Page 1
WTEREX
236502
HANDLERS,
OPERATOR'S
MANUAL
TH636C
TH644C
TH842C
TH844C
~
TEREX HANDLERS
455 N. Superior Ave.
Baraga, MI
(906) 353-6675 Fax (906) 353-7543
Ph.
http://www.terexlift.com
49908-0790
12/18/03
Page 2
Page 3
TABLE OF CONTENTS
SECTION
SECTION
SECTION
1
2
3
ROUGH
Introduction
Standards And Symbols
Safety 1-5
Training And Knowledge
Operator's
Management's Responsibilities 1-7
Maintenance And Repair
Operation Safety
GENERAL
General Safety Procedures
Jump
Proper Load
CONTROLS
Operator's Compartment
Joystick Control Functions
Joystick Control Functions (Button Pushed)
Service Brakes
Parking
Frame
Gauges
Hydraulic
Steering
Transmission
TERRAIN
Responsibilities
SAFETY
Starting
Brake
Sway Control
Pump Destroke Button
FORKLIFT
Chart
Use
AND
INSTRUMENTS
SAFETY
SECTION
1-1
1-3
1-4
1-5
1-6
1-8
1-9
2-1
2-3
2-8
2-9
3-1
3-3
3-4
3-5
3-6
3-6
3-7
3-8
3-8
3-9
3-9
SECTION
SECTION
4
5
OPERATION
Operation
Before Starting The Engine
Starting The Engine
Before
TransportingALoad
Placing A Load
MAINTENANCE
General Safety Practices
Service Intervals
Required Grease Intervals 5-6
Grease Fitting Locations
Daily Maintenance Procedures 5-8
50
Hour
100
250
500
750
1000
2000
Filter Guide
Recommended Fluids And Capacities 5-24
Hydraulic
And
Safety Guidelines
Operating The Forklift
PROCEDURES
Maintenance Procedures 5-12
Hour
Maintenance Procedures
Hour
Maintenance Procedures
Hour
Maintenance Procedures 5-18
Hour
Maintenance Procedures 5-20
Hour
Maintenance Procedures 5-21
Hour
Maintenance Procedures 5-23
Pressure
Settings 5-25
4-1
4-3
4-4
4-9
4-11
4-15
4-17
5-1
5-3
5-5
5-7
5-15
5-17
5-24
SECTION
6
MATERIALSAFETYDATASHEETS 6-1
Page 4
Page 5
SECTION 1
ROUGH TERRAIN
FORK
LIFT
SAFETY
1 - 1
Page 6
TABLE OF CONTENTS
SECTION 1 - ROUGH TERRAIN FORK LIFT SAFETY
Introduction
Standards And Symbols
Safety
Training And Knowledge
Operator's Responsibilities
Management's Responsibilities
Maintenance And Repair
Operation Safety
1-3
1-4
1-5
1-5
1-6
1-7
1-8
1-9
1-2
Page 7
~ROUGH
TERRAIN
FORK
LIFT
SAFETY
~]
a
Owners, Users, and Operators:
Terex (Handlers) appreciates your choice
number one priority is user safety, which is best achieved by our j oint efforts.
that you make a major contribution
1.
Comply with OSHA, Federal, State, and Local Regulations.
2.
Read, Understand, and Follow the instructions in this and other manuals
supplied with this
3. Use Good Safe
4. Only have trained/certified operators - directed by infonned and
knowledgeable supervision
NOTE: OSHA prohibits the alteration or modification
manufacturer's approval.
machine.
Work
INTRODUCTIOND
of
our machine for your application. Our
to
safety
if
you,
as
the equipment users and operators:
machine.
Practices in a common sense
- running the machine.
of
Use only factory approved parts to service or repair this
way.
this machine without written
We
feel
If
there is anything in this manual that is not clear or which you believe should be added,
please send your comments to the Manager
790,
Baraga, Michigan 49908. Telephone number 906-353-6675.
Thank
you!
THIS SYMBOL MEANS
of
Publications, Terex Handlers,
YOUR
SAFETY IS
P.O.
INVOLVED! READ, UNDERSTAND AND
FOLLOW
CAUTION DECALS ON
ALL DANGER, WARNING AND
YOUR
ROUGH
TERRAIN
FORKLIFT.
Box
1-3
Page 8
[LtROUGH TERRAIN FORK LIFT SAFETY
C STANDARDS AND SYMBOLS D
STANDARDS
Lt]
Many aspects
published by the American National Standards Institute. These Standards are updated on
a regular basis with addendas. Terex recommends that you purchase and refer
following standards.
of
rough terrain forklift operation and testing are discussed in standards
to
ANSI B56.6 - Rough Terrain Fork Lifts
This Standard can be purchased
American National Standards Institute
25
West 43nd Street, 4th Fl.
New York, New York, 10036
Tel.
212.642.4900
Fax. 212.398.0023
from:
the
SYMBOLS
The symbols below
the operation ofthis machine.
are
used
to
inform the operator
of
important information conceming
DANGER
which,
WARNING-Indicates a potentially hazardous situation
which,
illJury.
CAUTION - Indicates a potentially hazardous situation
which,
~ury.
ATTENTION - Indicates a situation which,
may result in property or equipment damage.
- Indicates an imminently hazardous situation
if
not avoided, will result in death or serious
if
not avoided, could result in death or serious
if
not avoided, may result in minor or moderate
if
not avoided,
1-4
injury.
Page 9
[&,ROUGH TERRAIN
C SAFETY n
FORKLIFT
SAFETY
~
These are general safetyrules, which must be followed.
and understand the
detailed specific
to
Operator's Manual
this
machine.
as
there are instructions, which are more
You
are
also required to read
TRAINING AND KNOWLEDGE
1.
Safety must always be the operator's most important concern.
2.
TIns
machine must only be operated by trained personnel, who have demonstrated
their ability to
3.
Comply with
Administration (OSHA) standards, including 29CFR191 0.178; and the American
National Standards Institute (ANSI) B56.61atest edition.
do
so
safely.
the
requirements
of
current Occupational Safety and Health
4.
Read and Understand all Decals
5.
Read and Understand the Rating Chart.
6.
Know that the machine can safety lift each load before attempting to lift.
and
Warnings.
1-5
Page 10
(&ROUGH
« OPERATOR'S RESPONSIBILITIES D
1.
Read
and
2.
Know
lights.
3.
Make
signals are functional before operating.
4. Keep the machine clean, including all instrumentation, windows, lights and other
glazed surfaces.
5.
Use protective clothing and safety equipment. Always use approved safety
equipment such as: gloves, safety boots,
protection where necessary.
the location and the purpose
sure the machine is
TERRAIN FORK LIFT SAFETY
understand the Operator's Manual.
ofthe
controls, instruments and indicator
in
proper order and all operational aids and warning
hard
hats, safety glasses and ear
&]
6. Wear protective clothing that is snug and belted where required.
7. Store tools and other necessary items in the toolbox.
8. Never lift a load without a Load Rating Chart
9.
Know
10.
Be
medications that might affect the operator's eyesight, hearing,
11. Keep people, equipment and material
12. Keep a fully charged fire extinguisher and first aid kit
be
13. Know about movements
14.
Make
outriggers
the load to be lifted.
alert, physically fit and free from the influences
out
familiar with how to use these items.
of
other machinery, trucks and personnel at
sure everyone is
(if
so equipped.)
in
a safe place before moving the boom, forks, load
in
ofthe
the cab.
of
alcohol, drugs
work
area.
in
the cab at all times, and
or
or
reactions.
the
jobsite.
or
15. Start and stop movements smoothly and swing at speeds that will keep the load
under control.
1-
6
Page 11
(itROUGH
TERRAIN FORK LIFT SAFETY it]
fi
MANAGEMENT'S RESPONSIBILITIES n
1.
Ensure operators
2.
Have a supervisor
3.
Crew members given specific safety responsibilities and instructed
unsafe conditions
4.
Supply the weight on the load to be lifted
5.
Verify
as
that all crewmembers
well
as
instructions in the manuals.
are
competent, physically
at
the job site
to
the
supervisor.
to
are
familiar with OSHA,ANSIB56.6 requirements
fit,
trained and
be responsible for job safety.
to
the operator.
if
required licensed.
to
report any
1-7
Page 12
[&ROUGH
TERRAIN FORK LIFT SAFETY
&]
~
MAINTENANCE AND REPAIR D
1.
Practice safe maintenance procedures. Perform
accordance with instructions provided by the manufacturer in the manuals. Also
heed the warnings on the placards and decals on the machine.
2.
Always use supports
or forks.
3.
Shut off the engine
instructions specifically require
4.
Always make sure the machine
lubrication.
5.
Replace
6.
Always use a piece
all
shields
and
braces when working
and
lockout the machine while working on the machine unless
the
engine
is
stationary prior
and
guards after performing
of
cardboard or paper to search for leaks.
to
all
on,
be
running.
service.
maintenance
under or around the machine
to
performing adjustments or
and
repairs in
7.
When performing work on the hydraulic
L Lower the boom to horizontal.
11
Support the boom with supports or braces.
111.
Shut down the
N.
Relieve
v.
Ensure
VI. Repair or replace any damaged line, hose or fitting before
applying pressure.
8.
Always have tires serviced and mounted by a qualified person with the proper
tools and guards.
9.
Always
10.
Only perform welding
use
an
inflation
all
on
engine.
all
pressure before disconnecting
connections
cage
during
the machine with approval
system:
lines.
are
tight before applying pressure.
tire
inflation.
from
the manufacturer.
1-
8
Page 13
[!tROUGH
TERRAIN FORK LIFT SAFETY
~]
~
OPERATION SAFETY D
1.
