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K-D HAWK M30-2/4 H - Hawkins Equipment

1. A AJUST N CLEAN C CHECK P BLEED D DESCALE R CHANGE G GREASE V DRAIN CHANGE ENGINE Engine oll I amp V6l A caus C 44 44 44 44 44 44 Cooling liquid 8 6 C 44 44 44 44 44 44 ab rr C 44 44 44 44 44 44 Cyclonic prefilter OPTION N 44 44 44 44 44 44 Dry air filter cartridge N 44 R 44 44 44 Radiator core 44 44 44 44 44 Fuelfilter 44 44 44 44 44 Alternator fan crankshaft belt tension A A 44 44 44 44 Engine V V 44 44 44 Engine oil filter R R 44 44 44 Fuel filter cartridge R R 44 44 44 Fuel feed pump N 44 44 44 Engine crankcase breather N R 44 44 44 A sen 44 44 Safety dry air filter cartridge R 44 44 Engine silent blocks 44 44 ENGINE Tales CP 4 44 Valves clearances 44 44 Cooling IKgultd y oni ewe eee ook 35 e ae V 44 soe 4 Water pump and the thermostat 44 Alternator and the starter motor 44 Bleed
2. GROUND ENGINE BLOCK OR FRAME Start the engine on the jumper vehicle and allow it to run at high idle for about 5 minutes Start the forklift Make sure that the engines in both vehicles are at low idle before disconnecting the jumper cables Remove the cables in reverse order of installation Remove the negative cable from the forklift frame or engine ground Remove the negative cable from the jumper vehicle Remove the positive cable from the forklift Remove the positive cable from the jumper vehicle If the forklift fails to start after several attempts seek assistance from a qualified mechanic or contact your nearest dealer INTRODUCTION TO SAFETY
3. Open the engine compartment Loosen the wingnut 1 and remove the cover 1 Fig D3 1 Remove the airfilter wingnut 2 Fig D3 2 and the airfilter cartridge 3 taking care to avoid spilling the dust Leave the safety cartridge in place The following parts must be cleaned with a damp clean lint free cloth e The inside of the filter housing and cover e The inside of the filter inlet hose The gasket surfaces in the filter and in the cover Check tubing and connections between the air filter and the engine and the condition of the clogging indicator on the filter housing Before installing check the condition of the new cartridge See FILTERS CARTRIDGES AND BELTS Insert the cartridge into the filter housing and push it into place tighten the wingnut Reassemble the cover positioning the valve downwards D4 FUEL FILTER CARTRIDGE CHANGE Open the engine compartment 2 Carefully clean the exterior of the filter and bracket to prevent debris from entering the system 3 Place a receptacle under the tank and empty thru drain plug 1 Fig D4 4 Unscrew fuel bowl and filter 2 Fig D4 5 Discard inclosed fuel cartridge not shown 6 Clean the inside of the filter head and the housing using a brush and clean diesel fuel 7 Install new fuel filter into bowl and rotate 90 clockwise the filter should lock in place Screw filter bowl assembly onto filter housing until bowl shou
4. Loosen nut 1 Fig A4 remove cover 2 Fig A4 and empty the tank Clean the prefilter unit with a clean dry cloth and reassemble the unit IMPORTANT When cleaning take care not to allow impurities into the dry air filter 5 TRANSMISSION OIL LEVEL 4 SPEED MODELS CHECK Park the lift truck on level ground with the engine cold and at idle Open the engine compartment Remove the dipstick 1 Fig A5 Check the level at the upper notch If necessary add oil See LUBRICANTS AND FUEL A6 TIRE PRESSURE AND WHEEL NUT TORQUE CHECK WHEEL NUTS TIGHTENING TORQUE FRONT TIRES 444 ft lbs REAR TIRES 260 ft lbs Check the condition of the tires watch for cuts tears wear etc Check the torque load of the wheel nuts See fig A6 Non IMPORTANT compliance can damage and rupture the wheel bolts and cause distortion to the wheels Check and adjust the tire pressures if necessary See CHARACTERISTICS Section 2 DESCRIPTION Ensure the air hose is correctly connected to the tire valve before inflating WARNING land keep all persons at a distance during inflation Follow the recommended tire pressures given 47 REMOVABLE RADIATOR FEATHER SCREEN CHECK Check the condition of the screen If dirty the screen must be removed for cleaning Use compressed air directed from the radiator side of the screen Mild detergent may also be used If the screen becomes cracked or damaged it must be replace
5. u B ud FL T These checks are important for the proper working operation of the mast In case of technical problems consult your dealer IMPORTANT B5 MAsT GREASE Clean and lubricate the following points with grease See LUBRICANTS AND FUEL remove any surplus grease 1 Lubricators grease zerks on the side shift axles of the mast mounting 1 2 lubricators Fig B5 1 2 Lubricator of the side shift cylinder 2 1 lubricator Fig B5 1 3 Lubricators of the tilt cylinders 1 2 lubricators Fig B5 2 4 Lubricators of the chain rollers 1 2 lubricators Poultry masts only Fig B5 3 NOTE The mast guide rollers are permanently sealed and require no additional lubrication INTRODUCTION TO SAFETY B6 HYDRAULIC OIL LEVEL CHECK Park the lift truck on level ground with the engine stopped and the forks lowered to the ground On the right hand side of the forklift find the hydraulic tank oil level gauge 1 Fig B6 1 The level is correct when the guage is halfway full If necessary add oil See LUBRICANTS AND FUEL Open the engine compartment and remove the cap 2 Fig B6 2 Add oil by filler port 3 Fig B6 2 Clean the oil filler tube before adding fluid Always use a clean IMPORTANT funnel when filling Always maintain the proper oil level cooling depends on the oil flowing through the tank at the proper level Reinstall the cap B7 BRAKE OIL
6. 9 Never put any part of the body within the reach mechanism of the rough terrain forklift truck or other attach ments 10 Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury to personnel 11 Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck whether empty or loaded 12 Do not permit passengers to ride on rough terrain forklift trucks 13 Check clearance carefully before driving under electrical lines bridges etc 14 A rough terrain forklift truck is attended when the operator is less than 25 ft 7 6m from the truck which remains in his view 15 A rough terrain forklift truck is unattended when the operator is 25ft 7 6m or more from the truck which remains in his view or whenever the operator leaves the truck and it is not in his view 16 Before leaving the operator s position a bring rough terrain forklift truck to a complete stop b place directional controls in neutral apply the parking brake lower load engaging means fully unless supporting an occupied elevated platform stop the engine f if the rough terrain forklift truck must be left on an incline block the wheels g fully lower the load engaging means 17 Maintain a safe distance from the edge of ramps platforms and other similar working surfaces 18 Do no move railroad cars or trailer with a rough terrain forklift truck C d e
7. AIR FILTER NEEDS SERVICE INDICATOR 4 FUEL LEVEL METER 5 HOURMETER 6 ALTERNATOR VOLTAGE METER 7 HYDRAULIC OIL TEMPERATURE METER 8 ENGINE OIL PRESSURE METER 9 ENGINE WATER TEMPERATURE METER 10 LIGHT SWITCH 11 HORN SWITCH 12 IGNITION SWITCH 13 ACCELERATOR PEDAL 14 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF 15 DIFFERENTIAL LOCK PUSH BUTTON 16A GEAR LEVER AND TRANS CUT OFF 4 SPEED TRANSMISSION 16B 2 SPEED GEAR BOX SWITCH HYDROSTATIC OPTION 17 FORWARD REVERSE LEVER 18 PARKING BRAKE LEVER 19 HYDRAULIC CONTROLS 20 DOCUMENT STORAGE 21 BREAKER SWITCHES NOTE The terms LEFT RIGHT FRONT REAR refer to the location of forklift components in relation to the forklift operator seated normally facing forward 1 DRIVER S SEAT DESIGNED FOR COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS LONGITUDINAL ADJUSTMENT Push locking lever 1 to the left Slide the seat to the required position Release the lever and insure it returns to the locked position 2 SAFETY BELT Sit correctly on the seat Check that the seat belt is not twisted Place the seat belt at hip level and not across the stomach Attach the seat belt and insure that it locks Adjust the seat belt to your body shape without squeezing your hip In no event should the lift truck be used if the seat belt is defective any phy sical damage cuts tears etc If any defects are found replace the seat belt
8. IMPORTANT The engine does not contain a corrosion resistor and must be filled with a minimum mixture containing 25 ethylene glycol based antifreeze INTRODUCTION TO SAFETY G OCCASIONAL MAINTENANCE G1 FUEL SYSTEM BLEEDING BLEED Bleeding the fuel system may be required when Acomponent on the fuel system has been replaced or drained The fuel tank has been drained The fuel system has been run dry Ensure that the level of fuel in the tank is sufficient and bleed in the following order Open the engine compartment Turn the ignition switch on for three minutes on the lift truck to give the lift pump time to release air from the filter Turn the ignition switch off BLEEDING THE INJECTORS Remove the injectors cover 1 fig G1 1 Loosen high pressure connectors 2 fig G1 2 of all the injectors Activate the starter until the diesel fuel flows out free of air at high pressure connectors 2 fig G1 2 IMPORTANT Do not crank the engine continuously for more than 30 seconds at a time Allow the starter motor to cool for two minutes between cranking attempts Tighten the connection while the diesel fuel is flowing out tightening torque 22 ft lb The I C engine is then ready to be started Run the engine at idle for 5 minutes immediately after bleeding the fuel feed circuit to ensure that the injection pump has been bled thoroughly NOTE If the I C engine functions cor
9. INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 19 Do not use a rough terrain forklift truck for opening or closing railroad car doors 20 In areas classified as hazardous use only rough terrain forklift trucks approved for use in those areas 21 Report all accidents involving personnel building structures and equipment to the supervisor or as directed 22 Do not add to or modify the rough terrain forklift truck 23 Do not block access to fire aisles stairways and fire equipment 24 For rough terrain forklift trucks equipped with a differential lock the lock should not be engaged when driv ing on the road or at high speeds or when turning If the lock is engaged when turning there could be loss of steering control 25 Observe all traffic regulations including authorized speed limits Under normal traffic conditions keep to the right maintain a safe distance based on speed of travel from the truck ahead and keep the truck under control at all times 26 Yield the right of way to pedestrians and emergency vehicles such as ambulances and fire trucks 27 Do not pass another truck traveling in the same direction at intersections blind spots or at other danger ous locations 28 Slow down and sound the audible warning device s at cross aisles and other locations where vision is obstructed 29 Cross railroad tracks at an angle wher
10. OPERATING INSTRUCTIONS 1 7 HANDLING INSTRUCTIONS 1 11 LOAD HANDLING 1 13 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 16 BEFORE STARTING UP A NEW LIFT TRUCK 1 18 2 DESCRIPTION 2 1 IDENTIFICATION OF THE LIFT TRUCK 2 4 LIFT TRUCK CHARACTERISTICS 2 6 M30 2 H L amp M30 4 H L 2 9 MAST CHARACTERISTICS TABLE 2 10 LIFT TRUCK LOAD CHART 2 11 INSTRUMENTS AND CONTROLS 2 12 TOWING PIN 2 18 MAINTENANCE 3 1 FILTERS CARTRIDGES AND BELTS 3 3 LUBRICANTS AND FUEL 3 4 SERVICING SCHEDULE 3 6 A DAILY OR EVERY 10 HOURS SERVICE 3 8 B EVERY 50 HOURS SERVICE 3 10 EVERY 250 HOURS SERVICE 3 16 D EVERY 500 HOURS SERVICE 3 20 E EVERY 1000 HOURS SERVICE 3 26 F EVERY 2000 HOURS SERVICE 3 30 G OCCASIONAL MAINTENANCE 3 32 XV 1 OPERATING AND SAFETY INSTRUCTIONS INTRODUCTION TO SAFETY ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS ALL REPAIRS ON OUR LIFT TRUCK MUST BE MADE WITH ORIGINAL PARTS WHEN INSTALLING AFTER MARKET PARTS YOU RUN THE RISK Legally of being liable in the event of an accident Technically of causing breakdowns to occur or of reducing your lift truck s service life Using counterfeit parts or components not approved by the manufacturer may void contract war IMPORTANT z p ranty terms and lead the manufacturer to withdraw the lift truck s certificate of compliance BY USING ORIGINAL PARTS DU
11. Suspended Loads 1 DO NOT exceed the rated capacity of the telescopic handler as equipped for handling suspended loads The weight of the rigging must be included as part of the load 2 During transport DO NOT raise the load more than 12 inches 305 mm above the ground or raise the boom more than 45 degrees 3 Only lift the load vertically NEVER drag it horizontally 4 Use multiple pickup points on the load when possible Use taglines to restrain the load from swinging and rotating 5 Start travel turn and stop SLOWLY to prevent the load from swinging DO NOT exceed walking speed 6 Inspect rigging before use Rigging must be in good condition and in the U S comply with OSHA regulation 1910 184 Slings or 1926 251 Rigging equipment for material handling T Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft The load center must not exceed 24 inches 610 mm 8 DO NOT lift the load with anyone on the load rigging or lift equipment and NEVER lift the load over personnel 9 Beware of the wind which can cause suspended loads to swing even with taglines 10 DO NOT attempt to use frame leveling to compensate for load swing U S OSHA regulations effective November 8 2010 29 CFR Part 1926 Subpart CC Cranes and Derricks in Construction include requirements for employers that use powered industrial trucks forklifts configured to hoist
12. Transmission oil filter 4 Speed Transmission 5 Fuel filter cartridge CAT or PERKINS 6A Hydraulic return oil filter cartridge 4 Speed Transmission 500 H 6B Hydraulic return oil filter cartridge Hydrostatic Transmission 7 Suction strainer for hydraulic oil tank 9 Fan belt 10 Cyclonic vacuum cleaning pre filter cap and clamp 11 Air intake pre filter cap only 803071 Clamp B2236 15 12 Rain cap pre filter cap and clamp Clamp 13 Turbo II pre filter cap and clamp Servicing varies depending on operating conditions see SERVICING SCHEDULE LUBRICANTS AND FUEL ENGINE COMPONENT CAPACITY RECOMMENDATION ENGINE CRANKCASE 8 5 9 gts Shell Rotella 15w40 SEE ENGINE OIL Citgo C 600 15w40 SPECS BELOW COOLING CIRCUIT 5 gal Tulco 50 50 Premix Anti freeze FUEL TANK 26 gal Diesel fuel Grade 1 D TRANSMISSION COMPONENT CAPACITY RECOMMENDATION TRANSMISSION 4 SPEED MODELS 4 gal Shell Donax TG Dexron 111 Citgo Transgard ATF Dexron III GEARBOX HYDROSTATIC MODELS Shell Spirax DH80w90 Citgo Premium Gear MP 80w90 TRANSMISSION UNIVERSAL JOINT Shell Rentinax Am Citgo Lithoplex CM 2 MAST COMPONENT RECOMMENDATION MAST LIFTING CHAINS GREASING THE MAST Shell Rentinax Am Citgo Lithoplex CM 2 HYDRAULICS COMPONENT CAPACITY RECOMMENDATION HYDRAULIC OIL TANK 26 gal Shell Tellus T46 Citgo Transgard THF Lo Temp BRAKE COMPONENT RECOMMENDATION
13. by means of a winch or hook and move suspended loads horizontally In particular this regulation applies to any rough terrain forklift e g telescopic handler equipped with a jib or truss boom with a hook with or without a winch or a hook assembly attached to the forks Note This regulation is in addition to the OSHA regulation that requires specific forklift operator training 81910 178 1 When a forklift telescopic handler is configured and used for hoisting the employer must ensure that 1 Forklift lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manufacturer s instructions vi 5 Operator and crew members have been trained in safe use and operation of the equipment including how to avoid electrocution 6 During use no part of the equipment load line or load will be within the minimum clearance distance specified by OSHA 10 feet 3 0 m and more for lines rated over 50 kV of any energized power line and any taglines used are non conductive 7 In addition for lift equipment with a rated capacity greater than 2000
