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5. 10 MVT 628 T 5 ASSEMBLING THE FORKS Position the lift truck in such a manner that the forks are in front aligned longitudinally to the truck Fig A Incline the fork holder forwards push against the forks and then hook them in the upper guide by slewing the boom backwards and raising it Fig B With the forks raised off the ground move them manually towards the centre of the fork holder to insert them in the lower guide and then move them outwards to the required operating width Fig C making sure that they are inserted correctly in the upper and lower guides Fit the fork safety screw in the fork holder blocking it by means of the lock nut Fig D
6. 22 ME CL DE 49 3 MVT 628 T MANDITORY SERVICING REQUIRED FIRST 50 100 HOURS WITHIN 3 MONTHS ENGINE Change engine oil Change engine oil filter Change fuel filter Clean air filter Tightness check injection power supply Check cooling circuit Check belt s tension Valve clearance HYDROSTATIC TRANSMISSION Change suction filter Clean Return filter as for assembly Check oil level Check transmission inching control adjustment AXLES TRANSFER BOX Change differential brake housing Change oil of reduction gears Lubrification of pivots hinges and controls Oscilation lubrification Change transfer box oil HYDRAULIC CIRCUIT Change return filter s Check oil level Check tightness BREAKING CIRCUIT Check service brake operation Check brake fluid level as for assembly BOOM UNIT Lubrification of telescope s Lubrification of all pivot pins Wear pads adjustment tightness SAFETY SYSTEM MANISCOPIC Check operation and adjustment ACCESSORIES OPTIONS Check operation CAB Check control panel and all instruments check and control heating and air conditioning ELECTRIC CIRCUIT Battery level checking Lighting operation WHEELS Wheel nut tightness pressures GENERAL LUBRICA
7. MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE Waco IX 76712 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com MVT628 T E2 OPERATOR SERVICE MANUAL S N 411786 amp above THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK IT MUST BE READ AND UNDERSTOOD BY THE LIFT TRUCK OPERATOR CATALOG 6483719 R11 10 MVT 628 T MIT 8283 Turba INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS SAFETY MESSAGES 2 VII ae osonse eer CUTE SE VIII TABLE OF CONTENTS XV OPERATING AND SAFETY INSTRUCTIONS SECTION 1 DESCRIPTION SECTION 2 MAINTENANCE SECTION 3 ELECTRICAL AND HYDRAULIC SECTION 4 PICKING UP THE ATTACHMENTS SECTION 5 R05 05 ROUGH TERRAIN FORKLIFT TRUCK GENEHAL SAFETY STANDARDS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS STUDY THE OPERATOR SERVICE MANUALS The information in this manual provides general instructions for the safe operation and maintenance of your forklift truck This information is vital and must be clearly understood by the operator and serviceman Study
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9. B1 Clean air filter cartridge A B2 Check hydraulic oil level B3 Clean radiator grille B4 Check brake circuit oil level B5 Clean and grease telescopic boom pads B6 Clean and grease cab door pins M B7 Clean and grease front and rear wheel pivot pins M Clean and grease telescopic boom pivot pin B B9 Clean and grease the quick release coupling pivot pin M B10 Clean and grease the lifting cylinder top and end pins Clean and grease the compensating cylinder top and end pins E B12 Clean and grease the slewing cylinder top and end pins E Clean and grease the two rear axle float bushings Clean and grease cross journals and cardan shaft B C EVERY 250 HOURS SERVICE C1 Check alternator belt crankshaft tension C2 Check front and rear axle differential oil level C3 Check front and rear reduction gears oil level C4 Check transmission box oil C5 Check battery D EVERY 500 HOURS SERVICE OR YEARLY e D1 Empty and change engine oil D2 Change engine oil filter D3 Change air filter cartridge D4 Change fuel filter cartridge D5 Change transmission oil filter D6 Change hydraulic oil filter cartridge exhaust 7 Change cab ventilation filter cartridge A MVT 628 T E EVERY 1000 HOURS SERVICE OR YEARLY e E1 Change air filter security cartridge A E2 Drain out and replace hydraulic oil Replace hydraulic oil filte
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11. ADJUST HEADLIGHTS RECOMMENDED SETTING As per standard ECE 76 756 76 761 ECE20 Set to 2 of the dipped beam in relation to the horizontal line of the headlamp ADJUSTING PROCEDURE Place the lift truck unloaded and in the transport position and perpen dicular to a white wall on flat level ground Fig G7 Check the tyre pressures See chapter A5 CHECK THE TYRE PRESSURES AND THE WHEEL NUTS TORQUE in paragraph 3 MAINTENANCE Put the gear reverser lever in neutral and engage the parking brake CALCULATING THE HEIGHT OF THE DIPPED BEAM h2 h1 Height of the dipped beam in relation to the ground h2 Height of the adjusted beam Distance between the dipped beam and the white wall h2 h1 I x 2 100 35 4 ELECTRICAL AND HYDRAULIC MVT 628 T 4 ELECTRICAL SYSTEM STARTER MOTOR The starter motor is installed on the left of the engine and no mainte nance is required except cleaning and tightening of the terminals If the starter motor does not work properly consult your agent or dealer ALTERNATOR The alternator is installed on the left of the motor The alternator and regulator are designed to operate in a system polarised in one direc tion only so the following precautions must be taken when working on the battery charging circuit otherwise serious damage may be caused to the electrical equipment Never operate the alternator with the circuit ope
12. 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 Provides information special instructions or references about the lift truck IMPORTANT Precautions which must be taken to avoid damage to the lift truck Indicates a potentially hazardous situation which if not avoided 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 Eng
13. front and rear are related to the oper ator seated normally facing forward in the operator s seat If you have any questions about the forklift con sult your supervisor Failure to fully understand or obey safety warnings can result in serious injury or death 4 WORK SITE KNOWLEDGE Before operating on a work site learn the rules for movement of people forklifts and all other traffic Check the size weight and condition of the loads you will be expected to handle Verify that they are properly secured and safe to transport Learn where the loads are to be placed planning your route for a safe approach watching for hazardous conditions Will a signal man be required to help place the load Remove any debris which may cause tire damage or rupture Plan your route around problem areas or have them cor rected Inform the supervisor of any unsafe conditions observed at the site Examples of hazards power lines cables low clearance structures garage doors telephone pole guide lines fencing loose lumber build ing materials drop offs trenches rough soft spots oil spills deep mud steep 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
14. 24 mm hex wrench a Unscrew bolts 13 Fig G4 7 and 14 Fig G4 8 on the front axle b Insert the U shaped shim 15 Fig G4 9 on the bolts C Screw bolts 13 Fig G4 7 and 14 Fig G4 8 flush against the U shaped shims The parking brake is now reactivated and the wheels are blocked 30 MVT 628 T 3 Reactivate the hydrostatic pump using a 10 mm hex wrench and a 6 mm Allen wrench a lie down under the hydrostatic motor and identify the two HP lim iting devices on top 16 Fig G4 10 and the bottom 17 Fig G4 11 b Release lock nut 18 Fig G4 12 and unscrew screw 19 Fig G4 12 to bring limiting devices HP to height X Fig G4 12 Block lock nut 18 Fig G4 12 The lift truck hydrostatic circuit is now activated Engage the parking brake Switch off the emergency lights Carefully remove the blocks from the four wheels and make sure the parking brake works perfectly 31 3 MVT 628 T 5 LOAD THE LIFT TRUCK Take into account the position of the lift truck gravity center and the weight of the truck for lifting Fig G5 1 Place the hooks in the fastening points provided 20 Fig G5 2 and 21 Fig G5 3 32 MVT 628 T G 6 TRANSPORT LIFT TRUCK TO A PLATFORM Ensure that the safety instructions connected to the platform are respected before the loading of the
15. ELIMINATE THIS RISK EXTEND THE TELESCOPIC SYSTEM FAR ENOUGH TO ELIMINATE THE INTERFERENCE THE DISTANCE WILL DEPEND ON THE TRUCK AND THE ACCESSORY The maximum loads are defined by the lift truck s capacity bearing in mind the weight and centre of gravity of the accessory If the capacity of the accessory is below that of the lift truck never exceed this limit MVT 628 T ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly positioned take the necessary precautions to move it in the conditions of maximum safety Check that the locking pin is engaged in the support provided on the frame Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement MANUAL LOCKING Take the locking pin on the support and fix the accessory Fig C Do not forget to fit the split pin MANUAL RELEASE Proceed in reverse direction to the MANUAL LOCKING procedure taking care to replace the locking pin in the support on the frame REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking care to
16. FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801009 Hydraulic Coupling 234805 Location near the quick disconnect adapters Stop the engine and release hydraulic pressure before changing attachments Rotating Fan and Belt s 801008 Location on the radiator near the fan and on any fan belt pulley cover s KEEP HANDS Keep hands and clothing away from rotating fan and belts AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 XII SAFETY DECALS Gear Shift Pattern 33460 4 transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift transmission 9zcval Steering Mode 184276 4 wheel steer equipped models Location near the steering mode selection lever Identifies the steering mode selection ki 221322 ATTENTION CUIDADO _ ACHTUNG ATTENZIONE Mineral Oil Brake Reservoir 221322 or 234800 has LIQUIDE DE BRAKE LIQUID been replaced by 164091 BREMSFLUESSIGKEIT Location near the brake fluid reservoir where applicable 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 Refer to the Operator Service Manual for the correct brake fluid mineral oil to b
17. Respect the safety notices and instructions given on the lift truck is compulsory to replace all plates or stickers which no longer legible or which have become worn or damaged B AUTHORISATION TO OPERATE Or refer to the legislation for each particular country Only qualified personnel may use the lift truck Its use is subject to authorisation to operate being given by the appropriate manager in the user establishment The user should always carry this authorisation to operate with him while he is using the lift truck The driver is not competent to authorise the driving of the lift truck by another person In addition the vehicle should be used in accordance with good prac tice for the profession C MAINTENANCE The user must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety notice The operator is prohibited from carrying out any repairs or adjustments himself unless he has been trained for this purpose He must keep the lift truck properly cleaned if this is among his responsibilities Carry out daily maintenance See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAINTENANCE Ensure tyres are adapted to the nature of the ground See area of the contact surface of the tyres in the chapter CHARACTERISTICS in paragraph 2 DESCRIPTION THERE ARE SAND tyres LAND tyres Snow chains There are optiona
18. Revolving flashing light 26 Steering wheel adjuster lever USEFUL ADVICE Regardless of the operator s experience in this sector he must learn the position and function of all instruments and controls on board before putting the fork lift truck into operation When the ignition key is turned without starting the engine a test is automatically performed on the instrumentation all the lights come on and a beeper sounds this stops once the engine has started A check must be made on all the truck s instruments immediately after start up once the engine has warmed up and at regular inter vals during use so that any malfunctions can be noted at once and put right without delay If the instrument is not giving a correct reading stop the engine and take the necessary measures to restore correct operation immediately Using the fork lift truck without following these recommendations may have dangerous consequences 2 MVT 628 T 1 DRIVER S SEAT STANDARD FOR ENHANCED COMFORT THIS SEAT ALLOWS VARIOUS ADJUSTMENTS WEIGHT ADJUSTMENT The seat should be adjusted to the driver s weight with no one sitting on it Take the seat notch A as reference Turn the knob B as appropriate to the driver s weight N B To avoid health problems the weight setting should be checked and adjusted before the truck is put into operation ADJUSTING THE SEAT HEIGHT Bring the seat to the desired pos
19. SWITCH On off switch for rear window wiper OPERATING MODE Activating the two position switch will engage the operating system concerned for operating slowly and with greater precision The switch can also be engaged with the lift truck movin 13 2 MVT 628 T 5 STEERING SELECTION LEVER Fig 5 Before selecting one of the three steering options align the 4 wheels GERE SUELE SHORE with the axis of the truck MOVIMENT HIGHWAYS STEERING A Front and rear wheel steering in the same direction sideways or crab movement B Front wheel steering use on public highways C Front and rear wheel steering in opposite directions short or con centric steering Wheel alignment procedure Shift the steering selection lever to position C turn the steering wheel till the rear wheels are aligned shift the steering selection lever to posi tion B turn the steering wheel till the front wheels are aligned When both front and rear wheels are aligned one of the three types of steering mentioned above can be selected Wheel coordination may deteriorate with use carry out wheel re align ment as described in the procedure at least after every 20 hours ser vice 6 LIGHT HORN AND DIRECTION INDICATOR CONTROL LEVER Fig 6 The lever controls the lights and horn A Lights off direction indicator lights not working B Direction indicator lights signalling right C Direction indicator lights signalling le
20. Switch on the emergency lights Deactivate the hydrostatic pump using a 10 mm hex wrench and a 6 mm Allen wrench a lie down under the hydrostatic engine to identify the two HP limit ing devices on top 6 Fig G4 1 and the bottom 7 Fig G4 2 b Identify height X Fig G4 3 on both HP limiting devices C Release lock nut 8 Fig G4 3 and tighten screws 9 Fig G4 3 to reach the level of the lock nut 28 MVT 628 T 3 Deactivate the action of the negative parking brake using a 24 mm hex wrench a Unscrew bolts 10 Fig G4 4 and 11 Fig G4 5 on the front axle b Remove the U shaped shim 12 Fig G4 6 positioned on the bolts C Screw bolts 10 Fig G4 4 and 11 Fig G4 5 flush back in their seats Place danger or warning notices on the steering wheel and ignition key to indicate the lift truck status Carefully remove the blocks from the four wheels only after securing the lift truck to the means used for towing vehicles In the absence of hydraulic servo assistance for direction and brakes act gradually and forcefully on these two controls Avoid sudden jerky movements 29 3 MVT 628 T REACTIVATING NEGATIVE BRAKE AND HYDROSTATIC TRANS MISSION OF THE LIFT TRUCK Before freeing the lift truck from the vehicle towing means block all the four wheels to prevent accidental movement Activate the action of the negative parking brake using a
