Brouwer Kesmac 4500 User manual

KESMAC
TransportableForklifts
Operators Manual

Safety Precautions
Operate your forklift defensively. Exercise caution in driving and load
handling, and observe the safety points outlined below.
1. Do not operate the Kesmac forklift until you have completed your
employer’s training program as required by OSHA.
BE FULLY QUALIFIED.
2. ALLOW NO RIDERS.
3. KEEP YOUR ARMS, LEGS, SHOULDERS, HEAD, ETC. INSIDE
THE DRIVER’S COMPARTMENT.
4. DO NOT LIFT OBJECTS WHICH COULD EASILY FALL ON THE
OPERATOR OR A BYSTANDER.
5. WATCH OUT FOR PEDESTRIANS.
6. DO NOT TURN ON AN INCLINE.
7. DRIVE SLOWLY AROUND CORNERS.
8. AVOID SUDDEN STARTS OR STOPS.
9. WATCH CLEARANCES AND DIRECTION OF TRAVEL.
10. WHEN LEAVING THE FORKLIFT, LOWER THE FORKS
COMPLETELY, SET THE PARKING BRAKE, SHUT OFF THE
ENGINE, AND REMOVE KEY. BLOCK THE WHEELS WHEN
ON AN INCLINE OR WHEN SERVICING THE TRUCK.
11. DO NOT FILL THE FUEL TANK WHILE THE ENGINE IS
RUNNING.
12. REPORT ANY DAMAGE OR FAULTY OPERATION OF
FORKLIFT IMMEDIATELY. DO NOT OPERATE UNIT UNTIL
FAULT IS CORRECTED.
13. OBSERVE ALL TRAFFIC RULES AND DRIVE CAREFULLY.
14. OBSERVE THE FOLLOWING LOAD HANDLING TECHNIQUES:
a) Handle only loads within rated capacity of forklift as directed
by Kesmac.
b) Always centre the weight of wide loads between the forks.
c) Keep all loads against the carriage.
d) Never travel with load raised higher than necessary.
e) For better vision with bulky loads travel in reverse.
f) Lift and lower loads with the mast vertical or tilted slightly
back.
15. As a further safety precaution, it is recommended that a fire
extinguisher be carried in a convenient location on the machine at
all times.
16. When checking engine coolant, remove the radiator cap slowly to
relieve pressure and always use hand protection, if the engine is
hot.
17. Never use a naked flame to check the battery electrolyte level.
The acid gasses could explode.
18. Prevent battery electrolyte or hydraulic oil contacting your eyes or
sensitive parts of skin.
19. Always use lights, reflectors, and emblems to comply with
relevant regulations whenever the machine is being driven on
public roads.
20. When getting on or off the machine, always use the handles and
footsteps provided, do not jump.
21. Maintain steps and cab floor free from mud, ice or grease, and
loose objects that may obstruct the functioning of controls.
22. Do not drive the machine against solid objects. If a load is too
great to move, use alternative operating techniques which work
the machine within its capacity.
23. Always exercise caution when driving downhill.
24. Only start the engine or operate the machine from the driver’s
seat.
25. Before commencing work, test stabilizers, lights, horn and all
safety devices. Be sure that steering, transmission and engine
speed controls are working effectively.

CONTENTS
Forward 2
Safety Precautions 3
Decals
6
Specifications 10
Operating Controls 11
Controls 12
Retractable Leg – Option 14
Diff-Lock 15
Throttle & ‘Inching’ Pedal Controls 16
Instrument Panel 17
Operating Instructions 19
Daily Inspection 19
Battery Location 19
Operating – With/Without Load 21
Load Capacity Chart. Transporting Loads 22
Maintenance 26
Daily Inspection 26
Air Cleaner Service 28
Hydraulic System 30
Oil Change 31
Hydraulic Pump –Drive Belt Adjustment 32
Revised. Sept.06
Wheels and Tires 33
Electrical System 34
Electrical Schematic 35
Automotive Controller 36
Electrical Schematic 37
‘Blink’ Codes Translation 38
Fault Codes 39
Maintenance Schedule 40
Lubrication 42
Transportation 45
IMPORTANT
Record the Serial Number of the machine. It must be
quoted when ordering parts or making a service call.
1