14. 1 Fig D7 1 Hydrostatic Transmission Models Remove the cap 1 Fig D7 2 Remove the hydraulic return oil filter cartridge and install a new replacement cartridge See FILTERS CARTRIDGES AND BELTS Install the cover cap INTRODUCTION TO SAFETY D8 PARKING BRAKE MECHANISM GREASE Lift the protective boot 1 Fig D8 Clean and lubricate connections 2 Fig D8 with grease See LUBRICANTS AND FUEL Install the protective boot 1 Fig D8 D9 FRONT AXLE DIFFERENTIAL OIL DRAIN Park the lift truck on level ground with the engine stopped and the differential oil still warm IMPORTANT Dispose of the drain oil in an ecological manner Place a container under drain plugs 1 Fig D9 and remove the plugs Remove level 2 Fig D11 and filler plug 3 Fig D9 to ensure the oil drains properly Install and tighten drain plugs 1 Fig D9 Tightening torque 30 ft Ibs Fill with oil See LUBRICANTS AND FUEL by filler port 3 Fig D9 The level is correct when the oil level is flush with the edge of port 2 Fig D9 Check for leaks at the drain plugs Install and tighten level plug 2 and filler plug 3 Fig D9 Tightening torque 30 ft Ibs D10 ENGINE CRANKCASE BREATHER TIER 11 CLEAN AND INSPECT REPLACE Open the engine compartment From the left side of the engine locate the breather cover cap Fig D10 Remove the plastic breather cover cap pry from front or re
15. 44 44 Hydraulic return oil filter cartridge R R 44 44 44 po OI rm V 44 44 Suction strainer for hydraulic oil tank N 44 44 Filter cap for hydraulic oil tank R 44 44 Speeds of hydraulic movements 44 44 Condition of hoses 44 44 Condition of cylinders leakage shafts 44 44 Hydraulic circuit 4 Hydraulic circuit outputs 44 Hydraulic Oil tank N 44 Brake 01 69 C 44 44 44 44 44 Parking biake cisco rra ead vedas A 44 44 44 44 Parking brake mechanism G nunc bee eos Berater ache on oe V 44 44 Brake EIECUIE ack d ate p 44 44 Brake circuit pressure 44 44 tact uas seer s eed add qu Edad A 44 44 INTRODUCTION TO SAFETY A AJUST N CLEAN 1 year 1 year C CHECK P BLEED 2000 4000 D DESCALE R CHANGE 1000 hours hours 6 GREASE V DRAIN CHANGE hours hours hours hours CAB es 52 2 Ex X En 6 6 RR EES C 4 4 A 4S ira iae 44 44 Lift the cab SEE G OCCASIONAL MAINTENANCE ELECTRICITY Batte
16. Fig L maneuvering very gently and carefully When the load is in position apply the parking brake and place the forward reverse lever in neutral 1 14 INTRODUCTION TO SAFETY Place the load in a horizontal position 1 and lay it down on the pile 2 while checking the correct positioning of the load Fig M Maneuvering very gently and carefully lower the forks to release the load and reverse the lift truck Then lower the forks into the transport position TAKING UP A NON PALLETIZED LOAD Tilt the carriage 1 forwards and move the lift truck forward 2 while simultaneously crowding the carriage backwards to slip the forks under the load Fig N If necessary wedge the load with blocks 1 15 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK MAINTENANCE INSTRUCTIONS GENERAL Read the operator s manual carefully and ensure you understand it Stop the engine when servicing or repair is necessary Wear clothes suitable for the maintenance of the lift truck avoid wearing jewelry and loose clothes Tie and protect your hair if necessary Ensure the area is sufficiently ventilated before starting the lift truck Make sure that the disposal of process materials and spare parts is carried out in a safe and Make repairs immediately including minor repairs Repair all leaks immediately When replacing hydraulic hose assemblies use only factory approved compontents Tie wraps hose clamps
17. LEVEL CHECK Park the lift truck on level ground Remove the front sheet metal plate 1 Fig B7 1 The level is correct when it is at the MAXI level on the tank If necessary add oil See LUBRICANTS AND FUEL through the filler port 2 Fig B7 2 Reassemble the front sheet metal plate 1 Fig B7 1 IMPORTANT If the braking oil level is abnormally low consult your dealer INTRODUCTION TO SAFETY B8 BATTERY ELECTROLYTE LEVEL WHERE APPLICABLE 4 A CHECK The factory installed battery is maintenance free requiring no service to the electrolyte 2 E Open the engine compartment Check the connections to the battery 1 Fig B10 remove any corrosion on the terminals Apply petroleum jelly to prevent corrosion Check the battery mounts and over all condition of the battery for leaks cracks etc If the original battery is replaced with a serviceable battery follow the manufacturer s instructions for maintenance Handling and servicing a battery can be dangerous take the following precautions Wear protective goggles Keep the battery horizontal Never smoke or work near an open flame Work in a well ventilated area In the event of electrolyte being spilled onto the skin or splashed in the eyes rinse thoroughly with cold water for 15 minutes and call a doctor INTRODUCTION TO SAFETY B9 FRONT AXLE UNIVERSAL JOINT GREASE Clean and lubricate the following points with
18. by the operator and serviceman Study this manual and the Rough Terrain Forklift Safety Manual part no 422494 thoroughly and carefully before operating or servicing your forklift Contact your dealer or Manitou North America Inc if you have any ques tions concerning your forklift its operation service or parts Keep both manuals in the literature box on the forklift available for reference If either manual becomes illegible or is missing contact your dealer for replace ments immediately This manual cannot cover every situation that might result in an accident It is the respon sibility of the operator to always remain alert for potential hazards and be prepared to avoid them ADDITIONAL RECOMMENDED LITERATURE ANSI ITSDF B56 6 is the national consensus standard for rough terrain forklift trucks It contains rules about forklift safety maintenance safe operation training and supervision Forklift owners should learn this stan dard and make it available for their operators service personnel and supervisors These standards can be obtained free of charge from the Industrial Truck Standards Development Foundation ITSDF on their web site at www itsdf org The following references are examples from the standard addressing forklift operators A OPERATOR TRAINING QUALIFICATIONS 1 The user shall ensure that operators understand that safe operation is the operator s responsibility The user shall ensure that operators are knowled
19. gear THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE A CAUTION No Riders 420732 Location on the cab entrance s and on or near wheel fenders and engine cover Informs riders are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 A DANGER Boom equipped models Location on both sides Stay cl f raised b of the boom nose ay clear of raised boom unless properly supported Operator may be crushed Keep away from unsupported boom between falling boom and main frame Failure to comply may result in serious injury or death Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose A DANGER Keep machine at least 25 feet from overhead power lines Keep away from power lines Failure to comply may result in serious injury or death by electrocution 801007 XI INTRODUCTION TO SAFETY SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of ps A DANGER the operator near the hydraulic control lever READ OPERATOR S MANUAL Level machine at ground level before raising boom Do not adjust frame Frame leveling notice load must be lowered pfit above ground level If frame position is changed with a raised boom machine may become unstable and turn over Failure to follow instructions may result in serious injury or death Attachment and Boom Safety 801
20. make sure you are in control of your speed On damp slippery or uneven terrain drive slowly Brake gently never abruptly Operate the forward reverse lever with the lift truck in a stationary position and never abruptly Do not drive with your foot on the brake pedal or with the parking brake on Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel turn it gently and not abruptly Do not allow the engine to idle needlessly for a long period Never leave the engine on when the lift truck is unattended Look in the direction of travel and always ensure you have good visibility of the route ahead When working at night ensure that your lift truck is fitted with full beam lights There are optional solutions consult your agent or dealer Drive around obstacles Never move onto a loading platform without having first checked That it is suitably positioned and secured That the unit to which it is connected tractor trailer etc will not shift That this platform is prescribed for the total weight of the lift truck to be loaded That this platform is prescribed for the width of the lift truck Never move onto a foot bridge floor or freight lift without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Aw ARNING Take extreme care when operating around loading p
21. minutes then start the engine If necessary bleed the system See G1 FUEL SYSTEM BLEEDING E2 SAFETY DRY AIR FILTER CARTRIDGE CHANGE For the disassembly and reassembly of the cartridge see D3 DRY AIR FILTER CARTRIDGE Gently remove the air filter safety cartridge 1 Fig E2 taking care to avoid spilling the dust Clean the gasket surface on the filter with a damp clean lint free cloth Before installing check the condition of the new safety cartridge See FILTERS CARTRIDGES AND BELTS Carefully push the cartridge into the filter housing avoid damaging the filter s surface NOTE The time frame for replacement of the safety cartridge is given for reference only The safety cartridge must be changed for every two changes of the air filter cartridge INTRODUCTION TO SAFETY E3 TRANSMISSION OIL 4 SPEED ONLY DRAIN E4 TRANSMISSION HOUSING STRAINER 4 SPEED ONLY CLEAN Park the lift truck on level ground with the engine stopped the transmission oil warm DRAINING THE OIL Place a container under drain plug 1 Fig E3 1 and remove the plug Open the engine compartment Remove the dipstick 2 Fig E3 2 and filler plug 3 Fig E3 2 to help the oil drain properly IMPORTANT Dispose of the drain oil in an ecological manner CLEANING THE STRAINER Remove plate 4 Fig E3 3 set aside the O ring joint and sealing washer Allow the the oil to drain Remove and clean the s
22. only loads within the capacity of the rough terrain forklift truck c Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity with extra caution Stability and maneuverability may be adversely affected IV INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 46 When attachments are used extra care shall be taken in securing manipulating positioning and trans porting the load Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks when not handling a load 47 Completely engage the load with the load engaging means Fork length should be at least two thirds of load length Where tilt is provided carefully tilt the load backward to stabilize the load Caution should be used in tilting backward with high or segmented loads 48 Use extreme care when tilting load forward or backward particularly when high tiering Do not tilt forward with load engaging means elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load 49 The handling of suspended loads by means of a crane arm boom or other device can introduce dynam ic forces affecting the stability of a rough terrain forklift truck Grades and sudden starts stops and turns can cause the load to swing and create a hazard if not externally stabili
23. points on the seat Cleanliness of the strap and the locking mechanism The locking mechanism operation e Condition of the strap cuts frayed or curled edges NOTE If the forklift is involved in an accident replace the seat belt system immediately Under no circumstances should you use the lift truck if the seat belt is faulty catching locking cuts or tears etc Repair or replace the seat belt immediately 9 FRONT WHEELS REDUCERS OIL DRAIN Park the lift truck on level ground with the engine stopped and the reducer oil warm IMPORTANT Dispose of the drain oil in an ecological manner Drain and change each front wheel reducer s oil Place drain plug 1 Fig E9 in position A Place a container under the drain plug and remove the plug Let the oil drain completely Place the drain port in position B i e in a level position Fill with oil See LUBRICANTS AND FUEL through level port 1 Fig E9 The level is correct when the oil level is flush with the edge of the hole Install and tighten the drain plug 1 Fig E9 Tightening torque 30 ft Ibs INTRODUCTION TO SAFETY E10 REAR AXLE DIFFERENTIAL OIL 4WD MODELS DRAIN Park the lift truck on level ground with the engine stopped and the differential oil warm Dispose of the drain oil in an ecological manner IMPORTANT Place a container under the drain plugs 1 Fig E10 and remove them Remove level plug 2 Fig E10 and
24. reflex reactions of a person in the event of a malfunction incident fault etc during operation of the lift truck Behavior resulting from application of the principle of least action when performing a task For certain machines the foreseeable behavior of such persons as unauthorized apprentices teenagers handicap ped persons and trainees tempted to drive a lift truck Truck drivers tempted to operate a truck to win a bet in compe tition or for their own personal experience The person in charge of the equipment must take these criteria into account when assessing whether or not a person will make a suitable driver INTRODUCTION TO SAFETY GENERAL INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Read the operator s manual carefully making sure you understand it The operators manual must always be kept in the lift truck in the place provided and in the language understood by the operator Every operation or maneuver not described in the manual must be assumed to be prohibited Respect the safety notices and instructions given on the lift truck Itis mandatory to replace all plates or decals which are no longer legible or which have become worn or damaged B AUTHORIZATION TO OPERATE Refer to the legislation for each particular country Only qualified personnel may use the lift truck Its use is subject to authorization to operate being given by the appropriate manager in the user establishment The
25. rings and at the rear using the towing pin Fig G5 3 INTRODUCTION TO SAFETY G6 CAB TILTING LIFT Park the lift truck stop the engine and open the engine compartment RAISING THE CAB Remove the right and left side panels to gain access to the cab mounts Loosen both fastening bolts removing only the cab mount nut 1 Fig G6 1 2 places Using an approved overhead crane and sling Fig G6 2 slowly raise the cab IMPORTANT Remove any loose objects from the cab Watch closely for obstructions or interference as the cab is raised Do not raise the cab any higher than required to place the cab stand The gear shift boot will turn inside out 4 Speed Models only Lift the cab until the cab stand can be placed within the cab stand rest on the back of the cab 1 Fig G6 3 Lower the cab until fully supported by the stand LOWERING THE CAB Lift the cab slightly and return the cab stand to its clamp Slowly lower the cab watching for obstructions as the cab settles Install and tighten the cab s mounting hardware Reassemble the side panels Reshape the gear lever boot 4 Speed Models only Remove the lifting sling INTRODUCTION TO SAFETY G7 EMERGENCY JUMP STARTING Read and follow the instructions carefully If you have any questions ask for assistance from an experienced mechanic or contact your nearest dealer Before attempting a jump start determine the condition of th
