Hoist Fitness FR15/25 User manual

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
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PLANNEDMAINTENANCE
LUBRICATIONPOINTS
TIRE&WHEEL
POWERTRAIN
MAST,BOOM&ATTACHMENT
STEERAXLE
REFERENCEMATERIAL
HYDRAULIC
ELECTRICAL
OPERATORDISPLAY
SAFETYPRECAUTIONS
OPTIONALEQUIPMENT

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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INDEX
SafetySignsandSafetyMessages.....................................................1.1
GeneralSafetyRules.........................................................................1.2
MaintenanceSafetyPractices...........................................................1.4
Do’sandDon’ts...............................................................................1.10
Lockout/TagoutProcedure..............................................................1.11
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FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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SAFETY SIGNS AND SAFETY MESSAGES
Improper service operation can cause accidents. Don’t take chances with incorrect or damaged
equipment. Read and understand the procedures for safe driving and maintenance outlined
in the is manual. Don’t hesitate to ask for help. Stay alert! Follow safety rules, regulations, and
procedures. Avoid accidents by recognizing dangerous procedures or situations before they
occur. Drive and work safely and follow the safety signs and their messages on the truck and
in this manual.
Safety signs and messages are placed in this manual and on the truck to provide instructions
and identify specific areas where potential hazards exist and special precautions should be
taken. Know and understand the meaning of these instructions, signs, and messages. Damage
to the truck, death, or serious injury to you or other persons may result if these messages are
not followed. If warning decals are damaged, they must be replaced.
NOTICE
This message is used when special information, instructions, or identification
are required relating to procedures, equipment, tools, pressures, capacities,
and other special data.
IMPORTANT
This message is used when special precautions should be taken to ensure a
correct action or to avoid damage to or malfunction of the truck or a component
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury. It may also be used to alert against unsafe practices.
WARNING
Indicates a potentially hazardous situation which, if not avoided, may result in
death or serious injury.
DANGER
Indicates a potentially hazardous situation which, if not avoided, will result in
death or serious injury.
1.1

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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GENERAL SAFETY RULES
 Wear ALL Personnel Protective Equipment, or PPE, as dictated by the work being done
as well as any company policy. It is recommended that safety glasses, a hard hat and
protective footwear always be warn as well as hearing protection if noise is excessive.
 Do NOT wear loose clothing or jewelry that can catch on controls or other parts of the
forklift. Make sure long hair is tied back and out of the way of moving parts.
 Attach an “OUT OF SERVICE” or similar warning tag to the key switch before servicing
or repairing any forklift. Disconnect battery if leaving unattended.
 Keep ALL equipment guards and shield in place and installed correctly to prevent
vibration, rubbing and heat buildup.
 Keep a fire extinguisher and first aid kit available AT ALL TIMES.
 Use ONLY adequately rated lift equipment with capacity labeled or marked. Use
supports or straps on any component or structural member that may fall.
1.2

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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GENERAL SAFETY RULES (CONT’D)
 Support equipment and attachments properly when working beneath them. Do NOT rely
on the vehicle hydraulics or hydraulic jacks to support the equipment.
 Keep the forklift free of dirt and oil. Secure ALL loose items such as tools that are not
part of the forklift.
 ALWAYS use the proper tool for the job and keep tools clean and in good working order.
 NEVER stand under suspended loads or raised forks or implements.
 Beware of pedestrians in the area. NEVER assume they see you. Do NOT proceed until
they are aware of your intended actions and have moved clear of the area.
 Read and thoroughly understand the Owner’s and Operator’s Manual PRIOR to
operating the forklift.
 Obey ALL traffic rules and warning signs.
 Do NOT let any unauthorized personnel operate the forklift at any time. NEVER carry
passengers on ANY part of the forklift.
 Do NOT stand on or between the counterweight when extended.
 Do NOT climb on any part of the mast or overhead guard/cab structure or permit others
to do so.
 Stay clear of ALL rotating and moving parts.
1.3

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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MAINTENANCE SAFETY PRACTICES
Provisions for Maintenance
Powered industrial trucks may become hazardous if maintenance is neglected or repairs,
rebuilds or adjustments are performed contrary to manufacturer’s criteria. Therefore
maintenance and inspection shall be performed in accordance with the manufacturer’s
recommendations and the following practices:
 Planned maintenance, including but not limited to, lubrication and inspection shall be
performed in accordance with the Preventative Maintenance Schedule provided in this
manual.
 Only trained and authorized personnel shall be permitted to maintain, repair, adjust and
inspect industrial trucks in accordance with the provided specifications.
 Brakes, Steering Mechanisms, Control Mechanisms, Warning Devices, Lights, Lift
Overload Devices, Guards and Safety Devices, Steer Axle Articulation Stops, and Frame
Members shall be carefully and regularly inspected and maintained in a safe operation
condition.
Before Starting Any Maintenance
 Park the forklift in authorized areas ONLY
 Park the forklift on a level surface with the forks fully lowered and the mast tilted forward
such that the fork tips touch the ground. NEVER work on soft ground.
 Place the transmission in NEUTRAL
 Stop the engine AND set the Parking Brake
 Remove the key and tag the forklift OUT OF SERVICE
 Block the drive wheels. Block the load engaging means, mast, and chassis WHENEVER
working on them
1.4

