................16 checking .....................................10
filter change ...............................68
operation....................................36 controls .................................24-25
fluid change ...............................69
grease points.........................84-85
Grease points.................................84-85 fluid level check .........................13
lubrication..................................72
Heater fluid type/capacity ......................92
checking .....................................21 oil cooler, check .........................14
side thrust adjustment...............72
operation....................................31 refilling.......................................68
travel position.............................41
Hour meter, checking.........................18 Operation ......................................28-51
Travelling
Hydraulics control levers Operator inclines.......................................40
checking................................24-25 checklist .....................................91 without load ...............................41
operation...............................24-25 compartment .............................16 position ......................................41
Hydraulic cylinder locations ...............11 foreword .......................................4 stability of..............................37-40
Hydraulic oil safety ............................................6 with load.....................................47
fluid type/capacity ......................92 Operator’s checklist............................91 Warranty .............................................93
checking level.............................12 Overhead clearance ............................50 Windows
changing.....................................64
Parking ...............................................49 checking .....................................21
refilling.......................................64
Preventive maintenance chart ............53 operation....................................32
Preventive maintenance decals .....86-89 Windshield wipers
Ignition ...............................................16
checking .....................................21
Inspection, walk-around .................7-27 Safety
operation....................................31
general .........................................5
Instruments ..................................17-20
lifting ..........................................43
International symbols.........................90 LPG.............................................60
Introduction .........................................1 maintenance ..............................52
Lights operation....................................28
4WD............................................20 operator........................................6
cab..............................................21 travelling.....................................41
overhead guard ............................8 transporting................................50
rear.............................................14 Seat, adjustment.................................30
switch ...................................17, 20 Seat belt, checking..............................12
LPG tanks Serial numbers .....................................2
changing................................60-61
Shift-on-the-go, operation ..................36
checking .....................................14
Shut-down procedure...................26, 49
Loads
lifting ..........................................44 Stability..........................................37-40
lifting above ground ...................45 Startup procedure..............22-23, 34-35
lifting drums ..............................46 Symbols ..............................................90
lifting round objects ...................46
Thermostat .........................................67
placing........................................47

96
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358 Erie Street North
Harrow, Ontario, Canada N0R 1G0
Telephone: (519) 738-2255
Fax: (519) 738-3477
E-mail: sellick@mnsi.net
Website: www.sellickequipment.com

Sellick SD-80 Operators Manual Nov 1998

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Operator’s

Telephone number: ________________________________________

Delivery date: ____________________________________________

For extra copies of this manual, please order part #272252.

We at Sellick Equipment Limited, in the long-standing tradition of quality the

Sellick Equipment Limited November, 1998 SD Operator’s Manual

serial SD model and serial numbers

Forklift serial number: ______________________________________

Rear axle serial number: ____________________________________

Door key number: _________________________________________

Ignition key number: _______________________________________

Sellick dealer: ____________________________________________

Dealer address: ___________________________________________

Telephone number: ( ) ________________________________

Fax number: ( ) _____________________________________

E-mail address: ___________________________________________

SD Operator’s Manual November, 1998 Sellick Equipment Limited

Sellick Equipment Limited November, 1998 SD Operator’s Manual

Know your controls and instruments to ensure safe operation!

SD Operator’s Manual November, 1998 Sellick Equipment Limited

• Never leave your forklift unattended in areas open to the public.

• Carry all loads low at the minimum ground clearance.

• Know the rules and regulations required at your job site.

• Never drive up to anyone standing in front of a bench or other fixed object.

• Never disconnect safety devices installed on your forklift.

Sellick Equipment Limited November, 1998 SD Operator’s Manual

safety Operator safety

• An operator should not use drugs, alcohol or medications—prescription or

• Provide a first-aid kit for use in case of an

• Wear all the protective clothing needed

• If exposed to noise which is objectionable or uncomfortable, wear a suitable

SD Operator’s Manual November, 1998 Sellick Equipment Limited

Pre-operation, visual checks

Sellick Equipment Limited November, 1998 SD Operator’s Manual

1. Chassis and overhead guard

Figure 4: Use the 4WD in the

SD Operator’s Manual November, 1998 Sellick Equipment Limited

Read the Operator’s Manual. It is important the operator

Sellick Equipment Limited November, 1998 SD Operator’s Manual

SD Operator’s Manual November, 1998 Sellick Equipment Limited

Sellick Equipment Limited November, 1998 SD Operator’s Manual

Under the hood

SD Operator’s Manual November, 1998 Sellick Equipment Limited

8A. Transmission fluid (SS600 Series) walk-around

The SD model forklift is equipped with a dual

10. Engine coolant level

Sellick Equipment Limited November, 1998 SD Operator’s Manual

walk-around 11. Transmission oil cooler

Rear 12. Battery

13. Rear lights

14. LPG tanks - if applicable

Make sure the clamps (A) and

SD Operator’s Manual November, 1998 Sellick Equipment Limited

worn, report this immediately to your supervisor or service department.

Mounting the forklift

When mounting or dismounting, Caution

Sellick Equipment Limited November, 1998 SD Operator’s Manual

16. Operator’s compartment

SD Operator’s Manual November, 1998 Sellick Equipment Limited

Re-check all the instrument

17. Instrument panel (installed on trucks build

Sellick Equipment Limited November, 1998 SD Operator’s Manual

walk-around E Transmission oil temperature gauge

SD Operator’s Manual November, 1998 Sellick Equipment Limited