Taylor THDC-954 User manual
Maintenance ManualMaintenance Manual
THDC / THDCP - 954 / 955 / 974THDC / THDCP - 954 / 955 / 974
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DEATH OR SERIOUS INJURY MAY RESULT FROM IMPROPERDEATH OR SERIOUS INJURY MAY RESULT FROM IMPROPER
OPERATION OF THIS MACHINEOPERATION OF THIS MACHINE
TTAAYLORYLORMACHMACHINEINEWORKSWORKS,, INC.INC.
650NORTHCHURCHAVE650NORTHCHURCHAVENUENUE
LOUISVILLOUISVILLE,MISSISSIPPI39339-201LE,MISSISSIPPI39339-20177
DD OPERATOR OPERATORMUSTMUSTBE TRAINED AND KNOWLEDGEABLE OFBE TRAINED AND KNOWLEDGEABLE OF
THE OPERATOR’S GUIDE, SAFETY MANUAL, AND OSHATHE OPERATOR’S GUIDE, SAFETY MANUAL, AND OSHA
STANDARD SECTION 29 CFR 1910.178 FOR POWEREDSTANDARD SECTION 29 CFR 1910.178 FOR POWERED
INDUSTRIAL TRUCKS.INDUSTRIAL TRUCKS.
DD CAPCAPACITY IS WITH ACITY IS WITH MAST INMAST INVERTICALVERTICALPOSITION ANDPOSITION AND
LOAD RETRACTED.LOAD RETRACTED.
DD CAPACITY CAPACITYGREATLYGREATLYDECREASES WITH TILTING, HIGHDECREASES WITH TILTING, HIGH
LOAD LIFTING, ACCELERATION, BRAKING, SHARPLOAD LIFTING, ACCELERATION, BRAKING, SHARP
TURNING,TURNING,HIGH WIND VELOCITY,HIGH WIND VELOCITY,AND POOR YARDAND POOR YARD
CONDITIONS.CONDITIONS.
DD TILTILT (MAST T (MAST AND LOAD AND LOAD OUT)OUT)ONLYONLYWHEN LOAD IS OVERWHEN LOAD IS OVER
A A STSTACK.ACK.
DD VISIBILITY MAVISIBILITY MAY BE IMPY BE IMPAIRED BY STRUAIRED BY STRUCTURALCTURAL
DESIGN. (DESIGN. (ALWAYSALWAYSLOOK IN DIRECTION OF TRAVEL;LOOK IN DIRECTION OF TRAVEL;
DO NOT RELY ON MIRRORS.)DO NOT RELY ON MIRRORS.)
DD DO DO NOTNOTOPERATE WITH BYSTANDERS PRESENT.OPERATE WITH BYSTANDERS PRESENT.
DD ALWAYS ALWAYSTRAVEL WITH LOAD IN LOWEST POSSIBLETRAVEL WITH LOAD IN LOWEST POSSIBLE
POSITION THAT ALLOWS GOOD VISIBILITY.POSITION THAT ALLOWS GOOD VISIBILITY.
DD ALWAYS ALWAYSWEAR SEAT BELT WHILE MACHINE IS INWEAR SEAT BELT WHILE MACHINE IS IN
OPERATION.OPERATION.
DD DO DO NOTNOTATTEMPT TO JUMP FROM MACHINE IN EVENT OFATTEMPT TO JUMP FROM MACHINE IN EVENT OF
TIP OVER. REMAIN SEATED WITH SEAT BELT FASTENED.TIP OVER. REMAIN SEATED WITH SEAT BELT FASTENED.
3374 7153374 715
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
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CAUTIONCAUTION
Observe The Following Precautions For Maximum Safety Of Machine OperationObserve The Following Precautions For Maximum Safety Of Machine Operation
1. 1. Only traiOnly trained and responsible operned and responsible operators shall ators shall be permitted to handle lbe permitted to handle loads with thioads with this truck.s truck.
2. 2. OperOperate the trucate the truck from thk from the operate operator’s seaor’s seat onlyt only. . Do not alloDo not allow ridew riders.rs.
3. 3. TTest hydrauliest hydraulic controls fc controls for proper resor proper response before using the macponse before using the machine.hine.
4. 4. Know your lKnow your load. oad. Do not attemDo not attempt to lift pt to lift or transor transport loads iport loads in excess n excess of rated capacof rated capacityity..
5. 5. When the load obstrWhen the load obstructs the viewucts the view, operate the truck i, operate the truck in the reverse range.n the reverse range.
6. 6. Do not sDo not stand or wtand or work undork under an eleer an elevatevated load.d load.
7. 7. TTransransport tport the load low anhe load low and tiltd tilted backed back..
8. 8. AvAvoid suoid sudden sdden stops wtops with a lith a load.oad.
9. 9. CentCenter the load to evener the load to evenly disly distritribute the weibute the weight.ght.
10.10. Back dowBack down a n a ramramp in p in excexcess of 10 ess of 10 percpercent when loaded.ent when loaded.
11. Do not move the truck until the air system reaches rec11. Do not move the truck until the air system reaches recommended pressurommended pressure. e. Air pressure isAir pressure is
required for the service brakes.required for the service brakes.
12.12. Have defects repaiHave defects repaired immedired immediatelyately. . Do not operate a truck with damaged or defectiDo not operate a truck with damaged or defective sys-ve sys-
tems.tems.
13.13. When leaving truck, liftiWhen leaving truck, lifting mechanism shall be fully lowered, controls shall be neutralized, pow-ng mechanism shall be fully lowered, controls shall be neutralized, pow-
er shut off, parker shut off, parking brake set, and key removed. ing brake set, and key removed. Block wheels iBlock wheels if on incline.f on incline.
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TMW-057-3 (7/99)TMW-057-3 (7/99)
LIMITED WARRANTYLIMITED WARRANTY
Products manufactured by Taylor Machine Works, Inc. (“Taylor”) and sold are warranted by Taylor to be free fromProducts manufactured by Taylor Machine Works, Inc. (“Taylor”) and sold are warranted by Taylor to be free from
defects in material and workmanship, under normal use and service, when Taylor products are operated at ordefects in material and workmanship, under normal use and service, when Taylor products are operated at or
below rated capacity* below rated capacity* in accordance with operating in accordance with operating instructions.instructions.
This warranty is limited to repair or replacement, (as Taylor may elect, and at an establishment authorized byThis warranty is limited to repair or replacement, (as Taylor may elect, and at an establishment authorized by
Taylor) of such parts as shall appear to Taylor upon inspection to have been defective in material orTaylor) of such parts as shall appear to Taylor upon inspection to have been defective in material or
workmanship.workmanship.