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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MAINTENANCE SAFETY PRACTICES (CONT’D)
Cleaning
 When using compressed (pressurized) air always use a general purpose nozzle to blow
dust and dirt from work area. ALWAYS wear eye protection, protective clothing and
protective shoes. Visually inspect the area prior to using an air hose. The maximum
pressure should NOT exceed 30 psi.
 Use ONLY approved, safe cleaning agents and solvents.
 Clean exterior of all parts when repairing. ALWAYS wear eye protection when steam
cleaning.
 Do NOT use steam, solvent, or high pressure to clean electrical components.
Engine and Cooling System
 Stop the engine whenever possible BEFORE performing service.
 Always start and run the engine in a well ventilated area. Avoid prolonged running of the
engine in closed areas. Vent exhaust to outside. NEVER operate the engine in a closed
building.
 Do NOT remove the radiator cap when the engine is running or hot. Engine coolant is
hot and under pressure and can cause severe burns. Allow the truck to cool down to
where the radiator cap is cool to the touch. When removing the radiator cap, turn slowly
to relieve pressure.
 When adding coolant MAKE SURE it is compatible and will mix with existing coolant.
 Cooling system additives contain alkali the can cause personnel injury. Avoid contact
with the skin and eyes. Do NOT ingest.
 Keep objects ALL away from moving fan blades.
1.5

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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MAINTENANCE SAFETY PRACTICES (CONT’D)
 Do NOT use starting fluid. Use of starting fluid with an engine equipped with an intake
heater can result in severe engine damage.
 Do NOT tamper with or modify the exhaust in any way.
Fuel System
 All fuels are flammable and MUST be handled with care.
 NEVER refuel the machine while the engine is running.
 NEVER refuel or service the fuel system while smoking or near open flames or sparks.
 Fuel leaked or spilled on hot surfaces or components CAN CAUSE A FIRE.
 Before disconnecting any part of the fuel system on LP gas powered trucks, close LP
tank valves and run the engine UNTIL FUEL IS DEPLETED and engine stops. If the
engine will not run, close LP truck valve and vent fuel slowly in a non-hazardous area.
 Use extreme care to prevent contamination from dirt and moisture. Contaminated fuel
can result in SEVERE engine damage.
 ALWAYS clean up fuel spills.
Hydraulics
 Hydraulic systems present a HIGH PRESSURE FLUID HAZARD. System pressure
MUST be relieved PRIOR to repairing, adjusting, or disconnecting ANY part of the
hydraulic system, including loosening hoses and tubes. With the truck OFF, operate all
controls including steering and braking to relieve stored pressure. This will also prevent
unintended movement of the steering mechanism when servicing.
 NEVER use your hands to find a pressure leak. When check for leaks ALWAYS use a
board or piece of cardboard. ALWAYS wear proper hand and eye protection. Even a
pinhole size leak can penetrate skin. If ANY fluid is injected into the skin it must be
treated by a doctor IMMEDIATELY.
1.6

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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MAINTENANCE SAFETY PRACTICES (CON’TD)
 At operating temperature the hydraulic tank will be hot. Remove the hydraulic tank filter
cap and cleanout cover ONLY AFTER engine has been stopped and the filter cap and
cleanout cover are cool to the touch. Remove slowly to allow any trapped pressure to
escape.
 Hot fluid and components can cause personal injury. Do NOT allow hot oil or
components to contact the skin.
 Ensure ALL hydraulic connections are tight and keep ALL components in good repair.
 Inspect hoses for damaged or leaking end fittings, chafed or cut outer covering, localize
ballooning or swelling, and evidence of kinking or crushing. REPLACE if any of these
conditions are present.
 All fluids should be handled with care. If you ingest any fluid or get fluid in the eyes seek
IMMEDIATE medical attention.
Electrical
 Batteries give off flammable fumes which can explode. Keep sparks, flames and
cigarettes AWAY. Use a flashlight to check electrolyte level if necessary.
 BEFORE servicing the electrical system disconnect the battery negative (-) cable to
prevent short circuits.
 Battery electrolyte can cause personal injury if it contacts skin or eyes. ALWAYS wear
PPE and in case of contact rinse area thoroughly with water and seek IMMEDIATE
medical attention.
1.7

FR15/25,FR18/26,&FR25/35SERVICEMANUAL
SAFETYPRECAUTIONS
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MAINTENANCE SAFETY PRACTICES (CON’TD)
 Charge batteries in well ventilated areas ONLY.
 ALWAYS wash hands after handling batteries.
 Clean and tighten ALL electrical connections. Check for loose or frayed wires and if
found repair or replace BEFORE operating the forklift.
 Do NOT operate in the vicinity of overhead power lines. Electrocution can occur without
direct contact.
Wheels and Tires
 Do NOT attempt to service a tire unless you have the proper equipment and training.
 ALWAYS wear PPE.
 Do NOT rely on the vehicle hydraulics or a hydraulic jack to support the forklift. The
forklift MUST be supported by suitable blocks or stands.
 Keep tires inflated to correct pressure. Do NOT over inflate tires.
 Servicing tires is potentially DANGEROUS. See Section 4, “TIRE & WHEEL SAFETY”
for detailed warnings and precautions.
1.8