Home

MLT 735 -120 LSU Series 4-E3

1. 6 0 6 PLATE MANUFACTURER OF THE ATTACHMENT FIG 1 Model Serial No Year of manufacture 6 6 0 6 0 0 6 0 6 0 O 9 O O0 O 6 0 0 6 6 6 0 0 0 0 9 O 0 6 ooo 2 5 r IT AWARNING INTRODUCTION TO SAFETY CHARACTERISTICS MLT 735 120 LSU Series 4 E3 Type Fuel Diesel Number of cylinders Suction Injection system Ignition sequence Capacit Bore and stroke Compression ratio Nominal rating loaded Max rating unladen Power ISO TR 14396 Power SAE J 1995 Maximum torque ISO TR 14396 Air cleaner Type of cooling TURNER Electro hydraulic SACHS SACHS Front axle Differential
2. Place the lift truck with the jib fully lowered in front of and parallel to the attachment tilt the carriage forwards fig B Bring the carriage under the locking tube of the attachment slightly lift the jib incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to facilitate locking HAND LOCKING Jake the locking pin and the clip on the bracket fig A and lock the attachment fig D Do not forget to install the clip HAND RELEASING Proceed in the reverse order of paragraph HAND LOCKING while making sure you install the locking pin and the clip in the bracket fig A LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position er E XN Loue us 9 PT Kr Pet 0 ww Qt ie jit E ESEN BEAT 4 6 INTRODUCTION TO SAFETY B ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE OPTION TAKING UP AN ATTACHMENT Ensure that the attachment is in alignment to the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the rods on the locking cylinder are retracted fig A Place the lift truck with the jib fully lowered in front of and parallel to the attachment tilt the carriage forwards fig B Bring the carriage under the locking tube
3. Top up the level if necessary INTRODUCTION TO SAFETY D3 DRY AIR FILTER CARTRIDGE CHANGE In case of use in a heavily dust laden atmosphere there are pre filtration cartridges see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Also the checking and cleaning schedule of the cartridge must be reduced every 250 hours in a heavily laden dust atmosphere and with pre filtration Open the I C engine cover Loosen the bolts and remove cover 1 fig D3 Gently remove the cartridge 2 fig D3 taking care to avoid spilling the dust Leave the safety cartridge in place he following parts must be cleaned with a damp clean lint free cloth The inside of the filter and cover The inside of the filter inlet hose The gasket surfaces in the filter and in the cover Check pipes and connections between the air filter and the I C engine and the connection and state of the clogging indicator on the filter Before installing check the state of the new cartridge see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Introduce the cartridge into the filter axis and push it in pressing the edges and not the middle Reassemble the cover guiding the valve downwards D4 FUEL PRE FILTER CHANGE Open the I C engine cover Carefully clean the outside of the pre filter and its holder to prevent dust from getting into the system Place a container under the pre filter and drain it using drain plug 1 fig D
4. 1 Rough terrain forklift trucks can cause injury if improperly used or maintained 2 Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to oper ate rough terrain forklift trucks Unusual operating conditions may require additional safety precautions train ing and special operating instructions 3 Modifications and additions which affect capacity or safe operation shall not be preformed without the man ufacturer s prior written approval Where such authorization is granted capacity operation and maintenance instruction plates tags or decals shall be changed accordingly 4 If the rough terrain forklift truck is equipped with front end attachment s or optional forks the user shall see that the truck is marked to identify the forks or attachment s show the approximate weight of the truck and fork or attachment combination and show the capacity of the truck with forks or attachment s at maximum elevation with load laterally centered 5 The user shall see that all nameplates and caution and instruction markings are in place and legible 6 The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont B GENERAL SAFETY PRACTICES cont 7 Where steering can be accomplished with either hand and the steering mechanism is of a type that pre vents r
5. DRAINING THE OIL Open the I C engine cover Remove access panel 1 fig D1 1 Place a container under drain plug 2 fig D1 2 and unscrew the plug 3 fig D1 3 Take drain hose 4 fig D1 4 Place the end of the drain hose in the container and screw fully the union on draining port 5 fig D1 5 Remove filler cap 6 fig D1 6 in order to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner REPLACEMENT OF THE FILTER Remove I C engine oil filter 7 fig 01 3 discard the filter and the filter seal Clean the filter bracket with a clean lint free cloth Lightly grease the new oil filter seal and install the oil filter see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS on the filter bracket Tighten the oil filter by hand pressure only and lock the filter in place by a quarter IMPORTANT DEPT PR FILLING UP THE OIL Loosen clean and install the drain hose 4 fig D1 4 Install and tighten drain plug 3 fig D1 3 Install access panel 1 fig D1 1 Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL through filler port 8 fig D1 6 Wait a few minutes to allow the oil to flow into the sump Start the I C engine and let it run for a few minutes Check for possible leaks at the drain plug and the oil filter Stop the I C engine wait a few minutes and check the level between the two notches on dipstick 9 fig D1 6
6. G Right rear reverse light H Right tail light Right rear stoplight J Right rear indicator 33 REVOLVING LIGHT The magnetic revolving light must be clearly visible on the roof of the cab and plugged in to socket 1 34 STEERING WHEEL ADJUSTMENT LEVER This handle enables the angle and height of the steering wheel to be adjusted Pull handle 1 to adjust the steering wheel Push in handle 1 to lock the steering wheel in the desired position 35 SPIRIT LEVEL Enables the operator to check that the lift truck is in the horizontal position 36 SUN VISOR 2 33 37 ROOF LIGHT 38 HOOK 39 CIGAR LIGHTER 40 DIAGNOSTIC CONNECTOR 41 TOOL BOX 2 34 INTRODUCTION TO SAFETY TOWING PIN AND HOOK Located at the rear of the lift truck this device is used to attach a trailer Its capacity is limited for each lift truck by the authorized gross vehicle weight tractive effort and maximum vertical force on the coupling point This information is given on the manufacturer s plate fixed to each lift truck see 2 DESCRIPTION IDENTIFICATION OF THE LIFT TRUCK To use a trailer see current regulations in your country maximum running speed braking maximum weight of trailer etc Verify the trailer s condition before using it tire condition and pressures electrical connection hydraulic hose brake system Aw ARNING Do not tow a trailer or accessory which is not in proper worki
7. Gear box controls o Orr 66 Gear box pressures pp 1Ct Converter pressure o jj PO fe Tires pressure pp C lt lt lt lt lt lt lt lt lt lt lt lt Wheel nuts torque 1 G lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt Condition of wheels andtires 1 pp Orr lt lt lt lt lt lt Wheel RT Hibpads pf 6 E lt lt Jibpadswer pp Bearings and articulation ings SCS Sid Si OC ii Si rere HYDRAULIC Aydraufic ollevel Ice ee eee Hyjauicol pp eee ee IHtercapforhydrulicoltank I O Ree Distributor control head eee Speedsofhydrauio movements 0 0r Condition of cylinders leakage shafts OA eee Hydraulic circuit pressures pf Hydraulic circuit outputs pp Hydauicoltank pp pf pf eee 2 pa e INTRODUCTION TO SAFETY AFTER HE DAILY OR A ADJUST CHECK G GREASE N CLEAN P BLEED as EVERY R REPLACE V DRAIN CHANGE ed E 2 HOURS 8 BRAKE Brake oillevel p O ee lt lt lt lt lt lt lt lt lt lt lt Parking brake OA lt lt lt lt lt lt lt lt lt eec Parking brake levermechanism G e lt
8. HAND RELEASING AND DISCONNECTING THE ATTACHMENT Proceed in the opposite order to that described in MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT while making sure you put the locking pin back into the bracket fig A LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position 4 8 INTRODUCTION TO SAFETY D HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING OPTION TAKING UP AN ATTACHMENT Ensure that the attachment is in inalignment to the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the rods on the locking cylinder are retracted fig A Place the lift truck with the jib fully lowered in front of and parallel to the attachment tilt the carriage forwards fig B Bring the carriage under the locking tube of the attachment slightly lift the jib incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to facilitate locking HYDRAULIC LOCKING AND CONNECTING THE ATTACHMENT Put the valve in position A fig D that is to say the hydraulic circuit of the attachment locking open Switch button 1 fig E of the distributor lever forwards to completely lock the attachment on the carriage Stop the I C engine and keep the ignition on the lift truck Remove the pressure of the
9. Insure the hood s are properly secured and locked in place Make sure that the forward reverse lever is in neutral Turn the ignition key to the position to activate the electrical system Make sure the signal lights on the instrument control panel and fuel level indicators are working properly see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Turn the ignition key to position Il to preheat for 15 seconds then turn the ignition key fully the I C engine should then start Release the ignition key and let the I C engine run at idle Do not engage the starter motor for more than 15 seconds and perform preheating for 10 seconds between unsuccessful star ting attempts Insure all signal lights on the instrument control panel go off before driving the forklift Check all instruments and controls again after the I C engine is warm and at frequent intervals during use If an instrument does not show the correct display safely park the forklift and stop the I C engine Report the problem immedia tely and make necessary arrangements for repair or service INTRODUCTION TO SAFETY F DRIVING THE LIFT TRUCK SAFETY NOTICE Operators attention is drawn to the risks involved in using the lift truck in particular A ANGER Risk of losing control Risk of losing lateral and frontal stability of the lift truck The operator must remain in control of the lift truck In the event of the lift truck overturning do not tr
10. O m 2 o Forkswear ice Attachment carriage PP er e Condition of attachments PP o o SERE o 00 Ola D gt 50 3 0 E AA e 2 5 Y ci c C N O 2 O N 3 INTRODUCTION TO SAFETY A1 ENGINE OIL LEVEL CHECK Park the lift truck on level ground with the I C engine stopped and let the oil drain into the sump Open the I C engine cover Remove the dipstick 1 fig A1 Clean the dipstick and check the correct level between the two notches If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the filler port 2 fig A1 Check visually that there is no leakage or seepage of oil in the I C engine A2 COOLING LIQUID LEVEL CHECK Park the lift truck on level ground with the I C engine stopped and allow the I C engine to cool Open the I C engine cover Check the correct level in the middle of gauge 1 fig A2 If necessary add cooling liquid see 3 MAINTENANCE LUBRICANTS AND FUEL Slowly turn the cap of the radiator 2 fig A2 up to the safety stop Allow the pressure and the steam to escape Press down and turn the cap so as to release it Add cooling liquid via filler port 3 fig A2 up to the middle of gauge 1 fig A2 Lubricate slightly the filler neck in order to ease the removal of the radiato
11. 100 20 MANITOU MANITOU N gt ENEP 3w CONTROL INSTRUMENTS A I C ENGINE WATER TEMPERATURE Temperature zone A1 Blue zone 0 50 Use the lift truck with moderation wait for temperature to increase before normal operation A2 Green zone 50 100 Use lift truck normally A3 White red zone 100 105 Use lift truck with moderation monitor the temperature A4 Red zone 105 120 Stop the lift truck look for the cause of overheating NOTE Red indicator light comes on between zone A3 and A4 B HOOUR METER AND REV COUNTER C FUEL LEVEL Red zone C1 indicates that you are using the reserve supply and that time of use is limited D TIME DIAL SIGNAL LIGHTS A permanently lit or flashing warning lamp with the engine running is the sign of an operating fault The lighting of some lamps J y oobis I may be accompanied by an audible signal Do not ignore this warning consult your dealer without delay If one of the warning lamps comes on while the lift truck is in motion stop the lift truck under the safest possible conditions In order to comprehend the diagnostic and find cause of the malfunction refer to chapter 3 MAINTENANCE SERVICING SCHEDULE When activating the electrical system of the lift truck all the red and orange lamps and the panel s buzzer must light to indicate their good working order If one of the red lamps or the buzzer does not f
12. J PJ Rearladen __ PRESSURE S5psil 38 38 38 400 8024 Frontunladen J 162A8 IND POWER CL Frontladen_ GP TUBELESS Rearunladen Rearladen J PRESSURE 38psi 26 26 500 70R24 Frontunladen XMCL164A8 Frontladen PJ TUBELESS Rearunladen MLT 634 120 LSU POWERSHIFT S rie D E3 MLT 735 120 LSU POWERSHIFT S rie 4 E3 MLT 741 120 LSU POWERSHIFT S rie 4 E3 MLT 634 120 LSU S rie D E3 MLT 731 TA LSU S rie D E3 MLT 735 120 LSU S rie 4 E3 MLT 741 120 LSU S rie 4 E3 MLT 1035 L TA LSU S rie 4 E3 2 p N 7 co 5 MLT 731 TA S rie D E3 MLT 742 TA S rie 4 E3 eo L E N c Reden o PRESSURE 2 75 2 75 2 75 2 75 2 75 2 75 40psi 275 35 35 15 5R25 Frontuntaden XHA Retlden pp PY TUBELESS Rearunladen Rearladen 1 Jo PP PRESSURE 55 55 55 55 55 55 1200r20 Frontuntaden N _ NM XMINED2 J NEM NEM mE M Rearunladen 1 J
13. Stop the I C engine and remove the ignition key when service is necessary Read the operator s manual carefully Perform all necessary repairs immediately including minor repairs Repair all leaks immediately including minor leaks Insure disposal of all used materials and spare parts are carried out in a safe and ecological manner Beware of the risk of burns and or splashing of components while servicing the lift truck engine exhaust radiator fluids etc MAINTENANCE Perform periodic services see 3 MAINTENANCE to keep your lift truck in good working conditions Failure to perform the perio dic services may cancel warranty LUBRICANT AND FUEL LEVELS Use the recommended lubricants never use contaminated lubricants Do not fill the fuel tank while the I C engine is running Fill the fuel tank only in areas specified for this purpose Do not fill the fuel tank to the maximum level Do not smoke or approach the lift truck with a flame while the fuel tank is open or is being filled HYDRAULIC Do not attempt to loosen connections of hoses or any hydraulic component with the circuit under pressure BALANCING VALVE For inspection see 3 MAINTENANCE D EVERY 500 HOURS SERVICE It is dangerous to WARNING change the setting or remove the balancing valves or safety valves which may be fitted to your lift truck cylinders These operations must only be performed by approved personnel consu
14. USE THE RECOMMENDED LUBRICANTS AND FUEL For topping up do not mix the oils DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been organized with the dealer a diagnostic analysis of engine gear box and axle oils may be requested depending on the rate of use RECOMMENDED FUEL SPECIFICATION Use a high quality fuel to obtain optimal performance of the I C engine N590 diesel fuel type Auto CO C1 C2 C3 C4 BS2869 Class A2 e ASTM 0975 91 Class 2 2DA US DF1 US DF2 US DFA gt JIS K2204 1992 Grades 1 2 and Special Grade COMPONENT CAPACITY RECOMMENDATION ERE Shell Rotella 15w40 I C ENGINE 2 9 gal Citgo C 600 15w40 COOLING CIRCUIT Shell Donax TG Dexron Ill AM SI N Er Citgo Transgard ATF Dexron Ill Shell Spirax DH 80w90 AE EA BOA 2 3 GS Citgo Premium Gear MP 80w90 Shell Rentinax Am TRANSMISSION UNIVERSAL JOINT Citgo Lithoplex CM 2 COMPONENT RECOMMENDATION Shell Rentinax Am EDS Citgo Lithoplex CM 2 Shell Rentinax Am GREASING OF THE JIB Citgo Lithoplex CM 2 3 8 INTRODUCTION TO SAFETY COMPONENT CAPACITY RECOMMENDATION O Shell Tellus T46 HYDRAULIC OIL TANK Citgo Transgard THF Lo Temp COMPONENT RECOMMENDATION O Shell Donax TG Dexron III Citgo Transgard ATF Dexron Ill COMPONENT RECOMMENDATION Du WINDSCREEN WASHER TANK Windscreen washer fluid _ COMPONENT CAPACITY RECOMMENDATION Shell Donax TD
15. 4 10
16. INTRODUCTION TO SAFETY To prevent accidental loosening or release the lever is fitted with safety locking To apply the parking brake pull the lever backwards position A To loosen the parking brake release and push the lever forwards position B 19 STEERING SELECTION Before selecting one of the three possible steering positions bring the 4 wheels into alignment i e in the straight ahead position A GREEN WHEEL ALIGNMENT LAMPS These lamps come on to indicate the alignment of the wheels in relation to the lift truck Lamp A1 for the front wheels and lamp A2 for the rear wheels Before selecting one of the three possible steering positions bring all 4 wheels A CAUTION into alignment with regards to the lift truck axle Never change the steering mode while driving B STEERING SELECTION LEVER B1 Front drive wheels highway traffic B2 Front and rear drive wheels in opposite direction short steering lock an B3 Front and rear drive wheels in the same direction crab steering NN C SWITCH FOR ALIGNMENT OF THE WHEELS This switch enables the use of the device for alignment of the wheels The indicator light indicates its use CONTROL FOR ALIGNMENT OF THE WHEELS Connect the switch signal light ON Shift the steering selection lever B into position B2 short steering lock Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up Shift the steering s
17. LIFT TRUCK WITHOUT SLOPE CORRECTOR FRAME LEVELING USED ON TIRES Position the lift truck so that the bubble in the level is between the two lines see 2 DESCRIPTION INSTRUMENTS AND CONTROLS INTRODUCTION TO SAFETY E TAKING UP A LOAD FROM THE GROUND Position the lift truck perpendicular to the load with the boom retracted and the forks in a horizontal position fig E1 Adjust the fork spread and centering in alignment with the load fig E2 optional solu tions exist consult your dealer Never lift a load with a single fork Beware of the risks of pinching or crushing limbs when manually adjusting the forks Move the lift truck forward slowly 1 and bring the forks to the front of the load fig E3 if necessary slightly lift the boom 2 while taking up the load Bring the load into the transport position Tilt the load far enough backwards to ensure stability to avoid loss of load while bra king FOR A NON PALLETIZED LOAD Tilt the carriage 1 forwards and move the lift truck slowly forwards 2 insert the forks under the load fig E4 block the load if necessary Continue to move the lift truck forwards 2 tilting the carriage 3 fig E4 backwards to position the load on the forks Check the load s longitudinal and lateral stability INTRODUCTION TO SAFETY F TAKING UP AND LAYING A HIGH LOAD ON TIRES Do not raise the boom until you have first checked the level attitud
18. On the basis of experience there are a number of possible situations in which operating the lift truck is prohibited Such foreseeable abnormal uses the main ones being listed below are strictly forbidden The foreseeable abnormal behavior of neglect but not intending to put the machinery to any improper use The reflex reactions of a person in the event of a malfunction incident fault etc During operation of the lift truck Behavior resulting from application of the principle of least action when performing a task For certain machines the foreseeable behavior of such persons as unauthorized apprentices teenagers handicapped persons and trainees tempted to drive a lift truck Truck drivers tempted to operate a truck to win a bet in competition or for their own personal experience The person in charge of the equipment must take these criteria into account when assessing whether or not a person will make a suitable driver THE LIFT TRUCK A THE LIFT TRUCK S SUITABILITY FOR THE JOB MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator s manual in accordance to ASME B56 6 2002 Before commissioning the company manager must make sure that the lift truck is appropriate for the work to be done and per form tests as required in accordance with current legislation B ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS In a