21. VC Tilting cylinder VL Lifting cylinder VT Extension cylinder 4 MVT 628 T HYDRAULIC BRAKE STEERING MVT 628 T KEY TO HYDRAULIC BRAKE STEERING D Directional control valve DS Steering directional control valve F A Intake filter F R Drain filter FDAV Front axle disc brake FS Parking brake I D Power steering unit L S Load sensig M C Brake pump M V Fan motor P Gear double pump PI Hydrostatic pump P F Brake pedal R Hydraulic fliud tank RFS Lever brake of parking S Brake hydraulic fliud tank SM Valve for telescope and option control V D Steering cylinder MVT 628 T l L 1 OS NOISSINSNVAL _ Jana 18 MVT 628 T KEY TO HYDRAULIC TRANSMISSION EVDC Double displacement solenoid valve F A Intake filter F R Drain filter M Engine Hydrostatic motor P I Hydrostatic pump R Hydraulic fluid tank V I Inching valve 19 5 PICKING UP THE ATTACHMENTS MVT 628 T 5 INTRODUCTION The manufacturer makes available with warranty a vast range of accessories perfectly suited to your lift truck The accessories are supplied complete with a load diagram relating to your truck The user manual and the load diagram must be kept on the truck The use of the possible accessories is subject to the instructions in this manual Som
22. and allow it to idle for a few minutes Check that there are no leaks from the drain hole or oil filter Stop the engine wait a few minutes and then check the level using the relative dipstick 4 Fig D2 4 Top up if necessary 16 MVT 628 T 3 D 3 CHANGE AIR FILTER CARTRIDGE The air used to burn the fuel is purified by a dry air filter The lift truck should never ever be used if the air filter has been removed or is dam aged Slacken nut 5 Fig D3 1 remove cover 6 Fig D3 1 Now unscrew nut 7 Fig D3 2 that fixes filtering cartridge 8 Fig D3 2 remove this latter and discard Clean the inside part of the filter with a damp clean lint free cloth Never ever use compressed air Fit a new cartridge in place of the old one see FILTER ELEMENTS AND BELTS Table and fix it with wing nut 7 Fig D3 2 Replace cover 6 Fig D3 1 with the valve pointing downwards and lock it in place with nut 5 Fig D3 1 D 4 CHANGE FUEL FILTER CARTRIDGE The combustible material of some components of the engine for example certain seals can become extremely dangerous if it is burned Never allow this burnt material to come into contact with the skin or with the eyes Ensure that the starter switch is in the off position before servicing or repairs are made to the fuel system because fuel will be released if the lift pump has power Do not allow dirt to enter the fuel system Before a connect
23. and recently excavated or filled ground Never leave the engine running unattended Use the parking brake when depositing difficult loads or on sloping ground Never leave the truck parked with a raised load Never authorise anyone to approach or pass below a load Always think of safety and only transportwell balanced loads Never lift a load using one fork only Drive with care and with reflexes alert When the lift truck is not in use lower the forks to the ground and engage the parking brake Never leave the ignition key in the truck unattended 1 MVT 628 T Never leave the truck loaded on a gradient of over 1596 even with the parking brake engaged When lifting a load take care that nothing and no one interferes with the movement and adopt proper handling procedures only Comply with the data provided in the load diagrams Never transport another person on the lift truck With every change of equipment to avoid damaging the hydraulic pipe unions stop the 1 engine turn key to position release pressure from the circuit using the joystick Always check these pipe unions to ensure they are clean MVT 628 T GENERAL INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Read the operator s manual carefully making sure you understand it The operator s manual must always be kept in the lift truck in the place provided and in the language understood by the operator
24. brake applied on an incline which exceeds 15 15 1 MVT 628 T E VISIBILITY Constantly keep clear visibility of the road either direct view looking backwards when reversing or indirect view using the panoramic rear view mirrors to check for people animals holes obstacles change of slope etc Since visibility can be reduced on the right side when the jib is raised ensure clear visibility of the road before raising the jib and before undertaking any manoeuvres If the visibility in forward motion is not sufficient because of the bulki ness of the load drive in reverse motion This manoeuvre must remain exceptional and for short distances Ensure you have good visibility Clean windows adequate lighting correctly adjusted rear view mirror etc Signaling and lighting on the lift truck must take account of the condi tions of use The standard lighting system may not be sufficient for cer tain applications or night time road use Optional accessories are available Consult your agent or dealer IF NECESSARY CONSULT YOUR DEALER 16 MVT 628 T 1 LOAD HANDLING A WEIGHT OF LOAD AND CENTRE OF GRAVITY Carrying a load greater than the rated capacity for the lift truck or for the attachment is prohibited Before taking up a load you must know its weight and its centre of gravity The load chart relating to your lift truck is valid for a weight with its cen tre of gravity 24 in from the he
25. check that there is enough fuel in the tank and that the engine is at a standstill Unscrew drain plug 3 Fig A4 1 of the filter 4 Fig A4 2 two three turns and allow the fuel to drain out until it is free from impurities Screw the drain plug back on while the fuel it still draining Do not smoke and do not approach the vehicle with a flame when fill ing the tank or when the tank is open Never fill the tank when the engine is on If the tank has been empty for an extended period of time or if the fork lift truck has run out of fuel operate the lift pump for one minute to eliminate air from the filter Start the engine and check for leaks 3 MVT 628 T A 5 CHECK TYRE PRESSURE AND TIGHTENING OF WHEEL NUTS Fig A5 Check and adjust the tyre pressure if necessary see Specifications chapter WHEEL NUT TORQUE LOADING Check the condition of the tyres There should be no cuts signs of _ wear etc 465 ft Ib FRONT WHEEL REAR WHEEL 465 ft lb Check that the wheel nuts are correctly torqued see Table Fig A5 Follow these instructions to prevent breakage which could lead to accidents A 6 CHECK GREASING OF TELESCOPIC BOOM SLIDING BLOCKS Extract telescopic boom completely and check to make sure the tele scopic boom sliding blocks are greased properly if they are to be greased see point B5 MVT 628 T 3 B EVERY 50 HOURS SERVICE B 1 CLEAN AIR FILTER CARTRI
26. engine and check for leaks 17 3 MVT 628 T D 5 CHANGE TRANSMISSION OIL FILTER Using a suitable wrench remove transmission oil filter 14 Fig 05 1 and discard it together with the seal Clean the filter bracket with a clean lint free cloth Fill the new filter with oil see LUBRICANTS Table then fit it in place by hand checking that the seal which will have been previous ly lubricated has been correctly positioned Start the truck and check that there are no leaks To check the efficacy of the filter see the indicator 15 Fig D5 2 D 6 CHANGE HYDRAULIC OIL FILTER CARTRIDGE EXHAUST Using a suitable wrench remove hydraulic oil filter 16 Fig 06 and discard it together with the seal Clean the filter bracket with a clean lint free cloth Fill the new filter with oil see LUBRICANTS Table then fit it in place by hand checking that the seal which will have been previous ly lubricated has been correctly positioned Start the truck and check that there are no leaks D 7 CHANGE CAB VENTILATION FILTER CARTRIDGE Remove strap 17 Fig 07 Remove cab ventilation filtration cartridge 18 Fig 07 Clean the filter using a jet of compressed air Check the filter and if necessary replace with a new cartridge having the same features see FILTER ELEMENTS AND BELTS Table Refit the filter and strap 18 MVT 628 T 3 E EVERY 1000 HOURS SERVICE O
27. engine immediately and check the electrical system and the fan belt B RED ENGINE OIL PRESSURE LIGHT If the light and buzzer are activated during operation of the fork lift truck stop the engine immediately and look for the origin of the fault See oil level in engine sump C RED WATER TEMPERATURE INDICATOR LIGHT If the light and buzzer are activated during operation of the fork lift truck stop the engine immediately and look for the origin of the fault in the cooling circuit 10 MVT 628 T D RED AIR FILTER FOULING LIGHT The light and buzzer are activated when the air filter cartridge is fouled Switch off the truck and make the necessary repairs see frequency of cleaning and replacement procedures E LIGHT NOT USED F LIGHT NOT USED G RED BRAKE FLUID LEVEL LIGHT If the light and buzzer are activated during operation of the fork lift truck stop the engine immediately and check the brake fluid level If the level is relatively low contact your agent or dealer H RED LIGHT PARKING BRAKE The light indicates that the parking brake has been pulled on GREEN DIRECTION INDICATOR LIGHT This light comes on at the same time as the direction indicators and shows that they are operating correctly L GREEN LIGHT SIDE LIGHTS This light illuminates when the side lights are in operation M GREEN DIPPED HEADLIGHT LIGHT This light illuminates when the dipped headlights are switch
28. lift the load vertically NEVER drag it horizontally 4 Use multiple pickup points on the load when possible Use taglines to restrain the load from swinging and rotating 5 Start travel turn and stop SLOWLY to prevent the load from swinging DO NOT exceed walking speed 6 Inspect rigging before use Rigging must be in good condition and in the U S comply with OSHA regulation 1910 184 Slings or 1926 251 Rigging equipment for material handling T Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft The load center must not exceed 24 inches 610 mm 8 DO NOT lift the load with anyone on the load rigging or lift equipment and NEVER lift the load over personnel 9 Beware of the wind which can cause suspended loads to swing even with taglines 10 DO NOT attempt to use frame leveling to compensate for load swing U S OSHA regulations effective November 8 2010 29 CFR Part 1926 Subpart CC Cranes and Derricks in Construction include requirements for employers that use powered industrial trucks forklifts configured to hoist 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
29. of the lift truck are due to non application of the basic safety instructions By being aware of the risks to which you are exposed and by taking the necessary preventive measures you should be able to avoid accidents occurring Any operation or manoeuvre not described in the instructions is pro hibited 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 manu al and on the lift truck are not exhaustive Any bending of the rules in safety notices or the user maintenance or repair instructions for your lift truck may result in serious or even fatal accidents We would remind users of the risks in driving at excessive speed with regard to traffic conditions particularly Risk of loss of control on a poor quality track 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 be maintain his own safety that of others and of his equipment Always be aware of his stopping distance MVT 628 T On the basis of experience there are a number of possible situations in which operating the lift truck is contra indicated Such foreseeable abnormal uses the main ones being listed below are strictly forbidden Th
30. 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 Hook Here 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 ge Mast equipped models Location on the front and back side of the mast s outer rails A WARNING 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 _ WARNING Keep fingers away from the mast KEEP FINGERS crossbracing CLEAR OF CROSSBRACING HAND THROTTLE DANGER 804784 Boom equipped models option Location Near the hand throttle mechanism Reminder to operator set parking brake before operating hand throttle Disengage hand throttle before leaving the forklift A 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 SAFETY DECALS DANGER Acid in Battery 601014 EXPLOSION
31. parking brake engaged on gradients exceeding 1590 With the winch or equipment with a load hanging from the hook always adopt the following precautions Position the winch perpendicular to the load to be lifted The empty hook must be lowered slowly gently since if it is operated too quickly the cable wound round the drum may become slack causing serious problems for the cable the limit stop device etc If the cable tends to become twisted around the block release the fixed end hook pull the cable in the opposite direction until the twisting is eliminated then re connect the end unit Operate the control lever gently to prevent jerking of the load and possible problems in the winding of the cable onto the drum Raise the load vertically avoiding swaying and slanting lifting Check the cable daily if it is worn or damaged or has even one broken strand see ISO 4309 replace it immediately contact your dealer Check that the hydraulic hook raising and lowering limit stop is in good working order and that the brake holds with load applied Oil the revolving part of the hook periodically Check periodically that the cable is winding onto the drum correctly The following accessories are not intended for systems for lifting or moving people MVT 628 T 5 In view of their size when the boom is lowered and retracted some accessories may interfere with the front tyres and damage them if the board is tilted downward TO
32. 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 ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont D SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level Transporting suspended loads must ALWAYS be done slowly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid overturn The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards Grades and sudden starts stops and turns can cause the load to swing and create a hazard Guidelines for Free Rigging 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
33. place it in a safe position on firm flat ground MVT 628 T 5 ACCESSORY WITHOUT HYDRAULIC SYSTEM AND HYDRAULIC LOCKING OPTIONAL ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly positioned take the necessary precautions to move it in the conditions of maximum safety Check that the rods of the locking cylinder are retracted Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement HYDRAULIC LOCKING AND RELEASE OPTIONAL The accessory if any is locked and released using the optional con trol which may be operated by a push button or using the control lever itself depending on the type of truck For further information refer to the use and maintenance manual provided with the truck REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking care to place it in a safe position on firm flat ground MVT 628 T ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly po
34. temperature inside the cab C Valve closed fan delivering cold air D Valve completely open fan delivering warm air The intermediate positions allow regulation of the temperature 17 VENTILATION OUTLETS These allow direction of the ventilation jets inside the cab they are placed in the top of the cab Fig 17 1 and near the driver s feet Fig 17 2 AP Fig 17 1 17 2 18 MVT 628 T 18 CEILING LIGHT Fig 18 The switch is incorporated in the light unit It has two positions constant lighting and off 19 DOOR LOCK Outside lock To open the door take hold of the handle A Fig 19 1 and pull it outward Two keys for locking the cab are supplied with the truck Inside lock To open the door take hold of the handle B fig 19 2 and pull it inward 20 REAR WINDOW OPENING LEVER To open the rear window pull the lever C Fig 20 clockwise to the right and push on the window 19 2 MVT 628 T 21 UPPER HALF DOOR LOCK Closed position To open push the lock A Fig 21 1 down To close simply pull the handle B Fig 21 1 inward Open position Push the door towards the cab to engage in the bolt C Fig 21 3 To release press the knob D Fig 21 2 or use the lever E Fig 21 3 22 TOWBAR Fig 22 On the rear of the truck the towbar allows towing of a trailer For each truck the towing capacity is limited by the total authorise
