4 - Clark Omega - Operator Manual - Empty Container Handler - Revision 7d

Operators Manual
Empty Container Handler

Designed & Manufactured by:
Tel: +61 2 9477 8446 Fax: +61 2 9476 2241 email: omegaflt@clarkequipment.com
Clark Equipment Australia Empty Container Handler Version 5 -2-

Heavy Truck Warranty
Clark Equipment Australia (CEA) warrants the Omega industrial truck to be free of defects
in material and/or workmanship for a period of twelve (12) months or two thousand (2,000)
hours, whichever occurs first, after the date of sale of the industrial truck to the original retail
purchaser.
If any part of the machine proves defective in material and/or workmanship during the
warranty period, CEA (or authorised dealer) shall repair or replace free of charge, including
related labour, any such defective part.
1. Customer Responsibility
a) Maintenance of machine as per Operation and Maintenance Manuals.

b) Prompt dealer notification in writing, of any failure or abnormality.
c) Machine transportation.
d) Inspections to be done by CEA or authorised CEA dealer (Dealer).
e) All repairs must be performed by Dealer.
f) Provide the Dealer appropriate inspection opportunities and access to
machine for warrantable repairs, during normal business hours.
2. General Exclusions
Warranty does not apply in the following cases, and CEA shall not bear any of the
expenses, even when they occur during the warranty period or are incurred undertaking
warrantable repairs:
a. Damage or defects caused by accident, misuse, negligence or natural calamity.

b. Damage or defects caused by using other than CEA genuine parts or caused by
installing attachments to machine not authorised in writing by CEA or Dealer.
c. Damage or defects caused by failure to adhere to CEA maintenance schedule
and requirements.
d. Damage or defects caused by improper fluid levels or contaminated fuels, fluids
or filters.
e. Damage or defects arising from non-adherence to ‘Customer Responsibility’
above.
f. Change, alteration or modification to machine or any of its component/parts by
other than CEA or Dealer which in the sole judgment of CEA, affects the
performance, stability or purpose for which it was manufactured.
g. Slight defects which generally do not affect the stability or reliability of machine
h. Normal deterioration of machine and components.
i. Service maintenance, such as engine cleaning, replacement of consumable
parts, lubrication, brake adjustment, etc.
j. Consumable articles, such as oils, fluids, grease, fan belt, gaskets, fuses, brake
lining, filters, tyres, cables, carbon brushes, lamps, bulbs, fuel injection nozzles,
glow plugs, fuses, wiper blades, paint, decals and other similar parts.
k. Machine transportation.

l. Technician (and Dealer) travel expenses, including accommodation & meals, and
site costs such as site induction.
m. Repair labour for warrantable repairs performed outside of normal business hours
3. Parts Warranty
Machine Under Warranty
CEA warrants that any new genuine part sold by CEA or Dealer and installed in
the machine is free from defects in material and workmanship for a period of six
(6) months from the date of the delivery of such part to the customer, or on a
new machine still under warranty for the remaining period of warranty,
whichever is greater.
Machine Out of Warranty
Any new genuine part sold by CEA or Dealer and correctly installed in the
machine is warranted free from defects in material and workmanship for a
period of six (6) months from delivery of such part to the customer. The CEA
warranty for the new parts shall cover replacement parts cost only. No labour or
any other costs shall be considered.
If warranty is required to be claimed, please immediately contact your purchasing Dealer,

who will assess and arrange appropriate work.
Unless CEA otherwise agrees in writing, this warranty is in lieu of all other warranties
(except the warranty of title) and states CEA’s entire obligation with respect to defects in
new products made or sold by CEA. To the extent permitted by the Competition and
Consumer Act, 2010 (as amended) (“the Act”) CEA’s liability for a breach of conditional
warranty implied by the Act shall be limited in the case of goods supplied to the payment of
the cost of replacing such goods or acquiring equivalent goods and in the case of services
supplied the supplying of services again. Provided always that nothing herein contained is
intended to exclude, restrict, or modify where applicable the provision of the Act. In all
matters the decision of CEA is final.
IN NO EVENT SHALL CEA BE LIABLE FOR INCIDENTAL, SPECIAL OR

CONSEQUENTIAL DAMAGES.

The operator must be certified and authorised to run an industrial truck
(this is a requirement of the Work Health and Safety Act).
YOU can prevent accidents

First Learn safe operating rules in accordance to local statutory regulations
Second Read your Operator’s Manual.

If you do not understand it, ask your supervisor for help.
Learn about the unit you operate.
Know Your Truck
Then Practice operating your truck safely.
And Keep your truck in a safe operating condition with correct and timely maintenance.
IMPORTANT
Breaking these rules may cause serious or fatal injury.

Table of Contents
1 General Information ...................................................................... 9
1.1 Important Information ..........................................................................................................10
1.2 Safe Working Load ..............................................................................................................11
1.2.1 Rated Capacity .............................................................................................................12
1.2.2 Design Standards ..........................................................................................................12
1.2.3 Planned Maintenance ...................................................................................................13
1.3 Definition of Mast Vertical ..................................................................................................14
1.4 Terminology and Symbols ...................................................................................................15
2 Safety ......................................................................................... 16
2.1 Decals - Safety & Warning ..................................................................................................17
2.2 Safety Rules and Practices ...................................................................................................21
2.2.1 Daily Inspection ...........................................................................................................21
2.2.2 Operating Guidelines ...................................................................................................21
2.3 Work Site Layout .................................................................................................................24
2.4 Fire Hazard and Emergency Stop ........................................................................................25
2.4.1 Turbo Timer (optional) ................................................................................................25
2.4.2 Fire Prevention and Control .........................................................................................26
2.5 Electrical Hazards ................................................................................................................27
2.6 Refuelling .............................................................................................................................28
2.7 Exhaust Emission .................................................................................................................28
2.8 Seat Belt Usage ....................................................................................................................29
2.9 Modifications .......................................................................................................................29
2.10 Safety Features .....................................................................................................................30
2.11 Safe Work Practices for Container Handling .......................................................................31
2.11.1 Operating Conditions that Affect Stability ..................................................................32
3 Operator Controls ....................................................................... 35
3.1 Truck Model Description .....................................................................................................36
3.2 Operator’s Compartment Controls .......................................................................................36
3.3 Instrumental Panel ................................................................ Error! Bookmark not defined.
3.4 Console Controls ..................................................................................................................48
3.5 The Key / Start Switch .........................................................................................................49
3.6 Direction and Speed Control ................................................................................................49
3.7 Automatic Powershift Controller (APC)..............................................................................49
3.8 Accelerator Control Pedal ....................................................................................................50
3.9 Declutching Operation .........................................................................................................50
3.10 Wet Disc Brake System .......................................................................................................50
3.11 Parking Brake for Wet Disc Brake Trucks ..........................................................................51
3.12 Power Steering System ........................................................................................................51
3.13 Joystick Lever ......................................................................................................................52
3.13.1 Joystick Lever Operation ............................................. Error! Bookmark not defined.
3.13.2 Joystick Buttons Operation .......................................... Error! Bookmark not defined.

3.13.3 Automatic Twistlock Operation (optional) ..................................................................54
3.13.4 Lift and Lower Cut-out ................................................................................................54
3.14 Load Indicating System........................................................................................................55
3.14.2 Attachment Indicator Lights ........................................................................................55
3.14.3 Load Configuration ......................................................................................................55
3.14.4 Tilt Indicator.................................................................................................................56
3.15 Suspension Seat....................................................................................................................57
3.16 Other.....................................................................................................................................57
4 Operating Procedures ................................................................. 58
4.1 Defect Reporting ..................................................................................................................59
4.1.1 Immediate Action Defects............................................................................................59
4.1.2 Deferred Action Defects ..............................................................................................59
4.2 Preparation for Operation .....................................................................................................60
4.2.1 Inspection before Start-up ............................................................................................60
4.2.2 Start Up ........................................................................................................................60
4.2.3 Protection Systems .......................................................................................................61
4.3 Operating ..............................................................................................................................62
4.4 Travelling without a Load ....................................................................................................62
4.5 Handling a Load ...................................................................................................................63
4.5.1 Approach ......................................................................................................................63
4.5.2 Pick up..........................................................................................................................63
4.5.3 Travel ...........................................................................................................................64
4.5.4 Depositing a Load ........................................................................................................64
4.6 Stacking ................................................................................................................................65
4.6.1 Moving a Load from a Stack........................................................................................65
4.7 Double Empty Side Lift Container Handler.........................................................................66
4.8 Single Container Lifting Instructions ...................................................................................66
4.8.1 Lifting Operation ..........................................................................................................66
4.8.2 Container Disengagement ............................................................................................67
4.9 Double Container Lifting Instructions .................................................................................67
4.9.1 Lifting Operation ..........................................................................................................67
4.9.2 Container Disengagement ............................................................................................68
4.10 Shutdown .............................................................................................................................69
5 Trouble Shooting ......................................................................... 70
5.1 Container Handling ..............................................................................................................71
5.1.1 Hooks Remain Locked with the Container Weight off the Hooks ..............................71
5.1.2 The Red Light is illuminated .......................................................................................71
6 Appendices ................................................................................. 72
6.1 Specifications .......................................................................................................................73
6.2 Daily / Pre Start Check List .................................................................................................75

1 General Information
This manual contains information to help you operate this OMEGA industrial
truck in a safe manner and to achieve optimum performance.
It is NOT a Training Manual; it is a guide to assist certified and authorised
operators to safely operate the industrial truck by emphasising, explaining and
illustrating the correct procedures and controls. It cannot cover every possible
situation. You as the operator, must watch for hazards at all times and take
appropriate action consistent with safe operating practice.
As the operator of this key piece of industrial equipment your skill and attitude
can contribute positively to the productive performance of this machine and
safety in your work environment. A great deal of confidence has been placed in
your ability to operate this machine safely and efficiently; a planned approach to
machine movements, alertness to the requirements of the job and others around
you will mark you as a professional operator.
This manual is intended to be a permanently attached part of the industrial truck.

Keep it on the truck as a ready reference for anyone who may drive or service it.
If the truck you operate is not equipped with this manual, ask your supervisor to
obtain one and have it attached to the truck.
Remember, an OMEGA dealer is pleased to answer any questions about the
operation and maintenance of this industrial truck and will provide additional
information should it be required.