19. PHOTO NOT AVAILABLE 12 HYDRAULIC ATTACHMENT LOCKING Enables attachment locking to be controlled on the carriage and the use of a hydraulic attachment on the same hydraulic circuit see 4 OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE PICKING UP THE ATTACHMENTS 13 QUICK RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT HYDRAULIC ATTACHMENT LOCKING PHOTO NOT AVAILABLE 2 39 INTRODUCTION TO SAFETY 14 ELECTROVALVE ON JIB HEAD Enables use of two hydraulic functions on the attachment circuit PHOTO NOT AVAILABLE OPERATION Button 1 not engaged button 2 controls a hydraulic function Hold button 1 down button 2 controls another hydraulic function NOTE Switch 3 enables the hydraulic function controlled by button 1 to be locked Indicator 4 lights up to show when it is in use 15 JIB HEAD ELECTROVALVE HYDRAULIC ATTACHMENT LOCKING The addition of these two options enables the combining of several hydraulic functions PHOTO NOT AVAILABLE 16 PREARRANGED TRAILER LOCKING Enables the hydraulic connection of a braked trailer see 2 DESCRIPTION TOWING PIN AND HOOK 2 40 INTRODUCTION TO SAFETY 17 SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION Enables the use of a hydraulic attachment at the rear of the lift truck i e a trailer with hydraulic tipping OPERATION Switch 1 controls this predisposition 18 DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION SINGLE OR D
20. __ NEN PRESSURE 33 33 33 33 33 33 48psi 33 33 33 33 33 460 70R24 IT520 Fontwlden J gt 150A8 Frontiaden gt TUBELESS Rearunladen Rehdn 1l gt PRESSURE 41 41 41 41 41 41 60psi 41 41 41 41 41 445 70R24 Frontunaden gt 101536 Rotldn TUBELESS Rearunladen l O Reden PRESSURE 38 38 38 GOODYEAR 38 38 38 38 38 55 psi 38 38 38 460 65R24SF Dm TRISTEEL Frontladen j J TUBELESS pp J gt __ PRESSURE 3 3 3 3 3 3 pi 3 3 3 3 3 500 65R24 Frontumtaden T _ AN IND AGRO Fromtladen _ PP J J __ TUBELESS Reawlden J __ Rearladen PRESSURE 25 25 25 25 25 25 500 60 22 5 Front unladen 1 too fr oco fr c o TWIN 404 12PR Frontladen far c fr c o i Rearunladen J far fr pop Far gt Rerldn NEM NNNM _ NEM TRELLEBORG IMPORTANT When changing or replacing the tires and wheels u
21. fr Rearladen 1 J PP fa PRESSURE 34 34 34 34 34 34 52psi 36 49475 Front unten Frontladen 1 STABILARGE 28PR pearunladen I Rehdn 1177 PRESSURE 3 25 3 25 325 325 325 3 25 55psi 3 8 38 38 40 7020737 Frontunladen gt 150B44PR Frontladen J j J TUBELESS pp mm NEM om 5 mH om cm NM 405 70 24 __ mm MM EM SPT9 158A2 mm TUBELESS mm mm _ IMPORTANT When changing or replacing the tires and wheels use only the manufacturer s approved components as installed at the factory Any substitutes or modifications must first be approved by the manufacturer 2 8 INTRODUCTION TO SAFETY PRESSURE bar TIRE LOAD kg MLT 634 120 LSU POWERSHIFT S rie D E3 MLT 735 120 LSU POWERSHIFT S rie 4 E3 MLT 741 120 LSU POWERSHIFT S rie 4 E3 MLT 630 TA S rie D E3 MLT 634 TA LSU S rie D E3 MLT 634 120 LSU S rie D E3 MLT 731 TA S rie D E3 MLT 731 TA LSU S rie D E3 MLT 735 120 LSU S rie 4 E3 MLT 741 120 LSU S rie 4 E3 MLT 742 TA S rie 4 E3 MLT 1035 L TA LSU S rie 4 E3 PRESSURE 4 4 4 4 4 4 S8psi 4 4 4 4 155 8024 501 12pp Fontunladen p EA muss 1 oo o po Rearunladen J j Rearladen
22. position A CAUTION If you do not support the back rest when making adjustments it swings comple tely forwards LONGITUDINAL ADJUSTMENT FIG H Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position MAINTENANCE FIG 1 Dirt may adversely affect the correct functioning of the seat For this reason make sure your seat is always clean To clean or change the cushions simply remove them from the seat frame A CAUTION rocking head rest increases the risk of an accident Avoid wetting the cushion fabric when cleaning Check the resistance of the fabric on a small hidden area before using any fabric or plastic cleaner 2 15 INTRODUCTION TO SAFETY 1 BASIC PNEUMATIC DRIVER S SEAT OPTION DESIGNED FOR MAXIMUM COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS WEIGHT ADJUSTMENT FIG A It is advised that you adjust the seat according to your weight when sitting Switch on lift truck ignition Push or pull lever 1 until green appears in display 2 indicating correct adjustment according to your weight NOTE To avoid any health problems it is recommended that the weight should be checked and adjusted before starting up the lift truck SEAT HEIGHT ADJUSTMENT FIG B When weight adjustment has been carried out you can then modify seat height Keep the ignition on in the lift truck Push or pull lever 1 until green appears and adjust t
23. 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 dimensions used to establish rough terrain forklift truck capacity with extra caution Stability and maneuvera
24. CONDENSATE TRAY AND RELIEF VALVE COLLECTING COOLANT TO REPLACE FILTER DRIER REFILLING WITH COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES NOTE When opening the evaporator unit remember to replace the cover seal CONSULT YOUR DEALER WARNING DO NOT ATTEMPT REPAIRS ONLY A QUALIFIED AIR CONDITIONING SERVICEMAN SHOULD MAKE REPAIRS CONTACT YOUR DEALER Do not open the cooling circuit under any circumstances this will cause the coolant to be lost The coo ling circuit contains a gas which can be dangerous under certain conditions This gas coolant R 134a is WARNING colorless odorless and heavier than air If the gas is inhaled take the victim into fresh air give oxygen or artificial respiration if necessary and call a doctor If the gas is in contact with the skin wash it immediately under running water and remove any contaminated garments If the gas is in contact with the eyes rinse them in clear water for 15 minutes and call a doctor he compressor has an oil level gauge fig F2 Never unscrew this gauge because it would depressurizes the installation The oil level is only checked when changing the oil in the circuit 3 35 INTRODUCTION TO SAFETY G1 WHEEL CHANGE Aw ARNING In the event of a wheel being changed on the public highway make sure of the following points For this operation we advise you to use a properly rated hydraulic jack and s
25. FRONT AXLE DIFFERENTIAL Citgo Transgard THF Shell Spirax DH 80w90 FRONT WHEELS REDUCERS Citgo Premium Gear MP 80w90 FRONT WHEELS REDUCERS PIVOTS Shell Rentinax Am FRONT AXLE OSCILLATION Citgo Lithoplex CM 2 COMPONENT CAPACITY RECOMMENDATION Shell Donax TD REAR AXLE DIFFERENTIAL 1 9 gal Citgo Transgard THF Shell Spirax DH 80w90 Benn MERO REDUCERS 0 8 at Citgo Premium Gear MP 80w90 REAR WHEELS REDUCERS PIVOTS Shell Rentinax Am REAR AXLE OSCILLATION Citgo Lithoplex CM 2 COMPONENT RECOMMENDATION Shell Rentinax Am TILTING CORRECTOR Citgo Lithoplex CM 2 First 200 hrs Use Manitou Special Immersed Brakes 549 Lubricant 5 gal drum p n 545608 3 9 INTRODUCTION TO SAFETY SERVICING SCHEDULE PAS Every 10 hours during the first 50 hours then once at 250 hours Consult your dealer PA DAILY OR AFTER THE EVERY A ADJUST C CHECK G GREASE N CLEAN P BLEED FIRST 50 R REPLACE V DRAIN CHANGE HOURS OCCASIONALLY engine oil level Yo C j oss o Cooling liquid level PP S lt lt lt EEE ei pe A Fuel prefilter PG os Cyclonic pre filter PN lt lt lt Dry air filter cartridge YN lt lt lt R lt lt lt lt lt Radatorcoes pp N Tee e cc Condenser core OPTION Air conditioning PP lt lt lt lt lt lt lt lt lt lt lt lt cee Fan belt tension p
26. Remove dipstick 4 fig E3 4 and unscrew filling plug 5 fig E3 4 in order to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner CLEANING THE STRAINER Remove cover 2 fig E3 2 and set aside the O ring joint and sealing washer Allow the rest of the oil to drain away Remove and clean the strainer using a compressed air jet Clean the magnetic section on the plate Install the assembly and tighten up plate 2 fig E3 2 tightening torque 18 ft lb FILLING UP THE OIL Install and tighten drain plug 1 fig E3 1 tightening torque 33 ft lb Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 5 fig E3 4 and install the filler cap Start the 1 C engine and let it run for a few minutes Check any possible leaks from the drain plug or cover Stop the I C engine and within 5 minutes of the I C engine being stopped check on the dipstick 4 fig E3 4 the correct level between the two MIN and MAX marks Top up the level if necessary Install the cover plate 3 fig E3 3 4 E 2 Hi Ed E 1 NM dd 3 31 INTRODUCTION TO SAFETY E5 ANGLE GEARBOX OIL DRAIN Park the lift truck on level ground with the I C engine stopped the angle gear box oil still warm Place a container under drain plug 1 fig E5 1 and unscrew the plug Remove dipstick 2 fig
27. 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 Parkthe lifttruck see 1 OPERATING AND SAFETY INSTRUCTIONS DRIVING INSTRUCTIONS UNLADEN AND LADEN STOW THE LIFT TRUCK Fix the chocks to the platform at the front and at the back of each tire fig G5 1 Fix also the chocks to the platform in the inside of each tire fig G5 2 Stow the lift truck on the platform with enough resisting straps chains At the front of the lift truck on the fastening points 1 fig G5 3 and at the back on the towing pin 2 fig G5 4 Tighten the straps chains fig G5 5 e ep 3 38 4 ENGAGING THE ATTACHMENTS INTRODUCTION TO SAFETY 4 2 INTRODUCTION TO SAFETY INTRODUCTION 4 5 PICKING UP THE ATTACHMENTS 4 6 A ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE 4 6 B ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE OPTION 4 7 C HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE 4 8 D HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING OPTION 4 9 4 3 INTRODUCTION TO SAFETY 44 INTRODUCTION TO SAFETY INTRODUCTION Your lift truck must be used with interchangeable equipment These items are called ATTACHMENTS A wide range of attachments specially designed and perfectly suitable for your lift truck is available and guaranteed by MANITOU he a
28. a step Do Not Tow 494918 Hydrostatic equipped models Location on the dash in view of the operator A WARNING THIS VEHICLE IS EQUIPPED WITH A forklift will the transmission HYDROSTATIC TRANSMISSION DO NOT ATTEMPT refer to the operator s manual TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494918 XIV INTRODUCTION TO SAFETY SAFETY DECALS Boom equipped models Location on the boom coupler WA H 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 MENU Location at points provided on the forklift where straps or chains may be attached to secure the forklift to a trailer during transport 24653 Fork Safety 426641 Mast equipped models Location on the front and back side of the mast s outer rails at eye level 4 required Instructs personnel not to travel beneath or upon the lift truck forks Pinch Point Large 2 5 x 4 5 in 426643 Pinch Point Small 1 5 x 2 75 in 426642 Mast equipped models Location on the front and rear sides of the mast cross bracing 44 WARNING Keep fingers away from the mast KEEP FINGERS crossbracing CLEAR OF CROSSBRACING HAND THROTTLE DANGER 804784 Boom equipped model
29. jet aimed in the same direction as the cooling air flow fig B2 2 Clean with the fan running for best results NOTE An OPTIONAL straw defector and self cleaning fan can also be fitted 3 16 INTRODUCTION TO SAFETY B3 CONDENSER CORE OPTION AIR CONDITIONING CHECK CLEAN Remove the protective grid 1 fig B3 and clean it if necessary Visually check whether the condenser 2 fig B3 is clean and clean it if necessary Clean the condenser using a compressed air jet aimed in the same direction as the air flow fig B3 NOTE So as to enhance the cleaning carry out this operation with the fans running B4 TRANSMISSION UNIVERSAL JOINT GREASE Clean and lubricate the following points with grease see MAINTENANCE LUBRICANTS AND FUEL and remove the surplus grease 1 Lubricators of the universal joint engine Angle gear box 2 lubricators fig B4 1 2 Lubricators of the universal joint Transmission Front axle 3 lubricators fig B4 2 3 Lubricators of the universal joint Transmission Rear axle 3 lubricators fig B4 3 3 17 B5 JIB GREASE To be carried out weekly if the lift truck has been operated for less than 50 hours during the week Clean and lubricate the following points with grease see MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease 1 Lubricators of the jib axle 2 lubricators fig B5 1 2 Lubricators of
30. maneuvering very gently and carefully to remove the load Retract 2 and lower the boom 3 to bring the load into the transport position fig F5 X X X INTRODUCTION TO SAFETY LAYING A HIGH LOAD ON TIRES Approach with the load in the transport position aligning to the front of the pile fig F6 Set the handbrake and place the forward reverse lever in neutral Lift and extend the boom 1 2 until the load is above the pile respect load capacites see INSTRUCTIONS FOR HANDLING A LOAD If necessary move the lift truck 3 forward fig F7 driving very slowly and carefully Adjust the load to a horizontal position and place it on the pile by lowering and retracting the boom 1 2 until the load is stabilized fig FS If possible release the forks by alternately retracting and raising the boom 1 fig F9 Then move the forks into transport position If this is not possible back the lift truck 1 very slowly and carefully to release the forks fig FLO Then move the forks into transport position X X IX X x X X x X X X X INTRODUCTION TO SAFETY MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK GENERAL INSTRUCTIONS Ensure the area is sufficiently ventilated before starting the lift truck Wear clothes suitable for the maintenance of the lift truck avoid wearing jewelry and loose clothing Tie and protect your hair if necessary
31. necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Install the filter and protective casing D10 FRONT AND REAR AXLE DIFFERENTIAL OIL DRAIN Park the lift truck on level ground with the I C engine stopped and the differential oil still warm IMPORTANT Dispose of the drain oil in an ecological manner Place a container under drain plugs 1 fig D10 and unscrew the plugs Remove level plug 2 fig D10 and filler plug 3 fig D10 in order to ensure proper emptying Install and tighten drain plugs 1 fig D10 tightening torque 31 ft lb Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL through filler port 3 fig D10 The level is correct when the oil level is flush with the edge of port 2 fig D10 Check for any possible leaks at the drain plugs Install and tighten level cap 2 fig D10 tightening torque 31 ft lb and filler port fig D10 tightening torque 31 ft lb Repeat this operation for the rear axle differential 3 29 INTRODUCTION TO SAFETY E1 FUEL TANK CLEAN WARNING While carrying out these operations do not smoke or work near a flame Park the lift truck on level ground with the I C engine stopped Inspect the parts susceptible to leaks in the fuel circuit and in the tank In the event of a leak contact your dealer WARNING Never perform welding on the fuel system this could cause an explosion or a fire Place a container und
32. of the attachment slightly lift the jib incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to facilitate locking HYDRAULIC LOCKING Put the valve in position A fig D that is to say the hydraulic circuit of the attachment locking open Switch button 1 fig E of the distributor lever forwards to completely lock the attachment on the carriage Close the valve in position B fig D that is to say the hydraulic circuit of the attachment locking closed Aw ARNING Always close the valve in position B fig D after locking the attachment to avoid accidental unlocking Use the attachment safely HYDRAULIC RELEASING Put the valve in position A fig D that is to say the hydraulic circuit of the attachment locking open Switch button 1 fig E of the distributor lever backwards to completely release the attachment LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position INACTIVATE THE HYDRAULIC RELEASE CONTROL You can change an attachment without leaving the control post by cutting the electricity supply to the hydraulic control Leave the valve in position A fig D Use switch 2 fig F to cut the electricity supply to the hydraulic control The circuit is out of action when indicator 3
33. oscillation PP S G lt lt lt lt lt lt lt lt lt G C lt lt lt Front axle differential oillevel PP C lt lt lt Front wheels reducers oil level f C lt e lt lt lt Front axle differentialoil PV V f ee es cee Front wheels reducers oil So NV esje Wear of front axle brake discs pp per Front wheels reducers universa joint PP Jef Front wheels reducers clearance PP pp Jor REAR AXLE Rear wheels reducers pivots pp G lt lt lt lt lt lt lt lt lt lt lt lt 16 09 Rear axle oscillation PP PG lt lt lt lt lt lt lt lt lt G C Rear axle differential oil level pp C lt lt lt lt lt lt lt lt lt Rear wheels reducers oillevel J NT C lt lt lt lt lt lt lt lt lt Rear axle differential oil PV V Rear wheels reducers oil PV V Wearing of rear axle brake discs pp Rear wheels reducers universaljon Rear wheels reducers clearance pp le Tilting corrector 1 TR lt lt lt lt lt lt lt lt lt lt lt lt cee Structure 0 0 0 es 41 o o Ote po Bearings and articulation rings x
34. position that will interfere with the traffic flow and at least 3 5 ft from the track of a railway For prolonged parking on site protect the lift truck from bad weather particularly from frost check the level of antifreeze close and lock all lift truck accesses door window engine compartment INSTRUCTIONS Park the lift truck on flat ground or on an incline of less 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 When using an attachment with a grab or jaws or a bucket with hydraulic opening close the attachment completely Before stopping the lift truck after a hard working period let the I C engine idle for a few moments allowing the coolant and oil to lower the temperature of the I C engine and transmission Do not neglect this precaution in the event of frequent stops or stopping a hot engine the temperature of certain parts will rise significantly with the risk of badly damaging such parts Stop the I C engine Remove the ignition key Make sure all means of access to the lift truck are closed and locked door window engine compartment INTRODUCTION TO SAFETY H DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY SAFETY INSTRUCTIONS Operators driving on the public highway must comply with all current highway codes he lift truck must also comply with all current
35. ratings and clearances When referring to the location of forklift components the terms left right front and rear are related to the oper ator seated normally facing forward in the operator s seat If you have any questions about the forklift con sult your supervisor Failure to fully understand or obey safety warnings can result in serious injury or death 4 WORK SITE KNOWLEDGE Before operating on a work site learn the rules for movement of people forklifts and all other traffic Check the size weight and condition of the loads you will be expected to handle Verify that they are properly secured and safe to transport Learn where the loads are to be placed planning your route for a safe approach watching for hazardous conditions Will a signal man be required to help place the load Remove any debris which may cause tire damage or rupture Plan your route around problem areas or have them cor rected Inform the supervisor of any unsafe conditions observed at the site Examples of hazards power lines cables low clearance structures garage doors telephone pole guide lines fencing loose lumber build ing materials drop offs trenches rough soft spots oil spills deep mud steep 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 personne