FOREWORD
The operator’s manual must be kept on the machine at all times.
Read this manual carefully to help understand the correct and safe operating procedures, day to day service and
care of the machine, the safe working capacities and operating features that ensure safe and efficient operation.
If you do not understand any instruction or procedure ASK your immediate supervisor, or contact the factory
for clarification, before operating the machine.
All Kesmac machines are tested and inspected before leaving the factory to ensure that all safety devices and
warning decals are in place.
Do not operate the machine if any safety device or warning decal is damaged or missing.
IMPORTANT
To ensure the long term safe and satisfactory performance of the machine, the maintenance and service
procedures outlined in this manual must be followed.
It is in the customers interest that the machine is serviced and maintained as recommended, and not abused in
any way, as the warranty may be voided.
Warranty is provided as Kesmac Inc’s commitment to customer service and satisfaction.
Kesmac reserves the right to change the design and/or specifications without notice or obligation to modify
previously manufactured machines.
Questions relating to service procedures that are beyond the scope of this manual should be directed to your
Kesmac dealer or to the factory service department.
2

SAFETY PRECAUTIONS
It is important, when carrying out service or repair work on
Kesmac Forklifts, to follow all of the operating and service
safety procedures that are outlined in this manual to en-
sure your own safety and that of any bystanders.
It is not possible to identify all situations that may arise that
could affect the safety of service personnel, bystanders
and the machine, therefore Kesmac cannot list all possible
precautions that may prevent accidents.
The owner, operator, and service personnel must assume
responsibility for their own safety, the safety of others and
of the machine, by following all safety instructions and fully
understanding the proper and safe operation of the mach-
ine as outlined in the manual.
The operator should at all times be aware of any potential
safety hazards and take corrective action immediately if a
dangerous situation should arise.
IF YOU DO NOT UNDERSTAND ……..ASK
BE A QUALIFIED OPERATOR/SERVICE PERSON BY:
• Reading and following the instructions in this
manual and those on the safety decals.
• Receiving training on the correct and safe oper-
ration of the machine.
• Asking your supervisor, your Kesmac Dealer, or
contacting the factory for explanation of anything
you do not understand concerning the operation of
the machine.
• Explaining the instructions in this manual, and on
the safety decals, to anyone that does not under-
stand them that may be involved in its operation.
WARNING
Kesmac Forklifts must not be used for any purpose
other than that for which they are designed.
Before starting the machine the operator must check
that all safety devices and warning decals are in place
and in good condition.
3

SAFETY PRECAUTIONS
Safety Alert Symbol. Hazards are identified by this symbol followed by the signal words :
DANGER : WARNING : CAUTION.
DANGER
INDICATES AN IMMEDIATE HAZARDOUS SITUATION THAT IF NOT CORRECTED
OR AVOIDED WILL RESULT IIN SERIOUS INJURY OR DEATH.
WARNING
INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT IF NOT CORRECTED
OR AVOIDED COULD RESULT IN SERIOUS INJURY.
CAUTION
INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT IF NOT CORRECTED
OR AVOIDED MAY RESULT IN A MINOR OR MODERATE INJURY.
Always follow safe operating and maintenance practices to ensure your own safety and that of others.
Warning and safety decals are prominently displayed and strategically placed on the machine. Before operating the
machine check that all warning and safety decals are in place, are not damaged and are easily readable.
See the following pages for the locations of the safety decals. It is important that you familiarize yourself with the
decals and their locations.
Do not operate the machine if drugs, alcohol or medication are being used that will affect your alertness and/or
physical co-ordination.
Seek professional advice before operating the machine if there is any doubt about the side affects of any medication
being taken that may put your safety, or that of others, at risk.
4

SAFETY PRECAUTIONS
IMPORTANT
For reasons of clarity, some illustrations may show safety guards removed.
The Forklift MUST NOT BE OPERATED with any safety devices removed.
FORKLIFT TIRES, WHEELS AND WHEEL NUTS
IMPORTANT
Do not operate the Forklift if any of the tires are badly worn or damaged.
The tires fitted to the machine are to Kesmac specifications.
Replacement tires must meet the Kesmac specifications.
Do not exceed the operating pressure shown on the tire sidewall.
The wheel retaining nuts must be checked regularly for tightness.
Operating the machine with loose wheel nuts will result in damage to, and
require the replacement of, wheel components.
WARNING
When removing wheel assemblies exercise extreme caution.
Use only a hoist with adequate lift capacity, and suitable tools and equipment.
It is recommended that only experienced and qualified personnel dismantle the
wheel assemblies.
5

3
2
1
10
4
11
5
6
7
9
8
HYDRAULIC OIL TANK COVER
FRONT/FLOOR BOARD PANEL
11
3
10 4
8
1
5
7
6
2
9
REAR WHEEL/BATTERY
ENGINE COMPARTMENT
9