Always inspect the machine
broken structures,
damaged or leaking parts prior to operation
2.
Onlyinspectthe coolant level when the engine and coolant are cool.
3.
Be sure that all guards and screens are secure and in the proper place.
4.
fuspect for and clear the work area
proper machine operation. Any obstructions that cannot be cleared should be
clearly marked
5.
Refueling:
ll.
ill.
lV.
and
and
avoided during operation.
1.
Always
Fill the
Handle
the
machine while smoking or near open
Always
daily.
Check for leaks, worn hoses, loose belts,
loose or missing bolts. Repair orreplace any worn,
of
the machine.
of
any obstructions that could interfere with
stop the engine before refueling the machine.
fuel
tank outdoors.
fuel
with
care,
as
it
is
clean
up
spilled
highly flammable.
flames.
fuel.
Do
not refuel
6.
Make sure the machine and access system is clean and free
debris.
7.
When getting on and off the machine,
handrails provided,
8.
Always remain completely inside the
9.
Always wear
10.
Always completely lower the boom with the forks resting on the ground before
any work is performed on or around the machine.
11.
Do not operate the machine while people are under or near an elevated boom
whether the boom is loaded or unloaded. Falling objects from the forks or
attachment may cause serious injury or death.
and
always maintain a three point contact.
the
seat belt while operating the machine.
face
the machine, use the steps and
cab
enclosure while operating the machine.
of
dirt, oil, grease or
1-9
Page 14
(&ROUGH
C OPERATION SAFETY D
12.
Maintain an appropriate clearance
below for minimum safe approach distances.
TERRAIN FORK LIFT SAFETY
from
electrical power lines. See the chart
&]
13.
Power
Lifting
o
50
200
350
500
750
Loads:
Minirmnn
Line
Voltage
to
50
kV
to
200 kV
to
350 kV
to
500 kV
to
750 kV
to
1000 kV
1.
Using the load chart, confirm that the load is within the rated
capacity
n.
Level the machine using the level gauge before lifting loads. Use
the sway control to level the machine only when the boom is
horizontal or
horizontal may cause the machine
m.
Verifythatthe load is secured on the forks before performing a lift.
Rearrange the load
IV.
Before lowering a maximum load, always retract the boom
completely.
v.
Use proper attachments, such as a truss boom,
loads.
of
Safe Approach Distance
the machine
lower.
for
the required configuration.
Using the sway control with the boom above
if
necessary.
Required Clearance
10
ft.
(3.00
15
ft.
(4.60
20
ft.
(6.10
25
ft.
(7.62
35
ft.
(10.67
45
ft.
(13.72
to
overturn.
to
m)
m)
m)
m)
m)
m)
lift suspended
at
14.
lfthe
load to be lifted exceeds the capacity ofthe machine
configuration:
1.
Move the machine closer to the load
will be within the allowable load chart specifications.
11.
Divide the load into smaller pieces.
m.
Get a larger machine capable
15.
Always move a load
not obstructed. Keep the boom at or below horizontal, with the load close to the
ground.
16.
Tilt the
the load.
forks
back towards the machine slightly during travel to ensure stability
so
that you have maximum machine stability and visibility
1-10
of
so
hand ling the load.
for
the given
that the weight ofthe load
is
of
Page 15
[LtROUGH TERRAIN FORK LIFT SAFETY
C OPERATION SAFETY D
17.
Inspect the path
18.
Traveling on slopes!
19.
Always position
mode.
20. Always position the machine and set the park brake before lifting a load.
21. Do not allow riders
of
travel before beginning movement. Avoid holes and dropoffs.
grades.
1.
Ascend
ll.
When loaded,
ill.
When unloaded,travel with the attachment downhill.
Iv.
Avoid
and
descend slowly and with caution.
always
turning, travel straight
all
wheels in line with the machine before switching the steering
on
the machine or
travel with the load uphill.
up
and
down.
forks.
Lt]
22.
Do not transport or lift personnel into position with this
23. When leaving
the
operator's station:
1.
Place the directional controls in neutral.
n.
Apply the parking brake.
ill.
Lower the attachment to the ground.
forklift.
1-11
Page 16
Page 17
SECTION
2
GENERAL
SAFETY
2
-1
Page 18
TABLE OF CONTENTS
SECTION 2 - GENERAL SAFETY
General Safety Procedures
Jump Starting
Proper Load Chart
Use
2-3
2-8
2-9
2-2
Page 19
GENERAL SAFETY PROCEDURES
SAFETY ALERT
Stop and take time to read
all safety messages to avoid injury and/or death.
SYMBOL
ALL
safety alert messages. Follow
LLWARNING
ALWAYS wear eye protection and personal safety equipment.
THE OPERATOR
The operator must be fully trained and qualified to operate this
machine.
Before start-up or machine operation, the operator must learn
the location and purpose
1.
Controls
2.
Instruments
3.
Indicator lights
4.
Safety and instruction labels
of
the:
ACCIDENT PREVENTION
Use protective clothing and safety equipment. Always use
approved safety equipment such
safety hard hats, goggles and ear protection when necessary.
Wear protective clothing that is snug and belted where
required.
as:
gloves, safety boots,
FIRE PREVENTION/FIRST AID
Install a first-aid kit and fire extinguisher in the operator's cab.
KEEP
TIlE
FIRST-AID KITandFIREEXTINGUISHER
properly maintained. Follow the instructions provided with the
first-aid kit and fire extinguisher.
2-3
Page 20
GENERAL
SAFETY
WELDING PRECAUTIONS
ffiCAUTION
Any unauthorized welding
possible personal injury.
member. All unauthorized welding will void the warranty.
can
cause structural failure or
DO
NOT
weld
on
any structural
PROCEDURES
HAND HOLDS
AND
STEPS
ffiWARNING
Slips and falls can cause serious injury.
When getting
point contact with steps and hand rails while facing the machine.
DO
NOT
NEVER jump on or
Be careful
handrails when getting on and
ALWAYS
REFUELING
Fires can cause death or severe personal injury.
on
and
off
the machine, always maintain a three
use the steering wheel or any other controls as handrails.
off
the machine.
of
slippery conditions on platforms, steps and
off
the machine.
shut
off
the engine before leaving the operator's station.
&
WARNING
c
Handle fuel with care.
machine while smoking
ALWAYS
fuel tank outdoors.
Prevent fires
debris.
stop the engine before refueling the machine. Fill the
by
ALWAYS
It
keeping the machine clean
clean up spilled fuel.
is highly flammable. DO
or
when near open flames or sparks.
NOT
of
trash, grease and
refuel the
2-4
Page 21
GENERAL
SAFETY
PROCEDURES
HYDRAULIC
SAFETY
~WARNING
Hot hydraulic oil can cause severe bums. DO NOT work on
the hydraulic system
120 degrees
Before ANYONE works on the hydraulic system:
1.
Lower the
2.
Support the
3.
Shutdown the engine.
4.
Remove the key from the ignition.
5.
Clean the area
F.
if
the oil temperature exceeds
(49 degrees C).
boom
to the horizontal position.
boom
to avoid unintentional lowering.
arOlUld
the oil reservoir cap (A).
FLUIDS UNDER PRESSURE
~WARNING
Escaping fluid under pressure can penetrate the skin and can
cause serious personal injury.
Use a piece
DO NOT use hands. Before disconnecting hydraulic lines, be
sure to relieve all line pressure. Before applying pressure to the
system, be sure that all cOlmections are tight. DO NOT apply
pressure to a damaged line, hose or fitting.
If
injured
medical treatment must be administered immediately. A serious
infection or reaction can result without proper medical
treatment.
of
cardboard or paper to search for leaks.
by
escaping fluid, see a doctor at once. Proper
SERVICE TIRES SAFELY
ffiWARNING
An
improperly mOlmted over-pressurized tire can result
explosion causing possible personal injury. An inflation cage
or other safety device must
DO NOT attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
have the proper qualifications to perform the
dealer or qualified repair service perform the repair.
be
used during tire inflation.
If
you do not
job
in
tire
have your
2-5
Page 22
GENERAL
SAFETY
GENERAL
ffi
USE
SEAT
Always wear the seat belt while operating the machine to
reduce the risk
BELT
of
personal injury.
ffi
PRACTICE
Unauthorized modifications to the machine may impair the
safety, machine function and/or affect machine life.
ALWAYS use a safety support or brace when working on,
under, or around the machine or forks.
SAFE
CAUTION
CAUTION
MAINTENANCE
SAFETY
PROCEDURES
(
,
<
j
--'
,.
'"
..
<
~
,.,
':1
".
:'5
.1
,~
'"
'-'
.,.
...
:;
l-
i;
<C
C
r
DO
NOT
adjust or lubricate the machine while it is
SHUT
OFF
the engine and
working on the machine unless maintenance instructions
require the engine to be running.
REPLACE
NEVER
all the shields and guards after servicing.
use the machine as a platform for lifting persomleL
ffi
LOCKOUT
the ignition while
CAUTION
in
motion.
BOOMSAFETY
DO
NOT
enter the
when the forks are
(See
diagram
Serious personal injury could result
unexpectedly drop.
ANY work is perfonned in the
Before
the boom must be
must be resting
DANGER
off
at
right for DANGERAREA).
COMPLETELY
on
the ground.
AREA
the ground or while the engine is running.
under or around the
if
DANGER
lowered and the forks
the boom should
AREA
boom
2-6
Page 23
it
GENERAL SAFETY
GENERAL SAFETY PROCEDURES
AVOID ELECTRICAL POWER LINES
& DANGER
REQUIRED CLEARANCE
OPERATIONNEARHIGHVOLTAGEPOWERLlNESAND
OPERATION
OR
MAST
IN
TRANSIT
LOWERED.