36. road use codes If necessary there are optional solutions Contact your dealer INSTRUCTIONS Make sure the revolving light is in place switch it on and verify its operation Check for the good working order and cleanness of lights indicators and windshield wiper Switch off the overhead work lights if the lift truck is equipped with them Select the steering mode HIGHWAY TRAFFIC see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Retract the boom completely and place the attachment at 12 in above the ground Place the frame in the level or central position as per model of lift truck Lift the stabilizers to the maximum and turn the blocks inward as per model of lift truck ANG ER Do not allow the lift truck to coast in neutral using either the forward reverse lever gear shift lever or transmission cut off button Coasting on a slope will lead to excessive speed which may make the lift truck uncontrollable steering brakes and may cause serious mechanical damage DRIVING THE LIFT TRUCK WITH A FRONT MOUNTED ATTACHMENT You must comply with current regulations in your country covering the possibility of driving on the public highway with a front mounted attachment on your lift truck If highway legislation in your country authorizes road use with a front mounted attachment you must at least e Protect and label any sharp and or dangerous edges on the attachment see 4 ADAPTABLE ATTACHMENTS IN OPTION
37. sure the trailer is blocked in place and independently supported ON THE COUPLING LADDER Set the coupling fitting 4 according to the height of the trailer ring Remove the clip 5 lift the trailer pin 6 and place or remove the trailer ring 2 35 INTRODUCTION TO SAFETY C HYDRAULIC TRAILER HOOK OPTIONAL NOTE The rear view mirror OPTION is mandatory with the hydraulic trailer tow hook Never use the tow hook to raise the rear of the lift truck when changing the rear A CAUTION wheel for example Raise the hydraulic tow hook to release the hook lock 1 by pressing the upper part of switch 2 Pull the knob 3 retain this position and press the lower part of switch 2 to lower the tow hook Release knob 3 Couple or uncouple the trailer A CAUTION When uncoupling make sure that the trailer is supported independently Raise the trailer hook by pressing the upper part of switch 2 and then lower the hook to verify that the lock pin is in proper contact with hook 1 lock D REAR ELECTRIC SOCKET Connect the male plug to the female socket 1 on the lift truck and make sure the lights of the trailer or the light bar are working properly A Left rear indicator B OPTION Rear fog lights C Earth D Right rear indicator E Rear lights F Rear stoplight G Reversing light E CONNECTING THE BRAKE SYSTEM OPTION Connect the brake hose to the provided brake unit 1 on the lift truck Ma
38. with the hand pump 3 fig A4 2 A5 CYCLONIC PREFILTER CLEAN The cleaning interval is given as a guide however the pre filter must be emptied as soon as impurities reach the MAX level on the tank Loosen nut 1 fig A5 remove cover 2 fig A5 and empty the tank Clean the pre filter unit with a clean dry cloth and reassemble the unit IMPORTANT When cleaning take care not to let impurities into the dry air filter 3 13 INTRODUCTION TO SAFETY A6 GEAR BOX OIL LEVEL CHECK Park the lift truck on level ground with the jib raised the I C engine cold and stopped Check the oil within 5 minutes of the I C engine being stopped Remove the plastic cap 1 fig AG Remove the dipstick 2 fig AG Wipe the dipstick and check the correct level between the two MIN and MAX marks If necessary add oil see 3 MAINTENANCE E3 GEAR BOX OIL Check visually that there is no leakage or seepage of oil in the transmission A7 TIRES PRESSURE AND WHEEL NUTS TORQUE CHECK Check the condition of the tires to detect cuts wear etc Check the torque load of the wheel nuts Non compliance with this instruction can cause damage and rupture to the wheel bolts and distortion to the wheels Wheel nuts tightening torque Front tires 465 ft lb Rear tires 465 ft lb Check and adjust the tire pressures if necessary see 2 DESCRIPTION FRONT AND REAR TIRES NOTE There is an OPTIONAL wheel
39. without being certain that they are approved for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Be extra careful maneuvering around loading bays trenches scaffolding soft terrain and manholes Make sure the ground is stable and firm under the wheels and or stabilizers before lifting or removing the load If necessary add sufficient wedging under the stabilizers where applicable Make sure that the scaffolding loading platform pilings or ground is capable of bearing the load Never stack loads on uneven or soft ground they may tip over When working near power lines ensure that the safety distance is sufficient between the working area of the lift truck and the power lines D ANG ER You must consult your local electrical agency You could be electrocuted or seriously injured if you operate or park the A lift truck too close to power lines APANG ER During high winds do not attempt moving loads that may catch the wind or cause the fork lift to be unstable 1 7 INTRODUCTION TO SAFETY D VISIBILITY While maneuvering maintain clear visibility throughout the route In reverse either look directly behind you or use the panoramic rear view mirrors In any case avoid backing over long distances Visibility may be reduced on the right hand side when the boom is raised before lifting the boom make sure that the movement can be made in a safe manner If the
40. your foot on the brake pedal or with the parking brake on Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel turn it gently and not abruptly Never leave the I C engine running while the lift truck is unattended Do not leave the cab while the lift truck has a raised load Watch where you are going and always make sure you have good visibility along the route Use the rear view mirrors frequently Drive around obstacles Never drive on or along the edge of a ditch or steep slope It is dangerous to use two lift trucks simultaneously to handle heavy or over sized loads do not attempt such operations always procure the proper equipment for the job INSTRUCTIONS Always drive the lift truck with the forks or attachment to the transport position i e at 12 in from the ground the boom retrac ted and the carriage sloping backwards Select the appropriate steering mode for the working conditions Shift the forward reverse lever to the desired direction of travel Release the parking brake and accelerate gradually until the lift truck moves off STOPPING PARKING THE LIFT TRUCK SAFETY NOTICE When the lift truck is stationary or if the operator has to leave his cab even for a moment place the forks or attachment on the ground apply the parking brake and place the forward reverse lever in neutral Make sure that the lift truck is not parked in any
41. 11 FRONT AND REAR WHEEL REDUCER PIVOTS GREASE Clean and lubricate the points 1 8 lubricators fig B11 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease B12 REAR AXLE OSCILLATION GREASE Clean and lubricate the points 1 2 lubricators fig B13 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease 3 21 INTRODUCTION TO SAFETY Carry out the operations described previously as well as the following operations C1 FAN BELT TENSION CHECK ADJUST Open the 1 C engine cover Checkthe belt for signs of wear and cracks and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Loosen screw 1 fig C1 1 on the tension pulley Loosen lock nut 2 fig C1 1 and C1 2 and screw 3 fig C1 1 and C1 2 Tighten the screw 2 fig C1 1 and C1 2 until the belt is as close as possible to the groove of the pulley 4 fig C1 1 Make a mark on the head of screw 3 fig C1 1 and C1 2 and tighten turning it 5 times Tighten the lock nut 2 fig C1 1 and C1 2 Retighten screw 1 fig C1 1 on the tension pulley 3 22 INTRODUCTION TO SAFETY C2 ALTERNATOR CRANKSHAFT BELT TENSION CHECK ADJUST For this operation we suggest you to use a tension meter fig C2 1 Open the I C engine cover Unscrew the fastening screws 1 fig C2 2 Lay down the protective guard 2 fig C2 2 Checkthe belt
42. 4 Unscrew locking screw 2 fig D4 Remove housing 3 fig D4 and discard cartridge 4 fig D4 as well as the seals of the cartridge Clean the inside of the pre filter head and the housing using a brush immersed in clean diesel oil Install the assembly with a new pre filter and new seals see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Pressurize the circuit by means of the hand pump 5 fig D4 3 21 INTRODUCTION TO SAFETY D5 FUEL FILTER CHANGE Open engine hood and lift the battery cover Carefully clean the outside of the filter and its holder to prevent dust from getting into the system Place a container under the fuel filter 1 fig D5 1 and undo the filter Fill up the new fuel filter see MAINTENANCE FILTERS AND BELTS with clean diesel Install the filter onto its holder Tighten the oil filter by hand pressure only and lock the filter in place by a quarter IMPORTANT m ES Pressurize the circuit by means of the hand pump 2 fig D5 2 Remove the container from under the filter Start up the I C engine and make sure there is no leakage D6 GEAR BOX OIL FILTER CHANGE Remove the cover plate 1 fig D6 1 Unscrew and discard gear box oil filter 2 fig D6 2 Carefully clean the filter head with a clean lint free cloth Slightly lubricate the new seal and fit the seal on the filter Fill up the new gear box oil filter see 3 MAINTENANCE FILT
43. A X lt lt lt lt lt lt lt lt lt lt lt Alternator crankshaft belt tension A lt lt lt lt lt lt lt lt lt lt lt Compressor belt tension OPTION Airconditioning A G A lt lt lt lt lt lt lt lt lt lt lt LC engine oil PP V j j Ve 666 6461 LC engine oil filter R S R lt lt lt icc 4461 Fuel prefiter PP R S R lt lt lt lt lt lt o 0 0 0 1 R R lt lt lt 666 1 666 Ni fice Safety dry airfiltercartridge Rc ics engine silent blocks ri lC engine rates j j Ot Valves clearances PP ce Cooling liquid ce Radiator ee Water pump and the thermostat PP J ee Alternator and the starter motor ri Turbo compressor o PP JO ef 20 gt 2 o o 2 O 2 Oil pp G lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt Transmission universal joint 1 G lt lt lt lt lt lt lt lt lt G C Angle gear box oil level_______________ eee ee 6 ccs Gear box oil filter PRP R ss Jf Gearboxol TE o Vi 66 Gear box sump strainer___________ N 66 Angle gear box oil PPM PP VP JP SSilen5Dnocksinthegearbx o Z ce lt lt
44. E5 2 and unscrew filler cap 3 fig E5 2 in order to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner Install and tighten drain plug 1 fig E5 1 tightening torque 18 ft lb Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 3 fig E5 2 and install the filler cap Check the correct level between the MINI and MAX marks on dipstick 2 fig E5 2 Check for any possible leaks at the drain plug E6 HYDRAULIC OIL DRAIN E7 SUCTION OIL STRAINER FOR HYDRAULIC OIL TANK CLEAN ES FILTER CAP FOR HYDRAULIC OIL TANK CHANGE E9 DISTRIBUTOR CONTROL HEAD FILTER CHANGE Park the lift truck on level ground with the I C engine stopped and telescope jib retracted and lowered as far as possible Before any intervention thoroughly clean the area surrounding the drain plugs and IMPORTANT the suction cover on the hydraulic tank DRAINING THE OIL Place a container under drain plug 1 fig E6 1 and unscrew the plug Remove filler cap 2 fig E6 2 in order to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil an ecological manner CLEANING THE STRAINER Remove suction cover 3 fig E6 3 Remove and clean the strainer using a compressed air jet check its condition and replace if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Install the strainer and tighten the suction cover fig E6 3
45. ERS CARTRIDGES AND BELTS with oil see 3 MAINTENANCE LUBRICANTS AND FUEL Install the filter making sure that the seal is correctly positioned and tightened Tighten the oil filter by hand pressure only and lock the filter in place by a quarter IMPORTANT en 4 Install the cover plate 1 fig 06 1 3 28 INTRODUCTION TO SAFETY D7 HYDRAULIC RETURN OIL FILTER CARTRIDGE CHANGE Stop the I C engine and remove the pressure from the circuits by acting on the hydraulic controls Thoroughly clean the outside of the filter and its surroundings before servicing IMPORTANT prevent any pollution from entering the hydraulic circuit Place a container under hydraulic drain filter 1 fig D7 Unscrew the body of the filter Remove the hydraulic return oil filter cartridge and fit new replacement cartridge see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Make sure that the cartridge is correctly positioned and install the body of the filter Tighten the oil filter by hand pressure only and lock the filter in place by a quarter IMPORTANT d ps D8 PARKING BRAKE LEVER MECHANISM GREASE Clean and grease articulation axles 1 fig D8 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL D9 CAB VENTILATION FILTER CLEAN Lift up protective casing 1 fig D9 Lift out cabin ventilation filter 2 fig D9 Clean the filter with a compressed air jet Check its condition and change if
46. HECK Park the lift truck on level ground Loosen screw 1 fig B 1 and remove the access panel for braking oil tank and windscreen washer tank 2 fig B7 1 The level is correct when it is at the MAX level in tank 3 fig B7 2 If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the filler port Pivot the tank 3 fig B7 2 to access the filler cap 4 fig B 2 Check visually that there is no leakage in the tank and pipes WARN ING If the braking oil level is abnormally low consult your dealer 3 19 INTRODUCTION TO SAFETY B8 WINDSCREEN WASHER LIQUID LEVEL CHECK Loosen screw 1 fig B8 1 and remove the access panel for braking oil tank and windscreen washer tank 2 fig B8 1 Check visually the level If necessary add windscreen washer liquid see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 3 fig B8 2 B9 CAB DOOR GREASE Clean and lubricate the points 1 4 lubricators fig B9 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease B10 CAB VENTILATION FILTER OPTION AIR CONDITIONING CLEAN Lift up protective casing 1 fig B10 Lift out cabin ventilation filter 2 fig B10 Clean the filter with a compressed air jet Check its condition and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Install the filter and protective casing 3 20 INTRODUCTION TO SAFETY B
47. ING LIGHT J FRONT AND REAR WORKING LIGHTS K JIB HEAD LIGHT OPTION L REAR WINDOW DEFROSTING OPTION M SIDE WINDSCREEN WIPER ROOF WINDSCREEN WIPER OPTION 2 22 INTRODUCTION TO SAFETY N DUAL EFFECT HYDRAULIC TOWING HOOK OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS O SINGLE OR DUAL EFFECT REAR HYDRAULIC PREDISPOSITION OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS P ATTACHMENT HYDRAULIC LOCKING DEVICE OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS Q OPTION JIB SUSPENSION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS R NEUTRALIZATION OF HYDRAULIC MOVEMENTS When driving on the road it is highly recommended that you cut off all the hydraulic movements The lamp shows when it is in use 6 LIGHTS SWITCH HORN AND INDICATOR SWITCH The switch controls the visual and sound alarms A All lights are off the direction indicators do not flash The right hand direction indicators flash C The left hand direction indicators flash D The sidelights and the rear lights are on E The dipped headlights and the rear lights are on F The main beam headlights and the rear lights are on G Headlight signal Pressing the switch sounds the horn NOTE The positions D E F G can be carried out without the ignition being on 2 23 INTRODUCTION TO SAFETY 7 FRONT AND REAR WINDSCREEN WIPER SWITCH FRONT WINDSCREEN WIPER Fron
48. INTRODUCTION TO SAFETY MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE WACO TX 6 12 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Inc Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com MLT 735 120 LSU Series 4 E3 OPERATOR S MANUAL THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY THE OPERATOR 547977AS R11 10 INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS SAFETY MESSAGES VII SAFETY DECALS ENE VII TABLE OF CONTENTS OPERATING AND SAFETY INSTRUCTIONS 1 3 DEP 23 MAINTENANCE casamos 3 3 ENGAGING THE ATTACHMENTS 4 3 INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENEHAL SAFETY STANDAHDS INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS STUDY THE OPERATOR SERVICE MANUALS The information in this manual provides general instructions for the safe operation and maintenance of your forklift truck This information is vital and must be clearly understood by the operator and serviceman Study this manual and the Rough Terrain Forklift Safety Manual part no 422494 thoroughly and carefully before operating or servicing your forklift Contact your deal
49. N WIPER SWITCH 8 IGNITION SWITCH 9 BRAKING OIL TANK AND WINDSCREEN WASHER ACCESS PANEL 10 ARMREST AND STORAGE 11 CAR RADIO OPTION 12 FUSES AND RELAYS IN THE CAB 13 FUSES AND RELAYS UNDER THE ENGINE HOOD 14 ACCELERATOR PEDAL 15 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF 16 GEAR LEVER AND TRANSMISSION CUT OFF 17 FORWARD NEUTRAL REVERSE GEAR SELECTION 18 PARKING BRAKE LEVER 19 STEERING SELECTION 20 HYDRAULIC CONTROLS AND TRANSMISSION CUT OFF 21 FUNCTION FILES 22 HEATER CONTROL 22 AIR CONDITIONING CONTROLS OPTION AIR CONDITIONING 23 CAB FILTER VENTILATORS 24 WINDSCREEN DEMISTER VENTS 25 HEATING VENTS 26 DOOR LOCK 27 LOCKING HANDLE FOR UPPER HALF DOOR 28 UNLOCKING BUTTON FOR UPPER HALF DOOR 29 HANDLE FOR REAR WINDOW OPENING 30 DOCUMENT HOLDER 31 FRONT LIGHTS NOT ILLUSTRATED 32 REAR LIGHTS NOT ILLUSTRATED 33 FLASHING LIGHT NOT ILLUSTRATED 34 STEERING WHEEL ADJUSTMENT LEVER 35 SPIRIT LEVEL 36 SUN VISOR 37 ROOF LIGHT 38 HOOK 39 CIGARETTE LIGHTER 40 DIAGNOSTIC SOCKET 41 TOOL BOX NOT ILLUSTRATED NOTE Terms such as RIGHT LEFT FRONT REAR are meant for an observer seated in the driver s seat facing forward 2 13 INTRODUCTION TO SAFETY 1 DRIVER S SEAT DESIGNED FOR MAXIMUM COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS WEIGHT ADJUSTMENT FIG A It is advised that the weight be adjusted when the driver is not sitting in
50. NOT raise the load more than 12 inches 305 mm above the ground or raise the boom more than 45 degrees 3 Only lift the load vertically NEVER drag it horizontally 4 Use multiple pickup points on the load when possible Use taglines to restrain the load from swinging and rotating 5 Start travel turn and stop SLOWLY to prevent the load from swinging DO NOT exceed walking speed 6 Inspect rigging before use Rigging must be in good condition and in the U S comply with OSHA regulation 1910 184 Slings or 1926 251 Rigging equipment for material handling T Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft The load center must not exceed 24 inches 610 mm 8 DO NOT lift the load with anyone on the load rigging or lift equipment and NEVER lift the load over persomnel 9 Beware of the wind which can cause suspended loads to swing even with taglines 10 DO NOT attempt to use frame leveling to compensate for load 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 wi
51. ODCOD ANTI THEFT SYSTEM OPERATION Switch on the lift truck the red indicator 1 will flash Enter your user code followed by V to validate the green indicator 2 will come on Start the lift truck within the next 60 seconds otherwise the anti theft system will be reactivated and the red indicator 1 will flash NOTE If you make a mistake when entering the code press key A to cancel and re enter the code in full If you wait more than 5 seconds between key presses or do not complete entering the code the anti theft system will be reactivated and the red indicator will flash 8 FINTRONIC ANTI START SYSTEM OPERATION Switch on the lift truck and set the black key A next to the antenna B maximum 80 mm Wait a few seconds for red LED C to go out before starting the lift truck NOTE You can restart the lift truck within 20 seconds of stopping it after this time the anti start system reacts and LED C flashes red 2 38 INTRODUCTION TO SAFETY 9 ELECTRICAL JIB PROVISION Enables an electrical function to be used at the head of the jib OPERATION Hold button 1 down and move button 2 forwards or backwards NOTE Switch 3 enables the function controlled by button 1 to be locked Indicator 4 lights up to show when it is in use 10 QUICK RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT PHOTO NOT AVAILABLE 11 EXTERIOR DRAIN BACK Enables connection of an attachment for which drain back is required