This warranty period shall begin on the delivery date of the product to the Purchaser and end on the earlier ofThis warranty period shall begin on the delivery date of the product to the Purchaser and end on the earlier of
twelve (12) monttwelve (12) months or hs or two thousand (2000two thousand (2000) hours. ) hours. During the first six (6) months or one thousand (1000) hours,During the first six (6) months or one thousand (1000) hours,
Taylor will provide genuine Taylor parts, labor, and travel time to replace or repair any part furnished by Taylor andTaylor will provide genuine Taylor parts, labor, and travel time to replace or repair any part furnished by Taylor and
found to be defective in material and workmanship. found to be defective in material and workmanship. If a defect in material and workmanship is found durIf a defect in material and workmanship is found during theing the
first six (6) months and/or one thousand (1000) hours whichever occurs first of the warranty period, Taylor willfirst six (6) months and/or one thousand (1000) hours whichever occurs first of the warranty period, Taylor will
replace lubricating oil, replace lubricating oil, filters, antifreeze, and other serfilters, antifreeze, and other service items made unusable by the defect. vice items made unusable by the defect. In the second sixIn the second six
(6) months and/or second one thousand (1000) hours after the delivery date of the truck, Taylor will approve parts(6) months and/or second one thousand (1000) hours after the delivery date of the truck, Taylor will approve parts
onlyonly. . Only genuine TaylOnly genuine Taylor parts provided by Taylor’s Sudden Service, Inc. will be used during the warranty period.or parts provided by Taylor’s Sudden Service, Inc. will be used during the warranty period.
THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY:THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY:
1. 1. Normal maiNormal maintenanntenance servicece services and parts or supplies uses and parts or supplies used therein includ therein including, withoding, without limitationut limitation, en-, en-
gine tune-up, wheel alignment, brake and linkage adjustment, lubrication services, tightening andgine tune-up, wheel alignment, brake and linkage adjustment, lubrication services, tightening and
adjusting such as bolts, screws, hoses, fittings, etc., replacement of fuses, bulbs, filters, tune-upadjusting such as bolts, screws, hoses, fittings, etc., replacement of fuses, bulbs, filters, tune-up
parts, fluids and brake and clutch linings, glass; shop supplies such as rags, oil dry, hand soaps,parts, fluids and brake and clutch linings, glass; shop supplies such as rags, oil dry, hand soaps,
degreasers, cleaning solutions including brake clean, etc.; and adjustments which are a part ofdegreasers, cleaning solutions including brake clean, etc.; and adjustments which are a part of
the required or recommended predelivery inspection and periodic inspections in accordance withthe required or recommended predelivery inspection and periodic inspections in accordance with
Operator’s ManuOperator’s Manual. al. ElectricaElectrical componenl components includints including wiring will be excluded after the first six (6)g wiring will be excluded after the first six (6)
months or one thousand (1000) hours whichever occurs first.months or one thousand (1000) hours whichever occurs first.
2. 2. Normal deNormal deterioratiterioration of appeaon of appearance durance due to use and expoe to use and exposure; or condisure; or conditions resutions resulting from mislting from mis--
use, negligence, or accident.use, negligence, or accident.
3. 3. Any produAny product on which any of the requct on which any of the required or recomired or recommendemended periodd periodic inspecic inspections or servitions or services haveces have
not been made.not been made.
4. 4. Any parts or accesAny parts or accessoriessories, installed o, installed on the product whin the product which were not manch were not manufactureufactured or installed or installed byd by
Taylor whether or not such parts or accessories were selected, recommended or installed by Tay-Taylor whether or not such parts or accessories were selected, recommended or installed by Tay-
lor (includilor (including without limitationng without limitation, , enginengines, tires, es, tires, batteriebatteries, air s, air condiconditionerstioners, air , air dryers, etc.). dryers, etc.). SuchSuch
parts or accessories shall be covered by the warranties given by the manufacturers thereof andparts or accessories shall be covered by the warranties given by the manufacturers thereof and
any claim thereof shall be made to such manufacturers.any claim thereof shall be made to such manufacturers.
5. 5. Loss of time, incoLoss of time, inconveninvenience, losence, loss of equipmes of equipment use, other consnt use, other consequenequential damatial damages or other mat-ges or other mat-
ters not specifically included.ters not specifically included.
Taylor parts and assemblies which are furnished and installed under this warranty are themselves withinTaylor parts and assemblies which are furnished and installed under this warranty are themselves within
the coverage of the machine warranty and are covered only for the duration of the original machinethe coverage of the machine warranty and are covered only for the duration of the original machine
warranty period.warranty period.
NOTE:NOTE: All International warrantAll International warranty parts shipments are Fy parts shipments are F.O.B. point of debar.O.B. point of debarkation, duties, tarifkation, duties, tariffs, or localfs, or local
taxes excluded.taxes excluded.
This warranty is expressly in lieu of any other warranties, expressed or implied, including any warranty ofThis warranty is expressly in lieu of any other warranties, expressed or implied, including any warranty of
merchantability or fitness for a particular purpose.merchantability or fitness for a particular purpose.
ReplaceReplacement parts are warranted for ninety (90) days to ment parts are warranted for ninety (90) days to be free from be free from defectdefects in s in matermaterial or workmanshipial or workmanship. . PartsParts
onlyonly, , no no labor.labor.
Taylor Machine Works, Inc. does not authorize any person to create (for Taylor) any other obligation or liability inTaylor Machine Works, Inc. does not authorize any person to create (for Taylor) any other obligation or liability in
connection with Taylor products.connection with Taylor products.
*For example, *For example, a maca machine rated hine rated capacity capacity at any at any stipulated load stipulated load center is center is the rated the rated lift capacity lift capacity at less at less thanthan
load centerload center. . That is, a That is, a machinmachine rated at 20,000 pounds at e rated at 20,000 pounds at 24-in24-inch load center connotes 20,000 poundsch load center connotes 20,000 pounds
is the maximum lift capacity even though the load center may be less than 24-iis the maximum lift capacity even though the load center may be less than 24-inches. nches. Subjecting TSubjecting Tayloraylor
products to conditions or loads exceeding those stipulated is justification for immediate cancellation ofproducts to conditions or loads exceeding those stipulated is justification for immediate cancellation of
warranty for products involved.warranty for products involved.
TAYLOR MACHINE WORKS, INC.TAYLOR MACHINE WORKS, INC.
650 North Church Avenue650 North Church Avenue
Louisville, Mississippi 39339Louisville, Mississippi 39339
(662) 773-3421 / Fax 662-773-9146(662) 773-3421 / Fax 662-773-9146
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IntroductionIntroduction
TTHHDDCC--99554 4 - - 99555 5 ((66//9999) ) IInnttrroo
This manual is to be used as a guide for lubrication and maintenance as well as general equipment care.This manual is to be used as a guide for lubrication and maintenance as well as general equipment care.