26. should never be taken for granted Even experienced operators can be seriously injured or killed by ignor ing refusing to enforce or forgetting to follow safe operating procedures Do not assume you know all safe ty issues concerning the decals Before operating the lift truck learn the meaning s of the decals as described in this manual If any decal becomes illegible or missing have it replaced immediately Always replace decals using the same decal part no unless otherwise specified by the manufacturer For replace ment decals not found in your parts manual contact your nearest dealer If you have any questions contact your supervisor or nearest dealer for advice before operating your forklift 801011 Before Starting 801011 Boom equipped models Location on the brake fluid cover panel to the left and below the dash panel BEFORE STARTING OR OPERATING Safety Instructions 420792 Read and understand all safety and operating Mast equipped models Location on or near the operator manual AR storage case and or on the dash panel Clear the area of bystanders Locate and know operations of controls Instructions for the forklift operator before operating the forklift Fasten seat belt Keep all shields in place Operate only from operator s seat SAFETY INSTRUCTIONS 1 Read and understand operator s manual before you operate this truck If the operator s manual is missing a new Carry load as l
27. site protect the lift truck from bad weather particularly from frost check the level of antifreeze close the rear windows lock the cab doors and ensure that the hood is properly secured where applicable INSTRUCTIONS Park the lift truck on flat ground or on an incline of less than 15 grade Release the accelerator pedal and stop the lift truck Place the forward reverse lever in neutral Apply the parking brake Lower the forks or attachment to rest on the ground Turn the engine off Remove the pressure in the hydraulic circuits by using the hydraulic controls Remove the ignition key Check the closing and locking of doors windows and hood where applicable For your safety and the safety of others before leaving the driver s cab ensure that you have F DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY SAFETY INSTRUCTIONS When driving a lift truck on roads open to public traffic observe the provisions of the Highway Code When on public roads lift truck drivers must abide by the general provisions relative to highway traffic The lift truck must conform to the provisions of the Local Highway Code If necessary optional solutions exist consult your dealer A CAUTION Transport of loads on the public highway is forbidden and attachments mounted on the lift truck must be fitted with equipment in accordance with regulations or removed INTRODUCTION TO SAFETY INSTRUCTIONS Ensure that the fla
28. 009 Boom equipped models Location on both sides of the boom nose ATTACHMENT AND BOOM SAFETY Improper operating techniques can cause the machine to tip over Refer to machine load charts and operator s manual for proper operating techniques Important reminders of attachment and boom safety Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as a manlift Attachment must be properly locked to the carrier before raising boom Use only approved attachments on this machine Do not work under raised boom or attachments unless supported FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801009 Hydraulic Coupling 234805 Location near the quick disconnect adapters Stop the engine and release hydraulic pressure before changing attachments Rotating Fan and Belt s 801008 Location on the radiator near the fan and on any fan belt pulley cover s KEEP HANDS Keep hands and clothing away from rotating fan and belts AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 XII INTRODUCTION TO SAFETY SAFETY DECALS Gear Shift Pattern 33460 4 speed transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift transmission 9 5 81 Steering Mode 184276 4 wheel steer equipped mo
29. 50 psi 26 gal tank INTRODUCTION TO SAFETY SPECIFICATIONS Travel speeds forward reverse loaded unloaded approx 4 Speed 81 in Models 1st gear 2 5 mph 2nd gear 5 0 mph 3rd gear 10 mph 4th gear 16 mph 4 Speed 77 in Model 1st gear 2 0 mph 2nd gear 4 0 mph 3rd gear 8 0 mph 4th gear 12 mph Hydrostatic 81 in Models Low gear 9 mph High gear 17 mph Hydrostatic 77 in Model Low gear 8 0 mph High gear 15 mph Standard lift height varies per Mast Model 10 to 22 ft Mast Side Shift 6 in total Load center 24 in INTRODUCTION TO SAFETY M30 2 H amp M30 4 H 81 cab 77 cab 17 5X24 wl 14 5R20 R4 drive XM 27 drive 34 37 wl rotator 148 196 199 w rotator 67 5 67 5 68 5 9 5 9 5 175185 435 L version M30 TIRES MAKE SIZE FRONT 77 Cab MICHELIN 375X75R20 FRONT 77 Cab 15X19 5 FRONT 81 Cab TITAN 17 5X24 IMPORTANT FRONT 81 Cab GOOD YEAR 16 9 24 FRONT 81 Cab MICHELIN 17 5X24 When changing or replacing the tires and REAR 77 Cab 412X165 wheels use only the manufacturer s approved REAR 77 Cab MICHELIN 12X16 5 XZSL 65 PSI components as installed at the factory Any REAR 81 Cab 12X16 5 substitutes or modifications must first be h f REAR 81 Cab MICHELIN 12X16 5 XZSL 2 9 INTRODUCTION TO SAFETY MAST CHARACTERISTICS TABLE SOME DIMENSIONS MAY VARY DEPENDING ON CARR
30. BRAKE CIRCUIT Shell Donax TG Dexron III Citgo Transgard ATF Dexron Ill ENGINE OIL SPECIFICATIONS CG4 CH4 ACEA E3 ES 40 Caution The above oils are to the minimum specification 30 20 10 0 10 20 30 40 50 C Irecommended Higher grades may be used but not until after the 22 4 14 32 50 68 86 104 1229 first service nor for light load applications INTRODUCTION TO SAFETY FRONT AXLE COMPONENT CAPACITY RECOMMENDATION FRONT AXLE DIFFERENTIAL 1 8 gal Shell Donax TD Citgo Transgard Tractor Hyd Fluid FRONT WHEELS REDUCERS Shell Spirax DH80w90 Citgo Premium Gear MP 80w90 REAR AXLE 2WD COMPONENT RECOMMENDATION ALL GREASE FITTINGS Shell Rentinax Am Citgo Lithoplex CM 2 REAR AXLE 4WD COMPONENT CAPACITY RECOMMENDATION REAR AXLE DIFFERENTIAL 1 8 gal Shell Donax TD Citgo Transgard Tractor Hyd Fluid REAR WHEELS REDUCERS Shell Spirax DH80w90 Citgo Premium Gear MP 80w90 REAR WHEELS REDUCER PIVOTS Shell Rentinax Am Citgo Lithoplex CM 2 REAR AXLE OSCILLATION DIAGNOSTIC ANALYSIS OF OIL In the event of a maintenance or service contract with the dealer you may be requested to provide a sample of a selected component s oil for diagnostic analysis INTRODUCTION TO SAFETY
31. E OIL Place a container under drain plug 1 Fig E5 1 and remove the drain plug Open the engine compartment Remove filler cap 2 Fig E5 2 to allow the oil to drain properly IMPORTANT Dispose of the drain oil in an ecological manner CLEANING THE STRAINER Remove the side panel 3 Fig E5 3 Disconnect the filter housing hose 4 Fig E5 3 4 speed transmission models On the hydrostatic transmission models disconnect the 5 filter housing hoses and the electrical connection not shown Remove the entire hydraulic return oil filter housing 5 Fig E5 3 From within the tank remove the strainer Clean the strainer check its condition and replace if necessary See FILTERS CARTRIDGES AND BELTS Install the strainer a new hydraulic oil filter and the hydraulic return oil filter housing 5 Fig 55 3 Tightening torque 40 ft Ibs Connect the hose 4 Fig E5 3 Install the side panel 3 Fig E5 3 FILLING WITH OIL Clean and install the drain plug 1 Fig E5 1 Tightening torque 26 ft Ibs Fill with oil See LUBRICANTS AND FUEL through filler port 6 Fig E5 2 Clean the oil filler port before adding fluid Always use a clean IMPORTANT funnel when filling Check the oil level 7 Fig E5 4 it should appear halfway up the guage glass Check the system for leaks INTRODUCTION TO SAFETY E8 SEAT BELT CHECK SEAT BELT Check the following points e Connection at the anchoring
32. ESEL Identifies the fuel tank and use of diesel fuel 161 101 No Step 496735 NOTICE Location varies depending on the forklift model NO STEP 435735 Instructs personnel not to use the designated area as a step Do Not Tow 494918 Hydrostatic equipped models Location on the dash in view of the operator A WARNING THIS VEHICLE IS EQUIPPED WITH A ri forklift will the transmission HYDROSTATIC TRANSMISSION DO NOT ATTEMPT refer to the operator s manual TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494918 XIV INTRODUCTION TO SAFETY SAFETY DECALS Boom equipped models Location on the boom coupler WA R N N G near where the retaining shaft 15 installed THE ATTACHMENT RETAINING SHAFT MUST BE IN PLACE AND SECURED WITH THE SAFETY SNAP PIN BEFORE TRUCK OPERATION Reminder to operator install attachment retaining shaft and safety pin before operations 421016 Hook Here 24653 MENU Location at points provided on the forklift where straps or chains may be attached to secure the forklift to a trailer during transport 24653 Fork Safety 426641 Mast equipped models Location on the front and back side of the mast s outer rails at eye level 4 required Instructs personnel not to travel beneath or upon the lift truck forks Pinch Point Large 2 5 x 4 5 in 426643 Pinch Point Small 1 5 x 2 75 in 426642 Mast equipped mo
33. IAGE OR ACCESSORIES SUPPLIED DIMENSIONS SHOWN IN INCHES 1 6 INTRODUCTION TO SAFETY OHE MFH OHL Y Optional 20 to 45 Z Optional 10 to 15 OHE OVERALL HEIGHT WITH MAST FULLY EXTENDED MFH MAXIMUM FORK HEIGHT WITH MAST FULLY EXTENDED OHL OVERALL MAST HEIGHT WITH FORKS FULLY LOWERED FFH FREE FORK HEIGHT FORK HEIGHT BEFORE RAISING MAST RAILS LIFT TRUCK LOAD CHART Refer to the Lift Truck Identification Plate attached within the cab for maximum load Capacities MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 MAST MODEL vasr s 5 UNLADEN WEIGHT A inches cues MAX CAPACITY MY 12s uP TO 6 MAX CAPACITY Les n ATNFH 8 INCHES au TIRE PRESSURE FRONT ME esi TIRE PRESSURE REAR RR psi CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH FORK UPRIGHTS VERTICAL FOR OTHER CAPACITIES CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSHASME MANUFACTURED IN INSTRUMENTS AND CONTROLS USE THE PHOTOS BELOW FOR COMPONENT IDENTIFICATION AND LOCATION ONLY INSTRUMENTS CONTROLS AND OPTIONS SHOWN VARY AND MAY NOT BE INCLUDED ON YOUR FORKLIFT MODEL TEMPERATURE ENGINE OIL PRESSURE HYDRAULIC OIL TEMPERATURE INTRODUCTION TO SAFETY DESCRIPTION 1 DRIVER S SEAT 2 SAFETY BELT 3A PARK BRAKE ON INDICATOR 3B
34. INTRODUCTION TO SAFETY MANITOU MANITOU NORTH AMERICA INC 6401 Imperial Drive Waco 76712 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com K D HAWK M30 2 4 H HYDROSTATIC amp 4 SPEED TRANSMISSIONS TIER Il ENGINE OPERATOR SERVICE MANUAL S N 751211 752093 amp above THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS CATALOG 806328 R11 10 INTRODUCTION TO SAFETY M SERIES FORKLIFT MODEL DESCRIPTION M 30 2 81 FORKLIFT OPTIONAL CAB HEIGHTS MODEL 81 81 IN CAB 77 77 IN CAB FORKLIFT RATED CAPACITY lt 30 6 000 LBS FORKLIFT DRIVETRAIN 2 2WD 2 WHEEL DRIVE 4 4WD 4 WHEEL DRIVE TRANSMISSION H HYDROSTATIC OMITTED 4 SPEED CONVERTER NOTE Lift trucks equipped with the TIER Engine have wheels that are painted Manitou white Lift trucks equipped with the TIER Engine have wheels that are painted Manitou silver Dimensions may vary depending on tires additional options etc INTRODUCTION TO SAFETY M SERIES POWERTRAIN COMPONENT IDENTIFICATION TURNER 4 SPEED TRANSMISSION IDENTIFICATION PLATE LEFT HAND SIDE OF TRANSMISSION HYDROSTATIC TRANSMISSION PUMP IDENTIFICATION PLATE BOTTOM SIDE OF PUMP MANUFAC
35. Ibs 907 kg the employer must ensure that a An accessible fire extinguisher is on the forklift b Monthly and annual inspections are performed and documented and records retained three months for monthly one year for annual c Before November 10 2014 operators must have had the additional training and qualification certification required by OSHA regulations 81926 1427 and 81926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a detailed description Vil ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont CONCLUSION 1 ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard 29 CFR 1910 178 as described by the Occupational Safety and Health Administration OSHA They must be qualified as to their visual hearing physical and mental ability to operate the equipment safely NEVER use drugs or alcohol while operating a forklift NEVER operate or allow anyone to operate forklift when mental alertness or coordination is impaired An operator on prescription or over the counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the f
36. NG THE FILTER Remove engine oil filter 3 Fig D1 1 discard the filter and the filter seal Clean the filter bracket with a clean lint free cloth Fill the new oil filter See FILTERS CARTRIDGES AND BELTS with engine oil and lightly grease the seal Install the oil filter on the filter bracket Tighten the oil filter by hand pressure only and lock the filter in IMPORTANT place by a quarter turn FILLING UP THE OIL Install and tighten the drain plug 1 Fig D1 1 Tightening torque 25 ft Ibs Fill with oil LUBRICANTS AND FUEL by filler port 4 Fig D1 2 or optional filler port on the right side of the engine near the fuel injection pump not shown NOTE For this operation we recommend a funnel and hose Wait a few minutes to allow the oil to settle into the sump Start the engine and let it run for a few minutes Check for possible leaks at the drain plug and the oil filter Stop the engine wait a few minutes and check that the level is between the MAXI and MINI notches on dipstick 5 Fig D1 3 Adjust the level if necessary INTRODUCTION TO SAFETY D3 DRY AIR FILTER CARTRIDGE CHANGE When operating in heavy dust use pre filtration cartridges see FILTERS CARTRIDGES AND BELTS Also check and clean the filter cartridges more frequently Change the cartridge in a clean location with the engine stop IMPORTANT ped Never run the engine with the air filter removed or dama ged
37. RING MAINTENANCE OPERATIONS YOU ARE LEGALLY Any user who procures parts from another vendor does so at his own risk COVERED Any user who modifies his lift truck or has it modified by a service company must consider that a new item of equipment has been brought onto the market and therefore takes liability for it Any user who copies original parts or has them copied is taking a risk from the legal viewpoint The certificate of compliance only binds the maker for parts chosen or produced under the maker s control The practicalities of maintenance terms are set out by the maker The maker is in no way liable in the event of the user not complying with such terms YOU GET THE THE MANUFACTURER BRINGS TO THE USER BENEFIT OF THE MANUFACTURER S His know how and skill KNOW HOW Guaranteed quality work Original replacement parts Help with preventive maintenance Effective help with diagnosing faults Enhancements gained from feedback Training for operating staff The manufacturer knows the details of the lift truck design and therefore has the best technological capability to carry out maintenance INTRODUCTION TO SAFETY DRIVER S OPERATING INSTRUCTIONS WARNING WHENEVER YOU SEE THIS SYMBOL IN MEANS WARNING BE CAREFUL YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK Most accidents connected with the use maintenance and repair of the lift truck are due to neglect of the basic forklift sa
38. RODUCTION TO SAFETY LIFT TRUCK CHARACTERISTICS ENGINE AND FUEL SYSTEM Engine Models Number of cylinders Number of strokes Suction Injection system Ignition sequence Clearance of rocker valve Cold Inlet Exhaust Capacity Bore Stroke Compression ratio Nominal rating loaded Rating slow unladen Max rating unladen Power ISO TR 14396 CV KW Maximum torque ISO TR 14396 Air cleaner Injection pump Capacity Crankcase Oil Fuel Tank COOLING CIRCUIT Type Fan Number of blades Diameter Thermostat Start opening Full opening Capacity ELECTRIC CIRCUIT Earth Battery Alternator Type Tension regulator Starter Type 4 SPEED TRANSMISSION 4 SPEED MODELS Type Torque converter Gear box Number of forward reverse speeds Gear reverser Capacity TIER II PERKINS 1104C 44 CAT 3054C 4 in line 4 Natural Direct 1 3 4 2 0 20 mm 0 008 in 0 45 mm 0 018 in 4 4 L 269 cu in 105mm 4 13 in 127 mm 5 0 in 19 3 1 2200 rpm 825 rom 2500 rpm 84hp 61 5 kw 223 filbs O 1400 rpm Dry 3 microns Delphi Type DP210 8 5 9 ats 26 gal tank By water Suction Puller 10 457 mm 18 in 77 C to 85 180 F 92 C to 98 C 203 F 5 gal Negative 12 V 900 CCA 32 F 750 CCA 0 F 12 V 65 Amp Incorporated into the alternator 12V TURNER POWERTRAIN SYSTEMS SACHS 4 El