52. ON THE RANGE ATTACHMENT SHIELDS The attachment must not be loaded Make sure that the attachment does not mask the lighting range of the forward lights e Make sure that highway legislation in your country does not require other obligations OPERATING THE LIFT TRUCK WITH A TRAILER When using a trailer observe the regulations in your country maximum travel speed braking maximum weight of trailer etc Do not forget to connect the trailer s electrical equipment to that of the lift truck The trailer s braking system must comply with current legislation If pulling a trailer with assisted braking the lift truck must be equipped with a trailer braking mechanism In this case do not forget to connect the trailer braking equipment to the lift truck he maximum vertical pull on the trailer hook must not exceed 3350 ft lbs he authorized maximum weight must not exceed the maximum weight authorized by the manufacturer consult the manufactu rer s plate on your lift truck IF NECESSARY CONSULT YOUR DEALER INTRODUCTION TO SAFETY INSTRUCTIONS FOR HANDLING A LOAD A CHOICE OF ATTACHMENTS Only attachments approved by MANITOU can be used on its lift trucks Make sure the attachment is appropriate for the work to be done see 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE Make sure the attachment is correctly installed and locked onto the lift truck carriage Make sure that your lift truck attachments w
53. PERATOR The risk of accident while operating servicing or repairing your lift truck can be reduced if you follow the safety ins tructions and safety measures detailed in this manual Failure to respect the safety and operating instructions or the instructions for repairing or servicing your lift truck can lead to serious injury or fatal accident Only the operations and maneuvers described in this operator s manual may be performed The manufacturer cannot predict all possible situations of risk Consequently the safety instructions given in the operator s manual and on the lift truck itself are not conclusive At any time as an operator you must envision within reason the possible risk to yourself to others or to the lift truck itself during use GENERAL INSTRUCTIONS A OPERATOR S MANUAL Read the operator s manual carefully he operator s manual must always be kept good condition and in the place provided on the lift truck You must report any plates and decals which are no longer legible or are damaged B AUTHORIZATION FOR USE Only qualified authorized personnel may operate the lift truck This authorization is given in writing by the company manager in charge of using the lift truck and must be carried by the operator during operations The operator is not authorized to allow others to operate the lift truck C MAINTENANCE he operator must notify his manager immediately if his lift truck is not in
54. RUCK Perform daily maintenance see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE Make sure the lights indicators and windshield wipers are working properly Make sure the rear view mirrors are in good condition clean and properly adjusted Make sure the horn and backup alarm works properly B DRIVER S OPERATING INSTRUCTIONS he operator is advised to familiarize himself with the position and operation of all controls and instruments before operating the lift truck Wear clothes suited for driving the lift truck avoid loose clothing Make sure you have the appropriate protective equipment for the job to be done Prolonged exposure to high noise levels may cause hearing problems It is recommended to wear ear muffs to protect against excessive noise Always pay attention when using the lift truck Do not listen to the radio or music using headphones or earphones Never operate the lift truck when hands or feet are wet or slippery For increased comfort adjust the seat to your requirements adopt a comfortable reach of the forklift controls A CAUTION Under no circumstances should the seat be adjusted while the lift truck is moving he operator must always be properly seated in the driver s cab It is prohibited to have arms legs or generally any part of the body protruding from the cab of the lift truck he safety belt must be worn adjusted to the operator s size he control levers must n
55. Rear axle Differential No o 7 Pressure bar 34 ELECTRIC CIRCUIT en Standard Option Alternator BRAKE CIRCUIT gt Mechanical Manual SOUNDANDWBRAION O o according to standard NF EN 12053 407 ensured according to directive 2000 14 EC modified by directive 2005 88 EC 107 ensured Average weighted acceleration on driver s body m s2 according to standard NF EN 13059 The average weighted acceleration transmitted to the driver s hand arm system according to standard ISO 5349 2 m s2 2 5 2 6 INTRODUCTION TO SAFETY Hydraulic pump ss Filtration PG HYDRAULIC MOVEMENTS gt Telescoping motions ib raised gt Tilting J 0000 o o SPECIFICATIONS AND WEIGHTS Speed of movement for lift truck in standard configuration on flat ground except particular conditions Front unladen Rearunaden lb 1 2 A4d 7824 gt Weight per axle with standard attachment jib extended rJ O Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting KEENE Drag strain on the coupling hook PG 2 7 INTRODUCTION TO SAFETY FRONT AND REAR TIRES MICHELIN DUNLOP PRESSURE bar TIRE LOAD kg PRESSURE 34 34 34 34 34 34 S0psi 34 34 34 36 3 4 460 70R24 Frontunladen XMCL 15948 Frontladen j J j J TUBELESS Reawlden
56. Roof windscreen wiper 104 F4 Stop I C engine electrovalve 7 54 OPTION Attachment easy hydraulic connection 7 54 F5 Revolving light 7 5A F6 Wheel alignment 5A F OPTION Cutting off simple hydraulic movements 104 FS Forward neutral reverse selector 15 Transmission cut off 15A Reverse lights 154 OPTION Reverse buzzer alarm 154 F9 Control panel 54 F10 Sound alarm 154 Stop switch 15 F11 OPTION Jib head light 10A F12 Indicator power supply 104 F13 Heating 304 F14 Cigar lighter 10A F15 OPTION Oil cooler 254 F16 OPTION Air conditioning 7 54 F17 OPTION Electrovalve on jib head 104 OPTION Electrovalve on jib head attachment hydraulic locking device 10 OPTION Electrical jib provision 10 OPTION Anti theft device provision 10 OPTION Anti theft system 104 OPTION Anti start system 104A OPTION Self cleaning fan 104 OPTION Electrovalve on jib head self cleaning fan 15 RZ OPTION Hydraulic towing hook 104 EL OPTION Single or dual effect rear hydraulic predisposition 10A F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 OPTION Two dual effect rear hydraulic 15A A OPTION Hydraulic towing hook single or dual effect rear hydraulic MEL TH sc predisposition 154 OPTION Dual effect rear hydraulic predisposition single effect r
57. S AND CONTROLS TOWING PIN AND HOOK DESCRIPTION AND USE OF THE OPTIONS 2 3 2 10 2 12 2 36 2 38 INTRODUCTION TO SAFETY IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement of our products our range of telescopic lift trucks may undergo certain modifications without prior notice When you order parts or when you require any technical information always specify NOTE For the owner s convenience it is recommended that a note of these numbers be made in the spaces provided at the time of the delivery of the lift truck LIFT TRUCK MANUFACTURER S PLATE FlG A A MANITOU Model 2 Serial No Chassis No Year of manufacture For any further technical information regarding your lift truck refer to chapter 2 DESCRIPTION CHARACTERISTICS C ENGINE FIG B 1 C engine No m GEAR BOX FIG C Type MANITOU Yeference ee nenne ine here een ee Renee Serial No ANGLE GEARBOX FIG D Type MANITOU EEE resistiendo aceras Serial No uh kunn Ido INTRODUCTION TO SAFETY FRONT AXLE FIG E Type Serial No MANITOU reference REAR AXLE FIG F Type Serial No MANITOU reference CAB FIG G Type Serial No IB FIG H MANITOU reference Date of manufacture 6 oo 0 9
58. TIONS A OPERATOR S MANUAL B AUTHORIZATION FOR USE C MAINTENANCE D MODIFICATION OF THE LIFT TRUCK E LIFTING PEOPLE OPERATING INSTRUCTIONS UNLADEN AND LADEN BEFORE STARTING THE LIFT TRUCK DRIVER S OPERATING INSTRUCTIONS ENVIRONMENT VISIBILITY STARTING THE LIFT TRUCK DRIVING THE LIFT TRUCK STOPPING THE LIFT TRUCK DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY INSTRUCTIONS FOR HANDLING A LOAD x pg I 1 L GG oBOOoX000 1 14000000 T 6 nm MO 0 2 ap RR RRP A CHOICE OF ATTACHMENTS B MASS OF LOAD AND CENTER OF GRAVITY C N A D HORIZONTAL ATTITUDE OF THE LIFT TRUCK 111 E TAKING UP A LOAD ON THE GROUND 1 49 F TAKING UP AND LAYING A HIGH LOAD ON TIRES 1 13 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 15 GENERAL INSTRUCTIONS 1 15 MAINTENANCE 1 15 LUBRICANT AND FUEL LEVELS 1 15 HYDRAULIC 1 15 ELECTRICITY 1 15 WELDING 1 15 WASHING THE LIFT TRUCK 1 16 F THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME 1 17 INTRODUCTION 1 17 PREPARING THE LIFT TRUCK 1 17 PROTECTING THE I C ENGINE 1 17 PROTECTING THE LIFT TRUCK 1 17 BRINGING THE LIFT TRUCK BACK INTO SERVICE 1 18 INTRODUCTION TO SAFETY INSTRUCTIONS TO THE COMPANY MANAGER THE OPERATOR Only qualified authorized personnel may operate the lift truck The authorization is to be given to the operator in writing by the company manager Authorization must be carried by the operator during all operations
59. U NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 www manitou na com TRUCK MODEL SERIAL NUMBER MEN YEAR oF mec 0 TIRE PRESSURE FRONT e NI TIRE PRESSURE REAR RER PSI FOR CAPACITIES REFER TO THE APPROPRIATE LIFT CHART OR CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME 56 6 MANUFACTURED IN BT XVI MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 MAST MODEL MA ATTACHMENTS 5 G3 UNLADEN WEIGHT MAA Les YEAR OF MFG IS A OE c MAX CAPACITY MN LBS ACKO INCHES MAX CAPACITY LBS AT MFH B eae INCHES TIRE PRESSURE e Ps TIRE PRESSURE CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH FORK UPRIGHTS VERTICAL FOR OTHER CAPACITIES CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME E MANUFACTURED IN MN ENTEN Cow s cu iul 496538 GROUND INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY 1 OPERATING AND SAFETY INSTRUCTIONS INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY TABLE OF CONTENTS INSTRUCTIONS TO THE COMPANY MANAGER 1 4 THE OPERATOR 1 THE LIFT TRUCK 1 A THE LIFT TRUCK S SUITABILITY FOR THE JOB t B ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS 1 C MODIFICATION OF THE LIFT TRUCK 1 INSTRUCTIONS 1 MAINTENANCE 1 INSTRUCTIONS FOR THE OPERATOR 1 6 GENERAL INSTRUC
60. UAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION OPERATION Switch 1 is used to select one or other of the rear hydraulic predispositions 2 41 INTRODUCTION TO SAFETY 19 DUAL EFFECT TOWING HOOK SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION OPERATION Switch 1 is used to select control of the towing hook see 2 DESCRIPTION TOWING PIN AND HOOK or rear hydraulic predisposition 20 ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION This OPTION must only be used with an attachment requiring continuous hydraulic movement of type brush supply bucket mixer spray It is strictly forbidden handling operations or with other options winch crane jib crane jib with winch hook etc CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT Make sure the potentiometer C is set to O96 Switch button A to the front or the back depending on the type of attachment press button B and release button A The red indicator 1 flashes to indicate that it is in operation Set the required flowrate using potentiometer C o stop continuous hydraulic movement of the attachment move switch A forwards or backwards or press button B Indicator 1 goes out Set potentiometer C to O96 NOTE If the operator leaves the driver s cab the continuous hydraulic movement will automatically stop and must be restarted 2 42 INTRODUCTION TO SAFETY 21 JIB SUSPENSION The jib is suspended
61. When driving on the road it is highly recommended that you cut off all the hydraulic movements see 2 DESCRIPTION 5 SWITCH PANEL lle e 21 FUNCTION FILES These files contain the description of the hydraulic controls and the load charts for the attachments used on the lift truck 2 30 INTRODUCTION TO SAFETY 22 HEATER CONTROL A HEATING FAN CONTROL This 3 speed control regulates warm or cold air through the heating ventilators B HEATING TEMPERATURE CONTROL Allows the temperature inside the cab to be adjusted B1 With the valve closed the fan delivers fresh air B2 With the valve opened completely the fan delivers warm air The intermediate positions allow the temperature to be adjusted 22 AIR CONDITIONING CONTROLS OPTION AIR CONDITIONING IMPORTANT The air conditioning operates only while the lift truck engine is running During use keep the doors and windows closed In the winter To ensure correct operation and efficiency of the air conditioning unit run the compressor once a week for a few minutes to lubricate the internal seals In cold weather Warm the 1 C engine before switching on the compressor this will allow the coolant that has collected in the liquid state at the lowest point of the compressor circuit to turn into gas by the heat given off by the 1 C engine otherwise the compressor is liable to be damaged by pumping coolant in the liquid state when operated If your ai
62. afety support Park the lift truck away from traffic if possible on even and hard ground Put the warning lights on Immobilize 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 fig G1 1 Lift the wheel until it comes off the ground and put in place the safety support under the axle fig G1 2 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 Install 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 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE for tightening torque G2 FRONT HEADLAMPS ADJUST RECOMMENDED SETTING as per standard ECE 76 756 76 761 ECE20 Set to 296 of the dipped beam in relation to the horizontal line of the headlamp ADJUSTING PROCEDURE Park the lift truck unloaded and in the transport position and perpendicular to a white wall on flat level ground fig G6 Check the tire pressures see 2 DESCRIPTION CHARACTERISTICS Place the forward reverse selector in neutral and release the parking brake CALCULATING THE HEIGHT OF THE DIPPED BEAM H2 e h1 Height of the
63. ain that the engine is at idle speed prior to disconnecting jumper cables 801015 Jump start instructions MANITOU NORTH AMERICA INC 6401 IMPERIAL DR E WACO TX 76712 www manitou na com Attachment Plate 425995 Location on the optional removeable forklift attachment MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE Important manufacturer information about the attachment Record this information for use when contacting the maufacturer for parts and service COUNTRY OF MANUFACTURE UNLADEN WEIGHT LB CAPACITY LB HORIZONTAL CENTER OF GRAVITY IN B OPERATING PRESSURE PSI LAWARNING This attachment affects the capacity of the lift truck Check the operator service manual or load chart for net capacity with this attachment f If the load chart is not available contact the factory 05405005 gt Overhead Guard Data Plate B6109 Location attached to the overhead guard THIS OVERHEAD GUARD CONFORMS TO ANSI DESIGN RECOMMENDATION THIS OVERHEAD GUARD HAS PASSED AN IMPACT TEST OF FT LBS DO NOT REMOVE THIS OWERHEAD GUARD Overhead guard conformity 496550 Forklift Data Plate 496550 Boom equipped models MANITOU Forklift Data Plate 496538 Mast equipped models Location within the operator s compartment Important forklift truck identification Record this information for use when contacting the manufacturer for parts and service MANITO
64. anner so as not to cause injury to personnel 11 Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck whether empty or loaded 12 Do not permit passengers to ride on rough terrain forklift trucks 13 Check clearance carefully before driving under electrical lines bridges etc 14 A rough terrain forklift truck is attended when the operator is less than 25 ft 7 6m from the truck which remains in his view 15 A rough terrain forklift truck is unattended when the operator is 25ft 7 6m or more from the truck which remains in his view or whenever the operator leaves the truck and it is not in his view 16 Before leaving the operator s position a bring rough terrain forklift truck to a complete stop b place directional controls in neutral apply the parking brake lower load engaging means fully unless supporting an occupied elevated platform stop the engine f if the rough terrain forklift truck must be left on an incline block the wheels g fully lower the load engaging means 17 Maintain a safe distance from the edge of ramps platforms and other similar working surfaces 18 Do no move railroad cars or trailer with a rough terrain forklift truck C d e INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 19 Do not use a rough terrain forklift truck for opening or clo
65. assembly so as to obtain the belt tension required Retighten screws 3 fig C3 2 Put the protective guard back 2 fig C3 1 If the compressor belt has to be changed check the tension again after the first IMPORTANT 20 hours of operation 3 23 INTRODUCTION TO SAFETY C4 ANGLE GEAR BOX LEVEL CHECK Park the lift truck on level ground with the jib raised and the I C engine stopped Remove level plug 1 fig C4 Wipe the dipstick and check the correct level between the MINI and MAX marks If necessary add oil see 3 MAINTENANCE E5 ANGLE GEAR BOX OIL C5 PARKING BRAKE CHECK ADJUST Park the lift truck on a slope less than 15 6 with the rated load in the transport position Check the tightening adjustment by locking the parking brake in position A fig C5 he adjustment is correct when the lift truck is held stationary on a slope Carry out adjustments if necessary Press and release the brake pedal then release the parking brake putting it in position B fig C5 Progressively tighten the end piece of the lever 1 fig C5 and recheck braking Repeat the operation until the correct braking adjustment is obtained C6 CAB VENTILATION FILTER OPTION AIR CONDITIONING CHANGE Lift up protective casing 1 fig C6 Lift out cabin ventilation filter 2 fig C6 and fit new replacement filter see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Install the protective cas
66. been replaced by 164091 JA BREMSFLUESSIGKEIT _ Location near the brake fluid reservoir where applicable LIQUIDO DE FRENO gt LIQUIDO FRENI Utiliser IMPERATIVEMENT de l huile min rale IMPERATIVE to use mineral oil Verwenden Sie UNBEDINGT Mineral l Usar IMPERATIVAMENTE de aceite mineral Utilizzare IMPERATIVAMENTE oli olio minerale Refer to the Operator Service Manual for the correct brake fluid mineral oil to be used in the brake system IMPERATIVE to use MINERAL OIL Recommendation ATF DEXRON i N SHELL _ 164091 234800 n 234800 XIII INTRODUCTION TO SAFETY SAFETY DECALS Hydraulic Oil 234798 or 76573 Location on the hydraulic tank or filler cap Identifies the hydraulic reservoir tank or filler cap N 234798 Hydraulic Oil 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAULIC OIL Identifies the hydraulic reservoir tank HYDRAULIK OL ACEITE HIDRAULICO OLIO IDRAULICO N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap Indicates required minimum to maximum anti freeze protection 220F to 400F 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 NOTICE Location varies depending on the forklift model NO STEP ADET IG Instructs personnel not to use the designated area as
67. bility may be adversely affected IV INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 46 When attachments are used extra care shall be taken in securing manipulating positioning and trans porting the load Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks when not handling a load 47 Completely engage the load with the load engaging means Fork length should be at least two thirds of load length Where tilt is provided carefully tilt the load backward to stabilize the load Caution should be used in tilting backward with high or segmented loads 48 Use extreme care when tilting load forward or backward particularly when high tiering Do not tilt forward with load engaging means elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load 49 The handling of suspended loads by means of a crane arm boom or other device can introduce dynam ic forces affecting the stability of a rough terrain forklift truck Grades and sudden starts stops and turns can cause the load to swing and create a hazard if not externally stabilized When handling suspended loads a do not exceed the truck manufacturer s capacity of the rough terrain forklift truck as equipped for handling suspended loads b only lift the load vertically and ne