A A separate separate section section is is provided provided to to discuss discuss each each major major componencomponent t or or system. system. This This method method of of presentingpresenting
the maintenance instructions enables Taylor Machine Works, Inc. to assemble a maintenance manual withthe maintenance instructions enables Taylor Machine Works, Inc. to assemble a maintenance manual with
explicit instructions on the exact equipment installed on the machine.explicit instructions on the exact equipment installed on the machine.
No single rule in the booklet can be followed to the exclusNo single rule in the booklet can be followed to the exclusion of others. ion of others. Each rule must be considerEach rule must be considered ined in
light of the other rules, the knowledge and training of the man (operator), the limitations of the machine,light of the other rules, the knowledge and training of the man (operator), the limitations of the machine,
and the workplace environment.and the workplace environment.
Warnings and cautions are included to reduce the probability of personal injury, when performing mainte-Warnings and cautions are included to reduce the probability of personal injury, when performing mainte-
nance procedures which if imprnance procedures which if improperly performoperly performed could be ed could be potentiallpotentially hazardous. y hazardous. Failure to comply wiFailure to comply withth
these warnings and cautions can result in serious injury and possible death.these warnings and cautions can result in serious injury and possible death.
All All circumstances circumstances and and conditions conditions under under which which service service will bwill be e performed performed cannot cannot be be anticipated. anticipated. Do Do notnot
perform any service if you are unsure perform any service if you are unsure that it can that it can be done be done safelysafely. . Contact your TContact your Taylor Dealer or Taylor Dealer or Tayloraylor
Machine Works, Inc. if you have questions about the proper service techniques.Machine Works, Inc. if you have questions about the proper service techniques.
WARNING:WARNING:Operating this powered industrial truck when it is in need of repair can result inOperating this powered industrial truck when it is in need of repair can result in
death or serious injury to the operator or other personnel or cause severe property damage.death or serious injury to the operator or other personnel or cause severe property damage.
Machine checks must be performed daily:Machine checks must be performed daily:
1. 1. beforbefore the mace the machine is plhine is placed in seaced in servirvice,ce,
2. 2. by qualifiby qualified, trained, ed, trained, and skilland skilled personnel wed personnel who have proper toolho have proper tools and knowls and knowledge, andedge, and
3. 3. in accorin accordance with tdance with the Operator’s Guihe Operator’s Guide, Maintenancde, Maintenance Manual and Safete Manual and Safety Check by Check booklet.ooklet.
MaintenanMaintenance ce ManualManual
!!
..
Operators GuideOperators Guide
!! ..
Regularly ScheduledRegularly Scheduledmaintenance, lubrication, and safety inspections will help ensure a safe andmaintenance, lubrication, and safety inspections will help ensure a safe and
productive work life for the machine and the operator(s).productive work life for the machine and the operator(s).
WARNING:WARNING:Do not operDo not operate the truck if it is in need of repairate the truck if it is in need of repair. . Remove the igniRemove the ignition key andtion key and
attach a “Lock-out” tag.attach a “Lock-out” tag.
WARNING:WARNING:Do not attempt to perform maintenance procedures unless you have beenDo not attempt to perform maintenance procedures unless you have been
thoroughly trained and you have the proper tools.thoroughly trained and you have the proper tools.
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
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THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)IntroIntro
WARNING:WARNING:Use only genuine TUse only genuine Taylor replacemenaylor replacement parts. t parts. Lesser quality partLesser quality parts may s may fail,fail,
resultresulting in ing in propproperty damage, erty damage, personal injurpersonal injury y or death.or death.
Maintenance and / or service personnel who find it necessary to operate this machine, even for a shortMaintenance and / or service personnel who find it necessary to operate this machine, even for a short
period of time, must fully understand all operational literature including:period of time, must fully understand all operational literature including:
•• OSHA operating ruOSHA operating rules found in 29 CFR 1910.les found in 29 CFR 1910.178; Appendix A in Safety Chec178; Appendix A in Safety Checkk
•• ANSI B56.1 rules for operatiANSI B56.1 rules for operating a powered industrial trng a powered industrial truck; Appendix B in Safety Checkuck; Appendix B in Safety Check
•• The Operator’s The Operator’s Guide for the mGuide for the machineachine
•• The manufacThe manufacturer’s Safturer’s Safety Bookletety Booklet
•• The manufacThe manufacturer’s Safturer’s Safety Videoety Video
•• The manufactThe manufacturer’s Servurer’s Service Bulletiice Bulletinsns
•• The content and meaning of alThe content and meaning of all machine decall machine decalss
WARNING:WARNING:Know how to avoid slip and fall accidents such as those described in the Slip andKnow how to avoid slip and fall accidents such as those described in the Slip and
Fall Accidents Section of Safety Check.Fall Accidents Section of Safety Check.
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SafetySafety
TTHHDDC C / / TTHHDDCCP P - - 99554 4 / / 99555 5 / / 99774 4 ((RReevv. . 0066//0033) ) SSaaffeettyy--11
Safety FirstSafety First
Important Safety InstructionsImportant Safety Instructions
Observe these rules. They are recognized asObserve these rules. They are recognized as
practices that reduce the risk of injury to yourselfpractices that reduce the risk of injury to yourself
and others, or damage to the container handlingand others, or damage to the container handling
truck or load.truck or load.
This manual contains maintenance and serviceThis manual contains maintenance and service
procedures for procedures for fillifilling, ng, lubriclubricating, removing, repair-ating, removing, repair-
ing, and installing various components comprisinging, and installing various components comprising
a container handla container handling trucing truck. k. Because of the sBecause of the sizeize
and weight of the container handling truck, andand weight of the container handling truck, and
high pressures in some of the components andhigh pressures in some of the components and
systemsystems, improperly performing service on s, improperly performing service on thethe
truck can be dangerous.truck can be dangerous.
Warnings and cautions are included to reduce theWarnings and cautions are included to reduce the
probabilitprobability y of of personal injurypersonal injury, , when when performperforminging
maintenance procedures which maintenance procedures which if improperlyif improperly
performed cperformed could be potentially hazould be potentially hazardous. ardous. FailureFailure
to comply with these warnings and cautions canto comply with these warnings and cautions can
result in serious injury and possible death.result in serious injury and possible death.
No single rule in the booklet can be followed toNo single rule in the booklet can be followed to
the exclusthe exclusion of othersion of others. . Each rule muEach rule must be con-st be con-
sidered in light of the other rules, the knowledgesidered in light of the other rules, the knowledge
and training of the man (operator / maintenance),and training of the man (operator / maintenance),
the limitations of the machine, and the workplacethe limitations of the machine, and the workplace
environment.environment.
