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MT732T Series A MT932 Series A

1. 1 14 FORKLIFT SAFETY CONTENTS D LAYING A HIGH LOAD ON TIRES Under no circumstances should you lay down a load if the lift truck is not in horizontal position See paragraph HORIZONTAL POSITION OF THE LIFT TRUCK X Approach the load in the transport position in front of the pile Fig L Lift and extend the boom 1 2 until the load is above the pile if necessary move the lift truck forward 3 Fig M maneuvering very gently and carefully See E VISIBILITY in chapter HANDLING INSTRUCTIONS for visibility of the road Apply the parking brake and place the forward reverse lever in neutral Place the load in a horizontal position and lay it down on the pile by lowering and retracting the boom 1 2 in order to position the load correctly Fig N Free the forks by alternately retracting and lifting the boom 3 Fig N or if possible by reversing the lift truck 3 See E VISIBILITY in chapter HANDLING INSTRUCTIONS for visibility of the road Then bring the boom into the transport position X X X E TAKING UP A NON PALLETIZED LOAD Tilt the carriage 1 forwards and extend the boom 2 while simultaneously crowding the carriage backwards to slip the forks under the load Fig O If necessary wedge the load X F N A G HORIZONTAL POSITION OF THE LIFT TRUCK Apart from the transverse slope of the ground sev
2. FORKLIFT SAFETY CONTENTS CHARACTERISTICS MT 732 S rie A MT 732 Turbo S rie A FRONT AND REAR TIRES STANDARD OPTION 18 19 5 16PR 1224 TL ALLIANCE OPTION 400 70 20 T37 150B TL 14PR 3 25 Bar DUNLOP 47 psi IMPORTANT When changing or replacing the tires and wheels use 405 70R24 EM SPT9 TL 158A2 5Bar only the manufacturer s approved components as DUNLOP 72 psi installed at the factory Any substitutes or modifications must first be approved by the 440 70 24 T37 147B TL 2 8 Bar manufacturer DUNLOP 41 psi 400 80 24 T37 153B TL 3 2 Bar DUNLOP 46 psi OPTION 15 5 80 24 SGI TL 12PR 4 Bar GOODYEAR 58 psi 460 70 24 17520 TL 150A8 3 3 Bar GOODYEAR 48 psi 222221 445 70R24 115101510 4 1 Bar GOODYEAR 50 psi 15 5x25 12PR SGLDL2A 3Bar GOODYEAR 44 psi OPTION 17 5LR24 XM27 TL 145A8 MICHELIN HYDRAULIC CIRCUIT Type of pump Gear pump with flow divider Capacity 43 77 cm3 2 67 cu in Lifting tilting telescoping attachment circuit Max rating capacity unladen 105 L mn 27 7 gal min Pressure 250 Bar 3625 psi Steering circuit Max rating capacity unladen 105 L mn 27 7 gal min Pressure 140 Bar 2030 psi Filtration Return 20 micron Up to machine No 166043 15 micron From machine No 166044 Suction 125 micron FORKLIFT SAFETY CONTENTS SPECIFICATIONS Level of sound pressure in the driver s cab LpA According to standard prEN 12053 1995 MT 73
3. C C C C C C C Angle gear box oil level C C C C C Transmission oil filter R R R R R Transmission oil V V V V Transmission housing strainer N N N Angle gear box oil V V V V Transmission silent blocks C c Transmission controls C c Transmission pressures C CG Converter pressure C CG TIRES Tires pressure C C C C C C C Wheel nuts torque C C C C C C C Condition of wheels and tires C c Change a wheel BOOM Doom PAGS ue B se ss G BOOM ee on G G G G G G Boom pads C c Condition of boom unit Cc CG Bearings and articulation rings C CG HYDRAULICS Hydraulic oil level C C C C C C Hydraulic return oil filter cartridge H H H H H Balancing C C C C C FIYGFAUNCON MEM V V V Suction strainer for hydraulic oil tank N N N Filter cap for hydraulic oil tank R R R Speeds of hydraulic movements Cc c Cc Hydraulic pump pipe filter NU N N Condition of hoses and flexibles pipes cC c C Con
4. Check for any possible leaks at the drain plugs Refit and tighten level plug 2 and filler plug 3 Fig D11 Tightening torque 34 to 49 N m or 25 36 ft Ibs Repeat this operation for the rear axle differential FORKLIFT SAFETY CONTENTS D12 BLANKING CAP ON THE INDUCTION MANIFOLD CHECK If the cap on the induction manifold 1 Fig D12 have cracks or heat damage renew the cap immediately Failure to change a cracked or damaged rubber cap may cause the entry of air that is not filtered this can IMPORTANT result in severe damage to the I C engine If any other type of cap is found to be fitted it is to be removed and the correct cap fitted immediately D8 BALANCING VALVE CHECK To be performed after the first 50 hours of operation and then every 500 hours Park the lift truck on level ground apply the handbrake and set the forward reverse gear to neutral ROLE OF BALANCING VALVES The balancing valves protect the user from any risk due to a fall in hydraulic pressure or an exploding hose during hydraulic operations WARNING Keep everyone well away during these inspections In all cases the balancing valve s concerned must be repaired or replaced if hydraulic movement continues after the engine has been switched off Never use the lift truck with a defective balancing valve TESTING EACH HYDRAULIC MOVEMENT LIFTING CIRCUIT Start up the lift truck and raise the boom to about 45
5. Remove and clean the strainer using a compressed air jet check its condition and replace if necessary See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Refit the strainer and tighten the suction cover 3 Fig E6 3 Tightening torque 81 or 60 ft lbs making sure the seal is in the correct position 3 30 FORKLIFT SAFETY CONTENTS FILLING UP THE OIL Clean and refit drain plug 1 Fig E6 1 Tightening torque 21 to 28 ft Ibs Fill up with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler port 4 Fig E6 2 Use a clean container and funnel and clean the Observe the oil level on indicator 5 Fig E6 4 the oil level should be at the level of the red point Check for any possible leaks at the drain plug Replace filler cap 2 Fig E6 2 with a new filler cap See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE POLLUTION ABATEMENT OF THE HYDRAULIC CIRCUIT MLT629 Turbo S rie A Let the engine run Accelerator pedal at halfway travel for 5 minutes without using anything on the lift truck then for 5 more minutes while using the hydraulic movements Except the steering system and the 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 possible through the hydraulic return oil filter MLT633 LS Turbo S rie A MLT730 120 LS Turbo S
6. With the engine running at mid speed lower the boom While the boom is being lowered switch off the internal combustion engine movement should slow down as the engine speed falls and stop when the engine stops TELESCOPING CIRCUIT Start up the lift truck and raise the boom as far as it will go extending the telescope s completely With the engine running at mid speed retract the boom While retracting the boom switch off the engine movement should slow down as the engine speed falls and stop when the engine stops TILT CIRCUIT Place the nominal load on the forks anchor it securely to prevent it from falling off during the test Start up the lift truck and tilt the carriage backwards lifting the boom sufficiently to allow the carriage to tilt With the engine running at mid speed tilt the carriage forwards While it is tilting switch off the internal combustion engine movement should slow down as the engine speed falls and stop when the engine stops FORKLIFT SAFETY CONTENTS E EVERY 1000 HOURS SERVICE Carry out the operations described previously as well as the following operations E1 FUEL TANK CLEAN WARNING While carrying out these operations do not smoke or work near a flame Place the lift truck on level ground with the engine stopped Inspect the parts susceptible to leaks in the fuel circuit and in the tank In the event of a leak contact your dealer WARNING Neve
7. HYDRAULIC CIRCUIT Type of pump Gear pump with flow divider Capacity 43 77 cm3 2 67 cu in Lifting tilting telescoping attachment circuit Max rating capacity unladen 105 L mn 27 7 gal min Pressure 250 Bar 3625 psi Steering circuit Max rating capacity unladen 105 L mn 27 7 gal min Pressure 140 Bar 2030 psi Filtration Return 20 micron Up to machine No 166043 15 micron From machine No 166044 Suction 125 micron FORKLIFT SAFETY CONTENTS SPECIFICATIONS Level of sound pressure in the driver s cab LpA 82 5 dB According to standard prEN 12053 1995 Level of sound power in the LwA environment 105 dB According to directive 2000 14 CE guaranteed Travel speed of the lift truck Except particular conditions Forward 27 3 km h 17 mph Reverse Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Jib retracted 27 3 km h 17 mph 9000 mm 354 3 in 3200 kg 7055 Ib 610 mm 24 in 68 kg 150 Ib Unladen lifting 6 75 40 m mn 131 ft min Laden lifting 7 38 36 5 m mn 120 ft min Unladen lowering 5s 53 5 m mn 176 ft min Laden lowering 4 76 57 m mn 187 ft min Telescoping motions Lifting jib Unladen extending 12 25 25 5 m mn 83 6 ft min Laden extending 13 35 23 4 m mn 76 8 ft min Unladen retracting 8s 39 m mn 128 ft min Laden retracting 7 65 41 m mn 134 5 ft min
8. MLT 629 MLT 633 WHEEL NUTS TIGHTENING TORQUE 630 15 96 FRONT TIRES N m 465 ft lbs 630 15 96 REAR TIRES N m 465 ft lbs FORKLIFT SAFETY CONTENTS B EVERY 50 HOURS SERVICE Carry out the operations described previously as well as the following operations B1 DRY AIR FILTER CARTRIDGE CHECK CLEAN In case of use in a heavily dust laden atmosphere there are pre filtration cartridges See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Also the checking and cleaning of the cartridge must be increased If the clogging indicator light comes on this operation must be carried out as quickly as possible IMPORTANT 1 hour maximum The cartridge must not be cleaned more than seven times after which the cartridge must be changed For the disassembly and reassembly of the cartridge see D3 DRY AIR FILTER CARTRIDGE in SECTION 3 MAINTENANCE Clean the filter cartridge using a compressed air jet Max pressure 43 psi directed from the top to the bottom and from the inside towards the outside at a minimum distance of 1 5 inches from the cartridge wall Cleaning is completed when there is no more dust on the cartridge SAUTION SAUTION Use proper eye and face protection when handling compressed air Respect the safety distance of 1 5 inches between the air jet and the cartridge to avoid tearing or IMPORTANT making a hole in the cartridge The cartridge must not be blown anywhere near
9. Preheating engine 20 From the machine No 158864 MLT 629 Turbo Serie A MLT 730 120 LS Turbo Serie A MLT 633 LS Turbo Serie A MLT 730 120 LS Turbo S rie A MLT 633 LS Turbo Serie A FORKLIFT SAFETY CONTENTS 14 ROOF LIGHT 15 ACCELERATOR PEDAL 16 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF The pedal applies brakes on the front and rear wheels by a hydraulic brake system and allows the lift truck to be slowed and stopped The transmission cut off switch enables free travel by disengaging the transmission See ltem 39 USE OF TRANSMISSION CUT OFF in SECTION 2 DESCRIPTION 17 GEAR LEVER AND TRANSMISSION CUT OFF In order to change speeds it is necessary to cut the transmission by pressing the button 1 on the lever See Item 39 USE OF TRANSMISSION CUT OFF in SECTION 2 DESCRIPTION 1 gear To the right backwards 2 gear To the right forwards 3 gear To the left backwards 4 gear To the left forwards USING THE GEARS ON THE GEARBOX On these lift trucks with a torque converter it is not necessary to automatically start up in 1 speed and progress up the gears The choice of gear ratio should be made carefully according to the nature of the work being carried out A poor choice may result in the extremely rapid elevation of the transmission oil temperature through excessive slipping of the converter which could lead to serious damage to the transmission it is essen
10. DEVICE OPTION MLT 629 730 S rie A MT 732 932 S rie A MT 732 Turbo S rie A TAKING UP AN ATTACHMENT Ensure that the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the rods on the locking cylinder are retracted Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HYDRAULIC LOCKING OPTION Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Push the lever of the distributor 1 Fig E forwards in order to completely lock the attachment on the carriage Close the valve in position B Fig D that is to say the hydraulic circuit of the attachment locking closed Always close the valve in position B Fig D after the locking of the attachment in order to avoid accidental unlocking and in order to use the attachment safely HYDRAULIC RELEASING OPTION Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Pull the lever of the distributor 1 Fig E backwards in order to unloc
11. Load center Weight of forks Each Lifting motions Boom retracted Unladen lifting Load lifting Unladen lowering Load lowering Telescoping motions Lifting boom Unladen extending Laden extending Unladen retracting Laden retracting Reverse tilt time unladen Forward tilt time unladen Lift truck weight with standard attachment Unladen Rated load Axle weight with attached equipment Transport position Front unladen Rated load Rear unladen Rated load Tensible strain at coupling hook Unladen Rated load Break out force with bucket According to standard ISO 8313 81 dBA 25 km h 15 5 mph 25 km h 15 5 mph 6050 mm 238 18 in 3300 kg 7 275 26 Ib 610 mm 24 in 72 kg 158 73 Ibs 6 15 41 5 m mn 7 58 33 8 m mn 5s 50 7 m mn 46s 55 m mn 5 25 24 2 m mn 6 2 6 20 3 m mn 4 26 30 m mn 41s 30 7 m mn 29s 49 5 s 2 7 S 54 ie 7030 kg 15 498 Ib 10330 kg 22 773 Ib 3060 kg 8675 kg 3970 kg 1655 kg 6 746 Ib 19 125 Ib 8 752 Ib 3 648 Ib M 5400 daN 12 139 ft Ib 8600 daN 19 332 ft lb 5200 daN 11 689 ft lb Dn OND TS FORKLIFT SAFETY CONTENTS DIMENSIONS AND LOAD CHART MLT 633 LS Turbo S rie A Eu 7 F T Ca Ke GE 3
12. Reverse tilt time unladen 2 8 S 44 8 s Forward tilt time unladen 2 38 54 6 s Lift truck weight with standard attachment Unladen 7640 kg 16 843 Ib Rated load 10840 kg 23 898 Ib Axle weight with attached equipment Transport position Front unladen 3270 kg 7209 Ib Rated load 9090 kg 20 040 Ib Rear unladen 4370 kg 9634 Ib Rated load 1750 kg 3858 Ib Tensible strain at coupling hook Unladen Rated load Break out force with bucket According to standard ISO 8313 5750 daN 12 926 ft Ib 8200 daN 18 433 ft Ib 7400 daN 16 635 ft Ib FORKLIFT SAFETY CONTENTS DIMENSIONS AND LOAD CHART MT 932 S rie A Ex BEIN 74 d IH JD e E win j I H N I BS N 241090 6 5 4 2 6 10 4 75 3 60 240 144 6 58 540 420 2 95 1 90 SUIVANT NORME EN 1459 annexe B FORKLIFT SAFETY CONTENTS MT 932 S rie A 5913 mm 232 8 in 1846 mm 72 7 in 865 mm 34 1 in 2260 mm 89 0 in B D o EN Z FORKLIFT SAFETY CONTENTS INSTRUMENTS AND CONTROLS FORKLIFT SAFETY CONTENTS DESCRIPTION 1 DRIVER S SEAT 2 SAFETY BELT 3 CONTROL AND SIGNAL LIGHTS PANEL 4 N A 5 SWITCH PANEL 6 SWITCH AND LAMPS FOR ALIGNMENT OF THE WHEEL
13. When refueling smoking in the area shall not be permitted the engine shall be stopped and the opera tor shall not be on the rough terrain forklift truck 55 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before restarting engine 56 Do not use open flames when checking electrolyte level in storage batteries liquid level in fuel tanks or the condition of LPG fuel lines and connectors 57 Do not lift personnel with the forklift If the forklift must be used to lift people precautions for the protec tion of the personnel must be taken see ITSDF B56 6 chapter 5 15 Elevating Personnel ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont D SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level Transporting suspended loads must ALWAYS be done slowly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid overturn The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards Grades and sudden starts stops and turns can cause the load to swing and create a hazard Guidelines for Free Rigging Suspended Loads 1 DO NOT exceed the rated capacity of the telescopi
14. CHARACTERISTICS MLT 633 LS Turbo S rie A FRONT AND REAR TIRES STANDARD 7 5LR24 XM27 TL 145A8 MICHELIN OPTION 14 9x24 T35 Stabilarge 18PR DUNLOP 400 70 20 T37 150B TL 14PR DUNLOP 405 70R24 EM SPT9 TL 158A2 DUNLOP DOE IMPORTANT When changing or replacing the tires and wheels use only the manufacturer s approved components as OPTION 15 5 80 24 SGI TL 12PR installed at the factory Any substitutes or GOODYEAR modifications must first be approved by the manufacturer 460 70 R24 IT520 TL 150A8 GOODYEAR 445 70R24 510 151G GOODYEAR OPTION 15 5R25 XHA MICHELIN 1200R20 X MINE D2 MICHELIN OPTION 500 60 22 5 TWIN 404 12PR TRELLEBORG HYDRAULIC CIRCUIT Type of pump Variable displacement piston pump Capacity 60 cm 23 6 cu in Lifting tilting telescoping attachment circuit Max rating capacity unladen 144 L mn 38 gal mn Pressure 270 Bar 3 915 psi Steering circuit Max rating capacity unladen 144 L mn 38 gal mn Pressure 140 Bar 2 030 psi Braking circuit Max rating capacity unladen 144 L mn 38 gal mn Pressure 40 Bar 580 psi Filtration Return 20 Micron Suction 125 Micron FORKLIFT SAFETY CONTENTS SPECIFICATIONS Level of sound pressure in the driver s cab According to standard prEN 12053 1995 MLT 633 LS Turbo S rie A Travel speed of the lift truck Forward Reverse Standard lift height Rated capacity with standard attachment