68. brake Protect all exposed cylinder rods from corrosion Cover the tires NOTE If the lift truck is to be stored outdoors cover it with a waterproof covering INTRODUCTION TO SAFETY BRINGING THE LIFT TRUCK BACK INTO SERVICE Remove the waterproof adhesive tape from all the holes Install the intake hose Install and reconnect the battery Remove the protection from the cylinder rods Perform the daily service see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE Engage the parkbrake and remove the axle stands Empty and replace the fuel and fuel filter see 3 MAINTENANCE D EVERY 500 HOURS SERVICE Refit and set the tension on the drive belts see 3 MAINTENANCE C EVERY 250 HOURS SERVICE Turn the I C engine using the starter to allow the oil pressure to rise Reconnect the engine cut off solenoid Lubricate the lift truck components see MAINTENANCE SERVICING SCHEDULE WARNING Insure the area is adequately ventilated before starting the lift truck Start the lift truck following the safety instructions and regulations see OPERATING INSTRUCTIONS UNLADEN AND LADEN Run all of the boom s hydraulic movements verifying the full travel of each cylinder 2 DESCRIPTION INTRODUCTION TO SAFETY 2 2 INTRODUCTION TO SAFETY TABLE OF CONTENTS IDENTIFICATION OF THE LIFT TRUCK CHARACTERISTICS FRONT AND REAR TIRES DIMENSIONS AND LOAD CHARTS INSTRUMENT
69. ddition to standard equipment mounted on your lift truck additional options are available road lighting stop lights flashing light reverse lights front light rear light light at the boom head etc he operator must take into account the operating conditions to determine the lift truck s signalling and lighting equipment requirements Contact your dealer Take into account climatic and atmospheric conditions of the work site Protection against frost see 3 MAINTENANCE LUBRICANTS AND FUEL Adaptation of lubricants ask your dealer for information 1 C engine filtration see MAINTENANCE FILTERS CARTRIDGES AND BELTS For operation under average climatic conditions i e between 15 C and 35 C 5 to 95 F correct levels of lubricants in all the circuits are provided in production For operation under more severe climatic IMPORTANT conditions before starting up it is necessary to drain all the circuits then add the correct levels of lubri cants properly suited to the relevant ambient temperatures It is the same for the cooling fluid Contact your dealer for information if necessary A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher consult your dealer Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated premises It is prohibited to use the lift truc
70. dipped beam in relation to the ground gt h2 Height of the adjusted beam Distance between the dipped beam and the white wall 3 36 INTRODUCTION TO SAFETY G3 LIFT TRUCK IMPORTANT Do not tow the lift truck at more than 15 mph Place the forward reverse selector in neutral and the gear shift in neutral Release the hand brake Put the warning lights on If the 1 C engine is not running there will be no steering or braking assistance Operate the steering and pedal slowly avoiding sudden abrupt movements TOW G4 LIFT TRUCK SLING Take into account the position of the lift truck center of gravity for lifting fig G4 1 Place the hooks in the fastening points provided fig G4 2 and G4 3 3 37 INTRODUCTION TO SAFETY G5 LIFT TRUCK ON A PLATFORM TRANSPORT WARNING Ensure that the safety instructions for the platform are followed before loading the A lift truck and that the driver of transport is informed about the dimensions and weight of the lift truck WARNING Ensure that the platform has dimensions and load capacity sufficient for transporting A the lift truck Check also the allowable pressure on the contact surface of the platform trailer For lift trucks equipped with a turbo charged l C engine block off the exhaust IMPORTANT outlet to avoid rotation of the turbo shaft it may spin without lubrication during transport LOAD THE LIFT
71. e of the lift truck see INSTRUCTIONS FOR HANDLING A LOAD D TRANSVERSE ATTITUDE OF THE LIFT TRUCK REMINDER Make sure that the following operations can be performed with clear visibility see OPERATIONS INSTRUCTIONS UNLADEN AND LADEN D VISIBILITY TAKING UP A HIGH LOAD ON TIRES Ensure that the forks will easily pass under the load Lift and extend the boom 1 2 until the forks are level with the load moving the lift truck 3 forward if necessary fig F1 moving very slowly and carefully Keep the shortest distance possible to place the forks under the load between the pile and the lift truck fig F1 and use the shortest possible length of boom Place the forks in front of the load by alternately extending and retracting the boom 1 or if necessary moving the lift truck forward 2 fig F2 Set the parkbrake and place the forward reverse gear to neutral Slightly lift the load 1 and incline the carriage 2 backwards to stabilize the load fig F3 Tilt the load sufficiently backwards to ensure its stability Respect load capacites see INSTRUCTIONS FOR HANDLING A LOAD If the lift truck is overloaded return the load to the place from which it was taken If possible lower the load without shifting the lift truck Lift the boom 1 to raise the load retract 2 and lower the boom 3 to bring the load into the transport position fig F4 If this is not possible back the lift truck 1
72. ear hydraulic predisposition 154 F18 Front working light 15A F19 OPTION Rear window defrosting 15 F20 OPTION Pneumatic seat 104 F21 Front windscreen wiper and windscreen washer 104 F22 OPTION Jib suspension 10A F23 Right sidelight 7 5A Sidelight indicator light 7 5A Control panel lighting 7 54 OPTIONAL Number plate lighting 7 5A F24 Left sidelights 7 54 F25 Right indicators 7 54 F26 Left indicators 7 54 9681 2 25 INTRODUCTION TO SAFETY F27 Low beam 154 Low beam indicator light 154A Rear fog light 154A F28 Main beam 154 Main beam lamp 154 F29 Warning lights 15 Roof light 15 OPTIONAL permanent 154 F30 Lights horn and indicator switch 25 F31 Starter 204 F32 Electroproportional hydraulic control modules 3A OPTION Jib suspension 5A OPTION Cutting off aggravating hydraulic movements 5A OPTION Attachment hydraulic control forced operation 5A KO OPTION Air conditioning K1 Relay cutting transmission to hydraulic controls K2 Transmission cut off relay K3 Reverse gear relay K4 Forward gear relay K5 Buzzer K6 OPTIONAL Electrovalve on jib head OPTION Electrical jib provision OPTION Electrovalve on jib head attachment hydraulic locking device K7 OPTION Cutting off simple hydraulic movements KS Safety system sta
73. election lever B into position B1 highway traffic Before driving on public roads it is necessary to set the alignment of the rear wheels and to drive in front wheel steer Long WARNING distance travel requires periodically stopping the lift truck to check the rear wheel s alignment using the green lamps In case of anomalies consult your dealer 2 29 INTRODUCTION TO SAFETY 20 HYDRAULIC CONTROLS AND TRANSMISSION CUT OFF Aw ARNING Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve In the event of suspected malfunction contact your dealer ANY ALTERATION MAY VOID THE WARRANTY WARN ING Use the hydraulic controls carefully without sudden movements to avoid accidents caused by shaking the lift truck NOTE If necessary use the steering to reset the hydraulic control steering accumulator A Lifting and tilting control lever Telescoping control button C Attachment control button D Jib head electrovalve option control button LIFTING THE LOAD The lever A backwards when lifting The lever A forwards when lowering TILT OF CARRIAGE The lever A to the left for reverse tilt TELESCOPING Button B forwards for extending Button B backwards for retracting ATTACHMENT The button C forwards or backwards OPTION JIB HEAD ELECTROVALVE Button D see 2 DESCRIPTION DESCRIPTION AND USE OF ELECTRICAL AND HYDRAULIC OPTIONS NOTE
74. er drain plug 1 fig E1 1 and unscrew the plug Remove filling plug 2 fig E1 2 in order to ensure that the oil is drained properly Rinse out with ten litres of clean diesel through filler port 3 fig E1 2 Install and tighten the drain plug tightening torque 26 ft lb Fill the fuel tank with clean diesel filtered through the filler port Install the filling cap E2 SAFETY DRY AIR FILTER CARTRIDGE CHANGE For the disassembly and reassembly of the dry air filter cartridge see 3 MAINTENANCE D3 AIR FILTER CARTRIDGE Gently remove the dry air filter safety cartridge 1 fig E2 taking care to avoid spilling the dust Clean the gasket surface on the filter with a damp clean lint free cloth Before installing check the state of the new safety cartridge see 3 MAINTENANCE FILTERS AND BELTS Introduce the cartridge into the filter axis and push it in pressing the edges and not the middle NOTE The schedule for changing the safety cartridge is given for reference only It must be changed for every two changes of the dry air filter cartridge 3 30 INTRODUCTION TO SAFETY E3 GEAR BOX OIL DRAIN E4 GEAR BOX SUMP STRAINER CLEAN Park the lift truck on level ground with the I C engine stopped the gear box oil still warm DRAINING THE OIL Place a container under drain plug 1 fig E3 1 and under cover 2 fig E3 2 and unscrew the drain plug Remove cover plate 3 fig E3 3
75. er or Manitou North America Inc if you have any ques tions concerning your forklift its operation service or parts Keep both manuals in the literature box on the forklift available for reference If either manual becomes illegible or is missing contact your dealer for replace ments immediately This manual cannot cover every situation that might result in an accident It is the respon sibility of the operator to always remain alert for potential hazards and be prepared to avoid them ADDITIONAL RECOMMENDED LITERATURE ANSI ITSDF B56 6 is the national consensus standard for rough terrain forklift trucks It contains rules about forklift safety maintenance safe operation training and supervision Forklift owners should learn this stan dard and make it available for their operators service personnel and supervisors These standards can be obtained free of charge from the Industrial Truck Standards Development Foundation ITSDF on their web site at www itsdf org The following references are examples from the standard addressing forklift operators A OPERATOR TRAINING QUALIFICATIONS 1 The user shall ensure that operators understand that safe operation is the operator s responsibility The user shall ensure that operators are knowledgeable of and observe all safety rules and practices 2 Create an effective operator training program centered around user company s policies operating condi tions and rough terrain forklift truck
76. ers are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 A DANGER Boom equipped models Location on both sides Stay cl f raised b of the boom nose ay clear of raised boom unless properly supported Operator may be crushed Keep away from unsupported boom between falling boom and main frame Failure to comply may result in serious injury or death Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose 4h DANGER Keep machine at least 25 feet from overhead power lines Keep away from power lines Failure to comply may result in serious injury or death by electrocution 801007 XI INTRODUCTION TO SAFETY SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of ps A DANGER the operator near the hydraulic control lever READ OPERATOR S MANUAL Level machine at ground level before raising boom Do not adjust frame Frame leveling notice load must be lowered JOE above ground level If frame position is changed with a raised boom machine may become unstable and turn over Failure to follow instructions may result in serious injury or death Attachment and Boom Safety 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 man
77. ever be used for climbing onto or down from the lift truck etc If any of the control components are fitted with an engagement device manual throttle etc it is forbidden to leave the cab without first placing these controls in neutral Never carry passengers on the lift truck or in the cab C ENVIRONMENT Always comply with all worksite safety regulations If you have to use the lift truck in a dark area or at night make sure it is equipped with working lights During handling operations make sure that no one is in the way of the lift truck or its load Do not allow personnel to come near the working area of the lift truck or pass beneath an elevated load When using the lift truck on an incline before lifting the boom follow the instructions given in the Section INSTRUCTIONS FOR HANDLING A LOAD D HORIZONTAL ATTITUDE OF THE LIFT TRUCK Travelling on a longitudinal slope Drive and brake gently Moving without load Forks or attachment facing downhill e Moving with load Forks or attachment facing uphill Never move onto a loading platform without having first checked That it is suitably positioned and made secure That the unit to which it is connected tractor etc will not shift That the platform is approved for the total weight of the lift truck to be loaded That the platform is approved for the overall size of the lift truck Never move onto a foot bridge floor or freight lift
78. fig F is on AW ARNING Always cut the electrical power to the circuit using switch 2 fig F after each change of attachment to avoid involuntary release Use the attachment safely INTRODUCTION TO SAFETY C HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE TAKING UP AN ATTACHMENT Ensure that the attachment is in alignment to the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the locking pin and the clip are in position in the bracket fig A Place the lift truck with the jib fully lowered in front of and parallel to the attachment tilt the carriage forwards fig B Bring the carriage under the locking tube of the attachment slightly lift the jib incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to facilitate locking MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT Jake the locking pin and the clip on the bracket fig A and lock the attachment fig D Do not forget to install the clip Stop the 1 C engine and keep the ignition on the lift truck Remove the pressure of the hydraulic circuit by operating switch 1 fig E on the distributor lever backwards and forwards 4 or 5 times Connect the rapid connectors according to the attachment s hydraulic movements IMPORTANT Make sure that the rapid connectors are clean When not in use protect the openings with the caps provided
79. for signs of wear and cracks and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Check the belt tension between the pulleys of the crankshaft and of the alternator NEW BELT At a pressure of 4 ft lb on strap 3 fig C2 3 the displacement must be about 3 16 in BELT AFTER 20 HOURS OF OPERATION At a pressure of 4 ft Ib on strap 3 fig C2 3 the displacement must be about 3 16 in Carry out adjustments if necessary Loosen screws 4 fig C2 3 by two to three thread turns Swivel the alternator assembly so as to obtain the belt tension required Retighten screws 4 fig C2 3 tightening torque 16 ft lb Put the protective guard back 2 fig C2 2 If the alternator belt has to be changed check the tension again after the first 20 IMPORTANT hours of operation C3 COMPRESSOR BELT TENSION OPTION AIR CONDITIONING CHECK ADJUST Open the I C engine cover Unscrew the fastening screws 1 fig C3 1 Lay down the protective guard 2 fig C3 1 Checkthe belt for signs of wear and cracks and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Check the belt tension between the pulleys of the crankshaft and of the compressor Under a normal pressure exerted with the thumb 10 ft Ib the belt should move approximately 3 8 in Carry out adjustments if necessary Loosen screws 3 fig C3 2 with two to three thread turns Swivel the compressor
80. g a compressed air jet max pressure 45 psi directed from the top to the bottom and from the inside towards the outside at a minimum distance of 1 1 2 in from the cartridge wall Cleaning is completed when there is no more dust on the cartridge Avoid tearing or making a hole in the cartridge The cartridge must not be blown anywhere near the air filter box Never clean the IMPORTANT E s s s cartridge by tapping it against a hard surface Your eyes must be protected during this intervention Clean the cartridge seal surfaces with a damp clean lint free cloth and grease with a silicone lubricant Check visually the outer condition of the air filter and its mounts Verify the condition of the hoses and their mounts also Do not clean the dry air filter cartridge by washing it in liquid Do not clean the safety cartridge located inside the filter cartridge IMPORTANT 4 tow 7 pens change it for a new one if it is dirty or damaged B2 RADIATOR CORES CLEAN In a heavy dust atmosphere clean the radiator core every day Do not use a water IMPORTANT Jet or high pressure steam as this could damage the radiator fins Open the I C engine cover If necessary clean the suction grid on the engine hood Using a soft cloth clean the radiator cores in order to remove as much dirt as possible Undo the screw 1 fig B2 1 of the fuel radiator and pivot for easier cleaning Clean the cores using a compressed air
81. g the decals Before operating the lift truck learn the meaning s of the decals as described in this manual If any decal becomes illegible or missing have it replaced immediately Always replace decals using the same decal part no unless otherwise specified by the manufacturer For replace ment decals not found in your parts manual contact your nearest dealer If you have any questions contact your supervisor or nearest dealer for advice before operating your forklift 801011 Before Starting 801011 Boom equipped models Location on the brake fluid cover panel to the left and below the dash panel BEFORE STARTING OR OPERATING Safety Instructions 420792 Read and understand all safety and operating Mast equipped models Location on or near the operator manual A O E storage case and or on the dash panel Clear the area of bystanders Locate and know operations of controls Instructions for the forklift operator before operating the forklift Fasten seat belt Keep all shields in place Operate only from operator s seat Carry load as low as possible avoid steep slopes and drive slowly on rough terrain to avoid machine overturn SAFETY INSTRUCTIONS Read and understand operators manual before you operate this truck If the operator s manual is missing a new Refer to operator s manual for jump starting instructions manual may be obtained through your local dealer or directly from Manitou N A Inc Waco T
82. g way A Control with signal light on B At the required temperature C To the desired position 1 2 or 3 NOTE Direct the ventilators onto the cab s windows for increased efficiency 2 31 INTRODUCTION TO SAFETY 23 CAB FILTER VENTILATORS See 3 MAINTENANCE D EVERY 500 HOURS SERVICE 24 WINDSCREEN DEMISTER VENTS For optimum effectiveness close the heating ventilators 25 HEATING VENTS These heating vents enable the air to be directed to the interior of the cabin and onto the side windows 26 DOOR LOCK Two keys are provided with the lift truck to enable the cabin to be locked 27 LOCKING HANDLE FOR UPPER HALF DOOR 28 UNLOCKING BUTTON FOR UPPER HALF DOOR 29 HANDLE FOR REAR WINDOW OPENING EMERGENCY EXIT Use the rear window as an emergency exit if it is impossible to leave the cab by the door NOTE There is an OPTIONAL rear window stay 30 DOCUMENT HOLDER Ensure that the operator s manual is in its place in the document holder 2 32 INTRODUCTION TO SAFETY 31 FRONT LIGHTS A Left front indicator B Left front dipped headlight C Left front main beam D Left front sidelight E Right front indicator F Right front dipped headlight G Right front main beam H Right front sidelight 32 REAR LIGHTS A Left rear indicator B Left rear stoplight C Left tail light D Left rear reverse light E Left rear fog light F Right rear fog light
83. gainst penetration of water steam or cleaning agents particularly electrical components hose connections and the fuel injection pump Remove any residue of fuel oil or grease from the lift truck FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE CONSULT YOUR DEALER INTRODUCTION TO SAFETY IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent damage to the lift truck while it is removed from service for an extended period of time IMPORTANT it is recommended that your dealer perform the following procedures for lift truck storage and returning it to service PREPARING THE LIFT TRUCK Clean the lift truck thoroughly Check for and repair any fuel oil water or air leaks Replace or repair any worn or damaged parts Wash the painted surfaces of the lift truck with clear cold water and dry them Touch up the paint where necessary Park the lift truck see OPERATING INSTRUCTIONS UNLADEN AND LADEN Make sure the boom cylinder rod ends are all in retracted position Release the pressure in the hydraulic circuits PROTECTING THE l C ENGINE Fill the tank with fuel see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE Empty and replace the antifreeze see MAINTENANCE F EVERY 2000 HOURS SERVICE Allow the I C engine to run at idle for a few minutes then switch off Replace the 1 C engine oil and oil filter