1.1 Important Information
1. Be aware of the Work Health and Safety Act (WHS Act) as well as State
laws that require operators must be trained, certified and authorised in the
safe operation of industrial trucks.
• Operators must not operate the industrial truck if they are under
the influence of drugs or alcohol.
• Operator must be in good health, fit and be alert. The operator
should not have any disability which may affect the competent safe
control of the industrial truck, or a health condition which may be
aggravated by the operation of the truck.
2. It should be understood that the industrial truck does not have a vehicle type
suspension; the frame is mounted directly to the axles, to which the heavy
ply industrial tyres, at high inflation pressures, are mounted. Although a
hydraulic accumulator is fitted in the lift system to dampen and reduce shock
or impact effects when travelling, rubber mounting of the cabin and a
comfortable seat, it is impossible to remove all the movements to the
operator, especially if yard conditions are not smooth.
3. If you think you need further training, ask your supervisor.
Safe operation is of primary importance. Inadequate operator training, lack of

experience, ignoring basic safety and poor maintenance are major factors in
industrial truck incidents.
Many accidents involving industrial trucks are due to the human element.
Industrial trucks must be operated at all times in a sensible and responsible
manner and within their performance capabilities. Accidents have occurred with
un-laden industrial trucks, turning severely at some speed causing the truck to
turn over sideways. Equally, this type of problem can occur when turning to a
stack with an elevated load across an incline or on a pot holed or uneven
surface, therefore, always turn with load in lowered, travelling position and
when square, in front of stack.
The requirements in the Australian Work Health and Safety (WHS) Regulations
dealing with qualifications of operators and identification of authorised
operators place a responsibility on the owner to only authorise employees
having adequate skill, knowledge and sense of responsibility.
The operation of industrial trucks on gradients is completely dependent upon the
type, size and purpose of the particular industrial truck. Each application has to
be treated on its merits with the industrial truck manufacturer or distributors
recommending what limitations need to be applied to the conditions of use.
Clark Equipment Australia Empty Container Handler Version 5 - 10 -

1.2 Safe Working Load
“Safe working load” is difficult to determine and varies due to; travel speed,
height of load above the ground, load centre, load off-set, gradient, surface
condition, uneven surface, travelling across a grade, severity of turning and / or
braking, condition of machine, maintenance, tyre condition and tyre inflation.
Tip-over accidents occur while industrial trucks are travelling forward with the
load elevated in front of the truck. The main cause for tipping forward is the loss
of stability due to high deceleration under braking. Sharp turning or turning on
an incline can cause lateral tip over especially when combined with braking.
On industrial trucks fitted with side shifting carriages or attachments, the load
must always be centralised before travelling. This will also reduce stressing of
the industrial truck and increase its safe, productive working life.
Operators are particularly reminded that the load MUST always be
CENTRALISED and to pay particular attention to CENTRALISING the load
before travelling with industrial trucks fitted with side shifting carriages or
attachments.
Operators must be aware of the requirements of the Australian Standard AS2359
Part 2 (Operation), Part 6 (Safety Code) and conform to these requirements
when operating this industrial truck.

1.2.1 Actual Capacity
The actual capacity of this OMEGA industrial truck conforms to the
requirements of Australian Standard AS2359.3 (1995) and is contained in the
nameplate of the truck. This shows the maximum load in kilograms that the
truck is designed to transport and stack at the stated load centre distance. The
industrial truck must only be used reasonably and appropriately under normal
operating conditions as per the Australian Standard AS2359.2 (Operation),
AS2359.6 (Safety Code) .
This Rating covers
• Stacking (on hard level surfaces);
• Travelling with the load on
substantially firm, smooth and
prepared surfaces;
• Operating with the load ‘centre-of-
gravity’ approximately on the
longitudinal centre line of the truck.
This is achieved by side-shifting the
load to “CENTRALISE” it before
travelling.
It remains the operator’s sole responsibility to drive the machine in a safe

NOTE and responsible manner. Excessive speed, hard braking, sharp cornering
and poor load configuration can all lead to the unit becoming dangerously
unstable.
Load centre is defined as the distance horizontally forward of the front vertical face of the
carriage where the centre of gravity is located.
Compliance with stability tests set out in AS2359 cannot ensure
Warning
prevention of forward or lateral tip-over under full braking.
1.2.2 Design Standards

This OMEGA industrial truck has been designed and built to be safe and
efficient. As manufactured, it meets all the applicable requirements of
Australian Standard AS2359-1995 Powered Industrial Trucks.

1.2.3 Planned Maintenance
Clark Equipment Australia (CEA) recommends that a Planned Maintenance
(PM) and safety inspection program be performed by a trained and authorised
mechanic on a regular basis. The PM will provide an opportunity to make a
thorough inspection of the safety and operating condition of the industrial truck.
Necessary adjustments and repairs can be done during the PM, which will
increase the life of components and reduce unscheduled downtime.
Regular maintenance and care of the industrial truck is not only important for
economy and utilisation reasons; it is essential for safety. A faulty industrial
truck is a potential source of danger to the operator, and to other personnel
working near it. The recommended schedule of maintenance must be strictly
followed.
This machine contains no asbestos

NOTE

1.3 Definition of Mast Vertical
Figure 1
Typical relationship of rated load in lowest position (300 mm above ground)
with mast vertical
"A" is the point on the ground vertically below the top rear corner of the
container.
Figure 2 - shows normal deflection when load is lifted to stacking position

which causes the load to be positioned further in front of truck. This is not
mast vertical!
"B" is the new extended point on the ground vertically below the top rear
corner of the container, caused by mast deflections.
Figure 3 – shows truck in the mast vertical position with mast slightly tilted
back to allow load to be vertically above the position “A”.
When the load is in elevated position, bring the point "B" back to the original
point "A".
The lost load centre due to mast deflection is now removed
This is mast vertical and the basis for the trucks rating test
Tilting the mast forward passed this position reduces the trucks rating or
stability

1.4 Terminology and Symbols
The following terms and symbols are used in this manual to draw attention to
important information. You should make yourself familiar with the meaning of
the terms and symbols involved.
This term is used when special information, instruction or identification is

NOTE required
IMPORTANT! This term is used when special precautions should be taken.
This term is used as a reminder of unsafe practices that can result in

CAUTION! personal injury if proper precautions are not taken.
WARNING This message is used when a hazard exists which can result in injury or
death if proper precautions are not taken.
DANGER This message is used when an extreme hazard exists.
The TERMINOLOGY and SYMBOLS used are VERY IMPORTANT for you and THOSE
AROUND YOU.

2 Safety

2.1 Decals - Safety & Warning
Safety and warning decals are placed in conspicuous locations on OMEGA
industrial trucks. They are there to warn you of essential procedures and the
need for care to avoid personal injury or damage. If any of these decals are
damaged or missing, they should be immediately replaced. Replacement decals
are available from your OMEGA dealer.
In Case of Rollover decal

This decal is located in the operator’s cab to remind you that staying in the cab
provides the best chance to avoid injury in the event of a truck tipping over.
Lift trucks can be tipped over if operated improperly. Experience with lift truck
accidents has shown that the driver cannot react quickly enough to jump clear of
the truck and overhead guard as the truck tips.
Warning Rotating Fan decal

This safety decal is displayed at various positions under the engine cowling, to
warn of the danger of injury from rotating fans when the engine is running. Be
sure that you keep your hands, fingers, arms and clothing away from rotating
fans. Don’t stand in line with a spinning fan. Although rare fan blades can
break at high speed and be thrown out of the engine compartment
Emergency Stop decal
This is located in the operator cabin where fitted. If the truck has emergency
stop buttons at access/egress points the decal will be there.
Emergency Exit decal

This is located on the right hand door.
Towing decal
Located at the rear of the machine adjacent to the tow point to remind
operators to ensure they understand the limitations of towing, as
described in the Operator Manual
Rotating Component decal

Located on the engine cowling to warn of the existence of various rotating
components inside, when the engine is running.

Battery Voltage warning
This decal is located at the battery compartment to warn of the existence of
voltage issues.
Accumulator warning decal

Located on or adjacent to accumulators to remind service personnel
to remove the pressure from the system before performing work on
or around the accumulators.
Lift and Tie Down Point decals

Positioned around the truck to indicate either lift or tie down point locations.
Jacking Point decal

Positioned at various places underneath the truck to indicate the locations for
safe jacking.
Battery Isolator decal

Shows the location of the battery power isolator switch (located either in or
adjacent to the battery compartment).
Tyre Deflation decal

To be found on all wheels. It is to warn of the need for some air to be
released from the tyres, before removing the wheels.
Hydraulic Oil decal

Located on the right hand side of the truck to indicate the location of the
hydraulic oil fill point and level indicators.
Diesel Fuel decal

Located on the left hand side of the machine to indicate the location of the diesel
fuel fill point and level indicators.

Operator Safety Warning Plate
The operator’s warning plate, located inside the cabin, describes basic
instruction for safe operation of an industrial truck. Read and understand
these instructions and other safety messages in this manual and on the lift
truck.

NOTE In Australia, only a trained and appropriately authorised operator is
allowed to operate this industrial truck. The operator must comply with
the requirements of Australian Standard AS2359.2 (Operation), AS2359.6
(Safety Code).
Operate your industrial truck safely; drive defensively; watch for other
people; know your truck’s capabilities and limitations.
Safety is everyone’s concern and everyone’s responsibility.
Keep Away From Attachment decal

This safety decal is placed on the upright to warn of the danger of injury from attachments
when they are in the raised position. Do not ride on or stand under attachments (which
include forks). The attachments can fall and cause injury or death. Always make sure that
the attachments are in the fully lowered position when they are not being used to handle a
load, or when the industrial truck is parked.
Upright Warning decal

This safety decal is placed on the upright to warn of the danger of injury from
movement between rails, chains, sheaves, fork carriage and other parts of the
upright assembly. Do not climb on or reach into the upright. Personal injury will
result if any part of your body is put between moving parts of the upright.

2.2 Safety Rules and Practices
2.2.1 Daily Inspection
At the beginning of each shift, inspect the truck and complete a daily
inspection sheet. A copy can be found in the Appendix 6.2.
Check for damage and maintenance problems.
Have necessary repairs made before you operate the truck.
Do not make repairs unless you have been trained to do so. Lift truck
mechanics are trained professionals. They know how to make repairs
safely.
2.2.2 Operating Guidelines

The operator’s primary safety responsibility is to perform the task of operating
the industrial truck efficiently and productively without endangering his or her
own safety or that of others in the work area.
Alert and careful attention to safe operation of the industrial truck is essential.
Australian Standard requirements, relevant State laws, company laid down
safety procedures and this Operator’s Manual are all intended to help you
develop a ‘safety first’ attitude to operating the industrial truck.
Don’t mix drugs or alcohol with your job
Don’t block safety equipment
Don’t smoke in ‘no smoking’ areas or when

refuelling.
Do watch for pedestrians.
Do wear safety equipment when required.