FOR
NORMAL VOLTAGE
WITH
NO
LOAD AND BOOM
IN
it
Normal Voltage, kV
(Phase to Phase)
Operation Near High Voltage Power Lines
to
50
50
to
Over
Over 200 to
Over
Over
Over
Operation
Always remain completely inside the cab enclosure while
operating the machine.
in
to
Over 0.75
Over 50 to 345
Over 345 to
Over
200
350
350t0500
500
to
750
750to
1000
Transit With No Load and
0.75
to
50
750
750to
1000
LL
WARNING
Minimum Required
Clearance, ft. (m)
10(3.05)
15(4.60)
20(6.10)
25(7.62)
35(10.67)
45 (13.72)
Boom
Lowered
4(1.22)
6«1.83)
10(3.05)
16(4.87)
20(6.10)
LL
WARNING
Never operate this machine under the influence
alcohol and/or medication which can cause drowsiness.
&
WARNING
Never transport or lift personnel into position with this
forklift.
It
is not designed
as
a personnel lifting device.
of
drugs,
2-7
Page 24
GENERAL
JUMP STARTING
Location: The battery is located under the fuel tank I battery
box cover (A).
JUMP STARTING
Jump starting at the battery or battery replacement is required
when the battery is discharged to the point where the battery
will not crank the starter.
& WARNING
Never jump start the machine directly to the starter or the starter
solenoid. Serious injury or death could result from the machine
moving forward
or
backward.
SAFETY
A
& WARNING
To avoid personal injury when jump starting with another
machine, be certain that the machines are not touching. Never
jump start a frozen battery as it will explode. Keep sparks and
flames away from the battery. Lead acid batteries generate
explosive gases when charging. Wear safety glasses when
working near batteries.
12
The booster battery must be a
for jump starting must have a negative ground electrical system.
To jump start the machine, proceed as follows:
1.
COlU1ect
(+) post
2.
Connect the other end
positive
3.
Connect one end
negative
4.
Make the fmal cable connection to the engine block
the furthest ground point away from the battery.
the positive (+) jumper cable to the positive
of
the discharged battery.
(+) post
(-) post
of
the booster battery.
of
the second jumper cable to the
of
the booster battery.
volt type. The machine used
of
the same jumper cable to the
or
5.
Start the engine.
6.
Remove the jlUllper cables in the reverse order
comlection (i.e. negative cable ground connection first, etc.)
oftheir
2-8
Page 25
LL
GENERAL SAFETY
PROPER LOAD CHART USE
& WARNING
NEVER raise a load and drive to position
machine to turnover. When placing a load, always move a
loaded machine with the boom angle indicator (B) at
or less. When the machine is as close as possible to where the
load needs to be placed, set the parking brake, raise the load,
then place the load into position.
it.
This can cause the
0 degrees
LL
B
of
The load chart shows the operating limits
maintained and operated machine. To use the load chart the
operator must know the weight
and "up" it is to be placed.
the load chart, three options can be used:
1.
Move the machine closer to the load so that the weight
the load will fall within the load chart specifications.
2.
Divide the load into smaller pieces so that each piece falls
into load chart specifications.
3. Get a larger machine capable
specifications.
of
the load and how far "out"
If
the load is heavier than stated on
of
handling the load within
a properly
of
2-9
Page 26
GENERAL
TEREX HANDLERS
SAFETY
PROPER LOAD CHART USE
TH636C
FrET
---
METEF~·-·(7
..
:)2)
1
(I;;,
1(j'1(4.~::;(<;.;)
LIFT
CAPACITY
CHART I TH636C
TEREX HANDLERS
TH644C
LIFT
CAPACITY
CHART!
TH644C
2-10
Page 27
~
GENERAL SAFETY
PROPER LOAD CHART USE
TH842C
~
TEREX
HANDLERS
TH844C
LIFT
CAPACITY
CHART / TH842C
(1 ;
TEREX
( 61
',~'li;J!I;:'Plt
p,
N
HANDLERS
r\'f~V
~
[--:/\MF
WITH
2-11
Page 28
Page 29
SECTION 3
CONTROLS
AND
INSTRUMENTS
3-1
Page 30
TABLE OF CONTENTS
SECTION 3 - CONTROLS
Operator's Compartment
Joystick Control Functions
Joystick Control Functions (Button Pushed)
Service Brakes
Parking Brake
Frame Sway Control
Gauges
Hydraulic Pump Destroke Button
AND
INSTRUMENTS
3-3
3-4
3-5
3-6
3-6
3-7
3-8
3-8
Steering
Transmission
3-9
3-9
3-2
Page 31
~
CONTROLS
AND
INSTRUMENTS
]
C
Accelerator Pedal
l.
Joystick 4-way Controller
2.
Transmission Control Lever
3.
Steering Selector
4.
Service Brake Pedal
5.
Parking Brake Warning Light
6.
Load Chart
7.
OPERATOR'S COMPARTMENT
8.
Hourmeter
9.
Gauges
10.
Machine Level Gauge
Plug
/12
11.
12.
Seat
Frame Level Switch
13.
14.
Seat Belt
Volt Access.
Parking Brake Handle
15.
Pump
16.
17.
18.
19.
20.
21.
Off
Windshield Wiper
Ignition Switch
Auxiliary Hydraulics
Steering Wheel
Headlight Switch
Button
24
20
D
22.
Heater Switch
Plug / Turn Signal Wires
23.
24.
Interior Rear View Mirror
25.
Frt.Axle Differential Lock
2
7
13
21
22
3
23
DASH
PANEL
17 19 18
VIEW
11
ELECTRIC
12
VOLT
FRONT
ETHER
ACCESSORY
AXLE
DIFFERENTIAL
AID
&
PLUG
LOCK
14
FUSE
PANEL
VIEW
3-3
Page 32
(
A -
BoomDown
B -
BoomUp
CONTROLS
AND
INSTRUMENTS
U JOYSTICK CONTROL FUNCTIONS D
B
i -
i
]
C -
D -
Boom
Out
BoomIn
o
...
B
A
... C
E -
Boom
Down and Out
F - Boom Up and In
G - Boom Up and Out
H - Boom Down and
In
3-4
Page 33
[
CONTROLS
AND
INSTRUMENTS
]
fi
A - TiltDown
B - TiltBack
JOYSTICK CONTROL FUNCTIONS (BUTTON PUSHED) D
B
~
A
B
3-5
Page 34
SERVICE BRAKES
The brake pedal is the operator's control for the service brakes.
Pushing the service brake pedal (A) activates the service
brakes for all four wheels.
The brakes should
machine movement.
be
applied during normal operation to stop
PARKING BRAKE
&
WARNING
Failure to set the parking brake before leaving the machine may
result in unintended machine movement and possible injury or
death and/or damage to the machine or property.
The parking brake should
gets
off
the machine. To engage the parking brake, move
handle (B) to the "BRAKE ON" position.
be
engaged anytime the operator
B
3-6
Page 35
CONTROLS
AND
INSTRUMENTS
FRAME
SWAY
Lt,WARNING
Always ensure that the machine level indicator (D) is at zero (0)
degrees before raising the boom. Raising the
unlevel machine
in
injury
or
death.
may
cause the machine to overturn, resulting
boom
with an
Lt,WARNING
Use the frame sway control to level the machine only when the
boom
angle indicator is at 0 degrees or less. Using the frame
sway control when the angle indicator is more than
may
cause the machine to overturn, resulting in injury
The
frame sway control (C)
frame sway control is used in conjunction with the machine
level indicator (D) located in the center
that the interior rear view mirror is mounted on. The sway
control switch is either toggled to the left or right depending
on
the particular requirement.
is
located
on
the dash panel. The
of
the cross support
0 degrees
or
death.
CONTROL
c
D
3-7
Page 36
The following gauges are used to monitor the
machine:
GAUGES
1 -Fuel Level
Oil Temperature, Powershift Transmission
2 -
3 -
Oil Pressure, Powershift Transmission
4 - Voltmeter
5 -Water Temperature, Engine
Oil Pressure, Engine
6 -
HYDRAULIC PUMP DE
&
DANGER
Depressing the pump destroke button while operating the machine
will cause an immediate loss
creating a very dangerous situation. Hydraulic functions that
will be affected are:
and RETRACT,
FORK
PARKING
functions will operate as long as the button is depressed. The
service brakes will continue to function
has a sufficient gas charge.
of
hydraulic power, possibly
TILT, LIFT,
BRAKE
BOOM
and SWAY. None
if
the accumulator backup
EXTEND
of
these
STROKE
1)
(
6)
\,
BUTTON
A
/-
'\
';1
(
\
c)
\
I.)
((
/
,J
\ \
\
2 ) I
/ /
5
( 3 )
()
) (
The pump de stroke button (A) is the black push button
switch located
on
the dash panel.
For example, when starting the machine for the frrst time on a
degree
F.
day, depress the pump destroke button while starting
the engine. Continue to depress the button for
after the engine starts.
Once the engine is rumring smoothly,
15
to 20 seconds
release the button and the hydraulic pump will engage.
Depressing the pump destroke button will not be required for
all other stmis
to
cool completely.
of
the day, unless the engine has been allowed
30
3-8
..
I .
,
o
I I
(
\'
Page 37
STEERING
In addition to the steering wheel, the machine has another
steering control, the steering selector switch.
The steering selector switch (B) is a three-position switch.
The three positions are: 4-wheel, 2-wheel , and oblique.
Switch positions are selected and function
as
follows:
4-WHEEL
2-WHEEL
OBLIQUE
Before changing steering selections, make sure all four wheels
are
in
line. Failure to align the wheels to the proper settings
before changing steering positions
This may result in injury to personnel andlor damage to the
machine
(CRAB)
or
property.