35. the carriage sloping backwards For obvious reasons regarding the lift truck s stability and clear visibil ity of the surrounding environment only move the lift truck when the jib is in the transport position Do not manoeuvre the lift truck with the jib 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 ade quate and get another person to guide you along if necessary Never shift the position of the load while the lift truck is in motion Never drive too fast or brake abruptly when carrying a load During handling drive at low speed Check the load particularly when turning corners and especially if it is very bulky Secure unstable loads Handle loads with caution at slow speed without sudden jerks when moving them at significant heights and jib extention In the event of high winds or storms do not carry out handling work that jeopardizes the stability of the lift truck and its load Do not change direction sharply and at high speed In the event of the lift truck overturning do not try to leave the cab DO NOT TRY TO JUMP CLEAR STAY IN THE CAB WITH YOUR SEAT BELT FASTENED Apply the parking brake when lifting or depositing a difficult load or when on an incline Do not stop the lift truck with the load in an elevated position Do not leave a laden lift truck with the parking
36. the coolant is removed from the engine This is important if the system is drained after it has been flushed with water or if an antifreeze solution too weak to protect the system from frost has been used Tighten drain plugs 2 Fig G1 2 and 1 Fig G1 1 again Slowly fill the cooling system until the fluid reaches 1 2 in below the filling neck Screw fill plug 3 Fig G1 3 back on again Leave the engine to idle for a few minutes Check that there are no leaks Check that the level is more or less at the base of the filler cap and top up with more liquid if necessary The engine has no anti corrosion elements and must be filled all year round with a mixture containing at least 25 anti freeze 25 G 2 CHECK INJECTOR MAINTENANCE A faulty atomiser must be renewed by a person who has had the cor rect training Regular maintenance of the atomisers is not necessary The atomiser nozzles should be renewed and not cleaned and renewed only if an atomiser fault occurs Some of the problems thet may indicate that new nozzles are needed are listed below Engine will not start or is difficult to start Not enough power Engine misfires or runs erratically High fuel consumption Black exhaust smoke Engine knocks or vibration Excessive engine temperature CONSULT YOUR AGENT OR DEALER 26 MVT 628 T MVT 628 T 3 G 3 REPLACE A WHEEL In the event of a wheel bei
37. the maufacturer for parts and service ETA CAPACITY LB HORIZONTAL CENTER OF GRAVITY OPERATING PRESSURE PSI 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 425995 Overhead Guard Data Plate B6109 Location attached to the overhead guard THIS OVERHEAD GUARD CONFORMS TO ANSI DESIGN RECOMMENDATION THIS OVERHEAD GUARD Overhead guard conformity HAS PASSED AN IMPACT TEST OFL JFT LBS DU NOT REMOVE THIS GUARD 496550 496538 MANITOU MANITOU NORTH AMERICA INC Forklift Data Plate 496550 Boom equipped models Forklift Data Plate 496538 MANITO MANITOU NORTH AMERICA INC Mast equipped models WACO TX 76712 Ld Location within the operator s compartment www manitou na com TRUCK MODEL Important forklift truck identification Record mu os UNLADEN WEIGHT ES this information for use when contacting the uNLADEN WEIGHT YEAR manufacturer for parts and service BL MAX CAPACITY Ru up TO 6 MAX CAPACITY LBS AT MFH iux TIRE PRESSURE FRONT es TRE PRESSURE REAR EEE psi CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH FORK UPRIGHTS VERTICAL FOR OTHER CAPACITIES CONTACT THE FACTORY
38. 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 jewellery and loose clothes Tie and protect your hair if nec essary Ensure the area is sufficiently ventilated before starting the lift truck Make sure that the disposal of process materials and of spare parts is carried out in total safety and ecological way Carry out all repairs immediately even if the repairs concerned are minor Repair all leaks immediately even if the leak concerned 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 or safety valves which may be fitted to the cylinders of your lift truck can be dangerous A balancing valve must only be removed when the cylinder concerned is at rest and the hydraulic circuit is depressurised This operation can only be carried out by authorised staff Do not smoke or approach the lift truck with a flame when 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
39. 460 7991 yoyms Jadim usa os do pue 5 USSJISPUIM 140 4 2461 yay ms 1460 Adus lswsg MVT 628 T Old 6d 14 9d Gd Vd Ld EEIN LW 9N GIN VIN CIN LIN LL I 011 61 81 41 97 Vi L1 Key vel Gel vcl CCl yms 1euonipuo2 81 uoyAs 1669 4 JSUONIPUO 2 q8e Gg qei uos jene 1 q81 5 1669 4 1461 99 eJunsseJd 1311 9984 G qe1 yoyms eJunsseJd 9984 2e uoo eJnjeJeduue 9IMNeIp H 9991 4 2 4 qe1 YIMS qe qei YIHMSOJIILU L qey Alddns Jamod vog 9514 298 pesn JON WOE 9604 2981 pesn JON 9514 1 pesn JON 9514 1991 5 1569 4 ve 9614 2984 pesn jou Ajddns Jamod 2 asny 9 qei uiejs s woog VOL 9514 y qe1 pesn JON asny p qey 1401 vor qei Ajddns voL 9514 c qei 10
40. 700 kg 12566 Ibs Vibrations Arm accaleration lt 2 5 m s Body feet or seated part acceleration lt 0 5 m s Noise level The noise level guaranteed LwA 105 dB in accordance with Directive 2000 14 CE modified by Directive 2005 88 CE Acustic pressure level in the driving seat in accordance with EN 12053 LpA 80 8 dB MVT 628 T 14 43 ft 21 23 ft 11 88 ft 6 53 ft 7 35 ft 17 39 ft 7 84 ft 15 09 ft 123 12 1 57 in MVT 628 T 2 LOAD CHART LOAD CHART WITH FORKS 019001857 30 22 N 211742 2 MVT 628 T INSTRUMENTS AND CONTROLS MVT 628 T DESCRIPTION Driver s seat Seat belt Monitoring instrument and indicator light panel Switch console Steering selection lever Light horn and parking light lever Key switch Casing giving access to brake fluid tank and windscreen washing liquid 9 Brake fluid tank 10 Windscreen washing liquid tank 11 Casing giving access to fuses and relays 12 Accelerator pedal service brake and inching pedal 13 Direction reverser lever 14 Hydraulic parking brake lever 15 Hydraulic movement controls 16 Heating controls 17 Ventilation inlets 18 Ceiling light 19 Door lock 20 Rear window opening lever 21 Upper half door lock 22 Towbar 23 Front lights 24 Rear lights 25
41. 95 F correct levels of lubricants in all the circuits are checked in production For operation under more severe climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the rele vant ambient temperatures It is the same for the cooling liquid For more information contact your agent or dealer Protection against frost See chapter LUBRICANTS AND FUEL in paragraph 3 MAINTENANCE Adaptation of lubricants Ask your dealer for information Engine filtration Lighting Working headlight Optional solutions exist consult your dealer Use of a lift truck is prohibited in protected areas e g refinery explo sive atmosphere For use in these areas specific equipment is avail able as an option Consult your dealer IF NECESSARY CONSULT YOUR DEALER MVT 628 T 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 cab The operator must always be in his normal position in the driver s cab It is prohibited to have arms or legs or generally any part of the body protruding from the driver s cab of the lift truck Always re
42. AKING UP A HIGH LOAD Under no circumstances should you pick up a load if the lift truck is not in a horizontal position Ensure that the forks will easily pass under the load Position the lift truck perpendicular to the load with the forks in a hor izontal position Fig G manoeuvring gently and carefully See para graph E VISIBILITY in the chapter HANDLING INSTRUCTIONS for visibility of the road Always think about keeping the distance necessary to fit the forks under the load between the pile and the lift truck Fig G and use the shortest possible length of Jib Stop with the forks in front of the load Fig H Engage the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 and incline the forks carriage 2 backwards to stabilize the load Fig 1 Tilt the load sufficiently backwards to ensure its stability loss of load on braking without upsetting the balance of the load in so doing If possible lower the load without shifting the lift truck Lift the jib 1 to release the load retract 2 and lower the jib 3 to bring the load into the transport position Fig J this is not possible back the lift truck up Manoeuvring very gently and carefully See paragraph E VISIBILITY in the chapter HANDLING INSTRUCTIONS for visibility of the road back up the lift truck 1 to release the load retract 2 and lower the jib 3 to bring the load into th
43. ANCE CONSULT YOUR DEALER 21 1 MVT 628 T BEFORE STARTING UP A NEW LIFT TRUCK INTRODUCTION Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the mechanic However before commencing to operate 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 the controls and instruments before operating the lift truck Do not attempt to start a new lift truck before the following checks have been carried out LUBRICATION Check that all the correct grades of oils and greases that are required are available see chapter SERVICING SCHEDULE in paragraph 3 MAINTENANCE and top up if necessary For operation under average climatic conditions i e between 5 F and 95 correct levels of lubricants in all the circuits are checked in production For operation under more severe climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the relevant ambi ent temperatures It is the same for the cooling liquid Contact your dealer for information if necessary
44. AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS DESIGN STANDARDS ANSI ASME MANUFACTURED IN TIRE PRESSURE FRONT RR psi TIRE PRESSURE REAR GROUND FOR CAPACITIES REFER TO THE APPROPRIATE LIFT CHART OR CONTACT THE FACTORY AS RELFASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME B56 6 MANUFACTURED IN XVI MVT 628 T TABLE OF CONTENTS 1 INSTRUCTIONS ORIGINAL SPARE PARTS AND TOOLS 1 USER INSTRUCTIONS FOR THE LIFT TRUCK OPERATOR 2 Warnings 2 General instructions 5 Driving instructions 7 Handling instructions 1 Load Handling 1 LIFT TRUCK MAINTENANCE INSTRUCTIONS 20 BEFORE STARTING UP A NEW LIFT TRUCK 22 2 DESCRIPTION SPECIFICATIONS DIMENSIONS LOAD CHART INSTRUMENTS AND CONTROL a 3 MAINTENANCE FILTERING ELEMENTS AND BELTS 1 LUBRICANTS 3 MAINTENANCE SCHEDULE 4 A Daily or every 10 hours service 6 B Every 50 hours service 9 C Every 250 hours service 14 D Every 500 hours service or yearly 16 E Every 1000 hours service or yearly 19 F Every 2000 hours service or yearly 24 G Occasional or annual maintenance 25 4 ELECTRICAL AND HYDRAULIC SYSTEM ELECTRICAL SYSTEM Electrical system key Wiring diagram Tables NO HYDRAULIC UNIT 14 Hydraulic movements 14 Hydraulic steering and brakes 16 Hydraulic transmission 18 5 PICKING UP THE ATTACHMENTS INTRODUCTION GENERAL RECOMMEND
45. ATIONS FOR USE OF ALIFT TRUCK 2 ACCESSORY WITHOUT HYDRAULIC SYSTEM AND MANUAL LOCKING 4 ACCESSORY WITHOUT HYDRAULIC SYSTEM AND HYDRAULIC LOCKING OPTIONAL 5 ACCESSORY WITH HYDRAULIC SYSTEM AND MANUAL LOCKING OPTIONAL 6 ACCESSORY WITH HYDRAULIC SYSTEM AND HYDRAULIC LOCKING OPTIONAL 7 USING THE ITA TYPE FORK HOLDER 8 XV MVT 628 T INTRODUCTION Our telescopic fork lift trucks are designed with the sole aim of offering the operator extremely simple operation and the mechanic the easiest possible maintenance However before putting the truck into operation for the first time the operator must read this manual and make sure he understands the various topics it covers it has been drawn up to help to solve any operating and maintenance problem Following these instructions the operator will be able to make full use of his telescopic fork lift truck s potential Right left forward and back are as seen by someone in the truck driver s seat looking forward When ordering spare parts or for all information of a technical nature users are requested always to specify Constructor s nameplate FIG 1 Model eee Series MEE Serial N MANITOU nn O Year of manufacture WACO TY 76712 www manitou na com TRUCK MODEL SERIAL mues uncacen TIRE PRESSURE FRONT __ TIRE PRESSURE FOR CAPACITIES REFER THE APPROPRIATE LIFT CHART OR CON
46. DGE Unscrew nut 1 Fig B1 1 and remove cover 2 Unscrew nut 3 Fig B1 2 fixing cartridge 4 Use compressed air to clean the cartridge directing the jet from the inside towards the outside Clean the inside part of the housing of the filter with a clean damp lint free cloth protecting the engine input tube Check the state of the cartridge Defective cartridges must be immediately replaced Refit cartridge 4 Fig B1 2 inside the filter and fix it in place with nut 3 Fig B1 2 Fit cover 2 Fig B1 1 in place with the valve pointing downwards and fix it with nut 1 Fig B1 1 Never ever wash an air filter cartridge B 2 CHECK HYDRAULIC OIL LEVEL Position the truck on a flat surface with the engine switched off and the telescopic boom retracted and raised as high as possible and with the slewing cylinder closed Unscrew filler plug 5 Fig B2 1 The oil level is correct when it covers the dipstick by about 2 cm 6 Fig B2 2 If necessary top up with oil see LUBRICANTS Table through filler hole 5 Fig B2 1 Always keep the oil at the maximum level to ensure optimum perfor mance Fig B2 2 3 MVT 628 T B 3 CLEAN RADIATOR GRILLE To prevent the radiator from clogging it must be cleaned with a jet of compressed air from the inside towards the outside Fig B3 This is the only way to clean off the debris B 4 CHECK BRAKE CIRCUIT OIL L
47. DRY AIR FILTER Ensure that the air filter is undamaged and not blocked Tighten the fastening devices if necessary Never run the 1 C engine with the air filter removed or damaged COOLING CIRCUIT Always check the cooling liquid level before starting up the lift truck HYDRAULIC CIRCUIT Visually check for leakage or oil leaks from the connections hoses pipes and unions Tighten or check the defective connections if nec essary Also check the oil level in the tank 22 MVT 628 T 1 BRAKING SYSTEM Check by a visual examination that there are no leaks or oil oozing in the hoses connections and unions If necessary tighten or repair the defective connections Also check the oil level in the tank Use only the recommended oil to avoid damaging the brake circuit see chapter LUBRICANTS in section 3 MAINTENANCE TYRES Make sure that the wheel nuts are correctly tightened See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAIN TENANCE and that the tyre pressures are correct See chapter CHARACTERISTICS in paragraph 2 DESCRIPTION FUEL SYSTEM Check that all fuel lines are secured 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 chapter B EVERY 50 HOURS SERVICE in paragraph 3 MAIN TENANCE Check the components of the electrical sy
48. ETY PRACTICES cont 7 Where steering can be accomplished with either hand and the steering mechanism is of a type that pre vents road reactions from causing the handwheel to spin power steering or equivalent steering knobs may be used When used steering knobs shall be of a type that can be engaged by the operator s hand from the top and shall be within the periphery of the steering handwheel 8 Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable when properly operated However improper operation faulty maintenance or poor housekeeping may con tribute to a condition of instability and defeat the purpose of the requirements 9 Users shall give consideration to special operating conditions The amount of forward and rearward tilt to be used is governed by the application Although the use of maximum rearward tilt is allowable under certain conditions such as traveling with the load lowered the stability of a rough terrain forklift truck as determined by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation of trucks with excessive off center loads 10 Some of the conditions which may affect stability are ground and floor conditions grade speed loading rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment dynamic and static forces imprope
