Home

rough terrain forklift truck general safety standards

1. Steering direction Provided by flow distributor Loadsensing Pressure Filtration Suction Return Air contained in the tank SPECIFICATIONS Level of sound pressure in the driver s cabin According to norm prEN 12053 1995 Travel speed of the lift truck Front unladen Rear unladen Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Telescopes retracted Unladen lifting Rated load lifting Unladen lowering Rated load lowering Telescoping motions Lifting boom Extending of telescopes unladen Extending of telescopes laden Retracting of telescopes unladen Retracting of telescopes laden Reverse tilt time unladen Forward tilt time unladen Lift truck weight with standard attachment Unladen Rated load Axle weight with standard attachment Transport position Front unladen rated load Rear unladen rated load Drawbar pull Rated load TIRES OTR Mud Shark 31x 15 50 15 NHS Front tire load Rear tire load Gear 9 51 gpm 36 L min 3625 psi 250 Bar 1 86 cm 12 cm tr 1740 psi 120 Bar 100 Microns 10 Microns 5 Microns dB 7 76 mph 12 5 km h 7 76 mph 12 5 km h 135 in 3429 mm 5500 Ib 2495 kg 24 in 610 mm 119 Ib 54 kg 9 45 40 ft min 12 2 m min 10 1s 37 1 ft min 11 3 m min 7 1s 52 8 ft min 16 1 m min 7 1s 52 8 ft min 16 1 m min 5 9 40 7 ft min 12
2. 26 26 26 426 26 26 28 28 26 26 230 0 32 33 FORKLIFT SAFETY CONTENTS A EVERY DAY OR EVERY 10 WORKING HOURS SERVICE A1 CHECK THE ENGINE OIL LEVEL Park the truck on level ground with the engine stopped allowing the oil to settle Open the engine compartment Remove the dipstick 1 Fig A1 1 Clean the dipstick and check that the oil level is between the notches necessary add oil See LUBRICANTS by the filler port 2 Fig A1 2 A2 CHECK THE COOLING LIQUID LEVEL Park the 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 up to the safety stop Allow any pressure or steam to escape Press down and turn the cap to remove it If necessary add cooling liquid up to 1 2 in below the filler port 2 Fig A2 Slightly lubricate the filler neck to ease the removal of the radiator cap IMPORTANT f the cooling liquid is hot add only hot cooling liquid AS CHECK THE FUEL LEVEL Keep the fuel tank near full to reduce condensation in the tank due to atmospheric conditions Open the access compartment seat support Remove cap 1 Fig A3 Fill the fuel tank with clean fuel filtered through a strainer or a clean lint free cloth through filler port 2 Fig A3 Re install the cap Never smoke or approach with a flame duri
3. In the event of a leak contact your dealer Never weld onto or near the fuel tank this could provoke Awarnine Place a container under drain plug 1 Fig E5 1 and remove the plug Open the access panel under the seat for fuel filling Remove cap 2 Fig E5 2 Flush the tank with 2 gal of clean fuel through filler port 3 Fig E5 2 Reinstall and tighten drain plug 1 Fig E5 1 Fill the fuel tank with clean fuel filtered through a strainer or a clean lint free cloth Reinstall the filler plug 2 Fig E5 2 Re prime the system by activating fuel feed pump 4 Fig E5 3 If necessary bleed the system See SECTION 11 E6 N A FORKLIFT SAFETY CONTENTS E7 CHANGE THE SAFETY AIR FILTER CARTRIDGE Disassemble the air filter cartridge See D1 Remove and replace the air filter safety cartridge 1 Fig E7 Reassemble the unit See D1 ES CHECK THE WEAR OF THE BOOM PADS ConsuLr YOUR DEALER E9 CHECK THE BRAKE ADJUSTMENT YOUR DEALER E10 N A E11 CHECK THE ENGINE SILENTBLOCS ENGINE MOUNTS Consutr your DEALER E12 CHECK THE ENGINE SPEEDS CoNSULT YOUR DEALER E13 CHECK THE CARRIAGE CoNSULT YOUR DEALER E14 CHECK THE CONDITION OF THE WHEELS AND TIRES Consutr your DEALER E15 CHECK THE SPEEDS OF THE HYDRAULIC MOVEMENTS Consutr YOUR DEALER E16 CHECK THE CONDITION OF THE ATTACHMENTS YOUR DEALER E17 CLEAN THE SCREEN FILTE
4. Displacement MAX MIN Flow rate at 3 000 rpm MAX MIN Working pressure BOOST PUMP Cubic capacity Flow rate at 3 000 rpm MAX MIN Boost pressure Max rpm FRONT WHEEL REDUCER Type Cubic capacity Working pressure REAR WHEEL REDUCER Type Cubic capacity Working pressure BRAKE Type Service brakes Parking brakes A4VG 56 DA variable displacement pump with automatic power governor Electromagnetic 12V Hydraulic through outside valve TH 7 3 42 in tr 56 cm tr O in tr cm tr 44 4 gom 168 l min O gpm l min 6090 psi 420 bar 513 1n 7 1f 8 4 cm tr 6 66 gpm 25 2 l min O gpm l min 406 435 psi 28 30 bar MSEO5 POCLAIN Motor wheel with brakes fixed displacement 38 1 in tr 6090 psi 625 cm tr 420 bar MSEO5 POCLAIN Motor wheel fixed displacement 45 8 in tr 750 cm tr 6090 psi 420 bar Multidisc brake immersed in oil Hydrostatic Electrically controlled on dashboard on the front wheels through hydraulic pressure break FORKLIFT SAFETY CONTENTS TMT 320 FL TURBO HT HYDRAULIC CIRCUIT Lifting tilting telescoping travel circuit stabilizer Type of pump Flow rate at full speed Pressure Capacity Steering direction Provided by flow distributor Loadsensing Pressure Filtration Suction Return Air contained in the tank SPECIFICATIONS Level of sound pressure in the driver s cabin Accor
5. During washing avoid the articulations electrical components and connections Protect against penetration of water steam or cleaning agents all components susceptible of being damaged particularly electrical components electrical connections and the injection pump IMPORTANT Clean and remove all excess fuel oil and grease from the lift truck FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS BEFORE STARTING UP A NEW LIFT TRUCK INTRODUCTION Our lift trucks are designed with the operator and mechanic in mind providing comfortable handling and simplified maintenance However before operating the lift truck the user should carefully read and understand the various chapters of this manual which has been provided to solve driving and maintenance problems By following 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 Do not attempt to start a new lift truck before the following checks have been performed LUBRICATION Check that all the correct grades of oils and greases that are required are installed see SERVICING SCHEDULE in SECTION 3 MAINTENANCE and top up if necessary For operation under average climatic conditions e between 15 C and 35
6. E lt c lt a _ Lu 4 L LA 4 0 FEET 3ft3in Im 494706 O METRES O MEIRES FORKLIFT SAFETY CONTENTS lin 3 38m 10 FEET 1ft4in 0 40m Oin m Iftilin 0 60m O METERS 5 2 gt e g 2 C q N amp 9 c c D 9 lt lt 4ft8in 2ft7in 1 44m 0 80m 2ft3in 0 70m 110 1 0 METERS IL 495922 5 19 gt lt o 9 O ve c 9 c 9 E lt FORKLIFT SAFETY CONTENTS 20 FORKLIFT SAFETY CONTENTS 21 INSTRUMENTS AND CONTROLS 2nd Mounting FORKLIFT SAFETY CONTENTS DESCRIPTION 1 DRIVER S SEAT 2 SAFETY BELT 3 SIGNAL LAMP PANEL 4 FUEL LEVEL GAUGE AND HOURMETER 5 N A 6 SWITCH PANEL 7A FLOW DIVIDER SWITCH S N 750269 amp ABOVE 7B FLOW DIVIDER SWITCH S N 750268 amp BELOW 8 N A 9 IGNITION SWITCH 10 SOUND ALARM SWITCH HORN 11A FUSES S N 750268 amp BELOW 11B FUSES S N 750269 amp ABOVE 12A SOCKETS FOR TRUCK TRAILER 1ST MOUNTING 12B SOCKET FOR TRUCK TRAILER 2ND MOUNTING 13 OPENING LEVER ACCESS TO TANKS 14 ACCELERATOR PEDAL 15 INCHING PEDAL 16 FORWARD REVERSE LEVER 17 HYDRAULIC CONTROL DISTRIBUTOR LEVERS 18A REAR LIGHTS AND INDICATORS S N 750268 amp BELOW 18B REAR LIGHTS AND INDICATORS S N 750269 amp
7. Slightly lift the load 1 and incline the carriage back 2 to stabilize the load Fig If possible lower the load without shifting the lift truck Lift the boom 1 to release the load retract 2 and lower the boom 3 to bring the load into the transport position Fig J If this is not possible carefully back the lift truck Maneuvering gently back the lift truck to remove the load 1 retract and lower the boom 2 3 and bring the load into the transport position Fig K A LAYING A HIGH LOAD ON TIRES X Approach with the load in the transport position in front of the pile Fig L XI X FORKLIFT SAFETY CONTENTS Lift and extend the boom 1 2 until the load is above the pile if necessary move the lift truck forward 3 Fig M maneuvering very gently and carefully Apply the parking brake and place the forward reverse lever in neutral Place the load in a horizontal position and lay it down on the pile by lowering and retracting the boom 1 2 in order to position the load correctly Fig N Free the forks by alternately retracting and lifting the boom 3 Fig N or if possible by reversing the lift truck 3 Then bring the boom into the transport position TAKING UP A NON PALLETIZED LOAD Tilt the carriage 1 forwards and extend the boom 2 while simultaneously crowding the carriage backward to slip the forks under the load Fig O If necessary wedge
8. 23 23 23 23 23 23 23 23 23 24 FORKLIFT SAFETY CONTENTS G Every 2400 WORKING HOURS SERVICE G1 G2 G3 G4 G5 G6 G7 G8 G9 Check the hydraulic circuit pressures and discharge rates Consult your dealer Check the hydrostatic transmission circuit pressures Consult your dealer Check and adjust the governing start r p m of the hydrostatic transmission Consult your dealer Make sure the transmission cut off hydraulic valves are in good working order Consult your dealer Check the steering system Consult your dealer Clean the hydraulic oil tank Consult your dealer Check the injectors Consult your dealer Check and scale the radiator Consult your dealer Check the water pump and thermostat Consult your dealer G10 Check the condition of the boom assembly Consult your dealer H Every 4800 WORKING HOURS SERVICE H1 H2 H3 H4 Check the wear of the brake disks on the front wheel motors Consult your dealer Check the rear wheel motor pivot Consult your dealer Check the steering ball joints Consult your dealer Check the alternator and the starter motor Consult your dealer OCCASIONAL MAINTENANCE Drain the fuel system Change a wheel Tow the lift truck Sling the lift truck Transport the lift truck on a flatbed trailer CO 26 26 26 26
9. Do not mask the lighting range of the front headlamps Set safety shields in place on any attachments or remove the attachment IF NECESSARY CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS HANDLING INSTRUCTIONS A GENERAL Ensure the lift truck s attachments function correctly Do not attempt to perform operations which exceed the capacities of your lift truck or attachments It is prohibited to increase the counterweight value in any way It is prohibited to transport or carry persons in or on the lift truck Avoid traveling for long distances in reverse B ATTACHMENTS Ensure that the attachment is correctly fitted and locked in place Conform to the limits on the load chart for the lift truck and or attachment Ensure that palettes cases etc are in good order and suitable for the load to be lifted Position the forks perpendicular to the load to be lifted taking account of 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 quick fit hydraulic connections on the attachment system are clean and protected Before each change of an attachment with hydraulic function in order to avoid damaging the quick fit hydraulic connections Place the attachment in the closed position flat on the ground For unstable attachments IMPORTANT ensure they are secure