People
• The operator is the only one who should be on a truck, unless
special seating arrangements have been provided.
• Never transport personnel on the attachment of an industrial
truck.
• Watch where you are going; look in the direction of travel.
Pedestrians may use the same roadway you do. Sound your horn at all
intersections or blind spots.
• Ensure people stand back, even when you are parked, sound your
horn to warn them.
• Watch for people in your work area even though your truck has
warning lights and a reverse alarm. They may not watch for you.
• Always keep your body within the confines of the truck.
Load
• Travel with load near operating surface and with upright tilted
back to cradle load whenever possible.
• Never lift or lower load when the truck is in motion.
• Attachments should be raised to clear surface obstructions.
• When the size and shape of bulky loads restrict your vision,
operate your truck in reverse to improve visibility.
• Always make certain that your load is well stacked and evenly
positioned and never carry loose or uneven material. Unstable loads are
a hazard to you and to your fellow workers.
• Never turn on a grade, either loaded or unloaded.
DANGER When right-angle stacking or moving with a raised load to clear low
objects, avoid sharp turns and move slowly.
• With wide loads, drive with extreme care and be alert to load end
swing when turning.
• Remember, wide and long loads will reduce the capacity of the
truck.
• Do not stack or carry loads above the carriage. Always ensure
your load is supported by the carriage or a factory approved load back
rest.

Truck
• Be aware of rear end swing and be alert to prevent rear end swing
damage to material in the operating area.
• Moving into overhead structures can tip a truck over.
• Be aware that your truck does not move into overhead electrical
cables or wires.
• Know the height of your truck and check your clearance.
The distance required to stop an industrial truck will depend on its speed
and the load being carried: it cannot be stopped instantly. Always allow a
WARNING
safe, effective stopping distance to prevent collisions, forward tip over
and avoid endangering others.
• Reduce speed and travel slowly over any surface drains, ditches,
pot holes and uneven or rough surfaces. Avoid braking in these
conditions as this may cause tip over either forward or sideways.
Know the weight of your truck and load. Check and be aware of
WARNING
capacities (surface you are travelling on, load, where the load is being
stored).
• Do not move or store materials in damaged containers or skids.
Items can fall through them causing severe injury or death!
• Be sure the container or skid you are using is in good condition
and does not have defective or missing components and fasteners.
DANGER Operating on mud, gravel, oil, ice and sand can cause the truck to fall
over.

2.3 Work Site Layout
1. The ideal work site should have a strict system to enforce the
separation of pedestrians, bystanders and vehicles (authorised or not).
2. The recommended yard work site is a level concrete or bitumen
surface, 2% max. slope, free of potholes, having gradual sloping
surface drains and having clearly marked boundaries.
3. Well defined access ways must be marked for travelling. This machine
is heavy. Ensure that the access-ways are capable of supporting its
mass.
4. Aisle ways should be of sufficient width to safely turn to 90 degrees in
front of stack without lifting the widest load, and to travel along aisles
without lifting container above the height for which the truck has been
rated.
5. Layout should provide good visibility for industrial truck operator, to
avoid congestion, the need for sudden braking and tight turning.
Adequate yard lighting is needed for operation at night.
6. Depressions or potholes can develop on bitumen and dirt surfaces,
especially in the storage areas where the industrial truck is repeatedly
positioned for stacking. Ensure these are repaired.
7. Prevent the need for the industrial truck to load/unload on gradients
and slopes or travel across these inclines.
8. Overhead obstructions (e.g. powerlines) must be identified and
avoided.
9. Work areas are to be kept clean, free of dunnage, timber, bricks or
other objects.
10. Operate on wharves and/or elevated floors only after thoroughly
checking the safe loads that can be supported by the floor, the laden
axle loads of the truck and the total laden truck weight.
11. Staff should be warned of dangers when entering the industrial truck
working areas. Industrial trucks have rear axle steering; can turn
quickly, lock to lock. Industrial truck operator is often preoccupied
with load and may not have good visibility when commencing to
reverse.
Refer to the NSW Workcover brochure, “Making Your Forklift Work For You”, for more
information on making industrial trucks in your workplace safe.

2.4 Fire Hazard and Emergency Stop
In the event of a fire or an emergency:
• Brake and stop the industrial truck
• PRESS the RED EMERGENCY button
• Switch off the ignition
• Leave the industrial truck immediately and in a careful manner – DO NOT
panic.
Pressing the red emergency button will shut down the engine
immediately, reducing the flow of fuel, hydraulic oil, and the forced air
IMPORTANT! flowing over the hydraulics, transmission and engine to the radiator, all of
which may be feeding or fanning the fire.
2.4.1 Turbo Timer (optional)

Switching off the ignition completely will disconnect the electrics. If optioned
with the 3 minute turbo timer, the switching off of the ignition switch will allow
the engine to continue to run for 3 minutes, allowing cooling of the turbocharger
and engine, and unfortunately, possibly feeding a fire and making it more
difficult to extinguish. In this case, use of the red emergency stop button is
essential.

2.4.2 Fire Prevention and Control
DO NOT OPERATE A DIRTY TRUCK – report the matter to your supervisor
and ask for it to be cleaned and inspected for leaking hydraulics.
A dirty or oily truck is a fire hazard – this condition makes it impossible to carry
out maintenance properly and prevents early detection of leaks, damaged and
faulty hydraulic, electrical and fuel components.
Your acceptance and operation of an industrial truck in this condition can place
your life and others in great danger.
Remember, this truck can work hard and will get hot. It contains large amounts
of fuel, oil, rubber, other flammable materials and electrics components.
The industrial truck requires attention to cleanliness both inside and out and
must be maintained as recommended, and in accordance with, industry and
Work Health & Safety Acts and Regulations.
Fire extinguishers are installed on the industrial truck. Due to varying customer
requirements, contact your supplier or the manufacturer for details on the
installation of more fire extinguishers or fire suppression system.
NOTE Those attempting to extinguish any fire should take care when lifting or
opening service panels or doors as they may become exposed to the
escaping fire. Extreme care should be taken as pneumatic tyres and their
rims can explode.

2.5 Electrical Hazards
Always check for electrical hazards, be they above or below.

In the event the industrial truck comes in contact with electrical powerlines:
• Remain inside the cabin.
• Do not touch any metallic objects
• Activate the emergency stop button
• Warn those around of the danger that the machine is ‘live’.
• Do not exit the industrial truck
• Seek appropriate help
DANGER In the event that you cannot stay inside the cabin (e.g. machine is on fire)
jump well clear of the cabin, avoiding all contact with the metal frame (or
wires).

2.6 Refuelling
Diesel fuel is a petrochemical and is thus not only poisonous if swallowed, but
also if left on the skin for extended periods.
Handle fuel with care, as it is flammable and can pose an environmental risk if
spilled.
Always stop the truck before refuelling and do not overfill.
Do not smoke or have open flames/sparks when refuelling
Secure the fuel cap when finished refuelling and clean up any spilt fuel.
Avoid fire hazards and have fire protection equipment present in the work area.
Do not use an open flame to check for level or fuel leakage, electrolyte or
coolant. Do not use open pans of fuel or flammable cleaning fluid for cleaning
parts.
2.7 Exhaust Emission

Internal combustion engines emit levels of carbon dioxide and carbon monoxide
(a colourless and odourless toxic gas) that can be hazardous if breathed in.
Always ensure adequate ventilation is present when using this truck, to prevent
a build-up of gases.
Catalytic converters can be fitted to your truck if it must be used in an area with
limited ventilation. Contact your supplier or the manufacturer for details on
these catalytic converters. You will need an Occupational Hygienist or
Occupational Gas Tester to investigate the usage of trucks in a workplace with
restricted ventilation, regardless of the catalytic converter.

2.8 Seat Belt Usage
The seat belt must be used at ALL times when operating the industrial truck for
the safety of the operator. It should be snugly adjusted to suit the operator.
Unfortunately, accidents can happen and they usually happen unexpectedly and
outside the operator’s ability to take corrective action. Forward tip over, sharp
turning, collisions and violent braking are potential hazards – hence the operator
must have the protection of the seat belt to guard against the unexpected, and
personal injury.
Some operators dislike the use of a seat belt. For greatest operator acceptance
and comfort, the lap type seat belt fitted to the industrial truck is most suitable,
as it provides more freedom of movement to the operator than other types and
does not inhibit the operator’s shoulders when partially turning to look in the
reverse direction. Travelling in reverse can occupy a high proportion of the
trucks cycle time.
Operator should be aware that the park brake is applied automatically when the
ignition switch is turned off. For this reason it is also important that the operator
always has the seat belt snugly fitted, as in the rare chance that there is a failure
in the electrical circuit when the truck is travelling, the park brake could be
unexpectedly applied.
2.9 Modifications
Unauthorised modification is not permitted.
The following is extracted from ISO/DIS 3691-1.2
“No modifications or alterations to the truck, which may effect, for example,
capacity, stability or safety requirements of the truck, shall be made without the
prior written approval of the original truck manufacturer. This includes changes
affecting, for example, braking, steering, visibility and the addition of
removable attachments.”

2.10 Safety Features
Engine Emergency Stop
Engine emergency stop button is located on the Control Panel on the right hand
side of the seat in the cab. It shuts the engine down when depressed.
Optional engine emergency stop buttons can be fitted to the normal access /
egress points of the industrial truck.
Accumulator for Braking
The brakes are engaged by hydraulic pressure and cooling of the brakes is by
hydraulic oil circulation. A low brake pressure indicator and an audible alarm
sound when hydraulic pressure in the brake circuit is low.
At start up, this alarm may sound until sufficient pressure is built up in the brake
circuit, indicating the truck is then safe to operate.
OMEGA machines are fitted with an accumulator to provide braking capability
to bring the machine to a safe stop in the event of an engine failure.
“Auto” Application of Park Brake
The park brake is automatically spring applied when the ignition is turned off. If
the park brake is not manually applied by means of the park brake switch prior
to turning off the ignition the park brake will remain applied when the unit is
restarted.
To release the park brake under these circumstances the park brake switch must
be applied and released.
The park brake indicator light will show the status of the system irrespective of
the switch position.
Load Lowering
In the event of engine failure, or with the engine stopped, an accumulator in the
joystick pilot hydraulic circuit permits the load to be safely lowered.
Accumulator for Lift Circuit Hydraulics
This accumulator dampens out the impact loads or shocks, increasing their safe
working life. Importantly, the accumulator also reduces these impact vibrations
to the operator, especially when travelling over rough surface conditions.
When correctly charged, the accumulator will allow the load to move up &
down slightly when travelling over bumps – this can be observed by the
operator, the absence of this feature should be reported for maintenance.