49. EVEL Place the truck on a flat surface with the engine off Remove the casing giving access to the braking fluid tank The oil must be 3 8 in under the maximum level f necessary add oil through the filler orifice 7 Fig B4 see LUBRI CANTS Table In case of an abnormal drop in the level consult your agent or dealer B 5 CLEAN AND GREASE TELESCOPIC BOOM PADS This operation must be carried out every 50 hours up to the first 250 hours and periodically every 1000 hours service Extend the telescopic boom completely Using a brush apply a layer of grease see LUBRICANTS Table on the four sides of the telescopic boom Fig B5 1 Operate the telescopic boom a number of times to distribute the grease uniformly Remove excess grease Fill with the proper grease the greaser 8 Fig B5 2 and 9 Fig B5 3 Fig B5 1 10 MVT 628 T 3 To be carried out weekly if the lift truck has been operat ed for less than 50 hours during the week In the event of prolonged use in an extremely dusty or oxidising atmosphere reduce this interval to 10 work ing hours or every day B 6 CLEAN AND GREASE CAB DOOR PINS B 7 CLEAN AND GREASE FRONT AND REAR WHEEL PIVOT PINS B 8 CLEAN AND GREASE TELESCOPIC BOOM PIVOT PIN B 9 CLEAN AND GREASE THE QUICK RELEASE COUPLING PIVOT PIN B 10 CLEAN AND GREASE THE LIFTING CYLINDER TOP AND END PINS B 11 CLEAN A
50. HAZARD Can cause blindness or severe injury Protect eyes Location in or near the battery Keep away from sparks flames and cigarettes storage compartment exercise caution when using tools that can cause sparks Keep battery level and caps tight Addresses battery hazards 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 801013 Jump Start Battery 801015 WARNIN t AS AKT ar 1 Wear eye protection 2 Connect ends of one cable to positive terminals of both batteries Location In or near the battery storage 3 Connect one end of remaining cable to negative terminal of good battery 4 Connect other end compartment of cable to engine block or reliable chassis ground of vehicle being started DO NOT CONNECT TO BATTERY 5 To prevent damage to electrical components of vehicle being started make certain that the engine is at idle speed prior to disconnecting jumper cables 801015 Jump start instructions MANITOU MANITOU NORTH AMERICA ING 5401 WAC Attachment Plate 425995 ven Location on the optional removeable forklift attachment 800 133 3304 w manitau na cao SERIAL NUMBER YEAR OF MANUFACTURE Important manufacturer information about the attachment Record this information for use BEE COUNTRY OF MANUFACTURE DENEN when contacting
51. ND GREASE THE COMPENSATING CYLINDER TOP AND END PINS B 12 CLEAN AND GREASE THE SLEWING CYLINDER TOP AND END PINS Fig B7 2 11 INTRODUCTION MVT 628 T iJ 1101 9 big ave 21118 13 E 21018 014 014 12 MVT 628 T 3 B 13 CLEAN AND GREASE THE TWO REAR AXLE FLOAT BUSHINGS B 14 CLEAN AND GREASE CROSS JOURNALS AND CARDAN SHAFT 13 3 MVT 628 T C EVERY 250 HOURS SERVICE 1 CHECK ALTERNATOR BELT CRANKSHAFT TENSION The tension of the alternator fan belt must be adjusted so that by exercising a normal pressure with the thumb the belt flexure is about 3 4 in Fig C1 If the tension is wrong slacken screws 1 and 2 Fig C by 20r 3 turns and turn the alternator unit so that the belt tension is correct Tighten screws 1 and 2 again Fig C Check the condition of the belt signs of wear or cracks and replace it if necessary see operation N E8 C 2 CHECK FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL Set the truck on a horizontal surface with the engine off Check the oil level in the front axle differential Remove plug 3 Fig C2 1 The oil must be flush with the edge of the hole If necessary add oil through fill hole 3 Fig C2 1 See LUBRI CANTS Table Repeat this operation for the rear axle differential through the hole of level and filling 4 Fig C2 2 C 3 CHECK FR
52. ONT AND REAR REDUCTION GEARS OIL LEVEL Place the truck on a horizontal surface with the engine stopped Check the level on the final drive of each front wheel Set the level cap 5 Fig horizontal Remove the cap the oil must be up to the surface of the hole Top up with oil if necessary see LUBRICANTS Table Carry out the same operation on the final drive of each rear wheel 14 MVT 628 T 3 C 4 CHECK TRANSMISSION BOX OIL Place the truck on a horizontal surface with the engine off and the oil in the reduction gear still hot Remove the level and filler plug 6 Fig C4 the oil should appear at the surface of the hole Add oil if necessary See LUBRICANTS Table Replace and tighten the level and filling plug 6 Fig C4 C 5 CHECK BATTERY Check the level of the electrolyte in each battery cell When the ambient temperature is high the level should be checked more frequently than once every 250 hours Maintenance Check connections 7 Fig C5 1 Check eleclrolyte levels regularly 8 Fig C5 1 Add distilled or dem ineralised water if necessary Never add acid Battery needs lo be recharged if tesion drops below 12 3 V specific gravity of 1 21 If vehicle is not being used for a while disconnect the battery Charging off the vehicle Remove vents 8 Fig C5 1 Only use direct current DC Connecl with w
53. R YEARLY E 1 CHANGE AIR FILTER SECURITY CARTRIDGE Dismantle the air filter cartridge see operation D3 Unscrew nut 1 Fig E1 and remove the air filter safety cartridge 2 Fig E1 Clean the inside of the filter using a clean damp cloth that leaves no residue Never wash an air filter cartridge Fit a new cartridge having the same features see FILTER ELE MENTS AND BELTS Table in place of the old one removed and fix using nut 1 Fig E1 Refit the assembly see operation E 2 DRAIN OUT AND REPLACE HYDRAULIC OIL Before carrying out these operations make sure the truck is parked on a level surface the engine is switched off and the boom is raised Place a container under drain plug 3 fig E2 1 and 4 fig E2 2 Remove the plug and drain out the oil To speed up drainage aerate by removing filler plug 5 fig E2 3 When the tank is empty refit and tighten drainage plug 3 fig E2 1 and 4 fig E2 2 and proceed with dismantling the hydraulic oil filter cartridge intake suction screen See operation E3 19 3 MVT 628 T E3 REPLACE HYDRAULIC OIL FILTER CARTRIDGE INTAKE SUCTION HOSE Remove flange 6 Fig E3 1 to access the hydraulic oil filter car tridge Unscrew the intake suction screen located at the bottom of the tank and replace with one having similar features see FILTER ELEMENTS AND BELTS Table Filling the tank Refit and
54. RATING SAFETY RULES AND PRACTICES cont 19 Do not use a rough terrain forklift truck for opening or closing railroad car doors 20 In areas classified as hazardous use only rough terrain forklift trucks approved for use in those areas 21 Report all accidents involving personnel building structures and equipment to the supervisor or as directed 22 Do not add to or modify the rough terrain forklift truck 23 Do not block access to fire aisles stairways and fire equipment 24 For rough terrain forklift trucks equipped with a differential lock the lock should not be engaged when driv ing on the road or at high speeds or when turning If the lock is engaged when turning there could be loss of steering control 25 Observe all traffic regulations including authorized speed limits Under normal traffic conditions keep to the right maintain a safe distance based on speed of travel from the truck ahead and keep the truck under control at all times 26 Yield the right of way to pedestrians and emergency vehicles such as ambulances and fire trucks 27 Do not pass another truck traveling in the same direction at intersections blind spots or at other danger ous locations 28 Slow down and sound the audible warning device s at cross aisles and other locations where vision is obstructed 29 Cross railroad tracks at an angle wherever possible Do not park closer than 6 ft 1 8m to the nearest rail of a railroad track 30 Ke
55. TACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSHASME B55 6 MANUFACTURED 1 On engine FIG 2 The engine number XVI MVT 628 T On hydrostatic drive FIG 3 MANITOU reference N Serial N On front and rear axle FIG 4 Axle type and model Serial N of front axle Serial N of rear axle 1 Axle type and model 2 Serial N MANDU BF He RAAT On cab FIG 5 Cab No I 7 a 5 A rs a 118 To allow you to indicate these numbers with greater ease you advised to make a note of them immediately in the spaces above Since the MANITOU policy is to aim for constant improvement of our products our range of telescopic fork lift trucks may be subject to some modifications without any obligation on us to inform our clientele y SERIE j we LE L i XVII 1 OPERATING AND SAFETY INSTRUCTIONS MVT 628 T 1 ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS 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 Technically of causing breakdowns to occur or of reducing your lift truck s service life Using counterfeit parts or components not approved by the manufac turer may put an end to contract warranty terms and lead the maker to
56. TION OF MACHINE TEST OF MACHINE Hydraulic test with nominal load Driving test steering and breaking 2 MVT 628 T 3 LUBRICANTS COMPONENTS FOR LUBRICATION CAPACITY RECOMMENDED PRODUCT Engine Front wheel final drive Rear wheel final drive Front axle differential Gearbox Rear axle differential Hydraulic fluid tank Braking circuit General greasing Cooling circuit Fluel tank Shell Rotella 15w40 or Citgo C 600 15w40 Shell Spirax DH80x90 or Citgo Premium Gear MP80w90 Shell Donax TD or Citgo Transgard Tractor Hydraulic Fluid Shell Tellus T46 or Citgo Transgard THF Lo Temp Shell Donax TG Dexron or Citgo Transgard ATF Dexron Ill Shell Rentinax Am or Citgo Lithoplex CM 2 Shell Rentinax Am or Citgo Lithoplex CM 2 Tulco 50 50 Premix Anti freeze Diesel fuel grade 1 D Hydrostatic transmission filter hydraulic filter and engine filter oil and filter must be changed after the first 50 working hours to guarantee Safety FIRST 200 HRS MANITOU SPECIAL IMMERSED BRAKES 549 5 GAL DRUM PART NO 545608 3 MVT 628 T MAINTENANCE SCHEDULE A DAILY OR EVERY 10 HOURS SERVICE Check engine oil level A2 Check cooling circuit filling A3 Check fuel level A4 Check and clean fuel filter A5 Check tyre pressure and tightening of wheel nuts A6 Check greasing of telescopic boom sliding blocks B EVERY 50 HOURS SERVICE
57. _ l 1 Ll BEE 2 SLN N SLN MVT 628 T 31871 MVT 628 T k gt N 95 N eids euijegueo euoisseuuo be eueg ON N N ON N N ss X 251 X OY OY 91 9 a 7 2 va SIN Q SI Q 164 94 ZN 9 31871 12 N 95 gt o eids euoisseuuo be eueg ym JN Su NIN Vox GNS vil ZU S LN ES UN 5 624 i Baur i 3 i PE OSN ST m 7 1 4 i rel Lod ZN 914 A zip ed NG e c m EN T mt peo Q Q O 1 LEX 000 1 e 94 AS Sen VEN N 213487 NY LIN 5 1 31971 MVT 628 T HYDRAULIC MOVEMENT N A gue e Bee ES 14 MVT 628 T KEY TO HYDRAULIC MOVEMENT A Pressur booster D Directional control valve F A Intake filter F R Drain filter I D Power steering unit L S Load sengig MCM Control lever M V Fan motor P Gear double pump Hydrostatic pump R Hydraulic fluid tank SM Valve for telescope and option control V A Optional cylinder VC Compensation cylinder
58. and that the truck is on a flat surface To obtain an accurate indication wait a few minutes after the engine has been switched off to allow the oil to flow into the crankcase Remove dipstick 1 Fig and after having cleaned it check the level of the oil Top up through fill hole if necessary consult the LUBRICANTS Table A 2 CHECK COOLING CIRCUIT FILLING Make reference to the G1 point for the procedure of filling of the cool ing system If it is necessary to add some coolant during the mainte nance wait until the engine is cold Remove the cap slowly because it could take place a dangerous spillage of coolant if the water is under pressure and still warm The added coolant in phase of maintenance must be of the same type of that one originally used in order to fill up the system MVT 628 T 3 A 3 CHECK FUEL LEVEL Place the truck on a horizontal surface with the engine stopped To minimise the condensation due to weather conditions the fuel tank should be kept full as far as possible Remove the cap 2 Fig Through the filler intake fill the tank with clean Diesel fuel filtered by a rose pipe or a clean cloth which does not leave residues Replace the 2 Fig Never smoke or approach with naked lights during filling or when the tank is open Never fill up with the engine running A 4 CHECK AND CLEAN FUEL FILTER Before this operation is carried out
59. ard 1 Fig B To change a fuse remove it and replace it with a new one of the same quality and rating In case of an electrical blackout check all the fuses and check whether a short circuit has occurred Never attempt to repair a blown fuse Rel 14 R12 Rel 13 Intermittenza Rel 3 Rel 4 Rel 5 Rel 6 Rel 7 or e I a Aek MVT 628 T DESCRIPTION OF FUNCTIONS OF THE FUSES DESCRIPTION Brake lights Rexroth travel system Engine stop Horn Solenoid valve electric cooling fan Conditioner Heating Front windscreen wiper screen washer Rear and upper screen wiper screen washer Direction indicator lights instrumentation Front working lights Rear working lights Reversing lights and beeper Electric fan first speed Electric fan second speed Electric fan third speed Front right and rear left side lights Front left and rear right side lights Dipped headlights Full beam headlights Thermal starter Emergency lights ceiling light Radio not used Power supply available Revolving flashing light Not used Manoeuvre switching solenoid valve system Key controlled power supply not use
60. ceed the capacities of your lift truck or attachments It is prohibited to increase the counterweight value in any way t is strictly prohibited to carry or to lift up persons using the lift truck unless the vehicle is specially equipped for this purpose and has the corresponding certificate of conformance for lifting people Avoid travelling for a long distance in reverse When lifting or lowering the boom ensure the control lever is moved slowly and smoothly whether operating with or without a load B ATTACHMENTS Ensure that the attachment is correctly fitted and locked to its frame Conform to the limits on the load chart for the attachment Position the forks perpendicular to the load to be lifted taking account of the load s centre 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 If not utilised place the attachment in horizontal on the ground For unstable attachments ensure they are secured using wedges Ensure that rapid hydraulic connections on the attachment system are clean and protected Carry out the following procedure before changing hydraulic attach ments to prevent damage to the quick release couplings stop the I C engine turn key to position release pressure from the circuit using the joystick C ENVIRONMENT Verify that the lighting in suitable Ensu
61. d Conditioner pressure switch Not used Not used Not used DESCRIZIONE 10 15 A Not used 10 15 A Not used 10 15 A Not used 10 15 A Hydraulic movements chamging 10 15 A Forward travel 10 15 A Reverse travel 10 15 A Reversing beeper and lights 20 30 A Engine starter 20 30 A Electric cooling fan second speed 20 30 A Not Used 20 30 A Conditioner 42 46 W Intermittence unit 20 30 A Position lights feeding 20 30 A Not Used 4 MVT 628 T LIGHTNING Blown lamps must be replaced immediately Do not handle a new lamp with bare or dirty hands any trace of grease oil or sweat will evaporate when the lamp heats up and stain the reflector Never touch or attempt to polish the reflector Do not open the light except to change the lamp BATTERY The battery s efficiency drops as the temperature falls and it ceases to function at about 40 F Do not attempt to use the starter motor if the battery has been exposed to temperatures around 20 F In such cases heat the battery by placing it in warm water up to 5 cm below the capsi In case of very low temperatures take the battery out of the truck and keep it in a warm room until the moment of use 4 peddip yuo 14674 2463 peddip juoy y qe3 146 1 qe