15. Controls telescope extend BUTTON C Controls telescope retract BUTTON D E Controls the additional attachment BUTTON F Enables transmission cut off to channel all power from the I C engine to hydraulic movements See Item 39 USE OF TRANSMISSION CUT OFF in SECTION 2 DESCRIPTION BUTTON G OPTION Boom head electrovalve MT 732 Turbo MT 932 S rie A LEVER A Controls the lifting of the load and the tilt of the carriage The lever backwards when lifting The lever forwards when lowering The lever to the left for reverse tilt The lever to the right for forward tilt LEVER B Controls the telescoping The lever backwards for the retraction The lever forwards for the extension NOTE Only for MT 932 S rie A When completely retracting the telescopes insistently operate the control so as to allow all the telescopes to retract fully LEVER C Controls the additional attachment BUTTON Enables transmission cut off to channel all power from the engine to hydraulic movements See Item 39 USE OF TRANSMISSION CUT OFF in SECTION 2 DESCRIPTION 2 40 FORKLIFT SAFETY CONTENTS 22 LOAD CHARTS FILE This file includes the description of the hydraulic controls and the load charts of the attachments used on the lift truck 23 HEATER CONTROL DESCRIPTION OF THE HEATER CONTROLS The fan control Fig A Item A is a 3 speed switch that regulates flow of warm or cold air through the ventilat
16. F correct levels of lubricants in all the circuits are installed at production For operation under more IMPORTANT severe climatic conditions before starting up it is necessary to drain all of the circuits and install correct levels of lubricants suited to the relevant ambient temperatures It is the same for the engine cooling system Contact your dealer for information if necessary DRY AIR FILTER Ensure that the air filter is undamaged and not blocked Tighten the fastening devices if necessary IMPORTANT Never run the engine with the air filter removed or damaged COOLING SYSTEM Do not start the lift truck without checking the radiator coolant level or if the fan belt is damaged or broken HYDRAULIC SYSTEM Check by a visual examination that there are no leaks from the hoses connections and unions If necessary tighten or repair the defective connections Also check that the tank oil level is correct BRAKING SYSTEM Check by a visual examination that there are no leaks from the hoses connections and unions If necessary tighten or repair the defective connections Also check the oil level in the tank WARNING Ensure that the recommended oil is used in order to avoid serious damage to the braking system 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 SE
17. PERKINS 1004 40TW AM 80922 or AM 81337 PERKINS 1004 40T AK 80920 or AK 81335 PERKINS 1004 40TW AM 80922 or AM 81337 PERKINS 1004 40T AK 80920 or AK 81335 PERKINS 1004 42 AR 81026 or AR 81334 PERKINS 1004 40T AK 80920 or AK 81298 or AK 81336 1004 42 AR 81026 1004 42 AR 81334 4 in line 4 Natural Direct 1 3 4 2 0 20 mm 0 45 mm 4233 cm 103 mm 127 mm 18 5 1 2200 rpm 930 rpm 5 2350 rpm 80 cv 60 kw 290 Nm at 1400 rpm Dry 3y By water Puller 10 508 mm 1004 40T AK 80920 1004 40T AK 81335 4 in line 4 Compressed turbo Direct 1 3 4 2 0 20 mm 0 45 mm 3990 cm 100 mm 127 mm 17 25 1 2200 rpm 930 rpm 5 2400 rpm 104 cv 76 5 kw 394 Nm at 1400 rpm Dry 3 u 77 C to 85 C 92 C to 98 C TURNER POWERTRAIN SYSTEMS SACHS A A Electro hydraulic 1004 40T AK 81298 1004 40T AK 81336 4 in line 4 Compressed turbo Direct 1 3 4 2 0 20 mm 0 45 mm 3990 cm 100 mm 127 mm 17 25 1 2200 rpm 930 rpm 2400 rpm 100 cv 74 6 kw 402 6 Nm at 1400 rpm Dry 3y 1004 40TW AM 80922 1004 40TW AM 81337 4 in line 4 Compressed turbo Direct 1 3 4 2 0 20 mm 0 45 mm 3990 cm 100 mm 127 mm 17 25 1 2200 rpm 930 rpm 5 2380 rpm 121 cv 90 5 kw 434 Nm at 1500 rpm Dry 3 u FORKLIFT SAFETY CONTENTS ANGLE GEAR BOX Type FRONT AXLE Type Limited slip differential Hub reducers REAR AXLE Type Hub reducers BRAKE Service brake
18. Tellus T46 Texaco Rando HDZ46 BRAKE COMPONENT RECOMMENDATION O RD BRAKE CIRCUIT Shell Donax TG Dexron Texaco Havoline Dexron lll COMPONENT RECOMMENDATION DOOR Shell Rentinax Am Texaco Havoline WBCG WINDSCREEN WASHER TANK windshield washer fluid il FORKLIFT SAFETY CONTENTS FRONT AND REAR AXLES COMPONENT CAPACITY RECOMMENDATION FRONT AXLE DIFFERENTIAL 7L 1 8gal Shell Donax TD Texaco TDH 1893 REAR AXLE DIFFERENTIAL 7L 1 8gal Shell Donax TD Texaco TDH 1893 FRONT WHEELS REDUCERS 0 75 L 19 gal Shell Spirax DH 80w90 Texaco Multi gear EP 80w90 REAR WHEELS REDUCERS 0 75 L 19 gal Shell Spirax DH 80w90 Texaco Multi gear EP 80w90 FRONT AND REAR WHEELS Shell Rentinax Am REDUCERS PIVOTS Texaco Havoline WBCG REAR AXLE OSCILLATION Shell Rentinax Am Texaco Havoline 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 A AJUST N CLEAN 1 year 1 year C CHECK P BLEED or 2000 4000 D DESCALE R CHANGE 10 1000 hours hours G GREASE V DRAIN hours hours hours hours ENGINE I C engine
19. on the optional removeable forklift attachment LC NN 3 CH MAMIFACTURE jS NM ME a Important manufacturer information about the attachment Record this information for use when contacting the maufacturer for parts and service nonmanta CENTER or onam E DIPERATIEG PRESSURE Sa AWARNING d This attachment affecta the dl capaci n of the ft truck Chock the operator or Iced chart lor nat capacity with tnis attachment tma load chart Ig rint canine tha actor Overhead Guard Data Plate B6109 Location attached to the overhead guard THIS OVERHEAD GUARD CONFORMS TO ANSI DESIGN RECOMMENDATION THIS OVERHEAD GUARD Overhead guard conformity HAS PASSED AN IMPACT TEST DEI LBS DO NOT REMOVE THIS OVERHEAD GUARD 496550 Forklift Data Plate 496550 Boom equipped models Forklift Data Plate 496538 Mast equipped models ICD MANHGU INO Location within the operator s compartment K D MANITOU INC WACO TEXAS 78705 TRUCK MODEL TRUCK MODEL MAST MODEL ED 5 SERIAL NUMBER Ee Important forklift truck identification Record 5 EE 5 TE UNLADEN WEIGHT ID this information for use when contacting the UNLADEN WEIGHT YEAR OF MFG j manufacturer for parts and service YEAR OF RE dee eT MAX CAPACITY Les UP TO B INCHES max CAPACI
20. If the lamps E F G H 1 J Kand the buzzer come on when the lift truck is running stop the I C engine immediately and check the electrical circuit as well as the alternator belt RED I C ENGINE OIL PRESSURE LAMP If the lamp and the buzzer come on when the lift truck is running stop the engine immediately and look for the cause See oil level in engine crankcase J RED I C ENGINE WATER TEMPERATURE LAMP If the lamp and the buzzer come on when the lift truck is running stop the engine immediately and investigate the cooling system for the cause of the malfunction K RED LAMP AIR FILTER OR HYDRAULIC RETURN FILTER CLOGGED The lamp and buzzer come on when the air filter cartridge or the hydraulic return oil filter cartridge is clogged up Stop the lift truck and carry out the necessary repairs See cleaning and replacement requirments FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE L GREEN INDICATOR LAMP M GREEN SIDELIGHTS LAMP N GREEN LOW BEAM LAMP O BLUE MAIN BEAM LAMP 4 N A 5 SWITCH PANEL A WARNING LIGHTS This switch enables the L H and R H indicators to be switched on simultaneously with the ignition off The signal light indicates that the switch is being used B FLASHING LIGHT C REAR FOG LIGHT D FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER This two position switch when set on the down position and simultaneously pressed allows the windscreen washer and the w
21. MAINTENANCE FORKLIFT SAFETY CONTENTS D5 FUEL FEED PUMP CLEAN Open the compartment Loosen connection 1 Fig D5 1 lift hose 2 Fig D5 1 and protect the aperture Remove connection 3 Fig D5 2 and lift strainer 4 Fig D5 2 Carefully clean the strainer and connection using a brush soaked in clean diesel fuel and dry them with a low pressure jet of compressed air Reassemble connection 3 Fig D5 2 ensuring that the watertight seal is in the correct position Tightening torque 20 N m or 14 ft Ibs Reconnect hose 2 Fig D5 1 and check that the feed pump is watertight Reprime the circuit by activating the feed pump If necessary bleed the fuel circuit See G1 FUEL SYSTEM in SECTION 3 MAINTENANCE D6 TRANSMISSION OIL FILTER CHANGE Remove the cover plate 1 Fig D6 1 Unscrew and discard the transmission oil filter 2 Fig D6 2 Carefully clean the filter head with a clean lint free cloth Slightly lubricate the new seal and fit the seal on the filter Fill up the new transmission oil filter See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE Refit the filter making sure that the seal is correctly positioned and tightened Tighten the transmission oil filtrer by hand pressure IMPORTANT only and lock the filter in place by a quarter turn Put back the cover plate 1 Fig D6 1 FORKLIFT
22. S rie A TAKING UP AN ATTACHMENT Ensure that the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the locking pin and the clip are in position in the bracket Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HAND LOCKING AND CONNECTING THE ATTACHMENT Take the locking pin and the clip on the bracket Fig A and lock the attachment Fig D Do not forget to refit the clip Stop the engine and keep the ignition on the lift truck Remove the pressure of the hydraulic circuit by pressing buttons 1 and 2 Fig E on the distributor lever 4 or 5 times Connect the rapid connectors according to the logic of the attachment s hydraulic movements Make sure that the rapid connectors are clean and IMPORTANT protect the holes which are not used with the caps provided HAND RELEASING AND DISCONNECTING THE ATTACHMENT Proceed in the reverse order of paragraph HAND LOCKING AND CONNECTING THE ATTACHMENT while making sure you put back the locking pin and the clip in the bracket Fig A LAYING AN ATTACHMEN
23. SAFETY CONTENTS D7 HYDRAULIC RETURN OIL FILTER CARTRIDGE CHANGE Stop the engine and remove the pressure from the circuits by acting on the hydraulic controls Thoroughly clean the outside of the filter and its IMPORTANT surroundings before any intervention in order to prevent any risk of polluting the hydraulic circuit Place a container under hydraulic drain filter 1 Fig D7 Unscrew the body of the filter Remove the hydraulic return oil filter cartridge and fit new replacement cartridge See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Make sure that the cartridge is correctly positioned and refit the body of the filter D8 PARKING BRAKE MECHANISM GREASE Clean and grease articulation axles 1 Fig D8 with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE D9 CAB VENTILATION FILTER CLEAN Lift up protective casing 1 Fig D9 Lift out cabin ventilation filter 2 Fig D9 Clean the filter with a compressed air jet Check its condition and change if necessary Refit the filter and protective casing FORKLIFT SAFETY CONTENTS D10 BATTERY ELECTROLYTE DENSITY CHECK 1 240 The electrolyte density varies depending on the temperature concerned but a on minimum of 1260 at 16 C 61 F must be maintained In the shaded area 1 260 Fig D10 the battery is in a normal charge condition Readings above this 1 270 zone indicate that the battery needs
24. 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 attachment dynamic and static forces imp
25. and 6 Fig F1 5 of the oil cooler and rinse via outlet hole 5 Fig F1 5 until clean water flows from input hole 6 Fig F1 5 Reconnect the two hoses FILLING THE LIQUID Retighten drain plug 2 Fig F1 2 Tightening torque 20 N m or 15 ft Ibs and 3 Fig F1 3 Tightening torque 7 to 12 N m or 5 9 ft Ibs Slowly fill up the cooling circuit See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE to 12 mm 1 2 in under filler port 7 Fig F1 4 Put back filler cap 4 Fig F1 4 Run the engine at idle for a few minutes Check for any possible leaks Put back the shroud 1 Fig F1 1 Check the level and refill if necessary The 1 C engine does not contain any corrosion resistor and must be filled during the whole year with a minimum mixture containing 25 of ethylene glycol based antifreeze IMPORTANT FORKLIFT SAFETY CONTENTS G OCCASIONAL MAINTENANCE G1 FUEL SYSTEM BLEED These operations are to be carried out only in the following cases A component of the fuel system replaced or drained drained tank Running out of fuel Ensure that the level of fuel in the tank is sufficient turn the ignition key to notch 1 to establish electrical contact and bleed in the following order Open the engine compartment BLEEDING THE FUEL FILTER Loosen bleed screw 1 Fig G1 1 Activate feed pump 2 Fig G1 2 until the diesel fuel flows out free from air at th
26. and right rear view mirrors frequently and ensure that they are kept in good condition are clean and correctly adjusted When working at night ensure that your lift truck is fitted with full beam lights There are optional solutions consult your agent or dealer Drive around obstacles Never move onto a loading platform without having first checked That it is suitably positioned and made fast That the unit to which it is connected 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 Ayan na 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 transport position approximately 300 mm 12 in from the ground Engage the gear required See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION Select the desired steering mode Shift the forward reverse lever to the desired direction of travel Release the parking brake and accelerate gradually until the lift truck moves off FORKLIFT SAFETY
27. 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 cab It is prohibited to have arms or legs or generally any part of the body protruding from the driver s cab of the lift truck Always 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 e g climbing onto or down from the lift truck etc If the control components are fitted with a forced operation lever lock device it is forbidden to leave the cab without first putting these controls in neutral Never allow a passenger to travel on the lift truck in the driver s cab BEFORE STARTING THE LIFT TRUCK If the lift truck is new refer to BEFORE STARTING UP A NEW LIFT TRUCK in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS Check the condition of the tires and the tire pressures See CHARACTERISTICS in SECTION 2 DESCHIPTION Before starting the lift truck check the different levels Engine oil Hyd
28. as d LI Y A DM 4000Lb SEET d L AA E De i ZC D m QFaat 24in N 23351z 3 sam Tam 22 Sins k 2 1 t Bm i 3 E 1 OMerers An Auen can sanua ASME 56 60 9983 LIO FORKLIFT SAFETY CONTENTS B D EN o R MLT 633 LS Turbo S rie A 1200 mm 47 24 in 2560 mm 100 78 in 1142 mm 44 96 in 1047 mm 41 22 in 4462 mm 175 66 in 4367 mm 171 92 in 3920 mm 154 33 in 5662 mm 222 91 in 1850 mm 72 83 in 1850 mm 72 83 in 455 mm 17 91 in 440 mm 17 32 in 440 mm 17 32 in 760 mm 29 92 in 865 mm 34 05 in 1260 mm 49 60 in 45 mm 1 77 in 1720 mm 67 71 in 125 mm 4 92 in 47 5 53 3475 mm 136 81 in 7322 mm 288 26 in 3995 mm 157 28 in 2300 mm 90 55 in 2490 mm 98 03 in 4630 mm 182 28 in 1205 mm 47 44 in 3700 mm 145 66 in 2305 mm 90 74 in 12 133 9 FORKLIFT SAFETY CONTENTS CHARACTERISTICS MLT 730 120 LS Turbo S rie A FRONT AND REAR TIRES STANDARD 7 5LR24 XM27 TL 145A8 MICHELIN OPTION 14 9x24 T35 Stabilarge 18PR DUNLOP 400 70 20 T37 150B TL 14PR DUNLOP 440 70 24 T37 1478 TL When changing or replacing the tires and wheels use only the manufacturer s approved components as installed at the factory Any substitutes or modifications must first be approved by the manufacturer OPTION 15 5 80 24 SGI TL 12PR GOODYEAR 460 70 R24 IT520 T
29. buttons 3 and 4 control another hydraulic function NOTE Switch 5 enables the hydraulic function controlled by button 2 to be locked Indicator 6 lights up to show when it is in use 12 Boom HEAD ELECTROVALVE PREARRANGED HYDRAULIC ATTACHMENT LOCKING The addition of these two options enables the combining of several hydraulic functions 13 Boom HEAD ELECTROVALVE ELECTRICAL BOOM PROVISION MLT MODELS ONLY Adding these two options lets you combine several hydraulic functions The hydraulic attachment locking system can be added to this combination of options NOTE In these combinations of options the transmission cut out button changes place and is located at 5 FUNCTIONING Without pressing buttons 1 and 2 buttons 3 and 4 control a hydraulic function By pressing buttons 1 and 2 buttons 3 and 4 control another hydraulic function Option availability varies according to model country FORKLIFT SAFETY CONTENTS 14 N A 15 PREARRANGED TRAILER LOCKING Enables the hydraulic connection of a braked trailer 16 SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION Enables the use of a hydraulic accessory at the rear of the lift truck e g a trailer with hydraulic tipping MLT 629 Turbo MT732 932 S rie A Lever 1 controls this predisposition MLT 730 120 LS S rie A MLT 633 LS Turbo S rie A Switch 2 controls this predisposition Option availability varies ac