39. TER OF GRAVITY Before taking up a load you must know its weight and center of gravity The load chart relating to your lift truck is valid for a weight with its center of gravity 24 in from the heel of the forks Fig A For other capacities consult your dealer For irregular loads determine the center of gravity in the transverse direction before handling Fig B For loads with a moving center of gravity i e liquids take into account the variations of the center of gravity in order to determine the load to be hand led Consult your agent or dealer Be vigilant and take extra care to limit these variations as much as possible TAKING UP A LOAD ON THE GROUND Position the lift truck perpendicular to the load with the forks in a horizontal position Fig C Adjust the fork spread and centering in relation to the load Fig D Optional solutions exist consult your dealer Beware of the risks of trapping or injuring limbs when manually adjusting the forks Always maintain an equal distance between the forks and the center of the carriage in order to keep the load completely stable Move the lift truck forward slowly 1 maneuvering the forks under the load Fig E if necessary slightly lift the mast 2 while approaching the load Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 incline the mast 2 backwards in the transport position F
40. TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont B GENERAL SAFETY PRACTICES cont 7 Where steering can be accomplished with either hand and the steering mechanism is of a type that pre vents road reactions from causing the handwheel to spin power steering or equivalent steering knobs may be used When used steering knobs shall be of a type that can be engaged by the operator s hand from the top and shall be within the periphery of the steering handwheel 8 Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable when properly operated However improper operation faulty maintenance or poor housekeeping may con tribute to a condition of instability and defeat the purpose of the requirements 9 Users shall give consideration to special operating conditions The amount of forward and rearward tilt to be used is governed by the application Although the use of maximum rearward tilt is allowable under certain conditions such as traveling with the load lowered the stability of a rough terrain forklift truck as determined by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation of trucks with excessive off center loads 10 Some of the conditions which may affect stability are ground and floor conditions grade speed loading rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operate
41. TURER S SERIAL NO PLATE REAR 4WD STEER AXLE INSIDE THE CAB IDENTIFICATION PLATE HYDROSTATIC MOTOR IDENTIFICATION PLATE BOTTOM SIDE OF PUMP 2 SPEED GEARBOX HYDROSTATIC MODELS IDENTIFICATION PLATE RIGHT SIDE OF GEARBOX MAST SERIAL NO a PLATE RIGHT SIDE OF MAST MANUFACTURER S SERIAL NO STAMPED VERTICALLY FRONT RIGHT SIDE OF FORKLIFT FRAME REAR CENTER UPPER HALF OF AXLE ENGINE IDENTIFICATION PLATE RIGHT HAND SIDE OF ENGINE BLOCK FRONT DRIVE AXLE IDENTIFICATION PLATE FRONT CENTER UPPER HALF OF AXLE INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS SAFTETY MESSAGES VII DECALS anne ernennen soe as a VIII TABLE OF CONTENTS XV OPERATING AND SAFETY INSTRUCTIONS i24 DESCRIPTION 2 1 MAINTENANCE 3 1 R05 05 INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS STUDY THE OPERATOR SERVICE MANUALS The information in this manual provides general instructions for the safe operation and maintenance of your forklift truck This information is vital and must be clearly understood
42. and protective hose sleeves which are damaged or missing must be replaced Secure all hose assemblies to prevent hose damages keep hoses away from sharp corners rubbing movements and interference with forklift operations Do not attempt to loosen unions hoses or any hydraulic component with the circuit under pressure The handling and removal of the balancing valves which may be fitted to the cylinders of your lift truck can be dangerous A balancing valve must be removed only after the cylinder is at rest and AX WARNING y y the hydraulic circuit is depressurized This operation must be performed by authorized service personnel only Do not smoke or approach the lift truck with a flame while the fuel tank is open or is being filled Take care not to burn yourself Exhaust radiator engine etc Disconnect the negative cable terminal from the top of the battery before working on the electrical circuit or on the lift truck i e welding Do not drop or place metallic objects on the battery When welding on the lift truck connect the negative cable from the equipment directly to the part being welded so as to avoid high tension current passing through the alternator 5 MAINTENANCE The maintenance and compliance of the lift truck are mandatory Perform daily maintenance See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE Do not run the engine without the air filter or with oil water o
43. ar edges Remove the breather cover 4 screws Remove the rubber diaphragm and diaphragm spring Clean and inspect all of the components and the breather cavity Replace the diaphragm and spring if worn or damaged Reinstall the assembly Make sure the components are installed correctly IMPORTANT Engine damage may occur if the breather is not working properly INTRODUCTION TO SAFETY E EVERY 1000 HOURS SERVICE Carry out the operations described previously as well as the following operations FUEL TANK CLEAN A WARNING Do not smoke or work near a flame while performing these tasks Park the lift truck on level ground with the engine stopped Inspect the entire fuel system and fuel tank for leaks In the event of a leak contact your dealer WARNING Never perform welding or any other major repair unless certified such action could cause an explosion or fire Place a container under drain plug 1 Fig E1 1 remove the cap 2 Fig E1 2 and the drain plug Allow the fuel to drain flush the tank with 2 gal of clean diesel fuel Install and tighten drain plug 1 Fig E1 1 Tightening torque 26 ft Ibs Fill the fuel tank with clean fuel See LUBRICANTS AND FUEL filtered through a strainer or a clean lint free cloth and install the cap 2 Fig E1 2 Open the engine compartment Re prime the fuel system by activating the fuel feed pump turn the ignition switch on for 3
44. d INTRODUCTION TO SAFETY EVERY 50 HOURS SERVICE Carry out the operations described previously as well as the following operations DRY AIR FILTER CARTRIDGE CHECK CLEAN When operating in heavy dust use pre filtration cartridges See FILTERS CARTRIDGES AND BELTS Also check and clean the cartridges more frequently IMPORTANT If the clogging indicator light comes on check the air filter as quickly as possible 1 hour maximum The cartridge must not be cleaned more than seven times after which the cartridge must be changed For disassembly and reassembly of the cartridge see D3 DRY AIR FILTER CARTRIDGE Clean the filter cartridge using a compressed air jet Max pressure 43 psi directed from the top to the bottom and from the inside to the outside at a minimum distance of 1 5 in from the cartridge wall Cleaning is completed when no dust remains on the cartridge caon Use proper eye and face protection when handling compressed air Respect the safety distance of 1 5 inches between the air jet and the cartridge to avoid tearing or making IMPORTANT a hole in the cartridge The cartridge must not be blown anywhere near the air filter box Never clean the cartridge by tapping it against a hard surface Clean the cartridge seal surfaces with a clean damp lint free cloth and lightly lubricate with a silicone lubricant IMPORTANT Do not clean the dry air filter cartridge by wash
45. d without a load on the attachment dynamic and static forces improper tire inflation and the judgement exer cised by the operator C OPERATING SAFETY RULES AND PRACTICES 1 Safe operation is the responsibility of the operator 2 This equipment can be dangerous if not used properly The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself other personnel the rough terrain forklift truck and other material 3 The operator shall be familiar with the operation and function of all controls and instruments before under taking to operate the rough terrain forklift truck 4 Before operating any rough terrain forklift truck truck operators shall have read and be familiar with the operator s manual for the particular truck being operated 5 Before starting to operate the rough terrain forklift truck a be in operating position and fasten seat belt b place directional controls in neutral apply brakes d start engine 6 Do not start or operate the rough terrain forklift truck any of its functions or attachments from any place other than the designated operator s position 7 Keep hands and feet inside the operator s designated area or compartment Do not put any part of the body outside the operator compartment of the rough terrain forklift truck 8 Never put any part of the body into the mast structure or between the mast and the rough terrain forklift truck
46. d gear To the left backwards 4th gear To the left forwards USING THE GEARS ON THE GEARBOX On lift trucks with a torque converter it is not always necessary to start in 1st gear and progress up through the gears IMPORTANT The choice of gear ratio should be made according to the work to be performed A poor choice may over heat the transmission through excessive converter slipping which could lead to serious damage to the transmission It is essential to stop and change gears or the working conditions if the transmission oil temperature light comes on General examples for transmission gear selection On paved or maintained roadways Start off in 3rd gear changing to 4th as conditions permit On hills start off in 2nd gear changing to 3rd and 4th as conditions permit e With a trailer on maintained roadway Start off in 2nd gear changing to 3rd as conditions permit e Load Handling 3rd gear 2nd gear in restricted spaces e Heavy handling 1st gear e Loading 2nd gear 16B 2 SPEED GEAR BOX SWITCH HYDROSTATIC OPTION To change gears Bring the lift truck to a complete stop keep the brake pedal fully engaged and switch the forward reverse lever to neutral Activate the toggle switch A to change gears Your selection will illuminate the choosen gear 1 low gear for loading heavy handling 2 high gear for road use trailer towing general handling NOTE The gear box automatically returns to high
47. d periodic on job operator evaluation i understanding of nameplate data and operator instructions and warning information appearing on the rough terrain forklift truck B GENERAL SAFETY PRACTICES 1 Rough terrain forklift trucks can cause injury if improperly used or maintained 2 Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to oper ate rough terrain forklift trucks Unusual operating conditions may require additional safety precautions train ing and special operating instructions 3 Modifications and additions which affect capacity or safe operation shall not be preformed without the man ufacturer s prior written approval Where such authorization is granted capacity operation and maintenance instruction plates tags or decals shall be changed accordingly 4 If the rough terrain forklift truck is equipped with front end attachment s or optional forks the user shall see that the truck is marked to identify the forks or attachment s show the approximate weight of the truck and fork or attachment combination and show the capacity of the truck with forks or attachment s at maximum elevation with load laterally centered 5 The user shall see that all nameplates and caution and instruction markings are in place and legible 6 The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity INTRODUCTION TO SAFETY ROUGH
48. dels Location near the steering mode selection lever Identifies the steering mode selection 221322 ATTENTION CUIDADO ACHTUNG _ATTENZIONE Mineral Oil Brake Reservoir 221322 or 234800 has a been replaced by 164091 JA BREMSFLUESSIGKEIT _ Location near the brake fluid reservoir where applicable LIQUIDO DE FRENO gt LIQUIDO FRENI Utiliser IMPERATIVEMENT de l huile min rale IMPERATIVE to use mineral oil Verwenden Sie UNBEDINGT Mineral l Usar IMPERATIVAMENTE de aceite mineral Utilizzare IMPERATIVAMENTE oli olio minerale Refer to the Operator Service Manual for the correct brake fluid mineral oil to be used in the brake system IMPERATIVE to use MINERAL OIL Recommendation ATF DEXRON N SHELL _ 164091 234800 n 234800 XIII INTRODUCTION TO SAFETY SAFETY DECALS Hydraulic Oil 234798 or 76573 Location on the hydraulic tank or filler cap Identifies the hydraulic reservoir tank or filler cap N 234798 Hydraulic Oil 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAULIC OIL Identifies the hydraulic reservoir tank HYDRAULIK OL ACEITE HIDRAULICO OLIO IDRAULICO N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap Indicates required minimum to maximum anti freeze protection 22 F to 40 F Diesel Fuel 161101 Location on the fuel tank near the filler cap DI
49. dels Location on the front and rear sides of the mast cross bracing 44 WARNING Keep fingers away from the mast KEEP FINGERS crossbracing CLEAR OF CROSSBRACING HAND THROTTLE DANGER 804784 Boom equipped models option Location Near the hand throttle mechanism Reminder to operator set parking brake before operating hand throttle Disengage hand throttle before leaving the forklift DANGER A DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK OPERATE HAND THROTTLE ONLY WITH PARKING BRAKE SET FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH 804784 XV INTRODUCTION TO SAFETY SAFETY DECALS DANGER Acid in Battery 801014 Location in or near the battery storage compartment EXPLOSION HAZARD Can cause blindness or severe injury Protect eyes Keep away from sparks flames and cigarettes exercise caution when using tools that can cause sparks Keep battery level and caps tight ACID POISON HAZARD Causes severe burns Contains sulfuric acid In event of contact flush with water and see a doctor Keep out of reach of children 801014 Addresses battery hazards READ OPERATOR S MANUAL JUMP START NEGATIVE GROUNDED BATTERY 1 Wear eye protection 2 Connect ends of one cable to positive terminals of both batteries Jump Start Battery 801015 Location in or near the battery storage compartment 3 Connect one end of remaining cable to negative ter
50. ds are defined by the capacity of a lift truck taking into account the attachment s mass and center of gravity In the event of the attachment having less capacity than the lift truck never exceed its limit C ENVIRONMENT Signaling and lighting on the lift truck must conform to the conditions of use In addition to the standard equipment mounted on your lift truck options are available road lighting flashing light front lights rear lights etc Consult your agent or dealer Take care when raising the load always checking that no object or person is in the path of movement avoid any incorrect or abrupt maneuvers When working around power lines or cables ensure that the safety distance between the working area of the lift truck and the power line is sufficient Consult your local electrical agency You could be electrocuted or seriously injured if you operate or WARNING park the lift truck too close to power cables You must ensure that the safety rules on the site conform to the local regulations regarding forklift operations near power cables Do not allow personell near the working area of the lift truck or allow them to pass beneath an elevated load When operating on a slope before raising the mast ensure that the terrain is as level as possible Lift trucks fitted with frame leveling may work on a steeper incline provided the greatest part of the slope is corrected Travelling on a longitudinal slope D