84. good working order or does not comply with the safety standards he operator is prohibited from performing repairs or adjustments unless he has been trained for this purpose He must keep the lift truck properly cleaned if this is among his responsibilities he operator must carry out daily maintenance see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE he operator must ensure that the tires are suited for the work site There are optional solutions consult your dealer SAND tires LAND tires Snow chains Do not operate the lift truck if the tires are incorrectly inflated damaged or excessively worn Bad tires can put your ZUGE safety or that of others at risk or cause damage to the lift truck The installation of foam inflated tires is prohibited and is not guaranteed by the manufacturer prior authorization is required D MODIFICATION OF THE LIFT TRUCK For your safety and others you must not change the structure or settings of the various components used on your lift truck hydraulic pressure calibrating limiters engine speed addition of extra equipment addition of counterweight unapproved attachments etc The manufacturer cannot be held responsible for such modifications E LIFTING PEOPLE he use of working equipment and load lifting attachments to lift personnel is strictly forbidden INTRODUCTION TO SAFETY OPERATING INSTRUCTIONS UNLADEN AND LADEN A BEFORE STARTING THE LIFT T
85. he gearbox oil temperature is abnormally high Stop the I C engine and look for the cause gear box oil level possible leak radiator etc RED BRAKING OIL LEVEL WARNING INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately and look for the cause braking oil level possible leak etc In the event of an abnormal dropping of the level consult your dealer RED PARKING BRAKE LAMP 3 This lamp comes on when the parking brake is applied ATTERY CHARGE WARNING INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately and look for the cause electric circuit alternator belt alternator etc EE RED I C ENGINE OIL PRESSURE WARNING INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately and look for the cause engine oil level possible leak etc RED I C ENGINE WATER TEMPERATURE WARNING INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately and look for the cause coolant level possible leak radiator etc RED AIR FILTER OR HYDRAULIC RETURN FILTER CLOGGED INDICATOR LIGHT The lamp and buzzer come on when the air filter cartridge or the hydraulic return oil filter cartridge is clogged up Stop the I C engine and carry out the necessary repairs see cleaning and replacement requirements in chapte
86. he height of the seat while checking that the green in display 2 remains visible IMPORTANT 7o avoid causing damage do not activate the compressor for over 1 minute SEAT BACK REST ANGLE ADJUSTMENT FIG C The back rest angle of the seat may be adjusted to suit the individual Press the left hand button while pushing on the seat or relaxing pressure on the seat to find a comfortable position SEAT DEPTH ADJUSTMENT FIG D The depth of the seat may be adjusted to suit the individual Press the right hand button while raising or lowering the seat to find the desired position EXTENDING THE HEAD REST FIG E The height of the back rest can be adjusted by pulling it upwards the notches will click up to the stop The head rest can be removed by applying sufficient pressure to pull it off the stop 2 16 INTRODUCTION TO SAFETY LUMBAR ADJUSTMENT FIG F This increases the comfort of the seat and the driver s freedom of movement Turn the handle either left or right to adjust the height or depth of the lumbar support ADJUSTMENT OF THE ANGLE OF THE BACK REST FIG G Support the back rest pull the lever and position the back rest to find the desired position A CAUTION If you do not support the back rest when making adjustments it swings comple tely forwards HORIZONTAL SHOCK ABSORBER FIG H In certain conditions e g driving with a trailer it is advised that a horizontal shock absorber be used The dr
87. herefore the best technical ability to provide maintenance 3 5 INTRODUCTION TO SAFETY MLT 735 120 LSU Series 4 E3 I C ENGINE OIL FILTER Part number 746954 Change 500 H e ALTERNATOR BELT um gt Part number 244288 DRY AIR FILTER CARTRIDGE A Part number 563416 uM A FAN BELT Clean 50 H Part number 257524 Change 500 H SAFETY DRY AIR FILTER CARTRIDGE SAN COMPRESSOR BELT Part number 563415 OPTION AIR CONDITIONING Change 1000 H 4 Part number 244237 FUEL FILTER CYCLONIC PREFILTER Part number 747351 N Part number 224713 Change 500 H Se Clean 10 H FUEL PRE FILTER Part number 747462 Change 500 H AUTOMATIC VACUUM CLEANING PRE FILTER OPTION Part number 226611 This schedule is given for reference only see 3 MAINTENANCE SERVICING SCHEDULE for cleaning and changing GEAR BOX OIL FILTER Part number 561749 Change 500 H HYDRAULIC RETURN OIL FILTER CARTRIDGE SUCTION STRAINER FOR HYDRAULIC OIL TANK Part number 236094 Part number 224726 Change 500 H Clean 1000 H FILTER CAP FOR HYDRAULIC OIL TANK DISTRIBUTOR CONTROL HEAD FILTER Part number 62415 7 Part number 254780 Change 1000 H Change 1000 H CAB VENTILATION FILTER WITH AIR CONDITIONING Part number 225052 Clean 50 H Change 250 H CAB VENTILATION FILTER WITHOUT AIR CONDITIONING Part number 225052 Clean 500 H 3 6 INTRODUCTION TO SAFETY 3 1 INTRODUCTION TO SAFETY
88. hydraulic circuit by operating switch 1 fig E on the distributor lever backwards and forwards 4 or 5 times Connect the rapid connectors according to the attachment s hydraulic movements IMPORTANT Make sure that the rapid connectors are clean When not in use protect the openings with the caps provided Close the valve in position B fig D that is to say the hydraulic circuit of the attachment locking closed Aw ARNING Always close the valve in position B fig D after locking the attachment to avoid accidental unlocking Use the attachment safely HYDRAULIC RELEASING AND DISCONNECTING THE ATTACHMENT Close the attachment Put the valve in position A fig D that is to say the hydraulic circuit of the attachment locking open Switch button 1 fig E of the distributor lever backwards to completely release the attachment Stop the I C engine and keep the ignition on the lift truck Remove the pressure of the hydraulic circuit by operating switch 1 fig E on the distributor lever backwards and forwards 4 or 5 times Disconnect the rapid connectors of the attachment IMPORTANT Make sure that the rapid connectors are clean When not in use protect the openings with the caps provided LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position 4 9 INTRODUCTION TO SAFETY
89. ing C7 HEATING BLOCK NON RETURN VALVE CLEAN Since non return valve 1 fig C7 is located under the cab it is possible for it to become obstructed with spattered mud for example Clean if necessary 3 24 INTRODUCTION TO SAFETY C8 FRONT AND REAR DIFFERENTIAL OIL LEVEL CHECK Park the lift truck on level ground with the I C engine stopped Remove level plug 1 fig C8 The oil should be flush with the edge of the hole If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the filler port 2 fig C8 Replace and tighten the level plug 1 fig C8 tightening torque 30 ft lb Repeat this operation for the rear axle differential C9 FRONT AND REAR WHEELS REDUCERS OIL LEVEL CHECK Park the lift truck on level ground with the I C engine stopped Check the level on each front wheel reducer Place level plug 1 fig C9 in the horizontal position as shown Remove the level plug the oil should be flush with the edge of the hole If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the same hole Replace and tighten the level plug 1 fig C9 tightening torque 30 ft lb Repeat this operation on each rear wheel reducer 3 25 INTRODUCTION TO SAFETY D1 I C ENGINE OIL DRAIN D2 I C ENGINE OIL FILTER CHANGE Park the lift truck on level ground let the I C engine run at idle for a few minutes then stop the 1 C engine
90. is necessary to cut the transmission by pressing the button 1 on the lever 1st gear to the right backwards 2nd gear to the right forwards 3rd gear to the left backwards 4th gear to the left forwards USING THE GEARS ON THE GEAR BOX On these lift trucks with a torque converter it is not necessary to automatically start up in 1st speed and progress up the gears The choice of transmission gear ratio should be made carefully according to the nature of the work being carried out A poor choice may result in the rapid rise of the transmission oil temperature through excessive slipping of the converter which could A CAUTION lead to serious damage to the transmission it is essential to stop and change the working conditions if the transmission oil temperature indicator light comes on This poor choice may also result in a reduction in the lift truck s performance in forward gear When the forward force increases the forward speed in the gear for example in 3rd gear may be lower than the forward speed that could be obtained with the 2nd instead of 3rd gear In general we would advise you to use the following gears according to the nature of the work being carried out On the road Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it In hilly areas set off in 2nd gear and go up to 3rd if the conditions and state of the road permit it With a trailer on the road Set off in 2nd gear a
91. iver s seat is thus better able to absorb jerks in the direction of travel Position 1 Horizontal shock absorber fitted Position 2 Horizontal shock absorber removed LONGITUDINAL ADJUSTMENT FIG 1 Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position SERVICING FIG J Dirt may adversely affect the correct functioning of the seat For this reason make sure your seat is always clean To clean or change the cushions simply remove them from the seat frame A CAUTION 4 rocking head rest increases the risk of an accident Avoid wetting the cushion fabric when cleaning Check the resistance of the fabric on a small hidden area before using any fabric or plastic cleaner 2 17 INTRODUCTION TO SAFETY 1 DELUXE PNEUMATIC DRIVER S SEAT OPTION DESIGNED FOR MAXIMUM COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS WEIGHT ADJUSTMENT FIG A It is advised that you adjust the seat according to your weight when sitting Switch on lift truck ignition Pull or push lever 1 briefly Adjustment is automatic NOTE To avoid any health problems it is recommended that the weight should be checked and adjusted before starting up the lift truck SEAT HEIGHT ADJUSTMENT FIG B When weight adjustment has been carried out you can then modify seat height Keep the ignition on in the lift truck Pull or push lever 1 and ad
92. just the seat height IMPORTANT avoid causing damage do not activate the compressor for over 1 minute SEAT BACK REST ANGLE ADJUSTMENT FIG C The back rest angle of the seat may be adjusted to suit the individual Press the left hand button while pushing on the seat or relaxing pressure on the seat to find a comfortable position SEAT DEPTH ADJUSTMENT FIG D The depth of the seat may be adjusted to suit the individual Press the right hand button while raising or lowering the seat to find the desired position EXTENDING THE HEAD REST FIG E The height of the back rest can be adjusted by pulling it upwards the notches will click up to the stop he head rest can be removed by applying sufficient pressure to pull it off the stop LUMBAR ADJUSTMENT FIG F This increases the comfort of the seat and the driver s freedom of movement Press the raise and lower switches to adjust the curvature of the seat back to your requirements INTRODUCTION TO SAFETY ADJUSTMENT OF THE ANGLE OF THE BACK REST FIG G Support the back rest pull the lever and position the back rest to find the desired position A CAUTION If you do not support the back rest when making adjustments it swings comple tely forwards HORIZONTAL SHOCK ABSORBER FIG H In certain conditions e g driving with a trailer it is advised that a horizontal shock absorber be used The driver s seat is thus better able to absorb jerks in the direc
93. k in areas where there is a risk of fire or which are poten tially explosive i e refineries fuel or gas depots stores of inflammable products For use in these areas specific equipment is available ask your dealer for information C MODIFICATION OF THE LIFT TRUCK For your safety and that of others you must not change the structure or settings of the various components used on your lift truck i e hydraulic pressure calibrating limiters I C engine speed addition of extra equipment addition of counterweight unapproved attachments etc The manufacturer cannot be held responsible for unauthorized modifications INTRODUCTION TO SAFETY INSTRUCTIONS he operator s manual must always be in good condition and kept in the place provided on the lift truck and in the language used by the operator he operator s manual and any plates or decals which are no longer legible or are damaged must be replaced immediately MAINTENANCE Maintenance or repairs other than those detailed in part 3 MAINTENANCE must be carried out by qualified personnel consult your dealer and under the necessary safety conditions to maintain the health of the operator and any third party Your lift truck must be inspected periodically to ensure that it remains in compliance The frequency of this inspection is defined by current legislation in the country in which the lift truck is used INTRODUCTION TO SAFETY INSTRUCTIONS FOR THE O
94. ke sure the trailer brakes are working properly and test the effects of braking before taking the trailer onto the public highway INTRODUCTION TO SAFETY 1 BATTERY CUT OFF 2 REVERSE BUZZER ALARM 3 NUMBER PLATE 4 NUMBER PLATE LIGHTING 5 REAR REFLECTORS 2 37 INTRODUCTION TO SAFETY 6 PREHEATING ELEMENT Enables the engine to be kept warm during prolonged periods of parking and thus improves engine starting SUPPLY CHARACTERISTICS OF PREHEATING SYSTEM Rated range of power 220 240V 50 60Hz Current consumed 4 5A GY Equipment in class 1 Equipment connectable only on feeder circuit TT or TN Category of insulation 2 PHOTO NOT AVAILABLE ENVIRONMENTAL CONDITIONS FOR USE Maximum ambient temperature for using preheating 77 F e Pollution level 2 CONDITIONS FOR CONNECTION AND USE OF PREHEATING he preheating system should not be used for an external ambient temperature higher than 77 F It is essential that the power supply to the preheating system is Effected with a cable that conforms to the installation standards in force and contains a protective earth conductor Contains an appropriate sectioning system Incorporate an appropriate safety system against short circuits fuses or circuit breaker and a differential circuit breaker with 30 mA sensitivity Only connect and disconnect from the power supply while the unit is off and the I C engine is stopped 7 M
95. l building structures and equipment to the supervisor immediately Always remain alert conditions are constantly changing at the work site TECHNICAL SUPPORT All data provided in this manual is subject to production changes addition of new models and improved prod uct designs If a question arises regarding your forklift please consult your dealer or K D Manitou Inc for the latest information When ordering service parts or requesting technical information be prepared to quote the applicable Model Serial Numbers VIII SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL SHOWN BELOW IT IDENTIFIES POTENTIAL HAZARDS WHICH IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH Also observe the safety messages places throughout this manual providing special instructions telling you when to take precautions and to identify potential hazards The safety messages are highlighted and outlined in a box similar to those shown in the examples below SAFETY ALERT SYMBOL NOTE or NOTICE Provides information special instructions or references about the lift truck IMPORTANT Precautions which must be taken to avoid damage to the lift truck Indicates a potentially hazardous situation which if not avoided 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
96. llowing points Fixing of the anchoring points on the seat Cleanness of the strap and the locking mechanism Triggering of the locking mechanism Condition of the strap cuts curled edges REELED BELT WITH TWO ANCHORING POINTS Check the points listed above together with the following points The correct winding of the belt Condition of the reel guards Roller locking mechanism when the strap is given a sharp tug NOTE After an accident replace the seat belt Aw ARNING Under no circumstances should you use the lift truck if the seat belt is damaged Repair or replace the seat belt immediately E11 FRONT AND REAR WHEELS REDUCERS OIL DRAIN Park the lift truck on level ground with the I C engine stopped and the reducers oil still warm IMPORTANT Dispose of the drain oil in an ecological manner Drain and change each front wheel reducer Place drain plug 1 fig E11 in position A Place a container under the drain plug and unscrew the plug Let the oil drain fully Place the drain port in position B i e in a level port Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by level port 1 fig E11 he level is correct when the oil level is flush with the edge of the hole Install and tighten the drain plug 1 fig E11 tightening torque 31 ft lb Repeat this operation on each rear wheel reducer 3 33 INTRODUCTION TO SAFETY F EVERY 2000 HOURS OF SERVICE Car
97. load being carried obstructs forward view travel with the load trailing 32 Ascend or descend grades slowly and with caution a When ascending or descending grades in excess of 5 loaded rough terrain forklift trucks should be driven with the load upgrade b Unloaded rough terrain forklift trucks should be operated on all grades with the load engaging means downgrade 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 capacity 39 Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so
98. lt lt lt Parking brake mechanism on the transmission 1 1 966 lt lt lt lt lt lt Brake oi D Brake oil Brake system cs Brake system pressure pp ce Brake o o qo AR ss E STEERING Steering J PO ee Steering swivel joints pp pOr Windscreen washer liquid level pp C lt lt lt lt lt lt lt lt lt lt lt lt cee Cab door 5 1 1 1 1 j GY lt lt lt lt lt lt Cab ventilation filter OPTION Air conditioning N R lt lt lt lt lt lt lt lt Heating block non return valve pp N lt lt lt lt lt lt lt lt lt Cab ventilation filters N I lt lt 66 1 gt Seatbelt AJ i ee Condition of the rear view mirrors pp C Structure 0 0 0 es 61 Air conditioning OPTION _ C m r m O zt lt wp pf pf OO 7 1 Condition of wiring harness and cables or Warning indicators pp lt lt lt lt Front headtights f fy fa AJ O 2 gt gt lt m Front wheels reducers pivots pp G lt lt lt lt lt lt lt lt lt lt lt lt 16 09 Front axle
99. lt your dealer Y WARNING The HYDRAULIC ACCUMULATORS which may be fitted on your lift truck are under high pressure it is dangerous to dismantle them This operation must only be performed by approved personnel consult your dealer ELECTRICITY Do not short circuit the starter relay to start the lift truck If the forward reverse gear is not in neutral the lift truck will start to move immediately Do not drop metallic objects on the battery Disconnect the battery before working on the electrical circuit WELDING Always disconnect the battery before performing welding operations on the lift truck When welding on the lift truck connect the negative cable from the welding equipment directly to the part being welded so as to avoid high tension current passing through the alternator Never perform welding or work which directs heat onto an inflated tire The heat may increase the air pressure which can cause the tire to explode If the lift truck is equipped with an electronic control unit disconnect it before welding to avoid the risk of causing irreparable damage to electronic components INTRODUCTION TO SAFETY WASHING THE LIFT TRUCK Clean the lift truck before servicing Remember to close and lock all access to the lift truck door window s engine compartment During washing avoid the articulations electrical components and connections Protect components susceptible of being damaged a
