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MSI30D-121128-203025-547041ASD-Rev 11

1. OPERATING AND SAFETY INSTRUCTIONS FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS BY ALLOWING NON ORIGINAL PARTS TO BE USED YOU RUN THE RISK Legally of being liable in the event of an accident Technically of causing breakdowns to occur or of reducing your lift truck s service life Using counterfeit parts or components not approved by the manufacturer may put an end to IMPORTANT a E il 4 ve contract warranty terms and lead the maker to withdraw the lift truck s certificate of compliance BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS YOU ARE LEGALLY Any user who procures parts from another vendor does so at his own risk COVERING YOURSELF Any user who modifies his lift truck or has it modified by a service company must consider that a new item of equipment has been brought onto the market and therefore takes liability for it Any user who copies original parts or has them copied is taking a risk from the legal viewpoint The certificate of compliance only binds the maker for parts chosen or produced under the maker s control The practicalities of maintenance terms are set out by the maker The maker is in no way liable in the event of the user not complying with such terms YOU GET THE THE MANUFACTURER BRINGS TO THE USER BENEFIT OF THE MANUFACTURER S His know how and skill KNOW HOW Guaranteed quality work Original
2. Slide the new wheel onto the hub Hand tighten the nuts lubricate them if necessary Remove the wedges under the axle and lower the lift truck Tighten the wheel nuts with a torque wrench See A DAILY OR EVERY 10 HOURS SERVICE for tightening torque H3 TOW THE LIFT TRUCK IMPORTANT NEVER try to push or pull the lift truck to start it Such a maneuver would cause serious damage to the hydrostatic transmission You must first remove the wheel reducers before any towing While the wheel reducers are removed the forklift has no braking system Properly block all wheels or secure the forklift to a drawbar and towing vehicle before removing the wheel reducers Tag the forklift noting that it does not have a braking system UNLOCKING THE FRONT WHEEL REDUCERS Perform this operation on both front wheel reducers Place a container under the reducer Remove the retaining ring 1 Fig H3 1 Remove the plug 2 Fig H3 1 a little oil will then escape Place a 6mm hex head bolt into the threads of the drive shaft 3 Fig H3 2 Remove the drive shaft and protect it with a clean cloth Re install the plug 2 Fig H3 1 and the retaining ring 1 Fig H3 1 so as to protect the wheel reducers during the towing After towing proceed in the reverse order NOTE When reassembling ensure that the drive shaft grooves and the gears coincide do not force the installation Top up the level of oil in the whe
3. HTA ee T E aisi ES j CABIN OPTION FIG G o m Type a Serial No m Masr FiG H Mast identification No PLATE MANUFACTURER OF THE ATTACHMENT FIG 1 Model Serial No Year of manufacture A This attachment affects the a capacity of the lift truck Check the operator service manual or load chart for net capacity with this attachment a FORKLIFT SAFETY CONTENTS CHARACTERISTICS ENGINE UP TO MACHINE N 139125 Type Number of cylinders Number of strokes Injection system Ignition sequence Rocker arm clearance Hot Inlet Exhaust Capacity Bore Stroke Volumetric ratio Nominal running speed Without soundproofing Nominal running speed With soundproofing Idle speed Full speed Power DIN 70 020 Power DIN 6270 B Power SAE Power BS AU 141 a 1971 Maximum torque Air cleaner ENGINE FROM MACHINE N 139126 Type Number of cylinders Number of strokes Injection system Ignition sequence Rocker arm clearance Hot Inlet Exhaust Capacity Bore Stroke Volumetric ratio Nominal running speed Idle speed Full speed Power ISO 3046 1 Power ISO TR 14396 Power SAE Maximum torque ISO 3046 1 Maximum torque ISO TR 14396 Air cleaner PERKINS 903 27 3 4 Direct 1 2 3 0 20 mm 008 in 0 45 mm 018 in 2700 cm 164 7 cu in 95 mm 3 74 i
4. A2 1 If necessary add cooling liquid through the filler port 2 Fig A2 1 When the expansion tank is empty check the level in the radiator before filling the expansion tank Disassemble the cover plate 3 Fig A2 2 ALWAYS ALLOW THE RADIATOR TO COOL BEFORE OPENING THE RADIATOR CAP Slowly rotate the radiator cap 4 Fig A2 3 to the safety stop Allow any pressure to escape Press down and turn the cap to release it FORKLIFT SAFETY CONTENTS DO NOT ADD COOLANT TO A HOT RADIATOR ALLOW THE ENGINE TO COOL IMPORTANT Add coolant through the filler port 5 Fig A2 3 See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Slightly lubricate the filler plug to ease opening and closing the radiator cap CHECK THE FUEL LEVEL Keep the fuel tank near full to reduce as much as possible any condensation due to the atmospheric conditions Remove cap 1 Fig A3 Fill the fuel tank with clean fuel See LUBRICANTS AND FUEL in SECTION MAINTENANCE filtered through a strainer or a clean lint free cloth through filler port 2 Fig A3 Put the cap back 1 Fig A3 Never smoke or approach with a flame during filling operations or when the tank is open Never refill while engine is running 44 CHECK THE TIRE PRESSURES AND THE WHEEL NUTS TORQUE Check the condition of the tires to detect damage from cuts wear etc WHEEL TORQUE Check the torque load of the wheel
5. C1 Check and adjust the tension of the belt Alternator Fan Crankshaft 3 17 C2 Drain the fuel filter 3 17 D Every 400 WORKING HOURS SERVICE To be carried out once a year if the lift truck has not reached the 400 hours service in the year D1 Drain and change the engine oil D2 Change the engine oil filter 3 18 D3 Change the dry air filter cartridge 3 18 D4 Change the fuel filter cartridge 3 19 D5 Change the hydraulic return oil filter cartridge 3 19 D6 Change the oil tank breather 3 20 D7 Check the density of the battery electrolyte 3 20 D8 Check clean and lubricate the mast lifting chains 3 20 D9 Check the wear of the forks 3 21 Consult your dealer FORKLIFT SAFETY CONTENTS E Every 800 WORKING HOURS SERVICE To be carried out once a year if the lift truck has not reached the 800 hours service in the year E1 Drain and change the hydraulic oil 3 22 E2 Clean the suction strainer of the hydraulic oil tank 3 22 3 Change the hydrostatic transmission oil filter cartridge 3 22 E4 Drain and change the cooling liquid 3 23 E5 Drain and clean the fuel tank 3 25 6 Change the safety dry air filter cartridge 3 25 E7 Check the brake circuit pressure E8 Check the brake adjustment E9 Check the engine silentblocs E10 Check the engine speeds E11 Check the attachment carriage E12 Check the condition of the wheels and tires E13
6. Check that the level is correct in the expansion pan Close the radiator cap 5 Fig E4 5 Close the expansion pan cap and put it back onto its support Fill up the expansion pan to the maximum level Allow the engine to run at idle for a few minutes Check for possible leaks Check the level and top up if necessary Reassemble the cover plate 4 Fig E4 4 Note Heating bleeding is carried out automatically in machines with cabs and from S N 139 126 IMPORTANT The engine does not contain any corrosion resistor and must be filled with a minimum mixture containing 25 ethylene glycol based antifreeze FORKLIFT SAFETY CONTENTS E5 DRAIN AND CLEAN THE FUEL TANK AA WARNING While performing these operations do not smoke or work near a flame Park the truck on level ground with the engine stopped and cold Check visually and by touching the parts susceptible of having leaks in the fuel circuit and tank In the event of a leak contact your dealer Never perform welding or any other major repair unless certified such action could provoke an explosion or a fire Place a container under the drain plug 1 Fig E5 1 and remove the plug Let the fuel drain clean with 2 5 gal of clean fuel by filler port 2 Fig E5 2 Install and tighten drain plug 1 Fig E5 1 Tightening torque 30 to 40 N m or 22 30 ft Ibs Fill the fuel tank with clean fuel fil
7. ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 19 Do not use a rough terrain forklift truck for opening or closing railroad car doors 20 In areas classified as hazardous use only rough terrain forklift trucks approved for use in those areas 21 Report all accidents involving personnel building structures and equipment to the supervisor or as directed 22 Do not add to or modify the rough terrain forklift truck 23 Do not block access to fire aisles stairways and fire equipment 24 For rough terrain forklift trucks equipped with a differential lock the lock should not be engaged when driv ing on the road or at high speeds or when turning If the lock is engaged when turning there could be loss of steering control 25 Observe all traffic regulations including authorized speed limits Under normal traffic conditions keep to the right maintain a safe distance based on speed of travel from the truck ahead and keep the truck under control at all times 26 Yield the right of way to pedestrians and emergency vehicles such as ambulances and fire trucks 27 Do not pass another truck traveling in the same direction at intersections blind spots or at other danger ous locations 28 Slow down and sound the audible warning device s at cross aisles and other locations where vision is obstructed 29 Cross railroad tracks at an angle wherever possible Do not park
8. Unscrew the suction strainer at the bottom of the tank clean with the help of a compressed air jet check its condition and change it if necessary Reassemble the strainer the filter and re connect the clogging indicator HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE CHANGE Unscrew the cap 7 Fig E1 4 Remove the hydrostatic transmission oil filter cartridge 8 Fig E1 4 and replace it with a new one Ensure that the cartridge is correctly positioned and refit the cover IMPORTANT Do not operate the lift truck without a cartridge It protects against the deterioration of the hydraulic transmission circuit the hydrostatic pump and the wheel reducers FILLING WITH OIL Clean and refit drain plug 1 Fig E1 1 Tightening torque 29 to 39 N m or 21 29 Fill with oil See LUBRICANTS AND FUEL in SECTION MAINTENANCE by filler port 9 Fig E1 2 IMPORTANT Always use a clean container and funnel when filling FORKLIFT SAFETY CONTENTS Examine the oil level on the dipstick 10 Fig E1 2 the oil level should be equal distance between the lower and upper marks Check for leaks at the drain plug Refit the cover 2 Fig E1 2 IMPORTANT If air bubbles have formed during the draining it may be necessary to bleed the system at the pump inlets If so consult your dealer POLLUTION ABATEMENT PURGING OF THE HYDRAULIC CIRCUIT Let the engine run accelerator pedal h
9. 7 Panel of signal lights Fuel level gauge Hourmeter 5A 8 Front windscreen wiper and windscreen washer 10A 9 OPTION Flashing light unit 10A 10 Gear reverser OPTION Reverse lights OPTION Reverse gear horn 10A 11 Sound alarm Parking brake Transmission cut off OPTION Stop switch 10A 12 OPTION Flashing alarm light 7 5A 13 OPTION Right sidelights OPTION Fuel level gauge lighting OPTION Hourmeter lighting 5A 14 OPTION Left sidelights 5A 15 OPTION Right indicators 7 5A 16 OPTION Left indicators 7 5A 17 OPTION Dipped headlight 10 16 OPTION Main beams OPTION main beam lamp 10A 19 OPTION Roof light 3A 20 OPTION 21 OPTION 22 OPTION 23 OPTION 24 Overhead guard lifting 5A NOTE Replace a worn fuse with a new fuse of equal quality and capacity Do not re use a repaired fuse 10 WINDSCREEN WASHER TANK 11 ACCELERATOR PEDAL 12 PEDAL TRANSMISSION CUT OFF AND SERVICE BRAKES This pedal operates in two steps First the pedal acts upon an electric switch which puts the transmission into neutral so as to slow down the lift truck Then the pedal acts upon a hydraulic valve which progressively gives rise to a pressure drop in the brakes so as to stop the lift truck NOTE A hydraulic transmission cut off OPTION is available to allow the transmission to be cut progressively FORKLIFT SAFETY CONTENTS 13 FORWARD REVERSE LEVER The
10. DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY SAFETY INSTRUCTIONS When driving a lift truck on roads open to public traffic observe the provisions of the Highway Code Lift truck drivers driving on the public highway must abide by the general provisions relative to highway traffic The lift truck must conform to the provisions of the Highway Code necessary optional solutions exist consult your dealer AUTION Transport of loads on the public highway is forbidden and attachments mounted on the lift truck must be fitted with equipment in accordance with regulations or removed FORKLIFT SAFETY CONTENTS INSTRUCTIONS Ensure that the flashing light is in position and that it is working Check the good working order and cleanness of lights indicators and windscreen wiper Check the adjustment of the rear view mirrors Ensure that the fuel level is sufficient Place the attachment at 300 mm 12 in from the ground G OPERATING THE LIFT TRUCK WITH A TRAILER For using a trailer consult the regulations in force in your country Maximum travel speed braking maximum weight of trailer etc Do not forget to connect the lift truck s electrical equipment to that of the trailer Do not use a non braked trailer if the unit weight of a load exceeds that imposed by the highway code Do not use a non braked trailer without braking equipment for the trailer on the lift truck Do not forget to connect the l
11. FORKLIFT SAFETY CONTENTS MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK MAINTENANCE INSTRUCTIONS A GENERAL Read the operator s manual carefully and ensure you understand it Stop the engine when an intervention is necessary Wear clothes suitable for the maintenance of the lift truck avoid wearing jewellery and loose clothes Tie and protect your hair if necessary Ensure the area is sufficiently ventilated before starting the lift truck Make sure that the disposal of process materials and spare parts is carried out in a safe and Carry out all repairs immediately even if the repairs concerned are minor Repair all leaks immediately Do not attempt to loosen unions hoses or any hydraulic component with the circuit under pressure The handling and removal of the balancing valves which may be fitted to the cylinders of your lift truck can be dangerous A balancing valve must be removed only after the cylinder is at rest and AAWARNING 8 y y the hydraulic circuit is depressurised This operation must be performed by authorized service personnel only Do not smoke or approach the lift truck with a flame when the fuel tank is open or is being filled Take care not to burn yourself Exhaust radiator engine etc Disconnect the negative cable terminal from the top of the battery before working on the electrical circuit or on the lift truck i e Welding Do not drop metallic items