Handle right
Handle directly centered
Handle left
Lt
CAUTION
of
center
of
center
may
cause haphazard steering.
TRANSMISSION
The transmission control (C) has one lever that controls both
directional and speed requirements.
of
the steering column.
It
is located on the left side
To shift into Forward gear gently pull the lever toward you and
move the lever upward.
To shift into Neutral move the lever to the center position.
To shift into Reverse gear gently pull the lever toward you and
tl1e
move
To shift into a lower speed rotate the lever clockwise.
To shift into a higher speed rotate the lever counter-clockwise.
When shifting the transmission from forward to reverse while
the machine is in motion the transmission control (C) must be
in
Forward / 1st
Forward/2nd Medium speed/Medium torque
Forward /3rd High speed/Low torque
lever downward.
1 st or 2nd gear only.
Low speed/High torque
3-9
c
Page 38
Page 39
....
I
I
SECTION
4
OPERATION
4 -1
Page 40
TABLE OF CONTENTS
SECTION
Operation And Safety Guidelines
Before Starting The Engine
Starting The
Before Operating The Forklift
Transporting A Load
Placing A Load
4 - OPERATION
Engine
4-3
4-4
4-9
4-11
4-15
4-17
4-2
Page 41
OPERATION
OPERATION AND SAFETY GUIDELINES
~WARNING
Your safety and the safety
Know the positions and functions
Understand the speed, braking, steering, stability, and load chart characteristics
Operator's Manual and ask questions
fully understand, and follow these operation and safety guidelines.
1.
DO NOT operate this machine while people are under
Falling objects from the forks or attachment may cause serious injury or death.
2. ALWAYS remain completely within the cab enclosure while operating this machine. Falling debris can cause serious
personal injury
3.
NEVER
extend a load beyond the load chart band. Machine
or
of
those around you depends upon you using care and judgement in the operation
of
all controls before attempting to operate this machine. All equipment has limitations.
of
this machine before operating.
of
your supervisor until you know the machine's limitations.
or
death.
near an elevated
tum
over, component damage, injury or death could occur.
boom
whether the boom is loaded or unloaded.
of
this equipment.
Read
It
is very important to read,
the
4. ABSOLUTELY
5.
NEVER
6.
INSPECT and clear the working area
obstructions cannot
7.
DO
NOT
pressurized coolant.
8.
ALWAYS wear the seat belt when operating this machine.
9.
ALWAYS inspect the machine daily. Check for leaks, worn hoses, loose belts, or anything out
and/or replace any worn, damaged or leaking parts immediately. Failure to do so can cause injury or death.
10.
CHECK
11.
CHECK
back-up alarm, and
12.
DO
NOT
13.
DO NOT attempt to start the engine
14.
CARRY A LOAD so that you have maximum machine stability and visibility is
NO
RIDERS SHOULD BE ALLOWED ON TIDS MACIDNE
lower a maximum load before retracting it. Machine turn over, component damage, injury or death could occur.
of
any obstructions (rocks, fence, wire, etc.) that could cause machine damage.
be
cleared, mark the obstructions with a stake or other marker that will
check the engine coolant level
to be sure that all guards and screens are secure and in their proper place.
to be sure that all safety devices such as parking brake, service brake, level gauge, neutral start safety switch,
hom
are functioning properly. Always make sure
travel on
tenain
or
in dangerous areas that could cause the machine to tip over.
if
the engine has recently been run. Injury could occur from escaping hot
minor
by
towing or pushing. Damage to the powershift transmission could result.
OR
ATTACHMENTS.
be
clearly visible to the operator.
ofthe
is adjusted properly.
not
obstructed.
If
ordinary. Repair
IS.
ALWAYS level the machine as indicated on the machine level indicator before raising boom. Raising the
unlevel machine may cause the machine to overturn causing injury or death.
16.
USE the frame sway control to level the machine only when the boom position is horizontal
sway control when the
17.
DO
NOT depress the punlP de stroke button while operating the machine. This button should be used only during cold start
ups. Depressing the button while operating the machine will cause an immediate loss
affect fork tilt, lift,
the accumulator backup has a sufficient gas charge.
boom
is higher than a horizontal position may cause the machine to overturn causing injury or death.
boom
extend and retract, sway and all other hydraulic functions. Brakes will continue to function
4-3
or
lower. Using the frame
of
hydraulic power that will
boom
with
an
if
Page 42
BEFORE· STARTING THE ENGINE
& WARNING
DO NOT perform any procedures in this section, "BEFORE
STARTING ENGINE", unless the machine's engine is turned
and the parking brake is applied and the engine is cool. Failure
to do so may result
equipment.
Walk around the machine and check for any parts that are
missing, worn, damaged,
damaged parts.
in
serious injury, death or damage to the
or
leaking. Repair and/or replace
off
CHECK
NOTE: Refer
ENGINE
Location: Dipstick (A).
To
Check: The machine must be level.
specifications and capacities.
OIL
LEVEL
Check when the engine is cold.
Remove the dipstick from the engine.
Oil should read between the add and the
full marks.
Replace the dipstick.
to
page 5-24
of
this manual for the proper oil
John Deere
A
4-4
Page 43
BEFORE STARTING THE ENGINE
~WARNING
DO
NOT
check the coolant level
recently. Injury
may
occur from hot escaping pressurized coolant.
CHECKENGINECOOLANTLEVEL
Location: Tank cap (B).
To
Check: Coolant should be visible in the top
ifthe
engine has been run
OPERATION
B
of
the tank.
NOTE:
NOTE: All John Deere engines require "John Deere Cool Gard"
OPEN
Location:
To
WATER
Open:
If
coo/allt needs
mixture
antifreeze.
to
be added
Available
to
of
fi'011l
be added fill with a 50/50
water alld ethylene-glycol based
(-34 degrees
to
coolant whenever changing or adding coolant.
you local John Deere
SEPARATOR
Water separator filter (C).
Shut
off
the engine.
Tum
the valve
F)
on
the bottom
dealer.
of
the water
separator filter counterclockwise.
Drain
until
clear fuel is present.
John Deere
NOTE:
Retighten the valve.
If
more than 2
is
filter
replacement
oz.
required
on
of
file! are drained, refilling
to
prevent hard starting. Refer
page 5-19
of
this manual.
of
to
the
filter
4-5
Page 44
BEFORE STARTING THE ENGINE
CHECK
HYDRAULIC
Location:
To
Check:
NOTE: Refer
specifications and capacities.
OIL LEVEL
Sight glass (A). Behind the rear panel.
Move
the machine to level ground.
Level the frame.
Completely retract the boom.
Position the forks level.
Lower the
Oil
to
page 5-24
should
boom
to
the ground.
be
visible
of
112
way in the sight glass.
this manual for the proper oil
A
INSPECT
Location:
To Check:
Guideline:
AIR
CLEANER
Air cleaner assembly.
Remove the rear
elements.
Inspect the filter elements for contamination.
Inspect the tubing going to the filter body
from the engine for cracks or leaks. Inspect
the air cleaner body and gaskets for cracks
or leaks.
of
the canister, remove the
LtWARNING
Due to various operating conditions, the air cleaner's
be
elements should
requires.
changed
as
often as the environment
4-6
Page 45
BEFORE STARTING THE ENGINE
CHECK
Location: Dipstick (B)
To
NOTE: Refer to page 5-24
TRANSMISSION OIL LEVEL
Check: Level the machine.
Place the transmission control in neutral.
Set the parking brake.
The engine must
Bring the transmission oil temperature to a
minimum
Remove the dipstick. The oil level should
be between the add and full marks.
Replace the dipstick.
specifications and capacities.
of
be
running to check.
180 degrees
of
this manual for the proper oil
F.
B
& WARNING
Serious personal injury can result from a loose or damaged fan.
on
Never pry
failure.
CHECK
To
Check: Visually inspect the cooling fan (C) for cracks,
a fan because this may cause fan damage and/or
ENGINE
FAN
loose bolts, bent or loose blades etc.
c
4-7
Page 46
BEFORE STARTING THE ENGINE
CHECK
Location:
To
Setting:
All tires require a calcium chloride ballast
filling to be operated safely. The loss
machine stability and cause a rollover hazard resulting
damage, injury or death.
TIRE FOR
Check: Check the tire pressure with the tire cold and a
PROPER
Wheel ends.
properly functioning air pressure gauge. Position
the valve stem (A) to the top
50
PSI.
&
INFLATION
DANGER
of
ballast can affect
ofthe
tire.
or
an optional foam
A
in
4-8
Page 47
OPERATION
STARTING THE ENGINE
&
DANGER
Any problems discovered in the steps prior to "BEFORE
STARTING
machine
NEVER
the operator's compartment, the parking brake (B)
position and the transmission control (C) in the neutral
position. Attempting to start the machine from outside the
operator's compartment may result in property damage, serious
injury
THE
ENGINE" should be
is
started.
&
DANGER
attempt to start the machine without being seated in
or
death.
conected
before the
in
the
on
~--
&
DANGER
If
the machine should start with the transmission control lever
in
gear, stop operation at once
(C)
injmy
or
death
may
occur. Have a qualified service technician
repair the machine.
in
Insert the ignition key
clockwise until the engine starts. Release the key when the
engine starts.
the ignition switch (D). Rotate the key
or
property damage, serious
o
4-9
D
Page 48
OPERATION
STARTING THE ENGINE
LtCAUTION
If
the engine fails to start within 30 seconds release the key,
wait at least 2 minutes to allow the starter motor to cool before
trying again.
trouble shoot and correct the problem.
the engine is mnning. This may cause damage to the starter
motor.