51. e forklift s battery if it is damaged has corroded connections or weak electrolyte it will have to be serviced or replaced before proceeding Jump starting the forkllift requires a good fully charged 12 volt battery or a vehicle with a 12 volt negative ground electrical system Park the jumper vehicle next to the disabled forklift do not allow the vehicles to touch Improper jump starting procedures can result in battery explosion Follow jump start instructions carefully Do not allow the jumper cable clamps to contact each other or any metal surfaces except as instructed while attaching or removing the cables Use only a 12 volt negative ground system to jump start your forklift Set the parking brake and turn off all electrical components on both vehicles Turn the jumper vehicle engine off Connect the jumper cables in the following sequence STEP 1 Clamp the positive jumper cable to the good battery s positive terminal STEP 2 Clamp the other end of the positive cable to the dead battery s positive terminal STEP 3 Clamp the negative jumper cable to the good battery s negative terminal STEP 4 Clamp the other end of the negative cable to a solid metel point on the frame or engine ground at least 18 inches away from the battery Keep the clamps away from the engine fan and belts GOOD BATTERY DEAD BATTERY Jumper Vehicle STEP 1 s JUMPER CABLES L m TO
52. ectro hydraulic 4 gal INTRODUCTION TO SAFETY HYDROSTATIC TRANSMISSION HYDROSTATIC MODELS HYDROSTATIC PUMP Type Gear reverser Inching control Main pump Capacity Capacity MINI MAX flow rate Working pressure HYDROSTATIC MOTOR Type FRONT AXLE Type Hub reducers Differential lock Capacity REAR AXLE 4WD ONLY Type Hub reducers Capacity BRAKE Service brake Type Parking brake Type HYDRAULIC CIRCUIT Type of pump Capacity Flow rate at full speed Steering direction Flow rate at full speed Pressure Filtration Return Suction Accumulator Capacities Pressure Capacity REXROTH Variable displacement A4VG56DA With variable cubic capacity and with automatic power governor Electromagnetic 12V Hydraulic by valve TH7 56 3 42 in 0 cm 141 68 L min 37 43 gal min 5510 psi REXROTH Variable displacement A6VM107DA DANA Epicyclic Foot button Hydraulic Differential 1 8 gal Reducers 0 2 gal DANA Epicyclic Differential 1 8 gal Reducers 0 2 gal Foot pedal Hydraulic brake applied on the front wheels Multidisc brake immersed in oil Mechanical hand lever applied on the front wheels Multidisc brake immersed in oil Gear pump with flow divider 37 cm3 2 26 cu in 92 5 L mn 24 18 gal min Load control system 145 Bar 2102 psi 10 Microns 100 Microns 0 7 L 0 74 qts 100 Bar 14
53. ed Ignition on I Fuel pre heating Ill The engine starts returns to position as soon as the key is released 2 14 INTRODUCTION TO SAFETY 13 ACCELERATOR PEDAL Controls engine speed speed of hydraulic movements and travel speed 14 SERVICE BRAKE AND TRANSMISSION CUT OFF PEDAL The brake pedal acts on the front wheels using hydraulic braking for slowing and stopping the lift truck On the Hydrostatic Model the pedal provides progressive transmission cut off allowing for a gradual approach delicate handling at full power On the 4 Speed Model the pedal fully disengages the transmission allowing full power for load handling 15 DIFFERENTIAL LOCK PUSH BUTTON OPTION When engaging the differential lock some loss of steering may occur shift to 1st gear and steer straight ahead before applying the diff lock The differential lock causes both front wheels to turn at the same time increasing traction on slippery terrain To engage the differential lock with your left foot lift the switch cover then press and hold the foot switch down Release the switch to disengage the differential lock Push the switch cover down 16A GEAR LEVER AND TRANSMISSION CUT OFF 4 SPEED TRANSMISSION To change speed gears it is necessary to disengage the transmission by pressing button 1 dump valve on the gear shift lever Gear selections are as follows 1st gear To the right backwards 2nd gear To the right forwards 3r
54. erkins engine Cat engine filler port on the right side of the engine near the fuel injection pump not shown A2 COOLING LIQUID LEVEL CHECK ALLOW THE ENGINE TO COOL BEFORE OPENING THE A CAUTION RADIATOR CAP Park the lift truck on level ground with the engine stopped allow the engine to cool Open the engine compartment Slowly turn the radiator cap 1 Fig A2 counterclockwise to the safety stop Allow any pressure and vapor to escape Press down and continue to turn the cap to release it If necessary add cooling liquid Gee LUBRICANTS AND FUEL until 1 2 inch 12 mm below the filler port 2 Fig A2 Lubricate the radiator filler neck lightly to help the radiator cap open easily A3 FUEL LEVEL CHECK Keep the fuel tank near full when possible to reduce condensation Remove cap 1 Fig Fill the fuel tank with clean fuel See LUBRICANTS AND FUEL filtered through a strainer or a clean lint free cloth Reinstall the cap 1 Fig Never smoke or approach with a flame during filling operations or when the tank is open Never refill while engine is running IMPORTANT The fuel tank is vented through the filler cap When replacing it always use an original part with venting INTRODUCTION TO SAFETY A4 CYCLONIC PREFILTER OPTION CLEAN The cleaning interval is given as a guide however the prefilter must be emptied as soon as impurities reach the MAXI level on the tank
55. ever possible Do not park closer than 6 ft 1 8m to the nearest rail of a railroad track 30 Keep a clear view of the path of travel and observe other traffic personnel and safe clearances 31 If the load being carried obstructs forward view travel with the load trailing 32 Ascend or descend grades slowly and with caution a When ascending or descending grades in excess of 5 loaded rough terrain forklift trucks should be driven with the load upgrade b Unloaded rough terrain forklift trucks should be operated on all grades with the load engaging means downgrade c On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface d Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up or down 33 Under all travel conditions operate the rough terrain forklift truck at a speed that will permit it to be brought to a stop in a safe manner 34 Travel with load engaging means or load low and where possible tilted back Do not elevate the load except during stacking 35 Make starts stops turns or direction reversals in a smooth manner so as not to shift load and or overturn the rough terrain forklift truck 36 Do not indulge in stunt driving or horseplay 37 Slow down for wet and slippery surfaces 38 Before driving over a dockboard or bridge plate be sure that it is properly secured D
56. everse lever is in neutral Turn the ignition key to the position to activate the electrical system Check the level on the fuel level gauge Turn the ignition key to position to preheat for 6 15 seconds Do not engage the pre heat for more than 60 seconds at one time Damage to the glow plug s IMPORTANT could occur Do not engage the starter motor for more than 15 seconds and apply preheating for 6 10 IMPORTANT seconds between unsuccessful starting attempts INTRODUCTION TO SAFETY Press the accelerator pedal and turn the ignition key fully the engine should then start Release the ignition key and let the engine run at idle Check all control instruments immediately after starting when the engine is warm and at regular intervals during use this will help to quickly detect any problems which should be corrected without delay If the instruments indicate a problem safely park the forklift and arrange for the necessary repairs D DRIVING THE LIFT TRUCK SAFETY NOTICE Always drive the lift truck with the forks or attachment at approximately 300 mm 12 in from the ground i e in the transport position Familiarize yourself with the lift truck on the terrain where it will be used Ensure that the service brakes horn and the backup alarm are working properly Drive according to and at an appropriate speed for the conditions and state of the terrain Slow down before executing a turn In all circumstances
57. fety instructions By being aware of the risks to which you are exposed and by taking the necessary preventive measures you can avoid accidents Any operation or maneuver not described in the instructions is prohibited however any person who does use another method must first ensure that he is not putting himself another person or the lift truck in danger The manufacturer is not able to anticipate all possible risk situations Therefore the safety instructions and notices given in the user manual and on the lift truck are not conclusive Bending the rules in safety notices maintenance or repair instructions for your lift truck may result in serious or even fatal accidents We would remind users of the risks in driving at excessive speed with regard to traffic conditions particularly Risk of loss of control on loose rough terrain Increased stopping distance The user must remain in full control of his lift truck and should Adapt his speed to each situation in order to maintain his own safety that of others and of his equip ment Always be aware of his stopping distance On the basis of experience there are a number of possible situations in which operating the lift truck is prohibited Such foreseeable abnormal uses the main ones being listed below are strictly forbidden The foreseeable abnormal behavior resulting from ordinary neglect but does not result from any wish to put the machinery to any improper use The
58. filler plug 3 Fig E10 to help drain the oil properly Install and tighten the drain plugs 1 Fig E10 Tightening torque 32 ft lbs Fill with oil See LUBRICANTS AND FUEL through filler port 3 Fig E10 The level is correct when the oil level is flush with the edge of port 2 Fig E10 Check for leaks at the drain plugs Install and tighten level plug 2 and filler plug 3 Fig E10 Tightening torque 32 ft Ibs E11 REAR WHEELS REDUCERS OIL 4WD MODELS DRAIN Park the lift truck on level ground with the engine stopped and the reducers oil warm Dispose of the drain oil in an ecological manner IMPORTANT Drain and change both rear wheel reducers Place drain plug 1 Fig E11 in position A Place a container under the drain plug and remove the plug Let the oil drain fully Place the drain port in position B i e in a level position Fill with oil See LUBRICANTS AND FUEL through level port 1 Fig E11 The level is correct when the oil is flush with the edge of the hole Install and tighten the drain plug 1 Fig E11 Tightening torque 32 ft Ibs E12 GEARBOX OIL HYDROSTATIC MODELS DRAIN Park the lift truck on level ground with the engine stopped and the gearbox oil warm Dispose of the drain oil in an ecological manner IMPORTANT Place a container under the drain plug 1 Fig E12 and remove it Remove level plug 2 Fig E12 to help drain the oil properly Install a
59. geable of and observe all safety rules and practices 2 Create an effective operator training program centered around user company s policies operating condi tions and rough terrain forklift trucks The program should be presented completely to all new operators and not be condensed for those claiming previous experience 3 Information on operator training is available from several sources including rough terrain forklift truck man ufacturers users government agencies etc 4 An operator training program should consist of the following a careful selection of the operator considering physical qualifications job attitude and aptitude b emphasis on safety of stock equipment operator and other personnel c citing of rules and why they were formulated d basic fundamentals of rough terrain forklift truck and component design as related to safety e g in Ib N m loading mechanical limitations center of gravity stability etc e introduction to equipment control locations and functions Explain how they work when used properly and problems when used improperly f supervise practice on operating course remote from normal activity and designed to simulate actual operations e g lumber stacking elevating shingles to the roof etc g oral written and operational performance tests and evaluations during and at completion of the course h refresher courses which may be condensed versions of the primary course an
60. gear when the engine is stopped INTRODUCTION TO SAFETY 17 FORWARD REVERSE LEVER Before operating this control the lift truck should be stopped or traveling at a very slow speed When in the neutral position the shifter sets in a lock or indent preventing accidental shifting movement FORWARD Lift slightly and push the lever upwards Position A REVERSE Lift slightly and pull the lever downwards Position B NEUTRAL To start the lift truck the lever must be in neutral Position C NOTE The backup alarm must sound when the lift truck is shifted to reverse 18 PARKING BRAKE LEVER To prevent accidental release the lever is equipped with safety locking To apply the parking brake pull the lever backwards Position A To disengage the parking brake release and push the lever forwards Position B 19 HYDRAULIC CONTROLS Do not attempt to alter the hydraulic system pressure by interfe ring with the pressure regulating valve In the event of suspected malfunction contact your dealer LEVER A Controls load lifting Move the lever back for load lifting Move the lever forward for load lowering LEVER B Controls mast tilting Move the lever back to tilt the mast backward Move the lever forward to tilt the mast forward LEVER C Controls mast side shift Move the lever back to shift the mast to the right Move the lever forward to shift the mast to the left LEVER D Controls optional attac
61. ghtening torque 30 ft Ibs C6 REAR AXLE DIFFERENTIAL OIL LEVEL 4WD MODELS CHECK Park the lift truck on level ground with the engine stopped Remove level plug 1 Fig C6 The oil should be flush with the edge of the hole If necessary add oil See LUBRICANTS AND FUEL by the filler port 2 Fig C6 Replace and tighten the level plug 1 Fig C6 Tightening torque 30 ft Ibs INTRODUCTION TO SAFETY C7 REAR WHEELS REDUCERS OIL LEVEL 4WD MODELS CHECK Park the lift truck on level ground with the engine stopped Check the level on each rear wheel reducer Place level plug 1 Fig C7 in the horizontal position Remove the level plug the oil should be flush with the edge of the hole If necessary add oil See LUBRICANTS AND FUEL by the same hole Replace and tighten the level plug to 30 INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY D EVERY 500 HOURS SERVICE Carry out the operations described previously as well as the following operations D1 ENGINE OIL DRAIN D2 ENGINE OIL FILTER CHANGE Park the lift truck on level ground let the engine run at idle for a few minutes to warm the oil stop the engine DRAINING THE OIL Open the engine compartment Place a container under the drain plug 1 Fig D1 1 and unscrew the plug Remove filler cap 2 Fig D1 2 to ensure the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner REPLACI
62. grease See LUBRICANTS AND FUEL remove surplus grease 1 4 Speed Transmission Models only Lubricators of the front driveshaft 1 2 lubricators Fig B11 1 and B11 2 2 Hydrostatic Transmission Models only Lubricator of the universal joint 1 1 lubricator Fig 11 3 B10 REAR AXLE 2WD GREASE Clean and lubricate the following points with grease See LUBRICANTS AND FUEL remove surplus grease 1 Lubricator of the wheel bearings 1 2 lubricators Fig B12 1 2 Lubricators of the steering pivot pins 4 lubricators Fig B12 1 Item 2 and Fig B12 2 Item 1 3 Lubricators of the steering axle pivots located on the front and rear of the steer axle pivot points 2 lubricators Fig 12 3 INTRODUCTION TO SAFETY B11 REAR AXLE 4WD GREASE Clean and lubricate the following points with grease See LUBRICANTS AND FUEL remove surplus grease 1 Lubricators of the rear driveshaft 3 lubricators Fig B13 1 and 13 2 2 Lubricators of the rear wheels reducers pivots 4 lubricators Fig 13 3 3 Lubricators of the rear axle pivot 2 lubricators Fig B13 4 INTRODUCTION TO SAFETY EVERY 250 HOURS SERVICE Carry out the operations described previously as well as the following operations ALTERNATOR BELT TENSION CHECK ADJUST Park the lift truck on level ground Open the engine compartment Check the belt for signs of wear and cracks change if nece