12. refinery explosive atmosphere For use these areas specific equipment is available as an option Consult your dealer FORKLIFT SAFETY CONTENTS OPERATING INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Wear clothes suited for driving the lift truck avoid loose clothes Never operate the vehicle when hands or feet are wet or soiled with greasy substances For increased comfort adjust the driver s seat to your requirements and adopt the correct position in the driver s cab The operator must always be in his normal position in the driver s seat lt is prohibited to have arms or legs or any part of the body protruding from the driver s cab of the lift truck Always remember to fasten your seat belt and adjust it to your requirements The control levers must never in any event be used for any other than their intended purposes i e climbing onto or down from the lift truck etc Never allow a passenger to travel on the lift truck or in the driver s cab B BEFORE STARTING THE LIFT TRUCK If the lift truck is new refer to BEFORE STARTING UP A NEW LIFT TRUCK in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS Check the condition of the tires and the tire pressures See CHARACTERISTICS in SECTION 2 DESCRIPTION Before starting the lift truck check the different levels Engine oil Hydraulic reservoir oil Hydrostatic transmission oil Cooling liquid Also check for possible leakage of
13. When activating the electrical system of the lift truck all the lamps and the panel s buzzer must light to indicate their good working order If one of the lamps or the buzzer does not function carry out the necessary repairs A Red engine oil pressure lamp Red water temperature lamp C Red hydrostatic transmission oil filter clog lamp FORKLIFT SAFETY CONTENTS D Red air filter clog lamp E Not used Red alternator charge lamp G Red parking brake lamp H OPTION Green indicator lamp OPTION Blue main beam lamp J Not used A RED ENGINE OIL PRESSURE LAMP If the lamp or the buzzer come on while the lift truck is running stop the engine immediately and look for the cause See oil level in engine crankcase RED WATER TEMPERATURE LAMP If the lamp or the buzzer come on while the lift truck is running stop the engine immediately and investigate the cooling system for the cause of the malfunction C RED HYDROSTATIC TRANSMISSION OIL FILTER CLOG LAMP This lamp informs the operator about the good working condition of the filter cartridge If it is clogged the red lamp and the buzzer light up For replacement see FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE NOTE Let the lift truck run after a cold start the lamp should go out once the hydraulic oil has reached its operating temperature D RED AIR FILTER CLOG LAMP The lamp or the buzzer come on when the filter cartridge is
14. a winch or hook and move suspended loads horizontally In particular this regulation applies to any rough terrain forklift e g telescopic handler equipped with a jib or truss boom with a hook with or without a winch or a hook assembly attached to the forks Note This regulation is in addition to the OSHA regulation that requires specific forklift operator training 81910 1 78 1 When a forklift telescopic handler is configured and used for hoisting the employer must ensure that 1 Forklift lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manufacturer s instructions VI 5 Operator and crew members have been trained 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
15. clogged Stop the lift truck and carry out the necessary repairs For cleaning and replacement see FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE F RED ALTERNATOR CHARGE LAMP If the lamps D F or the buzzer come on while the lift truck is running stop the engine immediately and check the electrical circuit as well as the alternator belt 3 RED PARKING BRAKE LAMP This lighted lamp indicates that the parking brake is engaged H OPTION GREEN INDICATOR LAMP It is illuminated when the indicators are on and indicates that they are functioning properly OPTION BLUE MAIN BEAM LAMP The lamp is illuminated when main beam lights are on 4 FUEL LEVEL GAUGE AND HOURMETER A FUEL LEVEL GAUGE HOURMETER It shows the number of hours the lift truck has run FORKLIFT SAFETY CONTENTS 5 SWITCH PANEL 1 ASSEMBLY 1 and 2 ASSEMBLY A Parking brake switch B Front windscreen wiper switch and windscreen washer C OPTION rear windscreen washer switch D OPTION heater fan switch E Overhead guard lifting switch OPTION warning light switch G OPTION working head light switch or OPTION left working head light switch OPTION flashing alarm light switch OPTION working tail light switch or OPTION left working tail light switch 2 ASSEMBLY J OPTION Cold country heater fan switch K OPTION NOTE For the first assembly the layout of the switches may be diff
16. closer than 6 ft 1 8m to the nearest rail of a railroad track 30 Keep a clear view of the path of travel and observe other traffic personnel and safe clearances 31 If the load being carried obstructs forward view travel with the load trailing 32 Ascend or descend grades slowly and with caution a When ascending or descending grades in excess of 5 loaded rough terrain forklift trucks should be driven with the load upgrade b Unloaded rough terrain forklift trucks should be operated on all grades with the load engaging means downgrade 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 slow
17. components Have it repaired by authorized service personnel Learn the functions of all controls gauges indicator lights etc on the forklift Know the speed gear ranges braking and steering capabilities load ratings and clearances When referring to the location of forklift components the terms left right front and rear are related to the oper ator seated normally facing forward in the operator s seat If you have any questions about the forklift con sult your supervisor Failure to fully understand or obey safety warnings can result in serious injury or death 4 WORK SITE KNOWLEDGE Before operating on a work site learn the rules for movement of people forklifts and all other traffic Check the size weight and condition of the loads you will be expected to handle Verify that they are properly secured and safe to transport Learn where the loads are to be placed planning your route for a safe approach watching for hazardous conditions Will a signal man be required to help place the load Remove any debris which may cause tire damage or rupture Plan your route around problem areas or have them cor rected Inform the supervisor of any unsafe conditions observed at the site Examples of hazards power lines cables low clearance structures garage doors telephone pole guide lines fencing loose lumber build ing materials drop offs trenches rough soft spots oil spills deep mud steep inclines railroad
18. in minor or moderate injury May also alert unsafe practices Indicates a potentially hazardous situation which if not avoided may result in death or serious injury Indicates an imminently hazardous situation which if not avoided will result in death or serious injury CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust and some of its constituents are known to the State of California to cause cancer birth defects or other reproductive harm WARNING Battery posts terminals and related accesories and related accessories contain lead and lead compounds Wash hands after handling FORKLIFT SAFETY CONTENTS SAFETY DECALS The purpose of this chapter is to introduce you to the safety messages decals and nameplates found on your forklift truck The decals are identified by name part number location and a brief description The forklift model logos and other misc decals not shown can be found in your forklift parts manual The decals illustrated may not be exactly the same as those installed on your forklift installation of the decals varies depending on the forklift model series decal updates etc The size and location of some decals limit the amount of information that can be placed upon it 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 sh
19. lift truck must be stationary when operating the forward reverse lever FORWARD From Position C Lift slightly and push the lever up to Position A REVERSE From Position C Lift slightly and push the lever down to Position B NEUTRAL To start the truck the lever must be in neutral Position C NOTE OPTIONAL reverse lights exist these lights are automatically turned on when shifting into reverse gear The backup alarm must sound when engaging the reverse gear 14 HYDRAULIC CONTROL DISTRIBUTOR LEVERS LEVER A Controls the load lifting and the mast tilting Move lever backward to raise the forks Move lever forward to lower the forks Move lever to the right to tilt mast forward Move lever to the left to tilt mast back NOTE The engine r p m automatically increases when lifting the load LEVER Designed for additional optional equipment control 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 15 DOCUMENT HOLDER Make sure that the operator s manual is in the right place i e in the document holder 16 DOCUMENT CLIP 17 TOWING PIN Located at the back of the truck this pin makes it possible to couple a trailer The capacity is limited for each lift truck by the Permissible Total Moveable Weight P T M W the drawbar pull and the m
20. lift truck parallel to the semitrailer Park the lift truck See DRIVING INSTRUCTIONS in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS SECURE THE LIFT TRUCK Fix the chocks to the semitrailer at the front and at the back of each tire Fig H5 1 Fix also the chocks to the semitrailer in the inside of each tire Fig H5 2 Secure the lift truck onto the semi trailer with sufficiently resistant straps Secure the front by passing above the articulation fittings 1 Fig H5 3 of the mast and to the back onto the towing pin 2 Fig H5 4 Tighten the straps Fig H5 5 FORKLIFT SAFETY CONTENTS H6 LIFT THE OVERHEAD GUARD CABIN IN CASE OF ELECTRICAL FAILURE Supply a spare battery of the same type as the one used for the lift truck and battery cables Unlock the overhead guard cabin with lever 1 Fig H6 1 in position A Turn on the ignition in the lift truck Remove the panel 2 Fig H6 2 to access the electric pump relay Connect the negative cable to the battery and make a good ground connection on the lift truck Fig H6 3 Connect the positive cable to the battery and contact the terminal 3 Fig H6 4 Terminal fed by a red wire NOTE The overhead guard cabin will start to rise as soon as the terminal 3 Fig H6 4 is contacted Lift the overhead guard cabin until reaching a dimension of 140 mm 5 5 in between the hood and the cowling Fig H6 5 Beyond this dimension there
21. motion The simultaneous use of two lift trucks to handle heavy or bulky loads is a dangerous maneuver requiring specific precautions to be taken This should only be done in exceptional circumstances and in the presence of a handling manager Never drive too fast or brake abruptly when carrying a load Check the load particularly when turning corners and especially if it is very bulky Secure unstable loads Handle loads with caution at slow speed without sudden jerks when moving them at significant heights and mast extention In the event of high winds or storms do not carry out handling work that jeopardizes the stability of the lift truck and its load particularly if the load catches the wind badly AXWARNING Do not change direction sharply and at high speed In the event of the lift truck overturning do not try to leave the cab during the incident YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB Apply the parking brake when lifting or depositing a difficult load or when on an incline Do not park the lift truck with the load in an elevated position Do not leave a laden lift truck with the parking brake applied on an incline which exceeds 15 E VISIBILITY If the visibility in forward motion is not sufficient because of the bulkiness of the load drive in reverse motion This maneuver must remain exceptional and for short distances Ensure you have good visibility Clean wind
22. nuts See fig A4 Non compliance with NUTS LOADING this instruction can cause damage rupture of the wheel bolts and distortion to the wheels 400 15 Check and adjust the tire pressures if necessary See CHARACTERISTICS FRONT WHEEL Nm SECTION 2 DESCRIPTION 250 340 ft Ibs 110 15 AA WARNING REAR WHEEL N m 70 94 ft lbs Check that the air hose is correctly connected to the tire valve before inflating and keep all persons at a distance during inflation Follow the recommended tire pressures given FORKLIFT SAFETY CONTENTS EVERY 50 WORKING HOURS SERVICE B1 CLEAN THE DRY AIR FILTER CARTRIDGE In case of use in a heavily dust laden atmosphere inspect frequently and see FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION UP TO MACHINE 139 125 Unscrew nut 1 Fig B1 1 and remove cover 2 Fig B1 1 Unscrew nut 3 Fig B1 1 and lift out filter cartridge 4 Fig B1 1 Leave the safety cartridge in place Clean the filter cartridge using a low pressure air jet max 40 psi directed only from the inside to the outside surface of the cartridge IMPORTANT Respect the safety distance of 1 5 in between the air jet and the cartridge to avoid tearing or making a hole in the cartridge The cartridge must not be blown anywhere near the air filter box Never clean the cartridge by tapping it agai
23. operating on a slope before raising the mast ensure that the terrain is as horizontal as possible However lift trucks fitted with level correction may work on a steeper incline provided that the greatest part of the slope is corrected Travelling on a longitudinal slope e Drive and brake gently PN A e Moving without load Forks or attachment facing downhill lige e Moving with load Forks or attachment facing uphill Ensure that scaffolding loading platform or pile is capable of bearing the weight Ensure the stability and solidity of the ground before depositing a load 1 11 FORKLIFT SAFETY CONTENTS D HANDLING Always consider safety only transport balanced and correctly secured loads to avoid any risk of tipping Fully engage forks under the load and transport it in the low position Approximately 12 in from the ground the mast tilting backwards For obvious reasons regarding the lift truck s stability and clear visibility of the surrounding environment only move the lift truck when the mast is in the travel position Approximately 12 in from the ground Do not maneuver the lift truck with the mast in the raised position unless under exceptional circumstances and then with extreme caution at very low speed and using gentle braking Ensure that visibility is adequate and get another person to guide you along if necessary Never shift the position of the load while the lift truck is in