62. d weight for travel on the public highway the traction force and the maximum verti cal stress on the towing pin These data are shown on the manufactur er s data plate applied to each truck Other optional solutions are available for towing trailers for further information contact your agent or dealer Only trucks registered as agricultural tractors are allowed to tow trail ers on the public highway Check the trailer s braking and light systems and connect them to the truck Reduce the speed of the truck Follow your country s highway code Make sure that the split pin is properly positioned on the towbar 20 MVT 628 T 2 23 FRONT LIGHTS A Front left direction indicator light Fig 23 1 B Front left side light Fig 23 1 C Front left dipped headlight and full beam headlight Fig 23 1 D Front right side light Fig 23 2 E Front right dipped headlight and full beam headlight Fig 23 2 F Front right direction indicator light Fig 23 2 24 REAR LIGHTS A Rear left direction indicator light Fig 24 1 B Rear left brake light Fig 24 1 C Rear left side light Fig 24 1 D Rear left reversing light Fig 24 1 E Rear left fog light Fig 24 1 F Rear right fog light Fig 24 2 G Rear right reversing light Fig 24 2 H Rear right side light Fig 24 2 Rear right brake light Fig 24 2 J Rear right direction indicator light Fi
63. dimensions used to establish rough terrain forklift truck capacity with extra caution Stability and maneuverability may be adversely affected IV ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 46 When attachments are used extra care shall be taken in securing manipulating positioning and trans porting the load Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks when not handling a load 47 Completely engage the load with the load engaging means Fork length should be at least two thirds of load length Where tilt is provided carefully tilt the load backward to stabilize the load Caution should be used in tilting backward with high or segmented loads 48 Use extreme care when tilting load forward or backward particularly when high tiering Do not tilt forward with load engaging means elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load 49 The handling of suspended loads by means of a crane arm boom or other device can introduce dynam ic forces affecting the stability of a rough terrain forklift truck Grades and sudden starts stops and turns can cause the load to swing and create a hazard if not externally stabilized When handling suspended loads a do not exceed the truck manufacturer s capacity of the rough terrain forklift truck a
64. djusted and fas tened Never try to start the lift truck by pushing or towing it This movement could seriously damage the transmission If it is nec essary to tow the lift truck relieve the hydrostatic transmission See chapter H OCCASIONAL MAINTENANCE under section 3 MAIN TENANCE 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 ignition key to position Il to preheat for 15 seconds If the environmental conditions require it Do not engage the starter motor for more than 15 seconds and carry out the preheating for 10 seconds between unsuccessful attempts Press the accelerator pedal and turn the ignition key fully the 1 C engine should then start Release the ignition key and let the 1 C engine run at idle Before operating in very cold environment wait for the engine and hydraulic systems to heat up adequately 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 1 C engine and immediately carry out the necessary operations MVT 628 T D DRIVING THE LIFT TRUCK SAFETY NOTICE Always drive the lift truck with the
65. e transport position Fig K 18 MVT 628 T MVT 628 T 1 D LAYING A HIGH LOAD Under no circumstances should you lay down a load if the lift truck is not in a horizontal position Approach the load in the transport position in front of the pile Fig L Lift and extend the jib 1 2 until the load is above the pile if neces sary move the lift truck forward 3 Fig M manoeuvring very gently and carefully See paragraph E VISIBILITY in the chapter HAN DLING INSTRUCTIONS for visibility of the road 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 jib 1 2 in order to position the load cor rectly Fig N Free the forks by alternately retracting and lifting the jib 3 Fig N or if possible by reversing the lift truck 3 See paragraph E VISIBIL ITY in the chapter HANDLING INSTRUCTIONS for visibility of the road Then bring the jib into the transport position E TAKING UP A LOAD WITHOUT PALLET Tilt the carriage 1 forwards and extend the jib 2 while simultane ously crowding the carriage backwards to slip the forks under the load Fig O If necessary wedge the load 2 VES MOZO 19 1 MVT 628 T TRUCK MAINTENANCE INSTRUCTIONS MAINTENANCE INSTRUCTIONS A GENERAL Read
66. e foreseeable abnormal behaviour 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 inci dent fault etc during operation of the lift truck Behaviour resulting from application of the principle of least action when performing a task For certain machines the foreseeable behaviour of such persons as 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 Get to know the telescopic fork lift truck on the terrain where it is to be used Transport the load with the boom lowered and fully retracted Position the forks at right angles to the load to be lifted Drive the truck at a speed appropriate to conditions and the state of the ground Never go too fast or brake sharply with a load When picking up a load check that the ground is as even as possi ble Never attempt to carry out operations which exceed the lift truck s capabilities Never raise a load in excess of the lift truck s capacity and never increase the size of the ballast Drive around obstacles Take care over electrical wires trenches
67. e ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801011 Use of Seat Belt 801012 Boom equipped models Location to the right of the operator near the hydraulic control lever Instructs the operator to always wear the seat belt during operations and never jump from an over turning forklift Lie ar coq 1 Ct Al p JULIA PN Wei m GER t ek ER operating Machine Never jump from a tippi nag Ire tn m rec IB Hag EE ilk OUS IMPLY ICGLR SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever EMERGENCY STOPPING Identifies the Emergency Parking Brake Lever AND PARKING BRAKE F THIS VEHICLE IS EQUIPPED WITH A BACK UP Alarm Must Sound 496162 ALARM WHEN BACKING THE Location on the dash in direct view of the operator 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 CAUTION No Riders 420732 Location on the cab entrance s and on or near wheel fenders and engine cover Informs riders are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 DANGER Boom equipped models Location on bot
68. e specific uses require adaptation of the accessory not included in the optionals in the catalogue Other solutions are possible contact your agent or dealer for further information Only accessories approved and CE certificates by the manufacturer can be used on our lift trucks The manufacturer will have no liability in case of modifications or use of accessories without his knowledge 5 MVT 628 T GENERAL RECOMMENDATIONS FOR USE OF A LIFT TRUCK WHEN YOU SEE THIS SYMBOL CAUTION TAKE CARE YOUR SAFETY OR THAT OF THE TRUCK IS AT STAKE Follow the data provided in the load diagram Never attempt to raise loads greater than those permitted in the load diagrams supplied with the machine Transport the load in low position with telescopic boom fully retracted Drive the truck at a speed suitable to the conditions and the state of the ground When the truck is empty travel with the telescopic boom lowered and fully retracted Never go too fast or brake sharply with a load When the load is lifted check that no one can get in the way of the operation and take care not to carry out incorrect procedures Never attempt operations which exceed the lift truck s capacity Take care over electrical cables Never leave the truck parked with a raised load Never authorise anyone to approach or pass under the load Always think of safety and only transport well balanced loads Never leave the truck loaded with the
69. e used in the brake system ATTENTION BRAKE LIQUID IMPERATIVE to use MIN E RAL Ol Lo Recom mendation ATF DEXRON II SHELL 4 n 164091 234800 n 234800 SAFETY DECALS Hydraulic Oil 234798 or 76573 Location on the hydraulic tank or filler cap Identifies the hydraulic reservoir tank or filler cap N 234798 Hydraulic Oil 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAU LIC OIL Identifies the hydraulic reservoir tank HYDRAULIK OL ACEITE HIDRAULICO OLIO IDRAULICO 4 N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap Indicates required minimum to maximum anti freeze protection 220 to 40 F Diesel Fuel 161101 Location on the fuel tank near the filler cap DIESEL Identifies the fuel tank and use of diesel fuel 161 101 No Step 496735 Location varies depending on the forklift model NOTICE Instructs personnel not to use the designated area as a step NO STEP 498735 Do Not Tow 494918 Hydrostatic equipped models Location on the dash in view of the operator A WARNING THIS VEHICLE IS EQUIPPED WITH A 2 ns forklift will the transmission HYDROSTATIC TRANSMISSION DO NOT ATTEMPT Operators Mandel TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494918 XIV SAFETY DECALS Boom equipped models Location
70. ed on 11 2 MVT 628 T N BLUE FULL BEAM HEADLIGHT LIGHT This light illuminates when the full beam headlights are in operation O RPM COUNTER P HOUR COUNTER Indicates the number of hours the truck has worked The hours are shown on the dial up to multiples of one thousand RPM x 100 electronic 000050A Q FUEL LEVEL GAUGE The red zone indicates that the fuel level is low and the truck can only be used for a limited time R MAX WATER TEMPERATURE INDICATOR When each red light switches on a buzzer also starts to sound When the ignition key is turned to the first catch with the engine off a check is performed All the lights illuminated and a buzzer starts to opera tion everything returns to normal once the engine starts 12 MVT 628 T 2 4 SWITCH CONSOLE Fig 4 A FLASHING LIGHT SWITCH B REAR FOG LIGHT SWITCH C EMERGENCY LIGHT SWITCH D WINDSCREEN WIPER WASHER SWITCH E REAR WINDOW WIPER SWITCH F OPERATING MODE A FLASHING LIGHT SWITCH On off switch for the rotating flashing light B REAR FOG LIGHT SWITCH On off switch for the rear fog light C EMERGENCY LIGHT SWITCH Pressing this switch activates all the direction indicators simultaneous ly To stop press the switch again D WINDSCREEN WIPER WASHER SWITCH Switch with 3 positions for wiper 2 and for washer 3 To stop the washer simply release the switch REAR WINDOW WIPER
71. el of the forks Fig A For a load with a higher centre of gravity consult your agent or dealer For irregular loads determine the centre of gravity in the transverse direction before handling Fig B For loads with a moving centre of gravity e g liquids take account of the variations in the centre of gravity in order to determine the load to be handled Consult your agent or dealer and be vigilant and take extra care to limit these variations as far as possible TAKING UP A LOAD ON THE GROUND Position the lift truck perpendicular to the load with the jib retracted and the forks in a horizontal position Fig C Adjust the fork spread and centering in connection with the load Fig D Optional solutions exist consult your dealer Beware of the risks of trapping or squashing limbs when manually adjusting the forks Always maintain an equal distance between the forks and the centre of the carriage in order to keep the load completely stable Slowly move the life truck forward 1 and stop with the forks in front of the load Fig E if necessary slightly lift the jib 2 while taking up the load Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 tilt the carriage backwards 2 in the transport position Fig F Tilt the carriage sufficiently backwards to ensure the load s stability when braking whilst maintaining the load balance C T
72. elescopic boom push the joystick to the right To retract the telescopic boom pull the joystick to the left To tilt the forks press the button B on the joystick and push the joy stick forward To lift the forks again press the button B on the joystick and push the joystick backward To control the optional press the button B on the manipulator and push the manipulator to the right and left Do not attempt to alter the hydraulic system pressure In case of suspected malfunction consult your dealer or agent Any alteration may render the warranty null and void 15 A Decompression of optional circuit This operation must be carried out every time a supplementary acces sory is to be connected to the lift truck 1 Switch off the 1 engine and position the ignition key point 7 pages 2 14 in position I 2 Press the button B on the manipulator and push the manipulator to the right and left When the operation is complete the optional circuit is depressurised this facilitates coupling and uncoupling of the quick release couplings in the boom head N B The operation must be carried out immediately after the engine is switched off and not for more than 3 seconds for each command 17 2 MVT 628 T 16 HEATING CONTROLS Fig 16 A FAN KNOB This 3 speed knob allows distribution of warm or cold air from the outlet B TEMPERATURE REGULATOR KNOB This knob allows regulation of the
73. ep 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 596 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 On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface d Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up or down 33 Under all travel conditions operate the rough terrain forklift truck at a speed that will permit it to be brought to a stop in a safe manner 34 Travel with load engaging means or load low and where possible tilted back Do not elevate the load except during stacking 35 Make starts stops turns or direction reversals in a smooth manner so as not to shift load and or overturn the rough terrain forklift truck 36 Do not indulge in stunt driving or horseplay 37 Slow down for wet and slippery surfaces 38 Before driving over a dockboard or bridge plate be sure that it is properly secured Drive carefully and slowly across the dockboard or bridge plate and never exceed its rated capacit
74. forks or attachment at approxi mately 12 in from the ground i e In the transport position Familiarise yourself with the lift truck on the terrain where it will be used Ensure that the service brakes and the sound 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 n 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 posi tion and never do so abruptly Always remember that hydraulic type steering is extremely sensitive to movement of the steering wheel so turn it gently and not jerkily Never leave the 1 engine on when the lift truck is unattended Look in the direction you are travelling and always keep clear visibility of the road Use the left and right rear view mirrors frequently and ensure that they are kept in good condition are clean and correctly adjusted Never use the truck in places poorly lighted When working at night ensure that your lift truck is fitted with full beam lights There are optional solutions consult your agent or deal er Drive around obstacles Never move onto a loading platform without having first checked That it is suitably positioned and madefast That the unit to which it is connected Wa