63. hment 20 DOCUMENT STORAGE Store the operator s manual in the document box on the lift truck Keep it available at all times INTRODUCTION TO SAFETY 21 BREAKERS Breakers are installed depending on forklift truck model and options provided BREAKER SWITCH IDENTIFICATION DECAL 3 O LIGHTS STARTER F N R O 3 O GAUGES 2WD AWD WIPERS HORN O HEATER 2 SPEED BEACON SHIFTER INTRODUCTION TO SAFETY 26C PRIMARY BREAKER AND FUSES Located under the hood on the right side of the forklift mounted on the front side of the hood support bracket Photo taken with cab in raised position Breaker Panel Fuse w reset 40A Item 1 Engine Pre heat Fuse 80A Item 2 Alternator Fuse 80A Item 3 Engine Pre heat Relay 4 Located behind air cleaner The towing capacity is rated for each model of lift truck tractive effort and maximum vertical force at the coupling point See IDENTIFICATION OF THE LIFT TRUCK in SECTION 2 DESCRIPTION Refer to local regulations for towing on public roadways maximum running speed braking requirments maximum weight of trailer etc Always check the trailer s condition before towing it tires electrical connections hydraulic hoses braking system etc Aw ARNING Do not tow a trailer or accessory which is not in proper working order Pulling a trailer in poor condition may effect the lift truck s steering braking and safe o
64. ig Tilt the load sufficiently backwards to ensure its stability to avoid loss of load on braking without upsetting the balance of the load TAKING UP A HIGH LOAD Under no circumstances should you pick up a load if the lift truck is not ina S horizontal level position See HORIZONTAL POSITION OF THE LIFT IX TRUCK x Ensure that the forks will easily pass under the load Position the lift truck perpendicular to the load with the forks in a horizontal position Fig G X lt 1 18 INTRODUCTION TO SAFETY Maneuvering gently and carefully place the forks under the load Fig H Apply the parking brake and place the forward reverse lever in neutral X Slightly lift the load 1 and incline the mast 2 backwards to stabilize the load Fig 1 CAUTION Tilt the load sufficiently backwards to ensure its stability to avoid loss of load on braking without upsetting the balance of the load Maneuvering very gently and carefully back the lift truck to clear the pile and bring the load into the transport position Fig J LAYING PLACING A HIGH LOAD Approach the pile with the load in the transport position Fig K Under no circumstances should you place a load if the lift truck is not in a horizontal position See HORIZONTAL POSITION OF THE LIFT TRUCK Lift the mast 1 until the load is above the pile and move the lift truck forward 2
65. ighten clockwise the end of lever 1 Fig C3 1 and recheck braking as described above Repeat the operation until the correct braking adjustment is obtained 3 16 INTRODUCTION TO SAFETY ADJUSTMENT OF THE PARKING BRAKE CABLE Park the lift truck on level ground chock the wheels Press and release the brake pedal then release the parking brake placing it in position B Fig C3 1 Loosen nuts 1 Fig C3 2 Tighten the cable by adjusting nuts 1 Fig C3 2 until a clearance of 0 06 in 1 5 mm between cams 2 Fig C3 2 and stops 3 Fig C3 2 is obtained Do not adjust the factory set cam stops If the park brake will not adjust properly consult your dealer C4 FRONT AXLE DIFFERENTIAL OIL LEVEL CHECK Park the lift truck on level ground with the engine stopped Remove level plug 1 Fig C4 The oil should be flush with the edge of the hole If necessary add oil See LUBRICANTS AND FUEL through the filler port 2 Fig C4 Replace and tighten the plugs Tightening torque 30 ft Ibs C5 FRONT WHEELS REDUCERS OIL LEVEL CHECK Park the lift truck on level ground with the engine stopped Check the level on each front wheel reducer Place level plug 1 Fig C5 in the horizontal position Remove the level plug the oil should be flush with the edge of the hole If necessary add oil See LUBRICANTS AND FUEL by the same hole Replace and tighten the level plug 1 Fig C5 Ti
66. immediately INTRODUCTION TO SAFETY 3 SIGNAL LAMPS 3A RED PARKING BRAKE ON LAMP This lamp comes on when the parking brake is applied 3B RED AIR FILTER NEEDS SERVICE LAMP The lamp comes on when the air filter cartridge is clogged Stop the lift truck and make the necessary repairs See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE 4 FUEL LEVEL Indicates the fuel level in the fuel tank 5 HOURMETER Indicates the number of hours the lift truck has operated Use the hourmeter for scheduling maintenance 6 ALTERNATOR VOLTAGE METER Indicates voltage output of the alternator while the engine is running Normal operating voltage is 12 14 volts 7 HYDRAULIC OIL TEMPERATURE METER Indicates hydraulic oil temperature Normal operating temperature is 190 205 F 210 F Max 8 ENGINE OIL PRESSURE METER Indicates engine oil pressure Normal oil pressure is 40 60 psi 9 ENGINE WATER TEMPERATURE METER Indicate engine water temperature Normal operating temperature is 190 215 F 220 F Max 10 LIGHT SWITCH Three position toggle switch top selection turns front and rear white lights on bottom selection turns front and rear red lights on center position turn all lights off 11 HORN SWITCH Press switch to sound horn 12 IGNITION SWITCH The key switch has five positions P Ignition off parking position O Ignition switched off and engine stopp
67. in a state of conformity we advise you to have your lift truck checked regularly by your agent or dealer This should be done at least once every 6 months INTRODUCTION TO SAFETY D ENVIRONMENT A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher There are optional solutions consult your agent or dealer Take into account climatic and atmospheric conditions of the operation site Protection against frost See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Proper lubricants Ask your dealer for information Engine filtration Proper lighting Work lights etc Optional solutions exist consult your dealer Use of a lift truck is prohibited in protected areas i e refinery explosive atmosphere For use in these areas specific equipment is available as an option Consult your dealer INTRODUCTION TO SAFETY OPERATING INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Wear clothes suited for driving the lift truck avoid loose clothes Never operate the vehicle when hands or feet are wet or soiled with grease or mud For increased comfort adjust the driver s seat to your requirements The operator must always be in his normal position in the driver s seat It is prohibited to have arms legs or any part of the body protruding from the cab of the lift truck Fasten your seat belt and adjust it to your requirements The contro
68. inclines railroad tracks curbs etc NEVER approach power lines gas lines or other utilities with the forklift Always verify that local state provincial and federal regulations have been met Report any accidents involving personnel building structures and equipment to the supervisor immediately Always remain alert conditions are constantly changing at the work site TECHNICAL SUPPORT All data provided in this manual is subject to production changes addition of new models and improved prod uct designs If a question arises regarding your forklift please consult your dealer or K D Manitou Inc for the latest information When ordering service parts or requesting technical information be prepared to quote the applicable Model Serial Numbers viii SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL SHOWN BELOW IT IDENTIFIES POTENTIAL HAZARDS WHICH IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH Also observe the safety messages places throughout this manual providing special instructions telling you when to take precautions and to identify potential hazards The safety messages are highlighted and outlined in a box similar to those shown in the examples below SAFETY ALERT SYMBOL NOTE or NOTICE Provides information special instructions or references about the lift truck IMPORTANT Precautions which must be taken to avoid damage to the lift truck Indicates a potentially hazardous situation which if not avoided ma
69. ing it in liquid Do not clean the safety cartridge located inside the filter cartridge change it for a new one if it is dirty or damaged B2 RADIATOR CORE CLEAN Open the engine compartment Clean the radiator Fig B2 with compressed air directed from the engine side to the outside This is the best way to clean the radiator without damaging the fins When handling straw grain or cereal clean the radiator core daily IMPORTANT 00 not use water jet or high pressure steam as this could damage the radiator fins FUEL FILTER CHECK Open the engine compartment Place a receptacle under the fuel filter and loosen the drain plug 1 Fig B3 Allow the diesel fuel to flow out until it is free from impurities and water Tighten the drain plug when clean diesel fuel flows out INTRODUCTION TO SAFETY B4 TENSION AND ALIGNMENT OF THE MAST LIFTING CHAINS CHECK ADJUST Park the lift truck on level ground with the mast in a vertical position and the forks lifted to approximately 8 in Check the alignment of the mast lifting chains between the carriage s chain fasteners and the chain rollers Fig B4 Manually verify the chain tension if necessary adjust as following while ensuring that the carriage remains perpendicular to the mast Adjust the tension by tightening or loosening the nut 1 Fig B4 1 Commercial Masts Fig B4 2 Poultry Masts while checking the alignment of the lifting chains
70. issing or unsafe components Have it repaired by authorized service personnel Learn the functions of all controls gauges indicator lights etc on the forklift Know the speed gear ranges braking and steering capabilities load ratings and clearances When referring to the location of forklift components the terms left right front and rear are related to the oper ator seated normally facing forward in the operator s seat If you have any questions about the forklift con sult your supervisor Failure to fully understand or obey safety warnings can result in serious injury or death 4 WORK SITE KNOWLEDGE Before operating on a work site learn the rules for movement of people forklifts and all other traffic Check the size weight and condition of the loads you will be expected to handle Verify that they are properly secured and safe to transport Learn where the loads are to be placed planning your route for a safe approach watching for hazardous conditions Will a signal man be required to help place the load Remove any debris which may cause tire damage or rupture Plan your route around problem areas or have them cor rected Inform the supervisor of any unsafe conditions observed at the site Examples of hazards power lines cables low clearance structures garage doors telephone pole guide lines fencing loose lumber build ing materials drop offs trenches rough soft spots oil spills deep mud steep
71. l level 44 44 44 44 Rear wheels reducers oil level 44 4 44 44 Rear axle differential oil V V 44 44 Rear wheels reducers 0 V V K 44 SIEEN ms aan een 44 Rear wheels reducers universal joint Steering swivel joints Rear wheels reducers clearance Ct GEARBOX HYDROSTATIC TRUCKS ONLY Gearbox oil level dd 44 44 44 Gearbox 01 V V 44 44 CHASSIS Structure 4 44 ATTACHMENTS Forks wear 44 44 44 Attachment 44 44 Condition of attachments Ce 44 44 To be done before starting up the new lift truck and a last time after 250 hours service Consult your dealer 3 7 INTRODUCTION TO SAFETY DAILY OR EVERY 10 HOURS SERVICE ENGINE OIL LEVEL CHECK Park the lift truck on level ground with the engine stopped and allow the oil to settle Open the engine compartment Remove the dipstick 1 Fig A1 1 Clean the dipstick and check the level between the MAXI and MINI notches If necessary add oil See LUBRICANTS AND FUEL through the valve cover filler port 2 Fig A1 2 on top of the P
72. l levers must never be used for any other than their intended purposes i e do not use for climbing onto or down from the lift truck etc Never allow a passenger to travel on the lift truck or in the driver s cab BEFORE STARTING THE LIFT TRUCK If the lift truck is new refer to BEFORE STARTING UP A NEW LIFT TRUCK in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS Check the condition of the tires and tire pressures CHARACTERISTICS in SECTION 2 DESCRIPTION Before starting the lift truck check the different levels Engine oil Hydraulic reservoir oil Transmission oil where applicable Cooling liquid radiator fluid Also check for possible leaks oil fuel or fluids from the lift truck Check the closing and locking latches on the hood Whatever the experience as a truck driver the operator is advised to familiarize himself with the position and operation of all controls and instruments before operating the lift truck STARTING THE LIFT TRUCK SAFETY NOTICE The lift truck must be started or maneuvered only when the operator is sitting in the driver s cab WARNING his seat belt fastened and adjusted Never try to start the lift truck by pushing or towing it Towing may cause severe damage to the transmission If necessary to tow the lift truck in an IMPORTANT emergency See OCCASIONAL MAINTENANCE in SECTION 3 MAINTENANCE INSTRUCTIONS Make sure that the forward r
73. latforms trenches and scaffolding Avoid recently dug or backfilled dirt and gravel When carrying loads the lift truck must not travel at soeeds in excess of 7 5 mph INSTRUCTIONS Raise the forks or attachment to the travel position approximately 300 mm 12 in from the ground Shift the forward reverse lever to the selected direction of travel Release the parking brake and accelerate gradually until the lift truck moves off INTRODUCTION TO SAFETY STOPPING PARKING THE LIFT TRUCK SAFETY NOTICE Before stopping the lift truck after a long working period let the engine idle for a few moments to allow the coolant and oil to lower the temperature of the engine and transmission Frequently stopping a hot engine will raise the temperature of some components with the risk of badly damaging them IMPORTANT Never leave the ignition key in the lift truck when the lift truck is unattended When the lift truck is stationary place the forks or attachment on the ground apply the parking brake and place the forward reverse lever in neutral If the driver has to leave the cab even for a moment it is essential to apply the parking brake and place the forward reverse lever in neutral Make sure that the lift truck is not parked in any position that will interfere with the traffic flow Make sure that the lift truck is parked at least 6 ft from the track of a railway In the event of prolonged parking on a
74. lder contacts filter head plus 1 4 90 turn to tighten 8 If necessary bleed the fuel circuit See G1 FUEL SYSTEM BLEEDING INTRODUCTION TO SAFETY D5 TRANSMISSION OIL FILTER 4 SPEED MODELS CHANGE Remove and discard the transmission oil filter 1 Fig D5 Carefully clean the filter head with a clean lint free cloth Fill the new transmission oil filter with oil See LUBRICANTS AND FUEL Lightly lubricate the new seal on the filter Install the filter insuring the seal is correctly positioned Tighten the transmission oil filter by hand pressure only lock the IMPORTANT filter in place by a quarter turn D6 MAST LIFTING CHAINS CLEAN CHECK GREASE Vigorously clean the chains 1 Fig D6 with a hard nylon brush and clean diesel fuel Rinse the chains with a soft brush and clean diesel fuel dry with compressed air Wipe the chains with a clean lint free cloth then examine them closely for any signs of wear Using a soft brush moderately lubricate the chains with engine oil See LUBRICANTS AND FUEL Remove all excess oil with a clean cloth IMPORTANT In case of technical problems consult your dealer D7 HYDRAULIC RETURN OIL FILTER CARTRIDGE CHANGE To prevent debris from entering the hydraulic circuit thoroughly IMPORTANT clean the filter housing before opening Open the engine compartment 4 Speed Transmission Models Remove the 4 screws and cover