24. q lt 0 I Ni O J OD jj 31183 8 5 8 813 lo S 2 8 o do Y Go o o 5 to e o laho vo 36 ru 0 2 5 oO o Y IM O LO IN O 9 90 ak Alla 1591515121585 S o le co r LO A EA Ju e Y Y 270 505 780 98 4 2 12 FORKLIFT SAFETY CONTENTS HL LL H1 H2 Lift height in mm Forward tilting Backward tilting Free acting lift in mm Overall height with folded mast in mm Overall height with spreaded out mast in mm Carriage overshooting H2 FORKLIFT SAFETY CONTENTS DIMENSIONS AND LOAD CHART H1 H1 U Ux m 02 02 gt rm K D MANITOU INC WACO TEXAS 76705 MAST MODEL MSI 30 D TEN LOAD CHART UNLADEN WEIGHT Located on the dashboard YEAR OF vrc gt E cues MAX CAPACITY MI es UPTO 8 PM eres max CAPACITY ATMEH 8 incues GROUND TIRE PRESSURE FRONT JR ps TIRE PRESSURE REAR CAPACITY WITH ATTAC
25. replacement parts Help with preventive maintenance Effective help with diagnosing faults Enhancements gained from feedback Training for operating staff The manufacturer knows the details of the lift truck design and therefore has the best technological capability to carry out maintenance FORKLIFT SAFETY CONTENTS DRIVER S OPERATING INSTRUCTIONS WARNING WHENEVER YOU SEE THIS SYMBOL IN MEANS WARNING BE CAREFUL YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK Most accidents connected with the use maintenance and repair of the lift truck are due to non application of the basic safety instructions By being aware of the risks to which you are exposed and by taking the necessary preventive measures you can avoid accidents Any operation or maneuver not described in the instructions is prohibited however any person who does use another method must first ensure that he is not putting himself another person or the lift truck in danger The manufacturer is not able to anticipate all possible risk situations Therefore the safety instructions and notices given in the user manual and on the lift truck are not conclusive Any bending of the rules in safety notices or the user maintenance or repair instructions for your lift truck may result in serious or even fatal accidents We would remind users of the risks in driving at excessive speed with regard to traffic conditions particularly Risk of
26. tracks curbs etc NEVER approach power lines gas lines or other utilities with the forklift Always verify that local state provincial and federal regulations have been met Report any accidents involving personnel building structures and equipment to the supervisor immediately Always remain alert conditions are constantly changing at the work site TECHNICAL SUPPORT All data provided in this manual is subject to production changes addition of new models and improved prod uct designs If a question arises regarding your forklift please consult your dealer or K D Manitou Inc for the latest information When ordering service parts or requesting technical information be prepared to quote the applicable Model Serial Numbers VIII SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL SHOWN BELOW IT IDENTIFIES POTENTIAL HAZARDS WHICH IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH Also observe the safety messages places throughout this manual providing special instructions telling you when to take precautions and to identify potential hazards The safety messages are highlighted and outlined in a box similar to those shown in the examples below SAFETY ALERT SYMBOL 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
27. with the cooling liquid see LUBRICANTS AND FUEL in the SECTION 3 MAINTENANCE through the filler port 6 Fig E4 5 Fill the expansion pan to the maximum level Allow the engine to run at idle for a few minutes Check for possible leaks Check the level and top up if necessary Refit the filler plug 5 Fig E4 5 Reassemble the cover plate 4 Fig E4 4 Install the filler plug 3 Fig E4 3 FORKLIFT SAFETY CONTENTS LIQUID FILLING FOR MACHINES WITH CABS OR FROM N 139 125 Reassemble the lower hose 1 Fig E4 1 Install the drain plug 2 Fig E4 2 tightening torque 8 to 12 N m or 6 9 ft Ibs Slowly fill the circuit with the cooling liquid see LUBRICANTS AND FUEL in the SECTION 3 MAINTENANCE through the filler port 6 Fig E4 5 Start up the I C engine and run at idle Open the cab heater control 7 Fig E4 6 Loosen the bleed screw 8 Fig E4 7 by two turns During the bleeding process top up the radiator with water Retighten the screw 8 Fig E4 7 when the water drained is free of air bubbles HEATING BLEEDING Maintain the engine at full speed throughout the duration of the bleeding process During the bleeding process top up the radiator with water until no air remains and the water level is stable at the top of the flange of the radiator Fill the expansion pan to 2 3 Lift it in order to fill up the hose between the expansion pan and the radiator
28. 00 12 CSE SC10 CONTINENTAL Solid 700R12 136 5 XZM 4 75 Bar MICHELIN Industrial 69 psi FORKLIFT SAFETY CONTENTS HYDRAULIC CIRCUIT UP TO MACHINE N 127568 Type of pump Gear pump Capacity 33 cm 13 cu in Lifting tilting attachment circuit Flow rate at full speed 80 L mn 21 13 gal mn Pressure 185 Bar 2 682 5 psi Steering direction Flow rate at full speed Load control system Pressure 125 Bar 1 812 5 psi Filtration Return 20 Microns Suction 100 Microns HYDRAULIC CIRCUIT FROM MACHINE N 127569 Type of pump Gear pump with flow divider Capacity 32 6 cm 12 83 cu in Lifting tilting attachment circuit Flow rate at full speed 73 L mn 19 28 gal mn Pressure 185 Bar 2 682 5 psi Steering direction 73 L mn 19 28 gal mn Flow rate at full speed 125 Bar 1 812 5 psi Pressure Filtration Return 20 Microns Suction 100 Microns SPECIFICATIONS UP TO MACHINE 127568 Level of sound pressure in the driver s cabin According to norm prEN 12053 1995 Overhead guard model dBA Cabin model 79 dBA Travel speed of the lift truck Forward unladen 21 km h 13 mph Reverse unladen 21 km h 13 mph Standard lift height 3300 mm Mat DUPLEX 129 92 in Rated capacity with standard mast 3000 kg 6 613 8 Ib Load center 610 mm 24 in Weight of forks Each 55 kg 121 25 Ib Lifting movement With standard mast Unladen lifting 0 54 m s
29. 1 77 ft sec Rated load lifting 0 48 m s 1 57 ft sec Unladen lowering 0 46 m s 1 5 ft sec Rated load lowering 0 49 m s 1 6 ft sec FORKLIFT SAFETY CONTENTS Weight of lift truck with standard mast Unladen Rated load Weight per axle with standard mast Transport position Front unladen rated load Rear unladen rated load Drawbar pull Unladen Rated load Maximum ramp negotiable in forward motion Unladen Rated load Break out force with bucket According to standard ISO 8313 SPECIFICATIONS FROM MACHINE N 127569 Level of sound pressure in the driver s cabin According to norm prEN 12053 1995 Overhead guard model Cabin model Travel speed of the lift truck Forward unladen Reverse unladen Standard lift height Rated capacity with standard mast Load center Weight of forks Each Lifting movement With standard mast Unladen lifting Rated load lifting Unladen lowering Rated load lowering Weight of lift truck with standard mast Unladen Rated load Weight per axle with standard mast Transport position Front unladen rated load Rear unladen rated load Drawbar pull Unladen Rated load 4515 kg 9 953 lb 7515 kg 16 567 Ib 1795 kg 6710 kg 2720 kg 805 kg 3 957 lb 14 793 lb 5 996 lb 1 774 lt 1300 daN 2 922 Ib 2500 daN 5 620 Ib 27 96 1 km h 6 mph 34 96 1 km h 6
30. ACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME MANUFACTURED IN Forklift Data Plate 496550 Boom equipped models Forklift Data Plate 496538 MANITO 45 Mast equipped models K D MANITOU INC Location within the operator s compartment TRUCK MODEL Important forklift truck identification Record this information for use when contacting the Las manufacturer for parts and service TIRE PRESSURE FRONT MN si TIRE PRESSURE REAR FOR CAPACITIES REFER TO THE APPROPRIATE LIFT CHART OR CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME B56 6 MANUFACTURED 496550 XVI FORKLIFT SAFETY CONTENTS TABLE OF CONTENTS 1 OPERATING AND SAFETY INSTRUCTIONS 1 1 ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS 1 3 DRIVER S OPERATING INSTRUCTIONS 1 4 e GENERAL INSTRUCTIONS 1 5 e OPERATING INSTRUCTIONS 1 7 e HANDLING INSTRUCTIONS 1 11 e LOAD HANDLING 1 13 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 16 BEFORE STARTING UP A NEW LIFT TRUCK 1 18 2 DESCRIPTION 2 1 IDENTIFICATION OF THE LIFT TRUCK 2 4 CHARACTERISTICS 2 6 MAST CHARACTERISTICS 2 12 DIMENSIONS AND LOAD CHART 2 14 INSTRUMENTS AND CONTROLS OVERHEAD GUARD MODEL 2 16 MAINTENANCE 3 1 FILTERS CARTRIDGES AND BELTS 3 3 LUBRICANTS AND FUEL 3 4 SERVICING SCHEDULE 3 6 XV
31. ANCE CONSULT YOUR DEALER 1 17 FORKLIFT SAFETY CONTENTS BEFORE STARTING UP A NEW LIFT TRUCK INTRODUCTION Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the mechanic However before operating the lift truck the user should carefully read and understand the various sections of this manual which have been provided to solve driving and maintenance problems By following these instructions the user will be able to take full advantage of the versatility of this lift truck The operator must familiarize himself with the positions and functions of all controls and instruments before operating the lift truck IMPORTANT Do not attempt to start a new lift truck before the following checks have been carried out LUBRICATION Check that all the correct grades of oils and greases that are required are available see SERVICING SCHEDULE in SECTION 3 MAINTENANCE and top up if necessary For operation under average climatic conditions i e between 15 C and 35 C 5 to 95 F correct levels of lubricants in all the circuits are checked in production For operation under more severe IMPORTANT climatic conditions before starting up it is necessary to drain all the circuits then add the correct levels of lubricants properly suited to the relevant ambient temperatures It is the same for the cooling liquid Contact your dealer for information if necessary DR
32. CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenance log listing repairs requested and completed for each forklift Also lock out tag procedures should be utilized If the forklift malfunctions park it safely remove the key tag Do Not Use and report the problem to the proper authority or authorized service personnel immediately ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont 2 CREATE A MAINTENANCE PROGRAM cont For the best forklift performance and operation a maintenance program is required Use the hour meter on the instrument panel to keep maintenance properly scheduled see SECTION TWO Servicing Schedule For repairs on major components engine transmission etc contact your nearest dealer for a Repair Manual Do not operate a forklift that is damaged or does not function properly Only authorized personnel may make repairs or adjustments to the lift truck After repairs the lift truck must be tested for safe operation before returning to service 3 FORKLIFT KNOWLEDGE Forklift trucks can cause serious injury if improperly used or maintained Study all of the manuals provided for your forklift model Learn the locations and meanings of all safety decals If any decals are illegible or miss ing have them replaced immediately Make sure all safety features provided by the original manufacturer are in place and function properly Do not operate a forklift with damaged missing or unsafe
33. Check the speeds of the hydraulic movements E14 Check the condition of the attachments E15 Clean the hydraulic pump tubular filter E16 Clean the brake solenoid valve filter E17 Check the injectors E18 Check and adjust the valves clearances Consult your dealer EvERY 2400 WORKING HOURS SERVICE F1 Drain and change the front wheel reducer oil 3 26 This operation should be carried out once a year if the lift truck has not reached 2400 hours service within the year F2 Check the hydraulic circuit pressures and discharge rates F3 Check the hydrostatic transmission circuit pressures F4 Check and adjust the governing start r p m of the hydrostatic transmission 5 Check the chain roller wear F6 Check the mast guide rolls F7 Check the mast bearing rollers F8 Check the mast lifting chains FQ Check the thickness of the mast wearing plates F10 Check the working order of the hydraulic valves for the transmission cut off and accelerator F11 Check the steering system F12 Clean the hydraulic oil tank F13 Check the oscillation of the rear axle F14 Check and scale the radiator F15 Check the water pump and the thermostat F16 Check the condition of the mast assembly F17 Check the alternator and the starter motor Consult your dealer Every 4800 WORKING HOURS SERVICE 31 Che
34. 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 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 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 Rigging equipment attached to the forks must secured such that it cannot move either sideways fore and aft The load center must not exceed 24 inches 610 mm 8 DO NOT lift the load with anyone on the load rigging or lift equipment and NEVER lift the load over persomnel 9 Beware of the wind which can cause suspended loads to swing even with taglines 10 DO NOT attempt to use frame leveling to compensate for load 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
35. ESPONSIBLE 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 riders are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 A DANGER Boom equipped models Location on both sides Stay clear of raised boom of the boom nose y unless properly supported Operator may be crushed Keep away from unsupported boom between falling boom and main frame Failure to comply may result in serious injury or death Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose 4h DANGER Keep machine at least 25 feet from overhead power lines Keep away from power lines Failure to comply may result in serious injury or death by electrocution 801007 XI FORKLIFT SAFETY CONTENTS SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of 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 LE 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 inj
36. ETY STANDARDS cont B GENERAL SAFETY PRACTICES cont 7 Where steering can be accomplished with either hand and the steering mechanism is of a type that pre vents road reactions from causing the handwheel to spin power steering or equivalent steering knobs may be used When used steering knobs shall be of a type that can be engaged by the operator s hand from the top and shall be within the periphery of the steering handwheel 8 Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable when properly operated However improper operation faulty maintenance or poor housekeeping may con tribute to a condition of instability and defeat the purpose of the requirements 9 Users shall give consideration to special operating conditions The amount of forward and rearward tilt to be used is governed by the application Although the use of maximum rearward tilt is allowable under certain conditions such as traveling with the load lowered the stability of a rough terrain forklift truck as determined by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation of trucks with excessive off center loads 10 Some of the conditions which may affect stability are ground and floor conditions grade speed loading rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachmen
37. FORKLIFT SAFETY CONTENTS MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE Waco 76712 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com 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 MSI 20 25 30 D MSI 20 25 30 D BUGGIE S N 121128 to 203025 OPERATOR S MANUAL THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK IT MUST BE READ AND UNDERSTOOD BY THE LIFT TRUCK OPERATOR CATALOG 547041AS R11 10 FORKLIFT SAFETY CONTENTS INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS lt SAFTETY MESSAGES eene nee ema aerea VII SAFETY DECALS VIII TABLE OF CONTENTS XV R03 04 FORKLIFT SAFETY CONTENTS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS FORKLIFT SAFETY CONTENTS 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 15 vital and must be clearly understood by the operator and serviceman Stud
38. HMENTS 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 1 MANUFACTURED IN 496538 FORKLIFT SAFETY CONTENTS 630 mm 24 80 in E F Fi 5 az 33 H H1 61 in 1260 mm 49 61 in 45 mm 1 77 in 1450 mm 57 09 in 100 mm 3 94 in 2525 mm 99 41 in 4525 mm 178 15 in U U 2105 mm 82 87 in 7 P1 P2 P3 S T V1 100 mm 3 94 in 1323 mm 52 09 in a LI us ION EM ma KA MM H H1 Standard mast DUPLEX 3M30 H H1 Option mast TRIPLEX 3M70 G G1 G2 Unladen G G1 G2 Rated load INSTRUMENTS AND CONTROLS OVERHEAD GUARD MODEL FORKLIFT SAFETY CONTENTS DESCRIPTION 1 DRIVER S SEAT 2 SAFETY BELT 3 SIGNAL LAMP PANEL 4 FUEL LEVEL GAUGE AND HOURMETER 5 SWITCH PANEL 6 HORN SWITCH 7 IGNITION SWITCH 8 KEY OPERATED BATTERY DISCONNECTING DEVICE 9 FUSE BOX 10 WNDSCREEN WASHER TANK 11 ACCELERATOR PEDAL 12 PEDAL OF TRANSMISSION CUT OFF AND OF SERVICE BRAKES 13 FORWARD REVERSE LEVER 14 HYDRAULIC CONTROL DISTRIBUTOR LEVERS 15 DOCUMENT HOLDER 16 DOCUMENT CLIP 17 TOWING PIN 18 OVERHEAD GUARD LIFTING NOTE All terms such as RIGHT LEFT FRONT REAR are meant for an observer as seated normally in the driver s seat facing straight ahead FORK
39. ILTER Open the engine compartment Visually check for the presence of water in the tank 1 Fig C2 and drain if necessary Place a receptacle under the tank and loosen drain the plug 2 Fig C2 by two of three turns Let the diesel fuel flow until it is free from impurities and water Tighten the drain plug FORKLIFT SAFETY CONTENTS D EVERY 400 WORKING HOURS SERVICE D1 DRAIN AND CHANGE THE ENGINE OIL D2 CHANGE THE ENGINE OIL FILTER Park the truck on level ground let the engine run at idle for a few minutes then stop the engine DRAINING THE OIL Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Place a container under drain plug 1 Fig D1 1 and unscrew the plug Remove filler cap 2 Fig D1 2 in order to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner REPLACE THE FILTER Remove engine oil filter 3 Fig D1 3 discard the filter and the filter seal Clean the filter bracket with a clean lint free cloth Lightly lubricate the new seal Refit the oil filter on the filter bracket IMPORTANT Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn FILLING UP THE OIL Refit and tighten drain plug 1 Fig D1 1 Tightening torque 30 to 40 N m or 22 30 ft Ibs Fill with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler p
40. LIFT SAFETY CONTENTS 1 DRIVER S SEAT FOR OPTIMAL COMFORT THIS SEAT CAN BE ADJUSTED IN DIFFERENT WAYS LONGITUDINAL ADJUSTMENT Pull the locking lever 1 upwards Slide the seat to the required position Release the lever and ensure it returns to the lock position SEAT SUSPENSION ADJUSTMENT Pull and lift up the locking lever 2 so as to place it into one of these five positions Position Light weight driver 110 Ib 50 kg Position B Intermediate Position C Middle weight driver Position D Intermediate Position E Heavy weight driver 265 Ib 120 kg ANGLE ADJUSTMENT OF THE BACK REST Pull the locking lever 3 backwards Tilt the back rest into one of the three possible positions Release the locking lever and ensure it returns to the lock position ANGLE ADJUSTMENT OF THE WHOLE SEAT Lift up the locking lever 4 Tilt the seat forwards or backwards Release the lever and ensure it returns to the lock position 2 SAFETY BELT FROM MACHINE N 134 092 Sit correctly on the seat Check that seat belt is not twisted Place the seat belt at hip level and not across the stomach Attach the seat belt and check that it locks Adjust the seat belt to your body shape without squeezing your hip In no event should the lift truck be used if the seat belt is defective any physical damage cuts tears etc Replace the seat belt immediately SIGNAL LAMP PANEL
41. N 2 DESCRIPTION B9 GENERAL GREASING Clean and lubricate the following points with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Remove any surplus grease 1 Lubricators of the head axles 1 Fig B9 1 on the tilt cylinders 2 lubricators 2 Lubricators of the head axles 2 Fig B9 2 on the steering cylinder 2 lubricators 3 Lubricators of the swivel pins 3 Fig B9 3 4 lubricators 4 Lubricators of the oscillation axle on the hind carriage 4 Fig B9 4 2 lubricators 5 Lubricators of cabin door 5 Fig B9 5 Cabin model 4 lubricators FORKLIFT SAFETY CONTENTS 3 16 FORKLIFT SAFETY CONTENTS EVERY 200 WORKING HOURS SERVICE C1 CHECK AND ADJUST THE TENSION OF THE BELT ALTERNATOR FAN CRANKSHAFT Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Check the belt for wear and cracks change it if necessary Check the tension of the belt between the fan and alternator pulleys Under a normal pressure exerted with the thumb the tension should be approximately 10 mm 3 8 in Carry out adjustments if necessary Loosen screws 1 Fig C1 by two to three turns Swivel the alternator assembly so as to obtain the belt tension required Retighten screws 1 Fig C1 IMPORTANT If the alternator belt has to be changed check the tension again after the first 20 hours of operation C2 DRAIN THE FUEL F
42. ON Open the filling cap 1 Fig B4 Check the level f necessary add windscreen washer liquid through filler port 2 Fig B4 FORKLIFT SAFETY CONTENTS B5 CHECK THE BATTERY ELECTROLYTE LEVEL Check the electrolyte level in each cell of the battery If the truck is working in a high temperature environment check the level more frequently Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Remove the caps 1 Fig B5 from each cell of the battery The correct level is at 3 8 in above the top of the plates in the battery If necessary top up the cells with clean distilled water Clean and dry caps 1 Fig B5 and refit in place Check the terminal connections lightly smear them with petroleum jelly to prevent corrosion Handling and servicing a battery can be dangerous take the following precautions Wear protective goggles Keep the battery horizontal Never smoke or work near an open flame Work in a well ventilated area In the event of electrolyte being spilled onto the skin or splashed in the eyes rinse thoroughly with cold water for 15 minutes and call a doctor B6 CLEAN THE RADIATOR CORE Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Clean the radiator with a compressed air jet directed from the front to the back Fig B6 This is the best way to efficiently remove debris IMP
43. ORTANT When handling straw grains or cereals clean the radiator core every day 7 CHECK AND ADJUST THE TENSION AND ALIGNMENT OF THE MAST LIFTING CHAINS Park the lift truck on level ground with the mast in a vertical position and the forks lifted at approximately 200 mm 8 in Check the alignment of the mast lifting chains between the carriage s chain fasteners and the chain rollers Manually verify the chain tension if necessary adjust as following while ensuring that the carriage is perpendicular to the mast Loosen the 1 Fig 57 Loosen the lock nut 2 Fig B7 of the chain tension adjuster Adjust the tension by tightening or loosening the nut 3 Fig B7 while checking the alignment of the lifting chains FORKLIFT SAFETY CONTENTS Tighten the lock nut 2 Fig B7 and the nut 3 Fig B7 Retighten the nut 1 Fig B7 These checks are important for the good working operation of the mast IMPORTANT In case of technical problems consult your dealer B8 GREASING WITH WIELAND RINGS Clean and lubricate the following points with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE and remove the surplus grease 1 Lubricators of the articulation axles at the foot of the mast 1 Fig B8 1 2 lubricators 2 Lubricators of the foot axles 2 Fig B8 2 on the tilt cylinders 2 lubricators NOTE Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTIO
44. S FORKLIFT SAFETY CONTENTS FILTERS CARTRIDGES AND BELTS SS RIA 5555 2 x O X N S AA d N N NN ANS 0 R o O MS N S X 2 4 O Y X X N N N XN S R eee S NX gt 6 ut n 8 En aval N S S HA 0 7 OR RR ISIN 22 X DR OR SS WS N N a T Ta m M 9 D a a 1 um 2 95 x Gc c ege m 55 a O 509425250 05000 050555090 11 Automatic vacuum cleaning pre filter OPTION 12 Air pre filter OPTION Up to machine N 139 125 machine N 139 126 FORKLIFT SAFETY CONTENTS LUBRICANTS AND FUEL COMPONENT CAPACITY RECOMMENDATION ENGINE 5 L 1 3 gal Shell Rotella 15w40 Texaco URSA Super 15w40 FRONT WHEEL REDUCERS 1 1 L 29 gal Shell Spirax DH 80w90 Texaco Multi gear EP 80w90 HYDRAULIC OIL TANK 95 L 25 gal Shell Tellus T46 Texaco Rando HDZ46 MAST LIFTING CHAINS Engine oil Shell Rentinax Am GENERAL GREASING Texaco Havoline WBCG COOLING CIRCUIT 11 L 2 9 gal Texaco Texguard Anti Freeze 45 55 Pre mix 220F FUEL TANK 73 51 19 4 gal Diesel fuel Grade 1 0 GREASING WITH WIELAND RINGS Shell Rentinax Am Texaco Havo
45. THE EVENT OF A BROKEN UNLOCKING CABLE Unlock the overhead guard cabin with lever 1 Fig H8 1 in position A Remove the air pre filter if installed Disassemble the cowling 2 Fig H8 2 By means of a tool screwdriver push the lock 3 Fig H8 3 toward the damaged cable while another operator raises the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION FORKLIFT SAFETY CONTENTS H9 EMERGENCY JUMP STARTING Read and follow the instructions carefully If you have any questions ask for assistance from an experienced mechanic or contact your nearest dealer Before attempting a jump start determine the condition of the forklift s battery if it is damaged has corroded connections or weak electrolyte it will have to be serviced or replaced before proceeding see D10 in SECTION 3 MAINTENANCE for electrolyte servicing Jump starting the forkllift requires a good fully charged 12 volt battery or a vehicle with a 12 volt negative ground electrical system Park the jumper vehicle next to the disabled forklift do not allow the vehicles to touch Improper jump starting procedures can result in battery explosion Follow jump start instructions carefully Do not allow the jumper cable clamps to contact each other or any metal surfaces except as instructed while attaching or removing the cables Use only a 12 volt negative ground system to jump start your forklift Set the parking b
46. Y AIR FILTER Ensure that the air filter is undamaged and not blocked Tighten the fastening devices if necessary IMPORTANT Never run the engine with the air filter removed or damaged COOLING SYSTEM Do not start the lift truck without checking the radiator coolant level or if the fan belt is damaged or broken HYDRAULIC SYSTEM Check for leaks from the hoses connections and components lf necessary tighten or repair the defective connections Also check that the tank oil level is correct TIRES Make sure that the wheel nuts are correctly tightened See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE and that the tire pressures are correct See CHARACTERISTICS in SECTION 2 DESCRIPTION FUEL SYSTEM Check that all fuel lines are secured necessary drain the fuel filter and bleed the fuel system of air ELECTRICAL CIRCUIT Check the level and the density of the electrolyte in the battery See EVERY 50 HOURS SERVICE in SECTION 3 MAINTENANCE Check the components of the electrical system the connections and fastening devices IF NECESSARY CONSULT YOUR DEALER 1 18 2 DESCRIPTION FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS 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 to o
47. ach the pile with the load in the transport position Fig K X Under no circumstances should you lay down a load if the lift truck is not a horizontal position See HORIZONTAL POSITION OF THE LIFT TRUCK X Lift the mast 1 until the load is above the pile and move the lift truck forward 2 Fig L maneuvering very gently and carefully When the load is in position apply the parking brake and place the forward reverse lever in neutral X 1 14 FORKLIFT SAFETY CONTENTS Place the load in a horizontal position 1 and lay it down on the pile 2 while checking the correct positioning of the load Fig M Maneuvering very gently and carefully lower the forks to release the load and reverse the lift truck Then lower the forks into the transport position TAKING UP A NON PALLETISED LOAD Tilt the carriage 1 forwards and move the lift truck forward 2 while simultaneously crowding the carriage backwards to slip the forks under the load Fig N necessary wedge the load with blocks HORIZONTAL LEVEL POSITION OF THE LIFT TRUCK Apart from the transverse slope of the ground several parameters can upset the horizontal position of the lift truck e The tire pressure The stability of the ground The balance of the load e Strong wind or stormy conditions Before handling any work check the points above and ensure that the lift truck 5 completely horizontal level 1 15
48. acity of the rough terrain forklift truck c Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity with extra caution Stability and maneuverability may be adversely affected IV FORKLIFT SAFETY CONTENTS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 46 When attachments are used extra care shall be taken in securing manipulating positioning and trans porting the load Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks when not handling a load 47 Completely engage the load with the load engaging means Fork length should be at least two thirds of load length Where tiltis provided carefully tilt the load backward to stabilize the load Caution should be used in tilting backward with high or segmented loads 48 Use extreme care when tilting load forward or backward particularly when high tiering Do not tilt forward with load engaging means elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load 49 The handling of suspended loads by means of a 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 sus