Report all mechanical problems to mechanics andReport all mechanical problems to mechanics and
supervisors.supervisors.
Proper Training:Proper Training:
TTaylor Machine aylor Machine WorkWorks, Inc. s, Inc. publishes Safetypublishes Safety
Check, TMW-072 a booklet citing some safetyCheck, TMW-072 a booklet citing some safety
precautions to observe during lift truck operation.precautions to observe during lift truck operation.
One copy is shipped with each lift truck; additionalOne copy is shipped with each lift truck; additional
copies are available at a nominal fee from thecopies are available at a nominal fee from the
authorized Taylor dealer from which the equip-authorized Taylor dealer from which the equip-
ment was ment was initialinitially purchased.ly purchased.
Minimum Required Personnel Safety EquipmentMinimum Required Personnel Safety Equipment
1. 1. HaHard rd HaHatt
2. 2. SafSafety ety ShoShoeses
3. 3. SafeSafety ty GlasGlassesses
4. 4. HeHeavy avy GlGloveovess
5. 5. HearHearing ing ProtProtectiectionon
6. 6. ReflReflectiective ve CloClothinthingg
Failure to follow the safety precautions outlined inFailure to follow the safety precautions outlined in
this manual can create a dangerous situation.this manual can create a dangerous situation.
Some of the common ways this can occur are asSome of the common ways this can occur are as
follows:follows:
1. 1. Use of hUse of hoisoisting deting devicvices not ces not capablapable ofe of
supporting the weight of the component beingsupporting the weight of the component being
lifted.lifted.
2. 2. ImpImproper aroper attacttachmenhment of slit of slings to heavngs to heavyy
components being hoisted.components being hoisted.
3. 3. Use of inUse of inadequadequate or rotate or rotten timten timbers fbers for sup-or sup-
port or improper alignment of supportingport or improper alignment of supporting
material.material.
4. 4. FailurFailure to secure to securely blocely block the wk the wheels, wheels, when dis-hen dis-
connecting or removing components that holdconnecting or removing components that hold
the container handling truck stationary underthe container handling truck stationary under
normal normal conditionsconditions..
5. 5. FaiFailurlure to read and undere to read and understanstand the safetd the safety pre-y pre-
cautions in this manual.cautions in this manual.
WARNING:WARNING: Know how to avoid accidentsKnow how to avoid accidents
such as those described in the Maintenance /such as those described in the Maintenance /
Service Accidents Section of Safety Check:Service Accidents Section of Safety Check:
Some Maintenance / Some Maintenance / ServicinServicing g AccidenAccidentsts
Listed below:Listed below:
1. 1. ImproperImproperly ly refueling refueling the the truck.truck.
2. 2. ImproperImproperly cly checking hecking for hyfor hydraulic draulic leaks leaks oror
diesel fuel leaks.diesel fuel leaks.
3. 3. ImproperImproperly ly checkichecking the ng the engine engine coolingcooling
system.system.
4. 4. ImproperImproperly cly checking hecking battery battery fluid lfluid levels evels oror
“jump” starting engines.“jump” starting engines.
5. 5. PuttPutting air in a multing air in a multi-pi-piece tiiece tire and rim assre and rim assem-em-
bly without proper tools and training.bly without proper tools and training.
6. 6. AttemptiAttempting to serng to service a vice a multimulti-piece ti-piece tire and rire and rimm
assembly without proper tools and training.assembly without proper tools and training.
7. 7. Using Using an iman improperly properly suited suited chain wchain whilehile
performperforming ing maintenancmaintenance.e.
8. 8. Using Using the contathe container handliner handling tring truck hyuck hydraulicdraulic
system as a substitute for a fixed stand.system as a substitute for a fixed stand.
9. 9. RelRelyinying on jacks or hg on jacks or hoistoists to suppos to support heavrt heavyy
loads.loads.
10.10. OperOperatinating a g a tructruck that is damagek that is damaged or d or in needin need
of repair.of repair.
11. Climbing on the mast of a forklift, on the top of11. Climbing on the mast of a forklift, on the top of
the cab, or other high places on the containerthe cab, or other high places on the container
handling truck.handling truck.
12.12. Operating a containOperating a container handling trucer handling truck whichk which
has been modified without the manufacturer’shas been modified without the manufacturer’s
approval. approval. This inclThis includes the attachmentudes the attachment, coun-, coun-
terweiterweight, ght, tires, etc.tires, etc.
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Safety-2Safety-2 THDC THDC / / THDCP THDCP - - 954 954 / / 955 955 / / 974 974 (Rev(Rev. . 06/03)06/03)
13.13. Lifting people with a forklLifting people with a forklift not properlyift not properly
equipped for elevating personnel.equipped for elevating personnel.
14.14. ImproperlImproperly using chaiy using chains.ns.
15. Improperly blocking and supporting mast, car-15. Improperly blocking and supporting mast, car-
riage, or attachment before repairing truck.riage, or attachment before repairing truck.
MaintenMaintenance ance / / Service Personnel:Service Personnel:
1. 1. Keep the trKeep the truck cluck clean, frean, free of oil, gree of oil, grease andease and
fuel.fuel.
2. 2. Steam cSteam clean / waslean / wash the truch the truck prik prior to perfor to performorm--
ing maintenancing maintenance. e. Wear antiWear anti-sli-slip footwearp footwear
when when performperforming ing maintenancmaintenance e proceduresprocedures..
3. 3. Use OSHUse OSHA approvA approved laddeed ladders and others and other proper properr
cleaning accessories to access hard to reachcleaning accessories to access hard to reach
maintenance places.maintenance places.
4. 4. Keep gratKeep gratings fings free of icree of ice, dire, dirt and gravt and gravel.el.
5. 5. RegularlRegularly inspecy inspect and replt and replace anti-ace anti-slip mslip masticastic
on the vehicle as needed.on the vehicle as needed.
6. 6. EnsurEnsure all sae all safety dfety decalecals are in ps are in place on tlace on thehe
vehiclevehicle..
WARNING:WARNING: Remove all rings, watches,Remove all rings, watches,
chains, other jewelrychains, other jewelry, , and all and all loose clothingloose clothing
before working around moving parts!before working around moving parts!
WARNING:WARNING: Do not operate the vehicle orDo not operate the vehicle or
attempattempt t to perform maintenanto perform maintenance ce on the on the vehiclevehicle
while under the influence of alcohol, drugs, orwhile under the influence of alcohol, drugs, or
any other medications or substances that slowany other medications or substances that slow
reflexes, alter safe judgement, or cause drows-reflexes, alter safe judgement, or cause drows-
iness.iness.