100. n forklift truck 55 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before restarting engine 56 Do not use open flames when checking electrolyte level in storage batteries liquid level in fuel tanks or the condition of LPG fuel lines and connectors 57 Do not lift personnel with the forklift If the forklift must be used to lift people precautions for the protec tion of the personnel must be taken see ITSDF B56 6 chapter 5 15 Elevating Personnel ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont D SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level Transporting suspended loads must ALWAYS be done slowly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid overturn The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards Grades and sudden starts stops and turns can cause the load to swing and create a hazard Guidelines for Free Rigging 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
101. nd go up to 3rd if the conditions and state of the road permit it Handling 3rd gear 2nd gear in restricted spaces Loading reclaiming with bucket manure fork etc 2nd gear Earth moving 1st gear 2 21 INTRODUCTION TO SAFETY 17 FORWARD NEUTRAL REVERSE GEAR SELECTION FORWARD Push the knob forward position A REVERSE Pull the knob backwards position B NEUTRAL The knob must be in the intermediate position to start the lift truck position C When operating this control the lift truck should be travelling at slow speed and not accelerating SAFETY FOR MOVING THE LIFT TRUCK Authorization to move the lift truck is controlled by an electronic unit The operator must observe the following sequence to move the truck forwards or backwards 1 sit down correctly in the driver s seat 2 release the parking brake 3 engage forward or reverse movement To stop the lift truck he must observe the following sequence 1 Set the forward reverse selector to neutral 2 engage the parking brake 3 get out of the lift truck NOTE If the operator leaves the driving cab with forward or reverse engaged a continuous alarm will sound When this alarm sounds the operator can simply sit back in the seat and continue advancing or reversing If the alarm contines the operator must sit back in the seat put the forward reverse selector back in neutral and select forward or reverse if he wishes to continue moving 2 28
102. ne year for annual c Before November 10 2014 operators must have had the additional training and qualification certification required by OSHA regulations 81926 1427 and 81926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a detailed description VII ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont CONCLUSION 1 ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard 29 CFR 1910 178 as described by the Occupational Safety and Health Administration OSHA They must be qualified as to their visual hearing physical and mental ability to operate the equipment safely NEVER use drugs or alcohol while operating a 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 malfunction
103. ng order Using a trailer in poor condition may effect the lift truck s steering and braking and safety and the I C engine is turned off Aw ARNING fa third party helps in coupling or uncoupling the trailer they must be continually visible to the driver until the lift truck is parked NOTE There is an OPTIONAL rear view mirror which allows the lift truck to be directed more closely to the trailer ring B PROJECTING HOOK COUPLING AND UNCOUPLING THE TRAILER To couple the trailer position the lift truck as close as possible to the trailer ring Put the handbrake on and switch off the I C engine Remove the clip 1 lift the trailer pin 2 and place or remove the trailer ring Risk of crushed fingers or hands Keep hands and fingers clear while coupling the trailer The safety clip 1 must be installed after coupling Before uncoupling make sure the trailer is blocked in place and independently supported B COUPLING LADDER OPTIONAL COUPLING AND UNCOUPLING THE TRAILER To couple the trailer position the lift truck as close as possible to the trailer ring Put the handbrake on and switch off the I C engine ON THE FIXED PIN Remove pin 1 remove rod 2 and raise latch 3 Insert or remove the trailer ring lower latch 3 and install rod 2 Risk of crushed fingers or hands Keep hands and fingers clear while coupling the trailer The safety clip 1 must be installed after coupling Before uncoupling make
104. not avoided will result in death or serious injury CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust and some of its constituents are known to the State of California to cause cancer birth defects or other reproductive harm WARNING Battery posts terminals and related accesories and related accessories contain lead and lead compounds Wash hands after handling INTRODUCTION TO SAFETY SAFETY DECALS The purpose of this chapter is to introduce you to the safety messages decals and nameplates found on your forklift truck The decals are identified by name part number location and a brief description The forklift model logos and other misc decals not shown can be found in your forklift parts manual The decals illustrated may not be exactly the same as those installed on your forklift installation of the decals varies depending on the forklift model series decal updates etc The size and location of some decals limit the amount of information that can be placed upon it For this reason additional detailed information not found on the decals is provided through out this manual Every decal placed on the lift truck is important they are constant reminders of safety and instructions that 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 concernin
105. oad 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 improper tire inflation and the judgement exer cised by the operator C OPERATING SAFETY RULES AND PRACTICES 1 Safe operation is the
106. ork properly Comply with the load chart limits for the lift truck and attachment used Do not exceed the rated capacity of the attachment Never lift a load in a sling without the attachment provided for the purpose There are optional solutions contact your dealer B MASS OF LOAD AND CENTER OF GRAVITY Before taking up a load you must know its mass and center of gravity The load chart for your lift truck is valid for a load in which the position of the center of gravity is 24 in from the base of the forks fig B1 For a higher center of gravity contact your dealer For irregular loads determine the center of gravity before any movement fig B2 and set it in the longitudinal axis of the lift truck Do not attempt to move a load heavier than the effective capacity defined on the lift truck load chart CAUTION For loads with a moving center of gravity i e liquids take into account the variations of the center of gravity in order to determine the load to be handled Consult your agent or dealer Be vigilant and take extra care to limit these variations as much as possible C N A D TRANSVERSE LEVEL ATTITUDE OF THE LIFT TRUCK The transverse or level attitude is the angle of tilt of the chassis with respect to the hori zontal Raising the boom while on a slope reduces the lift truck s lateral stability The transverse attitude must be set with the boom in the down position as follows 1
107. r MAINTENANCE FILTERS CARTRIDGES AND BELTS GREEN DIRECTION INDICATOR LAMP GREEN SIDELIGHTS LAMP GREEN LOW BEAM LAMP BLUE MAIN BEAM LAMP 0000 G 60 2 21 INTRODUCTION TO SAFETY 4 N A 5 SWITCHES NOTE The location of the switches may vary depending on the options A ELECTRICAL JIB PROVISION OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS B ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS C WHEEL ALIGNMENT LAMPS D WARNING LIGHTS E REAR FOG LIGHT F SELF CLEANING FAN OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS G STEERING SELECTION H TRANSMISSION CUT OFF The switch selects transmission cut off to the service brake pedal or the hydraulic controls lever Position 1 Indicator light on transmission cut off to service brake pedal effected Position 2 Indicator light off transmission cut off to hydraulic control lever effected USE OF TRANSMISSION CUT OFF Transmission cut off to brake pedal position 1 When loading Transmission cut off to hydraulic controls lever position 2 When driving For inching and continuous stopping and starting delicate handling In order to optimize hydraulic movements cut off transmission to the hydraulic controls lever Starting up on a slope NOTE In all cases transmission cut off can be effected using the gear lever I REVOLV
108. r cap Check visually that there is no leakage in the radiator and pipes WARNING To avoid any risk of spraying or burning wait until the engine has cooled down before removing the cooling circuit filler plug A If the cooling liquid is very hot add only hot cooling liquid 176 F In an emergency you can use clean water as a cooling liquid then change the cooling circuit liquid as soon as possible see 3 MAINTENANCE F1 COOLING LIQUID A3 FUEL LEVEL CHECK Keep the fuel tank full to reduce condensation due to the atmospheric conditions Remove cap 1 fig A3 Fill the fuel tank with clean fuel see MAINTENANCE LUBRICANTS AND FUEL filtered through a strainer or a clean lint free cloth through filler port 2 fig A3 Put the cap back 1 fig A3 Check visually that there is no leakage on the tank and hoses WARNING The fuel tank is vented via the filler plug When changing it always use an original part with vented hole NOTE A locking tank cap is available as an OPTION 3 12 INTRODUCTION TO SAFETY A4 FUEL PRE FILTER CHECK Open the I C engine cover Check for the presence of water in the pre filter bowl 1 fig A4 2 and empty it out if necessary Place a receptacle under the drain plug 2 fig A4 2 and loosen it in two to three thread turns Allow the diesel fuel to flow out until it is free from impurities and water Tighten the drain plug Pressurize the circuit
109. r conditioning does not seem to be working properly have it examined by your dealer see 3 MAINTENANCE H WAR NING Every TWO YEARS OPTION AIR CONDITIONING The air conditioning system is under high pressure repairs must be made by a professional airconditioning repairman DESCRIPTION OF THE AIR CONDITIONING CONTROLS A Air conditioning system ON OFF control switch with indicator lamp Only works when control switch C set to 1 2 or 3 B Air temperature control C Air flow and fan speed control When this control is set to 0 the air conditioning system will not work NOTE Possible losses of water under the lift truck are due to condensate discharges caused by the drying effect of the installation especially with high outside temperatures and high relative humidity For the air conditioning to perform properly the air intakes must not be blocked by frost snow or leaves When the facility is running at least one of the cab air grilles must be open so as to avoid any risk of freezing to the evaporator HEATING MODE The controls must be adjusted in the following way A Control with signal light off B At the required temperature C To the desired position 1 2 or 3 CONDITIONED AIR MODE The controls must be adjusted in the following way A Control with signal light on B At the required temperature C To the desired position 1 2 or 3 DEMISTING MODE The controls must be adjusted in the followin
110. 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 rough terrain forklift truck or other attach ments 10 Understand rough terrain forklift limitations and operate the truck in a safe m
111. rting switch relay K9 Flashing unit K15 Relay cutting power supply to proportional hydraulic controls Lift the lid 2 of the tool box for access to fuse F33 Electronic control unit 1A F34 Diagnostic socket 5A Remove the les casings 3 and 4 of the hydraulic control for access to relays K10 OPTION Jib suspension K11 OPTION Jib suspension K12 OPTION 13 FUSES AND RELAYS UNDER THE ENGINE HOOD Remove casing 1 and cover 2 for access to fuses and relays IMPORTANT Always replace a faulty fuse with another of equivalent rating Never use a fuse that has been repaired F40 Lift truck electrical equipment 40A F41 Lift truck electrical equipment 40 F42 Preheating C engine 80A F43 Alternator 804 F44 I C engine electronic control unit 304A F45 OPTION Diesel decongealant 154 K16 Engine preheating relay K20 OPTION Diesel decongealant 2 26 INTRODUCTION TO SAFETY 14 ACCELERATOR PEDAL NOTE There is an OPTIONAL hand operated accelerator in the cabin 15 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF The pedal applies on the front and rear wheels by an hydraulic brake system and allows the lift truck to be slowed down and stopped Depending on the position of the transmission cut off switch it enables the free travel to cut off transmission see 2 DESCRIPTION 5 SWITCHES PANEL 16 GEAR LEVER AND TRANSMISSION CUT OFF In order to change speeds it
112. ry out the operations described previously as well as the following operations F1 COOLING LIQUID DRAIN These operations are to be carried out if necessary or every two years at the beginning of winter Park the lift truck on level ground with the I C engine stopped and cold DRAINING THE LIQUID Open engine hood and lift the battery cover Place a container under hose 1 fig F1 1 on the radiator and drain plug 2 fig F1 2 of the engine block Remove the hose and loosen the drain plug Remove filling plug 3 fig F1 3 of the radiator Let the cooling circuit drain entirely while ensuring that the ports do not get clogged Check the condition of the hoses as well as the fastening devices and change the hoses if necessary Rinse the circuit with clean water and use a cleaning agent if necessary FILLING THE LIQUID Install and tighten the hose 1 fig F1 1 and drain plug 2 fig F1 2 tightening torque 30 ft lb Slowly fill up the circuit with cooling liquid see 3 MAINTENANCE LUBRICANTS AND FUEL to the middle of gauge 4 fig F1 3 through filler port 5 fig F1 3 Install the filling plug 3 fig F1 3 Run the I C engine at idle for a few minutes Check for any possible leaks Check the level and refill if necessary 3 34 INTRODUCTION TO SAFETY F2 AIR CONDITIONING OPTION CLEANING INSPECTION CLEANING CONDENSER AND EVAPORATOR COILS CLEANING
113. s The program should be presented completely to all new operators and not be condensed for those claiming previous experience 3 Information on operator training is available from several sources including rough terrain forklift truck man ufacturers users government agencies etc 4 An operator training program should consist of the following a careful selection of the operator considering physical qualifications job attitude and aptitude b emphasis on safety of stock equipment operator and other personnel C citing of rules and why they were formulated d basic fundamentals of rough terrain forklift truck and component design as related to safety e g in Ib N m loading mechanical limitations center of gravity stability etc e introduction to equipment control locations and functions Explain how they work when used properly and problems when used improperly f supervise practice on operating course remote from normal activity and designed to simulate actual operations e g lumber stacking elevating shingles to the roof etc g oral written and operational performance tests and evaluations during and at completion of the course h refresher courses which may be condensed versions of the primary course and periodic on job operator evaluation i understanding of nameplate data and operator instructions and warning information appearing on the rough terrain forklift truck B GENERAL SAFETY PRACTICES
114. s option Location Near the hand throttle mechanism Reminder to operator set parking brake before operating hand throttle Disengage hand throttle before leaving the forklift DANGER DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK OPERATE HAND THROTTLE ONLY WITH PARKING BRAKE SET FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH 804784 XV INTRODUCTION TO SAFETY SAFETY DECALS 4 DANGER Acid in Battery 801014 Location in or near the battery storage compartment EXPLOSION HAZARD Can cause blindness or severe injury Protect eyes Keep away from sparks flames and cigarettes exercise caution when using tools that can cause sparks Keep battery level and caps tight ACID POISON HAZARD Causes severe burns Contains sulfuric acid In event of contact flush with water and see a doctor Keep out of reach of children 801014 Addresses battery hazards READ OPERATOR S MANUAL JUMP START NEGATIVE GROUNDED BATTERY 1 Wear eye protection 2 Connect ends of one cable to positive terminals of both batteries Jump Start Battery 801015 Location in or near the battery storage compartment 3 Connect one end of remaining cable to negative terminal of good battery 4 Connect other end of cable to engine block or reliable chassis ground of vehicle being started DO NOT CONNECT TO BATTERY 5 To prevent damage to electrical components of vehicle being started make cert
115. s park it safely remove the key tag Do Not Use and report the problem to the proper authority or authorized service personnel immediately ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont 2 CREATE A MAINTENANCE PROGRAM cont For the best forklift performance and operation a maintenance program is required Use the hour meter on the instrument panel to keep maintenance properly scheduled see SECTION TWO Servicing Schedule For repairs on major components engine transmission etc contact your nearest dealer for a Repair Manual Do not operate a forklift that is damaged or does not function properly Only authorized personnel may make repairs or adjustments to the lift truck After repairs the lift truck must be tested for safe operation before returning to service 3 FORKLIFT KNOWLEDGE Forklift trucks can cause serious injury if improperly used or maintained Study all of the manuals provided for your forklift model Learn the locations and meanings of all safety decals If any decals are illegible or miss ing have them replaced immediately Make sure all safety features provided by the original manufacturer are in place and function properly Do not operate a forklift with damaged 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
116. se only the manufacturer s approved components as installed at the factory Any substitutes or modifications must first be approved by the manufacturer 2 9 INTRODUCTION TO SAFETY DIMENSIONS AND LOAD CHART MLT 735 120 LSU Series 4 E3 1200 47 2 gt 1870 73 6 1870 73 6 mg i m m m m m m m m m m m m m m m m m m m 2 1 m 435 17 1 435 17 1 789 31 1 n n n n n n n n n n n n n n 865 34 1 1260 49 6 n n n n 2337 92 0 ea gum HA NG CE NAN age fu A MA 2 10 INTRODUCTION TO SAFETY MLT735 USA 50 25 22ft64in 6 86m 20 An 65M 3r197in 1341 2 35M ft40in no 121m 7117 in standard AS 1 2 11 OFeet OMeters ME B56 6b 199 8 N 260353 INTRODUCTION TO SAFETY INSTRUMENTS AND CONTROLS 7 n UU ALT 2 12 INTRODUCTION TO SAFETY DESCRIPTION 1 DRIVER S SEAT 2 SAFETY BELT 3 CONTROL AND SIGNAL LIGHTS PANEL 4 N A 5 SWITCHES 6 LIGHTR SWITCH HORN AND INDICATOR SWITCH 7 FRONT AND REAR WINDSCREE
117. see MAINTENANCE D EVERY 500 HOURS SERVICE Add a preservative product to the engine oil Run the I C engine for a short time so that the oil and cooling liquid circulate Disconnect the battery and store it in a safe place away from the cold after charging it to a maximum Remove the injectors and spray a protective product into each cylinder for two seconds with the piston in low neutral position Turn the crankshaft once slowly and refit the injectors see I C engine REPAIR MANUAL Remove the intake hose from the manifold or turbocharger and spray the protective product into the manifold or turbocharger Cap the intake manifold or turbocharger hole with waterproof adhesive tape Remove the exhaust pipe and spray the protective product into the exhaust manifold or turbocharger Refit the exhaust pipe and block the outlet with waterproof adhesive tape NOTE The spray time is noted on the preservative packaging and must be increased by 50 for turbo engines Open the oil filler plug spray the protective product around the rocker arm shaft and install the filler plug Cap the fuel tank using waterproof adhesive tape Remove the drive belts and store them in a safe place Disconnect the engine cut off solenoid on the injection pump and carefully insulate the connection PROTECTING THE LIFT TRUCK Set the lift truck on axle stands so that the tires are not in contact with the ground and release the park