49. alfway for 5 minutes without using any controls on the lift truck then for 5 more minutes while using the hydraulic controls Except the steering system and service brakes Accelerate the engine at full speed for 1 minute then activate the steering system and the service brakes This operation makes a pollution abatement of the circuit through the hydraulic return oil filter E4 DRAIN AND CHANGE THE COOLING LIQUID These operations are to be carried out as necessary or once a year at the coming of winter Park the truck on level ground with the engine stopped and cold LIQUID DRAINING Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Remove the lower hose 1 Fig E4 1 of the radiator Loosen the drain plug 2 Fig E4 2 of the engine block Remove the filler plug 3 Fig E4 3 of the expansion pan and empty Remove the cover plate 4 Fig E4 4 Remove the filler plug 5 Fig E4 5 of the radiator Allow the cooling circuit to drain completely ensuring that the ports do not get blocked Check the condition of the hoses and fastening devices change them if necessary Flush the circuit with clean water and use a cleaning product if necessary LIQUID FILLING FOR MACHINES WITHOUT CABS OR FROM 139 126 Reassemble the lower hose 1 Fig E4 1 Install the drain plug 2 Fig E4 2 tightening torque 8 to 12 N m or 6 9 ft Ibs Slowly fill the circuit
50. ar intervals during use so as to quickly detect any faults and to be able to correct them without any delay If an instrument does not show the correct display stop the engine and immediately make the necessary repairs D DRIVING THE LIFT TRUCK SAFETY NOTICE Always drive the lift truck with the forks or attachment at approximately 300 mm 12 in from the ground i e in the transport position Familiarize yourself with the lift truck on the terrain where it will be used Ensure that the service brakes and the sound alarm s are working properly Drive according to and at an appropriate speed for the conditions and state of the terrain Slow down before executing a turn In all circumstances make sure you are in control of your speed On damp slippery or uneven terrain drive slowly Brake gently never abruptly Only use the lift truck s forward reverse lever from a stationary position and never do so abruptly Do not drive with your foot on the brake pedal or with the parking brake on Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel so turn it gently and not abruptly Do not allow the engine to idle needlessly for a long period Never leave the engine on when the lift truck is unattended Look in the direction of travel and always ensure you have good visibility of the route ahead When working at night ensure that your lift truck is fitted with f
51. aximum vertical drawbar pull on the towing pin This information is indicated on the manufacturer s plate on each lift truck See IDENTIFICATION OF THE LIFT TRUCK in SECTION 2 DESCRIPTION FORKLIFT SAFETY CONTENTS NOTE For towing optional solutions exist consult your dealer Before towing trailers ensure that the safety clip 5 fully engaged in the towing pin 18 OVERHEAD GUARD LIFTING Make sure that the mast is tilted forwards to a maximum and the engine is stopped before lifting the overhead guard UNLOCKING THE OVERHEAD GUARD With the engine stopped place the key switch in the on position Unlock the overhead guard with the lever 1 Fig A in position A LIFTING THE OVERHEAD GUARD Press the top of the switch 2 Fig B until complete lifting of the overhead guard Put the lever 1 back into position B Fig A Place the safety prop 3 Fig C into its stop 4 Fig C CAUTION Check for any objects left in the operator s area which may interrupt the lifting operation LOWERING THE OVERHEAD GUARD Return the safety prop back into its clip 5 Fig D Lower the overhead guard into its initial position by pressing the bottom of the switch 2 Fig B Ensure that the overhead guard is locked CAUTION Check for clearance and obstacles while lowering the overhead guard FORKLIFT SAFETY CONTENTS 3 MAINTENANCE FORKLIFT SAFETY CONTENT
52. bracing CLEAR OF CROSSBRACING HAND THROTTLE DANGER 804784 Boom equipped models option Location Near the hand throttle mechanism Reminder to operator set parking brake before operating hand throttle Disengage hand throttle before leaving the forklift DANGER A DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK OPERATE HAND THROTTLE ONLY WITH PARKING BRAKE SET FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH 804784 XV FORKLIFT SAFETY CONTENTS SAFETY DECALS DANGER Acid Battery 801014 N EXPLOSION HAZARD 7 Can cause blindness or severe injury Protect eyes Location in or near the battery Keep away from sparks flames and cigarettes exercise caution when using tools that can cause storage compartment sparks Keep battery level and caps tight ACID POISON HAZARD Addresses battery hazards Causes severe burns Contains sulfuric acid In event of contact flush with water and see a doctor Keep out of reach of children 801014 Jump Start Battery 801015 PARERE NG N EGATIVE 1 Wear eye protection 2 Connect ends of one cable to positive terminals of both batteries Location n or near the battery storage 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 compartme
53. ck the wear of the brake disks G2 Check the steering axle Consult your dealer FORKLIFT SAFETY CONTENTS H OCCASIONAL MAINTENANCE H1 H2 H3 H4 H5 H6 H7 H8 Bleed the fuel system Change a wheel Tow the lift truck Sling the lift truck Transport the lift truck on a flat semitrailer Lift the overhead guard or the cabin in case of electric failure Lift the overhead guard or the cabin in the event of an hydraulic failure in the lifting system Lift the overhead guard or the cabin in the event of a mechanical failure in the lifting system FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS A EVERY DAY OR EVERY 10 WORKING HOURS SERVICE A1 CHECK THE ENGINE OIL LEVEL Park the truck on level ground with the engine stopped and let the oil drain into the sump Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Remove the dipstick 1 Fig A1 1 Clean the dipstick and check the level between the MAXI and MINI notches 1 necessary add oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by the filler port 2 Fig A1 2 A2 CHECK THE COOLING LIQUID LEVEL Park the lift truck on level ground with the I C engine stopped and wait for the engine to cool down Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION The liquid must be at the MAXIMUM level in the expansion tank 1 Fig
54. el reducers See B3 CHECK THE FRONT WHEEL REDUCER OIL LEVEL FORKLIFT SAFETY CONTENTS TOWING THE LIFT TRUCK IMPORTANT Do not tow the lift truck at a speed exceeding 24 km h 15mph Place the forward reverse lever in neutral Loosen the hand brake Turn on the warning lights OPTION Because the power steering is inactive steering will be more difficult Operate the steering wheel slowly avoid abrupt movements and tight turns H4 SLING THE LIFT TRUCK Take into account the position of the lift truck s gravity center for lifting Fig H4 1 Place the hooks in the fastening points provided Fig H4 2 and H4 3 A 1084 mm 42 5 8 in 5 716 28 1 8 in MSI 30 D FORKLIFT SAFETY CONTENTS H5 TRANSPORT THE LIFT TRUCK ON A FLAT SEMI TRAILER Ensure that the safety instructions concerning the platform are followed before loading the lift truck and that the truck driver has been informed about the dimensions and the weight of the lift truck See CHARACTERISTICS in SECTION 2 DESCRIPTION Ensure that the platform has dimensions and a load capacity sufficient for transporting the lift truck Check also the pressure on the contact surface allowable for the platform in connection with the lift truck LOAD THE LIFT TRUCK Block the wheels of the semitrailer Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck Load the
55. erent depending on the option s fitted on the lift truck A PARKING BRAKE SWITCH To engage the parking brake press the bottom of the switch The signal lamp shows it is being used To disengage the parking brake press the top of the switch B FRONT WINDSCREEN WIPER SWITCH AND WINDSCREEN WASHER This two position switch when set in the down position and simultaneously pressed allows the windscreen washer and the windscreen wiper to be operated and when set in the up position the windscreen wiper operates E OVERHEAD GUARD LIFTING SWITCH See 18 OVERHEAD GUARD LIFTING for operation of the switch 6 HORN SWITCH 7 IGNITION SWITCH The key switch has five positions P Ignition off parking position O Ignition switched off and engine stopped Ignition on Heating Ill The engine starts return to position as soon as the key is released 8 KEY OPERATED BATTERY DISCONNECTING DEVICE Enables instant cut off of the battery from the electric circuit in the event of a short circuit or a fire 2 20 FORKLIFT SAFETY CONTENTS 9 FUSE BOX Remove the cover to gain access to the fuses 1 OPTION Light switch horn and indicators 154A 2 OPTION Warning lights 10A OPTION Rear windscreen wiper 7 54 4 OPTION Working tail lights 10A OPTION Left working tail light 104 5 OPTION Working head lights 104 OPTION Left working head light 104 6 OPTION Heating 15
56. ew cartridge making sure it is in the correct position Refit the cover guiding the valve downwards If the lift truck is being used in a heavily dust laden atmosphere see FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE D4 CHANGE THE FUEL FILTER CARTRIDGE Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Carefully clean the exterior of the filter and bracket to prevent the dust from entering the system Unscrew locking screw 1 Fig D4 Remove tank 2 Fig D4 and discard cartridge 3 Fig D4 and seals Clean the inside of the filter head and tank using a brush immersed in clean diesel oil Refit the assembly with a new cartridge and seals If necessary bleed the fuel circuit See H1 BLEED THE FUEL SYSTEM in SECTION 3 MAINTENANCE FORKLIFT SAFETY CONTENTS D5 CHANGE THE HYDRAULIC RETURN OIL FILTER CARTRIDGE D6 CHANGE THE OIL TANK BREATHER IMPORTANT To prevent debris from entering the hydraulic circuit thoroughly clean the outside of the filter and ts surroundings before servicing Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Unscrew the cover Remove the hydraulic return oil filter cartridge 1 Fig D5 and replace it with a new one Disassemble the cover 2 Fig D5 and change the oil tank breather 3 Fig D5 Ensure that the cartridge and the breather are correctly pos
57. f the body within the reach mechanism of the rough terrain forklift truck or other attach ments 10 Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury to personnel 11 Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck whether empty or loaded 12 Do not permit passengers to ride on rough terrain forklift trucks 13 Check clearance carefully before driving under electrical lines bridges etc 14 A rough terrain forklift truck is attended when the operator is less than 25 ft 7 6m from the truck which remains in his view 15 A rough terrain forklift truck is unattended when the operator is 25ft 7 6m or more from the truck which remains in his view or whenever the operator leaves the truck and it is not in his view 16 Before leaving the operator s position a bring rough terrain forklift truck to a complete stop b place directional controls in neutral apply the parking brake d lower load engaging means fully unless supporting an occupied elevated platform e stop the engine f if the rough terrain forklift truck must be left on an incline 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 FORKLIFT SAFETY CONTENTS
58. g F1 The oil level is correct when flush with the edge of the hole Install and tighten the drain plug 1 Fig F1 Tightening torque 60 70 N m or 44 to 52 ft Ibs FORKLIFT SAFETY CONTENTS OCCASIONAL MAINTENANCE H1 BLEED THE FUEL SYSTEM This series of operations is only to be carried out in the following cases A replaced or drained fuel circuit component drained tank Running out of fuel Ensure that there is sufficient fuel in the tank turn the ignition key to notch to turn on the contact Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION FUEL FILTER BLEEDING Loosen the bleed screw 1 Fig H1 1 Operate the fuel lift pump 2 Fig H1 2 until the diesel fuel flows free from air from the bleed screw Tighten the bleed screw 1 Fig H1 1 while the diesel fuel is flowing NOTE If the fuel lift pump lever is in maximum lift position turn the crankshaft by one turn BLEEDING IN THE INJECTION NOZZLES Loosen the fittings 3 Fig H1 3 at two of the injection nozzles Engage the starter motor until the diesel fuel escapes free of air from the fittings 3 Fig H1 3 Retighten these fittings while the diesel fuel escapes The engine is then ready to start H2 CHANGE A WHEEL In the event of a wheel being changed on the public highway make sure of the following points Stop the lift truck on hard level ground Park the
59. hange of an attachment with hydraulic function in order to avoid damaging the rapid hydraulic connections Place the attachment in the closed position flat on the ground For unstable attachments IMPORTANT ensure they are secured using wedges Switch off the 1 C engine Remove pressure from the attachment hydraulic system using the hydraulic controls ENVIRONMENT Signaling and lighting on the lift truck must take account of the conditions of use In addition to series equipment mounted on your lift truck a certain number of options are available such as road lighting stop lights flashing light reverse lights reverse buzzer alarm front light rear light etc Consult your agent or dealer Take care when raising the load that no object or person is in the way of movement and do not make any incorrect maneuvers In the case of work near power lines ensure that the safety distance is sufficient between the working area of the lift truck and the power line You must consult your local electrical agency You could be electrocuted or seriously injured if you operate or park the lift truck too close to power cables You are strongly advised to ensure that the AWARNING safety rules on the site conform to the local regulations in force regarding all types of work carried out close to power cables Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load When
