John Deere 485E, 486E, 488E Forklifts Operator’s Manual – PDF DOWNLOAD
FILE DETAILS:
John Deere 485E, 486E, 488E Forklifts Operator’s Manual – PDF DOWNLOAD
Division: Construction
Product Lines: Forklifts
Publication Type: Operator’s Manuals
Associated Models: 485E, 486E, 488E
Series: E SERIES
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
John Deere 485E, 486E, 488E Forklifts Operator’s Manual – PDF DOWNLOAD
Contents 5
Safety 9
Forklift Safety 9
Recognize Safety Information 10
Understand Signal Words 10
Follow Safety Instructions 10
Avoid Injury From Rollover Accidents Wear Your Seat Belt Do Not Attempt to Jump Clear of Tipping Machine—Serious or Fatal Crushing Injuries Will Result M 11
Avoid Injury From Backover Accidents Before Moving Machine, Be Sure All Persons Are Clear of Area Always Be Alert For Bystanders Moving Into the Work Area Use Horn or Other Signal to Wa 12
Avoid Injury From Rollaway Accidents To Prevent Rollaway, Always Make Sure Machine Is Properly Secured Before Leaving Operator’s Seat Death or Serious Injury May Result If You Attempt to 13
Inspect Machine 13
Use Handholds and Steps 14
Prevent Machine Runaway 14
Use Seat Belt Properly 14
Drive Machine Safely 15
Travel Safely 15
Avoid Power Lines 16
Beware of Exhaust Fumes 16
Keep Riders Off Machine 16
Handle Fuel Safely—Avoid Fires 17
Prepare for Emergencies 17
Handle Starting Fluid Safely 17
Clean Trash from Machine 18
Protect Against Flying Debris 18
Wear Protective Clothing 18
Protect Against Noise 19
Handle Chemical Products Safely 19
Use Safety Lights and Devices 20
Keep Overhead Guard Installed Properly 20
Warn Others of Service Work 21
Practice Safe Maintenance 21
Remove Paint Before Welding or Heating 22
Avoid Heating Near Pressurized Fluid Lines 22
Avoid High Pressure Fluids 23
Clean the Machine Regularly 23
Service Cooling System Safely 24
Store Attachments Safely 24
Support Raised Equipment 24
Prevent Battery Explosions 24
Dispose of Waste Properly 25
Safety Signs 26
Safety Sign 26
Safety Sign 26
Safety Sign 27
Safety Sign 28
Safety Sign 29
Safety Sign 30
Safety Sign 31
Safety Sign 32
Safety Sign 33
Safety Sign 33
Safety Sign 34
Operator’s Station 35
Instrument Panel 35
Indicator Lights 35
STOP Engine Indicator and Alarm 36
Engine Coolant Temperature Indicator 36
Seat Belt Indicator 37
Engine Oil Pressure Indicator 37
Alternator Voltage Indicator 37
Engine Air Filter Restriction Indicator 38
Transmission Oil Temperature Indicator 38
Four Wheel Drive Indicator—If Equipped 38
Park Brake Indicator and Switch 39
Operational Controls 39
Forklift Controls 40
Seat Belt—Operation 40
Seat Belt—Maintenance 41
Seat Controls—Suspension 41
Lights 42
Hour Meter 42
Operator’s Manual Holder 43
Vandal Protection 43
Pre Start Inspection 44
Inspect Machine Daily Before Starting 44
Operating the Engine 45
Check Instruments Before Starting 45
Starting the Engine 46
Using Booster Batteries—12 Volt System 48
Using Coolant Heater—If Equipped 49
Check Instruments After Starting 49
Warm Up Machine 49
Cold Weather Warm Up 50
Stalled Engine 50
Stopping the Engine—Normal Shutdown 51
Driving the Machine 52
Driving on Public Roads 52
Keep Riders Off Machine 53
Driving the Machine 53
Travel Speed 55
Parking the Machine 56
Operating the Machine 57
Fork Adjustment 57
Forklift Control Levers 59
Operating Differential Lock 60
Operating Four Wheel Drive—If Equipped 61