10. Retracting of telescopes unloaded Retracting of telescopes loaded 5 95 6 45 5 15 5 7 Reverse tilt time unloaded Forward tilt time unloaded Lift truck weight with standard attachment Unloaded Rated load Axle weight with standard attachment Transport position Front unloaded rated load Rear unloaded rated load Drawbar pull Rated load TIRES OTR Industrial 31 x 10 16 5 10 PR Front tire load Rear tire load 9 51 gpm 3625 psi 732 in 1740 psi 100 Microns 10 Microns 5 Microns dB 7 77 mph 7 77 mph 135 in 5500 Ib 24 in 119 Ib 40 0 ft min 37 1 ft min 52 8 ft min 52 8 ft min 40 7 ft min 37 4 ft min 46 9 ft min 42 0 ft min 5 35 105 5225 Ib 9634 Ib 1576 Ib 5986 Ib 1576 Ib 1576 Ib 4275 Ib 36 L min 250 Bar 12 cm tr 120 Bar 12 5 km h 12 5 km h 3429 mm 2495 kg 610 mm 54 kg 12 2 m min 11 3 m min 16 1 m min 16 1 m min 12 4 m min 11 4 m min 14 3 m min 12 8 m min 20 2 s 10 7 s 2370 kg 4370 kg 715 kg 2715 kg 1655 kg 1655 kg 1900 daN 61psi 4 2 bar unladen 882 Ib 400 kg unladen 3417 Ib 1550 kg laden 2976 Ib 1350 kg laden 3417 Ib 1550 kg FORKLIFT SAFETY CONTENTS TMT 320 FL HT HYDRAULIC CIRCUIT Lifting tilting telescoping travel circuit stabilizer Type of pump Flow rate at full speed Pressure Capacity
11. 3 9 A4 Check the tire pressure and the wheel nut torque 3 10 GREASING OF THE BOOM 5 Grease the boom axle 3 10 Grease the carriage axle 3 10 Grease the lifting cylinder foot and head axles 3 10 A8 Grease the compensation cylinder foot and head axles 3 10 A9 Grease the tilting cylinder foot and head axles 3 10 A10 Clean and grease the boom pads 3 11 Every 10 hours during the first 50 hours then once at 200 hours B EverY 50 WORKING HOURS SERVICE B1 Clean the dry air filter cartridge 3 12 In a heavy dust atmosphere service more frequently B2 Check the hydraulic oil level 3 12 B3 Check the battery electrolyte level 3 12 B4 Clean the radiator core 3 13 GENERAL GREASING B5 Lubricate the rear wheel pivot 3 13 B6 Lubricate the head axle of the steering cylinder 3 13 LUBRIFICATION OF THE STABILIZERS TMT 320 TMT 320 FL TMT 320 FL HT TMT 320 FL Turbo HT B7 Lubricate the axles of the stabilizers 3 14 FORKLIFT SAFETY CONTENTS C EvERY 200 WORKING HOURS SERVICE C1 C2 Drain and change the engine oil Change the engine oil filter Check and adjust the tension of the belt Alternator Fan Crankshaft D EvERY 400 WORKING HOURS SERVICE To be carried out once a year if the lift truck has not reached the 400 hours service in the year D1 D2 D3 04 05 06 Change the dry air filter cartridge Change the fuel filter cartridge Change the hydraulic retur
12. 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 Check the level and the density of the electrolyte in the battery See B EVERY 50 HOURS SERVICE in SECTION 3 MAINTENANCE Check the components of the electrical system the connections and fastening devices IF NECESSARY CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS 22 2 DESCRIPTION FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS TMT 320 TMT 320 FL MANITOU FORKLIFT SAFETY CONTENTS IDENTIFICATION OF THE LIFT TRUCK Our policy is to promote a constant improvement to our products for this reason our range of telescopic lift trucks may undergo certain modifications without prior notice When you order parts or when you require any technical information always specify NOTE For the owner s convenience it is recommended that a note of these numbers be made in the spaces provided at the time of the lift truck s delivery PLATE MANUFACTURER OF THE LIFT TRUCK FIG A Model Series Serial No Chassis No Year of manufacture ENGINE FIG Engine No TRANSMISSION FIG C Transmission type MANITOU parts No Serial No FRONT WHEEL REDUCER FIG D Remove cover plate to expose ID Plate Type Code Serial No MANITOU NORTH AMERICA I
13. 4 m min 6 45 37 4 ft min 11 4 m min 5 18 46 9 ft min 14 3 m min 5 75 42 ft min 12 8 m min 2 215 20 2 9 65 1065 10 7 9 5 5225 Ib 2370 kg 9634 Ib 4370 kg 1576 Ib 715 kg 5986 Ib 2715 kg 3649 Ib 1655 kg 3649 Ib 1655 kg 4275 Ib 1900 daN 46psi 3 2 bar unladen 992 Ib 450 kg laden 3197 Ib 1450 kg unladen 3527 Ib 1600 kg laden 3527 Ib 1600 kg 10 FORKLIFT SAFETY CONTENTS CHARACTERISTICS TMT 320 FL TURBO HT ENGINE Type Number of cylinders Number of strokes Injection system Ignition sequence Capacity Bore Stroke Volumetric ratio Nominal running speed Idle speed Full speed Power DIN 70 020 Power BS 5514 ISO 3046 DIN 6271 B Maximum torque Air cleaner COOLING CIRCUIT Type Fan Number of blades Diameter Thermostat Start opening Full opening ELECTRIC CIRCUIT Earth Battery Alternator Tension regulator Starter LISTER PETTER LPWT 4 4 4 Indirect 1 3 4 2 114 in 1860 cm 3 39 in 86 mm 3 15 in 80 mm 22 1 2800 rpm 1100 rpm 3000 rpm 53 1 cv 39 6 kw 55 4 cv 41 3 kw 110 ft Ib 149 Nm to 2000 rpm dry 3 microns By water Puller 5 12 4 in 315 mm 160 F 71 C 185 F 85 C Negative 12 V 105 Ah 12V 45A Incorporated into the alternator 12 V FORKLIFT SAFETY CONTENTS HYDROSTATIC TRANSMISSION HYDROSTATIC PUMP Type Gear reverser Inching starter MAIN PUMP
14. ABOVE 19 DOCUMENT HOLDER 20 LOAD CHART FILE NOTE nun as RIGHT LEFT FRONT REAR are reference points as observed by the driver seated normally facing orward FORKLIFT SAFETY CONTENTS 1 DRIVER S SEAT DESIGNED FOR MAXIMUM COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS LONGITUDINAL ADJUSTMENT Pull locking lever 1 towards the right Slide the seat to the required position Release the lever and insure it returns to the locked position SEAT SUSPENSION ADJUSTMENT Position lever 2 according to the driver s weight Position A light weight driver Position B middle weight driver Position C heavy weight driver ADJUSTMENT OF THE BACK REST ANGLE Rotate lever 3 to incline the back rest into the required position between 5 and 20 2 SAFETY BELT Operate lever 1 to wind or unwind the safety belt 3 SIGNAL LAMP PANEL When activating the ignition on the lift truck all the panel lamps must light to indicate their good working order If one of the panel lamps is not working carry out the necessary repairs Red engine oil pressure lamp Red water temperature lamp Red hydrostatic transmission oil filter clog lamp Red air filter clog lamp not used Red alternator charge lamp not used not used not used Red preheating lamp To nm gt e zo 9 A RED ENGINE OIL PRESSURE LAMP If the lamp or the buzzer come on while the lift truc
15. Check the adjustment of the rear view mirrors Ensure that the fuel level is sufficient Place the boom in the retracted position and the attachment at 300 mm 12 in from the ground AAWARNING While on the road do not use the transmission cut off to maintain engine braking on the lift truck G OPERATING THE LIFT TRUCK WITH A TRAILER ON A PUBLIC HIGHWAY When using a trailer consult the regulations in your country Maximum travel speed braking maximum weight of trailer etc Do not forget to connect the lift truck s electrical equipment to that of 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 daN 3372 lbs The authorized total towed weight A T T W must not exceed the maximum weight as authorized by the manufacturer Consult the manufacturer s plate on your lift truck OPERATING THE LIFT TRUCK WITH A FRONT END ATTACHMENT ON A PUBLIC HIGHWAY For driving with an attachment check the regulations currently applicable in your country he attachment must not exceed the overall width of the lift truck The length of the entire unit must not exceed the overall length of 6 metres 19 7 ft
16. 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 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 understand all safety and operating Mast equipped models Location on or near the operator manual 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 Ke
17. a lift truck is prohibited in protected areas e g refinery explosive atmosphere For use in these areas specific equipment is available as an option Consult your dealer D CLIMBING ONTO THE TRUCK Optional solutions exist consult your dealer To climb onto the truck it is strictly prohibited to use the lift truck hydraulic system if it is not equipped with a suitable hydraulic safety device kit IF NECESSARY CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS 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 greasy substances For increased comfort adjust the driver s seat to your requirements and adopt the correct position in the driver s seat The operator must always operate the forklift seated in the normal position in the cab It is prohibited to have arms legs or any part of the body protruding from the cab of the lift truck Remember to always fasten your seat belt and adjust it to your requirements The controls must never be used for any other than their intended purposes do not climb onto or down from the lift truck by grabbing the controls If the controls are fitted with a forced operation lever lock device it is forbidden to leave the cab without first placing these controls in neutral Never allow a passenger to travel on the lift tr
18. 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 forklift 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 dec
19. boom With a brush apply a coat of grease See LUBRICANTS on all 4 sides of the boom Fig A10 Telescope the boom several times in order to spread the coat of grease evenly Remove any surplus grease If the truck is used in an abrasive environment Dust IMPORTANT sand coal use lubricating varnish Dry lubrication Consult your agent or dealer EVERY 50 WORKING HOURS SERVICE CLEAN THE DRY AIR FILTER CARTRIDGE Use in a heavy dust atmosphere requires more frequent cleaning see FILTERS CARTRIDGES AND BELTS Open the engine compartment Unscrew nut 1 Fig B1 and remove cover 2 Fig B1 Unscrew nut 3 Fig B1 and lift out filter cartridge 4 Fig B1 Leave the safety cartridge in place Clean the filter cartridge using a low pressure air jet directed from the inside to the outside surface of the cartridge only Keep a safe distance between the nozzle and the IMPORTANT ji iru cartridge to avoid tearing or piercing it Clean the inside of the casing with a clean damp lint free cloth Check the condition of the filter cartridge replace the cartridge if necessary Refit the cartridge and cover Do not clean the dry air filter cartridge by washing it in liquid Do not clean the safety cartridge located inside the filter cartridge exchange it for a new one if it is dirty or damaged IMPORTANT B2 CHECK THE HYDRAULIC OIL LEVEL Park the lift truck