60. ic power governor Electromagnetic 12V 90 cm 35 43 cu in 0 cm 215 L mn 56 8 gal mn 500 Bar 7250 psi 18 7 cm 7 36 cu in 42 L mn 11 1 gal mn 30 Bar Transmission in neutral 435 psi A2FE With fixed capacity 28 cm 11 02 cu in CWD 2050 M BREVINI Multidisc brake immersed in oil 4 4 Foot pedal Hydraulic brake acting on front wheels through pressure break Switch Electro hydraulic brake acting on front wheels through pressure break FORKLIFT SAFETY CONTENTS MSI 30 D BUGGIE FRONT TIRES STANDARD 275 70 R22 5 G391 9 Bar GOOD YEAR Industrial 130 psi OPTION 10 5 R20 14PR MPT80 134G 5 6 Bar CONTINENTAL Mixed 81 psi 8 25 20 CSE SC10 CONTINENTAL Solid 285 70 R19 5 XZY 140 137L 8 Bar MICHELIN Industrial 116 psi 275 70 R22 5 G391 9 Bar IMPORTANT GOOD YEAR Industrial wide base 130 psi 10 5 820 14PR MPT80 1346 56 Bar When changing or pen the tires and wheels use CONTINENTAL Wide base mixed 81 psi only the manufacturer s approved components as installed at the factory Any substitutes or 15 5 55 R18 SPPG7 14PR 4 5 Bar ficati f i DUNLOP Wide base mixed modifications nn by the 15 5 55 R18 SPPG7 14PR 4 5 Bar DUNLOP Extra wide base mixed 65 psi 12 0x18 12PR T86 4 2 Bar DUNLOP Mixed 61 psi REAR TIRES STANDARD 700x12 14PR IC40 6 7 Bar CONTINENTAL Industrial 97 psi OPTION 27 10 12 12PR IC12 4 5 Bar CONTINENTAL Industrial or mixed 65 psi 7
61. ift truck s braking equipment to that of the trailer The maximum vertical pull on the trailer hook must not exceed 1500 daN 3372 lbs The authorized total towed weight A T T W must not exceed the maximum weight authorized by the manufacturer Consult the manufacturer s plate on your lift truck IF NECESSARY CONSULT YOUR DEALER 1 10 FORKLIFT SAFETY CONTENTS HANDLING INSTRUCTIONS A GENERAL Ensure the correct functioning of your lift truck s attachments Do not attempt to carry out operations which exceed the capacities of your lift truck or attachments It is prohibited to increase the counterweight value in any way It is prohibited to transport or carry persons in the lift truck unless it is equipped to do so Avoid traveling for a long distance in reverse B ATTACHMENTS Ensure that the attachment is correctly fitted and locked to its frame Conform to the limits on the load chart for the lift truck and or attachment Ensure that pallets cases etc are in good order and suitable for the load to be lifted Position the forks perpendicular to the load to be lifted taking account of the load s center of gravity Never lift a load with a single fork Never lift a sling load with a single fork or with the carriage Optional solutions exist consult your dealer Ensure that the quick fit or rapid hydraulic connections on the attachment system are clean and protected Before each c
62. is risk of interference between the windshield and the mast if the mast is tilted backwards Disconnect the ground from the lift truck Access the lift truck battery from the back between the hood and the cowling and properly jump start the battery see H9 EMERGENCY JUMP STARTING Verify that the mast is properly tilted forward for clearance then continue raising or lowering the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION FORKLIFT SAFETY CONTENTS H7 LIFT THE OVERHEAD GUARD CABIN IN THE EVENT OF HYDRAULIC FAILURE IN THE LIFTING SYSTEM Tilt the mast backwards to the maximum Unlock the overhead guard cabin with lever 1 Fig H7 1 in position A With the cabin model close the doors Remove the screws 2 Fig H7 2 from the roof Pass a sling around the upper crossbrace of the mast s inner rail Fig H7 3 and fasten the sling ends onto the roof with 14mm hex head bolts Length 50 mm minimum or 2 inches Fig H7 3 Start the 1 C engine Carefully lift the mast so as to stretch the sling Slowly tilt the mast forwards until you can apply the safety stay 3 Fig H7 4 into its stop 4 Fig H7 4 Lower the mast so as to release and remove the sling and the bolts Reinstall and tighten the screws 2 Fig H7 2 FORKLIFT SAFETY CONTENTS H8 LIFT THE OVERHEAD GUARD CABIN IN THE EVENT OF A MECHANICAL FAILURE IN THE LIFTING SYSTEM PROCEDURE IN
63. itioned and install the covers 07 CHECK THE DENSITY OF THE BATTERY ELECTROLYTE The electrolyte density varies depending on the temperature concerned but a minimum of 1260 at 16 C 61 F must be maintained Ben In the shaded area Fig D7 the battery is in a normal charge condition 1 250 Readings above this zone indicate that the battery needs to be recharged 1 260 The density should not vary more than 0 025 units between cells 1 270 1 280 Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Check the electrolyte density in each battery cell using a hydrometer 1 290 1 300 o 18 10 0 10 20 30 40 Do not perform this check immediately after adding distilled water Recharge F 0 14 32 50 68 86 104 the battery for at least an hour before checking the battery electrolyte density Handling and servicing a battery can be dangerous take the following precautions Wear protective goggles Keep the battery horizontal Never smoke or work near an open flame Work in a well ventilated area In the event of electrolyte being spilled onto the skin or splashed in the eyes rinse thoroughly with cold water for 15 minutes and call a doctor FORKLIFT SAFETY CONTENTS D8 CHECK CLEAN AND LUBRICATE THE MAST LIFTING CHAINS Wipe the mast lifting chains 1 Fig D8 with a clean lint free cloth then examine them closely for any signs of wear Vigor
64. lift truck See OPERATING INSTRUCTIONS paragraph E STOPPING THE LIFT TRUCK in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS Turn the warning lights on Immobilize the lift truck in both directions on the axle opposite to the wheel to be changed Loosen the nuts of the wheel to be changed REAR WHEEL Place the jack under the counterweight It must be situated in the middle and under the flat part of the counterweight Lift the rear of the truck and place wedges Approximately 260 mm or 10 in under the axle on the side of the wheel to be changed Fig H2 1 FORKLIFT SAFETY CONTENTS Completely loosen the wheel nuts and remove them Release the wheel with reciprocating movements and roll it aside Slide the new wheel onto the hub Hand tighten the nuts lubricate them if necessary Remove the wedges under the axle and lower the lift truck with the help of the jack Tighten the wheel nuts with a torque wrench See A EVERY DAY OR EVERY 10 WORKING HOURS SERVICE for tightening torque FRONT WHEEL Lift the carriage and tilt the mast back Put wedges under the foot of the mast on the side of the wheel to be changed Fig H2 2 Tilt the mast forwards so as to lift the wheel Place wedges under the chassis Approximately 300 mm or 12 in as near as possible to the wheel Fig H2 3 Loosen the wheel nuts and remove them Remove the wheel with reciprocating movements and roll it aside
65. line WBCG DIAGNOSTIC ANALYSIS OF OIL In the event of a maintenance or service contract with the dealer you may be requested to provide a sample of a selected component s oil for diagnostic analysis FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS AFTER THE FIRST 50 WORKING HOURS SERVICE D1 Drain and change the engine oil 3 18 D2 Change the engine oil filter 3 16 Change the fuel filter cartridge 3 19 D5 Change the hydraulic return oil filter cartridge 3 19 Change the oil tank breather 3 19 E3 Change the hydrostatic transmission oil filter cartridge 3 22 F1 Drain and change the front wheel reducer oil 3 28 A EVERY DAY OR EVERY 10 WORKING HOURS SERVICE 1 Check the engine oil level 3 10 A2 Check the cooling liquid level 3 10 A3 Check the fuel level 3 11 4 Check the tire pressure and the wheel nut torque 3 11 EvErY 50 WORKING HOURS SERVICE 51 Clean the dry air filter cartridge 3 12 In heavily dust laden atmosphere service more frequently B2 Check the hydraulic oil level 3 13 53 Check the front wheel reducer oil level 3 13 B4 Check the level of the windscreen washer liquid 3 13 5 Check the battery electrolyte level 3 14 56 Clean the radiator core 3 14 B7 Check and adjust the tension and alignment of the mast lifting chains 3 14 B8 Greasing with Wieland rings 3 15 B9 General Greasing 3 15 Every 200 WORKING HOURS SERVICE
66. loss of control on a poor quality track Increased stopping distance The user must remain in full control of his lift truck and should Adapt his speed to each situation in order to maintain his own safety that of others and of his equipment Always be aware of his stopping distance On the basis of experience there are a number of possible situations in which operating the lift truck is prohibited Such foreseeable abnormal uses the main ones being listed below are strictly forbidden The foreseeable abnormal behavior resulting from ordinary neglect but does not result from any wish to put the machinery to any improper use The reflex reactions of a person in the event of a malfunction incident fault etc during operation of the lift truck Behavior resulting from application of the principle of least action when performing a task For certain machines the foreseeable behavior of such persons as 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 ofthe equipment must take these criteria into account when assessing whether or not a person will make a suitable driver FORKLIFT SAFETY CONTENTS GENERAL INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Read the operator s manual carefully making sure you understand it The operator s manual must a
67. lways be kept in the lift truck in the place provided and in the language understood by the operator Every operation or maneuver not described in the manual must be assumed to be prohibited Respect the safety notices and instructions given on the lift truck It is mandatory to replace all plates or decals which are no longer legible or which have become worn or damaged 5 AUTHORIZATION TO OPERATE Refer to the legislation for each particular country Only qualified personnel may use the lift truck lts use is subject to authorization to operate being given by the appropriate manager in the user establishment The user should always carry this authorization to operate with him while he is using the lift truck The driver is not competent to authorize the driving of the lift truck by another person In addition the vehicle should be used in accordance with good practice for the profession MAINTENANCE The user must immediately advise his superior his lift truck is not in good working order or does not comply with the safety notice The operator is prohibited from carrying out any repairs or adjustments himself unless he has been trained for this purpose He must keep the lift truck properly cleaned if this is among his responsibilities Carry out daily maintenance See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE Ensure tires are adapted to the nature of the ground SAND tires LAND
68. ly across the dockboard or bridge plate and never exceed its rated capacity 39 Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so Approach elevators slowly and then enter squarely after the elevator car is properly leveled Once on the ele vator neutralize the controls shut off engine and set brakes It is advisable that all other personnel leave the elevator before truck is allowed to enter or leave 40 Avoid running over loose objects on the roadway surface 41 When negotiating turns reduce speed to a safe level and turn steering handwheel in a smooth sweeping motion Except when maneuvering at a very low speed turn the steering handwheel at a moderate even rate 42 Use special care when traveling without load as the risk of lateral overturning is greater 43 Improper use of stabilizer controls if so equipped could cause rough terrain forklift truck upset Always lower the carriage before operating stabilizer controls 44 For rough terrain forklift trucks equipped with lateral leveling a Always level the frame before raising the boom or mast with or without a load b Lateral leveling should not be used to position an 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 cap
69. mph daN dBA 79 dBA 19 5 km h 12 mph 19 5 km h 12 mph 3300 mm DUPLEX mast 129 9 in 2721 kg 6 000 Ib 610 mm 24 in 55 kg 121 Ib 1 7 ft sec 1 4 ft sec 1 5 ft sec 1 7 ft sec 0 49 m s 0 44 m s 0 46 m s 0 49 m s 4515 kg 9 954 Ib 7515 kg 16 567 lb 1795 kg 3 957 6710 kg 14 793 Ib 2720 kg 5 996 lb 805 kg 1 774 lb 1300 daN 2 922 Ib 2500 daN 5 620 Ib FORKLIFT SAFETY CONTENTS Maximum ramp negotiable in forward motion Unladen 27 a 1 km h 6 mph Rated load 34 a 1 km h 6 mph Break out force with bucket daN According to standard ISO 8313 CONTENTS FORKLIFT SAFETY MAST CHARACTERISTICS 3 L gt O lt I E lt LLI 2 LO LO LO LO 10 1 10 10 7 Lo o5 1 P Lo T 66 to 09 9 6 ASA to 4 4 4 ILO ev LO a LO Cito tO Elo LO Lo 110 16 S IO LO LO O x t9 IN B m9 C lt LO LO m LO LO Im LO m LO LO Im LO LO LO LO LO in DOUBLE MAST WITH TOTAL FREE ACTING LIFT mm TRIPLE MAST WITH TOTAL FREE ACTING LIFT mm in lt 0 lt lt q
70. n 127 mm 5 in 17 5 1 2250 rpm 2100 rpm 850 rpm 2400 rpm 52 3 Cv 38 5 kw 51 cv 37 5 kw 51 5 cv 37 9 kw 54 3 cv 40 kw 190 Nm a 1200 tr mn 140 ft lb Sec 3 microns PERKINS 903 27 LOW EMISSION 3 4 Direct 123 0 20 008 in 0 45 mm 018 in 2700 cm 1063 cu in 95 mm 3 74 in 127 mm 5 in 17 5 1 2100 rpm 850 rpm 2400 rpm 50 cv 37 kw 52 38 5 kw 54 cv 40 kw 190 Nm 1200 tr mn 140 ft lb 192 Nm 1200 tr mn 142 ft Ib Sec 3 microns FORKLIFT SAFETY CONTENTS COOLING CIRCUIT Type Fan Number of blades Diameter Thermostat Start opening Full opening ELECTRIC CIRCUIT Earth Battery Alternator Tension regulator Starter HYDROSTATIC TRANSMISSION HYDROSTATIC PUMP Type Gear reverser Main pump MAX displacement MINI displacement MAX flow rate Working pressure Boost pump Cubic capacity MAX flow rate Boost pressure MAX r p m HYDROSTATIC WHEEL ENGINE MOTOR Type Cubic capacity FRONT WHEEL REDUCERS Type BRAKE Type Number of steel disks Number of friction disks Service brakes Parking brakes By water Sucking up to machine n 130839 Blowing from machine n 130840 6 406 4 mm 16 in 80 84 C 176 183 2 F 96 C 204 8 F Negative 12 V 105 680 AEN 14V 55A Incorporated into the alternator 12 V 2 2 kw A4VG90DA With variable cubic capacity and with automat
71. ngine will raise the temperature of some components with the risk of badly damaging them IMPORTANT Never leave the ignition key in the lift truck when the lift truck is unattended When the lift truck is stationary place the forks or attachment on the ground apply the parking brake and put the forward reverse lever in neutral the driver has to leave the cab even for a moment it is essential to apply the parking brake and put the forward reverse lever in neutral Make sure that the lift truck is not parked in any position that will interfere with the traffic flow and at less than 6 ft from the track of a railway In the event of prolonged parking on a site protect the lift truck from bad weather particularly from frost check the level of antifreeze close the rear windows lock the cab doors and ensure that the hood is properly secured INSTRUCTIONS Park the lift truck on flat ground or on an incline less than 15 Release the accelerator pedal and stop the lift truck Place the forward reverse lever in neutral Apply the parking brake Lower the forks or attachment to rest on the ground Stop the engine with the ignition switch Remove the pressure in the hydraulic circuits by using the hydraulic controls Remove the ignition key Check the closing and locking of doors windows and hood Before leaving your driver s cab ensure that you have carried out all operations for parking the