Fork Inspection—All Masts Except 488E 21 5 Ft 62
Fork Inspection—488E 21 5 Ft Mast Only 64
Operating Tips 66
Traveling 67
Driving on a Slope 68
Lifting Capacity 68
Loading 69
Unloading 69
Elevated Loads 70
Suspended Loads 71
Transporting 72
Loading Machine on a Trailer 72
Towing 73
Fuels and Lubricants 74
Diesel Fuel 74
Lubricity of Diesel Fuel 74
Low Sulfur Diesel Fuel Conditioner 75
Handling and Storing Diesel Fuel 75
Do Not Use Galvanized Containers 76
Fuel Tank 76
Diesel Engine Oil 77
Transmission, Front Axle and Four Wheel Drive Oil 78
Hydraulic Oil 79
Grease 80
Alternative and Synthetic Lubricants 80
Lubricant Storage 81
Mixing of Lubricants 81
Engine Coolant 82
Periodic Maintenance 83
Attach Do Not Operate Tag 83
Service Your Machine at Specified Intervals 83
Check Hour Meter Regularly 84
Avoid Mud Build Up 84
Use Correct Fuels and Lubricants 84
Prepare Machine for Maintenance 85
Maintenance and Repair Record Keeping System 86
OILSCAN Plus®, COOLSCAN Plus® and 3 Way Coolant Test Kit 87
Maintenance and Repair Record Keeping System 88
89
Maintenance and Repair Record Keeping System 90
Maintenance—As Required 91
Drain Fuel Tank Water and Sediment 91
Check Tire Pressure 91
Tire Inflation Pressures 92
Check Park Brake 93
Inspect Belt 93
Lubricate Non Powered Front Wheel Bearings and Engine Door Hinges 94
Maintenance—Every 10 Hours or Daily 95
Check Engine Oil Level 95
Check Coolant Overflow Reservoir Level 95
Check Air Cleaner Restriction Indicator 96
Lubricate Four Wheel Drive Shaft Universal Joints and Spline—If Equipped 96
Lubricate Non Powered Steer Axle and Steering Cylinder Pivots 97
Lubricate Lift Cylinder Pins 97
Lubricate Steer Axle Universal Joints—If Equipped 98
Lubricate Mast Pivots and Trunnion Bar 98
Lubricate Mast Sprocket Bearings—6000 Lb and 8000 Lb 99
Lubricate Tilt Cylinder Eyeballs 99
Maintenance—Every 100 Hours 100
Lubricate Tilt Cylinder Pivot Pins 100
Lubricate Control Lever Pivots 100
Lubricate Carriage Chain 101
Lubricate Mast Channel 101
Maintenance—Every 250 Hours 102
Check Four Wheel Steer Axle Oil Level—If Equipped 102
Change Engine Oil and Filter 103
Check Battery Electrolyte Level and Terminals 104
Check Hydraulic Reservoir Oil Level 106
Check Transmission Oil Level 107
Check Four Wheel Drive Planetary Housing Oil—If Equipped 107
Check Differential Housing Oil Level 108
Check Carriage Chain Tension 108
Lubricate Front Axle Pin 109
Maintenance—Every 500 Hours 110
Replace Hydraulic Oil Filter 110
Replace Hydraulic Reservoir Breather 110
Check Air Intake Hose 110
Replace Fuel Filter 111
Check Coolant Conditioner 112
Lubricate Drive Axle Bearings 113
Lubricate Speed Control Linkage Pivot 113
Maintenance—Every 1000 Hours 114
Change Drive Axle Oil 114
Check Park Brake 115
Change Transmission and Torque Converter Oil and Filter 116
Change Hydraulic Reservoir Oil 117
Check Engine Speed Linkage 118
Change 4WD Planetary Housings Oil—If Equipped 119
Non Powered Axle—Clean, Pack, and Adjust Rear Wheel Bearings 120
Change MFWD Steer Axle Housing Oil—If Equipped 121
Clean Engine Crankcase Vent Tube 121
Remove Air Cleaner Elements 122
Install Air Cleaner Elements 123
Maintenance—Every 2000 Hours 124
Adjust Engine Valve Lash (Clearance) 124
Maintenance 127
Check Engine Speeds 127
Inspect Air Cleaner Elements 127
Clean Dusty Primary Element 128
Clean Dust Unloader Valve 128