75. ft D Side lights on E Dipped headlights and side lights on F Full beam headlights and side lights on G Lights flashing Press the tip of the lever to sound the horn 7 KEY SWITCH Fig 7 The switch has 4 positions Breaks electrical contact stops the engine Electrical contact Warm up Ignition and return to position 1 as soon as key is released 14 MVT 628 T 2 8 CASING GIVING ACCESS TO BRAKE FLUID AND SCREEN WASHING LIQUID Fig 8 Undo the screw A and remove the casing for access to the brake fluid and screen washing liquid tanks 9 BRAKE FLUID TANK Fig 9 10 SCREEN WASHING LIQUID TANK Fig 10 On the operator s left Remove the cap B make sure that the tank is always full Liquid to be used water window cleaning detergent use an anti freeze in winter 11 CASING GIVING ACCESS TO FUSES AND RELAYS Fig 11 Release and pull the block C to remove the casing for access to the fuses and relays 2 MVT 628 T 12 ACCELERATOR PEDAL SERVICE BRAKE AND INCHING PEDAL Fig 12 Pedal A can be used to vary the speed of the fork lift truck by adjust ing the engine rpm Pedal B acts on the front brakes and can be used to slow down and stop the truck During the first 3 4 in of its stroke the brake pedal acts as an inching pedal allowing precise slow movements in the rest of its stroke it produces the brakin
76. g 24 2 Fig 24 1 Fig 24 2 21 2 MVT 628 T 25 REVOLVING FLASHING LIGHT Fig 25 The revolving flashing light can be removed for example to reduce the dimensions of the truck or to prevent its theft Unscrew the nut A and remove the revolving flashing light Protect the support B with the cover C 26 STEERING WHEEL REGULATOR LEVER Fig 26 This lever allows adjustment of the height and angle of the steering wheel Turn the lever D anti clockwise E to loosen and adjust the steering wheel Turn the lever D clockwise F to lock the steering wheel in the cho sen position 22 3 MAINTENANCE MVT 628 T 3 FILTERING ELEMENTS AND BELTS a a 1 Engine oil filter 476 954 Replace Every 500 H 2 Air filter cartridge A 504 507 Clean Every 500 H 3 Transmission oil filter 485 695 Replace Every 500 H 4 Fuel filter cartridge 605 013 Replace Every 500 H 5 Hydraulic oil filter 606 047 Replace cartridge exhaust Every 500 H 6 Breather filter 674 796 Clean Every 1000 H 7 Hydraulic oil filter 013 752 Check cartridge intake Every 1000 H 8 Air filter safety 514 161 Check cartridge A Every 1000 H 9 Engine belt 503 965 Check Every 1000 H Every 500 H E Reduce the periodicity and advance the replacement in a dusty atmosphere 10 Cab ventilation 225 052 Clean filter cartridge
77. g effect 13 DIRECTION REVERSER LEVER Fig 13 The truck s travel direction must be reversed at low speed and without accelerating FORWARD TRAVEL Raise the lever slightly and push it forward Position C REVERSE Raise the lever slightly and pull it back Position D NEUTRAL When the truck is started the lever must be in neutral Position E The reverse travel lights indicate that the truck is travelling in reverse There is also a reverse warning beeper These instructions must be complied with to allow the transmission to operate correctly 14 HYDRAULIC PARKING BRAKE LEVER Fig 14 The parking brake acts on the front axle engage the parking brake pull the lever upwards Position F disengage the parking brake push the lever forwards Position G With the parking brake engaged lever in position F in addition to the indicator light on the dashboard lighting up the lift truck travel com mand is also prohibited 16 MVT 628 T 2 15 HYDRAULIC MOVEMENT COMMANDS Fig 15 The lift truck is provided with an electro hydraulic servo control to the right of the operator Servo control A can simultaneously activate various double acting elements such as lifting the load tilting the forks telescopic boom extension or optional command Fig 15 1 To lift the load pull the joystick backwards To lower the load push the joystick forwards extend the t
78. gain after 20 hours of service from when the belt was replaced see operation no C1 E 9 REPLACE TRANSMISSION HYDRAULIC OIL VENT Unscrew vent 21 Fig E9 on the oil tank and replace it with a new one see FILTER ELEMENTS AND BELTS Table Screw on the new vent by hand E 10 CHECK TELESCOPIC BOOM PADS FOR WEAR For these operations consult your agent or dealer 23 3 MVT 628 T EVERY 2000 HOURS SERVICE YEARLY F 1 CHECK ENGINE VALVE PLAY F 2 CHECK INJECTORS 3 CHECK ALTERNATORS AND STARTER MOTOR 4 CHECK TURBO COMPRESSOR FOR THESE OPERATIONS CONSULT YOUR AGENT OR DEALER 24 MVT 628 T 3 OCCASIONAL OR ANNUAL MAINTENANCE G 1 CHECK AND REPLACE COOLING CIRCUIT LIQUID IF NECESSARY Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged Place the truck on a horizontal surface stop the engine and leave it to cool down Undo the radiator drain cap 1 Fig G1 1 Undo the engine block drain cap 2 Fig G1 2 Remove the radiator filler cap 3 Fig G1 3 Allow the cooling circuit to empty completely making sure that no ori fices become blocked Check the condition and fixing of the hoses and replace them if nec essary Rinse out the system with clean water and use a detergent if neces sary To prevent forst damage ensure that all of
79. gon lorry etc will not shift That this platform is prescribed for the total weight of the lift truck to be loaded That this platform is prescribed for the width of the lift truck Never move onto a foot bridge floor or freight lift without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Take extreme care with loading platforms trenches scaffolding recently dug and or backfilled ground The loaded lift truck must not travel at speeds in excess of 6 km h MOVEMENT INSTRUCTIONS Check the transmission oil level Raise the forks or attachment to the transport position approximately 12 in from the ground Select the required steering mode Shift the forward reverse lever to the selected direction of travel Release the parking brake and accelerate gradually until the lift truck moves off 1 MVT 628 T E STOPPING THE LIFT TRUCK SAFETY NOTICE Before stopping the lift truck after a long working period leave the engine idling for a few moments to allow the coolant liquid and oil to lower the temperature of the engine and transmission This precaution must be strictly observed if the 1 engine frequently stops Never leave the ignition key in the lift truck when the lift truck is unat tended When the lift truck is stationary place the forks or attachment on the gr
80. gulations applicable in the country of use maximum permitted speed braking system maximum trailer weight etc Remember to connect the electrical system of the lift truck to that of the trailer Do not use a trailer if the unit weight of the load is greater than that specified by Highway Code Do not use a braked trailer if the lift truck does not have a trailer braking system Remember to connect the lift truck braking system to that of the trail er The total permitted weight for transport must not exceed the maxi mum permitted by the manufacturer See the lift truck manufacturer s identification plate H OPERATING THE LIFT TRUCK WITH A FRONT END ATTACH MENT ON A PUBLIC HIGHWAY For driving with an attachment check the regulations currently applicable in your country The attachment must not exceed the overall width of the lift truck Do not mask the lighting range of the front headlamps Set the attachments shields in place necessary fit the block spacer on the lifting and slewing cylinder Front dimensions of equipment indicated on all three sides with 4 in wide alternate white and red reflecting stripes slanting 45 Follow the specific instructions for each type of equipment IF NECESSARY CONSULT YOUR DEALER 12 MVT 628 T 1 HANDLING INSTRUCTIONS A GENERAL Ensure the correct functioning of your lift truck s attachments Do not attempt to carry out operations which ex
81. h sides y Stay clear of raised boom of the boom nose y r of rai unless properly supported Operator may be crushed Keep away from unsupported boom between falling boom and main frame Failure to comply may result in serious injury or death Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose A DANGER Keep machine at least 25 feet from overhead power lines Keep away from power lines Failure to comply may result in serious injury or death by electrocution 801007 XI SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of DANG ER the operator near the hydraulic control lever ma READ OPERATOR S MANUAL Frame leveling notice load must be lowered Attachment and Boom Safety 801009 Boom equipped models Location on both sides of the boom nose ATTACHMENT AND BOOM SAFETY Improper operating techniques can cause the machine to tip over Refer to machine load charts and operator s manual for proper operating techniques Important reminders of attachment and boom safety Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as a manlift Attachment must be properly locked to the carrier before raising boom Use only approved attachments on this machine Do not work under raised boom or attachments unless supported FAILURE TO
82. i understanding of nameplate data and operator instructions and warning information appearing on the rough terrain forklift truck B GENERAL SAFETY PRACTICES 1 Rough terrain forklift trucks can cause injury if improperly used or maintained 2 Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to oper ate rough terrain forklift trucks Unusual operating conditions may require additional safety precautions train ing and special operating instructions 3 Modifications and additions which affect capacity or safe operation shall not be preformed without the man ufacturer s prior written approval Where such authorization is granted capacity operation and maintenance instruction plates tags or decals shall be changed accordingly 4 If the rough terrain forklift truck is equipped with front end attachment s or optional forks the user shall see that the truck is marked to identify the forks or attachment s show the approximate weight of the truck and fork or attachment combination and show the capacity of the truck with forks or attachment s at maximum elevation with load laterally centered 5 The user shall see that all nameplates and caution and instruction markings are in place and legible 6 The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont B GENERAL SAF
83. ilh Charge at recommended bench rate i e 1096 of battery capacity The battery is fully charged when specific gravity has reached 1 28 Fig C5 2 1 23 under tropical climate When charge has completed 12 Switch off charger then disconnect 4290 Check electrolyte level 3 1 300 48 10 0 10 20 30 F 0 14 32 50 68 86 104 Fig C5 2 15 3 MVT 628 T D EVERY 500 HOURS SERVICE OR YEARLY D 1 EMPTY AND CHANGE ENGINE OIL D 2 CHANGE ENGINE OIL FILTER Position the lift truck on level ground allow the engine to idle for a few minutes and then switch it off Draining the crankcase Place a container under the drain plug of the engine oil sump 1 Fig D2 1 Then unscrew fill plug 2 Fig D2 2 to facilitate emptying Replacing filter Unscrew and remove oil filter 3 Fig 02 3 then discard it with its rel ative seal Clean the filter connector with a clean cloth Lightly lubricate the new seal and fit a new filter with the same specifi cations see FILTER ELEMENTS AND BELTS Table Tighten the new oil filter by exerting slight pressure by hand and lock it by turning it through a quarter of a turn Filling the crankcase Refit and tighten drain plug 1 Fig D2 1 Fill up with oil see LUBRICANTS Table through fill hole 2 Fig D2 2 Wait a few minutes to allow the oil to flow into the crankcase Start the engine
84. 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 Wik td il dd eif opea Mast equipped models Location on or near the operator manual ii a storage case and or on the dash panel Fia anm ol Locate and know operations of controls Instructions for the forklift operator before operating the forklift Fasten seat belt Keep all shields in place Operate only from operator s seat SAFETY INSTRUCTIONS load as low as possible avoid step slopes and drive slowly on rough terrain to avoid machine overturn 1 Read and understand operator s manual before you operate this truck If the operator s manual is missing a new manual may be obtained through your local dealer Rafer to operator s manual for jump starting instructions or directly from K D Manitou Inc Waco Tx WHEN PARKING OR SERVICING 2 Check truck for proper operation of all functions 3 Fasten seat belt 1 Lower boom to th
85. ine 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 SAFETY DECALS The purpose of this chapter is to introduce you to the safety messages decals and nameplates found on your forklift truck The decals are identified by name part number location and a brief description The forklift model logos and other misc decals not shown can be found in your forklift parts manual The decals illustrated may not be exactly the same as those installed on your forklift installation of the decals varies depending on the forklift model series decal updates etc The size and location of some decals limit the amount of information that can be placed upon it For this reason additional detailed information not found on the decals is provided through out this manual Every decal placed on the lift truck is important they are constant reminders of safety and instructions that 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
86. ion is dis connected clean thoroughly the area around the connection After a component has been disconnected fit a suitable cover to all open con nections Place a suitable container below the fuel filter assembly to retain spilt fuel oil Thoroughly clean the outside surfaces of the fuel filter assembly Open the drain tap 9 Fig DA 1 at the bottom of the filter casing to drain the fuel from the filter Loosen the filter casing Remove the casing and element from the fuel filter head Remove the filter element from the casing Press down on the filter element 10 Fig D4 2 against the spring pressure and rotate it to the left to release it from the filter casing 11 Fig D4 2 Put the new filter element see FILTER ELEMENTS AND BELTS Table inside the casing and press it down against the spring pressure rotate it to the right to lock it into the casing 11 Fig D4 2 Fit a new seal 12 Fig D4 2 to the casing and lightly lubricate the seal face with clean fuel oil Check that the tread 13 Fig D4 2 on the inside of the element is not damaged Fit the filter assembly to the fuel filter head and tighten by hand until it contacts the filter head Tighten the assembly a further 1 4 of a turn by hand Do not use a strap wrench Close the drain tap 9 Fig D4 1 and remove the container Before the starter motor is engaged operate the lift pump for one minute to eliminate air from the filter Start the
87. is badly positioned take the necessary pre cautions to move it in the conditions of maximum safety Check that the rods of the locking cylinder are retracted Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement HYDRAULIC LOCKING AND RELEASE OPTIONAL The accessory if any is locked and released using the optional con trol which may be operated by a push button or using the control lever itself depending on the type of truck For further information refer to the use and maintenance manual provided with the truck Remember to decompress the optional circuit whenever an extra accessory is to be connected to or disconnected from the lift truck this will simplify the engagement and disengagement of the snap couplings on the end of the boom REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking care to place it in a safe position on firm flat ground 9 MVT 628 T USING THE TYPE FOLK HOLDER CARRIAGE PICKING UP THE ACCESSORY Check to make sure the accessory is in a position to facilitate con nection of the quick release cou
88. ition until the catch is heard to engage If the seat is raised above the last catch it will return to the lowest posi tion ADJUSTING THE SEAT ANGLE The seat angle can be regulated individually Press the button on the left and at the same time push or release the seat to obtain the position desired ADJUSTING THE SEAT POSITION The seat position can be regulated individually Press the button on the right and move the seat forward or back to obtain the position desired SEAT BACK EXTENSION The height of the seat back extension can be adjusted the catches can be heard until the stop is reached The seat back extension can be removed by pulling until it moves beyond the last stop BACK SUPPORT This allows adjustment of both the seat conform level and the driver s freedom of movement Turn the knob to the right or left to adjust the height and depth of the back support MVT 628 T 2 ADJUSTING THE SEAT BACK ANGLE Lean against the back pull the lever and move the seat back into the position desired If the back is not held in place when adjusted it will tip completely forward LONGITUDINAL ADJUSTMENT Engage the locking lever in the position desired Once locked in place the seat cannot be adjusted further CLEANING Dirt may prevent the seat from functioning correctly it must therefore always be kept clean To clean or replace the cushions simply extract them from the frame