WARNING:WARNING: Never park the containerNever park the container
handlhandling truck on an ining truck on an incline. cline. Always park theAlways park the
container handling truck on a level surface;container handling truck on a level surface;
otherwise, the lift truck could possibly rollotherwise, the lift truck could possibly roll
resultresulting in ing in possiblpossible e injurinjury y to personnel orto personnel or
damage to the truck or other property.damage to the truck or other property.
WARNING:WARNING: Maintenance and serviceMaintenance and service
personpersonnel should never nel should never operate this lift operate this lift trucktruck
unless they are thoroughly familiar with Safetyunless they are thoroughly familiar with Safety
Check, TMW-072 and the Operator’s Guide forCheck, TMW-072 and the Operator’s Guide for
this lift truck.this lift truck.
WARNING:WARNING: Electrical, mechanical, andElectrical, mechanical, and
hydraulic safety devices have been installedhydraulic safety devices have been installed
on this container handling truck to help protecton this container handling truck to help protect
against personal injury and / or damage toagainst personal injury and / or damage to
equipequipment. ment. Under no circuUnder no circumstances shoumstances shouldld
any attempt be made to disconnect or in anyany attempt be made to disconnect or in any
way render any oway render any of these devices inf these devices inoperaboperable. le. IfIf
you discover that any safety device is mal-you discover that any safety device is mal-
functioning, Do Not operate the truck; notifyfunctioning, Do Not operate the truck; notify
appropriate maintenance personnel immedi-appropriate maintenance personnel immedi-
ately.ately.
WARNING:WARNING: Use only genuine TaylorUse only genuine Taylor
replacemreplacement parts. ent parts. Lesser qualitLesser quality parts mayy parts may
fail, resulting in property damage, personalfail, resulting in property damage, personal
injurinjury y or death.or death.
WARNING:WARNING: Keep all hydraulic com-Keep all hydraulic com-
ponents in good repair.ponents in good repair.
WARNING:WARNING: Relieve pressure on theRelieve pressure on the
hydrauhydraulic lic system before system before repairirepairing ng or adjustingor adjusting
or disconnecting.or disconnecting.
WARNING:WARNING: Wear proper hand and eyeWear proper hand and eye
protection when searching for leaks. Use woodprotection when searching for leaks. Use wood
or cardboard instead of hands.or cardboard instead of hands.
WARNING:WARNING: Under no circumstances,Under no circumstances,
without prior written approval from Taylorwithout prior written approval from Taylor
Machine Works, Inc. Engineering Department,Machine Works, Inc. Engineering Department,
shoulshould d the container handling truck be the container handling truck be modi-modi-
fied, i.e. adding of additional counterweights.fied, i.e. adding of additional counterweights.
As per OSHA 29 CFR1910.178 (a) (4).As per OSHA 29 CFR1910.178 (a) (4).
Container Handling Truck Lock-out / Tag-out:Container Handling Truck Lock-out / Tag-out:
The engine should be locked-out / tagged-out toThe engine should be locked-out / tagged-out to
prevent it from being inadvertently started beforeprevent it from being inadvertently started before
performperforming maintenancing maintenance or repairs. e or repairs. The batteryThe battery
should be locked-out / tagged-out to prevent acci-should be locked-out / tagged-out to prevent acci-
dental activation of the starter and possible start-dental activation of the starter and possible start-
ing thing the enginee engine. . RefRefer toer toLock-Out / Tag-Out Pro-Lock-Out / Tag-Out Pro-
cedurecedurein the back of this section for thein the back of this section for the
procedures to be followed to perform lock-out /procedures to be followed to perform lock-out /
tag-out.tag-out.
WARNING:WARNING: Turn the engine off andTurn the engine off and
remove the ignition key before entering the tireremove the ignition key before entering the tire
pivot area to prevent death or serious injurypivot area to prevent death or serious injury
from pivoting tires.from pivoting tires.
WARNING:WARNING: DeflatDeflate tires before removinge tires before removing
(the ti(the tires). res). Always remoAlways remove the valve core andve the valve core and
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TTHHDDC C / / TTHHDDCCP P - - 99554 4 / / 99555 5 / / 99774 4 ((RReevv. . 0066//0033) ) SSaaffeettyy--33
exhaust all air from a single tire and both tiresexhaust all air from a single tire and both tires
of a dual assembly prior to removing any rimof a dual assembly prior to removing any rim
components or wheel components such ascomponents or wheel components such as
nuts and rnuts and rim clampim clamps. s. Run a piece of Run a piece of wirewire
through the valve stem to make sure the valvethrough the valve stem to make sure the valve
stem is not damaged or plugged and all air isstem is not damaged or plugged and all air is
exhausted.exhausted.
WARNING:WARNING: Serious falls and injuries canSerious falls and injuries can
result from improper mounting or dismountingresult from improper mounting or dismounting
of the of the containcontainer er handlihandling truck.ng truck.
Mounting and Dismounting:Mounting and Dismounting:
1. 1. FacFace the contae the container hainer handlindling trucng truck when getk when get--
ting on or off the truck.ting on or off the truck.
2. 2. One hand aOne hand and twnd two feet oo feet or twr two hands o hands and oneand one
foot must be in contact with the truck at allfoot must be in contact with the truck at all
times (3 point contact).times (3 point contact).
3. 3. Use haUse handrandrails ails and other gnd other grab poirab points.nts.
WARNING:WARNING: Do not start the engine if theDo not start the engine if the
ignitignition switch, or ion switch, or engine control panel hasengine control panel has
been locked-out / been locked-out / tagged-tagged-out by out by maintenmaintenanceance
personnpersonnel. el. Doing so can resuDoing so can result in personlt in personalal
injurinjury and / or damage to the equy and / or damage to the equipmentipment. . If inIf in
doubt, contact the maintenance supervisor.doubt, contact the maintenance supervisor.
WARNING:WARNING: If maintenance requires run-If maintenance requires run-
ning the engine indoors, ensure the room hasning the engine indoors, ensure the room has
adequate flow-through ventilation!adequate flow-through ventilation!
WARNING:WARNING: Never operate the containerNever operate the container
handling truck without proper instruction.handling truck without proper instruction.
IgnorIgnorance ance of operational characteristiof operational characteristics cs andand
limitatlimitations can ions can lead to lead to equipequipment damage,ment damage,
personal injury, or death.personal injury, or death.
WARNING:WARNING: Do not operate the containDo not operate the containerer
handlihandling truck ng truck withowithout the ut the seat belt seat belt propproperlyerly
and securely fastened.and securely fastened.
WARNING:WARNING: Operating instructions, warn-Operating instructions, warn-
ings, and caution labels are placed on the con-ings, and caution labels are placed on the con-
tainer handling truck to alert personnel to dan-tainer handling truck to alert personnel to dan-
gers and to advise personnel of propergers and to advise personnel of proper
operatioperating procedng procedures (of the lift trures (of the lift truck). uck). Do notDo not
remove or obscure any warning, caution, dan-remove or obscure any warning, caution, dan-
ger, or instructional sign or label.ger, or instructional sign or label.