118. sing 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 Keep a clear view of the path of travel and observe other traffic personnel and safe clearances 31 If the
119. ssure Ya Connect or disconnect the rapid connectors of the hydraulic attachment PHOTO NOT AVAILABLE 2 43 INTRODUCTION TO SAFETY 2 44 3 MAINTENANCE INTRODUCTION TO SAFETY 3 2 INTRODUCTION TO SAFETY TABLE OF CONTENTS ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FILTERS CARTRIDGES AND BELTS LUBRICANTS AND FUEL SERVICING SCHEDULE A DAILY OR EVERY 10 HOURS SERVICE B EVERY 50 HOURS SERVICE C EVERY 250 HOURS SERVICE D EVERY 500 HOURS SERVICE E EVERY 1000 HOURS SERVICE F EVERY 2000 HOURS OF SERVICE G OCCASIONAL MAINTENANCE 33 3 5 3 6 INTRODUCTION TO SAFETY 3 4 INTRODUCTION TO SAFETY MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS YOU RISK Legally to be held responsible in the event of an accident Technically to generate operating failure or shorten the life of the lift truck BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS YOU BENEFIT Through its network MANITOU provides the user with EXPERTISE Know how and competence The guarantee of high quality work Original replacement components Help with preventive maintenance Efficient help with diagnosis Improvements due to experience feedback Operator training Only the MANITOU network has detailed knowledge of the design of the lift truck and t
120. t windscreen wiper off Front windscreen wiper low speed setting Front windscreen wiper high speed setting Front windscreen wiper intermittent setting gt REAR WINDSCREEN WIPER E Rear windscreen wiper off F Rear windscreen wiper on NOTE These functions will only work when the ignition is switched on 8 IGNITION SWITCH The key switch has five positions P Ignition off parking position O Ignition switched off and 1 engine stopped Ignition and pre heating I Not used Ill The I C engine starts return to position as soon as the key is released 9 BRAKING OIL AND WINDSCREEN WASHER TANK ACCESS PANEL Loosen screw 1 and lift up the braking oil and windscreen washer tank access panel See 3 MAINTENANCE B EVERY 50 HOURS SERVICE 10 ARMREST AND STORAGE Lift the armrest 1 to access the storage 11 CAR RADIO OPTION 2 24 INTRODUCTION TO SAFETY 12 FUSES AND RELAYS IN THE CAB Lift up the fuse and relay access panel 1 NOTE A decal on the inside of the access panel gives a clear display of the use of the components described below IMPORTANT Always replace a faulty fuse with another of equivalent rating Never use a fuse that has been repaired F1 Electronic control unit power supply 7 5A OPTION Attachment hydraulic locking device 7 54 F2 Working tail light 10A F3 Rear windscreen wiper 7 54 OPTION Side windscreen wiper
121. th or without a winch or a hook assembly attached to the forks Note This regulation is in addition to the OSHA regulation that requires specific forklift operator training 81910 178 1 When a forklift telescopic handler is configured and used for hoisting the employer must ensure that 1 Forklift lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manufacturer s instructions VI 5 Operator and crew members have been trained in 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 o
122. the cab Refer to graduation 1 of the seat Turn handle 2 depending on the driver s weight NOTE To avoid any health problems it is recommended that the weight should be checked and adjusted before starting up the lift truck SEAT HEIGHT ADJUSTMENT FIG B Raise the seat to the desired position until you hear the ratchet click If you raise the seat above the last notch stop the seat drops down to the lowest position SEAT BACK REST ANGLE ADJUSTMENT FIG C The back rest angle of the seat may be adjusted to suit the individual Press the left hand button while pushing on the seat or relaxing pressure on the seat to find a comfortable position SEAT DEPTH ADJUSTMENT FIG D The depth of the seat may be adjusted to suit the individual Press the right hand button while raising or lowering the seat to find the desired position EXTENDING THE HEAD REST FIG E The height of the back rest can be adjusted by pulling it upwards the notches will click up to the stop he head rest can be removed by applying sufficient pressure to pull it off the stop 2 14 INTRODUCTION TO SAFETY LUMBAR ADJUSTMENT FIG F This increases the comfort of the seat and the driver s freedom of movement Turn the handle either left or right to adjust the height or depth of the lumbar support ADJUSTMENT OF THE ANGLE OF THE BACK REST FIG G Support the back rest pull the lever and position the back rest to find the desired
123. the carriage axle 2 lubricators fig B5 2 3 Lubricator of the tilt cylinder foot axle 1 lubricator fig B5 3 4 Lubricator of the tilt cylinder head axle 1 lubricator fig B5 4 5 Lubricators of the carriage connecting rod axle 2 lubricators fig B5 5 6 Lubricator of the lifting cylinder foot axle 1 lubricator fig B5 6 7 Lubricator of the lifting cylinder head axle 1 lubricator fig 5 7 8 Lubricator of the compensation cylinder foot axle 1 lubricator fig B5 6 9 Lubricator of the compensation cylinder head axle 1 lubricator fig B5 8 AR BEN 7 LE Y 1 8 xe NS j BO j A umm S 5 27 o da 4 y 8 4 m TN luca GBL 3 18 INTRODUCTION TO SAFETY B6 HYDRAULIC OIL LEVEL CHECK Park the lift truck on level ground with the I C engine stopped and the jib retracted and lowered as far as possible Refer to gauge 1 fig B6 1 The oil level is correct when it is at the level of the red point If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL Remove cap 2 fig B6 2 Add oil by filler port 3 fig B6 2 IMPORTANT Use a clean funnel and clean the underside of the oil can before filling Put the cap back Check visually that there is no leakage in the tank and pipes Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank B7 BRAKE OIL LEVEL C
124. tightening torque 60 ft lb making sure the seal is in the correct position 3 32 INTRODUCTION TO SAFETY REPLACING THE DISTRIBUTOR CONTROL HEAD FILTER Remove the half clamp 4 fig E6 4 Undo the two couplings 5 fig E6 4 and replace the filter 6 fig E6 4 Be careful to mount the filter 6 fig D6 4 in the same direction as the arro IMPORTANT 2 2 proud id i Install the half clamp 4 fig E6 4 FILLING UP THE OIL Clean and install drain plugs 1 fig E6 1 tightening torque 29 to 39 N m Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 7 fig E6 2 Use a clean container and funnel and clean the underside of the oil can before IMPORTANT 22 Observe the oil level on dipstick 8 fig E6 5 the oil level should be at the level of the red point Check for any possible leaks at the drain plugs Replace filler plug 2 fig E6 2 with a new filler plug see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS HYDRAULIC CIRCUIT DECONTAMINATION This should be carried out by your dealer after each oil change The hydraulic oil used in the circuit must be at least equal in quality to class 8 according to NAS 1638 Your dealer will be able to clean the hydraulic circuit using an external unit and check the quality of the oil in order to ensure the long life of hydraulic components and main pump E10 SEAT BELT CHECK SEAT BELT WITH TWO ANCHORING POINTS Check the fo
125. tion of travel Position 1 Horizontal shock absorber fitted Position 2 Horizontal shock absorber removed DAMPING FIG 1 The damping of the seat can be adjusted to suit the nature of the terrain The comfort of the seat is thus adjustable to suit your requirements Position 1 Soft damping Position 2 Hard damping LONGITUDINAL ADJUSTMENT FIG J Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position MAINTENANCE FIG K Dirt may adversely affect the correct functioning of the seat For this reason make sure your seat is always clean To clean or change the cushions simply remove them from the seat frame A CAUTION 4 rocking head rest increases the risk of an accident Avoid wetting the cushion fabric when cleaning Check the resistance of the fabric on a small hidden area before using any fabric or plastic cleaner EE 2 SAFETY BELT Sit correctly on the seat Check that seat belt is not twisted Place the seat belt at hip level Attach the seat belt and check that it locks Adjust the seat belt to your body shape without squeezing your hip and without over slack WAR NING bo not operate the lift truck with a defective seat belt fixing locking cuts tears etc Repair or replace the seat belt immediately 2 19 INTRODUCTION TO SAFETY 3 CONTROL AND SIGNAL LIGHTS PANEL 15 10
126. to reduce shaking of the lift truck on rough ground e g moving straw in a field OPERATION Set the forks or attachment on the ground and relieve the front wheels a few centimetres only Press switch 1 set to position A the visual indicator comes on indicating that jib suspension is activated Press switch 1 set to position B the visual indicator goes out indicating that jib suspension is deactivated Jib suspension is active to a lifting height of 9 8 feet from the axis of articulation of the carriage with respect to the ground with the jib retracted When you move IMPORTANT beyond this height or make another hydraulic movement tilting telescoping attachment jib suspension is momentarily deactivated and the visual indicator of switch 1 goes out When the I C engine is off jib suspension is automatically deactivated 25 CLEANFIX SELF CLEANING FAN This system operated by switch 1 cleans the radiator core and the grille of the engine cover by reversing the air flow A CAUTION When in use protect eyes from risk of flying debris Position A The indicator light is on the fan operates in self cleaning mode for a few seconds once every 3 minutes Position B The indicator light is off the fan is in normal operating mode 26 ATTACHMENT EASY HYDRAULIC CONNECTION For easily connecting and disconnecting the attachment OPERATION Press the push button 1 to release the attachment circuit hydraulic pre
127. toolkit and anti puncture kit A8 JIB PADS CLEAN GREASE To be carried out every 10 hours during the first 50 hours service then once at 250 hours Extend the jib completely With a brush apply a coat of grease see 3 MAINTENANCE LUBRICANTS AND FUEL on the 4 sides of the telescope s fig A8 Telescope the jib several times in order to spread the coat of grease evenly Remove the surplus grease IMPORTANT If the lift truck is used in an abrasive environment dust sand coal use a dry graphite lubricate Contact your dealer 3 14 INTRODUCTION TO SAFETY 3 15 INTRODUCTION TO SAFETY B EVERY 50 HOURS SERVICE Carry out the operations described previously as well as the following operations B1 DRY AIR FILTER CARTRIDGE CHECK CLEAN In case of use in a heavily dust laden atmosphere there are pre filtration cartridges see MAINTENANCE FILTERS CARTRIDGES AND BELTS Also the checking and cleaning schedule of the cartridge must be reduced If the clogging indicator light comes on this operation must be carried out as quickly as possible 1 hour maximum The cartridge IMPORTANT must not be cleaned more than seven times after which the cartridge must be replaced Never use the lift truck without an air filter or with a damaged air filter For the disassembly and reassembly of the cartridge see 3 MAINTENANCE D3 DRY AIR FILTER CARTRIDGE Clean the filter cartridge usin
128. ttachments are delivered with a load chart concerning your lift truck The operators manual and the load chart should be kept in the places provided in the lift truck For standard attachments their use is governed by the instructions contained on this notice Some particular uses require the adaptation of the attachment which is not provided in the price listed options Optional solutions exist consult your dealer IMPORTANT Only attachments approved by MANITOU are to be used on our lift trucks The manufacturer s liability will be voided in case of modification s without prior written permission Maximum loads are defined by the capacity of a lift truck taking into account the attachment s mass and center of gravity In the event of the attachment having less capacity than the lift truck never exceed its limit Depending on their size certain attachments when the boom is lowered and or retracted or the tilt is activated may come into contact with the front tires and cause damage to them TO AVOID TIRE DAMAGE EXTEND THE TELESCOPE TO A SUFFICIENT DISTANCE TO AVOID DAMAGING THE TIRES 4 5 INTRODUCTION TO SAFETY A ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE TAKING UP AN ATTACHMENT Ensure that the attachment is in alignment to the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the locking pin and the clip are in position in the bracket fig A
129. ual for proper operating techniques Important reminders of attachment and boom safety Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as a manlift Attachment must be properly locked to the carrier before raising boom Use only approved attachments on this machine Do not work under raised boom or attachments unless supported FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801009 Hydraulic Coupling 234805 Location near the quick disconnect adapters Stop the engine and release hydraulic pressure before changing attachments Rotating Fan and Belt s 801008 Location on the radiator near the fan and on any fan belt pulley cover s KEEP HANDS Keep hands and clothing away from rotating fan and belts AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 XII INTRODUCTION TO SAFETY SAFETY DECALS Gear Shift Pattern 33460 4 speed transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift transmission drr Steering Mode 184276 4 wheel steer equipped models Location near the steering mode selection lever Identifies the steering mode selection 221322 ATTENTION CUIDADO ACHTUNG _ATTENZIONE Mineral Oil Brake Reservoir 221322 or 234800 has MOE PIE
130. unction carry out the necessary repairs A NOTE The indicator lights a go off after engine preheating Preheating is necessary When the lift truck is switched on the lamp comes on for 2 seconds and off as soon as preheating is ended Start the lift truck s I C engine ORANGE ENGINE WARNING INDICATOR LIGHT If the lamp comes on or flashes while the lift truck is in operation a diagnostic fault has been detected The lift truck will O ORANGE I C ENGINE PREHEATING INDICATOR LIGHT operate in reduced mode Consult your dealer without delay RED I C ENGINE STOPPED INDICATOR LIGHT If the lamp comes on or flashes when the lift truck is running stop the I C engine immediately and consult your dealer RED STEERING SYSTEM OIL PRESSURE WARNING INDICATOR LIGHT OPTION If the lamp comes on when the lift truck is running stop the I C engine immediately and look for the cause possible leak etc 2 20 INTRODUCTION TO SAFETY RED GEAR BOX OIL PRESSURE WARNING INDICATOR LIGHT The lamp and buzzer come on when there is an abnormal drop in gear box pressure in forward gear Stop the I C engine and look for the cause gear box oil level possible leak radiator etc NOTE The signal light operates in forward travel conditions only the signal should not be taken into account when the I C engine is running at idle or is stopped WM RED TRANSMISSION OIL TEMPERATURE FAULT NDICATOR LIGHT The lamp and buzzer come on when t
131. ver drag it horizontally C transport the load with the bottom of the load and the mast as low as possible d with load elevated maneuver the rough terrain forklift truck slowly and cautiously and only to the extent necessary to permit lowering to the transport position e use tag lines to restrain load swing whenever possible 50 At the beginning of each shift and before operating the rough terrain forklift truck check its condition giving special attention to a tires and their inflation pressure b warning devices C lights d lift and tilt systems load engaging means chains cables and limit switches e f steering mechanism 9 fuel system s 51 If the rough terrain forklift truck is found to be in need of repair or in any way unsafe or if it contributes to an unsafe condition the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 52 If during operation the 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 permitted the engine shall be stopped and the opera tor shall not be on the rough terrai
132. visibility in forward motion is not clear because of the bulkiness of the load drive in reverse motion This maneuver must remain exceptional and for short distances Ensure you have good visibility clean windows adequate lighting correctly adjusted rear view mirrors etc If visibility of your route is inadequate request a signal person for help Be sure to keep them in sight and outside the work area of the lift truck and load being handled E STARTING THE LIFT TRUCK SAFETY NOTICE Aw ARNING The lift truck must be started or maneuvered only when the operator is sitting in the driver s cab his seat belt fastened and properly adjusted Never try to start the lift truck by pushing or towing it such operation will cause severe damage to the transmission If neces sary to tow the lift truck in an emergency the transmission must be placed in the neutral position see 3 MAINTENANCE G OCCASIONAL MAINTENANCE If using an emergency battery for start up use a battery with the same specifications Insure correct battery polarity or when connecting to it Connect at first the positive terminals before the negative terminals Failure to respect polarity between batteries can cause serious damage to the electrical circuit The electrolyte in the A WARNING battery may produce an explosive gas Avoid flames and generation of sparks close to the batteries Never disconnect a battery while it is charging INSTRUCTIONS
133. x Ea Check truck for proper operation of all functions Vg E WHEN PARKING OR SERVICING 1 Lower boom to the ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine Fasten seat belt a FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801011 Use of Seat Belt 801012 Boom equipped models Location to the right of the operator near the hydraulic control lever A DANGER Always wear seat belt when Instructs the operator to always wear the seat belt during operations and never jump from an over turning forklift operating machine Never jump from a tipping machine Failure to comply may result in serious injury or death serious injury de 301012 INTRODUCTION TO SAFETY SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever EMERGENCY STOPPING Identifies the Emergency Parking Brake Lever AND PARKING BRAKE F ul 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 No Riders 420732 CAUTION Location on the cab entrance s and on or near wheel fenders and engine COVer Informs rid
134. y to leave the cab during the incident YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB Do not perform operations which exceed the capacities of your lift truck or attachments Always drive the lift truck with the forks or attachment in the transport position i e at 12 in above the ground the boom retrac ted and the carriage sloping backwards Carry only loads which are balanced and properly secured to avoid any risk of a load falling off Ensure that pallets cases etc are in good order and suitable for the load to be lifted Familiarize yourself with the lift truck on the terrain where it will be used Ensure that the service brakes are working properly The loaded lift truck must not travel at speeds in excess of mph Drive smoothly at an appropriate speed for the operating conditions land configuration load on the lift truck Do not use the hydraulic boom controls while the lift truck is moving Do not maneuver the lift truck with the boom in the raised position unless under exceptional circumstances and then with extre me caution at very low speed and using gentle braking Ensure that visibility is adequate Take turns slowly In all circumstances make sure you are in control of your speed On damp slippery or uneven terrain drive slowly Brake gently never abruptly Use the lift truck s forward reverse lever from a stationary position only and never abruptly Do not drive with

MLT 735 -120 LSU Series 4-E3

Contents

Download Pdf Manuals

Related Search

Related Contents