2.11 Safe Work Practices for Container Handling
Various conditions can affect your load stability. Care should be taken to ensure
the load is stable in the fore and aft condition as well as the left and right aspect.
Containers, by their nature are long and bulky loads, and as such, require
operating techniques suitable to these load conditions.
The OMEGA unit rating plate will detail the rated capacity, the details of the
container handling attachment used on the truck and maximum lift height that
the load can be raised for stacking.
If you are unsure of the load carrying characteristics of your unit, do not operate
unit until you have consulted your OMEGA supplier who will assist in
understanding the operating conditions of your unit when handling containers.
Special care is required if your truck is equipped with a Double Lift Attachment
and more so if it is a Telescopic 20-40 attachment as these are considerably
heavier than a fixed attachment.
The combination of Double Lift, Telescopic 20-40 attachment maximises the
performance and productivity of Container Handler and hence can require all
the unbuilt stability and capacity, both longitudinally and laterally, much more
than if the truck is fitted with a fixed or single container lifting attachment. The
Double Lift attachment also offers double the surface area for wind forces;
hence greater care must be exercised by the operator when using these
attachments in windy conditions, travelling at safe speeds to allow gentle
braking in congested work areas and where visibility is the direction of travel is
restricted. Check that back rest is fitted it reduces danger of the top container
accidentally falling backwards towards cabin.
• Always travel with load on back tilt.
• Do not travel with loads raised higher than container base just
above operators’ eye. (Truck must be rated to do this.)
• Lift and lower loads only to deposit or receive loads from
intended storage point.
• When it is absolutely necessary to move forward or rearward
with load raised, travel distance must be kept to a absolute minimum
and speeds kept to the slowest and safest possible until load can be
lowered to a safe position for travelling. Brake applications should not
be severely applied. Travel speed should be such that truck can be
brought to a stop with gentle braking, particularly in congested work
areas and when approaching or turning a corner where visibility is
reduced.
• When forward travel vision is obscured by the load, travel in the
reverse direction. Care should be taken to ensure obstructions are clear
of the load length which can be 12m wide when 40’ containers are
being handled.

• Service (foot) brake should be applied when loads are raised
while machine is stationary.
• Frequent inspections should be made to ensure pedestrians are
well clear of the machine during operation. Operators are encouraged to
move both body and head sideways to increase visibility around the
upright (reducing shadow) when travelling forward.
• Frequent inspections should also be made to ensure load is not
affected by obstructions affecting width or height such as powerlines,
fire hoses, doorways, container stacks, light poles and buildings.
• Operator should be aware that complete electrical failure will
cause the park brake to apply. In the rare and unlikely event that this
will happen while travelling, the operator will be securely held if the
seat belt has been snugly adjusted.
2.11.1 Operating Conditions that Affect Stability

OMEGA Container Handlers are rated for use on hard level surfaces. Refer to Australian Standard
AS2359 for details of this rating.
Units should not be operated on forward slopes
DANGER Pot holes have the same affect as operating on side slopes.

OMEGA Container Handlers most often are specified
with side shift function. This allows the container to
move to left or right for load positioning and also
allows load to be centralised when offset loads are
experienced.
CAUTION! Refrigerated Containers
Particular care should be taken when handling

refrigerated containers. These containers often are
equipped with refrigerated units in one end of the
container, substantially affecting container weight
distribution. Use side shift function to position the
load in the most stable, centralised position, as soon as
possible after engaging and before travelling.
If the truck is fitted with a double handling attachment, ensure the combined weight of the two
containers does not exceed the actual capacity of the truck, as shown on the nameplate.
Wind blowing against the surface of a container can

affect the stability of your container handling forklift
truck, both longitudinally and laterally (sideways).
A 40’ container has twice the surface area of a 20’

container and thus is affected more by winds loads.
Do not use the industrial truck if wind conditions are severe and load stability is reduced.

2.11.1.1 Using OMEGA Purpose built Container Handling Industrial trucks
• Before operating the unit, read and understand all operating
instructions relevant to the container handling attachment that is fitted
to your unit.
• Do not operate unit if warning indicators for lock and unlock
functional are non-functional.
• Do not operate unit if safety interlocks on lock mechanisms are
not functional.
• Check all operational functions on the attachments for safe
operation before use.
• Container handling attachments should be regularly checked for
structural cracking and wear on load carrying components. (Refer to
attachments Manufacturers Specifications for inspection details).
Regularly check twistlocks and lift points for wear and cracking. (Some
IMPORTANT statutory authorities require regular checking and certification of lifting
points).
• Some attachments have a greater capacity than the Container
Handling Truck will permit. The Truck Name Plate capacity must NOT
be exceeded.

3 Operator Controls

3.1 Truck Model Description
1. Drive Axle
2. Steer Axle
3. Counterweight
4. Lift points
5. Tilt cylinder
6. Mast and Lift chain
7. Lift cylinder
8. Attachment
9. Twist lock
3.2 Operator’s Compartment Controls
1. Gear Shift Lever (Forward, Reverse, Neutral)

2. Multi function stalk
a. Tail lights, Instrument lights & head lights
b. Turn indicator switch
c. Horn push button
3. Height adjustment handle
4. Key
5. Tilt angle pedal

3.3 Instrumental Panel
3.3.1 Main Page
1 12
2
3 13
4
14
5 15
20
6
21
7 16
22
8 17
9
10
11 18
19

ITEM DESCRIPTION SUMMARY
Indicator turns on (red) when hydraulic accumulator is not
1 Hydraulic accumulator charging indicator
charged (usually below 60 bar)
2 Parking brake indicator Indicator turns on (red) when parking brake is activated
3 Alternator indicator Indicator turns on (red) when engine alternator is not charged
4 Transmission position Shows current transmission gear position
4
5 Truck speed mode Shows current truck mode (Travel / Stack)
6 Fuel gauge Shows current fuel level
7 Current vehicle speed Shows current vehicle speed
Shows as Engine in high RPM mode (day mode),

8 Engine mode
as Engine in low RPM mode (night mode)

Shows the description for each function button, words in ‘[ ]’ is
9 Function description the function that active by combination buttons with ‘Esc +
function button’2. Details see next page
10 Function button Function buttons, details see next page
11 Engine speed Shows engine current RPM
12 Oil pressure indicator Indicator turns on (red) when engine oil pressure is low
13 Date and time Shows date and time
14 LOGO and build number Shows ‘OMEGA’ logo and build number
15 Max allowed vehicle speed Shows maximum allowed vehicle speed
1
16 Load Shows current load
17 Truck hours Shows total truck hours
18 Menu button Menu button
19 Esc button Esc button
20 Up button Up button, details see next page
21 OK button OK button, details see next page
22 Down button Down button, details see next page

Functions and Button
BUTTON DISPLAY DESCRIPTION
F1 ENG Displays engine page
F2 TRANS Displays transmission page
1
F3 WT CAL Displays weight calibration page
F4 SUM Displays container handling summary page
2 3
ESC +F1 [HL ON] / [HL OFF] Changes hydro Lever function status (ON/OFF)
2
ESC +F3 [MEASUREMENTS] Displays measurement page
5
UP N/A Increases wiper frequency
5
DOWN N/A Decreases wiper frequency
OK N/A ‘OK’ button is not used in main page
Note:
1. Available only with weight gauge fitted.
2. Uses combination of ‘ESC’ and function buttons, and press ‘ESC’ button first.
3. Available only with Hydro Lever fitted.
4. Available only with stability monitoring system fitted.
5. Operates only with wipers on.

3.3.2 Engine Page
1
2
6
7

Descriptions and Summary
1 Engine model and series number Shows the Engine model and series number
2 Engine parameters Shows Engine parameters. Details see below
3 Engine warning lamps Lamp turns on and flashes when engine error occurred
Shows the description for each function button. Details see
4 Function description
below
5 Function button Function buttons, details see below
6 Menu button Menu button, details see below
7 Esc button Esc button, details see below
Engine parameters
DISPLAY DESCRIPTION
TOTAL [hrs] Displays total engine hours (may be different from truck hours), in hour
IDLE [hrs] Displays total idle hours, in hour
TOTAL FUEL [l] Displays total fuel consumption, in litre
IDLE FUEL [l] Displays idle fuel consumption, in litre
FUEL RATE [l/hr] Displays current fuel consumption rate, in litres per hour
ACC PEDAL [%] Displays current acceleration pedal position, in %
OIL PRESS [kPa] Displays current engine oil pressure, in kPa
COLLANT [°C] Displays current engine coolant temperature, in °C
1
OIL TEMP [°C] Displays current engine oil temperature, in °C
ENGINE RPM [1/min] Displays current engine RPM, in 1/min

Holds engine page, otherwise engine page will be closed
F1 HOLD
automatically after a while.
F2 NIGHT / DAY Changes engine mode (night mode/day mode)
F3 N/A N/A
F4 N/A N/A
ESC N/A Closes engine page and back to main page
MENU N/A Displays menu page
UP N/A N/A
DOWN N/A N/A
OK N/A N/A
Note:
1. Available only with engine oil temperature sensor fitted.