75. minal of good battery 4 Connect other end of cable to engine block or reliable chassis ground of vehicle being started DO NOT CONNECT TO BATTERY 5 To prevent damage to electrical components of vehicle being started make certain that the engine is idle speed prior to disconnecting jumper cables 801015 Jump start instructions MANITOU NORTH AMERICA INC 6401 IMPERIAL DR E WACO TX 76712 www manitou na com Attachment Plate 425995 Location on the optional removeable forklift attachment MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE Important manufacturer information about the attachment Record this information for use when contacting the maufacturer for parts and service COUNTRY OF MANUFACTURE UNLADEN WEIGHT LB CAPACITY LB 5 HORIZONTAL CENTER OF GRAVITY IN B OPERATING PRESSURE PSI LAWARNING This attachment affects the capacity of the lift truck Check the operator service manual or load chart for net capacity with this attachment If the load chart is not available contact the factory 25995 Overhead Guard Data Plate 56109 Location attached to the overhead guard THIS OVERHEAD GUARD CONFORMS TO ANSI DESIGN RECOMMENDATION THIS GUARD HAS PASSED AN IMPACT TEST OF FT LBS DO NOT REMOVE THIS OVERHEAD GUARD Overhead guard conformity 496550 Forklift Data Plate 496550 Boom equipped models MANITOU Fo
76. nd tighten the drain plug 1 Fig E12 Tightening torque 32 ft Ibs Fill with oil See LUBRICANTS AND FUEL through filler port 2 Fig E12 The level is correct when the oil level is flush with the edge of port 2 Fig E12 Check for leaks at the drain plug Install and tighten level plug 2 Fig E12 Tightening torque 32 ft Ibs INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY F EVERY 2000 HOURS SERVICE Carry out the operations described previously as well as the following operations F1 COOLING LIQUID ANTIFREEZE DRAIN Perform this service as required or every two years Park the lift truck on level ground with the engine stopped and cold DRAINING THE LIQUID ALLOW THE ENGINE TO COOL BEFORE OPENING THE A CAUTION RADIATOR CAP Open the engine compartment Remove the radiator filler cap 1 Fig F1 1 Place a container below the drain valve 1 Fig F1 2 Turn the drain valve counterclockwise to open Allow the fluid to drain completely Inspect the radiator hoses and clamps replace if necessary Flush the circuit with clean water use a cleaning agent if necessary FILLING THE LIQUID Close the radiator drain valve Slowly fill the cooling circuit See LUBRICANTS AND FUEL to 1 2 in below the filler port 2 Fig F1 1 Install the filler cap 1 Fig F1 1 Run the engine at idle for a few minutes Check for leaks Check the level and refill if necessary
77. ng lights where applicable If the engine is not running there will be no steering or braking assistance Operate the steering and brake pedal slowly avoiding sudden or abrupt maneuvers HYDROSTATIC TRANSMISSION MODELS IMPORTANT LIFT TRUCKS EQUIPPED WITH HYDROSTATIC TRANSMISSIONS PUSHING OR TOWING WILL CAUSE DAMAGE TO THE TRANSMISSION DO NOT ATTEMPT TO PUSH OR TOW THE TRUCK TO START THE ENGINE G5 LIFT TRUCK ON A TRAILER TRANSPORT Ensure that the safety instructions concerning the trailer are followed before loading the lift truck and that the truck driver has been informed about the dimensions and the weight of the lift truck See CHARACTERISTICS in SECTION 2 DESCRIPTION Ensure that the platform has dimensions and a load capacity sufficient for transporting the lift truck Also verify the capacity of the contact surface on the trailer LOAD THE LIFT TRUCK Block the wheels of the trailer Adjust loading ramps to a minimum angle for loading the lift truck Load the lift truck parallel to the trailer Park the lift truck See DRIVING INSTRUCTIONS in Section 1 OPERATING AND SAFETY INSTRUCTIONS SECURE THE LIFT TRUCK Attach the chocks to the trailer at the front and at the back of each tire Fig G5 1 Also apply chocks to the trailer on the inside of each tire Fig G5 2 Secure the lift truck to the trailer with approved chain or straps Mount the forklift at the front using the mast tie down
78. nnections Also check that the tank oil level is correct TIRES Make sure that the wheel nuts are correctly tightened See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE and that the tire pressures are correct See CHARACTERISTICS in SECTION 2 DESCRIPTION FUEL SYSTEM Check that all fuel lines are secured If necessary drain the fuel filter and bleed the fuel system of air ELECTRICAL CIRCUIT The original equipment battery is maintenance free requiring replacement only when it has tested faulty If the original maintenance free battery has been replaced with one that requires maintenance check the battery owner s manual for proper care Check the components of the electrical system the connections and fastening devices IF NECESSARY CONSULT YOUR DEALER 1 18 2 DESCRIPTION INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement of our products our range of lift trucks may undergo certain modifications without prior notice to our customers MANITOU MANITOU NORTH AMERICA INC When ordering parts or seeking technical information be prepared to specify the waco Tk 18710 component s model and serial numbers NOTE It is recommended that the following numbers be placed the spaces provided A UNLADEN WEIGHT
79. oo fast or brake abruptly when carrying a load Check the load constantly particularly when turning corners and especially if it is bulky Secure unstable loads Handle loads with caution at slow speed without sudden jerks when moving them at significant heights and mast extention In the event of high winds or storms do not handle work that jeopardizes the stability of the lift truck and its load particularly if the load catches the wind WARNING Do not change direction sharply or at high speed DANGER In the event of the lift truck overturning do not try to leave the cab during the incident YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB Apply the parking brake when lifting or depositing a difficult load or when on an incline Do not park the lift truck with the load in an elevated position Do not leave a loaded lift truck with the parking brake applied on an incline which exceeds 15 E VISIBILITY If the visibility in forward motion is not sufficient because of the bulkiness of the load drive in reverse motion This maneuver must remain exceptional and only for short distances Ensure you have good visibility Clean windows adequate lighting correctly adjusted rear view mirror etc IF NECESSARY CONSULT YOUR DEALER pus INTRODUCTION TO SAFETY LOAD HANDLING Carrying a load greater than the rated capacity of the lift truck or attachment is prohibited WEIGHT OF LOAD AND CEN
80. orklift 2 CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenance log listing repairs requested and completed for each forklift Also lock out tag procedures should be utilized If the forklift malfunctions park it safely remove the key tag Do Not Use and report the problem to the proper authority or authorized service personnel immediately ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont 2 CREATE A MAINTENANCE PROGRAM cont For the best forklift performance and operation a maintenance program is required Use the hour meter on the instrument panel to keep maintenance properly scheduled see SECTION TWO Servicing Schedule For repairs on major components engine transmission etc contact your nearest dealer for a Repair Manual Do not operate a forklift that is damaged or does not function properly Only authorized personnel may make repairs or adjustments to the lift truck After repairs the lift truck must be tested for safe operation before returning to service 3 FORKLIFT KNOWLEDGE Forklift trucks can cause serious injury if improperly used or maintained Study all of the manuals provided for your forklift model Learn the locations and meanings of all safety decals If any decals are illegible or miss ing have them replaced immediately Make sure all safety features provided by the original manufacturer are in place and function properly Do not operate a forklift with damaged m
81. ot make repairs or adjustments unless specifically authorized to do so 54 When refueling smoking in the area shall not be permitted the engine shall be stopped and the opera tor shall not be on the rough terrain forklift truck 55 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before restarting engine 56 Do not use open flames when checking electrolyte level in storage batteries liquid level in fuel tanks or the condition of LPG fuel lines and connectors 57 Do not lift personnel with the forklift If the forklift must be used to lift people precautions for the protec tion of the personnel must be taken see ITSDF B56 6 chapter 5 15 Elevating Personnel ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont D SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level Transporting suspended loads must ALWAYS be done slowly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid overturn The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards Grades and sudden starts stops and turns can cause the load to swing and create a hazard Guidelines for Free Rigging
82. ow as possible avoid steep slopes and drive slowly on rough terrain to avoid machine overturn Refer to operator s manual for jump starting 9 instructions manual may be obtained through your local dealer or directly from K D Manitou Inc Waco Tx WHEN PARKING OR SERVICING 2 Check truck for proper operation of all functions 1 Lower boom to the ground 3 Fasten seat belt 2 Place controls in neutral 3 Apply parking brake 4 Stop engine FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801011 Use of Seat Belt 801012 Boom equipped models Location to the right of the operator near the hydraulic control lever A DANGER Always wear seat belt when Instructs the operator to always wear the seat belt during operations and never jump from an over turning forklift operating machine Never jump from a tipping machine Failure to comply may result in erious injury or death serious injury or de 801012 INTRODUCTION TO SAFETY SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever EMERGENCY STOPPING Identifies the Emergency Parking Brake Lever AND PARKING BRAKE F THIS VEHICLE IS EQUIPPED WITH A BACK UP Alarm Must Sound 496162 ALARM WHEN BACKING THE Location on the dash in direct view of the operator The backup alarm must sound when the forklift is placed in reverse
83. peration If a third party helps in coupling or uncoupling the trailer they must be constantly visible to the driver and A WARNING must wait until the lift truck has parked the parkbrake is on and the engine is switched off before hooking or unhooking the trailer A TOWING PIN Fic A COUPLING AND UNCOUPLING THE TRAILER To couple the trailer position the lift truck as close as possible to the trailer ring Park the lift truck engage the parkbrake and turn the engine off Remove the retainer clip 1 lift the trailer pin 2 and insert or remove the trailer ring Be careful not to get your fingers caught or crushed during this WARNING operation Do not forget to install the retainer clip 1 When coupling or uncoupling make sure that the trailer is properly supported all wheels chocked 3 MAINTENANCE INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY FILTERS CARTRIDGES AND BELTS Y RY 2 066 XK XY ER A 4 RK SN N Ahk 22 SS QV SS SS Y Ke N IR SSSA AAA 1 KEY gt QUA 2 AN NN NN 4 RO N d Mi 4 A DR RR N Q NN SOS N Y DESIGNATION 1 Engine oil filter CAT or PERKINS 2 Air filter cartridge Nelson steel canister 3 Safety air filter cartridge Nelson steel canister 4
84. prohibited to increase the counterweight value in any way It is prohibited to transport or carry persons in or on the lift truck unless it is equipped to do so Avoid traveling for a long distance in reverse ATTACHMENTS Ensure that the attachment is correctly fitted and locked to its frame Always conform to the limits on the load chart for the lift truck and or attachment Ensure that pallets cases etc are in good order and suitable for the load before it is lifted Position the forks perpendicular to the load to be lifted taking into account the load s center of gravity Never lift a load with a single fork Never lift a sling load with a single fork or with the carriage Optional solutions exist consult your dealer Ensure that the quick fit hydraulic connections on the attachment system are clean and protected IMPORTANT Before changing an attachment with hydraulic function s and to avoid damaging the quick fit hydraulic connections Place the attachment in the closed position flat on the ground For unstable attachments ensure they are secured using wedges or blocks Switch off the engine Remove pressure from the attachment hydraulic system by working the related hydraulic controls IMPORTANT Only specific attachments approved by MANITOU may be used on specific lift trucks The manufacturer s liability will be voided in case of modification s without prior written permission Maximum loa
85. r fuel leaks AX WARNING Wait for the engine to cool before removing the radiator cap Change the filter cartridges See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE LEVELS Use the recommended lubricants Never use contaminated lubricants Do not fill the fuel tank while the engine is running Fill the fuel tank only in the areas specified for this purpose Do not fill the fuel tank to the maximum level 1 16 INTRODUCTION TO SAFETY D WASHING Clean the lift truck or at least the service area on the truck before servicing Remember to close the doors and the windows of the cab when power washing During washing avoid the articulations electrical components and connections Protect components susceptible of being damaged from penetration of water steam or cleaning agents particularly electrical components connections and the injection pump IMPORTANT Keep the lift truck clean of any fuel oil or grease residue FOR ANY SERVICING OTHER THAN REGULAR MAINTENANCE CONSULT YOUR DEALER pui INTRODUCTION TO SAFETY BEFORE STARTING UP A NEW LIFT TRUCK INTRODUCTION Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the mechanic Before operating the lift truck the user should carefully read and understand the various sections of this manual which have been provided to solve driving and maintenance problems By follo
86. rectly for a short time then stops or functions irregularly check for possible leaks in the low pressure circuit If in doubt contact your dealer G2 WHEEL CHANGING CHANGE Use extreme caution when changing tires on the forklift especially when parked near the public highway Stop the lift truck on hard level ground Safely park the lift truck fully engaging the park brake Turn the warning lights on where applicable Properly secure the forklift place chocks on both sides of the tire opposite to the flat tire Break loose the wheel lug nuts on the flat tire NOTE For this operation use a 5 ton or higher capacity hydraulic jack and safety support jack stand Align the jack under the axle as near as possible to the flat tire Fig G2 Lift the wheel off the ground and secure the axle with a safety support Fig G2 Remove the lug nuts and the flat tire Install the new wheel onto the wheel hub Start the lug nuts by hand use lubricant if necessary Remove the security stand and lower the lift truck using the jack Tighten the lug nuts with a torque wrench See A DAILY OR EVERY 10 HOURS SERVICE for tightening torque 3 32 INTRODUCTION TO SAFETY G3 LIFT TRUCK TOWING 4 SPEED TRANSMISSION MODELS IMPORTANT Do not tow the lift truck at more than 15 mph Place the forward reverse lever and gear shift lever in neutral Release the parking brake Turn on the warni