20. can only be carried out by authorized staff 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 e g welding Do not drop metallic items on the battery When carrying out electric welding work on the lift truck connect the negative cable from the welding equipment directly to the part being welded so as to avoid high tension current passing through the alternator B MAINTENANCE The maintenance and compliance of the lift truck are mandatory Carry out 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 or fuel leaks WARNING Wait for the engine to cool before removing the radiator cap Change the filter cartridges See servicing schedules in FILTERS CARTRIDGES AND BELTS in SECTION MAINTENANCE C 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 areas specified for this purpose Do not fill the fuel tank to over flowing FORKLIFT SAFETY CONTENTS D WASHING Clean the lift truck or at least the area concerned before making repairs
21. 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 stabilized 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 e f steering mechanism 9 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 ro
22. 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 wherever 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
23. full distance of travel 8 Tilt the lift truck fully forward Lever 2 back 9 Extend the boom 5 max Lever 1 to the right Carefully exit the cab 10 With the support hook fully extend both support arms fig 1D 11 Retract the boom Lever 1 to the left Insure the lift truck is properly positioned above the support arms 12 To set the forklift on the support arms tilt the lift truck back Lever 2 forward 13 Make sure the support arms are locked in place fig 1E 14 Connect the electrical cable and straps fig IF 4 1G FORKLIFT SAFETY CONTENTS 2 UNLOADING THE LIFT TRUCK FROM THE TRAILER Ensure the tractor trailer is properly parked and secured utilizing wheel chocks as required TO UNLOAD THE MANITOU TMT 1 Learn the controls Execute all movements slowly All forklift movements are to be made by the operator positioned in the operator s seat with the seat belt fastened Take extra precaution when entering and exiting the cab while it is in the raised position 2 Disconnect trailer lift truck electrical cable and tie down straps 3 Raise the lift truck Lever 2 back the full distance of travel 4 Extend the boom 5 max push Lever 1 to the right 5 Carefully exit the cab With the support hook push the support bars back insure they are locked in place 6 Retract the boom push Lever 1 to the left 6 Slightly lower the forklift Lever 1 back until the front wheels touch the ground 7
24. lift truck has run Use the hourmeter to schedule routine maintenance FUEL LEVEL GAUGE Shows approximate level of fuel in the fuel tank To reduce condensation in the fuel tank keep the fuel level near full 2nd Mounting FORKLIFT SAFETY CONTENTS 5 NA 6 SWITCH PANEL A Parking brake switch B Front white work lights C OPTION A PARKING BRAKE SWITCH This switch engages the parking brake The lighted switch indicates the park brake is on B FRONT WHITE WORK LIGHTS Operates with the ignition switch turned on The lighted switch indicates the work lights are on FORKLIFT SAFETY CONTENTS 7 FLOW DIVIDER SWITCH This switch locks all 3 wheels into drive causing all 3 wheels to rotate at the same time and speed for temporary use in loose or muddy terrain NOTE This operation limits steering the forklift and is best utilized with the steer tire directed straight ahead before engaging the switch and during use Press and hold the switch as required Release the switch to resume normal operation 8 N A 9 GNITION SWITCH The key switch has five positions P Ignition off parking position O Ignition switched off and engine stopped Ignition on Heating Ill The engine starts return to position as soon as the key is released 10 SOUND ALARM SWITCH HORN FORKLIFT SAFETY CONTENTS 11A FUSES 1sr MOUNTING Loosen both knobs 1 and remove the fuse box acce
25. 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 equipment 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 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 handicapped persons and trainees tempted to drive a lift truck Truck drivers tempted to operate a truck to win a bet in competition 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 FORKLIFT SAFETY CONTENTS GENERAL INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Read the operator s manual carefully making sure you understand it The operator
26. s manual must always be kept in the lift truck in the place provided and in the language understood by the operator Every operation or maneuvre not described in the manual must be assumed to be prohibited Respect the safety notices and instructions given on the lift truck lt is mandatory to replace all plates or stickers which are no longer legible or which have become worn or damaged B AUTHORIZATION TO OPERATE Refer to current legislation 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 user should always carry this authorization to operate with him while he is using the lift truck The driver is not authorized to permit others to drive the lift truck In addition the vehicle should be used in accordance with good practice for the profession C MAINTENANCE he user must immediately advise his superior if his lift truck is not in good working order or does not comply with safety standards he operator is prohibited from performing 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 LAND tires Snow chains There ar
27. the load 42 ROJA NOS FORKLIFT SAFETY CONTENTS HANDLING THE LOAD USING STABILIZERS 320 320 FL TMT 320 FL HT TMT 320 FL TURBO HT Place the lift truck in the transport position Fig Q Engage parking brake Put forward reverse lever in neutral Bring the two stabilizers in contact with the ground Fig R NOTE On unstable terrain secure the stabilizers adequately with blocks MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK MAINTENANCE INSTRUCTIONS A GENERAL Read the operator s manual carefully and ensure you understand it Stop the engine when an intervention 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 ina safe and Carry out all repairs immediately even if the repairs are minor Repair all leaks immediately even if the leak is minor 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 Aw ARNING truck can be dangerous A balancing valve must only be removed when the cylinder concerned is atrest and the hydraulic circuit is depressurized This operation
28. 12 V 105 Ah 14V 45A Incorporated into the alternator 12V FORKLIFT SAFETY CONTENTS HYDROSTATIC TRANSMISSION HYDROSTATIC PUMP Type Gear reverser Inching starter MAIN PUMP Displacement MAX MIN Flow rate at 3 000 rpm MAX MIN Working pressure BOOST PUMP Cubic capacity Flow rate at 3 000 rpm MAX MIN Boost pressure Max rpm FRONT WHEEL REDUCER Type Cubic capacity Working pressure REAR WHEEL REDUCER Type Cubic capacity Working pressure REAR WHEEL REDUCER TMT 320 FL HT Type Cubic capacity Working pressure BRAKE Type Service brakes Parking brakes A4VG 40 DA variable displacement pump with automatic power governor Electromagnetic 12V Hydraulic through outside valve TH 7 2 44 in 40 cm tr in rev 0 cm tr 31 7 gpm 120 l min 0 gpm 0 l min 6090 psi 420 bar 513 in tr 8 4 cm tr 6 66 gpm 25 2 l min 0 gpm 0 l min 406 435 psi 28 30 bar MSE02 POCLAIN Motor wheel with brakes fixed displacement 24 3 in tr 398 cm tr 6090 psi 420 bar MSEO2 POCLAIN Motor wheel fixed displacement 24 3 in tr 398 cm tr 6090 psi 420 bar MSEO5 POCLAIN Motor wheel fixed displacement 45 8 in 750 cm tr 6090 psi 420 bar Multidisc brake immersed in oil Hydrostatic Electrically controlled on dashboard on the front wheels through hydraulic pressure break FORKLIFT SAFETY CONTENTS
29. 5 km h 7 77 mph 12 5 km h 113 in 2870 mm 5500 Ib 2495 kg 24 in 610 mm 119 Ib 54 kg 40 0 ft min 12 2 m min 37 1 ft min 11 3 m min 52 8 ft min 16 1 m min 52 8 ft min 16 1 m min 42 0 ft min 12 8 m min 38 4 ft min 11 7 m min 47 6 ft min 14 5 m min 43 0 ft min 13 1 m min 9 25 20 2 s 10s 10 7 s 4938 Ib 2240 kg 9348 Ib 4240 kg 1554 Ib 705 kg 5964 Ib 2705 kg 3384 Ib 1535 kg 3384 Ib 1535 kg 4275 lb 1900 daN 61psi 4 2 bar unladen 882 Ib 400 kg laden 2976 Ib 1350 kg unladen 3417 Ib 1550 kg laden 3417 Ib 1550 kg FORKLIFT SAFETY CONTENTS TMT 320 FL HYDRAULIC CIRCUIT Lifting tilting telescoping travel circuit stabilizer Type of pump Flow rate at full speed Pressure Capacity Steering direction Provided by flow distributor Load sensing Pressure Filtration Suction Return Air contained in the tank SPECIFICATIONS Level of sound pressure in the driver s cabin According to norm prEN 12053 1995 Gear Travel speed of the lift truck Front unloaded Rear unloaded Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Telescopes retracted Unloaded lifting Rated load lifting Unloaded lowering Rated load lowering 9 4 10 1 7 1 7 15 Telescoping motions Lifting boom Extending of telescopes unloaded Extending of telescopes loaded
30. 907 Ib 865 kg 6316 Ib 2865 kg 3571 lb 1620 kg 3571 Ib 1620 kg 5490 lb 2440 daN 46psi 3 2 bar unladen 992 Ib 450 kg laden 3197 lb 1450 kg laden 3527 lb 1600 kg FORKLIFT SAFETY CONTENTS DIMENSIONS AND LOAD CHART TMT 320 TMT 320 FL oie FORKLIFT SAFETY CONTENTS E 937in 2379 mm 1 952in 419mm 81 1in 2060 mm K1 5 91in 150mm T i 69 9in 1775 mm 86 6 in 2200 mm 87 3in 2218 mm M M1 N 103in 2611 mm 03 in 2616 mm Vi 756in 1919 mm 91 3in 2320 mm 91 7 2330 97 97 10 10 A eZ lt Nr wo St D E K K2 NUN M m N 0 492in 125mm EX EN DIMENSIONS AND LOAD CHART TMT 320 FL HT TMT 320 FL Turbo HT S FORKLIFT SAFETY CONTENTS TMT 320 FL HT TMT 320 FL Turbo HT 3 3in 1100 mm 58 3in 1481 mm 19 7 in 500 mm 1 57 in 40 mm 27 7 in 703 mm 62 9in 1598 mm 106 in 2698 mm 84 6in 2149 mm 13 9 in 353 mm 51 2in 1300 mm 110 2806 109 2770 84 3 2140 mm 100 in 2543 mm ER EN Ku IN c2 D K NUN M m N EM R v FORKLIFT SAFETY CONTENTS TMT 320 TMT 320 An American national standard ASME B56 6a 1994 5 n 3 Ld 2 lt Y 5 c 5 5 c 5 5
31. C 5 to 95 F correct levels of lubricants in all the circuits are filled in production For operation under more severe IMPORTANT climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants properly suited to the relevant ambient temperatures are installed It is the same for the engine cooling liquid 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 oil seeping from the hoses connections or unions If necessary tighten or repair the defective connections Also check that the hydraulic tank oil level is correct BRAKING SYSTEM Check leaks oil seeping from the hoses connections and unions If necessary tighten or repair the defective connections Also check the brake oil level in the tank WARNING Ensure that the recommended oil is used in order to avoid serious damage to the braking system FORKLIFT SAFETY CONTENTS 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