SPECIFICATIONS
4500 5000 5500
SPECIFICATIONS Fixed & Retractable Fixed & Retractable Fixed Onl
y
Load Capacity at 24 in./610 mm Load Centre. Lbs./kg 4500/2041 5000/2268 5500/2494
Lift Height** in./mm 120/3048 120/3048 120/3048
Side Shift - in./mm 6/152 6/152 6/152
Tilt 8 deg. Fwd & Back 8 deg. Fwd & Back 8 deg. Fwd & Back
Weight † lbs./kg Fixed 4810/2182 4850/2200 5550/2517
Width* in./mm Retractable 5120/2322 5160/2341 N/
A
Width* in./mm 96/2438 96/2438 96/2438
Length* in./mm Legs Extended (F.O.P.S. Folded) 96/2438 96/2438 96/2438
( )
Legs Retracted Less Forks 45/1143 45/1143 45/1143
Height* in./mm** Mast Lowered 95/2413 95/2413 95/2413
Mast Raised 155/3937 155/3937 155/3937
Truck Overhang* (Less Forks) in./mm 45/1143 45/1143 45/1143
Length Under Truck Platform* in./mm Retracted 000
(
Less Forks
)
Fixed 31/787 31/787 31/787
Minimum Turning Radius in./mm Legs Extended 57/1447 57/1447 57/1447
Tires. Selection of Standard 10/16.5 NHS 8 Ply 10/16.5 NHS 8 Ply 10/16.5 NHS 8 Ply
Skid - Steer, Trencher or Turf Tread Optional 29 or 33 x 12.50 - 15 NHS 8 Ply 29 or 33 x 12.50 - 15 NHS 8 Ply 29 or 33 x 12.50 - 15 NHS 8 Ply
Engine Kubota V 1505 Diesel. 4 Cyl. Kubota V 1505-T Turbo Diesel 4. Cyl. Kubota V 1505-T Turbo Diesel 4. Cyl.
Output 37.5 HP @ 3000/RPM 46.5 HP @ 3000/RPM 46.5 HP @ 3000/RPM
Gross Intermittent Gross Intermittent Gross Intermittent
Max Travel Speed*** 8 mph/13 kph 8 mph/13 kph 8 mph/13 kph
Drive 3 Wheel Hydrostatic 3 Wheel Hydrostatic 3 Wheel Hydrostatic
Fork Carriage I.T.A. Class 11 I.T.A. Class 11 I.T.A. Class 11
Forks (Standard) in./mm 4x1 1/2 x 46 (102 x 38 x 1168) 4x1 1/2 x 46 (102 x 38 x 1168) 4x1 1/2 x 46 (102 x 38 x 1168)
Optional Forks Available Available Available
Adjustable Forks in./mm Standard 16/406. Mntg. Standard 16/406. Mntg. Standard 16/406. Mntg.
Posi-Traction, Manually Activated Hydraulic Diff. Lock Standard Standard Standard
Theft/Vandalism Deterrence Standard Standard Standard
Manual or Power Operated Hook-Up Kits Available Available Available
Back Rest, Backup Alarm and Amber Strobe Light Available Available Available
Counter Balance Weight Kit Available Available Available
10
*Standard Tires, **Standard Lift Height, ***Finger Tip Hydrostatic direction control with Inching Pedal, † Dry Weight
Due to continual product development, specifications are subject to change without notice. Specialty products available upon request.

OPERATING CONTROLS
1 Steering Wheel
2 Control Levers
3 Hydraulic Oil. Temperature
4 Engine Coolant. Temperature
5 Engine Oil Pressure. Warning Light
6 Alternator Charge. Warning Light
7 Park Brake Switch
8 Legs Retract Switch. (Option)
9 Diff-Lock Switch
10 Horn Button
11 Pre-Heat. ‘ON’ Light
12 Working Lights Switch
13 Hour Meter
14 Ignition. Start Switch
15 Fuse Block
16 F-N-R Lever
17 Throttle Pedal
18 ‘Inching’ Pedal
Fig.1
11

CONTROLS
PARK BRAKE
See Fig.3
The Park Brake must be ‘ON’ to start the engine.
IMPORTANT
The Park Brake must be ‘ON’ before leaving the operator’s seat.
IGNITION SWITCH
Fig.2 Fig.2
To start the engine turn the key to the ‘RIGHT’, do not apply
the throttle until the engine is running.
Engine ‘Pre-Heat’ is required when the ambient temperature
is below 50 deg. F. (10 deg.C).
Hold the key in the Pre-Heat position for 5 to 10 seconds
Before starting the engine.
F-N-R LEVER
Fig.3
The F-N-R Lever must be in ‘NEUTRAL’ before starting the
engine.
IMPORTANT
If the engine is started with the F-N-R Lever in forward or
reverse, the machine will not move until the lever is put into
‘NEUTRAL’, and then into forward or reverse. Fig.3
12

