Princeton PIGGY BACK PB50, PIGGY BACK PB65 Operator's Manual
11/2002
625-242
OPERATOR’S
MANUAL
PRINCETON PIGGY BACK OPERATOR’S MANUAL
PIGGY BACK®PB50/PB65
You must read and understand this
manual before operating the forklift.
Keep this manual with the forklift.
NEED HELP
?
If you have a question on the operation of
this unit...
Or
If you have a problem on this or any other
Princeton product...
Contact your local dealer.
A comprehensive dealer listing is
available at www.piggy-back.com
Or call
Princeton Delivery Systems
1-800-331-5851
11 Seat Belt Safety Supplement
TRUCK DATA
Model No. _____________________________________
Serial No______________________________________
Weight (empty)_________________________________
Rated Capacity_________________________________
Gross Weight (loaded with Rated Load) _____________
Notice: The information in this manual was in effect at
the time of printing. Princeton Delivery Systems reserves
the right to make improvements and changes in specifications or designs without incurring obligation. Please
check with your Princeton dealer for possible updates or
revisions.
Copyright© 2002 Princeton Delivery Systems Inc. All rights reserved.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
CALIFORNIA
PROPOSITION 65 WARNING
Battery posts, terminals and related accessories contain lead and
lead compounds, chemicals known to the State of California to
cause cancer, birth defects, and other reproductive harm.
Wash hands after handling.
54
10 Specifications
KUBOTAENGINE: (See Kubota engine manual)
CAUTION: Do not use ether or starting fluid. Severe non-warrantable
engine damage will occur.
FUEL: Diesel fuel must not be mixed with gasoline, kerosene, or alcohol.
*Above 32 Degrees. #2D should be used.
*Below 32 Degrees. either #1D or a mix of #1D and #2D
may be used.
ENGINE OIL: Use only CC/CD/CE rating API index oil in your diesel
engine.
*CF is the highest rating and is highly recommended.
*Change the engine oil type according to the ambient
temperature.
above 77 F. (25 C.) SAE30 or SAE10W30
SAE10W40
32 F. (0 C.) to 77 F. (25 C.) SAE20 or SAE10W30
SAE10W40
below 32 F. (0 C.) SAE10 or SAE10W30
SAE10W40
COLD WEATHER START: When the ambient temperature is below 50 F
(10 C), pre-heating is needed. The Kubota engine is equipped with quick
glow plugs. Automatic preheating is made for about 6 to 10 seconds
when starter switch key is turned to preheating position.
Start: Your unit is equipped with an (externally switched) Syncro-Start
Solenoid (Model 1753ES/1751ES).
Caution: Multiple start attempts and excessive engine cranking
could cause damage to the solenoid. Therefore, it is our
recommendation that engine cranking (pull-in coil energized) be
limited to three (3) 30 second attempts with a cool down period
120 seconds (two minutes) between each cranking attempt. After
three (3) cranking attempts, the solenoid must be allowed to cool
down to ambient temperatures before making further cranking
attempts.
53
Introduction
Your PIGGY BACK Delivery System was bought knowing it will give long
and useful service. To get the value built into it a small amount of time
and expense is needed to learn safe, productive operation, and to do
regular inspections and service.
This manual will tell you how to safely operate, inspect, and maintain
your PIGGY BACK forklift. Keep it with the forklift as a ready reference.
As with the use of all heavy machinery, failure to carefully follow these
instructions and use common sense may result in serious injury.
If you have questions about operating, maintaining, or obtaining parts for
your forklift; contact your Princeton dealer. They are always glad to help.
Table of Contents
Section
Page
Introduction 2
To Forklift Owners 3
To Forklift Operators 4
How To Use This Manual 5
Safety Signal Words 6
Service Position--Engine Off 7
Service Position--Engine Running 7
Jacking And Blocking 8
1 General Safety Practices 9
2 Operating Safety Rules And Practices 11
3 Forklift Description 13
4 Starting 16
5 Operation 18
6 Transport 34
7 Moving ADisabled Forklift 42
8 Inspection 43
9 Lubrication 46
10 Specifications 49
11 Seat Belt Safety Supplement 54
10 Specifications
ENGINE OIL: Lube oils are differentiated according to their effi-
ciency and quality grade. Commonly used are the API
Specifications.