89. k on level ground with the engine off and the oil in the final drives still hot Empty the front wheel final drivers Make sure the drain and level plug 13 Fig E5 1 is pointing down wards A to facilitate oil flow Place a container under the drain plug and unscrew it Drain out all the oil Turn the outlet hole to horizontal position B to check the oil level sub sequently Fill with oil see LUBRICANTS Table through level hole 14 Fig E5 2 The level is correct when the oil reaches the top of hole 14 Fig E5 2 Refit drain plug 14 Fig E5 2 and tighten it Repeat the operation for all the final drives Fig E5 1 E 6 REPLACE TRANSMISSION BOX OIL the truck on a horizontal surface with the engine off and the oil in the reduction gear still hot Place a can under drain plug 15 Fig E6 and allow the oil to drain out Remove fill and level plug 16 Fig E6 to ensure that all oil drains out Refit and tighten plug 15 Fig E6 Fill with oil see LUBRICANTS Table through fill hole 16 Fig E6 Check for any leaks from the drain plug 21 E 7 EMPTY AND CLEAN FUEL TANK Never smoke or work near a flame during these operations Set the truck on a horizontal surface with the engine off Control manually and visually the parts subject to losses of the combustible circuit and tank In case of losses to contact
90. l solutions consult your agent or dealer Do not use a worn or damaged tyre The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer excepting prior authorisation 1 MVT 628 T 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 your self 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 frequency of such checks are defined by the current legislation of the country in which the lift truck is being operated Maintenance or repairs other than those detailed in part 3 MAINTE NANCE must be carried out by qualified personnel Consult your agent or dealer and under the necessary safety conditions to maintain the health of the operator and any third party 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 utilisation For operation under average climatic conditions i e between 5 F and
91. lift truck and that the driver of the means of transport is informed about the dimensions and the weight of the lift truck See chapter CHARACTERISTICS in paragraph 2 DESCRIPTION Ensure that the platform has got dimensions and a load capacity suffi cient for transporting the lift truck Check also the pressure on the con tact surface allowable for the platform in connection with the lift truck For lift trucks provided with supercharged engine plug the outlet to prevent the turbo shaft from turning without lubrication while the vehi cle moves LOAD THE LIFT TRUCK Block the wheels of the platform Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck Load the lift truck parallel to the platform Stop the lift truck See chapter DRIVING INSTRUCTIONS in para graph 1 OPERATING AND SAFETY INSTRUCTIONS 33 3 MVT 628 T STOW THE LIFT TRUCK Fix the chocks to the platform at the front and at the back of each tyre Fig G6 1 Also fit chocks on the inner side of each tyre Fig G6 2 Lock the lift truck on the platform with enough resisting ropes on the fastening points at the front of the lift truck 22 Fig G6 3 and in the towing thorn 23 Fig G6 4 on the posterior part Tighten the ropes Fig G6 5 Fig G6 5 34 MVT 628 T 3 G 7
92. make sure the fork check pin is inserted in the notch present on the fork carriage PERIODIC INSPECTION OF THE FORKS Check the thickness at the fork heel to make sure it is not less than 90 of the original thickness which for forks with constant section corresponds to the shoulder thickness see ISO standard 5057 Check for permanent deformation or alignment defects if any in con formity to ISO standard 5057 The difference in height of the tips must be less than 3 of the length of the horizontal part of the fork The permanent deformations must be checked by checking the angle or diagonal between the fork tip and shoulder Visually check the forks to make sure there are no cracks near the heel or the fork hook In case of doubt proceed with penetrant liquid testing Repairs if any are only permitted is carried out in conformity with the indications of ISO standard 5057 and documented accord ingly MVT 628 T DISASSEMBLING THE FORKS Remove the fork safety screw from the fork holder Fig A Shift the fork manually towards the centre of the fork holder lift it manually by the tip and position it slightly away from the centre on the side rest ing it on the lower guide Fig B Lower the boom and slew it for wards to rest the forks on the ground and detach them from the fork holder upper guide Fig C ATTENTION DANGER Take great care to prevent the forks from falling to the side
93. member to fasten your seat belt and adjust it to your require ments The control units must never in any event be used for any other than their intended purposes e g climbing onto or down from the lift truck portmanteau etc f the control components are fitted with a forced operation lever lock device it is forbidden to leave the cab without first putting these con trols in neutral Never allow a passenger to travel on the lift truck in the driver s cab B BEFORE STARTING THE LIFT TRUCK If the lift truck is new refer to chapter BEFORE STARTING UP A NEW LIFT TRUCK in paragraph 1 OPERATING AND SAFETY INSTRUC TIONS Check the condition of the tyres and the tyre pressures See chapter CHARACTERISTICS in paragraph 2 DESCRIPTION Before starting the lift truck check the different levels Engine oil Hydraulic reservoir oil Transmission oil Cooling liquid Brakes fluid Also check for possible leakage of oil Brakes fluid fuel or liquid from the lift truck Check the closing and locking of the hood Whatever his experience as a truck driver is the operator is advised to familiarize himself with the position and operation of all the controls and instruments before operating the lift truck 1 MVT 628 T C STARTING THE LIFT TRUCK SAFETY NOTICE The lift truck must only be started up or manoeuvred when the opera tor is sitting in the driver s cab with his seat belt a
94. n ensure that all termi nals are firmly tightened It is important not to remove the terminals on the back of the alternator while the engine is running as this may damage the alternator itself When fitting a battery check that the connections are correctly polarised It is essential for the cable marked to be connected to the positive terminal of the battery and the cable marked to be connected to the negative terminal on the battery and that there is a ground connection If a second battery is used to start the engine always connect termi nals of the same polarity Fig A Fit a battery with the same voltage as that installed on the truck If an external charger is used always connect the wire of the charger to the terminal of the battery and the wire of the charg er to the terminal of the battery and ground connection Never short circuit the alternator terminals or connect them to ground Never reverse the alternator connection on the battery Never remove or replace an electrical connection while the engine is running If electric arc welding is carried out on the truck directly connect the welder negative wire to the piece to be welded to ensure that the high voltage current cannot pass through the alternator and then discon nect the battery 4 MVT 628 T FUSES AND RELAY BOX The electric circuit is protected by fuses situated inside fuse holders located under the lower plate of dashbo
95. ng changed on the public highway make sure of the following points Stop the lift truck if possible on even and hard ground To pass on stop of lift truck See chapter DRIVING INSTRUCTIONS in paragraph 1 OPERATING AND SAFETY INSTRUCTIONS Put the warning lights on Immobilise the lift truck in both directions on the axle opposite to the wheel to be changed Unlock the nuts of the wheel to be changed Place the jack under the flared axle tube as near as possible to the wheel and adjust the jack 4 Fig G3 1 Lift the wheel until it comes off the ground and put in place the safety support under the axle 5 Fig G3 2 For this operation we advise you to use the hydraulic jack and the safety support Completely unscrew the wheel nuts and remove them Free the wheel by reciprocating movements and roll it to the side Slip the new wheel on the wheel hub Refit the nuts by hand if necessary grease them Remove the safety support and lower the lift truck with the jack Tighten the wheel nuts with a torque wrench See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAINTENANCE for tightening torque 27 MVT 628 T G 4 TOW LIFT TRUCK The lift truck can be towed at very low speeds for very short distances Block all four wheels to prevent accidental movement of the lift truck Set the reverser lever to neutral Disengage the parking brake
96. of the seat Risk of accident are increased when the seat tips up Take care not to wet the cushions fabric when cleaning them First check the fabric s resistance to the normal detergents for fabrics and plastics on a concealed surface 2 SEAT BELTS Fig 2 Sit on the seat correctly Check that the seat belt is not twisted Place the belt over your pelvis not over your stomach Fasten the seat belt and check that it is firmly engaged Adjust the belt to your physique so that it does not apply excess pres sure to your pelvic region The fork lift truck may never be used if the seat belt is faulty mounts fastening seams tears etc Repair or replace the seat belt immediately 2 MVT 628 T 3 MONITORING INSTRUMENT AND INDICATOR LIGHT PANEL Fig 3 Red alternator excitation light Red engine oil pressure light Red engine water temperature light Red air filter fouling indicator light Light not used Light not used Red brake fluid level light Red parking brake light Green direction indicator light Green side light light Green dipped headlight light Blue full beam headlight light Rpm counter Hour counter Fuel level gauge Engine water temperature DOTOZZT IOTMU0U00 gt 610 A RED ALTERNATOR EXCITATION LIGHT If lights A B C D F G and the buzzer are activated during operation of the fork lift truck stop the
97. on 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 forklift NEVER operate or allow anyone to operate a forklift when mental alertness or coordination is impaired An operator on prescription or over the counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the 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
98. ound place the gear lever in neutral apply the parking brake and put the forward reverse lever in neutral If the driver has to leave his 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 flow and at less than six ft 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 close the rear window lock the cab door and ensure that the hood is properly secured STOP INSTRUCTIONS Park the lift truck on flat ground or on an incline lower than 15 96 Place the forward reverse lever in neutral Apply the parking brake Completely retract the boom Lower the forks or attachment to rest on the ground Stop the I C engine Remove the ignition key Check the closing and locking of door rear window and hood Before leaving your driver s cabin ensure that you have carried out all operations for stopping the lift truck for your safety and the safety of others 10 MVT 628 T 1 F DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY SAFETY INSTRUCTIONS 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 pr
99. ovisions of the Highway Code If necessary optional solutions exist consult your dealer 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 else dismounted INSTRUCTIONS FOR DRIVING ON ROADS Ensure that the flashing light is installed and is in perfect working order Dipped headlights working also during hours and on roads where it is not obligatory to use visual and lighting indicator devices Check the headlights turn indicators and windscreen wipers to ensure they are clean and in perfect working condition Check the position of the rear view mirrors Check wheel alignment and select the steering mode TRAVELLING ON ROADS Position the rear axle steering mechanical block Ensure that the fuel level is sufficient Ensure that the truck is fitted with all the accessories required for traveling on roads depending on the model and country Keep the boom retracted and the attachment about 12 in above ground level Cut out the operating system control by means of the red button he vehicle can only circulate without load The vehicle must not be used for transporting the company personnel While on the road do not put the reverse gear in neutral to maintain lift truck exhaust brake 11 1 MVT 628 T G DRIVING THE LIFT TRUCK WITH TRAILER ON ROADS To use a trailer observe the re
100. pling If it is not oriented correctly take the precautions necessary to shift it to maximum safety condi tions Check to make sure the check pin is inserted in the support provided on the chassis Position the lift truck with the boom lowered in front and parallel to the accessory and incline the quick release coupling forwards Fig A Bring the quick release coupling under the accessory coupling tube raise the boom slightly and incline the coupling backwards to posi tion the accessory Fig B Disengage the accessory from the ground to facilitate blockage Check to make sure that the safety screw is present and blocked perfectly on the fork holder Fig C MANUAL BLOCK Take the check pin on the support and block the accessory Remember to fit the split pin Fig D MANUAL RELEASE Repeat the MANUAL BLOCK procedure in reverse order taking care to refit the check pin in the support on the chassis REMOVING AND PLACING THE ACCESSORY Repeat the ACCESSORY PICKUP procedure in reverse order taking care to place it in a safe position on compact level ground MVT 628 T 5 ADJUSTING THE OPENING OF THE FORKS Raise the lever of the forks check pin Fig A Move the forks manually to the required operating width Lower the check pin rod Fig B and move the forks until they are inserted in the locking notch present on the fork carriage Fig C When lifting loads with the lift truck first check to
101. practices 2 Create an effective operator training program centered around user company s policies operating condi tions and rough terrain forklift trucks The program should be presented completely to all new operators and not be condensed for those claiming previous experience 3 Information on operator training is available from several sources including rough terrain forklift truck man ufacturers users government agencies etc 4 An operator training program should consist of the following a careful selection of the operator considering physical qualifications job attitude and aptitude b emphasis on safety of stock equipment operator and other personnel C citing of rules and why they were formulated d basic fundamentals of rough terrain forklift truck and component design as related to safety e g in Ib N m loading mechanical limitations center of gravity stability etc e introduction to equipment control locations and functions Explain how they work when used properly and problems when used improperly f supervise practice on operating course remote from normal activity and designed to simulate actual operations e g lumber stacking elevating shingles to the roof etc 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