87. rive and brake gently e Moving without load Forks attachment facing downhill O e Moving with load Forks or attachment facing uphill Before depositing a load Ensure that the loading platform or pile is capable of bearing the weight Check the stability and firmness of the ground before depositing a load 1 11 INTRODUCTION TO SAFETY D HANDLING Always consider safety transport only balanced and correctly secured loads avoid any risk of tipping Fully engage forks under the load and transport it in a low position Approximately 12 in from the ground the mast tilting backwards For obvious reasons regarding the lift truck s stability and clear visibility of the surrounding area maneuver the lift truck only when the mast is in the tranport position Approximately 12 in from the ground and the mast tilting back Do not maneuver the lift truck with the mast in the raised position unless under exceptional circumstances and then with extreme caution at very low speed and using gentle braking Ensure that visibility is adequate Use a signal person to guide you along when necessary Never shift the position of the load while the lift truck is in motion The simultaneous use of two lift trucks to handle heavy or bulky loads is a dangerous maneuver requiring specific precautions This should only be done in exceptional circumstances and in the presence of a handling manager Never drive t
88. rive carefully and slowly across the dockboard or bridge plate and never exceed its rated capacity 39 Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so Approach elevators slowly and then enter squarely after the elevator car is properly leveled Once on the ele vator neutralize the controls shut off engine and set brakes It is advisable that all other personnel leave the elevator before truck is allowed to enter or leave 40 Avoid running over loose objects on the roadway surface 41 When negotiating turns reduce speed to a safe level and turn steering handwheel in a smooth sweeping motion Except when maneuvering at a very low speed turn the steering handwheel at a moderate even rate 42 Use special care when traveling without load as the risk of lateral overturning is greater 43 Improper use of stabilizer controls if equipped could cause rough terrain forklift truck upset Always lower the carriage before operating stabilizer controls 44 For rough terrain forklift trucks equipped with lateral leveling a Always level the frame before raising the boom or mast with or without a load b Lateral leveling should not be used to position an elevated load instead lower the load and reposition the rough terrain forklift truck 45 Handle only stable or safely arranged loads a When handling off center loads which cannot be centered operate with extra caution b Handle
89. rklift Data Plate 496538 Mast equipped models Location within the operator s compartment Important forklift truck identification Record this information for use when contacting the manufacturer for parts and service MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 www manitou na com TRUCK MODEL SERIAL NUMBER MEN MS es vear oF O TIRE PRESSURE FRONT TIRE PRESSURE REAR RER PSI FOR CAPACITIES REFER TO THE APPROPRIATE LIFT CHART OR CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME 56 6 MANUFACTURED IN EEE XVI MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 MAST MODEL MA ATTACHMENTS Es UNLADEN WEIGHT MAA Les YEAR OF 9 ES ches MAX CAPACITY MN Les ACKO INCHES MAX CAPACITY LBS AT MFH B eae INCHES TIRE PRESSURE e psi TIRE PRESSURE CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH FORK UPRIGHTS VERTICAL FOR OTHER CAPACITIES CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME E MANUFACTURED IN cu iul 1496638 GROUND INTRODUCTION TO SAFETY TABLE OF CONTENTS 1 OPERATING AND SAFETY INSTRUCTIONS 1 1 ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS 1 3 DRIVER S OPERATING INSTRUCTIONS 1 4 WARNING 1 4 GENERAL INSTRUCTIONS 1 5
90. ry electrolyte level C 44 44 44 44 44 Battery electrolyte density C 44 44 44 Condition of wiring harness and cables 44 44 Lights and signals 44 44 Warning indicators 44 44 FRONT AXLE Transmission universal G 44 44 44 4 Front axle differential oil level C 44 44 44 44 Front wheels reducers oil level 44 44 44 44 Front axle differential oil V V Front wheels reducers V V 44 44 Wearing of front axle brake discS 44 Front wheels reducers clearance REAR AXLE 2WD Swivel PINS G 44 44 44 4 Steering knuckle G 44 44 44 44 44 Rear axle 08 8 0 G 44 44 4 44 Direction 4 Rear axle REAR AXLE 4WD Transmission universal G 4 G C Rear wheels reducers pivots G 44 44 44 4 Rear axle 08 8 0 G 44 44 4 44 Rear axle differential oi
91. shing light is in position and that it is working properly where applicable Check for proper operation and cleanliness of lights turn indicators and windshield wiper s where applicable Check the adjustment of the rear view mirrors where applicable Ensure that the fuel level is sufficient Place the attachment at 300 mm 12 in from the ground OPERATING THE LIFT TRUCK WITH A TRAILER Before operating with a trailer consult the proper authority in your country maximum travel speed braking maximum weight of trailer etc Do not forget to connect the lift truck s electrical equipment to the trailer Do not use a non braked trailer if the unit weight of a load exceeds that imposed by the highway code Do not use a non braked trailer without braking equipment for the trailer on the lift truck Do not forget to connect the lift truck s braking equipment to that of the trailer The maximum vertical pull on the trailer hook must not exceed 1500 3372 lbs The authorized total towed weight A T T W must not exceed the maximum weight authorized by the manufacturer Consult the manufacturer s plate on your lift truck IF NECESSARY CONSULT YOUR DEALER 1 10 INTRODUCTION TO SAFETY HANDLING INSTRUCTIONS A GENERAL Check for the correct functioning of your lift truck s attachments Do not attempt operations which exceed the capacities of your lift truck or attachments It is
92. ssary See FILTERS CARTRIDGES AND BELTS Check the belt tension midway between the crankshaft pulley and alternator Using pressure exerted with the thumb the measureable play should be approximately 3 8 in Make adjustments if necessary Loosen screws 1 Fig C1 by two to three turns Swivel the alternator assembly to obtain the belt tension required Retighten screws 1 Fig C1 If the alternator belt has to be changed check the tension again IMPORTANT after the first 20 hours of operation C2 MAST UPRIGHTS CLEAN GREASE TO BE PERFORMED BEFORE OPERATING A NEW LIFT TRUCK AND ONCE AT 250 HOURS SERVICE Clean and remove the grease from the length of the mast uprights Fig C2 Check the rollers for wear and replace if necessary Lubricate very lightly with grease See LUBRICANTS AND FUEL the entire length of the mast uprights IMPORTANT In case of technical problems consult your dealer C3 PARKING BRAKE CHECK ADJUST Park the lift truck on a slope of less than 15 grade with the rated load in the transport position facing uphill Lock the parking brake in position A Fig C3 1 The park brake adjustment is correct when the lift truck is held stationary on the slope Make adjustments if necessary PARKING BRAKE ADJUSTMENT Park the lift truck on level ground stop the engine and chock the wheels Release the parking brake to position B Fig C3 1 Progressively t
93. the fuel SEE G OCCASIONAL MAINTENANCE TRANSMISSION HYDROSTATIC PUMP MOTOR Transmission oil C 44 44 44 44 44 44 Transmission oil filter o R R Transmission 01 V V 44 44 Transmission housing strainer N 44 44 Transmission controls 44 44 Transmission hydrostatic pump pressures 44 Hydrostatic motor pressures er Converter pressure 9 1 9 aa Vx E CS 44 TIRES Tires pressure C 44 44 44 44 44 44 Wheel nuts torque C 44 44 44 44 44 44 Condition of wheels and tires 44 44 Change a SEE 3 OCCASIONAL MAINTENANCE MAST Tension and alignment of the mast lifting chains C R 44 44 44 44 44 uc ware 44 44 44 44 44 Mast guide G 44 44 44 44 44 Mast uprights G Mast lifting chains G 44 Condition of mast unit 44 Mast guide 9 8 44 Mast bearing rollers 44 HYDRAULICS Hydraulic C 44 44 44
94. trainer Clean the magnetic section on the plate Reinstall the assembly and tighten the plate 4 Fig E3 3 Tightening torque 18 ft Ibs FILLING UP THE OIL Refit and tighten drain plug 1 Fig E3 1 Tightening torque 18 ft Ibs Fill with oil See LUBRICANTS AND FUEL through filler port 5 Fig E3 2 install the filling plug 3 Fig E3 2 With the engine running at idle check that the oil level is at the upper notch on dipstick 2 Fig E3 2 Check for leaks from the drain plug and cover INTRODUCTION TO SAFETY E5 HYDRAULIC OIL DRAIN 4 Speed Models be prepared to collect over 26 gal of fluid Hydrostatic Models be prepared to collect over 26 gal of fluid E6 SUCTION STRAINER FOR HYDRAULIC OIL TANK CLEAN E7 FILTER CAP FOR HYDRAULIC OIL TANK CHANGE FLUSHING THE HYDRAULIC CIRCUIT Let the engine run half throttle for 5 minutes without hydraulic movements then for 5 more minutes while using all hydraulic movements except the steering system Accelerate the engine at full soeed for 1 minute then activate the steering system This operation flushes the hydraulic circuit through the hydraulic return oil filter Park the lift truck on level ground with the engine stopped the mast tilted backwards and lowered as far as possible To prevent debris from entering the hydraulic circuit thoroughly clean the area surrounding the drain plug and the filter housing IMPORTANT DRAINING TH
95. upon delivery of the lift truck veas or uso __ A CAPACITY MM Les i ces P LIFT TRUCK IDENTIFICATION FIG A ME 5 mae Pressure en a Truck Model AA _ THE FACTORY AS RELEASED FROM THE rosas MENS Truck Serial No 2 __ mE mE Mast Model A A c Mast Serial No A A A ASA Attachment Attachment Serial No Date of manufacture For any further technical information regarding your lift truck refer to LIFT TRUCK CHARACTERISTICS ENGINE Fic B Engine No TRANSMISSION 4 SPEED MODELS ONLY Fia C Type MANITOU reference Serial No HYDROSTATIC TRANSMISSION HYDROSTATIC MODELS ONLY Fia D Model No Serial No HYDROSTATIC MOTOR HYDROSTATIC MODELS ONLY FIG E Type Serial No ENIRE po Ali lan 05 gus mi OF INTRODUCTION TO SAFETY GEARBOX 2 SPEED HYDROSTATIC MODELS ONLY FIG Type Serial No MANITOU reference 4 MPG FOR MANITOU DY T 1 a PPS Type Serial No MANITOU reference REAR AXLE 4WD MODELS ONLY Fic Type Serial No MANITOU reference OVERHEAD GUARD OR CAB Fia 1 Type Masr FIG J Mast Model No Mast Serial No MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 wwwW manitou na com MODEL SERIAL NUMBER INT
96. user should always carry this authorization to operate with him while he is using the lift truck The driver shall not authorize driving the lift truck by another person In addition the vehicle should be used in accordance with good practice for the profession C MAINTENANCE The user must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety notice The operator is prohibited from carrying out any repairs or adjustments himself unless he has been trained for this purpose He must keep the lift truck properly cleaned if this is among his responsibilities Carry out daily maintenance See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE Ensure tires are adapted to the nature of the ground SAND tires TURF tires Snow chains There are optional solutions consult your agent or dealer AAWARNING Replace worn or damaged tires immediately The fitting of foam inflated tires is prohibited and is not guaranteed by the manufacturer without IMPORTANT B E prior authorization For your safety and that of others making any modification to the structure or adjustment of the following components on your lift truck is prohibited Hydraulic pressure Setting of limiting devices Engine speed Adding additional equipment If this occurs the manufacturer will be released from any liability To enable the vehicle to be maintained
97. wing these instructions the user will be able to take full advantage of the versatility of this lift truck The operator must familiarize himself with the positions and functions of all controls and instruments before operating the lift truck IMPORTANT 00 not attempt to start a new lift truck before the following checks have been carried out LUBRICATION Check that the correct grades of oils and grease that are required are available see SERVICING SCHEDULE in SECTION 3 MAINTENANCE and top up if necessary For operation under average climatic conditions i e between 15 C and 35 C 5 to 95 F correct levels of lubricants in all the circuits are provided in production For operation under more severe IMPORTANT climatic conditions before starting up it is necessary to drain all the circuits then add the correct levels of lubricants properly suited to the relevant ambient temperatures It is the same for the cooling fluid Contact your dealer for information if necessary DRY AIR FILTER Ensure that the air filter is undamaged and not blocked Tighten the fastening devices if necessary IMPORTANT Never run the engine with the air filter removed or damaged COOLING SYSTEM Do not start the lift truck without checking the radiator coolant level or if the fan belt is damaged or broken HYDRAULIC SYSTEM Check for leaks from the hoses connections and components If necessary tighten or repair the defective co
98. y result in minor or moderate injury May also alert unsafe practices Indicates a potentially hazardous situation which if not avoided may result in death or serious injury Indicates an imminently hazardous situation which if not avoided will result in death or serious injury CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust and some of its constituents are known to the State of California to cause cancer birth defects or other reproductive harm WARNING Battery posts terminals and related accesories and related accessories contain lead and lead compounds Wash hands after handling INTRODUCTION TO SAFETY SAFETY DECALS The purpose of this chapter is to introduce you to the safety messages decals and nameplates found on your forklift truck The decals are identified by name part number location and a brief description The forklift model logos and other misc decals not shown can be found in your forklift parts manual The decals illustrated may not be exactly the same as those installed on your forklift installation of the decals varies depending on the forklift model series decal updates etc The size and location of some decals limit the amount of information that can be placed upon it For this reason additional detailed information not found on the decals is provided through out this manual Every decal placed on the lift truck is important they are constant reminders of safety and instructions that
99. zed When handling suspended loads a do not exceed the truck manufacturer s capacity of the rough terrain forklift truck as equipped for handling suspended loads b only lift the load vertically and never drag it horizontally c transport the load with the bottom of the load and the mast as low as possible d with load elevated maneuver the rough terrain forklift truck slowly and cautiously and only to the extent necessary to permit lowering to the transport position e use tag lines to restrain load swing whenever possible 50 At the beginning of each shift and before operating the rough terrain forklift truck check its condition giving special attention to a tires and their inflation pressure b warning devices c lights d lift and tilt systems load engaging means chains cables and limit switches f steering mechanism g fuel system s 51 If the rough terrain forklift truck is found to be in need of repair or in any way unsafe or if it contributes to an unsafe condition the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 52 If during operation the rough terrain forklift truck becomes unsafe in any way the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 53 Do n

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