Approved Oils:
Non-turbocharged Engines API-Specific
CC/SE CC/SF
CD/SE CD/SF
VISCOSITY: Because the viscosity of the lube oil is greatly influenced by the temperature, the choice of SAE-grade should be
governed by the ambient temperature at the engine site. Optimum
operating behavior will be attained if you use the chart below.
COLD WEATHER START: The Deutz engine is equipped with a
cold weather starting aid called “Glow Plugs”. When the temperature is below 40 F, you should use the pre-heat option. To pre-heat
the engine, turn the key to the “on” position until the pre-heat light
goes out. Then turn the key to the “start” position “the right”. If the
engine does not start, wait 1 minute before pre-heating the engine
again.
IMPORTANT: DO NOT OVERCRANK THE ENGINE
52
To Forklift Owners
ASME B56.1 and B56.6 are the standards for forklift operation,
rules and safety, maintenance, safe operation, training and supervision. You should read this manual and make it available to your
operators and their supervisors. You can get it from the American
Society of Mechanical Engineers, 345 East 47th Street, United
Engineering Center, New York, NY 10017.
ASME B56.1 and B56.6 are a key part of forklift safety. However,
making forklift operation safe involves other areas and responsibilities. The forklift owner is responsible to ensure their operators
have adequate training in operating the forklift. This training
includes, but should not be limited to, classroom and hands-on
training. Forklift safety involves the forklift itself, the environment it
works in, and the people who come in contact with it. Consider
your entire operation when addressing forklift safety.
The operator’s manual is not a training manual. It is a guide to
help trained and authorized operators safely operate their forklift
by showing the proper procedures. This manual combined with
adequate operator training will help reduce situations that may
cause an accident.
Operators must be trained and qualified to operate a forklift before
actually operating one.
Forklift training and operator awareness of the forklift work area
will help ensure a safe workplace for all your employees.
3
To Forklift Operators
Operators must become familiar with all forklift controls, procedures, and work areas. Understand what this forklift can do and its
limits. Understand and practice all safety rules.
Before driving a forklift, the user must inspect it completely to
insure safe operation. This is a requirement of OSHA, ANSI, and
ASME.
The operator is also responsible for understanding the environment the forklift is being operated in. Knowing how to operate the
forklift within their working environment is very important to overall
forklift safety.
Operate your forklift safely; careful driving is your responsibility.
Know your forklift’s capabilities and limits. Follow all instructions in
this manual.
4
10 Specifications
DEUTZ ENGINE: See Deutz engine manual)
CAUTION: Do not use ether or starting fluid. Severe non-warrantable engine damage will occur.
FUEL: Always use branded grades of diesel fuel having a sulfur
content of below 0.5%. In the case of higher sulfur content, the
periods between oil changes must be shortened.
The following fuel specifications are approved:
DIN 51 601
NATO Codes F54, F75 and F76
BS 2869: A1 and A2 (in case of A2, note sulfur content)
ASTM D 975-81 : 1-D and 2-D
VV-F-800a: DF-A, DF-1 and DF-2
WINTER-GRADE FUEL: At temperatures as low as -15 C (+5 F)
to -20 C (-4 F), kerosene should be mixed with the diesel fuel. The
necessary percentages for admixing are seen in the diagram
below.
51
10 Specifications
SPECIFICATIONS-FLUID CAPACITIES:
(All measurements listed below are completely empty/dry.)
HYDRAULIC OIL 17 US GALLONS
FUEL 8 US GALLONS
ENGINE OIL- DEUTZ 3FL1011 6.4 QUARTS
ENGINE OIL- DEUTZ 4FL1011 11.0 QUARTS
ENGINE OIL- KUBOTA 2003T 7.5 QUARTS
Fluids should be checked before starting, then run the
PIGGY BACK for 1 minute, shut engine off and re-check.