3.3.3 Transmission Page
1
2
3
6
7
TRANSMISSION PAGE

1 Transmission model and series number Shows the transmission model and series number
2 Transmission parameters Shows transmission parameters. Details see below
3 Transmission gear position Shows current transmission gear position
4 Function description Shows the description for each function button. Details below
Transmission parameters
DISPLAY DESCRIPTION
ENGINE RPM [1/min] Displays current engine RPM, in 1 per minute
SUMP TEMPERATURE [°C] Displays current transmission fluid temperature, in °C
TRAVELLED DISTANCE [km] Displays total travelled distance, in kilometre
VEHICLE SPEED [km/h] Displays current vehicle speed, in kilometre per hour
BRAKE PEDAL [%] Displays current brake pedal position, in %
GEAR LEVER POSITION Displays current gear lever position, FWD/NEUTRAL/REV
TRANSMISSION POSITION Displays current transmission gear position, 1/2/3/4
INPUT DIRECTION REVERSED Displays gear lever position input reversed or not, NO/YES
CALIBRATION ERROR Displays transmission calibration error code

Holds transmission page, otherwise it will be closed
F1 HOLD
automatically after a while.
F2 ERROR Displays transmission error page
F3 HEAT Make transmission in heating mode
F4 CAL Make transmission in calibration mode
ESC N/A Closes transmission page and back to main page
UP N/A N/A
DOWN N/A N/A
OK N/A N/A

3.3.4 Measurements Page
4
5
MEASUREMENTS PAGE

1 Measurements details Shows measurements details. See below
below
Measurements details
DISPLAY DESCRIPTION
PRESSURE (SP35) [bar/psi] Displays the current pressure of hydrolever in bar or psi
PRESSURE (SP500) [bar/psi] Displays the current pressure of lifting in bar or psi
TEMPERATURE [°C] Displays the current temperature of hydraulic oil in °C
ENGINE RPM [1/min] Displays the current engine RPM in 1/min

F1 PSI/BAR Switches the unit of pressure between psi and bar.
F2 N/A N/A
F3 N/A N/A
F4 N/A N/A
ESC N/A Closes measurements page and returns to main page
UP N/A N/A
DOWN N/A N/A
OK N/A N/A

3.3.5 Container Handling Summary
4
5
CONTAINER HANDLING SUMMARY PAGE

1 Container handling summary details Shows container handling summary details. See below
below
Transmission parameters
DISPLAY DESCRIPTION
TOTAL Displays the number of total container handled
TODAY Displays the number of container handled today
SINCE LAST RESET Displays the number of container handled since last reset
LAST RESET Displays the date and time of last reset

Holds container handling summary page, otherwise it will be
F1 HOLD
closed automatically after a while.
Reset button, which will reset the number of ‘since last reset’
F2 RES
and ‘last reset’ (date and time)
Displays container handling summary logs, which will show
F3 LOG
daily based number of total container handled.
F4 N/A N/A
Closes container handling summary page and back to main
ESC N/A
page
UP N/A N/A
DOWN N/A N/A
OK N/A N/A

3.4 Console Controls
1. Twist Lock Latch/Unlatch - The button allows the spreader attachment

twistlocks to be latched or unlatched. This function will only work
when the spreader attachment is sitting on top of a container and the
landing pins have depressed.
2. Stops Lock Unlock - This button locks or unlocks the spreader from
the 20/30/40 foot position. It must be unlocked prior to changing the
spreader position. The appropriate 20/30/40 button should then be
selected and held until the spreader reaches the desired position prior
to which point the lock button should be activated.
3. Powered Slope Pile (optional) - Depressing the rocker switch to the left
lowers the left hand side of the attachment. Depressing the right has
the reverse effect.
4. 20’-40’. - This switches the container handler between the 20’ and 40’
handling sizes. Pressing to the left will retract the spreader attachment
to the 20’ position. Pressing the button got the right will extend out the
spreader attachment to the 40’ position. This function cannot be done if
connected to a container, or not hanging freely.
5. Lift / Lower Override - If required the lift / lower twistlocks cut-outs
can be overridden by holding the spring loaded key. This override key
should, in exceptional circumstances, as it overrides safety circuits.
The override function should only be used to alleviate a temporary
CAUTION! situation. If the system is malfunctioning it should be repaired by a
qualified person at the earliest possible occasion.

3.5 The Key / Start Switch
• Turns the truck electrical system “on” and “off”.
• Connects and tests the warning indicator lights.
• Connects the starter motor circuit when the engine is to be started.
The Key Switch has Three Positions
1. Off
2. Run
3. Start
When the key is in the vertical “off” position all truck electrical circuits are
disconnected (shut off), and the key can be removed. From the “off” position the
key can be turned to the right (clockwise) to the “start” position where the
starter motor is engaged and part of the truck electrical system is energised.
When the key is released from the “start” position it will automatically return
left (counter clockwise) for a part of its travel to the “run” position where the
starter is disengaged and all the truck electrical system is “on”.
When the key is in the “accessories” position, this allows any ancillary
equipment to be operated with the engine off, i.e. two-way radio. This position
is achieved when switching the key counter clockwise (left) from the “off”
position.
The key switch has a mechanical “anti-restart” feature, which prevents the
engine starter from being engaged and damaged if the key switch is accidentally
turned from the “run” position to the “start” position while the engine is
running. If the engine stops running, the key switch must be turned to the “off”
position before it can again be turned to the “start” position.
3.6 Direction and Speed Control

Direction Control Lever
This lever controls direction-of-travel. Push forward for forward gear, pull back
for reverse gear; centre for neutral.
For safety, always bring the truck to a complete stop before shifting to the
IMPORTANT! opposite direction.
3.7 Automatic Powershift Controller (APC)

The Automatic Powershift Controller allows for the fully automatic gear shifting
of the OMEGA industrial truck.
The operator does not need to downshift or upshift, the APC unit does the
NOTE gear selections itself.

3.8 Accelerator Control Pedal
The speed of the engine and lift speed or truck travel speed is controlled with a
foot pedal mounted on the floor board and connected through electrical control
wire to the engine fuel controls. The pedal is designed for operation by the right
foot.
3.9 Declutching Operation

When the brake pedal is applied (normally open pressure switch mounted in the
brake circuit) the transmission is put in neutral as soon as the vehicle speed
drops below 1.5km/h.
The above operation allows the engine speed to be kept at high revs for
operation of the hydraulic system.
When the brake pedal is released, or the vehicle speed exceeds the declutch
speed (1.5km/h), the transmission direction is re-engaged only if the engine revs
are below 900 rpm.
3.10 Wet Disc Brake System

The brakes, located in the drive axle, are of a multiple wet disc design. The
brakes are released by hydraulic pressure and engaged with integral springs.
Cooling of the brakes is done by hydraulic oil circulation. There are no brakes
on the steer axle.
A low brake pressure indicator is lit to indicate low hydraulic oil pressure. This
system also incorporates an audible alarm which sounds when the hydraulic
pressure in the brake circuit is low. At start up this alarm will sound until
sufficient hydraulic pressure is built up for the brake circuit, indicating the
truck is safe to operate.
3.11 Speed Limiting
In order to improve the stability of the truck, automatic speed limits may be in
place, which vary depending on the configuration of the load. The truck may
be set with the following automatic speed limiting (please confirm this applies
to YOUR truck):
Unladen, spreader low – 25 km/hr

Laden, mast full back, container eye level or below – 15 km/hr
Laden, mast or container level not correct – 5 km/hr

3.12 Parking Brake for Wet Disc Brake Trucks
The park brake is mounted on the drive axle input flange. The park brake unit is
spring applied and hydraulically released. A switch on the dash electrically
activates a hydraulic solenoid which allows the oil to return to the tank which
activates the park brake. The brake system is accumulated which means there is
a store of hydraulic pressure, when the button is pushed the oil pressure is
directed again via the electrically operated hydraulic solenoid to release the park
brake.
• To apply the park brake, press the switch. This releases the
hydraulic pressure and allows the spring to activate.
• To release the brake, press the switch, this applies oil to the
calliper which releases the spring.
If ignition is switched off and park brake switch is not activated, park
brake will apply (system is failsafe) therefore if the truck is started
NOTE (ignition switch on) the park brake needs to be reset. This feature is only
available on wet disc brake units.
3.13 Power Steering System

With engine running, the steering system uses hydraulic power to position the
rear wheels. Turning the steering hand wheel, which is connected to the steering
gearbox control valve, hydraulic pressure is directed to the respective side of the
steering actuator, to give you positive steering.
If the engine quits while travelling, steering effort will increase
CAUTION substantially and the truck should be brought to a halt as quickly as
possible.

3.14 Joystick Lever
3.14.1 Joystick Lever Operation

Function required Action Reaction
Lift load Pull Joystick back Load raises
Lower load Push Joystick forward Load lowers
Tilt back Push Joystick left Mast tilts back
Tilt forward Push Joystick right Mast tilts forward

3.14.2 Joystick Buttons Operation

3.14.3 Automatic Twistlock Operation (optional)
This unit may be fitted with automatic twistlock operation. If fitted this feature
can be activated or deactivated in the control box fitted to the attachment. Refer
to the instructions in this manual under the attachment section.
When this feature is activated the twistlocks will automatically engage or latch
two (2) seconds after all four (4) land pins have seated on the top of the
container. On some attachments the time delay between all four land pins
seating and the twistlocks latching can be adjusted.
This feature only acts to engage or latch the twistlocks. Disengaging or
NOTE unlatching must be manually activated by the operator.
3.14.4 Lift and Lower Cut-out

This unit may be fitted with automatic lift and lower cut-out protection.
This feature has two purposes.
6. To prevent excessive lowering of the inner rail once the attachment has
landed on top of the container over lowering creates excessive slack in the
lift chains and overmast cables, which can lead to premature failure.
Lowering cut-out is achieved by the land pin signal activating a solenoid
valve, which shuts of pilot pressure to the joystick lowering function.
7. Lift cut-out is designed to prevent lifting of the attachment in the event
the twistlocks are not fully engaged (latched) or disengaged (unlatched).
The lift cut-out is achieved by the twistlocks signal activating a hydraulic
solenoid valve, which shuts off pilot pressure to the joystick lift circuit
unless a fully engaged (latched) green signal or fully disengaged
(unlatched) red signal is received.
8. Both the lift and lowering cut-out systems can be overridden in the
event of a system malfunction or hanging up on a container. This is
achieved by activating the override key switch located at the bottom of
the joystick console to the right of the operator’s seat.
The override function shall only be used to alleviate a temporary
CAUTION! situation. If the system is malfunctioning it must be repaired by a
qualified person at the earliest possible occasion.
In the event the unit must continue to operate ensure all other persons who may
use the unit are advised the override function has been activated.

3.15 Load Indicating System
3.15.1.1 Twistlocks
TWISTLOCKS ATTACHMENT TWISTLOCKS
LOCKED LANDED UNLOCKED
TRAVELLING STACKING
ONLY
3.15.2 Attachment Indicator Lights

Light Number Colour Condition
1 Green TWISTLOCK LOCKED
2 Amber ATTACHMENT LANDED ON ALL 4 CORNERS
3 Red TWISTLOCKS UNLOCKED
3.15.3 Load Configuration

Light Number Colour Position
4 Amber Mast on full backtilt
TRAVELLING Attachment fully retracted
Load BELOW max travel height
5 Red Mast NOT full backtilt

STACKING Attachment NOT fully retracted
ONLY Load ABOVE max travel height
In the AMBER load position this container handler is rated to travel

WARNING
forward with the container raised sufficiently to permit the operator to
view underneath the load. However excessive travel speed, excessive
cornering speed or hard braking may still create an unstable situation that
can result in a serious accident, personal injury or death.