32. Clean the radiator core with compressed air directed from the back to the front of the radiator Avoid high pressure washing which may damage the radiator When handling straw grains or cereals clean the IMPORTANT radiator core every day GENERAL GREASING Clean and lubricate the following points with grease See LUBRICANTS remove any surplus B5 LUBRICATORS OF THE REAR WHEEL PIVOT 3 lubricators e TMT 320 LUBRICATOR 1 Fig B5 1 LUBRICATORS 2 ET 3 Fig B5 2 e TMT 320 FL TMT 320 FL HT TMT 320 FL Turbo HT LUBRICATOR 1 Fig B5 1 LUBRICATOR 4 Fig B5 3 LUBRICATOR 5 Fig B5 4 B6 LUBRICATOR 6 OF THE HEAD AXLE OF THE STEERING CYLINDER FIG B6 1 lubricator FORKLIFT SAFETY CONTENTS GREASING OF THE STABILIZERS TMT 320 TMT 320 FL TMT 320 FL HT TMT 320 FL TURBO HT Clean and lubricate the following points with grease See LUBRICANTS remove any surplus B7 LUBRICATORS OF STABILIZER AXLES 7 FIG 2 lubricators FORKLIFT SAFETY CONTENTS 15 FORKLIFT SAFETY CONTENTS C EVERY 200 WORKING HOURS SERVICE C1 DRAIN AND CHANGE THE ENGINE OIL C2 CHANGE THE ENGINE OIL FILTER Park the truck on level ground run the engine at idle for a few minutes to warm the oil then stop the engine DRAINING THE OIL Open the engine compartment Place a container under drain plug 1 Fig C1 1 and unscrew the plug Remove drain hose 2 Fig C1 2
33. D 496550 MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 www manitou na com MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 ES MAST MODEL I mastsn ATTACHMENTS UNLADEN WEIGHT 0 ES eres MAX CAPACITY uP TO 8 inches MAX CAPACITY Les AT MFH B BEE INCHES TIRE PRESSURE FRONT TIRE PRESSURE REAR 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 TRUCK MODEL SERIAL NUMBER ME UNLADEN wE cHt vean or TIRE PRESSURE FRONT 5 5 TIRE PRESSURE IRE PRESSURE REAR 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 B56 6 MANUFACTURED MANUFACTURED IN XVI FORKLIFT SAFETY CONTENTS TABLE OF CONTENTS 1 INSTRUCTIONS 1 1 GENUINE SPARE PARTS 1 3 DRIVER S OPERATING INSTRUCTIONS 1 5 General instructions 1 6 Operating instructions 1 8 Handling instructions 1 12 Handling of a load 1 14 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 18 BEFORE STARTING UP A NEW LIFT TRUCK 1 20 2 DESCRIPTION 2 1 IDENTIFICATION OF THE LIFT TRUCK 2 4 CHARACTERISTICS 2 6 DIMENSIONS AND LOAD CHART 2 14 INSTRUMEN
34. 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 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 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 i
35. FORKLIFT SAFETY CONTENTS MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE WACO TX 76712 6803 AX WARNING The specially designed TMT Forks must be replaced with Factory Approved Forks only Contact your Dealer or Manitou North America Inc 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 IMPORTANT When changing or replacing the tires and wheels use only the manufacturer s approved components as installed at the factory Any substitutes or modifications must first be approved by the manufacturer For Parts Orders contact your Manitou Dealer or call Manitou North Amerida Inc Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com TMT 320 HT TMT 320 FL HT TURBO OPERATOR SERVICE MANUAL THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY THE LIFT TRUCK OPERATOR CATALOG 547043AS R11 10 FORKLIFT SAFETY CONTENTS INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS SAFTETY MESSAGES VII SAFETY DECALS VIII TABLE OF CONTENTS XV R05 03 FORKLIFT SAFETY CONTENTS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS FORKLIFT SAFETY CONTENTS ROUGH TERRAIN FORKLIFT TRUCK
36. 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 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 fro
37. HYDRAULIC CIRCUIT Lifting tilting telescoping travel circuit stabilizer Type of pump Flow rate at full speed Pressure Capacity Steering direction Provided by flow distributor Loadsensing Pressure Filtration Suction Return Air contained in the tank SPECIFICATIONS Level of sound pressure in the driver s cabin According to norm prEN 12053 1995 Travel speed of the lift truck Front unloaded Rear unloaded Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Telescopes retracted Unloaded lifting Rated load lifting Unloaded lowering Rated load lowering Telescoping motions Lifting boom Extending of telescopes unloaded Extending of telescopes loaded Retracting of telescopes unloaded Retracting of telescopes loaded Reverse tilt time unloaded Forward tilt time unloaded Lift truck weight with standard attachment Unloaded Rated load TMT 320 Gear 9 4 10 1 7 1 7 165 4 35 4 7 5 3 8 4 2 Axle weight with standard attachment Transport position Front unloaded rated load Rear unloaded rated load Drawbar pull Rated load TIRES OTR Industrial 31 x 10 16 5 10 PR Front tire load Rear tire load 9 51gpm 36 L min 3625 psi 250 Bar 1 86 in 12 cm tr 1740 psi 120 Bar 100 Microns 10 Microns 5 Microns dB 7 77 mph 12
38. Insure the drain end of the hose is in the drain pan oil will drain the moment the drain hose is attached to the coupling on the draining port 3 Fig C1 3 Remove filler cap 4 Fig C1 4 to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner REPLACEMENT OF THE FILTER Loosen 1 Fig C2 1 and rotate the battery housing for clearance Clean the filter bracket with a clean lint free cloth Remove engine oil filter 2 Fig C2 2 discard the filter and filter seal Lightly lubricate the new seal Install the new oil filter and seal Return the battery housing to its initial position Tighten the oil filter by hand pressure only and lock the IMPORTANT filter in place by a quarter turn d Mounting FORKLIFT SAFETY CONTENTS FILLING UP THE OIL Loosen clean and return the drain hose 2 Fig C1 2 Reinstall and tighten drain plug 1 Fig C1 1 Fill up with oil See LUBRICANTS by filler port 5 Fig C1 4 Allow the oil to settle Start the engine and let it run for a few minutes Check for leaks at the drain plug and oil filter Stop the engine allow the oil to settle then check the oil level It should be between the notches on the dipstick 3 Fig C2 3 Adjust the oil level if necessary C3 CHECK AND ADJUST THE TENSION OF THE BELT ALTERNATOR FAN CRANKSHAFT Open the engine compartment Check the belt for wear a
39. NC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 www manitou na com UNLADEN WEIGHT __ ES vean or Fc TIRE PRESSURE FRONT PSI TIRE PRESSURE REAR 8 es 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 B56 6 MANUFACTURED IN FORKLIFT SAFETY CONTENTS REAR WHEEL REDUCER FIG D Type Code Serial No amp Boom FIG F Boom No Date of manufacture FORKLIFT SAFETY CONTENTS CHARACTERISTICS TMT 320 TMT 320 FL TMT 320 FL HT ENGINE Type Number of cylinders Number of strokes Injection system Firing order Capacity Bore Stroke Compression ratio Nominal running speed Idle speed Full speed Power DIN 70 020 Power DIN 6270 B Power SAE Power BS AU 141 a 1971 Maximum torque Air cleaner COOLING CIRCUIT Type Fan Number of blades Diameter Thermostat Start opening Full opening ELECTRIC CIRCUIT Ground Battery Alternator Tension regulator Starter LISTER PETTER LPWS 4 4 4 Indirect 1 3 4 2 114 in 1860 cm 3 39 in 86 mm 3 15 in 80 mm 22 1 2800 rpm 950 rpm 3000 rpm 39 7 cv 29 2 kw 38 8 cv 28 6 kw 41 3 cv 30 4 kw 39 7 cv 29 2 kw 71 3 ft Ib 96 6 Nm to 2000 rpm dry 3 microns By water Puller 5 12 4 in 315 mm 160 F 71 185 F 85 Negative
40. ND 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 FORKLIFT SAFETY CONTENTS SAFETY DECALS Acid in Battery 801014 Location in or near the battery storage compartment Addresses battery hazards Jump Start Battery 801015 Location in or near the battery storage compartment Jump start instructions Attachment Plate 425995 4 DANGER 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 READ OPERATOR S MANUAL Keep out of reach of children 801014 WARNING _ 1 Wear eye protection 2 Connect ends of one cable to positive terminals of both batteries 3 Connect one end of remaining cable to negative terminal 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 preven
41. NT CAPACITY RECOMMENDATION PACKAGING REFERENCE ENGINE except Turbo 5 6 Litres Shell Rotella 15w40 1 5 gal Texaco URSA Super 15w40 6 5 Litres ENGINE Turbo 1 7 gal HYDRAULIC OIL TANK 35 Litres Shell Tellus T46 9 2 gal Texaco Rando HDZ46 Shell Tellus T32 2 F to 124 F 25 gal 803373 GENERAL GREASING Shell Rentinax Am Texaco Havoline WBCG BOOM PADS Shell Rentinax Am Texaco Havoline WBCG GREASING OF THE STABILIZERS GREASING OF THE BOOM Shell Rentinax Am Texaco Havoline WBCG COOLING CIRCUIT 8 Litres Texaco Texguard Anti Freeze 2 1 gal 45 55 Pre mix 22 F Shell Rentinax Am Texaco Havoline WBCG FUEL TANK 10 5 gal Diesel fuel Grade 1 D DIAGNOSTIC ANALYSIS OF OIL In the event of a maintenance or service contract with the dealer you may be requested a diagnostic analysis of engine transmission and axle oils according to the utilization rate FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS AFTER THE FIRST 50 WORKING HOURS SERVICE C1 Drain and change the engine oil 3 16 C2 Change the engine oil filter 3 16 D2 Change the fuel filter cartridge 3 18 D3 Change the hydraulic return oil filter cartridges 3 18 DA Change the oil container breather 3 18 Change the hydrostatic transmission oil filter cartridge 3 21 A EVERY DAY OR EVERY LO WORKING HOURS SERVICE A1 Check the engine oil level 3 9 A2 Check the cooling liquid level 3 9 Check the fuel level
42. R INSIDE THE HYDRAULIC TANK CONSULT YOUR DEALER EVERY 1600 WORKING HOURS SERVICE F1 CHANGE THE CRANKSHAFT FAN ALTERNATOR BELT YOUR DEALER FORKLIFT SAFETY CONTENTS 25 G EVERY 2400 WORKING HOURS SERVICE G1 CHECK THE HYDRAULIC CIRCUIT PRESSURES AND DISCHARGE RATES your DEALER G2 CHECK THE HYDROSTATIC TRANSMISSION CIRCUIT PRESSURES YOUR DEALER G3 CHECK AND ADJUST THE GOVERNING START R P M OF THE HYDROSTATIC TRANSMISSION YOUR DEALER G4 MAKE SURE THE TRANSMISSION CUT OFF HYDRAULIC VALVES ARE IN GOOD WORKING ORDER your DEALER G5 CHECK THE STEERING SYSTEM CONSULT YOUR DEALER G6 CLEAN THE HYDRAULIC OIL TANK YOUR DEALER G7 CHECK THE INJECTORS CONSULT YOUR DEALER G8 CHECK AND SCALE THE RADIATOR YOUR DEALER G9 CHECK THE WATER PUMP AND THE THERMOSTAT Consutr your DEALER G10 CHECK THE CONDITION OF THE BOOM ASSEMBLY ConsuLr YOUR DEALER FORKLIFT SAFETY CONTENTS 27 FORKLIFT SAFETY CONTENTS EVERY 4800 WORKING HOURS SERVICE H1 CHECK THE WEAR OF THE BRAKE DISKS ON THE FRONT WHEEL MOTORS your DEALER H2 CHECK THE REAR WHEEL MOTOR PIVOT YOUR DEALER CHECK THE STEERING BALL JOINTS ConsuLT YOUR DEALER H4 CHECK THE ALTERNATOR AND THE STARTER MOTOR CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS 29 FORKLIFT