Test the Coolant Freeze Protection Level 128
Servicing the Cooling System 129
Checking Coolant Hoses and Radiator 129
Draining the Cooling System 130
Filling the Cooling System 131
Do Not Service Injection Nozzles 131
Do Not Adjust Injection Pump 132
Draining Fuel Filter Sediment 132
Precautions for Alternator and Regulator 133
Prevent Acid Burns 134
Service Batteries Carefully 135
Checking Electrolyte Specific Gravity 136
Using Battery Charger 137
Replacing Batteries 137
Removing Batteries 138
Fuse Specifications 139
Remove and Install Halogen Bulb 140
Changing Reverse Warning Alarm Volume 140
Checking Neutral Start System 141
Adding Attachments/Accessories to Overhead Guard 141
Welding on Machine 142
Checking Machine Cycle Times 142
Bleeding Brakes (SN—897492) 143
Bleeding Service Brakes (S N 897493— ) 144
Check for Forklift Chain Slack 147
Bleeding Air from Lift Cylinders 148
Checking and Adjusting Toe In 149
Do Not Service Control Valves, Cylinders, Pumps or Motors 150
Hardware Torque Specifications 150
Checking Wheel Fasteners 151
Keep Overhead Guard Installed Properly 151
Metric Bolt and Cap Screw Torque Values 152
Service Recommendations for Metric Series Four Bolt Flange Fitting 153
Additional Metric Cap Screw Torque Values 154
Unified Inch Bolt and Cap Screw Torque Values 155
O Ring Groove Connections 156
Check Oil Lines and Fittings 157
Service Recommendations for O Ring Boss Fittings 158
Service Recommendations for Flat Face O Ring Seal Fittings 159
Service Recommendations for Inch Series Four Bolt Flange Fittings 160
Operational Checkout 162
Operational Checkout Procedure 162
Gauge and Indicator Check with Engine Off 162
FNR, Neutral Start Circuit and Reverse Warning Alarm Checks 163
Park Brake, Charge Indicator Light, Tachometer/Hour Meter Circuit and Engine Speed Control Linkage Checks 164
Brake System Checks 166
Steering System Checks 167
Transmission Neutral Disconnect Circuit Check 167
Driving Checks 168
Four Wheel Drive Driving Check—If Equipped 170
Hydraulic System Checks 171
Check Operation of Accessories (Engine Stopped) 172
Miscellaneous Checks 172
Troubleshooting 175
Engine 175
Hydraulic System 185
Electrical System 191
Power Train 196
Four Wheel Drive—If Equipped 202
Front Axle 203
Storage 206
Prepare Machine for Storage 206
Monthly Storage Procedure 207
Crime Prevention Tips 209
Help Prevent Crime 209
Record Identification Numbers 209
Keep Proof of Ownership 209
Park Indoors Out of Sight 209
When Parking Outdoors 210
Reduce Vandalism 210
Report Thefts Immediately 211
Specifications 212
485E, 486E, and 488E Forklift Specifications 212
485E, 486E, and 488E Forklift Features 215
485E, 486E, and 488E Forklift Dimensions 218
485E, 486E, and 488E Forklift Operating Information 221
485E, 486E, and 488E Forklift Tires 222
485E, 486E, and 488E Forklift SAE Operating Weights1 223
485E, 486E, and 488E Forklift Drain and Refill Capacities 224
Machine Numbers 225
Record Product Identification Number (PIN) 225
Record Engine Serial Number 225
Record Four Wheel Steer Rear Axle Housing Serial Number 225
Checklists 226
Maintenance and Repair Record Keeping System 226
227
Maintenance and Repair Record Keeping System 228
John Deere Service Literature 229
Technical Information 229
John Deere Service Keeps You On the Job 230
At Your Service When You Need It 230
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