3.15.4 Tilt Indicator
Shown on full back tilt.

3.16 Suspension Seat
To ensure a comfortable ride the following features are available. These can be
adjusted to suit your body size, weight and shape.
Fore and Aft Seat Adjustment
Lift lever and move seat forward or back. Release lever to lock into position.
Back Adjustment Angle
Lift lever on left hand side of seat and adjust seat back to suitable position.
Release the lever to lock.
Seat Weight Adjustment
Turn wheel at front of seat to the right to increase for weight – to the left to
reduce for weight (graduated in kilograms and pounds)
Seat Belt
The seat belt is self retracting. Bring the seat belt buckle over your body and
connect into the receiver. This seat belt is similar to that found in motor vehicles
and is operated in the same manner.
If the seat belt does not self retract, or is showing signs of abrasion or wear,
have it replaced.
3.17 Other
Lights
The OMEGA heavy lift truck is equipped with various 24 volt work lights in the
event that the lighting in the work area is insufficient to carry out tasks safely.
Locks and Latches
Various compartments are located around the OMEGA heavy lift truck. Many
of these have a locking facility for security.
Observers Seat (Optional)
An observer’s seat can be fitted, for the use of instruction to a new driver etc.
Under no circumstances must anyone ‘ride’ in the truck unless seat in an
authorised seat, complete with seat belt.
Electrical Box
All fuses are push reset, located behind left hand swing down panel. If fuses
continue to trip, consult an OMEGA service representative. Circuit overloads
can cause fire.

4 Operating Procedures

4.1 Defect Reporting
From time to time operators detect and have the need to report defects on their
equipment. Defects may be noticed by the operator during normal operations or
during inspection of the equipment. The type of defect may be either:
1. Physical – e.g. visible damage, oil leak, cracked window glass
2. Operational – e.g. poor performance, noise or vibration
Depending on the nature or criticality of the defect the operator will determine
whether the equipment can continue to operate or not. The nature or criticality
of the defect can be categorized as follows:
4.1.1 Immediate Action Defects

Immediate Action Defects are those that require immediate action to rectify the
condition. In this case the equipment cannot be operated unless the defect is
repaired immediately.
Upon detection of an Immediate Action Defect, the operator will notify
maintenance personnel and/or supervisor, and appropriate corrective action will
be arranged.
The operator may be required to fill out a Defect Report with details of the
equipment and the defect.
4.1.2 Deferred Action Defects

Deferred Action Defects are those that do not require immediate action to rectify
the condition. In this case the equipment can continue to operate safely with the
defect until corrective action can be arranged.
The operator may be required to complete a Defect Report with details of the
equipment and the defect.

4.2 Preparation for Operation
4.2.1 Inspection before Start-up
As an operator, it is your responsibility to carefully check the condition of the
industrial truck and be sure it is safe to operate. The ‘Daily Safety Inspection’
form (reference Appendix 6.2) has been developed as an aid in this examination
– copies of this form are available from an OMEGA dealer.
Industrial trucks should be inspected every eight (8) hours and at the start of
every shift. Before using an industrial truck, it is the operator’s responsibility to
check its condition and be sure it is safe to operate.
The Work Health and Safety Act inforce in each State (WHS Act) require that
the user examine their truck before each shift to be sure it is in safe working
order. Defects when found shall be immediately reported and corrected. The
truck shall be taken out of service until it has been restored to safe operating
condition.
Check for damage and maintenance problems, and have repairs made before you
operate the truck. Unusual noises or problems should be reported immediately to
the user’s supervisor or other designated authority.
Do not make repairs yourself unless you have been trained in industrial truck
repair procedures and authorised by your employer. Have a qualified mechanic
correct all discrepancies using genuine OMEGA or OMEGA approved parts.
If the truck becomes unsafe in any way, while you are operating it, STOP
OPERATING THE TRUCK and report the problem immediately and have it
corrected.
Check that all capacity, safety and warning plates or decals are attached and
legible.
Due to the precise tolerances of diesel injection systems, it is extremely

important that the fuel be kept clean and free of dirt or water. Dirt or
IMPORTANT! water in the system can cause severe damage to both the injection pump
and the injection nozzles.
4.2.2 Start Up
Before attempting to start the engine:
• Adjust the seat position to ensure comfortable operating position
• Ensure the gear selector is in ‘Neutral’ and the Park Brake is applied
• Adjust any mirrors/visual aides as required
• Turn off any lights or electrical equipment to reduce the load on the battery

• Do not crank the starter continuously for more than 30 seconds at a time. If the
engine does not start in 30 seconds, wait 2 or 3 minutes before attempting to
start again.
• When starting a cold engine, increase speed (RPM) slowly
• Do not run the engine at maximum power continuously until fully warmed up
• Idle the engine to warm up before operating the truck with a load
• Avoid extended (in excess of 10 minutes) and unnecessary idling of the
engine. If extended idling occurs or is anticipated beyond 10 minutes, turn
off the engine.
• CARBON MONOXIDE is colourless and odourless but can be present with
all other exhaust fumes
4.2.3 Protection Systems

Engine Protection System which monitors:
• Low engine oil pressure
• High engine temperature
• Low water level in radiator
• Turbo shutdown timer (optional) which idles the engine for three minutes after
the ignition key has been switched off.
Brake circuit and load lowering accumulator
In the event of an engine failure, provides braking capability to bring the
machine to a safe stop.
Park Brake
In the unlikely event accumulator pressure is lost, the park brake will be spring
applied.
Lift Circuit Accumulator
This is located between the main valve and the lift cylinder in the hydraulic lines
and its function is to dampen & reduce the shock or impact loading developed
when travelling with the load. It protects the structural members in the
attachment, carriage, boom and frame and reduces the effect of vibration and
jolting to the operator and is an important device in this area.

4.3 Operating
Check Travel Path is Clear
Before moving off, check that your intended travel path is clear of
obstructions and pedestrians. In particular check for overhead obstructions
such as powerlines, bridges or gantry’s. When moving, always be on the alert
for pedestrians, other vehicles and any obstructions. Watch where you are
going and if you cannot clearly see your way, do not move until you can be
certain it is safe to do so. Raise the attachment until it is clear off the ground
and provide a clear field of vision
Apply the Foot Brake
With the engine running, apply the foot brake before releasing the park brake.
Release the Park Brake
With the foot brake firmly applied, release the park brake.
Lift Direction Lever and Engage Desired Direction
With the foot brake applied and park brake released, lift the direction lever and
select the desired direction of travel.
Drive off Ensuring Clear Travel for Truck and Load
After checking to ensure there is a clear path for both truck and load, smoothly
accelerate in the required direction.
ALWAYS:
• Sound the horn at intersections or wherever vision may be
obstructed
• Stop gradually and smoothly by taking your foot off the
accelerator and apply firm pressure to the foot brake
• Bring the truck to a COMPLETE stop before shifting to the
opposite direction
4.4 Travelling without a Load

When travelling without a load, the attachment should be lowered.
Trucks equipped with heavy attachments e.g. container handler, behave as
partially loaded trucks even when operated without a load on the attachment.

4.5 Handling a Load
Without exception, only handle loads that are within the industrial trucks actual
capacity as shown on the industrial truck name plate. This rating specifies the
maximum load the industrial truck is rated to lift at various configurations in
accordance with the nominated standards which are with the mast vertical on
flat hard ground.
Other factors, such as special load handling attachments, loads having a high
centre of gravity or uneven terrain, may dictate that the safe working load is less
than the actual capacity. Under such conditions, the operator must reduce the
load carried so that the industrial truck remains stable.
• Handle only stable or safely arranged loads.
• Centre the load on the attachment.
• Always travel with the attachment lowered.
4.5.1 Approach
The approach to a storage area or machine should be at right angles (90 degrees)
to the storage area or machine.
4.5.2 Pick up
The length of the spreader must be adjusted to the size of the container to be
lifted by retracting the stops and then activating the extension button to extend
or retract the spreader beams to the correct length. At the required length, lift the
spreader high enough to give good visibility beneath it and to allow positioning
of the spreader ready to pick up the container.
It is important to remember that loads should only be lifted at the
NOTE specified lengths for which the spreader is designed. Lifting outside the
specified positions can result in serious damage to the spreader.
The spreader should now be side-shifting to the centre position and the reach
function should be in the fully retracted position.
Approach the container and line up the twistlocks with the container corner
fittings by using side shift and slew. Lower the container handler slowly and
enter the rear (nearest the truck) into the container corner fittings.
Once all four twistlocks (two on side-mount container handler attachments) are
fully seated and the landing pins fully depressed, the orange light will illuminate
in conjunction with the red light. Two seconds after the orange light illuminates
the twistlocks will automatically engage (if that feature is in automatic mode).
The green light will indicate that the twistlocks are correctly positioned and
locked. Alternatively if the twistlocks are in manual mode the operator can now
manually lock the twistlocks.

The container can now be lifted CAREFULLY. Once lifted, the orange light
will go out. To avoid damage to the locking mechanism, ENSURE the container
handler is fully down and both white lights are on before trying to lock/unlock
the container.
4.5.3 Travel
The safe operation of a laden or un-laden industrial truck is the responsibility of
the operator. Common sense in the operation of the machine is important. Only
loads that are within the machine’s rating conditions should be lifted.
Excessive travel speed, excessive cornering speed or hard braking can create an
unstable situation that can cause a serious accident, resulting in personal injury
or death. It is essential to use care and commonsense.
When travelling on gradients, the load should be uphill.
When turning with a load, watch for obstacles that may be struck by the load
extremities. Be aware of the truck’s rear end swing when turning to avoid
damage to the truck and other items in your work area.
CAUTION! Do not turn on slopes.

Pay attention to ground conditions in your travel path and work area. Rough,
uneven ground may affect truck and load stability – assess the conditions and
travel slowly.
When reversing make sure you have looked to see there are no bystanders or
pedestrians in your intended path. Remember that others may not be aware that
your industrial truck steering is at the rear, that the wheels can be turned to full
lock even when stationary and that the rear end can turn sharply and quickly.
Do not carry passengers unless an approved seating arrangement has been
provided.
Never travel with a container elevated.
Refer to 3.11 for speed limitations.
4.5.4 Depositing a Load

When approaching the new location for a container, such as a chassis or stack,
lower or raise the container to the required height and adjust the corner castings
so they are positioned above the corner locks of the chassis or stacked container.
Lower the container ensuring its corner castings are above the corner locks and
continue lowering the container until the ‘SEATED’ light is switched on and
then activate the twistlocks to the ‘UNLOCKED’ position. The spreader can
now be lifted and the truck backed away.