102. r cartridge intake suction rose E4 Empty and replace front and rear axle differential oil E5 Empty and drain front and rear wheels reduction gear oil E6 Replace transmission box oil E Empty and clean fuel tank E8 Replace alternator belt crankshaft E9 Replace transmission hydraulic oil vent E10 Check telescopic boom pads for wear F EVERY 2000 HOURS SERVICE OR YEARLY e F1 Check engine valve F2 Check injectors F3 Check alternators and starter motor F4 Check turbo compressor G OCCASIONAL OR ANNUAL MAINTENANCE e G1 Check and replace cooling circuit liquid if necessary G2 Check injector maintenance G3 Replace a wheel G4 Tow lift truck G5 Load the lift truck G6 Transport lift truck to a platform Adjust headlights For these operations consult your agent or dealer O To be carried out once a year if the lift truck has not completed the required number of operating hours A In an extremely dusty atmosphere reduce the frequency and replace earlier Every 50 hours up to the first 250 hours and periodically every 1000 hours service B in the event of prolonged use in an extremely dusty or oxidising atmosphere reduce this interval to 10 working hours or every day 3 MVT 628 T A DAILY OR EVERY 10 HOURS SERVICE A 1 CHECK ENGINE OIL LEVEL Before checking the oil level make sure that the engine is off
103. r tire inflation and the judgement exer cised by the operator C OPERATING SAFETY RULES AND PRACTICES 1 Safe operation is the responsibility of the operator 2 This equipment can be dangerous if not used properly The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself other personnel the rough terrain forklift truck and other material 3 The operator shall be familiar with the operation and function of all controls and instruments before under taking to operate the rough terrain forklift truck 4 Before operating any rough terrain forklift truck truck operators shall have read and be familiar with the operator s manual for the particular truck being operated 5 Before starting to operate the rough terrain forklift truck a be in operating position and fasten seat belt b place directional controls in neutral apply brakes d start engine 6 Do not start or operate the rough terrain forklift truck any of its functions or attachments from any place other than the designated operator s position 7 Keep hands and feet inside the operator s designated area or compartment Do not put any part of the body outside the operator compartment of the rough terrain forklift truck 8 Never put any part of the body into the mast structure or between the mast and the rough terrain forklift truck 9 Never put any part of the body within the reach mechanism of the
104. re that no person or object is in the vicinity before raising the load Don t make any sudden manoeuvres the case of work near aerial lines ensure that the safety distance 15 sufficient between the working area of the lift truck and the aerial line You must consult your local electrical agency 13 You could be electrocuted or seriously injured if you 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 the local regulations in force regarding all types of work carried out close to power cables Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load When using the lift truck on a slope before raising the jib ensure that the ground is horizontal Travelling on a longitudinal slope Drive and brake gently Moving without load Forks or attachment facing downhill Moving with load Forks or attachment facing uphill Ensure that scaffolding loading platform or pile are capable of bearing the weight Ensure the stability and solidity of the ground before depositing a load 14 MVT 628 T MVT 628 T D HANDLING Always consider safety and only transport balanced and correctly secured loads to avoid any risk of tipping Fully engage forks under the load and move it in the transport position The forks 12 in from the ground the jib retracted to the maximum and
105. regulation that requires specific forklift operator training 81910 178 1 When a forklift telescopic handler is configured and used for hoisting the employer must ensure that 1 Forklift lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manufacturer s instructions VI 5 Operator and crew members have been trained in 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 distance specified by OSHA 10 feet 3 0 m and more for lines rated over 50 kV of any energized power line and any taglines used are non conductive 7 In addition for lift equipment with a rated capacity greater than 2000 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 qualificati
106. 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 C 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 block the wheels g fully lower the load engaging means 17 Maintain a safe distance from the edge of ramps platforms and other similar working surfaces 18 Do no move railroad cars or trailer with a rough terrain forklift truck ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPE
107. s 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 brakes f steering mechanism g fuel system s 51 If the rough terrain forklift truck is found to be in need of repair or in any way unsafe or if it contributes to an unsafe condition the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 52 If during operation the rough terrain forklift truck becomes unsafe in any way the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 53 Do not make repairs or adjustments unless specifically authorized to do so 54 When refueling smoking in the area shall not be
108. service personnel immediately ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont 2 CREATE A MAINTENANCE PROGRAM cont For the best forklift performance and operation a maintenance program is required Use the hour meter on the instrument panel to keep maintenance properly scheduled see SECTION TWO Servicing Schedule For repairs on major components engine transmission etc contact your nearest dealer for a Repair Manual Do not operate a forklift that is damaged or does not function properly Only authorized personnel may make repairs or adjustments to the lift truck After repairs the lift truck must be tested for safe operation before returning to service 3 FORKLIFT KNOWLEDGE Forklift trucks can cause serious injury if improperly used or maintained Study all of the manuals provided for your forklift model Learn the locations and meanings of all safety decals If any decals are illegible or miss ing have them replaced immediately Make sure all safety features provided by the original manufacturer are in place and function properly Do not operate a forklift with damaged 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
109. sig Pressure 170 bars 2428 PSI SP CIFICATIONS Maximum speed Forward Reverse Unload 35 km h 21 7 mph Forward Reverse Loaded 10 km h 6 2 mph The maximum speed may be reduced depending on the laws which regulate road travel in different countries Gradeability best slip condition Unloaded 100 Loaded 68 Tire dimensions Front and rear 15 19 5 NHS SGL Tire pressures Front and rear 4 2 bars 60 PSI Lifting speed telescopic boom retracted unloaded 3 m min 6 5 sec 121 4 feet min Lowering speed telescopic boom retracted unloaded 46 7 m min 5 14 sec 153 feet min Telescopic boom speed Unloaded extension 16 1 m min 8 65 sec 52 8 feet min Telescopic boom speed Unloaded retract 28 5 m min 4 9 sec 93 5 feet min Reverse tilt time unladen 42 8 sec 3 15 sec Forward tilt time unladen 50 9 2 65 sec MVT 628 T Fork dimensions lenght x width x thickness 1200 x 125 x 40 mm 47 25x4 93x1 57 inches External fork spread 1350 mm 03 inches Spread by center 610 mm 24 inches Rated capacity with std equipment 2800 kg 6000 155 Weights with std carriage and forks 5600 kg 12345 lbs Axle ground weights with std equipment Front unloaded 2875 kg 6338 155 Rear unloaded 2 25 kg 6007 Ibs Loaded weights with std carriage and forks 8400 kg 18518 lbs Loaded and with telescopic arm retracted forks at 20 cm up Front 7270 kg 16027 lbs Rear 1130 kg 2491 lbs Drawbar pull Unload 4440 kg 9788 lbs Loaded 5
110. sitioned take the necessary precautions to move it in the conditions of maximum safety Check that the locking pin is engaged in the support provided on the frame Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement MANUAL LOCKING AND CONNECTION OF THE ACCESSORY Take the locking pin on the support and fix the accessory Fig C Do not forget to fit the split pin Switch off the engine Eliminate the accessory hydraulic circuit pressure using the optional control refer to the controls pages of the use and maintenance manual Connect the snap couplings following the description of the hydraulic movements of the accessory Keep the snap couplings clean and protect the unused orifices with the caps provided REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking care to place it in a safe position on firm flat ground MVT 628 T 5 ACCESSORY WITH HYDRAULIC SYSTEM AND HYDRAULIC LOCKING OPTIONAL ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it
111. stem the connections and fastening devices IF NECESSARY CONSULT YOUR DEALER 23 2 DESCRIPTION MVT 628 T 2 SPECIFICATIONS ENGINE Type Cylinders number Number of strokes Injection system Firing order Displacement Bore Stroke Volumetric ratio Nominal rpm Idling rpm Power ISO TR 14396 Maximum torque 1400 min COOLING SYSTEM Type Suction speed fan Number of blades Diameter Thermostat Complete open ELECTRICAL CIRCUIT Ground Battery Alternator Voltage regulator Starting BRAKE Service brake Parking brake PERKINS 1104C 44T 4 4 direct 1 3 4 2 4400 cm 260 cu in 105 mm 4 13 inches 127 mm 5 inches 17 5 1 2200 rpm 800 rpm 101 cv 74 5 kw 412 Nm 42 kgm Water cooled 2300 min 7 500 mm 19 69 inches 82 179 6 Negative 12 V 120 Ah 12V 75 Ah incorporated in the alternator 12 V Disc brakes in oil bath Foot pedal actuated on both axles Hydraulic actuated on front axle negative type 2 MVT 628 T TRANSMISSION Hydrostatic Pump and variable displacement engine Performance 0 35 km h 0 21 7 mph Reverser Electro hydraulic No of wheels 4 HYDRAULIC CIRCUIT Lifting tilting of telescopic boom and device Type of pump Gear type Delivery 80 L min 21 1 Gpm Pressure 235 bars 3357 PSI Steering circuit Type of pump Load sen
112. 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 ASME B56 6 is the national consensus standard for rough terrain forklift trucks It contains rules about fork lift safety maintenance safe operation training and supervision Forklift owners should learn this standard and make it available for their operators service personnel and supervisors These standards can be obtained from the American Society of Mechanical Engineers ASME 345 East 47th St United Engineering Center New York NY 10017 The following references are examples from the standard addressing forklift operators A OPERATOR TRAINING QUALIFICATIONS 1 The user shall ensure that operators understand that safe operation is the operator s responsibility The user shall ensure that operators are knowledgeable of and observe all safety rules and
113. tighten drainage plug 7 fig E3 2 Fill the oil tank see LUBRICANTS Table through filler hole 8 Fig E3 1 to the right level see operation No B2 Check for leakage through drainage hole 7 fig E3 2 Fit tank cover 8 fig E3 2 Use only filtered uncontaminated oil It may sometimes be necessary to allow the 1 engine to idle to bleed the pump infeed circuits if an air bubble has been formed during drainage If the air bubbles persist consult your agent or dealer E4 EMPTY AND REPLACE FRONT AND REAR AXLE DIFFERENTIAL OIL Put the truck on a horizontal surface with the engine off and the differ ential oil still warm Drain the oil from the front axle differential Place a can under drain plug 9 Fig E4 1 and allow the oil to drain out Remove level plug and fill plug 10 Fig E4 1 to ensure that all oil drains out Refit and tighten plug 9 Fig E4 1 Fill with oil see LUBRICANTS Table through fill hole 10 Fig E4 1 The level is correct when the oil reaches the top of level hole 10 Fig E4 1 Check for any leaks from the drain plugs Refit and tighten level plug and fill plug 10 Fig E4 1 Repeat these operations for the rear axle differential through the hole of filling 11 Fig E4 2 and level 12 Fig E4 2 20 MVT 628 T 3 E 5 EMPTY AND DRAIN FRONT AND REAR WHEELS REDUCTION GEAR OIL Position the truc
114. withdraw the lift truck s certificate of compliance BY USING ORIGINAL PARTS DURING MAINTENANCE OPERA TIONS YOU ARE LEGALLY COVERING YOURSELF Any user who procures parts from another quarter does so at his own risk Any user who modifies his lift truck or has it modified by a service com pany must consider that a new item of equipment has been brought onto themarket and therefore takes liability for it Any user who copies original parts or has them copied is taking a risk from the legal viewpoint he 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 THE MANUFACTURER BRINGS TO THE USER His know how and skill Guaranteed 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 mainte nance 1 MVT 628 T DRIVER S OPERATING INSTRUCTION WARNINGS 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
115. work on the lift truck connect the negative cable from the equipment directly to the part being welded so as to avoid high tension current passing through the alternator 20 MVT 628 T 1 MAINTENANCE The maintenance and the keeping in compliance of the lift truck are compulsory Carry out daily maintenance See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAINTENANCE Do not run the I C engine without air filter or with oil water or fuel leaks Wait for the 1 C engine to cool before removing the radiator cap Change the filter cartridges See servicing schedules in chapter FILTERS CARTRIDGES AND BELTS in paragraph 3 MAINTE NANCE C LEVELS Use the recommended lubricants Never use contaminated lubricants Do not fill the fuel tank when the engine is running Only fill up the fuel tank in areas specified for this purpose D WASHING Clean the lift truck or at least the area concerned before any inter vention Remember to close the door and the rear window of the cab During washing avoid the articulations and electrical components and connections If necessary protect against penetration of water steam or cleaning agents components susceptible of being damaged particularly electri cal components and connections and the injection pump Clean the lift truck of any fuel oil or grease trace FOR ANY INTERVENTION OTHER THAN REGULAR MAINTE N
116. y 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 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
117. yours agent or concessionaire Never try to carry out welding loneley that could cause an outbreak or a fire Place a receptacle under drain plug 17 Fig E7 1 and unscrew the plug Remove drain plug 19 Fig E7 2 Allow the fuel to drain out and clean with 2 gallons of clean fuel poured through fill hole Refit and tighten drain plug 17 Fig E7 1 Fill the tank with clean fuel filtered through a filter or clean cloth then refit plug 18 Fig E7 2 Before the starter motor is engaged operate the lift pump for one minute to eliminate air from the filter Start the engine at low idle for two minutes 22 MVT 628 T MVT 628 T 3 E 8 REPLACE ALTERNATOR BELT CRANKSHAFT Place the truck on a flat surface with the engine off Loosen the connection screw of alternator 19 and the set screw of the belt tensioner lever 20 Fig E8 by 2 or 3 thread turns and rotate the position of the alternator to loosen the tension of the belt so that it can be removed from the pulleys Replace the belt with another one with similar features see FILTER ELEMENTS AND BELTS Table and rotate the position of the alterna tor to apply the correct tension on the belt Tighten the set screw of the belt tensioner 20 Fig E8 and the alter nator connection screws 19 Fig Check the belt tension again to make sure it is still correct It is recommended to check the belt tension a
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