Attempting to start the engine
machine will result in damage to the powershift transmission
and will not start the engine!
could cause personal injury.
If
the engine fails to start after four attempts,
DO NOT turn the key
LtCAUTION
by
towing or pushing the
It
also is an unsafe practice that
if
4-10
Page 49
BEFORE OPERATING THE FORKLIFT
~CAUTION
If
any gauge reading does not fall within the set tolerances the
machine must be repaired before operation.
Check
the dash mounted gauges for logical readings.
112
to
180°F
240
to
12
to
180°F
40to
Full
to
280
14
to
80
200°F
PSI
200°F
PSI
(1) Fuel
'fransmission
(2)
Transmission
(3)
Volt
(4)
Engine
(5)
Engine
(6)
Water
Oil
PSI
Oil Temp.
Oil
PSI.
Temp.
1
-."-.-----
..
~
...
\,
\
!
2
j
)
3
'.
_ .. -
0
,
"
)
(
5
I
,
(
\
4
!
,
"
Operate the joystick controller momentarily
in
all directions.
STANDARD
H t E
'
0..
1-.··.
":-:-:~3/r-~
.'.?f
.....
-.~-
:::~
...
:-.~.
----
~$]J11]
I
I
"·l
..
I G
.....
[
I~~~~~I
BlJTION DEPRESSED FUNCTIONS
f.)·'.,'.}J'II'1
A
..
B
A
t
JOYSTICK
/
"
"-
...
FUNCTIONS
A - Boom
B -
Boom
C -
Boom
o
c
-Boom
E - Boom Down and Out
F - Boom
G - Boom
H - Boom
A -
17lt
B - Tilt
T
B
Down
Up
Ollt
In
Up
and In
Up
and Out
Down
Forward
Back
and
In
4
-11
Page 50
OPERATION
BEFORE OPERATING THE FORKLIFT
Operate the frame sway control (A) momentarily right and left.
]
Check the steering operation by turning the steering wheel (B)
114
tum
approximately
tires are not aligned properly, straighten the rear wheels with
the steeling selector valve (C) in the "4 wheel" position.
the steering selector valve to the "2 wheel" position. Bring the
front
tires into aligmnent with the rear tires. Place the steering
selector valve back into the "4 wheel" position.
in each direction.
lfthe
front and rear
Move
4-12
B
Page 51
OPERATION
BEFORE OPERATING THE FORKLIFT
ffiDANGER
Any problems with the service brakes or the parking brake
found while conducting the daily inspection should be
corrected inunediately. Failure to do so could result in injury or
death.
Activate the transmission using the transmission control
lever (D). As soon as the machine starts to move, apply the
service brake pedal. The machine should stop immediately.
Apply the parking brake (E). The machine should not
to be driven. Release the parking brake.
E
be
D
able
4-13
Page 52
OPERATION
BEFORE OPERATING THE FORKLIFT
ffiDANGER
Never operate the machine
so may result in serious injury
Place the transmission control lever (A) in reverse. The backup
alarm should sound.
alarm repaired immediately.
with
a faulty backup alarm. Doing
or
death.
If
it does not sound, have the backup
both
Check and adjust
exterior right hand mirror (C)
the interior rear view mirror (B) and the
if
required.
A
B
c
4-14
Page 53
OPERATION
TRANSPORTING A LOAD
~WARNING
Transporting a load with the boom extended and the boom
angle indicator arrow (D) reading more than
cause a roll over hazard.
0 degrees could
& WARNING
At no time should any load be suspended from the forks by
use
of
chains, ropes, straps etc.
the use
procedures should always be followed.
of
a truss (jib)
boom
If
a load must be suspended
is mandatory. Proper rigging
The forks should always be tilted back slightly during
transportation to ensure stability
The load should be kept
while traveling. Always move a loaded machine with the boom
angle indicator (D) at
as
0 degrees or less.
of
the load.
low to the ground as possible
D
4-15
Page 54
TRANSPORTING A LOAD
& WARNING
Slower speeds should be used whenever transporting a load.
Always bring the machine to a complete stop before reversing
the transmission control lever (A). Failure to do so can result in
damage to the load, the machine and/or bystanders.
A
Always keep the boom retracted to ensure greater stability.
Always place the load in the center and completely against the
of
back
IMPORTANT:
ments for prying wedged or frozen loads free. Damage to the
load, pallet and/or machine could result.
the fork frame. By doing so greater stability will result.
Never attempt to use the forks and/or attach-
4-16
Page 55
OPERATION
PLACING A LOAD
Lt WARNING
Do not sway the machine with the boom angle indicator arrow
(B) at more than 0 degrees.
over hazard which may result
Lt
Always apply the parking brake (C) before lifting and/or
placing a load. Failure to do so could allow the machine to roll
over which
may
result in injury or death.
it
Always bring the machine to a complete stop before applying
the parking brake (C). Failure to do so will damage the parking
brake disc packs, which may void the axle warranty.
Before placing a load, the frame should be leveled. This can be
done
by
the use
on the lower right hand side
operator.
of
the switch labeled sway control (D) located
By
doing so you could cause a roll
in
injury or death.
DANGER
CAUTION
of
the dash panel in front
of
the
B
Adjust the sway control (D) until the indicator ball on the level
gauge (E) is
011 the 0 degree mark.
4-17
Page 56
&
Traveling with a reading
angle indicator arrow (A)
DANGER
of
more than 0 degress
may
cause a rollover hazard.
PLACING A LOAD
on
the boom
A
Gradually move the 4-way controller towards the letter (B) to
lift the load vertically. Hold the controller back until the
required height has been achieved.
Gradually move the 4-way controller towards the letter (E) to
bring the load
load until the weight is completely
Gradually move the 4-way controller towards the letter (F) to
bring the
load. Once the forks are clear
DOWN
boom
and
OUT
into final position. Lower the
off
the forks.
UP
and IN. This will bring the forks out
ofload
the
boom
ofthe
can be lowered.
4-18
Page 57
OPERATION
PLACING A LOAD
TH644C, TH842C, TH844C ONLY!
When placing a load with the Model TH644C,
TH842C, or the TH844C the rear axle stabilizing
cylinders need to be taken into consideration. When
the boom reaches an angle
frame leveling and transmission functions are disabled
and the rear axle stabilizing cylinders become locked.
This
functions.
and enable the transmission functions, lower the
DOES NOT affect any boom or fork
To
unlock the rear axle stabilizing cylinders
of
60 DEGREES, all
boom to a position less than
60
degrees.
4-19
Page 58
Page 59
SECTIONS
MAINTENANCE PROCEDURES
5-1
Page 60
TABLE
OF
CONTENTS
SECTION 5 - MAINTENANCE PROCEDURES
General Safety Practices
Service futervals
Required Grease futervals
Grease Fitting Locations
Daily Maintenance
50
Hour
Maintenance Procedures
100
Hour
Maintenance Procedures
250
Hour Maintenance Procedures
500
Hour
Maintenance Procedures
750
Hour Maintenance Procedures
1000 Hour Maintenance Procedures
Procedures
5-3
5-5
5-6
5-7
5-8
5-12
5-15
5-17
5-18
5-20
5-21
2000
Hour Maintenance Procedures
Filter Guide
Recommended Fluids
Hydraulic
Pressure Settings
And
Capacities
5-2
5-23
5-24
5-24
5-25
Page 61
MAINTENANCE PROCEDURES
GENERAL SAFETY PRACTICES
BEFORE SERVICING
Read the entire Maintenance Procedure Section.
Familiarize yourself with all the safety precautions listed in
Sections 1
Pay close attention to all the safety alert symbols.
Be sure you understand the procedures detailed in this
section.
Wear personal protective equipment.
&
2.
Remove
Move the machine to a safe level work place.
Lower the
Shut down the machine.
Remove the key
Be careful not to spill fuels and lubricants.
Do not fill or
hot. Doing so could cause a fire and/or an explosion.
Do not smoke while refueling or working with fuel to avoid a
fire and/or explosion.
IMPORTANT! Always clean up spilled fuel and/or lubricants
to avoid polluting the earth.
lings and jewelry.
boom
and support all raised equipment.
ii-om
the ignition.
refhel the fuel tank while the engine is running or
5-3
Page 62
MAINTENANCE PROCEDURES
GENERAL SAFETY PRACTICES
HYDRAULIC
SAFETY
~WARNING
Hot hydraulic oil can cause severe bums. DO NOT work on
the hydraulic system
120 degrees
Before ANYONE works on the hydraulic system:
1.
Lower the
2.
SuppOli the
3.
Shutdown the engine.
4.
Remove the key from the ignition.
5.
Clean the area around the oil reservoir cap (A).
F.
FLUID UNDER
if
the oil system temperature exceeds
(49 degrees C.)
boom
to the horizontal position.
boom
to avoid unintentional lowering.
PRESSURE
ffi WARNING
Escaping fluid under pressure can penetrate the skin and can
cause serious personal injury.
Use a piece
DO NOT use hands! Before disconnecting hydraulic lines, be
sure to relieve all line pressure. Before applying pressure to the
system, be sure that all cOlmections are tight. DO NOT apply
pressure to a damaged line, hose or fitting.
of
cardboard or paper to search for leaks.
If
injured
medical treatment must
serious infection or reaction can result without proper
medical treatment.
by
escaping flnid, see a doctor at once. Proper
be
administered immediately. A
WELDING PRECAUTIONS
ffi WARNING
DO NOT weld on any structural member. Any unauthorized
welding can cause structural failure or possible personal
injury. All unauthorized welding
void the machine warranty.