43. SAFETY CONTENTS I OCCASIONAL MAINTENANCE 1 BLEED THE FUEL SYSTEM These operations may be required in the following cases A changed or drained component in the fuel system A drained tank Running out of fuel Insure the fuel level is sufficient turn the ignition key to notch 1 turning on the ignition Open the engine compartment Loosen the bleed screw 1 Fig 11 1 Operate the fuel lift pump 2 until airless fuel drains from the bleed screw Tighten the bleed screw 1 Fig 11 1 while the fuel is flowing NOTE If the fuel lift pump lever will not operate rotate the crankshaft one turn BLEEDING THE INJECTION NOZZLES Loosen the tube connections 3 Fig 11 2 of the injection nozzles Operate the starter motor until airless fuel drains from the tube connections 3 Fig 11 2 Tighten these connections while the fuel is flowing out Clean all spilt fuel residue The engine is now ready to start 2 CHANGE A WHEEL Park the lift truck on level solid ground Stop the lift truck See Driving the lift truck SECTON stopping the lift truck CHANGING THE FRONT WHEEL TMT 320 TMT320 FL TMT 320 FL HT TMT 320 FL Turbo HT Block the lift truck in both directions on the wheel opposite to the wheel to be changed Loosen the wheel nuts on the tire to be changed Place a block under the stabilizer 1 Fig 12 1 of the wheel to be changed Lower the stabilizers R
44. T TRUCK ONTO THE TRAILER s 2 UNLOADING THE LIFT TRUCK FROM THE TRAILER 2 34 Location of the control levers Lever 1 Controls lifting the load and telescoping the boom Lever N 2 Controls tilting the carriage and side shifting the boom FORKLIFT SAFETY CONTENTS 1 LOADING THE LIFT TRUCK ONTO THE TRAILER The mounting kit for the TMT must be supplied or approved in writting by Manitou North America Inc Ensure the tractor trailer is properly parked and secured utilizing wheel chocks as required TO LOAD THE MANITOU TMT ONTO THE TRAILER 1 Learn the controls Execute all movements slowly All forklift movements are to be made by the operator positioned in the operator s seat with the seat belt fastened Take extra precaution when entering and exiting the cab while it is in the raised position 2 Fully retract the boom Lever 1 left 3 Side shift the boom until centered move Lever 2 to the right or left to align the centering bar 1 as shown fig 1A 4 Align the forks to the trailer sleeves fig 1B insure the forks are equally spaced from the center of the carriage 5 Maneuver the forks into the sleeves make adjustments as required insure both forks are fully inserted and flush with the trailer bed fig 1C 6 Tilt the carriage back slightly until the forks are tight in the sleeves Lever 2 back 7 Raise the forklift off the ground Lever 1 forward the
45. TS AND CONTROLS 2 22 MOUNTING THE LIFT TRUCK ON THE TRACTOR TRAILER 2 31 3 MAINTENANCE 3 1 FILTERS CARTRIDGES AND BELTS 3 3 LUBRICANTS 3 4 SERVICING SCHEDULE 3 6 XV 1 OPERATING AND SAFETY INSTRUCTIONS FORKLIFT SAFETY CONTENTS ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS ALL MAINTENANCE ON OUR LIFT TRUCKS MUST BE CARRIED OUT USING ORIGINAL PARTS BY ALLOWING NON ORIGINAL PARTS TO BE USED YOU RUN THE RISK Legally of being liable in the event of an accident IMPORTANT Technically of causing breakdowns to occur or of reducing your lift truck s service life BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS YOU ARE LEGALLY Any user who procures parts from another vendor does so at his own risk COVERING YOURSELF 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 Guaran
46. Tilt the forklift back Lever 2 forward until the rear wheel is on the ground 8 Slowly back the forklift away from the trailer adjust fork angle as needed 8 03 05 3 MAINTENANCE FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS FILTERS CARTRIDGES AND BELTS 1er MONTAGE 1ste MONTAGE 1ro MONTAJE 1st MOUNTING aS gt c 49 C C Y EA 323223232 e 7s 2 amp me MONTAGE 2te MONTAGE 2do MONTAJE 2nd MOUNTING m E Um VI Y m Y AAA AS Seal 0 0 0 9 0 0 0 0 0 09 0 0 0 0 0 0 0 0 0 0 0 0 c SR 1er MONTAGE 1ste MONTAGE 1ro MONTAJE 7 1st MOUNTING OPTION Poulie de vilebrequin L Kurbelwelleriemenscheibe 2 Polea de cig enal F Crankshaft pulley Poulie de vilebrequin Kurbelwelleriemenscheibe Polea de cig enal Crankshaft pulley CHANGE 1 Engine oil filter Standard 400 H TMT 320 FL Turbo HT 200 H EEC AECE wm 8 Hydraulic return oil filter cartridge 203 787 400 H oil container breather EN 9 Hydraulic return oil filter cartridge 217 031 400 H oil container breather 11 Alternator belt Fan Crankshaft 552 500 1600 H 12 Automatic vacuum cleaning pre filter 160 945 3 3 FORKLIFT SAFETY CONTENTS LUBRICANTS COMPONE
47. als 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 missing 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
48. 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 Drive 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 so 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
49. ase the accelerator pedal and stop the lift truck Place the forward reverse lever in neutral Apply the parking brake Retract the boom completely Lower the forks or attachment to rest on the ground Stop the engine Remove the pressure in the hydraulic circuits by using the hydraulic controls Remove the ignition key Check that the hood is closed Aw ARNING Before leaving your cab ensure that you have carried out all operations for stopping and parking the lift truck for your safety and the safety of others 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 local Highway Code Lift truck drivers driving on the public highway must abide by the general provisions relative to highway traffic The lift truck must conform to the provisions of the Highway Code If necessary optional solutions exist consult your dealer 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 FORKLIFT SAFETY CONTENTS INSTRUCTIONS Ensure that the flashing light is in position and that it is working Check the good working order and cleanness of lights indicators and windscreen wiper where applicable Control the alignment of the wheels and select the steering mode HIGHWAY TRAFFIC
50. avelling on a longitudinal slope Drive and brake gently Di e Moving without load Forks or attachment facing downhill A Moving with load Forks or attachment facing uphill J F Ensure that scaffolding loading platform or pile is capable of bearing the weight Ensure the stability and solidity of the ground before depositing a load D HANDLING Always consider safety transport only balanced and correctly secured loads to avoid risk of tipping Fully engage forks under the load and transport it in the low position Approximately 300 mm 12 in from the ground with the boom fully retracted and the forks sloping back For obvious reasons regarding the lift truck s stability and clear visibility of the surrounding area operate the lift truck only when the boom is in the travel position Forks approximately 300 mm 12 in from the ground Do not maneuver the lift truck with the boom 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 and get another person to guide you along if 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
51. d 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 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 d lower load engaging means fully unless supporting an occupied elevated platform e stop the engine f if the rough terrain forklift truck must be left on an incline b
52. d using wedges Switch off the engine Remove pressure from the attachment hydraulic system using the hydraulic controls C ENVIRONMENT Signaling and lighting on the lift truck must suit the conditions of use In addition to the factory equipment mounted on your lift truck a certain number of options are available such as road lighting stop lights flashing light reverse lights reverse buzzer alarm front light rear light light at the boom head etc Consult your agent or dealer Take care when raising the load that no object or person is in the way of movement and avoid incorrect maneuvers In the case of work near power lines ensure that the safety distance is sufficient between the working area of the lift truck and the power line You must consult your local electrical agency You could be electrocuted or seriously injured if you WARNING operate or park the lift truck too close to power cables You are strongly advised to ensure that the safety rules on the site conform to local regulations regarding all types of work performed near power cables Do not allow personnel to approach the working area of the lift truck or pass beneath an elevated load When operating on a slope before raising the boom ensure that the terrain is as level as possible Lift trucks fitted with level correction may work on a steeper incline provided that the greatest part of the slope is corrected FORKLIFT SAFETY CONTENTS Tr
53. dal or with the parking brake on Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel so turn it gently and not abruptly Do not allow the engine to idle needlessly for a long period Never leave the engine running 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 made fast That the unit to which it is connected Trailer truck 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 approved for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Take extreme care with loading platforms trenches scaffolding recently dug and or backfilled Awarninc The loaded lift truck must not travel at speeds in excess of 12 km h 7 5 mph INSTRUCTIONS Check the transmission oil level Raise the forks or attachment to the travel position approximately 300 mm 12 in
54. ding to norm prEN 12053 1995 Travel speed of the lift truck Front unladen Rear unladen Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Telescopes retracted Unladen lifting Rated load lifting Unladen lowering Rated load lowering Telescoping motions Lifting boom Extending of telescopes unladen Extending of telescopes laden Retracting of telescopes unladen Retracting of telescopes laden Reverse tilt time unladen Forward tilt time unladen Lift truck weight with standard attachment Unladen Rated load Axle weight with standard attachment Transport position Front unladen rated load Rear unladen rated load Drawbar pull Rated load TIRES OTR Mud Shark 31x 15 50 15 NHS Front tire load Rear tire load Gear 9 4 10 1 7 16 7 165 5 9 s 6 4 5 1 5 75 unladen 3527 Ib 1600 kg 9 51 gpm 36 L min 3625 psi 250 Bar 32 in tr 12 cm tr 1740 psi 120 Bar 100 Microns 10 Microns 5 Microns dB 6 8 mph 11 km h 6 8 mph 11 km h 135 in 3429 mm 5500 Ib 2495 kg 24 in 610 mm 119 Ib 54 kg 40 ft min 12 2 m min 37 1 ft min 11 3 m min 52 8 ft min 16 1 m min 52 8 ft min 16 1 m min 40 7 ft min 12 4 m min 37 4 ft min 11 4 m min 46 9 ft min 14 3 m min 42 0 ft min 12 8 m min 9 38 20 2 s 10 s 10 7 s 5478 lb 2485 kg 9888 Ib 4485 kg 1