72. not clean the dry air filter cartridge by washing it in liquid Do not clean the safety cartridge located inside the filter cartridge change it for a new one if it is dirty or damaged FORKLIFT SAFETY CONTENTS B2 CHECK THE HYDRAULIC OIL LEVEL Park the lift truck on level ground with the 1 engine stopped and the mast lowered as far as possible Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Refer to gauge 1 Fig B2 The level is correct when it is equal distance between the lower and upper marks If necessary add oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE through filler port 2 Fig B2 IMPORTANT Always use a clean funnel and nozzle when filling Always maintain the correct oil level as cooling depends on the oil flowing through the tank B3 CHECK THE FRONT WHEEL REDUCER OIL LEVEL Park the lift truck on level ground with the engine stopped Check the oil level on each front wheel reducer Place the plugs 1 Fig B3 into a horizontal position Remove one of the plugs the oil must be flush with the port If necessary add oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE through the same port Replace the plug 1 and tighten it Fig Tightening torque 44 52 ft lb B4 CHECK THE LEVEL OF THE WINDSCREEN WASHER LIQUID Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTI
73. nst a hard surface Clean the inside of the casing with a clean damp lint free cloth Check the condition of the filter cartridge replace the cartridge if necessary Refit the cartridge and the cover IMPORTANT Do not clean the dry air filter cartridge by washing it in liquid Do not clean the safety cartridge located inside the filter cartridge change it for a new one if it is dirty or damaged FROM MACHINE N 139 126 Loosen the nuts and remove the cover 1 Fig B1 2 Release filter cartridge 2 Fig B1 2 Leave the safety cartridge in place Clean the filter cartridge using a low pressure air jet max 40 psi directed only from the inside to the outside surface of the cartridge at least 1 5 in from the cartridge wall Cleaning is complete when there is no more dust on the cartridge IMPORTANT Respect the safety distance of 1 5 in between the air jet and the cartridge to avoid tearing or making a hole in the cartridge The cartridge must not be blown anywhere near the air filter box Never clean the cartridge by tapping it against a hard surface Clean the inside of the casing with a clean damp lint free cloth Also clean the cartridge seal surfaces on the filter and cover Check the condition of the filter cartridge replace the cartridge if necessary Insert the cartridge making sure it is in the correct position Replace the cover guiding the valve downwards IMPORTANT Do
74. nt BATTERY 5 To prevent damage to electrical components of vehicle being started make certain that the engine is at idle speed prior to disconnecting jumper cables 801015 Jump start instructions 3120 GHOLSON RD WACO TX 76705 254 799 0232 olmanin e Attachment Plate 425995 Location on the optional removeable forklift attachment Important manufacturer information about the attachment Record this information for use when contacting the maufacturer for parts and service pacity of the lift truck i4 Check the operator service 1 manual or load chart for net iy 14 capacity with this attachment i If the load chart is not x available contact the factory FARE A Q5 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 L LBS DO NOT REMOVE THIS OVERHEAD GUARD Overhead guard conformity 496550 496538 OMT K D MANITOU INC WACO TEXAS 76705 TRUCK MODE _____ MAST MODEL mast S N E ____ UNLADEN WEIGHT ES YEAR OF vFG ches MAX CAPACITY MM R5 cres MAX CAPACITY LBS _____ BOUND cues TIRE PRESSURE FRONT w Psi TIRE PRESSURE REAR RRB ess CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH FORK UPRIGHTS VERTICAL FOR OTHER CAPACITIES CONT
75. nts unless specifically authorized to do so 54 When refueling smoking in the area shall not be permitted the engine shall be stopped and the opera tor shall not be on the rough terrain forklift truck 55 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before restarting engine 56 Do not use open flames when checking electrolyte level in storage batteries liquid level in fuel tanks or the condition of LPG fuel lines and connectors 57 Do not 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 5 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
76. ode 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 go now Location attached to the brake fluid reservoir BREMSFLUESSIGKEIT Refer to the Operator Service Manual for the correct brake fluid LIQUIDO DE FRENO _ mineral oil to be used in the brake system LIQUIDO FRENI Utiliser IMPERATIVEMENT de l huile min rale IMPERATIVE to use mineral oil Verwenden Sie UNBEDINGT Mineral Usar IMPERATIVAMENTE de aceite mineral Utilizzare IMPERATIVAMENTE olio minerale 234800 n 234800 XIII FORKLIFT SAFETY CONTENTS 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 HYDRAULIK L ACEITE HIDRAULICO OLIO IDRAULICO Identifies the hydraulic reservoir tank N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap N Indicates required minimum to maximum anti freeze protection 22 F to 40 F Diesel Fuel 161101 Location on the fuel tank near the filler cap Identifies the fuel tank and use of diesel fuel No Step 496735 NOTICE Location va
77. oil fuel or liquid from the lift truck Check the closing and locking of the hood Whatever his experience as a truck driver the operator is advised to familiarize himself with the position and operation of all the controls and instruments before operating the lift truck STARTING THE LIFT TRUCK SAFETY NOTICE Aw ARNING The lift truck must only be started up or maneuvered when the operator is sitting in the driver s cab with his seat belt adjusted and fastened Never try to start the lift truck by pushing or towing it Such operation may cause severe damage to the transmission If necessary to tow the lift truck in IMPORTANT an emergency the transmission must be placed in the neutral position See H OCCASIONAL MAINTENANCE in SECTION 3 MAINTENANCE INSTRUCTIONS Make sure that the forward reverse lever is in neutral Turn the ignition key to the position to activate the electrical system Check the level on the fuel level gauge Turn the ignition key to position Il to preheat for 15 seconds Do not engage the starter motor for more than 15 seconds and apply preheating for 10 seconds IMPORTANT between unsuccessful attempts FORKLIFT SAFETY CONTENTS Press the accelerator pedal and turn the ignition key fully the engine should then start Release the ignition key and let the engine run at idle Check all control instruments immediately after starting up when the engine is warm and at regul
78. on the battery When welding on the lift truck connect the negative cable from the equipment directly to the part being welded so as to avoid high tension current passing through the alternator B MAINTENANCE The maintenance and compliance of the lift truck are mandatory Carry out daily maintenance See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE Do not run the engine without the air filter or with oil water or fuel leaks WARNING Wait for the I engine to cool before removing the radiator cap Change the filter cartridges See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE LEVELS Use the recommended lubricants Never use contaminated lubricants Do not fill the fuel tank when 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 1 16 FORKLIFT SAFETY CONTENTS D WASHING Clean the lift truck or at least the area concerned before servicing Remember to close the doors and the windows of the cab During washing avoid the articulations electrical components and connections Protect components susceptible of being damaged from penetration of water steam or cleaning agents particularly electrical components connections and the injection pump IMPORTANT Clean the lift truck of any fuel oil or grease residue FOR ANY INTERVENTION OTHER THAN REGULAR MAINTEN
79. or s 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 K i Ino Waco WHEN PARKING OR SERVICING Check truck for proper operation of all functions 1 Lower boom to the ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine Fasten seat belt a XT 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 or c 507035 FORKLIFT SAFETY CONTENTS SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever EMERGENCY STOPPING Identifies the Emergency Parking Brake Lever AND PARKING BRAKE F THIS VEHICLE 15 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 R
80. ort 4 Fig D1 2 Wait a few minutes to allow the oil to flow into the sump Start the engine and let it run for a few minutes Check for possible leaks at the drain plug and the oil filter Stop the engine wait a few minutes and check the level between the two upper notches on the dipstick 5 Fig D1 3 Top up the level if necessary FORKLIFT SAFETY CONTENTS D3 CHANGE THE DRY AIR FILTER CARTRIDGE The air used to burn the fuel is purified by a dry air filter It is therefore very important that the truck should never be used with the cartridge removed or damaged Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION UP TO MACHINE 139 125 Unscrew nut 1 Fig D3 1 and remove cover 2 Fig D3 1 Unscrew nut 3 Fig D3 1 lift out and discard filter cartridge 4 Fig D3 1 Leave the safety cartridge in place Clean the inside of the casing with a clean damp lint free cloth Refit the new cartridge and the cover If the lift truck is being used in a heavily dust laden atmosphere see FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE FROM MACHINE N 139 126 Loosen the nuts and remove cover 1 Fig D3 Lift out and discard filter cartridge 2 Fig D3 Leave the safety cartridge in place Clean the inside of the casing with a clean damp lint free cloth Also clean the cartridge seal surfaces on the filter and cover Fit a n
81. ould never be taken for granted Even experienced operators can be seriously injured or killed by ignor ing refusing to enforce or forgetting to follow safe operating procedures Do not assume you know all safe ty issues concerning the decals Before operating the lift truck learn the meaning s of the decals as described in this manual If any decal becomes illegible or missing have it replaced immediately Always replace decals using the same decal part no unless otherwise specified by the manufacturer For replace ment decals not found in your parts manual contact your nearest dealer If you have any questions contact your supervisor or nearest dealer for advice before operating your forklift 801011 Before Starting 801011 Boom equipped models Location on the brake fluid cover panel to the left and below the dash panel BEFORE STARTING OR OPERATING Safety Instructions 420792 Read and understand all safety and operating Mast equipped models Location on or near the operator manual EEE 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 operat
82. ously brush the chains to remove any foreign matter using a hard nylon brush and clean diesel fuel Rinse the chains with a brush and clean diesel fuel dry them with a compressed air jet Moderately lubricate the chains with a brush and oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Remove the excess oil with a clean cloth along the full length of the mast chains IMPORTANT In case of technical problems consult your dealer FORKLIFT SAFETY CONTENTS E EVERY 800 WORKING HOURS SERVICE E1 DRAIN AND CHANGE THE HYDRAULIC OIL E2 CLEAN THE SUCTION STRAINER OF THE HYDRAULIC OIL TANK E3 CHANGE THE HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE Park the truck on level ground the 1 engine stopped and the mast lowered as far as possible DRAINING THE OIL Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION IMPORTANT Thoroughly clean the drain plug surroundings before servicing Place a container under the drain plug 1 Fig E1 1 and unscrew it Unscrew the cover 2 Fig E1 2 to ensure that the oil is drained properly IMPORTANT Dispose of the oil in an ecological manner STRAINER CLEANING Disconnect the clogging indicator 3 Fig E1 3 Disconnect the hose 4 Fig E1 3 at the level of the hydrostatic transmission oil filter 5 Fig E1 3 Unscrew the four screws 6 Fig E1 3 and remove the complete filter 5 Fig E1 3
83. ows adequate lighting correctly adjusted rear view mirror etc IF NECESSARY CONSULT YOUR DEALER FORKLIFT SAFETY CONTENTS LOAD HANDLING Carrying a load greater than the rated capacity for the lift truck or for the attachment is prohibited WEIGHT OF LOAD AND CENTER OF GRAVITY Before taking up a load you must know its weight and its center of gravity The load chart relating to your lift truck is valid for a weight with its center of gravity 24 in from the heel of the forks Fig A For a higher center of gravity consult your agent or dealer For irregular loads determine the center of gravity in the transverse direction before handling Fig B For loads with a moving center of gravity i e liquids take account of the variations in 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 far as possible TAKING UP A LOAD ON THE GROUND Position the lift truck perpendicular to the load with the forks in a horizontal position Fig C Adjust the fork spread and centering in connection with the load Fig D Optional solutions exist consult your dealer Beware of the risks of trapping or injuring limbs when manually adjusting the forks Always maintain an equal distance between the forks and the center of the carriage in order to keep the load completely stable Move the lift
84. pended loads a do not exceed the truck manufacturer s capacity of the rough terrain forklift truck as equipped for handling suspended loads b only lift the load vertically and never drag it horizontally 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 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 adjustme
85. rake and turn off all electrical components on both vehicles Turn the jumper vehicle engine off Connect the jumper cables in the following sequence STEP 1 Clamp the positive jumper cable to the good battery s positive terminal STEP 2 Clamp the other end of the positive cable to the dead battery s positive terminal STEP 3 Clamp the negative jumper cable to the good battery s negative terminal STEP 4 Clamp the other end of the negative cable to a solid metel point on the frame or engine ground at least 18 inches away from the battery Keep the clamps away from the engine fan and belts GOOD BATTERY DEAD BATTERY Jumper Vehicle JUMPER CABLES round __ TO GROUND ENGINE BLOCK STEP 4 OR FRAME Start the engine on the jumper vehicle and allow it to run at high idle for about 5 minutes Start the forklift Make sure that the engines in both vehicles are at low idle before disconnecting the jumper cables Remove the cables in reverse order of installation Remove the negative cable from the forklift frame or engine ground Remove the negative cable from the jumper vehicle Remove the positive cable from the forklift Remove the positive cable from the jumper vehicle If the forklift fails to start after several attempts seek assistance from a qualified mechanic or contact your nearest dealer