30. m 4 a MANIIDU 5 REAR REFLECTORS Option availability varies according to model country FORKLIFT SAFETY CONTENTS 6 ENGINE BLOCK HEATER 7 DIGICODE ANTI THEFT SYSTEM 8 ELECTRICAL BOOM PROVISION Enables an electrical or hydraulic function to be used at the head of the boom Option availability varies according to model country FORKLIFT SAFETY CONTENTS 9 EXTERIOR DRAIN BACK Enables connection of an attachment for which drain back is required 10 HYDRAULIC ATTACHMENT LOCKING Enables attachment locking to be controlled on the carriage and the use of a hydraulic attachment on the same hydraulic circuit See PICKING UP THE ATTACHMENTS in SECTION 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE 11 Boom HEAD ELECTROVALVE Enables use of two hydraulic functions on the attachment circuit To make connection of the rapid connectors easier IMPORTANT decompress the hydraulic circuit by pressing button 1 on the electrovalve FUNCTIONING MT 732 Turbo 932 S rie A Button 2 not engaged the lever controls a hydraulic function Pressing button 2 the lever controls another hydraulic function ECKE JS D BA v z Be d 11 d es Eu Option availability varies according to model country FORKLIFT SAFETY CONTENTS FUNCTIONING MLT MODELS Button 2 not engaged buttons 3 and 4 control a hydraulic function Pressing button 2
31. 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 capacity of the rough terrain forklift truck
32. open so as to avoid any risk of freezing to the evaporator FORKLIFT SAFETY CONTENTS AIR CONDITIONED MODE The controls must be adjusted in the following way A Control with signal light on B At the end of travel to the left C At the required speed 1 2 or 3 DEFROST MODE The controls must be adjusted in the following way A Control with signal light on B At the required temperature C At the required speed 1 2 or 3 HEATING MODE The controls must be adjusted in the following way A Control with signal light off B At the required temperature C At the required speed 1 2 or 3 NOTE 1 The hot water valve Item D engine compartment must be fully open counter clockwise for maximum heat or defrost The valve must be fully closed clockwise for maximum cooling when operating the air conditioning system 2 Forklift truck S N 169427 and below require a radiator replacement p n 224707 when adding the air conditioning option 24 CAB FILTER VENTILATORS See D EVERY 400 HOURS SERVICE in SECTION 3 MAINTENANCE 25 WINDSCREEN DEMIST VENTS For optimum effectiveness close the heating ventilators 26 HEATING VENTS These heating vents enable the air to be directed to the interior of the cabin and onto the side windows 27 DOOR LOCK Two keys are provided with the lift truck to enable the cabin to be locked 28 LOCKING HANDLE FOR UPPER HALF DOOR 29 RELEASING BUTTON FOR UPPER HALF DO
33. position in the bracket Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HAND LOCKING AND CONNECTING THE ATTACHMENT Take the locking pin and the clip on the bracket Fig A and lock the attachment Fig D Do not forget to refit the clip Stop the engine Remove the pressure of the hydraulic circuit by using the lever of the distributor 1 Fig E Connect the rapid connectors according to the logic of the attachment s hydraulic movements Make sure that the rapid connectors are clean and IMPORTANT protect the holes which are not used with the caps provided HAND RELEASING AND DISCONNECTING THE ATTACHMENT Proceed in the reverse order of paragraph HAND LOCKING AND CONNECTING THE ATTACHMENT while making sure you put back the locking pin and the clip in the bracket Fig A LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position FORKLIFT SAFETY CONTENTS E HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo
34. rear view mirrors to check for people animals holes obstacles change of slope etc Since visibility can be reduced on the right side when the boom is raised ensure clear visibility of the road before raising the boom and before undertaking any maneuvers f 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 windows adequate lighting correctly adjusted rear view mirror etc Signalling and lighting on the lift truck must take into account 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 light at the boom head etc Consult your agent or dealer IF NECESSARY CONSULT YOUR DEALER 1 12 FORKLIFT SAFETY CONTENTS LOAD HANDLING A WEIGHT OF LOAD AND CENTER OF GRAVITY Carrying a load greater than the rated capacity for the CAUTION lift truck or for the attachment is prohibited 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 load
35. rie A This should be carried out by your agent or dealer after each oil change The hydraulic oil used in the circuit must be at least equal in quality to class 8 According to NAS 1638 Your agent or dealer will be able to clean the hydraulic circuit using an external unit and check the quality of the oil in order to ensure the long life of hydraulic components and particularly of the main pump E9 SEAT BELT CHECK SEAT BELT WITH TWO ANCHORING POINTS Check the following points e Fixing of the anchoring points on the seat Cleanness of the strap and the locking mechanism e Triggering of the locking mechanism e Condition of the strap cuts curled edges REELED SEAT BELT WITH TWO ANCHORING POINTS Check the points listed above together with the following points The correct winding of the belt e Condition of the reel guards e Roller locking mechanism when the strap is given a sharp tug FORKLIFT SAFETY CONTENTS NOTE After an accident replace the seat belt Under no circumstances should you use the lift truck if the seat belt is faulty fixing locking it has cuts or WARNING od tears etc Repair or replace the seat belt immediately E10 FRONT AND REAR WHEELS REDUCERS OIL DRAIN Place the lift truck on level ground with the engine stopped and the reducers oil still warm IMPORTANT Dispose the drain oil in an ecological manner Drain and change each front wheel reducer Place
36. slope Carry out adjustments if necessary Press and release the brake pedal then release the parking brake putting it in position B Fig C6 Progressively tighten the end piece of the lever 1 Fig C6 and recheck braking Repeat the operation until the correct braking adjustment is obtained C7 VENTILATION FILTER OPTION AIR CONDITIONING CHANGE Lift up protective casing 1 Fig C7 Lift out cabin ventilation filter 2 Fig C7 and fit new replacement filter See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Refit the protective casing C8 HEATING BLOCK NON RETURN VALVE CLEAN Since non return valve 1 Fig C8 is located under the cab it is possible for it to become obstructed with spattered mud for example Clean if necessary FORKLIFT SAFETY CONTENTS C9 FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL CHECK Place the lift truck on level ground with the engine stopped Remove level plug 1 Fig C9 The oil should be flush with the edge of the hole If necessary add oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by the filler port 2 Fig C9 Replace and tighten the level plug 1 Fig C9 Tightening torque 34 to 49 N m or 25 36 ft Ibs Repeat this operation for the rear axle differential C10 FRONT AND REAR WHEELS REDUCERS OIL LEVEL CHECK Place the lift truck on level ground with the engine stopped Check the level
37. the air filter box Never clean the cartridge by tapping it against a hard surface Clean the cartridge seal surfaces with a damp clean lint free cloth and grease with a silicone lubricant IMPORTANT Do not clean the dry air filter cartridge by washing it in liquid Do not clean by any means the safety cartridge located inside the filter cartridge change it for a new one if it is dirty or damaged B2 RADIATOR CORE CLEAN Open the engine compartment In order to prevent the radiator becoming clogged clean the radiator with a compressed air jet directed from inside to outside This is the only way to clean the core of debris IMPORTANT When handling straw grain or cereal clean the radiator core daily FORKLIFT SAFETY CONTENTS B3 CONDENSER CORE OPTION AIR CONDITIONING CLEAN Open the engine compartment Loosen the wingnut 1 Fig B3 1 Raise and lock into place the radiator cowling 1 Fig B3 2 Swing the condenser unit forward 2 Fig B3 2 Clean the core with a blast of compressed air aimed from the inside towards the outside This is the only effective way of removing the impurities When handling straw grain or cereals clean the IMPORTANT condenser core every day B4 Boom GREASE To be carried out weekly if the lift truck has been operated for less than 50 hours during the week In the event of prolonged use in an extremely dusty or IMPORTANT damp atmospher
38. the points 1 2 lubricators Fig B12 with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE and remove the surplus of grease FORKLIFT SAFETY CONTENTS B13 TRANSMISSION UNIVERSAL JOINT GREASE Clean and lubricate the following points with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE and remove the surplus of grease 1 Lubricators of the universal joint engine Angle gear box 2 lubricators Fig B13 1 2 Lubricators of the universal joint Transmission Front axle 3 lubricators Fig B13 2 3 Lubricators of the universal joint Transmission Rear axle 3 lubricators Fig B13 3 FORKLIFT SAFETY CONTENTS C EVERY 250 HOURS SERVICE Carry out the operations described previously as well as the following operations C1 FAN BELT BELT TENSION CHECK ADJUST Open the engine compartment Check the belt for signs of wear and cracks and change if necessary See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Loosen screw 1 Fig C1 1 on the tension pulley Loosen lock nut 2 Fig C1 1 and C1 2 and screw 3 Fig C1 1 and C1 2 Bring the belt just into contact with pulley 4 Fig C1 1 On the lift truck check this operation by feel Make a mark on the head of screw 3 Fig C1 1 and C1 2 and tighten turning it 5 times Tighten the lock nut 2 Fig C1 1 and C1 2 When changing the fanbelt tighten screw 3 Fig C1 1 IMPORTA
39. the pressure on the contact surface allowable for the platform in connection with the lift truck For lift trucks equipped with a turbo charged l C engine block off the exhaust outlet to avoid rotation of the turbo shaft without lubrication when transporting the vehicle IMPORTANT LOAD THE LIFT TRUCK Block the wheels of the platform Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck Load the lift truck parallel to the platform Stop the lift truck See DRIVING INSTRUCTIONS in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS STOW THE LIFT TRUCK Fix the chocks to the platform at the front and at the back of each tire Fig G5 1 Fix also the chocks to the platform in the inside of each tire Fig G5 2 Stow the lift truck on the platform with enough resisting ropes At the front of the lift truck on the fastening points 1 Fig G5 3 and at the back on the towing pin 2 Fig G5 4 Tighten the ropes Fig G5 5 FORKLIFT SAFETY CONTENTS G6 FRONT HEADLAMPS ADJUST RECOMMENDED SETTING As per standard ECE 76 756 76 761 ECE20 Set to 2 of the dipped beam in relation to the horizontal line of the headlamp ADJUSTING PROCEDURE Place the lift truck unloaded and in the transport position and perpendicular to a white wall on flat level ground Fig G6 Check the tire pressures See A6 TIRES PRESSURE AND WHEEL NUTS TORQUE in SECTI
40. the rapid connectors are clean and IMPORTANT protect the holes which are not used with the caps provided Close the valve in position B Fig D that is to say the hydraulic circuit of the attachment locking closed Always close the valve in position B Fig D after the CAUTION locking of the attachment in order to avoid accidental unlocking and in order to use the attachment safely HYDRAULIC RELEASING AND DISCONNECTING THE ATTACHMENT Close the attachment Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Push the lever of the distributor 1 Fig E backwards in order to completely unlock the attachment on the carriage Stop the engine Remove the pressure of the attachment hydraulic circuit by using the lever of the distributor 1 Fig E Disconnect the rapid connectors of the attachment Make sure that the rapid connectors are clean and IMPORTANT protect the holes which are not used with the caps provided LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS G HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A TAKING UP AN ATTACHMENT Ensure t
41. the steering mode HIGHWAY TRAFFIC Check the adjustment of the rear view mirrors Ensure that the fuel level is sufficient Put the boom in the retracted position and the attachment at 300 mm 12 in from the ground On the road set off in 3 gear and go into 4 As model of lift truck when the conditions and state of the road allow In hilly areas set off in 2 gear and go into 3 when the conditions and state of the road allow A wARNING While on the road do not use the transmission cut off to maintain engine braking on the lift truck G OPERATING THE LIFT TRUCK WITH A TRAILER ON A PUBLIC HIGHWAY 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 lift truck s braking equipment to that of the trailer The maximum vertical pull on the trailer hook must not exceed 1500 daN 3372 Ib 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 When driving with a trailer set off in 2 gear and go into 3 when the condi
42. window 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 trace FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE 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 chapters of this manual which has been provided to solve driving and maintenance problems By following these instructions the user will be able to take full advantage of the versatility of this lift truck The operator must familiarize himself with the positions and functions of all the controls and instruments before operating the lift truck 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 F to 95
43. 10 HOURS SERVICE in SECTION 3 MAINTENANCE for tightening torque FORKLIFT SAFETY CONTENTS G3 LiFT TRUCK TOW IMPORTANT Do not tow the lift truck at more than 25 km h 15 mph Put the forward reverse lever and the gear shift in neutral As model of lift truck Release the parking brake Put the warning lights on If the 1 C engine is not running there will be no steering or braking assistance Operate the steering and pedal slowly avoiding sudden abrupt movements G4 LiFT TRUCK SLING Take into account the position of the lift truck gravity center for lifting Fig G4 1 Place the hooks in the fastening points provided Fig G4 2 and G4 3 1290 mm 50 78 in 1270 mm 50 in 629 1445 mm 56 88 in B 1115 mm 43 9 in MLT 633 1370 mm 53 94 in 1190 mm 46 85 in 730 1480 mm 58 27 in 1080 mm 42 52 in MT 732 1465 mm 57 68 in 1190 mm 46 85 in MT 932 lt E ee 6 Weg A FORKLIFT SAFETY CONTENTS G5 LiFT TRUCK ON A PLATFORM TRANSPORT 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
44. 2 S rie A MT 732 Turbo S rie A Level of sound power in the LwA environment According to directive 2000 14 CE guaranteed MT 732 S rie A MT 732 Turbo S rie A Travel speed of the lift truck Except particular conditions Forward Reverse Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Jib retracted Unladen lifting Laden lifting Unladen lowering Laden lowering Telescoping motions Lifting jib Unladen extending Laden extending Unladen retracting Laden retracting Reverse tilt time unladen Forward tilt time unladen Lift truck weight with standard attachment Unladen Rated load Axle weight with attached equipment Transport position Front unladen Rated load Rear unladen Rated load Tensible strain at coupling hook Unladen MT 732 S rie A MT 732 Turbo S rie A Rated load MT 732 S rie A MT 732 Turbo S rie A Break out force with bucket According to standard ISO 8313 82 5 dB 81 dB 105 dB 106 dB 27 3 km h 17 mph 27 3 km h 17 mph 6900 mm 271 6 in 3200 kg 7055 Ib 610 mm 24 in 68 kg 150 Ib 6 75 40 m mn 7 38 36 6 m mn 5s 53 5 m mn 4 78s 57 m mn 6 35 26 2 m mn 6 85 24 2 m mn 3 3 S 50 m mn 35 55 m mn 286 44 8 2 6 2 38 54 6 s 7250 kg 15 983 Ibs 10450 kg 23 038 Ibs 3060 kg 6746 Ibs 8785 kg 19 367 Ibs 4190 kg 9237 lbs 1665 kg 3