CONTROLS
CONTROL LEVERS
Fig.5 & 6
Do not operate the Control Levers when not seated in
the operator’s seat, except when loading or unloading the
Forklift on or off a truck or trailer.
LEVER ‘A’. Forward – Forks ‘DOWN’
Rearward – Forks ‘UP’
LEVER ‘B’. Forward – Tilt ‘FORWARD’
Rearward – Tilt ‘BACK’
LEVER ‘C’ Forward – Side Shift ‘LEFT’
Rearward – Side Shift ‘RIGHT’
LEVER ‘D’ Forward – Carriage ‘OUT’
Rearward – Carriage ‘IN’ Fig.4
LEVER ‘E’ Forward – Stabilizer ‘DOWN’
Rearward – Stabilizer ‘UP’
13

RETRACTABLE MODEL – Option
The Retractable Model allows the transport of the forklift
On a truck or trailer that does not have rear overhang.
DANGER
When operating a Retractable Model Forklift the
operator must observe the following procedure.
• Do not operate the machine when the legs
are retracted, except when mounting or dis-
mounting the forklift from a truck or trailer.
• The forks must be positioned in the fork
pockets with the legs fully extended before
retracting the legs.
• Do not raise the forks when the legs are re-
tracted.
Failure to follow these instructions may result
in the machine tipping, resulting in serious
injury or death.
14
To retract/extend the legs :
Fig.5
Position the Shift Lever in ‘NEUTRAL’ and start the engine.
The mast must be fully forward.
Put the Park Brake Switch in the ‘OFF’ position.
Press and hold down the ‘Extend/Retract’ Switch and at the
same time pull the Control Lever ‘D’ back, to retract the legs.
The Extend/Retract Switch can be released as soon as the
legs start to retract.
Release the Control Lever ‘D’ when the legs are fully
retracted.
To extend the legs push the Control Lever ‘D’ forward.
See pages 45-47 for transport/mounting instructions.
Fig.5

DIFF-LOCK
Fig.6
Traction may be lost as a result of poor ground conditions
or when driving up an incline.
The Diff-Lock can be applied to restore traction.
To apply the Diff-Lock :
Select ‘FORWARD’.
Push, and hold down, the Diff-Lock switch in the ‘ON’
position.
Slowly press the Throttle Pedal to increase the travel
speed.
Release the Diff-lock switch.
IMPORTANT
The Diff-Lock must be used for ‘straight line’ travel only.
The Diff-Lock must not be engaged if:
• the travel speed exceeds 4 mph.(6 Kph.)
• or if one of the wheels is ‘spinning’.
Fig.6
15

THROTTLE PEDAL
Fig.7
The Throttle pedal controls :
• Engine speed
• Vehicle speed
• Rate of operation of the hydraulic functions.
‘INCHING’ PEDAL
Fig.7
The ‘Inching’ Pedal reduces the vehicle speed in relation
to the throttle position. This allows for more precise control
when positioning, picking up, or placing a load.
Pressing the ‘Inching’ Pedal completely ‘down’ will bring the
forklift to a ‘stop’, while high engine speed can be main-
tained to allow the full speed operation of the hydraulic
functions without shifting to ‘NEUTRAL’.
WARNING
The Inching Pedal does not function as a Fig.7
‘park brake’.
It is recommended that the ‘park brake’
is applied when on an incline when loaded.
16

INSTRUMENT PANEL
Fig.8
LIGHTS SWITCH
The Lights Switch operates the Spot and Flood Lights that
are mounted on the F.O.P.S. Frame and the Reverse Flood
Light located in the rear panel.
ENGINE COOLANT. Temperature.
Normal operating temperature is 185 deg. F. (85 deg. C).
If the temperature exceeds this, allow the engine to ’idle’
for a short time. If the temperature remains high, switch the
engine ‘OFF’ immediately.
Check for any obvious signs of leaks.
Let the engine cool down before removing the radiator cap
in order to check the coolant level.
Rectify any leaks and top up the coolant before operating
the machine.
HYDRAULIC OIL. Temperature.
Normal operating temperature is 160 deg. F. (71 deg. C).
If the temperature approaches 200 deg. C. (93 deg. C.),
Let the engine ‘idle’ for a short time. If the temperature
remains high, shut down the machine immediately.
Check for hydraulic oil leaks.
Allow the system to cool down before checking the oil
level or attempting to rectify any leaks.
Fig.8
1. Hour Meter 7. Horn
2. Engine Temp. 8.Diff-Lock
3. Hydraulic Oil Temp’. 9. Parking Brake
4. Lights Switch 10. Alternator Lamp
5. Pre-Heat Lamp 11. Engine Oil Press’.
6. Retract/Extend Legs
17