Before perfonmng any authorized welding, be sure to disconnect the positive lead from the battery. Properly attach the
ground cable
welded. Failure to do so can cause electrical system damage.
of
the welder to the frame member that is being
or
repair procedures will
5-4
Page 63
MAINTENANCE PROCEDURES
CHECK
ENGINE
OIL
CHECK
COOLANT LEVEL
CHANGE HYDRAULIC
RETURN FILTER
CHANGE ENGINE
INSPECT ALTERNATOR BELT
ENGINE
CHANGE DIFFERENTIAL
OIL
(AXLE)
REPLACE FUEL FILTERS
COOLANT CONCENTRATION
CHECK
OPEN WATERSEPERATOR
CHECK
FLUSH AND PRESSURE
COOLING SYSTEM
CHECK
REPLACE TRANSMISSION
OIL
& FILTER
CHECK
CHANGE PLANETARY
REDUCTION
INSPECT AIR CLEANER
AND
AIR CLEANER SYSTEM
CUECK
CHECK
RETURN FILTER ELEMENT
ELEMENT
OIL
VALVE
ADJUSTMENT
ENGINE
FAN
TffiE
INFLATION
TRANSMISSION
AXLE
OIL
LEVELS
OIL
(AXLE)
HYDRAULIC
HYDRAULIC
OIL
& FILTER
TEST
OIL
LEVEL
DAILY
•
•
•
•
•
•
•
•
•
SERVICE INTERVALS
50Hrs.
.*
lOOHrs.
250Hrs. 500 Hrs. 750 Hrs.
•
.*
*
•
.*
.**
•
.*
•
•
•
•
•
•
D
1000Hrs. 2000 Hrs.
•
.*
•
* *
•
For procedures to perform the above listed items turn to the following pages: 5-8 thru 5-23.
For initial break-in period only.
*
* * For initiall 00 hours only.
John Deere engines require valve adjustment every 2000 hours only.
***
5-5
Page 64
REQUIRED GREASE INTERVALS
LOCATION
SMALL BOOM ROLLERS (4)
BASE END TILT CYLINDER
HEAD END TILT CYLINDER
FORK FRAME PIVOT PIN (2)
HEAD END LIFT CYLINDER (2)
BASE END LIFT CYLINDER (2)
FRONT DRJVESHAFT (3)
REAR DRJVESHAFT (3)
BASE END
HEAD END
BOOM PIVOT (2)
REAR AXLE TRUNlONS (4)
fRONT
FRONT AXLE
REAR AXLE PIVOT (2)
MIDDLE BOOM ROLLERS (4)
BASE END REAR LOCK UP
CYLINDER (2) 644C-842C-844C ONLY
HEAD END REAR LOCK
CYLINDER (2) 644C-842C-844C ONLY
SWAY
CYLINDER (2)
SWAY
CYLINDER (2)
AXLE TRUNJONS (4)
PNOT
(2)
UP
DAILY
•
•
•
•
•
•
•
•
•
50Hrs. 250Hrs
•
•
•
•
•
•
•
•
•
500Hrs.
5-6
Page 65
GREASE FITTING LOCATIONS
TH636C
TH644C & TH842C & TH844C
, I
1 1 1 1 I
5-7
Page 66
DAILY MAINTENANCE
Perform "BEFORE SERVICING PROCEDURES" before
attempting any
Perform "BEFORE OPERATING CHECKS" before attempting
any
of
the following checks.
of
the following checks.
John Deere
CHECK
Location:
To
ENGINE
Check:
OIL
Dipstick ( A).
The machine must
Check when the engine is cold.
Remove the dipstick from the engine.
The oil level should be between the add
and full marks.
Replace the dipstick.
NOTE: Refer
to
specifications and capacities.
page 5-24
& WARNING
Do
not check the coolant level
fUn.
Injury may occur from
LEVEL
be
level.
of
this manual for the proper oil
if
the engine has recently
hot
escaping pressurized coolant.
A
been
B
CHECKENGINECOOLANTLEVEL
Location:
To
Check:
NOTE:
Radiator cap (B).
Coolant should
If
coolant needs
antifreeze mix (-34 degrees
nitrite-molybdate based Supplemental Coolant Additive.
additive is required
liner erosion and pitting,
(lntiji'eeze or cooling system damage due to silicate dropout
can occur.
Contact your local John Deere dealer for an approved
antiji'eeze and Supplemental Coolant Additive,
be
visible in the top
to
be
added, jill with a
F)
with
to
prevent engine damage due
Do
not use high-silicate (lutomotive
of
50150
an
low silicate
approved nitrite or
the tank.
This
to
cylinder
5-8
Page 67
Serious personal
Never
pry
on
a fan
failure.
&
injury
because
DAILY MAINTENANCE
WARNING
can
result from a loose
this may cause fan damage and/or
or
damaged fan.
CHECK
To
OPEN
Location:
To
ENGINE
Check: Visually inspect the cooling fan (C) for cracks,
WATER SEPARATOR
Open:
FAN
loose bolts, bent
Water separator filter (D).
off
Shut
Turn the valve
counterclockwise.
Drain until clear fuel is present.
the engine.
or
loose blades, etc.
on
the
bottom
of
the filter
John Deere
D
NOTE:
Retighten the valve.
if
more than 2
filter
is
replacement on page
required
oz.
of
to
fuel are drained, refilling
prevent hard starting. Refer
5-19
of
this manual.
of
to
the
filter
5-9
Page 68
MAINTENANCE PROCEDURES
DAILY MAINTENANCE
CHECK
Location:
To
NOTE: Refer to page 5-24
TRANSMISSION OIL LEVEL
Dipstick (A)
Check: Level the machine.
Place the transmission control in neutral.
Set the parking brake.
The engine must
Bring the transmission oil temperature to a
minimum
Remove the dipstick. The oil level should be
between the add and full marks.
Replace the dipstick.
specifications
of
and
be
running to check.
180 degrees
of
this manual for the proper oil
capacities.
F.
A
CHECK
Location:
To
NOTE: Refer
HYDRAULIC OIL LEVEL
Sight glass (B). Behind the rear panel.
Check: Move the machine to level ground.
Level the frame.
Completely retract the boom.
Position the forks level.
Lower the
Oil should be visible
to
page 5-24
specificatiolls and capacities.
boom
of
this manual
to the grolmd.
112
way in sight glass (B).
for
the proper oil
5
B
-10
Page 69
MAINTENANCE PROCEDURES
DAILY
CHECK
Location: Wheel ends.
To
Setting:
TIRE
FOR
PROPER INFLATION
Check: With the valve stem (C) positioned to the top
the tire, check the tire pressure with the tire cold
and a properly functioning air pressure gauge.
50 PSI.
MAINTENANCE
of
ffiDANGER
All tires require a calcium chloride ballast or an optional foam
fill to be operated safely. The loss
machine's stability and cause a rollover hazard, resulting in
damage, injury
or
death.
of
ballast can affect the
c
INSPECT AIR CLEANER
Location:
To
Check:
Guideline:
Due to various operating conditions, the air cleaner's elements
should be changed as the environment requires.
Air cleaner assembly.
Remove the rear
the filter elements.
Inspect the filter elements for contamination.
Inspect the tubing going to the filter body
from the engine for cracks or leaks. Inspect
the air cleaner body and gaskets for cracks
or leaks.
&
WARNING
of
the canister, remove
5-11
Page 70
50 HOUR MAINTENANCE
Pelfonn "BEFORE SERVICING PROCEDURES" before
attempting any
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Pelfonn "BEFORE OPERATING CHECKS" before attempting
any
of
the following checks.
of
the following checks.
CHECK
Location:
To
CHANGE
Location:
To
HYDRAULIC
Retum filter gauge (A). Located behind the left hand
side screen,
left hand side
Check: Raise the
Extend the
Raise the engine speed to full RPM.
Retract the
The retum filter gauge reading should not read more
than 25
filter element must be changed.
HYDRAULIC
The retum filter element (C) is located inside the
retum filter assembly (B) on top
Change:
Retract the
Shut
reservoir
RETURN
on
ofthe
boom
boom
boom
PSI.
If
RETURN
boom
off
the engine. Release the pressure in the oil
by
loosening the filler / breather cap (D).
FILTER GAUGE
top
of
the oil reservoir and on the
retum filter assembly (B).
to the horizontal position.
cylinder fully.
cylinder at full speed.
the reading is more than 25 PSI, the
FILTER
and lower the forks to the ground.
ELEMENT
of
the oil reservoir.
A
D
F
NOTE:
& CAUTION
The retum filter assembly cover is spring loaded.
Loosen, but do not remove, the four cover bolts (E)
on the top
push down and rotate the cover clockwise to remove.
Remove the cover spring and pull the filter element
out using the swivel handle on the element. Make
sure both o-rings are
element, then transfer the bypass valve (F) into the
new filter element. Reinstall the filter element, cover
spring and cover, making sure the o-ring is in place
between the cover and the retum filter assembly.
This
use.
Intervals
ofthe
retum filter assembly. Carefully
in
place inside the new filter
change interval is only for the first initial 50 hours
Following initial replacement
on
page 5-5
of
this manual for standard change
of
filter see Service
5
of
-12
c
Page 71
MAINTENANCE PROCEDURES
50
HOUR MAINTENANCE
CHANGE TRANSMISSION OIL
Location:
Transmission filter (G).
Drain
plug (H).
Dipstick (I).
Bring
To
Change:
the transmission oil temperature to a
of
minimum
180 degrees
Remove the drain plug.
Allow the oil to drain completely into a
proper
collection container.
Clean the area around the filter thoroughly.
Remove the transmission filter.
Apply a thin fihn
to the new filter gasket surface and install
the filter according to the manufacturer's
specifications.
Install the drain plug.