Traveling:Traveling:
Start, stop, change direction and travel smoothly.Start, stop, change direction and travel smoothly.
Slow down while turning.Slow down while turning.
Obstructions And Clearances:Obstructions And Clearances:
Watch end clearances and overhead obstructions.Watch end clearances and overhead obstructions.
WARNING:WARNING: Do not release the parkingDo not release the parking
brake or attempt to move the container han-brake or attempt to move the container han-
dling truck if the air pressure gauge indicatesdling truck if the air pressure gauge indicates
that the air pressure is below 100 psi.that the air pressure is below 100 psi.
WARNING:WARNING: Make sure all ground person-Make sure all ground person-
nel know the rules and responsibilities set bynel know the rules and responsibilities set by
your emplyour employeroyer. . Make sure they know what youMake sure they know what you
are going to do and be sure they are clear ofare going to do and be sure they are clear of
the area before you move the container han-the area before you move the container han-
dling truck.dling truck.
WARNING:WARNING: Cameras are not substitutesCameras are not substitutes
for looking in the direction of and keeping afor looking in the direction of and keeping a
clear vieclear view of the path of traw of the path of travel. vel. NeveNever user use
them as them as substisubstitutes,tutes,AlwaysAlwayslook in the path oflook in the path of
travel.travel.
WARNING:WARNING: Total reliance on electricalTotal reliance on electrical
aids can be dangeroaids can be dangerous. us. The responThe responsibilisibility forty for
safe safe operatoperation of ion of the container handling truckthe container handling truck
shall remain with the operator who shallshall remain with the operator who shall
ensure that all warning and instructions pro-ensure that all warning and instructions pro-
vided are fully understood and observed.vided are fully understood and observed.
WARNING:WARNING: Do not operate the containDo not operate the containerer
handlihandling truck ng truck until both forward and until both forward and reversereverse
travel pathtravel paths are clear. s are clear. Do not opDo not operate the truerate the truckck
with with bystandbystanders ers presentpresent..
WARNING:WARNING: Do not move the containerDo not move the container
handlihandling truck ng truck until the surroundiuntil the surrounding area ng area hashas
been checked and is clear of personnel andbeen checked and is clear of personnel and
obstructions.obstructions.
WARNING:WARNING: Always look in the directionAlways look in the direction
of travel and keep a clear view of the path ofof travel and keep a clear view of the path of
travel; travel; slow down and soslow down and sound the hound the horn at crossrn at cross
aisles and other locations where vision may beaisles and other locations where vision may be
obscured.obscured.
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Safety-4Safety-4 THDC THDC / / THDCP THDCP - - 954 954 / / 955 955 / / 974 974 (Rev(Rev. . 06/03)06/03)
WARNING:WARNING: This equipment is not electri-This equipment is not electri-
cally insulatcally insulated. ed. ContContact with electriact with electricity cancity can
cause severe injucause severe injury or deathry or death. . ElectrocuElectrocutiontion
can occur withcan occur without dirout direct contact. ect contact. Do not opDo not oper-er-
ate this container handling truck in areas withate this container handling truck in areas with
energized power lines or a power supply.energized power lines or a power supply.
Check local, state and federal safety codes forCheck local, state and federal safety codes for
propproper clearance. er clearance. Use a groundUse a groundman to ensurman to ensuree
that there is proper clearance.that there is proper clearance.
WARNING:WARNING: Do not allow anyone on theDo not allow anyone on the
container handling truck during operation.container handling truck during operation.
WARNING:WARNING: Do not move the containerDo not move the container
handling truck onto a surface or area that hashandling truck onto a surface or area that has
not been not been approapproved ved for container handlinfor container handlingg
truck operattruck operation. ion. The container hanThe container handling trudling truckck
is heavy and could possibly break through anis heavy and could possibly break through an
insufficient surface and cause damage to theinsufficient surface and cause damage to the
truck or injury to personnel.truck or injury to personnel.
WARNING:WARNING: Do not operate the containerDo not operate the container
handlihandling truck over pothng truck over potholes and debris. oles and debris. ClearClear
the yard the yard of obstructioof obstructions.ns.
WARNING:WARNING: AvAvoid sudden startoid sudden starts ands and
stops.stops.
WARNING:WARNING: Serious falls or injuries canSerious falls or injuries can
result from riding on result from riding on the container handlingthe container handling
truck! truck! Do not ride on the contDo not ride on the container handlainer handlinging
truck.truck.
Handling Loads:Handling Loads:
WARNING:WARNING: If any abnormal operatingIf any abnormal operating
condition occurs while operating the containercondition occurs while operating the container
handling truck, move the truck to a safe park-handling truck, move the truck to a safe park-
ing area, if possible; when safe to do so, shuting area, if possible; when safe to do so, shut
down the truck and notify the appropriatedown the truck and notify the appropriate
maintenance personnel.maintenance personnel.
WARNING:WARNING: Do not allow anyone near theDo not allow anyone near the
contaicontainer handling truck - ner handling truck - certainlcertainly y not walk-not walk-
ing or standing under or beside the containering or standing under or beside the container
or lifting mechanism.or lifting mechanism.
WARNING:WARNING: Stacks of containers or mate-Stacks of containers or mate-
rials can cause “blind spots” for the operator.rials can cause “blind spots” for the operator.
It is essential, for safe operation, that theIt is essential, for safe operation, that the
ground crew stay clear of “blind spots” andground crew stay clear of “blind spots” and
stay within sight of the operator at all times.stay within sight of the operator at all times.
Do not allow anyone to walk in the travel aisle-Do not allow anyone to walk in the travel aisle-
ways.ways.
WARNING:WARNING: Do not move or lift containerDo not move or lift container
until all four twistlocks are fully locked (greenuntil all four twistlocks are fully locked (green
contaicontainer light illumner light illuminatedinated). ). The containThe containerer
could fall from the attachment causing deathcould fall from the attachment causing death
or serious injury to ground personnel or physi-or serious injury to ground personnel or physi-
cal damage to the container, container han-cal damage to the container, container han-
dling truck or dling truck or other yard other yard equipmequipment.ent.
WARNING:WARNING: Do not lift a loaded containerDo not lift a loaded container
that exceeds the rated capacity of the contain-that exceeds the rated capacity of the contain-
er handlier handling truck. ng truck. FailurFailure to do so, may resulte to do so, may result
in death, personal injury or damage to the con-in death, personal injury or damage to the con-
tainer handling truck.tainer handling truck.
WARNING:WARNING: Do not handle unstableDo not handle unstable
loaded containers.loaded containers.