45. 20A MAX Stop engine electrovalve 7 54 OPTION 7 54 Flashing light 7 5A Alignment of the wheels 5A OPTION Hydraulic movements cut off 10A Gear reverser 154 Transmission cut off 15A Control instruments panel 5A Sound alarm 15 Stop switch 154 ped Boom head light 10 Indicator power supply 10 Heating 30A OPTION 254 OPTION Fuel reheating 20 OPTION Air conditioning 7 54 OPTION Electrovalve on boom head 104 OPTION Electrovalve on boom head attachment hydraulic locking device 10 OPTION Electrical boom provision 104 OPTION Anti theft device provision 10 OPTION Rear hydraulic provision 10A OPTION Dual effect hydraulic towing hook 10 OPTION Front working head light 10A OPTION Rear window defrosting 15 OPTION Pneumatic seat 10A Front windscreen wiper and windscreen washer 104 OPTION Right sidelight 7 54 Sidelight indicator light 7 5A Control panel lighting 7 54 OPTION Service plate lighting 7 54 Left sidelights 7 54 Right indicators 7 54 Left indicators 7 5 Low beam 154 Low beam indicator light 15 Rear fog light 15 Main beam 15 Main beam lamp 15 Hazard warning lights power supply 15 Roof light 15A OPTION permanent 15 Light switch power supply horn and indicators 25
46. 670 Ibs 5500 daN 5500 daN 6800 daN 8500 daN 12 364 ft lbs 12 364 ft lbs 15 286 ft lbs 19 108 ft lbs gt Dn 7400 daN 16 635 ft Ibs Dn QL m e St St FORKLIFT SAFETY CONTENTS DIMENSIONS AND LOAD CHART MT 732 S rie A MT 732 Turbo S rie A SIP b N 241089 4 2 1 416 3 60 2 90 2 10 1 45 2 40 175 SUIVANT NORME EN 1459 annexe FORKLIFT SAFETY CONTENTS MT 732 Turbo S rie A 5913 mm 232 8 in 1846 mm 72 7 in 865 mm 34 1 in 2260 mm 89 0 in o ur xr lt um ur lt gt B D EE o EN Z FORKLIFT SAFETY CONTENTS CHARACTERISTICS MT 932 S rie A FRONT AND REAR TIRES STANDARD OPTION 18 19 5 16PR 1224 TL ALLIANCE DPNON 400 70 20 737 1508 TL 14PR 3 25 IMPORTANT DUNLOP 47 psi PORN When changing or replacing the tires and wheels use 440 70 24 137 MTB TL 28 Bar only the manufacturer s approved components as DUNLOP 41 psi installed at the factory Any substitutes or modifications must first be approved by the manufacturer 400 80 24 37 153BTL 3 2Bar DUNLOP 46 psi OPTION 15 5 80 24 SGI TL 12PR GOODYEAR 460 70 R24 17520 TL 15048 GOODYEAR 445 70R24 510 151G GOODYEAR OPTION 17 5LR24 XM27 TL 145A8 MICHELIN
47. ATOR S MANUAL Level machine al ground level before raising boom Do evel control when boom is raised not adjust frame ibove ground level If frame position is changed with a raised boom oT p ATTACHMENT AND BOOM SAFETY Improper operating techniques can cause the machine to tip over Refer to machine load charts and operator s manual for proper operating techniques Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as a manlift Attachment must be properly locked to the carrier before raising boom Use only approved attachments on this machine Do not work under raised boom or attachments unless supported FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS KEEP HANDS AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 FORKLIFT SAFETY CONTENTS SAFETY DECALS Gear Shift Pattern 33460 4 speed transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift transmission Steering Mode 184276 4 wheel steer equipped models Location near the steering mode selection lever Identifies the steering mode selection 221322 ATTENTION CUIDADO ACHTUNG ATTENZIONE Mineral Oil Brake Reservoir 221322 or 234800 mn NA Ds Location attached to the brake fluid reservoir BREM SFLUES
48. CONTENTS E STOPPING THE LIFT TRUCK SAFETY NOTICE Before stopping the lift truck after a long working period leave the engine idling for a few moments to allow the coolant liquid and oil to lower the temperature of the engine and transmission Do not forget this precaution frequently stopping the engine will raise the temperature of some components with 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 place the gear lever in neutral As model of lift truck apply the parking brake and put the forward reverse lever in neutral If the driver has to leave his cab even for a moment it is essential to place the gear lever in neutral As model of lift truck apply the parking brake and put the forward reverse lever in neutral Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at least 6 feet from the track of a railway In the event of prolonged parking on a site protect the lift truck from bad weather particularly from frost Check the level of antifreeze close the rear window lock the cab door and ensure that the hood is properly secured INSTRUCTIONS Park the lift truck on flat ground or on an incline that is less than 15 96 Release the accelerator pedal and stop the lift truck Place th
49. CONTENTS E5 ANGLE GEAR BOX OIL DRAIN Place the lift truck on level ground with the I C engine stopped the angle gear box oil still warm Place a container under drain plug 1 Fig E5 1 and unscrew the plug Remove dipstick 2 Fig E5 2 and unscrew filler cap 3 Fig E5 2 in order to ensure that the oil is drained properly IMPORTANT Dispose the drain oil in an ecological manner Refit and tighten drain plug 1 Fig E5 1 Tightening torque 20 to 29 N m or 15 21 ft Ibs Fill up with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler port 3 Fig E5 2 and refit the filler cap Check the correct level between the MINI and MAXI marks on dipstick 2 Fig E5 2 Check for any possible leaks at the drain plug E6 HYDRAULIC OIL DRAIN E7 SUCTION STRAINER FOR HYDRAULIC OIL TANK CLEAN E8 FILTER CAP FOR HYDRAULIC OIL TANK CHANGE Place the lift truck on level ground with the engine stopped and telescope boom retracted and lowered as far as possible Before any intervention thoroughly clean the area IMPORTANT surrounding the drain plugs and the suction cover on the hydraulic tank DRAINING THE OIL Place a container under drain plug 1 Fig E6 1 and unscrew the plug Remove filler cap 2 Fig E6 2 in order to ensure that the oil is drained properly IMPORTANT Dispose the drain oil in an ecological manner CLEANING THE STRAINER Remove suction cover 3 Fig E6 3
50. CTION 2 DESCRIPTION FUEL SYSTEM Check that all fuel lines are secured lf necessary drain the fuel filter and bleed the fuel system of air ELECTRICAL CIRCUIT Check the level and the density of the electrolyte in the battery See B EVERY 50 HOURS SERVICE in SECTION 3 MAINTENANCE Check the components of the electrical system 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 our customers When you order parts or when you require any technical information always specify NOTE For the owner s convenience it is recommended that a note of these numbers is made in the spaces provided at the time of the delivery of the lift truck PLATE MANUFACTURER OF THE LIFT TRUCK Fia A Model Series Serial No Chassis No Year of manufacture For any further technical information regarding your lift truck refer to CHARACTERISTICS in SECTION 2 DESCRIPTION LC ENGINE Fia B Engine No TRANSMISSION FIG C Type MANITOU reference Serial No ANGLE GEAR BOX Fia D Type MANITOU reference Serial No FORKLIFT SAFETY CONTENTS FRONT AXLE F
51. Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose Keep away from power lines XI EMERGENCY STOPPING AND PARKING BRAKE THIS VEHICLE IS EQUIPPED WITH A BACK UP ALARM WHEN BACKING THE ALARM MUST SOUND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE CAUTION NO RIDERS 4h DANGER Stay clear of raised boom unless properly supported Operator may be crushed between falling boom and main frame Failure to comply may result in serious injury or death 4h DANGER Keep machine at least 25 feet from overhead power lines Failure to comply may result in serious injury or death by electrocution 801007 FORKLIFT SAFETY CONTENTS SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of the operator near the hydraulic control lever Frame leveling notice load must be lowered Attachment and Boom Safety 801009 Boom equipped models Location on both sides of the boom nose Important reminders of attachment and boom safety Hydraulic Coupling 234805 Location near the quick 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 and clothing away from rotating fan and belts XII 4h DANGER READ OPER
52. Do not smoke or approach the lift truck with a flame when the fuel tank is open or is being filled Take care not to burn yourself Exhaust radiator engine etc Disconnect the negative cable terminal from the top of the battery before working on the electrical circuit or on the lift truck e g Welding Do not drop metallic items on the battery When carrying out electric welding work on the lift truck connect the negative cable from the equipment directly to the part being welded so as to avoid high tension current passing through the alternator MAINTENANCE The maintenance and the keeping in 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 air filter or with oil water or fuel leaks WARNING Wait for the I C engine to cool before removing the radiator cap Change the filter cartridges See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE C LEVELS Use the recommended lubricants Never use contaminated lubricants Do not fill the fuel tank when the engine is running Only fill up the fuel tank in areas specified for this purpose 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 door and the rear
53. ENSER AND EVAPORATOR COILS H2 CLEANING THE HOTWELL AND THE PRESSURE RELIEF VALVE H3 COLLECTING THE COOLANT TO REPLACE THE FILTER DRIER H4 RELOADING COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES NOTE When opening the evaporator unit remember to replace the cover seal Consult your dealer 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS INTRODUCTION A wide range of attachments studied and perfectly adapted to your lift truck is available and guaranteed by the manufacturer The attachments are delivered with a load chart concerning your lift truck The operators manual and the load chart should be kept in the places provided in the lift truck For standard attachments their use is governed by the instructions contained on this notice Some particular uses require the adaptation of the attachment which is not provided in the price listed options Optional solutions exist consult your dealer HYDRAULIC MOVEMENT CUT OFF Only attachments approved by the manufacturer are to be used on our lift trucks See IMPORTANT TECHNICAL SPECIFICATIONS OF ATTACHMENTS in SECTION 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE The manufacturer s liability will be denied in It is MANDATORY for all ATTACHMENTS WITH SUSPENDED LOAD CAPABILITY Hoist crane IMPORTANT boom crane boom with winch hook etc be used on a fork lift fitte
54. ESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 2 45 3 MAINTENANCE 3 1 FILTERS CARTRIDGES AND BELTS 3 3 LUBRICANTS AND FUEL 3 4 SERVICING SCHEDULE 3 6 A DAILY OR EVERY 10 HOURS SERVICE 3 8 B EVERY 50 HOURS SERVICE 3 11 C EVERY 250 HOURS SERVICE 3 18 D EVERY 500 HOURS SERVICE 3 22 E EVERY 1000 HOURS SERVICE 3 28 F EVERY 2000 HOURS SERVICE 3 33 G OCCASIONAL MAINTENANCE 3 34 EVERY TWO YEARS OPTION AIR CONDITIONING 3 40 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE 4 1 INTRODUCTION 4 3 PICKING UP THE ATTACHMENTS 4 5 XV 1 OPERATING AND SAFETY INSTRUCTIONS FORKLIFT SAFETY CONTENTS ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS ALL MAINTENANCE ON OUR LIFT TRUCKS MUST BE CARRIED OUT USING ORIGINAL PARTS BY ALLOWING NON ORIGINAL PARTS TO BE USED YOU RUN THE RISK Legally of being liable in the event of an accident 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 IMPORTANT may put an end to 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 quarter does so at his own risk COVERING YOURSELF Any user who modifies his lift truck or has it mod
55. FETY 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 closer than 6 ft 1 8m to the nearest ra
56. FORKLIFT SAFETY CONTENTS MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE WACO TX 76712 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Inc Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou na com 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 MLT629T Series A MLT633TLS Series A MLT730TW 120 LS Series A MT732T Series A MT932 Series A OPERATOR S MANUAL THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY USERS 547785AS R 11 10 FORKLIFT SAFETY CONTENTS INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS SAFTETY MESSAGES VII SAFETY DECALS VIII TABLE OF CONTENTS XV R03 04 FORKLIFT SAFETY CONTENTS ROUGH TERRAIN FORKLIFT TRUCK GENEHAL SAFETY STANDAHDS 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 is vital and must be clearly understood by the operator and serviceman Study this manual and the Ro
57. ICLE IS EQUIPPED WITH A SS S di d b in HYDROSTATIC TRANSMISSION DO NOT ATTEMPT A ne TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494918 XIV FORKLIFT SAFETY CONTENTS SAFETY DECALS Boom equipped models Location on the boom coupler WA R N N G near where the retaining shaft is installed THE ATTACHMENT RETAINING SHAFT MUST BE IN PLACE AND SECURED WITH THE SAFETY SNAP PIN BEFORE TRUCK OPERATION Reminder to operator install attachment retaining shaft and safety pin before operations 421016 A Hook Here 24653 EMI 24653 Location at points provided on the forklift where straps or chains may be attached to secure the forklift to a trailer during transport Fork Safety 426641 Mast equipped models Location on the front and back side of the mast s outer rails at eye level 4 required Instructs personnel not to travel beneath or upon the lift truck forks Pinch Point Large 2 5 x 4 5 in 426643 Pinch Point Small 1 5 x 2 75 in 426642 Mast equipped models Location on the front and rear sides of the mast cross bracing WARNING Keep fingers away from the mast KEEP FINGERS crossbracing CLEAR OF CROSSBRACING HAND THROTTLE DANGER 804784 Boom equipped models option Location Near the hand throttle mechanism Reminder to operator set parking brake before operating hand throttle Disengage hand throttle before leaving the forklif
58. IG E Type Serial No MANITOU reference REAR AXLE FIG F Type Serial No MANITOU reference CAB Fic G Type Serial No NIOU BF Boom Fic H VE MANITOU reference Date of manufacture S PLATE MANUFACTURER OF THE ATTACHMENT FIG I Model Serial No Year of manufacture FORKLIFT SAFETY CONTENTS CHARACTERISTICS ENGINE Type MLT 629 730 S rie A MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A MLT 633 730 120 LS POWERSHIFT S rie A MLT 730 Turbo POWERSHIFT S rie A MT 732 932 S rie A MT 732 Turbo S rie A Number of cylinders Number of strokes Suction Injection system Ignition sequence Clearance of rocker valve Cold Inlet Exhaust Capacity Bore Stroke Compression ratio Nominal rating loaded Rating slow unladen Max rating unladen Power ISO TR 14396 Maximum torque ISO TR 14396 Air cleaner COOLING CIRCUIT Type Fan Number of blades Diameter Thermostat Start opening Full opening TRANSMISSION MLT 629 730 S rie A MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A MT 732 932 S rie A MT 732 Turbo S rie A Type Torque converter Gear box Number of forward speeds Number of reverse speeds Gear reverser PERKINS 1004 42 AR 81026 or AR 81334 PERKINS 1004 40T AK 80920 or AK 81335
59. J Right rear indicator FORKLIFT SAFETY CONTENTS 35 REVOLVING LIGHT The revolving light pivots for space saving on the lift truck and can be detached to prevent theft Loosen nut 1 and remove the revolving light Protect mounting 2 with cap 3 36 SERVICE PLATE OPTION 37 STEERING WHEEL REGULATING HANDLE This handle enables the angle and height of the steering wheel to be adjusted Turn handle 1 towards A to loosen and adjust steering wheel Turn handle 1 towards B to lock steering wheel in the position required 38 SPIRIT LEVEL Enables the operator to check that the lift truck is in the horizontal position 39 USE OF TRANSMISSION CUT OFF NOTE In all cases transmission cut off can be effected using the gear lever TRANSMISSION CUT OFF TO BRAKE PEDAL POSITION A e When loading TRANSMISION CUT OFF TO HYDRAULIC CONTROLS LEVER POSITION B e When driving e For inching and continuous stopping and starting Delicate handling In order to optimise hydraulic movements cut off transmission to the hydraulic controls lever e Starting up on a slope DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 1 REAR ELECTRIC SOCKET Enables power supply connection for a trailer or signalling bar Left rear indicator Rear stoplight Left tail light Right tail light 9 9 Earth Right rear indicator 2 BATTERY CUT OFF REVERSE BUZZER ALARM 4 SERVICE PLATE LIGHTING