AND
FILTER
F.
of
clean transmission oil
... _---/
i
I I
G
NOTE:
NOTE: Refer
This
hours
filter see the
for the standard change interval.
specifications and capacities.
Fill the transmission through the dipstick
tube
(I) until the oil level
is
between the add
and full marks.
RlID
the engine for a minimum
of
at engine idle.
at
Check the oil level
the dipstick.
Raise the transmission oil temperature to a
minimum
of
180 degrees
F.
Recheck the oil at
the dipstick.
change interval
of
use.
to
page 5-24
is
Following the initial replacement
Service Intervals
only for the first initial 50
on
page 5-5
of
this manual for
the
of
proper oil
this manual
2 minutes
of
oil alld
5 -13
Page 72
MAINTENANCE PROCEDURES
50
HOUR
MAINTENANCE
CHECK
Location:
To
Check:
NOTE.-
AXLE
PLANETARY
Filler/drain
Always
with
position.
Remove
Oil
Replace the filler/drain plug.
Refer
specifications and capacities.
check
the filler/drain
the
should
to
page 5-24
OIL
plug
(A).
the
lubricant level
filler/ drain plug.
flow freely
of
this manual for the proper oil
plug
from
at
the 3
the hole.
in
the wheel
or
9 o'clock
end
A
1',\
\ !
I
CHECK
Location: Fill plug (B).
To
NOTE.-
AXLE
Check:
specifications
DIFFERENTIAL OIL
Check
plug (D).
Drain plug (C).
Move
the machine to level ground.
Remove
from the hole.
Replace the
Rtfer
to
the
page 5-24
and capacities.
check
plug.
check
plug.
of
this manual for
Oil
should
the
proper oil
flow freely
5
-14
B
c D
Page 73
MAINTENANCE PROCEDURES
100 HOUR MAINTENANCE
Perfonn "BEFORE SERVICING PROCEDURES" before
attempting
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
Complete all
time interval.
Perfoml "BEFORE OPERATING CHECKS" before attempting
any
any
of
the following checks.
"50
HOUR
of
the following checks.
MAINTENANCE" checks
prior
to this
CHANGE
Location:
To
Change:
NOTE:
NOTE: Refer to page
AXLE
DIFFERENTIAL
Fill plug (B).
Check
Drain plug (C).
Remove
Loosen
completely into a
Replace the drain plug.
Remove
Fill with oil through the fill plug hole until it
flows freely from the check plug hole.
Replace the check
This
time interval
5-5
page
specifications and capacities.
of
on
plug (D).
the drain plug.
the fill plug to allow the oil to drain
proper
collection container.
the check
is
this manual
5-24
plug
and
the fill plug.
plug
and
the fill plug.
for the first initial 100 hours. Refer to
for
additional service intervals.
of
this manual
for
the proper oil
B
c
D
5 -
15
Page 74
MAINTENANCE PROCEDURES
100 HOUR MAINTENANCE
CHANGE
AXLE
Location:
To
Change:
NOTE:
NOTE: Refer
This
page 5-5
specifications and capacities.
PLANETARY
END
OIL
Filler/drain plug (A).
Rotate the wheel
is at the lowest
end
until the filler/drain plug
point
of
the wheel end.
Remove the filler/drain plug and allow the oil
to drain completely into a proper collection
container.
Rotate the wheel end until the filler/drain plug
hole is at the 3
or
9 o'clock position.
Fill with oil until it flows freely from the filler/
drain plug hole.
Replace the filler/drain plug (A).
time interval is for the first initial J
of
to
page 5-24
this manual
for
additional service intervals.
of
this manual for the proper oil
00
hours. Refer
to
A
CHANGE TRANSMISSION OIL
To
Change:
Refer to the procedure listed on page 5-13
manual.
NOTE:
This
time interval is for the first initial 100 hours. Refer
page 5-5
of
this manual for additional service intervals.
AND
FILTER
of
to
this
5
-16
Page 75
MAINTENANCE PROCEDURES
250 HOUR MAINTENANCE
Pelfonn "BEFORE SERVICING PROCEDURES" before
attempting any
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
of
the following checks.
Complete all
time interval.
Complete all
this time interval.
Perfonn "BEFORE OPERATING CHECKS" before attempting
any
of
CHANGE HYDRAULIC
Location: The return filter element (C) is located inside the
To Change: Retract the
"50
HOUR
"100
the following checks.
return filter assembly (B)
off
Shut
reservoir
MAINTENANCE" checks prior to this
HOUR
the engine. Release the pressure in the oil
MAINTENANCE" checks prior to
RETURN
boom
and lower the forks to the ground.
by
loosening the filler I breather cap (D).
FILTER
on
top
ELEMENT
of
the oil reservoir.
D
F
LtCAUTION
The return filter assembly cover is spring loaded.
Loosen, but do not remove, the four cover bolts (E)
on
the top
push down and rotate the cover clockwise to remove.
Remove the cover spring and pull the filter element
out using the swivel handle
sure both o-rings are
element, then transfer the bypass valve (F) into the
new filter element. Reinstall the filter element, cover
spring and cover, making sure the o-ring is
between the cover and the return filter assembly.
of
the return filter assembly. Carefully
on
the element. Make
in
place inside the new filter
in
place
5-17
c
Page 76
500 HOUR MAINTENANCE
CHANGE
Location:
ENGINE
Oil filter (A).
OIL
AND
FILTER
Drain plug (B).
Fill cap (C).
To
Change: Operate the engine until the engine water
temperature
Tum
has
reached 140 degrees
the engine off.
Remove the drain plug (B).
Allow the oil to drain completely into a proper
collection container.
Clean the area thoroughly around the filter area.
Remove the engine oil filter.
of
Apply a thin film
clean engine oil to the new
oil filter gasket surface.
Fill the oil filter with clean engine oil before
installation.
F.
John Deere
NOTE."
Install the oil filter to the manufacturer's
specifications.
Clean the surface around the drain plug.
Install the drain plug.
Fill the engine with the proper oil through the oil
fill cap until the oil level is between the add
on
and the full marks
Run the engiue for a minimum
the dipstick.
of2
minutes at
engine idle.
Turn the engine off.
Once the engine has cooled recheck the oil level
at
the dipstick.
Refer to page 5-24
specifications
of
this manual
alld capacities.
for
the proper oil
5
-18
Page 77
MAINTENANCE PROCEDURES
500
HOlJR
Perform "BEFORE SERVICING PROCEDURES" before
attempting any
of
the following checks.
MAINTENANCE
Complete all "DAILY
time interval.
"50
Complete all
time interval.
Complete all
this time interval.
Complete all
tlus time interval.
Perform
any
REPLACE
"BEFORE OPERATING CHECKS" before attempting
of
the following checks.
HOUR
"100
HOUR
"250
HOUR
FUEL FILTERS
MAINTENANCE" checks prior to this
MAINTENANCE" checks prior to this
MAINTENANCE" checks prior to
MAINTENANCE" checks prior to
Location:
To
Change: Wipe all the dirt from the area surrounding
NOTE:
Filter (D).
Water separator (E).
the filter( s).
Remove the filter(s). Thoroughly clean the gasket
sealing surface after filter removal.
Fill the new filter( s) with fuel.
Install the new filter(s).
Install the filter( s) according to the filter
manufacturer's specifications.
John Deere engines only have one filter element.
filter and
waleI' separalOl:
11
is used
as
5
John Deere
D&E
a
-19
Page 78
CHECK
MAINTENANCE PROCEDURES
COOLANT
500 DOUR MAINTENANCE
A
CONCENTRATION
Location:
To
Check: Remove the radiator cap.
Radiator cap (A).
Factory recommended coolant concentration
50/50 mixture
is a
(-34 degrees F.) with
nitrite-molybdate
Additive. This additive is required to prevent
engine damage
pitting.
antifreeze
silicate dropout
Contact your local John Deere dealer for an
approved antifreeze
Additive.
Do
oflow
silicate antifreeze
an
approved nitrite
based
Supplemental Coolant
due
to cylinder liner erosion and
not
use high-silicate automotive
or
cooling system damage due to
can
occur.
and
Supplemental
750 HOUR MAINTENANCE
Perform "BEFORE SERVICING PROCEDURES" before
attempting any
of
the following checks.
or
Coolant
Complete all "DAILY MAINTENANCE" checks prior to this
time interval.
"50
Complete all
this time interval.
Complete all
this time interval.
Complete all
this time intervaL
Complete all
this time interval.
Perform
ing any
CHANGE
To
Change:
"100
"250
"500
"BEFORE OPERATING CHECKS" before attempt-
of
the following checks.
AXLE
Refer
5-16
HOUR
OILS
MAINTENANCE" checks prior to
HOURMAlNTENANCE"
HOUR
HOUR
to
ofthis
MAINTENANCE" checks prior to
MAINTENANCE" checks prior to
the procedures listed
manual.
on
checks prior to
pages 5 -15 &
5-20
Page 79
1000 HOUR MAINTENANCE
Perform "BEFORE SERVICING PROCEDURES" before
attempting any
Complete all "DAILY MAINTENANCE" checks prior to this
tinle interval.
of
the following checks.
Complete all "50
time interval.
Completeall
this time interval.
Complete all
this time interval.
Complete all "500 HOUR MAINTENANCE" checks prior to
this time interval.
Complete all "750 HOUR MAINTENANCE" checks prior to
this time interval.
Perform "BEFORE OPERATING CHECKS" before attempting any
of
MANUFACTURER ENGINE MANUALS
FROM
YOUR LOCAL
ADJUST
HOUR
MAINTENANCE" checks prior to this
"100 HOUR MAINTENANCE" checks prior to
"250 HOUR MAINTENANCE" checks prior to
the following checks.