If the load shifts in the container, stop the truckIf the load shifts in the container, stop the truck
immediately, lower the container and adjust theimmediately, lower the container and adjust the
side shift until load weight is centered and proper-side shift until load weight is centered and proper-
ly held. ly held. If the load shift iIf the load shift is too great for adjuss too great for adjustmenttment
with side shift, lower the container and rearrangewith side shift, lower the container and rearrange
the load before attempting to move the container.the load before attempting to move the container.
WARNING:WARNING: Never move containers overNever move containers over
personpersonnel nel or vehicles.or vehicles.
WARNING:WARNING: Do not back away from aDo not back away from a
rack or stack without complete release of therack or stack without complete release of the
contaicontainerner. . Failure to do so, may result in deathFailure to do so, may result in death
or serious bodily injury and property damageor serious bodily injury and property damage
caused by dropping a container on the truck, acaused by dropping a container on the truck, a
bystandbystander er or on or on the ground.the ground.
WARNING:WARNING: Position the container beforePosition the container before
travelitraveling to ng to eliminateliminate e interfinterference with erence with visibilvisibili-i-
ty in the direction of travel.ty in the direction of travel.
WARNING:WARNING: Use care when traveling withUse care when traveling with
or without a container.or without a container.
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TTHHDDC C / / TTHHDDCCP P - - 99554 4 / / 99555 5 / / 99774 4 ((RReevv. . 0066//0033) ) SSaaffeettyy--55
WARNING:WARNING: Never leave the containerNever leave the container
handlihandling truck ng truck with a with a containcontainer er suspendsuspended.ed.
The load could inadvertently lower and causeThe load could inadvertently lower and cause
serious injury or death.serious injury or death.
WARNING:WARNING: Be exact in load placement.Be exact in load placement.
Make sure the load will not tilt, fall or slide outMake sure the load will not tilt, fall or slide out
of positof position when releasedion when released. . Personal inPersonal injury orjury or
equipmequipment damage ent damage can result can result from unstablefrom unstable
placement of loads.placement of loads.
WARNING:WARNING: Do not unlatch a containerDo not unlatch a container
until you, the until you, the operatoperatoror, , have have determdetermined that itined that it
is safe to do so. is safe to do so. Never unlNever unlatch a contatch a containerainer
that is not positioned securely; the containerthat is not positioned securely; the container
could shift or fall.could shift or fall.
WARNING:WARNING: Do not back away from aDo not back away from a
rack or stack with a container until it is clear ofrack or stack with a container until it is clear of
the containthe container below it. er below it. FailurFailure to do so, maye to do so, may
result in death or serious bodily injury andresult in death or serious bodily injury and
property damage caused by dropping a con-property damage caused by dropping a con-
tainer on the truck, a bystander or on thetainer on the truck, a bystander or on the
ground.ground.
Battery Safety:Battery Safety:
WARNING:WARNING: Lighted smoking materials,Lighted smoking materials,
flames, arcs, or sparks may result in batteryflames, arcs, or sparks may result in battery
explosion.explosion.
1. 1. Keep all meKeep all metal tooltal tools away frs away from battom battery terery termi-mi-
nals.nals.
2. 2. Batteries Batteries contain scontain sulfuric ulfuric acid wacid which which will burill burnn
skin on contact; wear rubber gloves and eyeskin on contact; wear rubber gloves and eye
protection when working with batteries.protection when working with batteries.
3. 3. FluFlush eyes or wsh eyes or wash skash skin witin with water anh water and seekd seek
medical attention immediately in case ofmedical attention immediately in case of
contact.contact.
4. 4. When When jumjump sp starttarting:ing:
a. a. Do not leDo not lean over the baan over the batterttery whiy while makle makinging
connection.connection.
b. b. FirsFirst, connect, connect the posit the positive (tive (+) ter+) terminal ofminal of
the booster battery to the positive (+)the booster battery to the positive (+)
termiterminal nal of of the the dischardischarged ged batterybattery..
c. c. ThenThen, connec, connect the negatt the negative (-ive (-) term) terminal ofinal of
the booster battery to the engine or bodythe booster battery to the engine or body
ground (-). ground (-). Never CrNever Cross Polarioss Polarity ofty of
Terminals.Terminals.
d. d. DiscDisconnect cablonnect cables in exes in exact revact reverse orerse orderder..
Lock-Out / Tag-Out ProcedureLock-Out / Tag-Out Procedure
Purpose.Purpose. This procedure establishes the mini-This procedure establishes the mini-
mum requirements for lock-out / tag-out of energymum requirements for lock-out / tag-out of energy
sources that csources that could cause injurould cause injury to personnel. y to personnel. AllAll
employees shall comply with the procedure.employees shall comply with the procedure.
Responsibility.Responsibility.The responsibility for seeing thatThe responsibility for seeing that
this procedure is followed is binding upon allthis procedure is followed is binding upon all
employeesemployees. . All employAll employees shall be instees shall be instructed inructed in
the safety significance of the lock-out / tag-outthe safety significance of the lock-out / tag-out
procedure by (procedure by (designated indidesignated individual)vidual). . Each newEach new
or transferred affected employee shall beor transferred affected employee shall be
instructed by (designated individuals) in the pur-instructed by (designated individuals) in the pur-
pose and use of the lock-out / tag-out procedure.pose and use of the lock-out / tag-out procedure.
Preparation for Lock-Out / Tag-Out.Preparation for Lock-Out / Tag-Out. Employees Employees
authorized to perform lockout / tagout shall be cer-authorized to perform lockout / tagout shall be cer-
tain as to which switch, valve, or other energy iso-tain as to which switch, valve, or other energy iso-
lating devices apply to the equipment beinglating devices apply to the equipment being
locklocked out / tagged out. ed out / tagged out. MorMore than one energye than one energy
source (electrical, mechanical, or others) may besource (electrical, mechanical, or others) may be
involved. involved. Any questionAny questionable identifable identification ofication of
sources shall be cleared by the employees withsources shall be cleared by the employees with
their supervtheir supervisors. isors. Before lock-Before lock-out / tag-out com-out / tag-out com-
mences, job authorization should be obtained.mences, job authorization should be obtained.
Sequence of Sequence of Lock-OuLock-Out t / / TTag-Out Procedurag-Out Proceduree
1. 1. NotiNotify all affy all affecfected emplted employeeoyees that a lock-s that a lock-out /out /
tag-out is required and the reason therefor.tag-out is required and the reason therefor.
2. 2. If the equiIf the equipmenpment is opert is operatiating, shut ing, shut it down byt down by
the normal stopping procedure.the normal stopping procedure.
3. 3. OperOperate the swiate the switch, vatch, valvelve, or other ener, or other energy iso-gy iso-
lating device so that the energy source(s)lating device so that the energy source(s)
(electr(electrical, mechanical, hydraulic, etc.) ical, mechanical, hydraulic, etc.) is is dis-dis-
connected or isolated from the equipment.connected or isolated from the equipment.