55. drain oil in an ecological manner Use IMPORTANT E only clean equipment and funnel to fill the system FILLING THE OIL Install and tighten drain plug 1 Fig E1 1 Tightening torque 22 ft Ib Fill up with oil See LUBRICANTS through filler port 4 Fig E1 2 Observe the oil level on dipstick 5 Fig E1 2 the oil should be between the lower and upper marks Check for leaks at the drain plug Reinstall the cartridge 3 and the filler plug 2 Fig E1 2 into initial position FLUSHING THE HYDRAULIC CIRCUIT Park the lift truck on level ground Allow the engine to run at half throttle for 5 minutes without operating hydraulic movements then again for 5 minutes utilizing all hydraulic movements except the steering system and brakes Accelerate the engine to full speed for 1 minute then activate the steering system and brakes This operation directs debris in the hydraulic circuit into the hydraulic return oil filter It may be necessary to bleed the system at the inlet of IMPORTANT the pumps if air bubbles have formed during the draining if so consult your dealer E2 REMOVE AND CLEAN THE SUCTION STRAINER LOCATED INSIDE THE HYDRAULIC OIL TANK Access to the strainer requires removal of the hydrostatic transmission oil filter housing FORKLIFT SAFETY CONTENTS ES CHANGE THE HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE Remove cap 1 Fig ES Remove the hydrostatic transmissio
56. drive too fast or brake abruptly when carrying a load Check the load particularly when turning corners and especially if it is bulky Always secure unstable loads Handle loads with caution at slow speed and without abrupt movements when positioning them at significant heights and boom extention In the event of high winds or storms do not lift loads that jeopardize the stability of the lift truck particularly if the load catches the wind badly AAWARNING 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 leave the lift truck with the load in an elevated position Do not leave a laden 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 a bulky load drive in reverse motion This maneuver must remain exceptional and for short distances only Ensure you have good visibility adequate lighting correctly adjusted rear view mirror etc IF NECESSARY CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS LOAD HANDLING WEIGHT OF LOAD AND CENTER OF GRAVITY Before taking up a load you must know its weight and its center of gravity The load chart relating to
57. e optional solutions consult your agent or dealer AAWARNING A worn or damaged tire can result in the lift truck being temporarily out of service Unless previously approved foam inflated tires are prohibited and are not guaranteed by the IMPORTANT j zer manufacturer For your own and other people s safety it is forbidden to modify the structure and settings of the various components of your lift truck yourself Hydraulic pressure relief valve calibration engine running speed addition of extra equipment etc The same holds with regard to any suppression or modification of the safety systems in which case the maker would no longer be liable Regular inspection of your lift truck is mandatory if it is to be kept in conforming condition The WARNING frequency of such checks are defined by the current legislation of the country in which the lift truck is being operated FORKLIFT SAFETY CONTENTS 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 site of utilization Protection against frost See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Adaptation of lubricants Ask your dealer for information Engine filtration Lighting Working headlight Optional solutions exist consult your dealer Use of
58. 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 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 FORKLIFT SAFETY CONTENTS 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 tiltis 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
59. emove the wheel nuts Remove the wheel and roll it aside Slide the new wheel onto the wheel hub Install the nuts by hand if necessary lubricate them Lift the stabilizers Remove the block Torque the wheel nuts with a torque wrench See A DAILY OR EVERY 10 HOURS SERVICE for tightening torque FORKLIFT SAFETY CONTENTS CHANGING THE REAR WHEEL Block the lift truck in both directions on the front wheels Loosen the rear wheel nuts Place the hydraulic jack under the rear pivot Lift the wheel until it is raised from the ground Remove the wheel nuts Remove the wheel and roll it aside Slide the new wheel onto the wheel hub Tighten the nuts by hand if necessary lubricate them Lower the wheel to the ground Torque the wheel nuts with a torque wrench See A DAILY OR EVERY 10 HOURS SERVICE for tightening torque FORKLIFT SAFETY CONTENTS 3 TOWING THE LIFT TRUCK Towing the lift truck must be carried out at a very low IMPORTANT speed not exceeding 3 mph and at a distance as short as possible not exceeding 325 ft Remove the front cover 1 Fig 13 1 Loosen the high pressure relief valves 2 and 3 Fig 13 1 Measure and record distance X Fig 13 2 on both high pressure relief valves 2 and 3 Loosen the jam nuts 4 Fig B Tighten screw 5 Fig B until flush the jam nuts 4 Fig B After towing proceed in reverse order to repos
60. ep all shields in place Operate only from operator s seat SAFETY INSTRUCTIONS Read and understand operators manual before you operate Carry load as low as possible avoid steep slopes and drive slowly on rough terrain to avold machine overturn Refer to operator s manual for jump starting this truck If the operator s manual is missing a new instructions manual may be obtained through your local dealer or directly from K D Manitou Inc Waco Tx WHEN PARKING OR SERVICING Check truck for proper operation of all functions 1 Lower boom to the ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine Fasten seat belt 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 Instructs the operator to always wear the seat belt during operations and never jump from an over turning forklift A DANG Al avs wedr Seg operating machine Never Jump from a tipping FORKLIFT SAFETY CONTENTS SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever EMERGENCY STOPPING Identifies the Emergency Parking Brake Lever AND PARKING BRAKE 801010 THIS VEHICLE IS EQUIPPED WITH A BACK UP Alarm Must Sound 496162 ALARM WHEN BACKING THE Location
61. 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 FORKLIFT SAFETY CONTENTS E 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 allowing 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 while the lift truck is unattended When the lift truck is stationary place the forks or attachment on the ground place the gear lever in neutral 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 place the gear lever in neutral apply the parking brake and put the forward reverse lever in neutral Make sure that the lift truck is not stopped in any position that will interfere with the traffic and at less than one meter from the track of a railway In the event of prolonged parking on a site protect the lift truck from bad weather particularly from frost Check the level of antifreeze and ensure that the hood is properly secured INSTRUCTIONS Park the lift truck on flat ground or on an incline less than 15 Rele
62. fting to the right LEVER C controls the stabilizers The lever backwards when rising The lever forwards when lowering Do not attempt to alter the hydraulic system pressure by A CAUTION interfering with the pressure regulating valve In the event of suspected malfunction contact your dealer ANY ALTERATION MAY VOID THE WARRANTY 2 29 FORKLIFT SAFETY CONTENTS 18 REAR LIGHTS AND INDICATORS These lights function only while in the transport position attached to the tractor trailer lights A Turn indicators Brakelights Tail or running lights D Rear fog lamps optional 19 DOCUMENT HOLDER Store the Operator s Manual in the document holder under the driver s seat 20 LOAD CHART FILE TURBO MODELS This file includes the load chart for the Turbo Model Lift Truck and its attachments ALL MODELS EXCEPT TURBO The load chart decal s for all models except the Turbo Model Lift Truck are found immediately to the right of the driver at eye level FORKLIFT SAFETY CONTENTS MOUNTING THE LIFT TRUCK ON THE TRACTOR TRAILER Never mount the TMT Lift Truck to the trailer as shown below Use only the Mounting Kit as approved by Manitou North America Inc The approved kit mounts the lift truck below the trailer bed at the rear of the trailer Mounting the forklift higher than recommeded may result in damage to the lift truck serious FORKLIFT SAFETY CONTENTS Page 1 LOADING THE LIF
63. istance 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 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 VII 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 forkliftl NEVER operate or allow anyone to operate a forklift when mental
64. ition the HP valves to the X position 4 SLING THE LIFT TRUCK Take into account the center of gravity of the lift truck before lifting Fig 14 1 Place the hooks into the fastening points provided Fig 14 2 and 14 3 FORKLIFT SAFETY CONTENTS 5 TRANSPORT THE LIFT TRUCK ON A FLATBED TRAILER It is mandatory that the lift truck be backed onto the A WARN ING trailer in reverse and unloaded in forward motion Ensure safety procedures involving the flatbed trailer are observed before loading the lift truck and that the A WARNING driver has been informed about the dimensions and weight of the lift truck See chaper CHARACTERISTICS Ensure the flatbed trailer is the proper size and load Awa RNING capacity for transporting the lift truck Verify pressure point load capacity on the flatbed surface LOAD THE LIFT TRUCK Block chock the wheels of the semitrailer Use only approved capacity loading ramps avoid steep inclines Load the lift truck parallel to the semitrailer Stop and park the lift truck See DRIVING THE LIFT TRUCK in SECTION STOPPING THE LIFT TRUCK STOW THE LIFT TRUCK Fix the blocks to the semitrailer at the front and back of each tire Fig 15 1 Also fix the blocks to the semitrailer on the inside of the front wheels and on each side of the rear wheel Fig 15 2 Secure the lift truck to the semitrailer with approved straps or chains Utilize the tie downs pr
65. ive 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 operated 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 designate