86. ries depending on the forklift model Instructs personnel not to use the designated area as a step NO STEP Do Not Tow 494918 Hydrostatic equipped models Location on the dash in view of the operator A WARNING THIS VEHICLE IS EQUIPPED WITH A a nn ton HYDROSTATIC TRANSMISSION DO NOT ATTEMPT TO PUSH TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494918 XIV FORKLIFT SAFETY CONTENTS SAFETY DECALS Boom equipped models Location on the boom coupler WA R N N G near where the retaining shaft is installed THE ATTACHMENT RETAINING SHAFT MUST BE IN PLACE AND SECURED WITH THE SAFETY SNAP PIN BEFORE TRUCK OPERATION Reminder to operator install attachment retaining shaft and safety pin before operations 421016 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 cross
87. s and practices 2 Create an effective operator training program centered around user company s policies operating condi tions and rough terrain forklift trucks The program should be presented completely to all new operators and not be condensed for those claiming previous experience 3 Information on operator training is available from several sources including rough terrain forklift truck man ufacturers users government agencies etc 4 An operator training program should consist of the following a careful selection of the operator considering physical qualifications job attitude and aptitude 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 9 oral written and operational performance tests and evaluations during and at completion of the course h refresher courses which may be condensed versions of the primary course and periodic on job operator evalua
88. t dynamic and static forces improper tire inflation and the judgement exer cised by the operator C OPERATING SAFETY RULES AND PRACTICES 1 Safe operation is the responsibility of the operator 2 This equipment can be dangerous if not used properly The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself other personnel the rough terrain forklift truck and other material 3 The operator shall be familiar with the operation and function of all controls and instruments before under taking to operate the rough terrain forklift truck 4 Before operating any rough terrain forklift truck truck operators shall have read and be familiar with the operator s manual for the particular truck being operated 5 Before starting to operate the rough terrain forklift truck a be in operating position and fasten seat belt b place directional controls in neutral apply brakes d start engine 6 Do not start or operate the rough terrain forklift truck any of its functions or attachments from any place other than the designated operator s position 7 Keep hands and feet inside the operator s designated area or compartment Do not put any part of the body outside the operator compartment of the rough terrain forklift truck 8 Never put any part of the body into the mast structure or between the mast and the rough terrain forklift truck 9 Never put any part o
89. tered through a strainer or a clean lint free cloth and install the filler plug 3 Fig E5 2 CHANGE THE SAFETY DRY AIR FILTER CARTRIDGE Lift the overhead guard cabin See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Disassemble the dry air filter cartridge See D3 CHANGE THE DRY AIR FILTER CARTRIDGE in SECTION 3 MAINTENANCE UP TO MACHINE N 139 125 Remove 8 filter safety cartridge 1 Fig E6 1 and replace the safety cartridge with a new cartridge FROM MACHINE N 139 126 Remove 8 filter safety cartridge 1 Fig E6 2 and replace the safety cartridge with a new cartridge Reassemble the entire unit See D3 CHANGE THE DRY AIR FILTER CARTRIDGE in SECTION 3 MAINTENANCE FORKLIFT SAFETY CONTENTS EVERY 2400 WORKING HOURS SERVICE F1 DRAIN AND CHANGE THE FRONT WHEEL REDUCER OIL This operation should be performed once a year if the lift truck has not reached 2400 hours service within the year Park the truck on level ground with the engine stopped and the reducer oil still warm Drain and change each front wheel reducer Place drain plug 1 Fig F1 in position A Place a container under the drain plug and remove the plug Let the oil drain fully IMPORTANT Dispose of the oil in an ecological manner Place the drain port in position B i e in a level position Fill with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by level port 1 Fi
90. the employer must ensure that a An accessible fire extinguisher is on the forklift b Monthly and annual inspections are performed and documented and records retained three months for monthly one year for annual 6 Before November 10 2014 operators must have had the additional training and qualification certification required by OSHA regulations 81926 1427 and 81926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a detailed description VII ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont CONCLUSION 1 ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard 29 CFR 1910 178 as described by the Occupational Safety and Health Administration OSHA They must be qualified as to their visual hearing physical and mental ability to operate the equipment safely NEVER use drugs or alcohol while operating a forkliftl NEVER operate or allow anyone to operate a forklift when mental 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
91. tion i understanding of nameplate data and operator instructions and warning information appearing on the rough terrain forklift truck B GENERAL SAFETY PRACTICES 1 Rough terrain forklift trucks can cause injury if improperly used or maintained 2 Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to oper ate rough terrain forklift trucks Unusual operating conditions may require additional safety precautions train ing and special operating instructions 3 Modifications and additions which affect capacity or safe operation shall not be preformed without the man ufacturer s prior written approval Where such authorization is granted capacity operation and maintenance instruction plates tags or decals shall be changed accordingly 4 If the rough terrain forklift truck is equipped with front end attachment s or optional forks the user shall see that the truck is marked to identify the forks or attachment s show the approximate weight of the truck and fork or attachment combination and show the capacity of the truck with forks or attachment s at maximum elevation with load laterally centered 5 The user shall see that all nameplates and caution and instruction markings are in place and legible 6 The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity FORKLIFT SAFETY CONTENTS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAF
92. tires Snow chains There are optional solutions consult your agent or dealer AAWARNING A worn or damaged tire can result in the lift truck being temporarily out of service The fitting of foam inflated tires is prohibited and is not guaranteed by the manufacturer without IMPORTANT B P E y prior authorization For your safety and that of others making any modification to the structure or adjustment of the following components on your lift truck is prohibited Hydraulic pressure Setting of limiting devices Engine speed Adding additional equipment If this occurs the manufacturer will be released from any liability To enable the vehicle to be maintained in a state of conformity we advise you to have your lift truck checked regularly by your agent or dealer This should be done at least once every 6 months FORKLIFT SAFETY CONTENTS D ENVIRONMENT A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher There are optional solutions consult your agent or dealer Take into account climatic and atmospheric conditions of the site of utilization Protection against frost See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Adaptation of lubricants Ask your dealer for information Engine filtration Lighting Working headlight Optional solutions exist consult your dealer Use of a lift truck is prohibited in protected areas
93. truck forward slowly 1 maneuvering the forks under the load al Fig E if necessary slightly lift the mast 2 while approaching the load X Apply the parking brake and place the forward reverse lever in neutral S O Slightly lift the load 1 incline the mast 2 backwards in the transport position Fig F Tilt the load sufficiently backwards to ensure its stability loss of load on braking without upsetting the balance of the load in so doing TAKING UP A HIGH LOAD ON TIRES Under no circumstances should you pick up a load if the lift truck is not in a horizontal position See HORIZONTAL POSITION OF THE LIFT TRUCK X X Ensure that the forks will easily pass under the load Position the lift truck perpendicular to the load and with the forks in a horizontal position Fig G RX 1 13 FORKLIFT SAFETY CONTENTS Maneuvering gently and carefully place the forks under the load Fig H Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 and incline the mast 2 backwards to stabilize the load Fig CAUTION Tilt the load sufficiently backwards to ensure its stability loss of load on braking without upsetting the balance of the load Maneuvering very gently and carefully back the lift truck 1 to clear the pile and bring the load into the transport position Fig J X X LAYING A HIGH LOAD ON TIRES X Appro
94. ull beam lights There are optional solutions consult your agent or dealer Drive around obstacles Never move onto a loading platform without having first checked That it is suitably positioned and secured That the unit to which it is connected tractor trailer etc will not shift That this platform is prescribed for the total weight of the lift truck to be loaded That this platform is prescribed for the width of the lift truck Never move onto a foot bridge floor or freight lift without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Take extreme care with loading platforms trenches scaffolding recently dug and or backfilled Awarnine The loaded lift truck must not travel at speeds in excess of 12 km h 7 5 mph INSTRUCTIONS Raise the forks or attachment to the travel position approximately 300 mm 12 in from the ground Shift the forward reverse lever to the selected direction of travel Release the parking brake and accelerate gradually until the lift truck moves off FORKLIFT SAFETY CONTENTS E STOPPING THE LIFT TRUCK SAFETY NOTICE Before stopping the lift truck after long working period let the engine idle for a few moments to allow the coolant liquid and oil to lower the temperature of the engine and transmission Do not forget this precaution frequently stopping the e
95. ur customers Ko When you order parts or when you require any technical information always K D MANITOU INC WACO TEXAS 75705 specify MAST MODEL TE __ NOTE For the owner s convenience is recommended that a note of these wercor ay YEAR OF mea numbers is made in the spaces provided at the time of the delivery of A 54 the lift truck MAX CAPACTTY TES n ce Aime max CAPACITY BEG GROUND ches TIRE PRESSURE FRONT PM es TIRE PRESSURE REAR RE es CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH L FOR OTHER CAPACITIES CONTACT FORK UPRIGHTS VERTICAL FOR THE FACTORY AS RELEASED FROM TRE FACTORY THIS THUCK CONFORMS TO DESIGN STANDARDS ANSVASME PLATE MANUFACTURER OF THE LIFT TRUCK FIG A Ee Model Series Serial No Chassis No Year of manufacture 1 ENGINE FIG B Engine No HYDROSTATIC PUMP FIG C Pump No Codification type Manufacturer s No Year of manufacture HYDROSTATIC WHEEL ENGINES FIG D Manitou part number Codification type Engine No Manufacturer s No Year of manufacture FORKLIFT SAFETY CONTENTS FRONT WHEEL REDUCERS FIG E Type Serial No Date OVERHEAD GUARD FIG F Type Serial No e E A A P9 BEREICH SES F US ish Ed Herons iss 4
96. ury 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 manual for proper operating techniques Important reminders of attachment and boom safety Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as a manlift Attachment must be properly locked to the carrier before raising boom Use only approved attachments on this machine Do not work under raised boom or attachments unless supported FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801009 Hydraulic Coupling 234805 Location near the quick disconnect adapters Stop the engine and release hydraulic pressure before changing attachments Rotating Fan and Belt s 801008 Location on the radiator near the fan and on any fan belt pulley cover s KEEP HANDS Keep hands and clothing away from rotating fan and belts AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 XII FORKLIFT SAFETY CONTENTS SAFETY DECALS Gear Shift Pattern 33460 4 speed transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift transmission Steering M
97. y this manual and the Rough Terrain Forklift Safety Manual part no 422494 thoroughly and carefully before operating or servicing your forklift Contact your dealer or Manitou North America Inc if you have any ques tions concerning your forklift its operation service or parts Keep both manuals in the literature box on the forklift available for reference If either manual becomes illegible or is missing contact your dealer for replace ments immediately This manual cannot cover every situation that might result in an accident It is the respon sibility of the operator to always remain alert for potential hazards and be prepared to avoid them ADDITIONAL RECOMMENDED LITERATURE ANSI ITSDF B56 6 is the national consensus standard for rough terrain forklift trucks It contains rules about forklift safety maintenance safe operation training and supervision Forklift owners should learn this stan dard and make it available for their operators service personnel and supervisors These standards can be obtained free of charge from the Industrial Truck Standards Development Foundation ITSDF on their web site at www itsdf org The following references are examples from the standard addressing forklift operators A OPERATOR TRAINING QUALIFICATIONS 1 The user shall ensure that operators understand that safe operation is the operator s responsibility The user shall ensure that operators are knowledgeable of and observe all safety rule

MSI30D-121128-203025-547041ASD-Rev 11

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