60. L 150A8 GOODYEAR OPTION 445 70R24 XM47 TL 151G MICHELIN OPTION 500 60 22 5 TWIN 404 12PR TRELLEBORG HYDRAULIC CIRCUIT Type of pump Variable displacement piston pump Capacity 60 cm 23 6 cu in Lifting tilting telescoping attachment circuit Max rating capacity unladen 144 L mn 38 gal mn Pressure 270 Bar 3 915 psi Steering circuit Max rating capacity unladen 144 L mn 38 gal mn Pressure 140 Bar 2 030 psi Braking circuit Max rating capacity unladen 144 L mn 38 gal mn Pressure 40 Bar 580 psi Filtration Return 20 Micron Suction 125 Micron FORKLIFT SAFETY CONTENTS SPECIFICATIONS Level of sound pressure in the driver s cab According to standard prEN 12053 1995 MLT 730 LS Turbo S rie A Travel speed of the lift truck Forward Reverse Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Boom retracted Unladen lifting Load lifting Unladen lowering Load lowering Telescoping motions Lifting boom Unladen extending Laden extending Unladen retracting Laden retracting Reverse tilt time unladen Forward tilt time unladen Lift truck weight with standard attachment Unladen Rated load Axle weight with attached equipment Transport position Front unladen Rated load Rear unladen Rated load Tensible strain at coupling hook Unladen Rated lo
61. NT and C1 2 by one and a half turns having allowed the engine to idle for 30 minutes C2 ALTERNATOR CRANKSHAFT BELT TENSION CHECK ADJUST Open the I C engine compartment Unscrew the fastening screws 1 Fig C2 1 Lay down the protective guard 2 Fig C2 1 Check the belt for signs of wear and cracks and change if necessary See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Check the belt tension between the pulleys of the crankshaft and of the alternator Under a normal pressure exerted with the thumb 45N or 33 lbs the tension should be approximately 10 mm 3 8 Carry out adjustments if necessary Untighten screws 3 Fig C2 2 by two to three thread turns Swivel the alternator assembly so as to obtain the belt tension required Retighten screws 3 Fig C2 2 Put the protective guard back 2 Fig C2 1 If the alternator belt has to be changed check the IMPORTANT tension again after the first 20 hours of operation FORKLIFT SAFETY CONTENTS C3 FUEL FILTER DRAIN Open the engine compartment Visually check for the presence of water in tank 1 Fig C3 and drain if necessary Place a receptacle under the tank and loosen drain plug 2 Fig C3 by two or three turns Allow the diesel fuel to flow out until it is free from impurities and water Tighten the drain plug while the diesel fuel is running out C4 COMPRESSOR BELT TENSION O
62. ON 3 MAINTENANCE Put the gear reverser lever in neutral and release the parking brake CALCULATING THE HEIGHT OF THE DIPPED BEAM h2 e h1 Height of the dipped beam in relation to the ground h2 Height of the adjusted beam Distance between the dipped beam and the white wall G7 EMERGENCY JUMP STARTING Read and follow the instructions carefully If you have any questions ask for assistance from an experienced mechanic or contact your nearest dealer Before attempting a jump start determine the condition of 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 brake and turn off all electrical components on both vehicles Turn the jumper vehicle engine off Connect the jumper cables in
63. OR 30 HANDLE FOR REAR WINDOW OPENING 31 TOOL BOX AND DOCUMENT HOLDER Ensure that the operator s manual is in its place in the document holder FORKLIFT SAFETY CONTENTS 32 TOWING PIN Located at the back of the lift truck this pin makes it possible to couple a trailer The capacity is limited for each lift truck by the authorized total towed weight ATTW the drawbar pull and the maximum 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 NOTE For towing optional solutions exist consult your dealer Check the braking and lighting devices of the trailer and connect them on the lift truck Reduce the speed of the lift truck Consult the Highway Code currently in force in your country AA WARNING Before towing trailers ensure that the clip 1 is fully engaged in the towing pin 2 33 FRONT LIGHTS A Left front indicator B Left front dipped headlight C Left front main beam D Left front sidelight E Right front indicator F Right front dipped headlight G Right front main beam H Right front sidelight 34 REAR LIGHTS A Left rear indicator B Left rear stoplight C Left tail light D Left rear reverse light E Left rear fog light F Right rear fog light G Right rear reverse light H Right tail light Right rear stoplight
64. PTION AIR C ONDITIONING CHECK ADJUST Open the engine compartment Unscrew the fastening screws 1 Fig C4 1 Lay down the protective guard 2 Fig C4 1 Check the belt for signs of wear and cracks and change if necessary Check the belt tension between the pulleys of the crankshaft and of the compressor Under a normal pressure exerted with the thumb 45 N or 33 lbs the tension should be approximately 10 mm 3 8 Carry out adjustments if necessary Untighten screws 3 Fig C4 2 by two to three thread turns Swivel the compressor assembly so as to obtain the belt tension required Retighten screws 3 Fig C4 2 Put the protective guard back 2 Fig C4 1 If the compressor belt has to be changed check the IMPORTANT tension again after the first 20 hours of operation C5 ANGLE GEAR BOX OIL LEVEL CHECK Place the lift truck on level ground with the engine stopped Remove level plug 1 Fig C5 Wipe the dipstick and check the correct level between the MINI and MAXI marks If necessary add oil See E5 ANGLE GEAR BOX OIL in SECTION 3 MAINTENANCE FORKLIFT SAFETY CONTENTS C6 PARKING BRAKE CHECK ADJUST Place the lift truck on a slope less than 15 with the rated load in the transport position Check the tightening adjustment by locking the parking brake in position A Fig C6 The adjustment is correct when the lift truck is held stationary on a
65. S 7 LIGHT SWITCH HORN AND INDICATOR SWITCH 8 IGNITION SWITCH 9 BRAKING OIL TANK AND WINDSCREEN WASHER ACCESS PANEL 10 BRAKING OIL TANK 11 WINDSCREEN WASHER TANK 12 FUSES AND RELAY ACCESS PANEL 13 FUSE AND RELAY PLATE 14 ROOF LIGHT 15 ACCELERATOR PEDAL 16 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF 17 GEAR LEVER AND TRANSMISSION CUT OFF 18 FORWARD REVERSE LEVER 19 PARKING BRAKE LEVER 20 STEERING SELECTION LEVER 21 HYDRAULIC CONTROLS AND TRANSMISSION CUT OFF 22 LOAD CHARTS FILE 23 HEATER CONTROL 23 AIR CONDITIONING CONTROLS OPTION AIR CONDITIONING 24 CAB FILTER VENTILATORS 25 WINDSCREEN DEMIST VENTS 26 HEATING VENTS 27 DOOR LOCK 28 LOCKING HANDLE FOR UPPER HALF DOOR 29 RELEASING BUTTON FOR UPPER HALF DOOR 30 HANDLE FOR REAR WINDOW OPENING 31 TOOL BOX AND DOCUMENT HOLDER 32 TOWING PIN 33 FRONT LIGHTS 34 REAR LIGHTS 35 FLASHING LIGHT 36 SERVICE PLATE OPTION 37 STEERING WHEEL REGULATING HANDLE 38 SPIRIT LEVEL 39 USE OF TRANSMISSION CUT OFF NOTE All the terms such as RIGHT LEFT FRONT REAR are meant for an observer seated on driver s seat and looking in front of him FORKLIFT SAFETY CONTENTS 1 DRIVER S SEAT STANDARD DESIGNED FOR MAXIMUM COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS WEIGHT ADJUSTMENT FIG A It is advised that the weight be adjusted when the driver is not sitting in the cab Refer to graduation 1 of the se
66. SIGKEIT 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 l Usar IMPERATIVAMENTE de aceite mineral Utilizzare IMPERATIVAMENTE olio minerale LHMS 234800 n 234800 XIII FORKLIFT SAFETY CONTENTS SAFETY DECALS Hydraulic Oil 234798 or 76573 Location on the hydraulic tank or filler cap le N 234798 Identifies the hydraulic reservoir tank or filler cap Hydraulic Oil 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAULIC OIL HYDRAULIK L ACEITE HIDRAULICO OLIO IDRAULICO Identifies the hydraulic reservoir tank N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap Indicates required minimum to maximum anti freeze protection 220F to 40 F 30 C 40 C 22 F 40 F Diesel Fuel 161101 Location on the fuel tank near the filler cap DI E S E L Identifies the fuel tank and use of diesel fuel No Step 496735 NOTICE Location varies 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 E THIS VEH
67. T Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position FORKLIFT SAFETY CONTENTS F HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 S rie A MT 732 932 S rie A MT 732 Turbo S rie A TAKING UP AN ATTACHMENT Ensure that the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the rods on the locking cylinder are retracted Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HYDRAULIC LOCKING AND CONNECTING THE ATTACHMENT Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Push the lever of the distributor 1 Fig E forwards in order to completely lock the attachment on the carriage Stop the engine Remove the pressure of the attachment hydraulic circuit by using the lever of the distributor 1 Fig E Connect the rapid connectors according to the logic of the attachment s hydraulic movements Make sure that
68. T 732 Turbo S rie A G HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A FORKLIFT SAFETY CONTENTS A ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE TAKING UP AN ATTACHMENT Ensure that the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the locking pin and the clip are in position in the bracket Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HAND LOCKING Take the locking pin and the clip on the bracket Fig A and lock the attachment Fig D Do not forget to refit the clip HAND RELEASING Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back the locking pin and the clip in the bracket Fig A LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position FORKLIFT SAFETY CONTENTS B ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING
69. TOR SWITCH The switch controls the visual and sound alarms A All lights are off the direction indicators do not flash B The right hand direction indicators flash C The left hand direction indicators flash D The sidelights and the rear lights are on E The dipped headlights and the rear lights are on F The main beam headlights and the rear lights are on G Headlight signal Pressing the switch sounds the horn NOTE The positions D E F G can be carried out without the ignition being on 8 IGNITION SWITCH The key switch has five positions P Ignition off parking position O Ignition switched off and engine stopped Ignition on Il Heating Ill The engine starts return to position i as soon as the key is released 2 35 FORKLIFT SAFETY CONTENTS 9 BRAKING OIL TANK AND WINDSCREEN WASHER ACCESS PANEL Loosen screw 1 and lift up the brake fluid and windscreen washer access panel 10 BRAKING OIL TANK See B EVERY 50 HOURS SERVICE in SECTION 3 MAINTENANCE 11 WINDSCREEN WASHER TANK See B EVERY 50 HOURS SERVICE in SECTION 3 MAINTENANCE 12 FUSE AND RELAY ACCESS PANEL Lift up the fuse and relay access panel 1 13 FUSE AND RELAY PLATE A sticker on the inside of the access panel gives a clear display of the use of the components described below KO OPTION Air conditioning K1 OPTION Transmission cut off relay K2 Transmi
70. TROLYTE LEVEL CHECK Check the electrolyte level in each cell of the battery If the lift truck is working in a high temperature environment check the level more frequently than every 50 hours service Open the engine compartment Open battery cowl 1 Fig B10 1 and hold it open with locking device 2 Fig B10 1 Remove caps 3 Fig B10 2 from each cell of the battery The level is correct when it is 1 5 cm 1 2 in above the top of the plates in the battery If necessary top up the cells with clean distilled water that has been stored in a glass container Clean and dry caps 3 Fig B10 2 and refit in place and screw in firmly Check the terminal connections and lightly smear them with petroleum jelly to prevent the formation of corrosion Close the battery cowl Handling and servicing a battery can be dangerous take the following precautions Wear protective goggles Keep the battery horizontal Never smoke or work near a naked flame Work in a well ventilated area n 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 B11 FRONT AND REAR WHEELS REDUCERS PIVOTS GREASE Clean and lubricate the points 1 8 lubricators Fig B11 with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE and remove the surplus of grease B12 HEAR AXLE OSCILLATION GREASE Clean and lubricate
71. TY Les iod GROUND Y AT MFH B p x INCHES TIRE PRESSURE FRONT PSI TIRE PRESSURE REAR CAPACITY WITH ATTACHMENTS LISTED ABOVE ARE WITH FORK UPRIGHTS VERTICAL FOR OTHER CAPACITIES CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME MANUFACTURED IN TIRE PRESSURE FRONT 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 IN 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 CAUTION 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 MLT 629 Turbo S rie A 2 6and2 8 MLT 633 LS Turbo S rie A 2 6 and2 12 MLT 730 LS Turbo S rie A 2 6and2 16 MT 732 Turbo S rie A 2 6and2 20 MT 932 S rie A 2 6and2 24 DIMENSIONS AND LOAD CHART MLT 629 LS Turbo S rie A 2 10 MLT 633 LS Turbo S rie A 2 14 MLT 730 LS Turbo S rie A 2 18 MT 732 Turbo S rie A 2 22 MT 932 S rie A 2 26 INSTRUMENTS AND CONTROLS 2 28 D
72. Type Parking brake Type ELECTRIC CIRCUIT Earth Battery Alternator Type Tension regulator Starter Type TURNER POWERTRAIN SYSTEMS HURTH 45 Epicyclic HURTH Epicyclic Foot pedal Hydraulic servo brake applied on the front and rear wheels Multidisc brake immersed in oil Mechanical hand lever applied on the output shaft of transmission Disc brake Negative 12V 105 Ah 680 A EN 12V 65A Magneti Marelli A127 Incorporated into the alternator 12 V Magneti Marelli M127 FORKLIFT SAFETY CONTENTS CHARACTERISTICS MLT 629 Turbo S rie A FRONT AND REAR TIRES 17 5LR24 XM27 TL 145A8 STANDARD OPTION 14 9x24 T35 Stabilarge 18PR 3 4 Bar DUNLOP 49 psi 400 70 20 T37 150B TL 14PR 3 25 Bar DUNLOP 47 psi 440 70 24 T37 147BTL 2 8 Bar DUNLOP 41 psi OPTION 15 5 80 24 SGI TL 12PR GOODYEAR 460 70 R24 IT520 TL 150A8 GOODYEAR 445 70R24 IT510 151G GOODYEAR OPTION 15 5R25 XHA 2 75 Bar MICHELIN 40 psi 1200R20 X MINE D2 5 Bar MICHELIN 73 psi OPTION 500 60 22 5 TWIN 404 12PR TRELLEBORG HYDRAULIC CIRCUIT Type of pump Capacity Lifting tilting telescoping attachment circuit Max rating capacity unladen Pressure Steering circuit Max rating capacity unladen Pressure Braking circuit Max rating capacity unladen Pressure Filtration Return Suction IMPORTANT When changing or replacing the tires and wheels use only the manufac
73. ad Break out force with bucket According to standard ISO 8313 79 5 dBA 25 km h 15 5 mph 25 km h 15 5 mph 6900 mm 271 65 in 3000 kg 6 613 8 Ib 610 mm 24 in 72 kg 158 7 Ib 6 45 41 3 m mn 6 8 S 39 3 m mn 4 76 56 7 4 96 54 4 m mn 6 2 6 26 4 m mn 6 55 25 4 m mn 46s 35 9 m mn 4 56 36 7 m mn 2b5s 57 5 s 2 25 65 2 5 7140 kg 15 741 Ib 10140 kg 22 354 Ib 3330 kg 8640 kg 3810 kg 1500 kg 7 341 Ib 19 047 Ib 8 399 Ib 3 307 Ib 5500 daN 12 364 ft Ib 8600 daN 19 332 ft Ib 5600 daN 12 588 ft Ib ND ND M DIMENSIONS AND LOAD CHART MLT 730 120 LS Turbo S rie A FORKLIFT SAFETY CONTENTS ER D EM ER ES MLT 730 120 LS Turbo S rie A 1200 mm 47 24 in 2560 mm 100 78 in 1392 mm 54 80 in 1297 mm 51 06 in 4712 mm 185 51 in 4617 mm 181 77 in 3920 mm 154 33 in 5912 mm 232 75 in 1850 mm 72 83 in 1850 mm 72 83 in 455 mm 17 91 in 440 mm 17 32 in 440 mm 17 32 in 760 mm 29 92 in 865 mm 34 05 in 1260 mm 49 60 in 45 mm 1 77 in 1720 mm 67 71 in 125 mm 4 92 in 47 5 59 3475 mm 136 81 in 7572 mm 165 94 in 4215 mm 165 94 in 2300 mm 90 55 in 2490 mm 98 03 in 4825 mm 189 96 in 1205 mm 47 44 in 3 00 mm 145 66 in 2305 mm 90 74 in 12 3 133 8
74. and articulation rings GS ATTACHMENTS Forks wear QU D v ID Attachment carriage Ce D Condition of attachments ur Ge aw LIFT TRUCK Tow the lift truck Sling the lift truck Transport the lift truck on a platform 9 Every 10 hours during the first 50 hours then once at 250 hours Consult your dealer 3 7 FORKLIFT SAFETY CONTENTS A DAILY OR EVERY 10 HOURS SERVICE A1 ENGINE OIL LEVEL CHECK Place the lift truck on level ground with the engine stopped and let the oil drain into the sump Open the engine compartment Remove the dipstick 1 Fig A1 Clean the dipstick and check the level between the two MAXI and MINI notches f necessary add oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by the filler port 2 Fig A1 A2 COOLING LIQUID LEVEL CHECK Place the lift truck on level ground with the engine stopped and allow the engine to cool Open the engine compartment Slowly turn the cap of the radiator 1 Fig A2 counterclockwise up to the safety stop Allow the pressure and vapour to escape Press down and turn the cap so as to release the cap If necessary add cooling liquid See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE in order to top up the level t