4.6 Stacking
To put a load on a stack:
1. Approach slowly and align the truck and load squarely with the stack.
2. Lift the load when the industrial truck is close to the stack.
3. Move forward, slowly, until the load is almost touching the stack. Stop
close to the stack and further lift (raise) the load high enough to clear the top
surface of the stack. Move the load into position. Be careful not to damage
or move adjacent loads.
4. When the load is almost aligned with the stack beneath it, tilt the upright to
the vertical position to bring the load alignment correct and carefully lower
the load onto the top surface of the stack.
4.6.1 Moving a Load from a Stack

Approach the stack carefully, with truck lined up squarely with the load. With
upright mast vertical, raise the forks to the correct height for freely engaging the
load pallet. Adjust fork angle, as necessary, to fit squarely under the load. Move
forward until the forks are under the load.
With the mast vertical, raise the carriage until the load begins to lift. At this
point, apply the minimum back tilt which will stabilize the load.
Check your travel path, slowly back off until clear of the stack, stop, and then
lower the load to the travel position (200-300mm off the ground). Tilt slightly
back to travel. Be sure load is back flush against the carriage or front face of the
forks.
NOTE Certain loads may have to be transported as level as possible

4.7 Double Empty Side Lift Container Handler
The double empty side lift container handler (DE) is designed specifically to
handle either one or two empty ISO container in the range of 20’ to 40’. The
design uses a pair of hooks to clamp the two containers together. When lifting
two containers, the retaining hooks engage the top container first and are
compressed backward as the lifting hook is guided by the retaining hook, to
engage the lower container.
Once the hooks are correctly in place, lifting causes the hooks to travel down
against a spring and in doing so clamps the two containers casting blocks
between the retaining and lifting hooks. This clamped position is maintained
automatically by a spring actuated locking block. This locking mechanism
cannot be disengaged unless the operator actuates the unlock solenoid from
within the fork truck. Misalignment of the two containers of up to 40mm
forward or side can be tolerated.
The DE container handler can lift either a single or two containers on top of
each other. The following instructions are given to assist in the correct operation
of the container handler.
4.8 Single Container Lifting Instructions

4.8.1 Lifting Operation
Lifting should proceed as follows:
• Approach the container at an angle and with the mast tilted
slightly forward.
• Using the side shift to assist, engage one of the lifting hooks into
the top corner casting, straighten the truck up and enter the other hook,
noting that the touch pins are depressed.
• Verify that the amber light is illuminated, which indicates the
hooks are in the correct position within the corner casting.
• It is now safe to attempt taking the weight of the container.
Slowly raise the container and note that the hooks travel downward so
clamping the container corner casting between the retaining hook and
lifting hook.
• Verify that both green lights are on, indicating that the locking
mechanism has been engaged.
• It is now safe to carry the containers. Centre the load as much as
possible using the Side-shift operation, before proceeding to drive.

4.8.2 Container Disengagement
Lowering and disengaging the container should proceed as follows:
• Lower the container slowly to its final position.
• Just before the container is settled either on the ground or another
container, depress the unlock button to energise the unlock solenoid. It
is important that this is done in advance of the weight being taken off
the hooks or the automatic lock arrangement will not permit the hooks
to be released and result in unnecessary damage being inflicted on the
locking mechanism.
• Verify that the green lights have been extinguished, indicating
that the hooks are unlocked before proceeding to lower the container
further.
• Once the container is at rest, continue to slowly lower the handler
until the hooks are completely open. Note that only the amber light is
illuminated.
• It is now safe to either slowly reverse the truck or tilt the mast
back to remove the lower hooks out of the corner castings.
4.9 Double Container Lifting Instructions

4.9.1 Lifting Operation
Lifting should proceed as follows:
• Approach the container at an angle and with the mast tilted
slightly forward.
• Using the side shift to assist, engage one of the retaining hooks in
the lower corner castings of the top container, straighten the truck up
and engage the other retaining hook.
• Compress the retaining hooks by either driving forward or tilting
the mast forward and observe that the lifting hooks enter the top corner
castings of the lower container and noting that the touch pin is
depressed.
• Verify that the amber light is illuminated, which indicates the
hooks are in the correct position within the corner casting.
• It is now safe to attempt taking the weight of the containers.
Slowly raise the containers and note that the hooks travel downward so
clamping the two containers together.
• Verify that both green lights are on, indicating that the locking
mechanism has been engaged.
• It is now safe to carry the containers. Centre the load as much as
possible using the side shift operation, before proceeding to drive.

4.9.2 Container Disengagement
Lowering and disengaging the container should proceed as follows:
• Lower the containers slowly to their final position.
• Just before the container is settled either on the ground or on
another container, depress the unlock button to energise the unlock
solenoid.
It is important that this is done in advance of the weight being taken off
the hooks or the automatic lock arrangement will not permit the hooks to
IMPORTANT! be released and result in unnecessary damage being inflicted on the
locking mechanism.
• Verify that the green lights have been extinguished, indicating
that the hooks are unlocked before proceeding to lower the containers
further.
• Once the containers are at rest, continue to slowly lower the
handler until the hooks are completely open. Note that only the amber
light is illuminated.
• It is now safe to either slowly reverse the truck or tilt the mast
back to remove the lower hooks out of the corner castings.
• Once the amber light is extinguished or the lower hook is
sufficiently out of the lower casting, the handler should be inched
vertically to ensure the safe removal of retaining hooks.
There is a danger of catching the retaining hook on the corner casting as it
NOTE is removed.

4.10 Shutdown
Before shut-down, the truck should be safely parked with the attachment
lowered to its lowest point. Avoid parking on a grade. If the truck must be
parked on a grade, ensure the wheels are securely chocked. Never park in
emergency routes.
The following procedure should apply:
1. Bring the truck to a complete stop
2. Put the gear selector lever in the ‘N’ neutral position
3. Apply the park brake
4. Lower the attachment mechanism to its lowest point
5. Switch off the ignition and remove the ignition key
6. Chock the wheels if necessary
7. Lock the cabin door
8. Return the Daily / Pre start check sheet to your supervisor
NOTE Never park on a grade, unless the wheels are securely chocked in position
The OMEGA industrial truck can be fitted with a timer which will keep the
engine running for three (3) minutes after the ignition has been switched off.
This is to ‘cool’ the turbocharger and engine.

5 Trouble Shooting
The information below enables the operator to locate and to remedy straightforward faults, or the
consequences of operating errors. Fault locating operations should be performed in the order as set
out below.
If it was not possible to eliminate the fault by performing the remedial actions indicated below,
please inform the Manufacturer or trained representative, as more intricate faults can only be
rectified by specially trained and qualified service staff.
Starter does not turn.

Possible cause Remedial action
Travelling direction lever not in neutral position. Set the travelling direction lever to its neutral position.
Engine oil pressure warning lamp alight during truck operation.

Or Engine temperature indicator high.
Engine oil level low Check engine oil level
Transmission oil temperature warning lamp alight during truck operation.

Transmission oil level low Check transmission oil level
Engine running, but truck does not move.

Travelling direction lever in 'neutral position. Set the travelling direction lever to the required position.
Parking brake applied. Release the parking brake.
Truck does not reach its max. speed.

Transmission oil level low. Check the transmission oil level
Machine in LIMP mode Check APC error codes
Lifting speed too slow. Or Load cannot be raised to max. height.

Oil level in hydraulic reservoir low. Check the hydraulic oil level and top up, if required.
Steering binding.
Tyre inflation pressure of steer tyres low. Check the tyre inflation pressure
Steering play excessive

Check the hydraulic oil level. If this is OK, turn the
Air in steering system.
steering wheel several times from end stop to end stop.
If truck will not start
Emergency stop switch. Check the Emergency switch – reset if necessary.

5.1 Container Handling
There are few problems that will occur with the operation of the container
handler. In the event that the lights fail to illuminate or extinguish, it is
important that these be investigated before continuing to use the handler. All
abnormal operation of lights should be reported. The following points may
assist.
5.1.1 Hooks Remain Locked with the Container Weight off the Hooks
If the hooks are locked with the weight of container off the hooks, the unlocking
mechanism will not function. To allow the hooks to disengage:
• Tilt mast slightly forward.
• Raise the container.
• Depress the unlock button.
• Ensure green lights have extinguished.
• Lower container.
5.1.2 The Red Light is illuminated

The red light should rarely occur. If it is illuminated, either:
• The hooks are locked but not engaged within the corner casting.
• The hooks are locked but they are in an incorrect position within the corner
casting.
If the hooks are still in the corner casting and the red light is illuminated,
the situation could be dangerous and there is a risk of dropping the box. If
NOTE this occurs, stop the truck, lower the container and attempt to re-establish
the hooks into the correct position. If this is not possible, seek assistance.

6 Appendices

6.1 Specifications
Empty Container Handler Models

5 ECH-10 6 ECH-10 7 ECH-10 8 ECH-9
Load rating C Distance 1200
H Standard lift height 13,800 16,400 19,200
H1 Min pick up height 2300
Upright
Hmax Max height under
16,100 18,700 21,500
twistlocks
L1+x Length of load face 6700
B1 Width 4,018 4,135
Overall
dimensions H2 Overall height (lowered) 9,045 10,405 11,905
H3 Overall height (raised) 15,945 18,605 21,505
Turning radius R1 5,630 6,235
M1 Laden (minimum) 253 324
Ground
clearance M2 Laden middle of W’Base 278 350
Wheelbase Y 4,000 4,545
All measurements in the table above are in millimetres.