66. k is running stop the engine immediately and determine the cause See oil level in engine crankcase FORKLIFT SAFETY CONTENTS B RED WATER TEMPERATURE LAMP If the warning lamp lights while operating the lift truck stop the engine immediately and allow it to cool Check the cooling system for leaks C RED HYDROSTATIC TRANSMISSION OIL FILTER CLOG LAMP The warning lamp lights when the oil filter cartridge is clogged or damaged Stop the lift truck and carry out the necessary repairs See cleaning and changing schedules in Filters cartridges and belts Note This lamp may light in cold weather when starting the truck it will go out when the hydraulic oil reaches its working temperature D RED AIR FILTER CLOG LAMP The warning lamp lights when the air filter cartridge is clogged Stop the lift truck and carry out the necessary repairs See cleaning and changing schedules in Filters cartridges and belts RED ALTERNATOR CHARGE LAMP If the warning lamp lights while operating the lift truck immediately stop the engine and check the electrical circuit as well as the alternator belt J RED PREHEATING LAMP The warning lamp lights when the operator turns the ignition key in preheating position and goes out when the operator turns the key in engine starting position 4 FUEL LEVEL GAUGE AND HOURMETER 1st Mounting S N 750268 amp below 2nd Mounting S N 750269 amp above A HOURMETER It shows the number of hours the
67. lection Mineral Oil Brake Reservoir 221322 or 234800 Location attached to the brake fluid reservoir Refer to the Operator Service Manual for the correct brake fluid mineral oil t0 be used in the brake system 221322 ATTENTION CUIDADO ACHTUNG ATTENZIONE _ LIQUIDE DE FREIN BRAKE LIQUID BREMSFLUESSIGKEIT LIQUIDO DE FRENO 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 olio minerale i 234800 n 234800 XIII FORKLIFT SAFETY CONTENTS SAFETY DECALS Hydraulic Oil 234798 or 76573 Location on the hydraulic tank or filler cap le N 234798 Identifies the hydraulic reservoir tank or filler cap Hydraulic Oil 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAULIC OIL HYDRAULIK L ACEITE HIDRAULICO OLIO IDRAULICO _ Identifies the hydraulic reservoir tank 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 30 C 40 C 22 F 40 Diesel Fuel 161101 Location on the fuel tank near the filler cap Identifies the fuel tank and use of diesel fuel No Step 496735 NOTICE Location varies depending on the forklift model Instructs pers
68. lock 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 FORKLIFT SAFETY CONTENTS 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
69. m 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 knowledgeable 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 lumbe
70. n oil filter cartridge 2 Fig E3 and replace it with a new one Make sure the cartridge is correctly positioned reinstall the cap Do not operate the lift truck without the oil filter cartridge Serious damage may result in the transmission hydraulic circuit the hydrostatic wheel motors and pump IMPORTANT E4 DRAIN AND CHANGE THE COOLING LIQUID These operations are to be carried out as necessary or at least once a year with the coming of winter Park the truck on level ground with the engine stopped and cold DRAINING THE LIQUID Open the engine compartment Place a container under drain plug 1 Fig E4 1 of the radiator Remove filler cap 2 Fig E4 2 from the radiator Allow the cooling circuit to drain completely Check the condition of the hoses and fastening devices Replace the hoses if necessary Rinse the circuit with clean water use a cleaning agent if necessary FILLING THE LIQUID Reinstall the drain plug 1 Fig 4 1 Fill the cooling circuit slowly up to 1 2 in below the filler port 3 Fig E4 2 Reinstall the filler cap 2 Fig E4 2 Let the engine run at idle a few minutes Check for leaks Check the level and refill if necessary FORKLIFT SAFETY CONTENTS E5 DRAIN AND CLEAN THE FUEL TANK While performing these operations do not smoke or Awarnine Park the truck on level ground with the engine stopped Check for leaks in the fuel circuit and tank
71. n oil filter cartridges Change the oil container breather Check the density of the battery electrolyte Check the wear of the forks Consult your dealer E Every 800 WORKING HOURS SERVICE To be carried out once a year if the lift truck has not reached the 800 hours service in the year E1 E2 E3 E4 ES EG E7 ES E9 Drain and change the hydraulic oil Clean the suction strainer for hydraulic oil tank Change the hydrostatic transmission oil filter cartridge Drain and change the cooling liquid Drain and clean the fuel tank N A Change the safety dry air filter cartridge Check the wear of the boom pads Consult your dealer Check the brake adjustment Consult your dealer E10 E11 E12 E13 E14 E15 E16 E17 N A Check the engine silentblocs Consult your dealer Check the engine speeds Consult your dealer Check the attachment carriage Consult your dealer Check the condition of the wheels and tires Consult your dealer Check the speeds of the hydraulic movements Consult your dealer Check the condition of the attachments Consult your dealer Clean the hydraulic pump tubular filter Consult your dealer F Every 1600 WORKING HOURS SERVICE F4 Change the Crankshaft Fan Alternator belt 0 C www 16 16 Lf 18 18 18 18 19 19 20 20 21 21 22 23 23
72. nd cracks change it if necessary Check the belt tension between the pulleys of the crankshaft and alternator Under a normal pressure exerted with the thumb the tension should be approximately 10 mm 3 8 Make adjustments if necessary Loosen screws 1 Fig C3 by two to three turns Swivel the alternator assembly to obtain the belt tension required Retighten screws 1 Fig C3 FORKLIFT SAFETY CONTENTS D EVERY 400 WORKING HOURS SERVICE D1 CHANGE THE DRY AIR FILTER CARTRIDGE The air used to burn the fuel is purified by dry air filters It is very important that the lift truck engine not be operated with the cartridges removed or damaged Open the engine compartment Loosen nut 1 Fig D1 and remove cover 2 Fig D1 Remove nut 3 Fig D1 lift out and discard the filter cartridge 4 Fig D1 Leave the safety cartridge in place Clean the inside of the casing with a clean damp lint free cloth Install the new cartridge and filter cover When operating the truck in a heavy dust environment see FILTERS CARTRIDGES AND BELTS for additional precleaner protection D2 CHANGE THE FUEL FILTER CARTRIDGE Open the engine compartment Carefully clean the exterior of the filter and bracket to prevent dirt from entering the system Remove and discard cartridge 1 Fig D2 and seals Clean inside the filter bracket using a brush immersed in clean diesel oil Reinstall a new cart
73. nformation 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 may 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 FORKLIFT SAFETY CONTENTS 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
74. ng filling AWARNING operations or when the tank is open Never refill while engine is running FORKLIFT SAFETY CONTENTS A4 CHECK THE TIRE PRESSURE AND THE WHEEL NUT TORQUE Check and adjust the tire pressure if necessary See CHARACTERISTICS SECTION SPECIFICATIONS Check the condition of the tires cuts protrusions wear etc Check the torque load on the wheel nuts Fig A4 NOTE Neglect of proper torque can cause damage and rupture to the wheel bolts and distortion of the wheels GREASING THE BOOM Clean and lubricate at the following points with grease See LUBRICANTS remove any surplus A5 LUBRICATORS OF BOOM AXLE 1 FIG A5 2 lubricators A6 LUBRICATOR OF CARRIAGE AXLE 2 FIG A6 1 lubricator A7 LUBRICATORS OF LIFTING CYLINDER FOOT AXLE 3 FIG A7 1 1 lubricator AND HEAD AXLES 4 FIG A7 2 1 lubricator A8 LUBRICATORS OF COMPENSATION CYLINDER FOOT AXLE 5 FIG A8 1 1 lubricator AND HEAD AXLE 6 FIG A8 2 1 lubricator A9 LUBRICATORS OF TILTING CYLINDER FOOT AXLE 7 FIG A9 1 1 lubricator AND HEAD AXLE 8 FIG A9 2 1 lubricator WHEEL TORQUE NUTS LOADING 12 kg m 87 ft lb FRONT WHEEL to 15 kg m 108 ft lb 12 kg m 87 ft lb REAR WHEEL to 15 kg m 108 ft lb FORKLIFT SAFETY CONTENTS A10 CLEAN AND GREASE THE BOOM PADS To be carried out every 10 hours during the first 50 hours service then once every 200 hours Fully extend the telescopic
75. ng 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 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 81910 184 Slings or 81926 251 Rigging equipment for material handling 7 Rigging equipment attached to the forks must be secured such that it cannot move either sideways 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 persomnel 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
76. on level ground with the engine stopped the boom retracted and lowered as far as possible Open the access compartment seat support Refer to gauge 1 Fig B2 The level is correct when it is midway between the upper and lower marks If necessary add oil See LUBRICANTS Add oil by filler port 2 Fig B2 Always maintain the correct oil level cooling depends on adequate oil flowing through the tank B3 CHECK THE BATTERY ELECTROLYTE LEVEL The factory installed battery is maintenance free requiring no service to the electrolyte Open the engine compartment Check the connections to the battery 1 Fig B3 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 See CAUTION on the following page FORKLIFT SAFETY CONTENTS 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 B4 CLEAN THE RADIATOR CORE Open the engine compartment
77. on the dash in direct view of the operator ALARM MUST SOUND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE The backup alarm must sound when the forklift is placed in reverse gear No Riders 420732 Location on the cab entrance s and on or near wheel fenders and engine cover A CAUTION Informs riders are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 DANGER Boom equipped models Location on both sides Stay clear of raised boom of the boom nose y 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 4h 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 FORKLIFT SAFETY CONTENTS SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of the operator near the hydraulic control lever Frame leveling notice load must be lowered Attachment and Boom Safety 801009 Boom equipped models Location on both sides of the boom nose Important reminders of attachment and boom safety Hydraulic Coupling 234805 Location near the quick disc
78. onnect 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 and clothing away from rotating fan and belts XII 4h DANGER READ OPERATOR S MANUAL ve al ground level before ng boom Do adjust frame e 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 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 KEEP HANDS AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 FORKLIFT SAFETY CONTENTS 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 Steering Mode 184276 4 wheel steer equipped models Location near the steering mode selection lever Identifies the steering mode se