75. ar hydraulic predispositions Option availability varies according to model country FORKLIFT SAFETY CONTENTS 6 SWITCH AND LAMPS FOR ALIGNMENT OF THE WHEELS Before selecting one of the three possible steering positions bring the 4 wheels into alignment i e in the straight ahead position A GREEN LAMPS FOR ALIGNMENT OF THE WHEELS These lamps come on to indicate the alignment of the wheels in relation to the axle of the lift truck The lamp A1 for the front wheels and the lamp A2 for the rear wheels SWITCH FOR ALIGNMENT OF THE WHEELS This switch enables the use or not of the device for alignment of the wheels The indicator light indicates its use WHEEL ALIGNMENT PROCEDURE Connect the switch Signal light ON Shift the distributor control lever for steering selection 1 in position B 4 wheel steering Turn the steering wheel and bring the rear wheels into alignment until the lamp A2 is on Shift the distributor control lever for steering selection 1 in position A Highway traffic Turn the steering wheel and bring the front wheels into alignment until the lamp A1 is on Before driving on roads it is necessary to check the alignment of the rear wheels and to drive in front wheel steer During prolonged use of the front wheel steering mode periodically check the alignment of the rear tires using the green lamps WARNING In case of anomalies consult your dealer 7 LIGHT SWITCH HORN AND INDICA
76. at Turn handle 2 according to the driver s weight NOTE To avoid any health problems it is recommended that the weight should be checked and adjusted before starting up the lift truck SEAT HEIGHT ADJUSTMENT FIG B Raise the seat to the desired position until you hear the ratchet click If you raise the seat above the last notch Stop the seat drops down to the lowest position SEAT BACK REST ANGLE ADJUSTMENT FIG C The back rest angle of the seat may be adjusted to suit the individual Press the left hand button while pushing on the seat or relaxing pressure on the seat to find a comfortable position SEAT DEPTH ADJUSTMENT FIG D The depth of the seat may be adjusted to suit the individual Press the right hand button while raising or lowering the seat to find the desired position EXTENDING THE HEAD REST FIG E The height of the back rest can be adjusted by pulling it upwards The notches will click up to the stop The head rest can be removed by applying sufficient pressure to pull it off the stop LUMBAR ADJUSTMENT FIG F This increases the comfort of the seat and the driver s freedom of movement Turn the handle either left or right to adjust the height or depth of the lumbar support FORKLIFT SAFETY CONTENTS ADJUSTMENT OF THE ANGLE OF THE BACK REST FIG G Support the back rest pull the lever and position the back rest to find the desired position If you do not support the back res
77. ate an effective operator training program centered around user company s policies operating condi tions and rough terrain forklift trucks The program should be presented completely to all new operators and not be condensed for those claiming previous experience 3 Information on operator training is available from several sources including rough terrain forklift truck man ufacturers users government agencies etc 4 An operator training program should consist of the following a careful selection of the operator considering physical qualifications job attitude and aptitude b emphasis on safety of stock equipment operator and other personnel C citing of rules and why they were formulated d basic fundamentals of rough terrain forklift truck and component design as related to safety e g in Ib N m loading mechanical limitations center of gravity stability etc e introduction to equipment control locations and functions Explain how they work when used properly and problems when used improperly f supervise practice on operating course remote from normal activity and designed to simulate actual operations e g lumber stacking elevating shingles to the roof etc g oral written and operational performance tests and evaluations during and at completion of the course h refresher courses which may be condensed versions of the primary course and periodic on job operator evaluation i understanding of nam
78. be changed for every two changes of the air filter cartridge 3 28 FORKLIFT SAFETY CONTENTS E3 TRANSMISSION OIL DRAIN E4 TRANSMISSION HOUSING STRAINER CLEAN Place the lift truck on level ground with the I C engine stopped the transmission oil still warm DRAINING THE OIL Place a container under drain plug 1 Fig E3 1 and under cover 2 Fig E3 2 and unscrew the drain plug Remove cover plate 3 Fig E3 3 Remove dipstick 4 Fig E3 4 and unscrew filling plug 5 Fig E3 4 in order to ensure that the oil is drained properly IMPORTANT Dispose the drain oil in an ecological manner CLEANING THE STRAINER Remove cover 2 Fig E3 2 and set aside the O ring joint and sealing washer Allow the rest of the oil to drain away Remove and clean the strainer using a compressed air jet Clean the magnetic section on the plate Refit the assembly and tighten up plate 2 Fig E3 2 Tightening torque 18 to 31 N m or 13 22 ft lbs FILLING UP THE OIL Refit and tighten drain plug 1 Fig E3 1 Tightening torque 34 to 54 N m or 25 40 ft lbs Fill up with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler port 5 Fig E3 4 and refit the plug Check the level with the dipstick 4 Fig E3 4 See A5 TRANSMISSION OIL LEVEL in SECTION 3 MAINTENANCE Check any possible leaks from the drain plug or cover Put back the cover plate 3 Fig E3 3 FORKLIFT SAFETY
79. 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 tilt is provided carefully tilt the load backward to stabilize the load Caution should be used in tilting backward with high or segmented loads 48 Use extreme care when tilting load forward or backward particularly when high tiering Do not tilt forward with load engaging means elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load 49 The handling of suspended loads by means of a crane arm boom or other device can introduce dynam ic forces affecting the stability of a rough terrain forklift truck Grades and sudden starts stops and turns can cause the load to swing and create a hazard if not externally stabilized When handling suspended loads a do not exceed the truck ma
80. c handler as equipped for handling suspended loads The weight of the rigging must be included as part of the load 2 During transport DO NOT raise the load more than 12 inches 305 mm above the ground or raise the boom more than 45 degrees 3 Only lift the load vertically NEVER drag it horizontally 4 Use multiple pickup points on the load when possible Use taglines to restrain the load from swinging and rotating 5 Start travel turn and stop SLOWLY to prevent the load from swinging DO NOT exceed walking speed 6 Inspect rigging before use Rigging must be in good condition and in the U S comply with OSHA regulation 1910 184 Slings or 1926 251 Rigging equipment for material handling 7 Rigging equipment attached to the forks must be secured such that it cannot move either sideways fore and aft The load center must not exceed 24 inches 610 mm 8 DO NOT lift the load with anyone on the load rigging or lift equipment and NEVER lift the load over persomnel 9 Beware of the wind which can cause suspended loads to swing even with taglines 10 DO NOT attempt to use frame leveling to compensate for load swing U S OSHA regulations effective November 8 2010 29 CFR Part 1926 Subpart CC Cranes and Derricks in Construction include requirements for employers that use powered industrial trucks forklifts configured to hoist by means of a winch or hook and move suspended loads horizontally In
81. ces should you pick up a load if the lift truck is not in a horizontal position See paragraph G HORIZONTAL POSITION OF THE LIFT TRUCK 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 maneuvering gently and carefully See E VISIBILITY in chapter HANDLING INSTRUCTIONS for visibility of the road Be constantly aware of the distance between the forklift and pile using the shortest possible length of boom to place the forks under the load Fig G Bring the forks to stop in front of the load Fig H Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 and incline the carriage 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 in so doing If possible lower the load without shifting the lift truck Lift the boom 1 to release the load retract 2 and lower the boom 3 to bring the load Ms ine transport position Fig J If this is not possible back the lift truck up Maneuvering very gently and carefully See E VISIBILITY in chapter HANDLING INSTRUCTIONS for visibility of the road back up the lift truck 1 to release the load retract 2 and lower the boom 3 to bring the load into the transport position Fig K
82. cording to model country FORKLIFT SAFETY CONTENTS 17 DUAL EFFECT HYDRAULIC TOWING HOOK Raise the hydraulic towing hook to free the nut on hook 1 Fig A by pulling the lever on distributor 2 Fig B backwards or by pressing the top of switch 3 Fig C depending on the model of lift truck Pull handle 4 Fig D maintain this position and push lever 2 Fig B forwards or press the bottom of switch 3 Fig C depending on the model of lift truck to lower the towing hook Release handle 4 Fig D Hook up or unhook the trailer Raise the towing hook by pulling the lever on distributor 2 Fig B backwards or by pressing the top of switch 3 Fig C depending on the model of lift truck and then lower the hook again to check that the locking axis is correctly on the nut of hook 1 Fig A WARNING When unhooking ensure that the trailer is supported independently MLT 730 120 LS S rie A MLT 629T sri 629Turbo MT732 932 S rie A MLT 633 LS Turbo S rie A 18 DUAL EFFECT HYDRAULIC TOWING HOOK A SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION Switch 1 controls the towing hook or a rear hydraulic predisposition Option availability varies according to model country FORKLIFT SAFETY CONTENTS 19 SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION Switch 1 controls one or the other of the rear hydra
83. d remove cover 1 Fig D3 1 Gently remove the cartridge 2 Fig D3 1 taking care to avoid spilling the dust Leave the safety cartridge in place The following parts must be cleaned with a damp clean lint free cloth The inside of the filter and cover The inside of the filter inlet hose The gasket surfaces in the filter and in the cover Check pipes and connections between the air filter and the I C engine and the connection and state of the clogging indicator on the filter Before mounting check the state of the new cartridge See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Introduce the cartridge into the filter axis and push it in pressing the edges and not the middle Reassemble the cover guiding the valve Fig D3 2 D4 FUEL FILTER CARTRIDGE CHANGE Open the I C engine compartment Carefully clean the exterior of the filter and bracket to prevent the dust from entering the system Place a receptacle under the tank and empty using drain plug 1 Fig D4 Unscrew locking screw 2 Fig D4 Remove housing 3 Fig D4 and discard cartridge 4 Fig D4 as well as the seals of the cartridge Clean the inside of the filter head and the housing using a brush immersed in clean diesel oil Refit the assembly with a new cartridge and new seals See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE If necessary bleed the fuel circuit See G1 FUEL SYSTEM in SECTION 3
84. d with an AUTOMATIC case of modification or attachment adaptation performed without permission Certain attachments may when the boom is lowered and retracted or if tilt is activated in the full A WARNING forward or reverse tilt direction come into contact with the front tires and cause damage to them TO ELIMINATE THIS RISK KEEP THE BOOM AND ATTACHMENT EXTENDED SUFFICIENTLY TO AVOID SUCH CONTACT WITH THE TIRES Maximum loads are defined by the capacity of the lift truck and the attachment s weight and center of gravity In the event of the attachment having less capacity than the lift truck never exceed the attachment s limit FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS PICKING UP THE ATTACHMENTS A ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE B ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 S rie A MT 732 932 S rie A MT 732 Turbo S rie A C ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A D HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE MLT 629 730 S rie A MT 732 932 S rie A MT 732 Turbo S rie A E HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A F HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 S rie A MT 732 932 S rie A M
85. dition of cylinders leakage shafts er lt r Hydraulic circuit pressures Cc C Hydraulic circuit outputs C C Hydraulic oil tank Nr Nr FORKLIFT SAFETY CONTENTS A AJUST N CLEAN 1 year 1 year C CHECK BLEED 2000 4000 D DESCALE R CHANGE hours hours G GREASE V DRAIN MONIS BRAKE Brake oil level C C C C C C Parking brake A A A A A Parking brake mechanism G G G G Brake tne na x eee Brake CIFCUIE AR po RE Brake circuit pressure ES m m DIE LC Meee hae eee eee Windscreen washer liquid level C C C C C C ae G G G G G G Cab ventilation filter OPTION Air conditioning N R R R R R Heating block non return valve N N N N N Cab ventilation filter N N N N Seat Dell users doe una EE NEE Dd unes C C C Condition of the rear view mirrors Cc c C jin san OPTION Air conditioning ELECTRICITY Battery electrolyte level C C C C C C Battery electrolyte densi
86. drain plug 1 Fig E10 in position A Place a container under the drain plug and unscrew the plug Let the oil drain fully Place the drain port in position B i e in a level position Fill up with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by level port 1 Fig E10 The level is correct when the oil level is flush with the edge of the hole Refit and tighten the drain plug 1 Fig E10 Tightening torque 34 to 49 N m or 25 36 ft Ibs Repeat this operation on each wheel reducer FORKLIFT SAFETY CONTENTS F EVERY 2000 HOURS SERVICE Carry out the operations described previously as well as the following operations F1 COOLING LIQUID DRAIN These operations are to be carried out if necessary or every two years at the beginning of winter Place the lift truck on level ground with the I C engine stopped and cold DRAINING THE LIQUID Open the engine compartment Remove the shroud 1 Fig F1 1 Place a container under drain plug 2 Fig F1 2 of the radiator and drain plug 3 Fig F1 3 of the engine block and unscrew the plugs Remove filler cap 4 Fig F1 4 of the radiator Let the cooling circuit drain entirely while ensuring that the ports do not get clogged Check the condition of the hoses as well as the fastening devices and change the hoses if necessary Rinse the circuit with clean water and use a cleaning agent if necessary Disconnect hoses 5
87. e reduce this interval to 10 working hours or every day Clean and lubricate the following points with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE and remove the surplus of grease 1 Lubricators of the boom axle 2 lubricators Fig B4 1 2 Lubricators of the carriage axle 2 lubricators Fig B4 2 3 Lubricator of the tilt cylinder head axle 1 lubricator Fig B4 3 4 Lubricator of the tilt cylinder foot axle 1 lubricator Fig B4 4 5 Lubricators of the carriage connecting rod axle 2 lubricators Fig B4 5 Except MT 732 932 S rie A MT 732 Turbo S rie A 6 Lubricator of the lifting cylinder foot axle 1 lubricator Fig B4 6 7 Lubricator of the lifting cylinder head axle 1 lubricator Fig B4 7 8 Lubricator of the compensation cylinder foot axle 1 lubricator Fig B4 6 9 Lubricator of the compensation cylinder head axle 1 lubricator Fig B4 8 FORKLIFT SAFETY CONTENTS B5 HYDRAULIC OIL LEVEL CHECK Place the lift truck on level ground with the I C engine stopped and the boom retracted and lowered as far as possible Refer to gauge 1 Fig B5 1 The oil level is correct when it is at the level of the red point f necessary add oil See LUBRICANTS AND FUEL in SECTION MAINTENANCE Remove cap 2 Fig B5 2 Add oil by filler port 3 Fig B5 2 Clean the oil filler tube before adding fluid Always use IMPORTANT a clean funnel wh
88. e bleed screw NOTE If the lever on the feed pump is in the maximum raised position turn the crankshaft by one turn Tighten the bleed screw while the diesel fuel is flowing out BLEEDING THE HEATER PLUG Loosen connection 3 Fig G1 3 on the heater plug Activate feed pump 2 Fig G1 2 until the diesel fuel is flowing out free from air at the connection Tighten the connection while the diesel fuel is flowing out Immobilize the heater plug with a spanner before IMPORTANT loosening connection Fig G 1 3 BLEEDING THE INJECTION PUMP Loosen connection 4 Fig G1 4 of the low pressure fuel return circuit on the regulator housing Activate feed pump 2 Fig G1 2 until the diesel fuel is flowing out free from air at the connection Tighten the connection while the diesel fuel is flowing out E B i 5 y A 1 Ce tll er 4 k i d DEI tripi De TS 4 oe PL WE e a Gate Ke ks L eh KE ef L Rr 4 T ge EE B E Ap y m T 2 ur MT E Le T FORKLIFT SAFETY CONTENTS BLEEDING THE INJECTORS Loosen high pressure connectors 5 Fig G1 5 of two of the injectors Activate the starter until the diesel fuel flows out free of air at connections 5 Fig G1 5 Tighten the connection while the diesel fuel is flowing out Tightening torque 22 or 16 ft lbs The engine is then