Empty Container Handler Models
5 ECH- 6 ECH- 7 ECH-
8 ECH-9
10 10 10
Load capacity Rated Load kg 8,500 10,000 10,000 9,000
Backward/Forward
Tilt of Upright deg 4/2
degrees Std a/b
Travel- Laden/unladen km/hr 28/32.5
Lifting- Laden/unladen at
Speeds m/s 0.6/0.7
70% of load
Lowering-
m/s 0.55/0.53
Laden/Unladen
Max. Drawbar pull Laden kN 120
Gradeability
Laden % 30
1.6kph
Max.gradeability Laden % 34
Service weight kg 38,750 38,750 39,750 40,250
Laden front kg 387,50 38,750 39,750 40,250
Laden rear kg 8,450 8,450 8,800 8,650
Axle loading
Unladen front kg 22,730 22,730 24,400 26,400
Unladen rear kg 13,800 13,800 14,150 13,500
Battery Voltage / Capacity V/CCA 24 / 830
Fuel (diesel) L 550
Tank Capacity
Hydraulic L 500 580 600
Displacement cc 6700
CUMMINS
QSB-220 Max Torque Nm/RPM 949@1500
I.C.Engine Alternator A 70
6 cylinders
Fuel consumption L/hr 6-8
Transmission 3F/3R TE10 TE17
For attachments
Operation pressure MPa/psi 20.7/3100
(adjustable)
90° stacking aisle Aisle for container 20’/40’ mm 11,105 / 14,710
Sound level Per AS3713 dB(a) 80
Due to a policy of ongoing product improvement, specifications are subject to change without notice.

6.2 Daily / Pre Start Check List
Before using an industrial truck, it is the operator’s responsibility to check its
condition and be sure it is safe to operate.
As an aid in carrying out this inspection, CEA has prepared a form called the
‘Daily / Pre Start Check List’. We recommend that you use this form to make a
daily record of your inspections and truck condition.
Check for damage and maintenance problems, and have repairs made before you
operate the truck. Unusual noises or problems should be reported immediately to
your supervisor or other designated authority.
Do not make repairs yourself unless you have been trained in industrial truck
repair procedures and authorised by your employer. Have a qualified mechanic
correct all discrepancies using genuine OMEGA or OMEGA approved parts.
If the truck becomes unsafe while you are operating it, STOP OPERATING
THE TRUCK and report the problem immediately and have it corrected.
Industrial trucks should be inspected every 8 hours, or at the start of each shift
Hydraulic oil fill

Engine Oil
Fuel fill
Air filter
Transmission oil Radiator cap
“Ghost” view of truck

Coolant level
Engine must be turned off. The engine coolant level can be physically checked
by removing the radiator cap. Remove the cap only when the engine is cold.
First turn the cap slowly to release any pressure that may be in the radiator.
Some industrial trucks have a radiator cap which incorporates a pressure
relieving lever which should be activated before slowly turning and removing
the cap.
Do not remove the radiator cap when the radiator is hot.
DANGER
STEAM Steam from the radiator will cause severe burns.
It is a good safety practice to use a shop cloth to cover the radiator while it is
being removed. Wrap the cloth around the cap and turn it slowly to the first
stop. Step back while any pressure is released from the cooling system. When
you are sure all the pressure has been released, press down on the cap, with the
cloth in place, turn and remove it. Stand clear of the radiator opening; hot
coolant may splash out. Failure to follow these instructions could result in
serious personal injury from hot coolant or steam blow-out, this may also cause
damage to the cooling system or engine. The correct FULL level is the top edge
of the filler neck. If level is low,
Some industrial trucks may be fitted with remote check e.g. ‘Murphy’ Gauge or
remote header tank, so you will not need to remove the radiator cap.
Tyres and Rims
Checks to be made include:
• Tyres have correct inflation pressure
• Tyres are not damaged, torn, cut
• Wheel nuts are all present and tight
• Rims are not bent, damaged or buckled
Transmission Oil Level
Before making this check, run engine until unit is at operating temperature. This
is important as transmission oil temperature should be 900C and the engine
water jacket should be at operating temperature. Apply parking brake.
With the engine operating at idle and the transmission in NEUTRAL, check the
fluid on the dipstick. Fill if necessary to the FULL mark on the dipstick. (See
lubrication sheet for specifications).

Fuel Level and Fill
Site gauges are located at the left hand side of the truck. Check that diesel fuel
can be seen at the indicated mark.
Diesel fuel is a petrochemical and is thus not only poisonous if swallowed, but
also if left on the skin for extended periods.
• Handle fuel with care, as it is highly flammable and can pose an
environmental risk if spilled.
• Always stop the truck before refuelling and do not overfill.
• Do not smoke or have open flames/sparks when refuelling
• Secure the fuel cap when finished refuelling and clean up any spilt fuel.
• Avoid fire hazards and have fire protection equipment present in the work
area. Do not use an open flame to check for level or leaking fuel, electrolyte
or coolant. Do not use open pans of fuel or flammable cleaning fluid for
cleaning parts.
Batteries
Maintenance free batteries are normally fitted at the factory, so will not require
electrolyte checking. If non-maintenance free batteries have been fitted, ensure
the electrolyte level is correct. As this electrolyte is acidic, never check with the
engine running, and wear gloves and safety glasses, ensuring you avoid any
splashing onto your skin or the truck.
• Do not smoke, have sparks or any naked flames nearby when checking or
filling batteries.
Air Filter
Check the blockage indicator. If this indicates a blockage, the filter(s) may need
replacing.
Engine Oil Level
Engine must be turned off. Using the engine oil dipstick, pull the dipstick out,
wipe it with a clean cloth and re-insert it fully into the dipstick tube. Remove the
dipstick and check oil level.
Hydraulic Oil Level
Site gauges are located at the right hand side of the truck. Check that oil can be
seen at the indicated mark.
Mast
Inspect the mast chains to see they are well lubricated and there is no apparent
damage. Check the overmast cables to see they are not tangled or damaged
When in the cabin:
• Check the function of the tilt and lift system controls with the engine running.

• Tilt the mast fully back, then fully forward and then return it to the vertical
position.
Be sure that there is adequate overhead clearance before raising the
CAUTION! upright.
• Raise the mast to full height and then lower to the ground. Watch the upright
assembly as it rises. All movements of the upright, fork carriage and lift
chains must be even and smooth, without binding or jerking. Watch for
chain wobble or looseness; the chains should have equal tension and move
smoothly without noticeable wobble.
Attachment
Omega heavy lift trucks can be fitted with numerous types of attachments.
• Fork tynes – check the heel of the fork tyne is not excessively worn and that
the forks are not cracked, bent or otherwise damaged.
• Coil handler - check the coil probe is not cracked (heel), bent or otherwise
damaged.
• Tyre handler – check that there are no oil leaks from around the tyre handler
grab, and that all functions operate smoothly without binding or jerking.
• Container handler - check that there are no oil leaks from around the container
grab (spreader), and that all functions operate smoothly without binding or
jerking.

Daily / Pre Start Check List
Check before the start of each shift Date
Truck No. Operator Supervisor OK
Hour meter reading Type Model Serial No.
boxes accordingly OK Needs attention / repair
Visual Checks Operational Checks
Inspect for damage Cab doors open freely
Inspect for leaks Seat adjustment is correct
Wheel mounting nuts Seat belt is operational
Tyre pressure and condition All warning lights & buzzes
Transmission oil level Instruments operate correctly
Fuel level Horn for correct operation
Coolant level – NEVER CHECK HOT Back up alarm operates correctly
Air filter Brakes & park brake operation
Engine oil level Steering operates correctly
Hydraulic oil level All auxiliary hydraulic functions
Windscreen washer level Correct function of Mast/Boom
Rating plate is affixed Correct function of attachment
All glass clean on Cab
Remarks Remarks

6.3 Service Schedule
The service schedule on the following pages must be read in conjunction with the Omega Service
Manual. This manual does not provide the necessary information to undertake these operations.
Due to variability of operation, operating environments and maintenance practices, the service
schedule does not comprehensively list high hour items such as wheel bearings etc.

6.4 Safe Work Procedure


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Operators Manual

Empty Container Handler

Clark Equipment Australia Empty Container Handler Version 5 -2-

a) Maintenance of machine as per Operation and Maintenance Manuals.

a. Damage or defects caused by accident, misuse, negligence or natural calamity.

Clark Equipment Australia Empty Container Handler Version 5 -3-

Machine Under Warranty

Machine Out of Warranty

If warranty is required to be claimed, please immediately contact your purchasing Dealer,

IN NO EVENT SHALL CEA BE LIABLE FOR INCIDENTAL, SPECIAL OR

Clark Equipment Australia Empty Container Handler Version 5 -4-

YOU can prevent accidents

Second Read your Operator’s Manual.

Learn about the unit you operate.

Know Your Truck

Then Practice operating your truck safely.

Clark Equipment Australia Empty Container Handler Version 5 -5-

Clark Equipment Australia Empty Container Handler Version 5 -6-

Clark Equipment Australia Empty Container Handler Version 5 -7-

This manual is intended to be a permanently attached part of the industrial truck.

Clark Equipment Australia Empty Container Handler Version 5 -9-

Safe operation is of primary importance. Inadequate operator training, lack of

Clark Equipment Australia Empty Container Handler Version 5 - 10 -

Clark Equipment Australia Empty Container Handler Version 5 - 11 -

It remains the operator’s sole responsibility to drive the machine in a safe

1.2.2 Design Standards

Clark Equipment Australia Empty Container Handler Version 5 - 12 -

This machine contains no asbestos

Clark Equipment Australia Empty Container Handler Version 5 - 13 -

Figure 2 - shows normal deflection when load is lifted to stacking position

Clark Equipment Australia Empty Container Handler Version 5 - 14 -

This term is used when special information, instruction or identification is

IMPORTANT! This term is used when special precautions should be taken.

This term is used as a reminder of unsafe practices that can result in

DANGER This message is used when an extreme hazard exists.

Clark Equipment Australia Empty Container Handler Version 5 - 15 -

Clark Equipment Australia Empty Container Handler Version 5 - 16 -

In Case of Rollover decal

Warning Rotating Fan decal

Emergency Exit decal

Rotating Component decal

Clark Equipment Australia Empty Container Handler Version 5 - 17 -

Accumulator warning decal

Lift and Tie Down Point decals

Jacking Point decal

Battery Isolator decal

Tyre Deflation decal

Hydraulic Oil decal

Diesel Fuel decal

Clark Equipment Australia Empty Container Handler Version 5 - 18 -

Clark Equipment Australia Empty Container Handler Version 5 - 19 -

Safety is everyone’s concern and everyone’s responsibility.

Keep Away From Attachment decal

Upright Warning decal

Clark Equipment Australia Empty Container Handler Version 5 - 20 -

2.2.2 Operating Guidelines

Don’t mix drugs or alcohol with your job

Don’t block safety equipment

Don’t smoke in ‘no smoking’ areas or when

Do watch for pedestrians.

Do wear safety equipment when required.

Clark Equipment Australia Empty Container Handler Version 5 - 21 -