ARE
AVAILABLE
ENGINE
TEREX
VALVES
HANDLER DEALER.
To
Adjust: See engine manual for procedure.
CHECK FAN
To Check: See engine manual for procedure.
CHECK
To
Check: See engine manual for procedure.
CHANGE TRANSMISSION OIL
To
Change: Refer to procedure listed
FAN
BELT
BELT
manual.
TENSION
CONDITION
AND
FILTER
on
page 5-13
of
this
5
-21
Page 80
MAINTENANCE PROCEDURES
1000 HOUR MAINTENANCE
ADJUST
TO CHECK: Raise the
proper adjustment can be checked with a tape measure. Extend
the
side
end
directly above tlle estimated center.
TOLERANCE: The measurement from the top surface
boom to the lowest part
less than 2
TO ADJUST:
tighten the chain anchor (A), which
of
A. Tighten an adjustable wrench across the flat part
chain
B. With a 1 7/16 inch wrench tighten the one inch nut to
collapse the spring. Continue to tighten until the chain is in
tolerance.
EXTENSION
boom
fully, then retract the
of
the middle
of
the tape measure on the top surface
3/8 inches.
If
the large
just
boom
ahead
-RETRACTION
boom
to the horizontal position. The
boom
boom
section estimate the center. Place one
of
the extension chain should
the measurement is less than 2 3/8 inches,
tube, as follows:
of
the chain anchor (A).
CHAINS
about one inch.
of
the
is
located on the top, front
On
boom
of
of
be
the
either
the
no
--~=---------
--=---=======:====i
MIDDLE
BOOM
MIDPOINT
C. With a feeler gauge check the gap between the spring (B).
The gap should be no less than .030. The spring coils should
never be collapsed completely.
B A
5-22
Page 81
2000 HOUR MAINTENANCE
PerfOlm "BEFORE SERVICING PROCEDURES" before
attempting any
of
the following checks.
Complete all
time interval.
Complete all
time interval.
Complete all
this time interval.
Complete all
this time interval.
Complete all
this time interval.
Complete all
this time interval.
Complete all
tIus time interval.
to
Perfonn "BEFORE OPERATING CHECKS" before attempting
any
of
"DAILY MAINTENANCE" checks prior to this
"50
HOUR
"100
"250
"500
"750
"1000
the following checks.
MAINTENANCE" checks prior to this
HOUR
MAINTENANCE" checks prior to
HOUR
MAINTENANCE" checks prior to
HOUR
HOUR
MAINTENANCE" checks prior to
MAINTENANCE" checks prior to
HOUR
MAINTENANCE" checks prior
FLUSH AND PRESSURE TEST COOLING SYSTEM
To
Test:
See engine manual for procedure.
5 -23
Page 82
MAINTENANCE PROCEDURES
FILTER GUIDE
FILTER PART NO.
Engine Oil Filter /
Transmission Oil
Hydraulic Oil Reservoir Return Filter Element
Engine
Air
Engine
Air
Engine
Filler-Breather (Hydraulic Oil Reservoir)
Fuel
John
Deere 7-183-184
Filter
Cleaner Element / Primary
Cleaner Element / Safety 7-109-14
Filter /
John
Deere
7-126-349
7-118"'()2
7-109...04
7-183-45
7-272-11
RECOMMENDED FLUIDS AND CAPACITIES
DESCRIPTION
Engine Oil / John Deere
Transmission Oil
Axles
Differential
Planet
Ends
Hydraulic Oil Reservoir
Hydraulic System
Fuel
Tank
NOTE:
Fluid levels may vary slightly
CAPACITY TYPE
14 Quarts
13.6 Quarts
9 Quarts
1 Quart (Each End)
34 Gallons
50 Gallons
30 Gallons
fi-om
machine
to
machine so fluid levels should always be checked manually.
Refer
to
John
Deere
Chevron
Chevron Supreme
Chevron Supreme
Chevron
ChevronAW
# 2
Diesel
RPM
AW
Fuel
SAE
46
46
engine
lOW
80W90
80W90
manual
LS
LS
5
-24
Page 83
MAINTENANCE PROCEDURES
HYDRAULIC PRESSURE SETTINGS
GAUGE
MAIN
Location: Test
To
ToAdjust: Remove the acorn nut from the adjuster (C). Loosen
PORT
J (GJ)
PUMP
Check: Attach a pressure gauge to test port 1 (A). Start
PRESSURE
port
1 (A). Behind the right hand rear side screen.
Hydraulic pump (B). Under the transmission cover.
Adjuster (C). On the hydraulic pump.
the engine. Do not operate any controls. The
pressure reading should
TH636C
TH644C
TH842C
TH844C
the
jam
nut and turn the allen head adjusting screw
clockwise to increase the pressure and counterclockwise to decrease the pressure. Retighten the
nut. Replace the acorn nut.
be
as
follows:
2800
3000
3000
3000
PSI
PSI
PSI
PSI
jam
B c
GAUGEPORTJ
SERVICE
Location: Test port 1 (A). Behind the right hand rear side screen.
To
Check: Attach a pressure gauge to test port 1 (A). Start
ToAdjust:
(GJ)
BRAKE
the engine. Do not operate any controls. Apply
and release the service brakes a few times. With
the service brakes released, shut down the engine.
The pressure reading should be as follows:
Not
PSI after a period
brake circuit.
ACCUMULATOR
TH636C
TH644C
TH842C
TH844C
adjustable.
If
the pressure drops below 2000
2800
PSI
3000
PSI
3000
PSI
3000
PSI
of
two minutes, troubleshoot the
5-25
A
Page 84
HYDRAULIC PRESSURE SETTINGS
GAUGE
STEERING
Location: Test port 2 (A). Behind the right hand rear side screen.
To
ToAdjust: Loosen the
PORT
2 (G2)
SYSTEM
Control block (B).
Cartridge
Check: Attach a pressure gauge to test POlt 2 (A). Start the
engine. Do not operate any controls. The pressure
reading should
(C) and turn the allen head adjusting screw
clockwise to increase the pressure and
counterclockwise to decrease the pressure.
Retighten the
PRESSURE
On
the front face ofthe oil reservoir.
(C). On the control block.
be
as follows:
TH636C
TH644C
TH842C
TH844C
jam
nut on the steering cartridge
jam
nut.
2250
2250
2250
2250
PSI
PSI
PSI
PSI
GAUGE
PORT
3 (G3)
CONTROL (PILOT) PRESSURE
Location: Test port 3 (D). Behind the right hand rear side screen.
Control block (B).
Cartridge (E).
To
Check: Attach a pressure gauge to test port 3 (D). Start the
engine. Do not operate any controls. The pressure
reading should be as follows:
TH636C
TH644C
TH842C
TH844C
ToAdjust: Loosen the
and turn the allen head adjusting screw clockwise to
increase the pressure and counterclockwise to
decrease the pressure. Retighten the
On the front face
On the control block.
jam
nut on the controller cartridge (E)
of
the oil reservoir.
500
PSI
500
PSI
500
PSI
500
PSI
jam
nut.
E
B
5-26
Page 85
MAINTENANCE PROCEDURES
HYDRAULIC PRESSURE SETTINGS
GAUGE
TILT
Location: Test
To
To
PORT
4 (G4)
LIMITER
Check: Attach a pressure gauge to test port 4 (F). Start the
Adjust: Loosen the
PRESSURE
port
4 (F). Behind the right hand rear side screen.
Tilt Limiter Block (H).
Cartridge (I).
engine. Completely collapse the fork tilt cylinder and
hold in a dead head position. (The tilt cylinder
be
collapsed completely
pressure
as follows:
TH636C
TH644C
TH842C
TH844C
and turn the allen head adjusting screw clockwise
to increase the pressure and counterclockwise to
decrease the pressure. Retighten the
On
reading). The pressure reading should be
jam
On
the front
the Tilt Limiter Block.
and
nut on the tilt limiter cartridge
ofthe
dead headed
1200
PSI
1200
PSI
1200
PSI
1200
PSI
jam
oil reservoir.
to
nut.
must
get a
(1)
F
5-27
Page 86
Page 87
SECTION 6
MATERIAL
SAFETY
DATA
SHEETS
6-1
Page 88
TABLE OF CONTENTS
SECTION
6 -
MATERIAL
SAFETY
DATA
SHEETS
6-2
Page 89
MATERIAL SAFETY DATA SHEETS
The
Federal Occupational, Safety and Health Administration (OSHA) Standard 29
cases state and local Right -To-Know laws,
operating this equipment. This
antifreeze, brake fluid, battery acid and hydraulic fluid.
may
include information
may
require specific MSDS
on
substances contained in the equipment such as
be
ctr
1910.1200,
available to employees
and
prior
in
to
some
TEREX HANDLERS
product line.
Simply
will
provide, at
request them from your local
TEREX HANDLERS
P.O.
Box
790
Baraga,
To ensure a
machine model and serial number.
MI
49908-0790
prompt
response, please
no
cost, Material Safety
TEREX
be
sure to include your return address and zip code, along
Data
Sheets
which
HANDLER dealer
are
applicable to their
or
contact us at:
with
the
6-3
Page 90
MATERIAL SAFETY DATA SHEETS
The following warning is required on all
operating a
please contact us for a replacement at no charge.
TEREX HANDLERS
Box
P.O.
Baraga,
TEREX HANDLER
790
MI
49908-0790
Diesel engine exhaust and some
constituents are known to the State
of
defects, and other reproductive harm.
off
road equipment operating in the State
in
the State
Proposition 65 Warning
California to cause cancer, birth
of
CALIFORNIA
of
California.
California and do not see the approved warning label,
Our address is:
ofits
If
you are
6-4
Page 91
Page 92
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