50
How To Use This Manual
The illustrations and explanations in this manual will help you
improve your skill and knowledge as a professional forklift operator
while taking full advantage of the capabilities and safety features
of your forklift.
The manual is designed to be easy to read and find information
in.The sections are numbered. The page numbers are on the bottom leading edge of each page. The Table of Contents lists the
sections and their beginning page number.
This manual is meant to be permanently attached to your
forklift as a reference. If the manual gets lost or damaged call
your Princeton dealer, they are waiting to help.
5
Safety Signal Words
Know these safety signal words and remember their meaning.
CAUTION
Is a reminder of safety practices, that if not followed, may lead to
personal injury.
WARNING
Is used when a hazard exists which can result in injury or death if
proper precautions are not taken.
DANGER
Is used when extreme hazard exists which will result in death
or serious injury if proper precautions are not taken.
6
10 Specifications
49
109” (PB50)
114“ (PB65)
9 Lubrication
LUBRICANT KEY
(1) Lithium base multipurpose grease
(2) Air filter P/N 505-141, 505-142
(3)Hydraulic Fluid, Texaco Rando
HD46 (or equal).
(4) See engine manual
(5) Hydraulic Filter P/N 207-104
(6) Engine Oil Filter-see engine parts
manual
(7)SAE 10W30
(8)Fuel Filter P/N 504-598
(9) Motor Oil 30W-40W or chain lube
RECOMMENDED LUBRICA
TION
(A) 8-10 hours or daily
(B) 25-50 hours or monthly
(C) 150 hours or every 6 months
48
Service Position--Engine Off
1. Park forklift on flat level surface.
2. Tilt mast to vertical position.
3. Lower forks to floor.
4. Shut engine off.
5. Chock drive wheels.
Service Position--Engine Running
1. Park forklift on flat level surface.
2. Tilt mast to vertical position.
3. Set parking brake.
4. Shut engine off.
5. Chock drive wheels.
6. Raise rear of vehicle and block -- see jacking and blocking
section.
7. Raise front of vehicle and block -- see jacking and blocking
section.
8. Connect hose to exhaust -- do not run engine in closed area
without venting.
9. Operator must remain in seat while engine is running.
7
IMPORTANT INFORMATION ON THE FILTRATION
OF YOUR PB SERIES
Your PB Series unit is equipped with a “suction boost” filter. This filter
provides superior protection to the drive circuit. It is equipped with a
dash mounted notification light that indicates if the filter needs changed.
This light is additional information for the operator and is not a
substitute for filter changes during PM’s.
This light will normally illuminate* under three circumstances.
1) During cold weather operation, the light may illuminate until
the hydraulic oil warms. This generally takes 1 to 3 minutes of
operation.
2) During high-speed multi-function operation, the light may
illuminate temporarily.
3) If the light remains on at any other time the filter should be
changed.
*An illuminated light does not mean the filter is by-passing but indicates
contaminates in the hydraulic system.
A “break-in” filter change is recommended in the first 5-10 hours of
operation.
Jacking and Blocking
WARNING
Avoid the risk of injury or death.
Use jack stands when working
on raised truck.
Front Jacking
With forklift in Service Position
Engine Off:
1.Use a hydraulic jack of 5 ton
capacity minimum.
2.Position front jacks under
stabilizer feet.
3.Position jack stands under
carriage.
4.Slowly lower forklift onto
stands.
Rear Jacking
With forklift in Service
Position Engine Off:
1.Use a hydraulic jack of 5 ton
capacity minimum.
2.Position jack under frame at
rear.
3.Position jack stand under
frame.
4.Slowly lower forklift onto
stands.
WARNING
Avoid hydraulic line damage.
Do not jack or block forklift
frame near hydraulic lines.
8
C
C
9 Lubrication
47
Grease Fitting, top of tilt
cylinder-1, B
Mast Chains-9, B
Grease Fitting, bottom of tilt
cylinder-1, B
Grease Fitting, Side Shift
Cylinder-1, B
Side Shift Blocks-1, B
Side Shift Blocks-1, B