89. e forward reverse lever in neutral Apply the parking brake Place the gear lever in neutral As model of lift truck Retract entirely the boom 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 the door rear window and hood Aw ARNING Before leaving your driver s cabin ensure that you have carried out all operations for stopping the lift truck for your safety and the safety of others F DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY SAFETY INSTRUCTIONS When driving a lift truck on roads open to public traffic observe the provisions of the Highway Code Lift truck drivers driving on the public highway must abide by the general provisions relative to highway traffic The lift truck must conform to the provisions of the Highway Code If necessary optional solutions exist consult your dealer A CAUTION Transport of loads on the public highway is forbidden and attachments mounted on the lift truck must be fitted with equipment in accordance with regulations or removed 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 Control the alignment of the wheels and select
90. e 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 components Have it repaired by authorized service personnel Learn
91. e the lift truck is in motion The simultaneous use of two lift trucks to handle heavy or bulky loads is a dangerous maneuver requiring specific precautions 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 When handling drive in 3 gear and reduce to 2 in cramped spaces 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 boom 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 WARNING Do not change direction sharply and at high speed Y DANGER In the event of the lift truck overturning do not try to leave the cabin during the incident YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN Apply the parking brake when lifting or depositing a difficult load or when on an incline Do not stop the lift truck with the load in an elevated position Do not leave a laden lift truck with the parking brake applied on an incline which exceeds 15 E VISIBILITY Constantly keep clear visibility of the road either direct view looking backwards when reversing or indirect view using the panoramic
92. en filling Put the cap back Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank B6 BRAKE OIL LEVEL CHECK Place the lift truck on level ground Loosen screw 1 Fig B6 1 and remove the access panel for braking oil tank and windscreen washer tank 2 Fig B6 1 The level is correct when it is at the MAXI level on the tank f necessary add oil See LUBRICANTS AND FUEL in SECTION MAINTENANCE by the filler port 3 Fig B6 2 If the braking oil level is abnormally low consult your IMPORTANT S a d FORKLIFT SAFETY CONTENTS B7 WINDSCREEN WASHER LIQUID LEVEL CHECK Loosen screw 1 Fig B7 1 and remove the access panel for braking oil tank and windscreen washer tank 2 Fig B7 1 Check visually the level If necessary add windscreen washer liquid See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler port 3 Fig B7 2 B8 CAB DOOR GREASE Clean and lubricate the points 1 4 lubricators Fig B8 with grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE and remove the surplus of grease B9 CAB VENTILATION FILTER OPTION AIR C ONDITIONING CLEAN Lift up protective casing 1 Fig B9 Lift out cabin ventilation filter 2 Fig B9 Clean the filter with a compressed air jet Check its condition and change if necessary Refit the filter and protective casing FORKLIFT SAFETY CONTENTS B10 BATTERY ELEC
93. eplate 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 SAFETY STANDARDS cont B GENERAL
94. eral 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 any handling work check the points above and ensure that the lift truck is completely horizontal 1 15 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK MAINTENANCE INSTRUCTIONS A GENERAL Read the operator s manual carefully and ensure you understand it Stop the engine when an intervention is necessary Wear clothes suitable for the maintenance of the lift truck avoid wearing jewelry and loose clothes Tie and protect your hair if necessary Ensure the area is sufficiently ventilated before starting the lift truck Make sure that the disposal of process materials and of spare parts is carried out in total safety IMPORTANT and in a ecological way Carry out all repairs immediately even if the repairs concerned are minor Repair all leaks immediately even if the leak concerned is minor Do not attempt to loosen unions hoses or any hydraulic component with the circuit under pressure The handling and removal of the balancing valves which may be fitted to the cylinders of your lift truck can be dangerous A balancing valve must only be removed when the cylinder concerned is WARNING 8 y at rest the hyaraulic circuit is depressurised This operation can only be carried out by authorised staff
95. gine run at idle Check all control instruments immediately after starting up when the I C engine is warm and at regular intervals during use so as to quickly detect any faults and to be able to correct them without any delay If an instrument does not show the correct display stop the engine and immediately carry out the necessary 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 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 Never leave the engine on when the lift truck is unattended Look in the direction you are travelling and always keep clear visibility of the road Use the left
96. 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 disconnect fittings on the attachment system are clean and protected Before each change of an attachment with hydraulic function in order to avoid damaging the the quick disconnect fittings Place the attachment in the closed position flat on the ground For unstable attachments IMPORTANT ensure they are secured using wedges Switch off the I C engine Remove pressure from the attachment hydraulic system using the hyaraulic controls C ENVIRONMENT 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 aerial lines ensure that the safety distance is sufficient between the working area of the lift truck and the aerial 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 A WARNING safety rules on the site conform to the local regulations in force regarding all types of work carried out close to power cables Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load When using the lift truck on a slope before raising the boom ensure t
97. hat the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the rods on the locking cylinder are retracted Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HYDRAULIC LOCKING AND CONNECTING THE ATTACHMENT Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Press button 1 Fig E on the distributor lever to completely lock the attachment to the carriage Stop the engine and keep the ignition on the lift truck Remove the pressure of the hydraulic circuit by pressing buttons 1 and 2 Fig E on the distributor lever 4 or 5 times Connect the rapid connectors according to the logic of the attachment s hydraulic movements Make sure that the rapid connectors are clean and IMPORTANT protect the holes which are not used with the caps provided Close the valve in position B Fig D that is to say the hydraulic circuit of the attachment locking closed Always close the valve in position B Fig D after the CAUTION locking of the attachme
98. hat the ground is horizontal However lift trucks fitted with a slope corrector and or stabilizers can work on a steeper transverse slope providing this slope can be corrected See G HORIZONTAL POSITION OF THE LIFT TRUCK in next chapter LOAD HANDLING Travelling on a longitudinal slope e Drive and brake gently Moving without load Forks or attachment facing downhill Moving with load Forks or attachment facing uphill Ensure that scaffolding loading platform or pile are capable of bearing the weight Ensure the stability solidity of the ground before depositing A load 1 1 11 FORKLIFT SAFETY CONTENTS D HANDLING Always consider safety and only transport balanced and correctly secured loads to avoid any risk of tipping Fully engage forks under the load and move it in the transport position The forks 300 mm 12 in from the ground the boom retracted to the maximum and the carriage sloping backwards For obvious reasons regarding the lift truck s stability and clear visibility of the surrounding environment only move the lift truck when the boom is in the transport position Do not maneuver the lift truck with the boom in the raised position unless under exceptional circumstances and then with extreme caution at very low speed and using gentle braking Ensure that visibility is adequate and get another person to guide you along if necessary Never shift the position of the load whil
99. he reverse lights and the sound alarm on reverse motion As model of lift truck indicate that the lift truck is running in reverse motion 19 PARKING BRAKE LEVER To prevent accidental loosening or release the lever is fitted with safety locking To apply the parking brake pull the lever backwards Position A To loosen the parking brake release and push the lever forwards Position B FORKLIFT SAFETY CONTENTS 20 STEERING SELECTION LEVER HIGHWAY 4 WHEEL Before selecting one of the three possible steering positions bring the 4 wheels into alignment i e in the straight ahead position See Item 6 SWITCH AND LAMPS FOR ALIGNMENT OF THE WHEELS in SECTION 2 DESCRIPTION A Front wheel steer Highway traffic B Front and rear wheels steer in opposite direction 4 wheel steer C Front and rear wheels steer in the same direction Crab steer 21 HYDRAULIC CONTROLS AND TRANSMISSION CUT OFF Do not attempt to alter the hydraulic system pressure WARNING by interfering with the pressure regulating valve In the event of suspected malfunction contact your dealer ANY ALTERATION TO THE PRESSURE REGULATING VALVE MAY RENDER THE WARRANTY NULL AND VOID MLT MODELS LEVER A Controls the lifting of the load and the tilt of the carriage The lever backwards when lifting The lever forwards when lowering The lever to the left for reverse tilt The lever to the right for forward tilt BUTTON B
100. hine Nr 169427 From machine Nr 169428 238795 11 Cab ventilation filter Without air conditioning 11 Cab ventilation filter With air conditioning 12 Cyclonic pre filter In series from machine Nr 173893 224713 13 Automatic vacuum cleaning pre filter OPTION 226611 14 Turbo II pre filter Kit OPTION 800608 See SERVICING SCHEDULE in SECTION 3 MAINTENANCE for cleaning and changing 3 3 FORKLIFT SAFETY CONTENTS LUBRICANTS AND FUEL ENGINE COMPONENT CAPACITY RECOMMENDATION 1 Shell Rotella 15w40 Texaco URSA Super 15w40 MLT 629 Turbo S rie A MLT 633 LS Turbo S rie A MLT 730 120 LS S rie A MT 732Turbo 932 Series A COOLING CIRCUIT Texaco Texguard Anti Freeze 45 55 Pre mix 220F MLT 629 Turbo S rie A 5 L 6 2 gal MLT 633 LS Turbo S rie A 5 L 6 2 gal MLT 730 120 LS S rie A MT 732Turbo 932 Series A TRANSMISSION Shell Donax TG Dexron Texaco Havoline Dexron MLT 629 Turbo S rie A MLT 730 120 LS S rie A MLT 633 LS Turbo S rie A MT 732Turbo 932 Series A ANGLE GEAR BOX 2 25 L 59 gal Shell Spirax DH 80w90 Texaco TDH EP 80w90 TRANSMISSION UNIVERSAL JOINT Shell Rentinax Am Texaco Havoline WBCG BOOM COMPONENT RECOMMENDATION o o oo BEAD Havoline WBCG GREASING OF THE BOOM Shell Rentinax Am GEM BZ 1 HYDRAULICS COMPONENT CAPACITY RECOMMENDATION HYDRAULIC OIL TANK 125 L 33 gal Shell
101. ially 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 should never be taken for granted Even experienced operators can be seriously injured or
102. ified by a service company must consider that a new item of equipment has been brought onto the market and therefore takes liability for it Any user who copies original parts or has them copied is taking a risk from the legal viewpoint The certificate of compliance only binds the maker for parts chosen or produced under the maker s control The practicalities of maintenance terms are set out by the maker The maker is in no way liable in the event of the user not complying with such terms YOU GET THE THE MANUFACTURER BRINGS TO THE USER BENEFIT OF THE MANUFACTURER S His know how and skill KNOW HOW Guaranteed quality work Original replacement parts Help with preventive maintenance Effective help with diagnosing faults Enhancements gained from feedback Training for operating staff Only the manufacturer knows the details of the lift truck design and therefore has the best technological capability to carry out maintenance FORKLIFT SAFETY CONTENTS DRIVER S OPERATING INSTRUCTIONS 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 should be able to avoid accidents occurring Any
103. il of a railroad track 30 Keep a clear view of the path of travel and observe other traffic personnel and safe clearances 31 If the load being carried obstructs forward view travel with the load trailing 32 Ascend or descend grades slowly and with caution a When ascending or descending grades in excess of 5 loaded rough terrain forklift trucks should be driven with the load upgrade b Unloaded rough terrain forklift trucks should be operated on all grades with the load engaging means downgrade C On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary to clear the road surface d Avoid turning if possible and use extreme caution on grades ramps or inclines normally travel straight up or down 33 Under all travel conditions operate the rough terrain forklift truck at a speed that will permit it to be brought to a stop in a safe manner 34 Travel with load engaging means or load low and where possible tilted back Do not elevate the load except during stacking 35 Make starts stops turns or direction reversals in a smooth manner so as not to shift load and or overturn the rough terrain forklift truck 36 Do not indulge in stunt driving or horseplay 37 Slow down for wet and slippery surfaces 38 Before driving over a dockboard or bridge plate be sure that it is properly secured Drive carefully and slowly across the dockboard or bridge plate and
104. in accordance with good practice for the profession C MAINTENANCE The user must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety notice The operator is prohibited from carrying out any repairs or adjustments himself unless he has been trained for this purpose He must keep the lift truck properly cleaned if this is among his responsibilities Carry out daily maintenance See A DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 MAINTENANCE Ensure tires are adapted to the nature of the ground SAND tires LAND tires Snow chains There are optional solutions consult your agent or dealer AXWARNING 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 exceptin IMPORTANT P e y di prior authorization For your own and other people s safety it is forbidden to modify the structure and settings of the various components of your lift truck yourself Hydraulic pressure relief valve calibration engine running speed addition of extra equipment etc The same holds with regard to any suppression or modification of the safety systems in which case the maker would no longer be liable Regular inspection of your lift truck is mandatory if it is to be kept in conforming condition The frequency of such checks are defined by the curren
105. indscreen wiper to be operated and when set on the up position the windscreen wiper to be operated 2 33 FORKLIFT SAFETY CONTENTS REAR WINDSCREEN WIPER ROOF WIPER OPTION F TRANSMISSION CUT OFF The switch selects transmission cut off to the service brake pedal or the hydraulic controls lever See Item 39 USE OF TRANSMISSION CUT OFF in SECTION 2 DESCRIPTION Position Indicator light on transmission cut off to service brake pedal effected Position B Indicator light off transmission cut off to hydraulic control lever effected G SPEED INDICATOR H N A I WORKING HEAD LIGHT OPTION J WORKING TAIL LIGHT OPTION K BOOM HEAD LIGHT OPTION L REAR WINDOW DEFROSTING OPTION M OPTION OPTION Electrovalve on boom head OPTION Attachment hydraulic locking device OPTION Electrical boom provision OPTION Electrovalve on boom head attachment hydraulic locking device N OPTION OPTION Dual effect hydraulic towing hook OPTION Single effect rear hydraulic predisposition OPTION Dual effect rear hydraulic predisposition O OPTION OPTION Dual effect hydraulic towing hook single effect rear hydraulic predisposition OPTION Dual effect hydraulic towing hook dual effect rear hydraulic predisposition OPTION Dual effect rear hydraulic predisposition single effect rear hydraulic predisposition OPTION Two dual effect rear hydraulic predispositions OPTION Two single effect re