79. onnel not to use the designated area as a step NO STEP Do Not Tow 494918 Hydrostatic equipped models Location on the dash in view of the operator A WARNING Towina the forklift will d the t ar THIS VEHICLE IS EQUIPPED WITH A Pide di e b 2 HYDROSTATIC TRANSMISSION DO A ne TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494918 XIV FORKLIFT SAFETY CONTENTS SAFETY DECALS Boom equipped models Location on the boom coupler WA R N N G near where the retaining shaft is 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 gt Hook Here 24653 EMI 24653 Location at points provided on the forklift where straps or chains may be attached to secure the forklift to a trailer during transport 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 models Location on the front and rear sides of the mast cross bracing A WARNING Keep fingers away from the mast KEEP FINGERS crossbracing CLEAR OF CROSSBRACING HA
80. ovided on either side of the forklift also secure the front end as shown Fig 15 3 Properly tighten the straps or chains FORKLIFT SAFETY CONTENTS 434
81. r stacking elevating shingles to the roof etc 9 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 and 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
82. ridge and seals If necessary bleed the fuel circuit See SECTION 11 D3 CHANGE THE HYDRAULIC RETURN OIL FILTER CARTRIDGE Open the seat support access compartment Remove the cover 1 Fig D3 Remove the hydraulic return oil filter cartridge 2 Fig D3 replace it with a new one Make sure that the cartridge is correctly positioned reinstall the cover D4 CHANGE THE OIL CONTAINER BREATHER Remove the cover 3 Fig D4 Remove the oil container breather 4 Fig DA and replace it with a new one Make sure that the oil container breather is correctly positioned reinstall the cover FORKLIFT SAFETY CONTENTS D5 CHECK THE DENSITY OF THE BATTERY ELECTROLYTE The factory installed battery is maintenance free requiring no service to the electrolyte If the original battery is replaced with a serviceable battery follow the manufacturer s instructions for maintenance D6 CHECK THE WEAR ON THE FORKS CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS E EVERY 800 WORKING HOURS SERVICE E1 DRAIN AND CHANGE THE HYDRAULIC OIL Park the lift truck on level ground with the engine stopped the boom retracted and lowered as far as possible DRAINING THE OIL Place a container under drain plug 1 Fig E1 1 and remove the plug Open the seat support access compartment Remove the filler cap 2 Fig E1 2 Remove the return filter cartridge 3 to ensure a correct draining Dispose of the
83. 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 FORKLIFT SAFETY CONTENTS ROUGH 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 excess
84. ss cover 2 Remove the plastic covers to gain access to the fuses the functions of the fuses are as follows n 1 Fuel level gauge hourmeter E 2 Load status indicator device 3 Sound alarm 4 Signal light panel 5 Brake solenoid valve block assembly 6 Gear reverser reverse gear horn reverse light f Flow divider 8 Working headlight OPTION NOTE Replace fuses with those of the same quality and capacity Never reuse a repaired fuse 11B FUSES 2ND MOUNTING Loosen both knobs 1 and lower the fuse box 2 Remove the plastic cover to access the fuses the functions of the fuses are as follows FUSES RELAYS 1 10A Hourmeter A Engine Solenoid 2 10A Not Used amp C Fwd Rev Relay 10 Horn amp Not Used 4 10A Warning Lights F ot Used 5 10A Brake Valve G ot Used 6 10A Fwd Rev Lever 7 10A Diff Lock 8 15 Park Switch Light 9 10A Work Lights 10 10A Beacon O 11 10A Not Used 12 10A Not Used 13 15A Not Used 2 14 5A Not Used 15 54 Stop O 16 10A Option 804178 12 SOCKETS FOR TRUCK TRAILER 1ST MOUNTING Uv These socke
85. 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 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 1 78 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 the 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 d
86. t damage to electrical components of vehicle being started make certain that the engine is at idle speed prior to disconnecting jumper cables 801015 MANITOU NORTH AMERICA INC 6 R 2 401 IMPERIAL D WACO TX 76712 www manitou na com MODEL NUMBER Location on the optional removeable forklift attachment UICE Important manufacturer information about the attachment Record this information for use when contacting the maufacturer for parts and service Overhead Guard Data Plate B6109 Location attached to the overhead guard Overhead guard conformity Forklift Data Plate 496550 Boom equipped models Forklift 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 YEAR OF MANUFACTURE COUNTRY OF MANUFACTURE UNLADEN WEIGHT LB CAPACITY LB 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 22113425095 0 THIS OVERHEAD GUARD CONFORMS ANSI DESIGN RECOMMENDATION _____ THIS OVERHEAD GUARD HAS PASSED AN IMPACT TEST OF L______ FT LBS DO NOT REMOVE THIS OVERHEAD GUAR
87. teed quality work Original replacement parts Help with preventive maintenance Effective help with diagnosing faults Enhancements gained from feedback Training for operating staff Only the manufacturer knows the details of the lift truck design and therefore has the best technological capability to carry out maintenance FORKLIFT SAFETY CONTENTS DRIVER S OPERATING INSTRUCTIONS WHENEVER YOU SEE THIS SYMBOL IT 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 safety 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
88. tion key to position Il to preheat for 15 seconds IMPORTANT Do not engage the starter motor for more than 15 seconds at a time Engage preheating for 10 seconds between unsuccessful starting attempts FORKLIFT SAFETY CONTENTS 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 up when the engine is warm and at regular intervals during use so as to quickly detect any faults and to be able to correct them without any delay If an instrument does not show the correct display stop the engine and immediately carry out the necessary operations D DRIVING THE LIFT TRUCK SAFETY NOTICE Always drive the lift truck with the forks or attachment at approximately 12 in from the ground i e In the travel position Familiarize yourself with the lift truck on the terrain where it will be used Ensure that the service brakes 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 make sure you are in control of your speed On damp slippery or uneven terrain drive slowly Brake gently never abruptly Only use the lift truck s forward reverse lever from a stationary position and never do so abruptly Do not drive with your foot on the brake pe
89. ts connect to the tractor trailer during transport supplying rear lighting PLI n i FORKLIFT SAFETY CONTENTS 12B SOCKETS FOR TRUCK TRAILER 2ND MOUNTING This single socket connects the trailer lights to the forklift for proper rear lighting during transport 13 OPENING LEVER ACCESS TO TANKS 14 ACCELERATOR PEDAL v E y Nees X 1 4 15 INCHING PEDAL Progressively cuts the hydrostatic transmission enabling a slow approach with full engine power 16 FORWARD REVERSE LEVER When operating this control the truck should be travelling at very low speed and not accelerating FORWARD Lift then push the lever forward Position A REVERSE Lift then pull the lever backward Position B NEUTRAL To start the truck the lever must be in neutral Position C NOTE When in reverse gear the backup alarm must sound indicating the lift truck is in reverse Also the backup light is illuminated 17 HYDRAULIC CONTROL DISTRIBUTOR LEVERS LEVER A Controls lifting the load and telescoping the boom The lever backwards when lifting The lever forwards when lowering The lever to the left for retracting The lever to the right for extending LEVER B Controls the tilt of the carriage and side shifting the boom The lever backwards when reverse tilt The lever forwards when forward tilt The lever to the left for side shifting to the left The lever to the right for side shi
90. uck or in the driver s cab B 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 See CHARACTERISTICS in SECTION 2 DESCRIPTION Before starting the lift truck check the different levels Engine oil Hydraulic reservoir oil Cooling liquid Braking oil Also check for possible leakage of oil fuel or liquid from the lift truck Check the closing and locking levers of the hood Whatever his 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 C STARTING THE LIFT TRUCK SAFETY NOTICE The operator must be correctly seated in the driver s seat seat belt adjusted and fastened before AAWARNING j operating the lift truck Never try to start the lift truck by pushing or towing it Such operation may cause severe damage to the transmission If necessary to tow the lift truck IMPORTANT inan emergency the transmission must be placed in the neutral position See H OCCASIONAL MAINTENANCE in SECTION 3 MAINTENANCE INSTRUCTIONS Make sure that the forward reverse 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 igni
91. ugh 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 not 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 affecti
92. your lift truck is valid for a weight with its center of gravity 24 in from the heel of the forks Fig A For a higher center of gravity consult your agent or dealer For irregular loads determine the center of gravity in the transverse right to left direction before handling Fig B TAKING UP A LOAD ON THE GROUND Direct the lift truck perpendicular to the load with the boom retracted and 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 Move the lift truck forward slowly 1 maneuvering the forks under the load Fig E If necessary slightly lift the boom 2 while taking up the load Apply the parking brake and place the forward reverse lever in neutral Lift the load further 1 incline the carriage slightly back 2 into the transport position Fig F TAKING UP A HIGH LOAD ON TIRES Ensure that the forks will pass easily under the load Position the lift truck perpendicular to the load with the forks in a horizontal position Fig G maneuvering gently and carefully Keep constant watch while placing the forks under the load Fig G use the shortest possible length of boom NEVER EXCEED RATED CAPACITY ASES FORKLIFT SAFETY CONTENTS Position the forks completely under the load Fig H Apply the parking brake and place the forward reverse lever in neutral

rough terrain forklift truck general safety standards

Contents

Download Pdf Manuals

Related Search

Related Contents