Stored energy, such as that in capacitors,Stored energy, such as that in capacitors,
springs, elevated crane members, rotating fly-springs, elevated crane members, rotating fly-
wheels, hydraulic systemswheels, hydraulic systems, , and and airair, , gas,gas,
steam, or water pressure, etc. must also besteam, or water pressure, etc. must also be
dissipated or restrained by methods such asdissipated or restrained by methods such as
grounding, repositioning, blocking, bleeding-grounding, repositioning, blocking, bleeding-
down, etc.down, etc.
4. 4. Lock-out Lock-out / tag-/ tag-out the out the energy ienergy isolating solating devicesdevices
with an assigned individual lock / tag.with an assigned individual lock / tag.
5. 5. After eAfter ensurnsuring that no pering that no personnesonnel are expl are exposedosed
and as a check on having disconnected theand as a check on having disconnected the
energy sources, operate the push button orenergy sources, operate the push button or
other normal operating controls to make cer-other normal operating controls to make cer-
tain the equipment will not operate.tain the equipment will not operate.
CAUTION:CAUTION: Return operating controls toReturn operating controls to
neutral after the test.neutral after the test.
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Safety-6Safety-6 THDC THDC / / THDCP THDCP - - 954 954 / / 955 955 / / 974 974 (Rev(Rev. . 06/03)06/03)
6. 6. The equiThe equipment ipment is now los now lockecked out / taggd out / tagged out.ed out.
RestorRestoring Equipment to ing Equipment to ServiceService
1. 1. When thWhen the job is ce job is complomplete and equete and equipmipment isent is
ready for testing or normal service, check theready for testing or normal service, check the
equipment area to see that no one is exposed.equipment area to see that no one is exposed.
2. 2. When equipment When equipment is all cis all clearlear, remove al, remove all locks l locks //
tags. tags. The energy iThe energy isolating devsolating devices mices may beay be
operated to restore energy to equipment.operated to restore energy to equipment.
ProceduProcedure re InvolviInvolving More ng More Than One Than One Person.Person.
In the preceding steps, if more than one individualIn the preceding steps, if more than one individual
is required to lock-out / tag-out equipment, eachis required to lock-out / tag-out equipment, each
shall place his own personal lock / tag on theshall place his own personal lock / tag on the
energy isolenergy isolating device(ating device(s). s). One designated indi-One designated indi-
vidual of a work crew or a supervisor, with thevidual of a work crew or a supervisor, with the
knowledge of the crew, may lock-out / tag-outknowledge of the crew, may lock-out / tag-out
equipment for the whole crequipment for the whole crewew. . In such cases, itIn such cases, it
shall be the responsibility of the individual to carryshall be the responsibility of the individual to carry
out all steps of the lock-out / tag-out procedureout all steps of the lock-out / tag-out procedure
and inform the crew when it is safe to work on theand inform the crew when it is safe to work on the
equipment. equipment. AdditionalAdditionallyly, the designated individual, the designated individual
shall not remove a crew lock / tag until it has beenshall not remove a crew lock / tag until it has been
verified that all individuals are clear.verified that all individuals are clear.
Rules for Rules for Using Lock-Out / Using Lock-Out / TTag-Out Procedure.ag-Out Procedure.
All All equipment equipment shall shall be be locked locked out out / / tagged tagged out out toto
protect against accidental or inadvertent operationprotect against accidental or inadvertent operation
when such operation could cause injury to person-when such operation could cause injury to person-
nel. nel. Do not attempt to operDo not attempt to operate any switcate any switch, valve,h, valve,
or other energy isolating device bearing a lock /or other energy isolating device bearing a lock /
tag.tag.
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Major Components LocationsMajor Components Locations
THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)THDC / THDCP - 954 / 955 / 974 (Rev. 06/03)
NOTE: NOTE: All circuit drawAll circuit drawings illustraings illustrate the components in de-energizete the components in de-energized states. d states. CircCircuit drawings anduit drawings and
illustrations are drawn in the position of the operator facing forward, looking toward the mastillustrations are drawn in the position of the operator facing forward, looking toward the mast
assembly.assembly.
ATTATTACHMENTACHMENT
(Section 29)(Section 29)
MASTMAST
(Section 27)(Section 27)
CABCAB
(Section 20)(Section 20)
STEER AXLESTEER AXLE
(Section 13)(Section 13)
RADIATORRADIATOR
(Section 5)(Section 5)
ENGINEENGINE
(Section 1)(Section 1)
TRANSMISSIONTRANSMISSION
(Section 9)(Section 9)
DRIVE SHAFTDRIVE SHAFT
(Section 11)(Section 11)
DRIVE AXLEDRIVE AXLE
(Section 14)(Section 14)
TILT CYLINDERTILT CYLINDER
(Section 22)(Section 22)
LIFT CYLINDERLIFT CYLINDER
(Section 22)(Section 22)
FUEL TANKFUEL TANK
(Section 2)(Section 2)
HYDRAULIC TANKHYDRAULIC TANK
(Section 22)(Section 22)
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1-21-2 (Rev. (Rev. 11/94)11/94)
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ContentsContents
Maintenance ManualMaintenance Manual
SectionSection
IntroductionIntroduction
EEnnggiinne e 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FFuueel l SSyysstteem m 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Air Intake Intake System System 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EExxhhaauusst t SSyysstteem m 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCoooolliinng g SSyysstteem m 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EElleeccttrriiccaal l SSyysstteem m 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TTrraannssmmiissssiioon n 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TTrraannssmmiissssiioon n OOiil l CCoooolleer r 99AA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TTrraannssmmiissssiioon n CCoonnttrroolls s 99CC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DDrriivve e SShhaafft t 1111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SStteeeer r AAxxlle e 1133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DDrriivve e AAxxlle e 1144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BBrraakke e CCoonnttrrool l SSyysstteem m 1155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WWeet t DDiissc c BBrraakkees s CCoooolliinng g SSyysstteem m 1155CC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Air Dryer Dryer System System 15D15D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SStteeeerriinng g SSyysstteem m 1166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TTiirrees s aannd d WWhheeeells s 1177. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CChhaassssiis s 1188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCaab b 2200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Air Air Conditioning Conditioning System System 20A20A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HHeeaattiinng g SSyysstteem m 2200HH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HHyyddrraauulliic c SSyysstteem m 2222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCaab b TTiillt t SSyysstteem m 2222DD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator Accumulator 22E22E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MMaasst t AAsssseemmbblly y 2277. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCoonnttaaiinneer r AAttttaacchhmmeennt t 2299. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AppendicesAppendices
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