106. ing of the attachment in order to avoid accidental unlocking and in order to use the attachment safely HYDRAULIC RELEASING OPTION Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Press button 2 Fig E on the distributor lever to completely unlock the attachment LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position INACTIVATE THE HYDRAULIC RELEASE CONTROL You can change an attachment without leaving the control post by cutting the electricity supply to the hydraulic control Leave the valve in position A Fig D Use switch 3 Fig F to cut the electricity supply to the hydraulic control The circuit is out of action when indicator 4 Fig F is on Always turn off the circuit using switch 3 Fig F after CAUTION each change of attachment to avoid accidental unlocking and in order to use the attachment safely FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS D HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE MLT 629 730 S rie A MT 732 932 S rie A MT 732 Turbo S rie A TAKING UP AN ATTACHMENT Ensure that the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the locking pin and the clip are in
107. ities 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 A NOTE or NOTICE Provides information special instructions or references about the lift truck IMPORTANT Precautions which must be taken to avoid damage to the lift truck Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury May also alert unsafe practices Indicates a potent
108. k the attachment on the carriage LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position FORKLIFT SAFETY CONTENTS C ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE OPTION MLT 629 730 Turbo S rie A MLT 629 633 730 120 LS S rie A MLT 633 730 LS Turbo S rie A TAKING UP AN ATTACHMENT Ensure that the attachment is correctly positioned for locking onto the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the rods on the locking cylinder are retracted Fig A Park the lift truck with the boom lowered in front of and parallel to the attachment tilt the carriage forwards Fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment Fig C Lift the attachment off the ground to facilitate locking HYDRAULIC LOCKING OPTION Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Press button 1 Fig E on the distributor lever to completely lock the attachment to the carriage Close the valve in position B Fig D that is to say the hydraulic circuit of the attachment locking closed Always close the valve in position B Fig D after the CAUTION lock
109. killed by ignor ing refusing to enforce or forgetting to follow safe operating procedures Do not assume you know all safe ty issues concerning the decals Before operating the lift truck learn the meaning s of the decals as described in this manual If any decal becomes illegible or missing have it replaced immediately Always replace decals using the same decal part no unless otherwise specified by the manufacturer For replace ment decals not found in your parts manual contact your nearest dealer If you have any questions contact your supervisor or nearest dealer for advice before operating your forklift 801011 Before Starting 801011 Boom equipped models Location on the brake fluid cover panel to the left and below the dash panel BEFORE STARTING OR OPERATING Safety Instructions 420792 Read understand all safety and operating Mast equipped models Location on or near the operator manual E storage case and or on the dash panel Clear the area of bystanders Locate and know operations of controls Instructions for the forklift operator before operating the forklift Fasten seat belt Keep all shields in place Operate only from operator s seat SAFETY INSTRUCTIONS Read and understand operators manual before you operate Carry load as low as possible avoid steep slopes and drive slowly on rough terrain to avold machine overturn Refer to operator s manual for jump sta
110. loth Fill the new oil filter See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE with I C engine oil and lightly grease the seal Refit the oil filter on the filter bracket Tighten the oil filter by hand pressure only and lock the IMPORTANT filter in place by a quarter turn FILLING UP THE OIL Loosen clean and put back in place the drain hose 3 Fig D1 2 Refit and tighten drain plug 2 Fig D1 1 Fill up with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler port 5 Fig D1 4 Wait a few minutes to allow the oil to flow into the sump Start the I C engine and let it run for a few minutes Check for possible leaks at the drain plug and the oil filter Stop the I C engine wait a few minutes and check the level between the two MAXI and MINI notches on dipstick 9 Fig D1 4 Top up the level if necessary FORKLIFT SAFETY CONTENTS D3 DRY AIR FILTER CARTRIDGE CHANGE In case of use in a heavily dust laden atmosphere there are pre filtration cartridges See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Also checking and cleaning the cartridge must be increased up to 250 hours in a heavily laden dust atmosphere with pre filtration Change the cartridge in a clean location with the IMPORTANT engine stopped Never run the engine with the air filter removed or damaged Open the engine compartment Loosen the bolts an
111. m mn 2 68 48 4 m mn 2 36 54 8 m mn 35 48 6 2 6 2 68 56 1 s 6370 kg 14 043 Ib 9270 kg 20 437 Ib 3160 kg 6 967 Ib 8110 kg 17 880 Ib 3210 kg 7 077 Ib 1160 kg 2 557 Ib 5000 daN 11 240 ft lbs 7500 daN 16 860 ft Ibs 4050 daN 9 104 ft lbs ERD m m m m M FORKLIFT SAFETY CONTENTS DIMENSIONS AND LOAD CHART MLT 629 Turbo S rie A Sa T y JE Y N 228956 Scam glm 2 90m 1 45 Til in vin Gltiin Ahin m 1 28m JF1CLAFL p 1592 N 4 3 2 1 Meters An American national standard ASME B56 6b 1998 FORKLIFT SAFETY CONTENTS B D o CR MLT 629 Turbo S rie A 1200 mm 47 24 in 2560 mm 100 78 in 1142 mm 44 96 in 1047 mm 41 22 in 4497 mm 177 04 in 4603 mm 181 22 in 3955 mm 155 70 in 5697 mm 224 29 in 1850 mm 72 83 in 1850 mm 72 83 in 455 mm 17 91 in 440 mm 17 32 in 440 mm 17 32 in 795 mm 31 29 in 865 mm 34 05 in 1260 mm 49 60 in 45 mm 1 77 in 1720 mm 67 71 in 125 mm 4 92 in 47 5 53 3475 mm 136 81 in 7322 mm 288 26 in 3995 mm 157 28 in 2300 mm 90 55 in 2490 mm 98 03 in 4630 mm 182 28 in 1205 mm 47 44 in 3 00 mm 145 66 in 2305 mm 90 74 in 12 133 9 FORKLIFT SAFETY CONTENTS
112. ndicator light E comes on between zone and B4 C FUEL LEVEL Red zone C1 indicates that you are using the reserve supply and that time of use is limited SIGNAL LIGHTS When activating the electrical system of the lift truck all the red lamps and the panel s buzzer must light to indicate their good working order If one of the red lamps or the buzzer does not function carry out the necessary repairs D RED TRANSMISSION OIL PRESSURE LAMP The lamp and the buzzer come on when the pressure in the transmission when driving forward is abnormally low Stop the lift truck and look for the cause Insufficient transmission oil level internal leak in the transmission etc NOTE The signal light operates in forward travel conditions only the signal should not be taken into account when the engine is running at idle or is stopped RED TRANSMISSION OIL TEMPERATURE LAMP The lamp and the buzzer come on when the converter oil temperature is abnormally high Stop the lift truck and look for the cause of this overheating FORKLIFT SAFETY CONTENTS F RED BRAKING OIL LEVEL LAMP If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately and check the braking oil level In the event of an abnormal dropping of the level consult your dealer G RED PARKING BRAKE LAMP This lamp comes on when the parking brake is applied H RED ALTERNATOR CHARGE LAMP
113. nguisher is on the forklift b Monthly and annual inspections are performed and documented and records retained three months for monthly one year for annual c Before November 10 2014 operators must have had the additional training and qualification certification required by OSHA regulations 81926 1427 and 81926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a detailed description VII ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont CONCLUSION 1 ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard 29 CFR 1910 178 as described by the Occupational Safety and Health Administration OSHA They must be qualified as to their visual hearing physical and mental ability to operate the equipment safely NEVER use drugs or alcohol while operating a forklift NEVER operate or allow anyone to operate a forklift when mental alertness or coordination is impaired An operator on prescription or over the counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the forklift 2 CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenanc
114. nt in order to avoid accidental unlocking and in order to use the attachment safely HYDRAULIC RELEASING AND DISCONNECTING THE ATTACHMENT Close the attachment Put the valve in position A Fig D that is to say the hydraulic circuit of the attachment locking open Press button 2 Fig E on the distributor lever to completely unlock the attachment Stop the engine and keep the ignition on the lift truck Remove the pressure of the attachment hydraulic circuit by pressing buttons 1 and 2 Fig E on the distributor lever 4 or 5 times Disconnect the rapid connectors of the attachment Make sure that the rapid connectors are clean and IMPORTANT protect the holes which are not used with the caps provided LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS
115. nufacturer s capacity of the rough terrain forklift truck as equipped for handling suspended loads b only lift the load vertically and never drag it horizontally C transport the load with the bottom of the load and the mast as low as possible d with load elevated maneuver the rough terrain forklift truck slowly and cautiously and only to the extent necessary to permit lowering to the transport position e use tag lines to restrain load swing whenever possible 50 At the beginning of each shift and before operating the rough terrain forklift truck check its condition giving special attention to a tires and their inflation pressure b warning devices C lights d lift and tilt systems load engaging means chains cables and limit switches e f steering mechanism 9 fuel system s 51 If the rough terrain forklift truck is found to be in need of repair or in any way unsafe or if it contributes to an unsafe condition the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 52 If during operation the rough terrain forklift truck becomes unsafe in any way the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 53 Do not make repairs or adjustments unless specifically authorized to do so 54
116. o 12 mm 1 2 in below the filler port 2 Fig A2 Lubricate slightly the filler neck in order to facilitate the setting and the removal of the radiator cap ALLOW THE ENGINE TO COOL BEFORE ADDING CAUTION ENGINE COOLANT A3 FUEL LEVEL CHECK 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 3 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 WARNING operations or when the tank is open Never refill while engine is running NOTE A locking tank cap is available as an OPTION FORKLIFT SAFETY CONTENTS A4 CYCLONIC PREFILTER CLEAN STANDARD MLT 629 Turbo S rie A MLT730 120 LS Turbo S rie A MLT 633 LS Turbo S rie A The cleaning interval is given as a guide however the prefilter must be emptied as soon as impurities reach the MAXI level on the tank Loosen nut 1 Fig A4 remove cover 2 Fig A4 and empty the tank Clean the prefilter unit with a clean dry cloth and reassemble the unit IMPORTANT When cleaning take care not to let impurities into the ary air filter A5 TRANSMISSION OIL LEVEL CHECK Park the lift truck on level ground with the boom raised the I C engine cold and stopped Car
117. oil level C C C C C C C Cooling liquid level C C C C C C C F ielllevel iua dose ehe e ses C C C C C C C Cyclonic prefilter N N N N N N N Dry air filter cartridge N N R R R R Radiator Condenser core OPTION Air conditioning N N N N N N Fan belt tension A A A A A A Alternator crankshaft belt tension A A A A A A m chi V V V V V Compressor belt tension OPTION Air conditioning A A A A A I C engine oil V V V V V engine oil filter H H H H H Fuel filter cartridge R R R R R Fuel feed pump N N N N Blanking cap on the induction manifold C C C C QU EUR ET LR ocean N N N Safety dry air filter cartridge R R R engine silent blocks C c I C engine rates C c Valves clearances C c Cooling liquid V V mier MEME N D N D Water pump and the thermostat C CG Alternator and the starter motor C CG Turbocompressor Only for the Turbo C CG Bleed the fuel system TRANSMISSION Transmission oil level
118. on each front wheel reducer Place level plug 1 Fig C10 in the horizontal position Remove the level plug the oil should be flush with the edge of the hole If necessary add oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by the same hole Replace and tighten the level plug 1 Fig C10 Tightening torque 34 to 49 N m or 25 36 ft lbs Repeat the same operation on each wheel reducer FORKLIFT SAFETY CONTENTS D EVERY 500 HOURS SERVICE Carry out the operations described previously as well as the following operations 01 ENGINE OIL DRAIN 02 ENGINE OIL FILTER CHANGE Place the lift truck on level ground let the engine run at idle for a few minutes then stop the engine DRAINING THE OIL Open the I C engine compartment Place a container under drain plug 1 Fig D1 1 and unscrew the plug 2 Fig D1 1 Take drain hose 3 Fig D1 2 Place the end of the drain hose in the container and screw fully the union on draining port 4 Fig D1 3 Remove filler cap 5 Fig D1 4 in order to ensure that the oil is drained properly IMPORTANT Dispose of the drain oil in an ecological manner REPLACEMENT OF THE FILTER Open the battery cowl 6 Fig D1 5 and lock it in open position by using the bracket 7 Fig D1 5 Remove engine oil filter 8 Fig D1 6 discard the filter and the filter seal Clean the filter bracket with a clean lint free c
119. 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 exhaustive Any bending of the rules in safety notices or the user maintenance or repair instructions for your lift truck may result in serious or even fatal accidents We would remind users of the risks in driving at excessive speed with regard to traffic conditions particularly Risk of loss of control on a poor quality track Increased stopping distance The user must remain in full control of his lift truck and should Adapt his speed to each situation in order to 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 contra indicated Such foreseeable abnormal uses the main ones being listed below are strictly forbidden The foreseeable abnormal behaviour resulting from ordinary neglect but does not result from any wish to put the machinery to any improper use The reflex reactions of a person in the event of a malfunction incident fault etc during operation of the lift truck Beha
120. ors The heat control Fig A Item B adjusts warm air temperature Close the valve counter clockwise for minimum heat Open the valve clockwise for maximum heat Intermediate positioning allows the temperature to be adjusted 23 AIR CONDITIONING CONTROLS OPTIONAL AIR CONDITIONING In winter So as to ensure correct operation and complete efficiency of the air conditioning unit start up the compressor once a week if only for a short spell so as to lubricate the internal seals In cold weather Warm the engine before switching on the compressor so as to allow the coolant that has collected in the liquid state at the lowest point of the compressor circuit to turn into gas under the effect of the heat given off by the engine as the compressor is liable to be damaged by coolant in the liquid state DESCRIPTION OF THE AIR CONDITIONING CONTROLS A Control switch with signal light indicating start up of the air conditioning compresser the engine must be running B Heating temperature control C Fan speed control In position O the fan is off NOTE Possible losses of water under the forklift truck are due to condensate discharges caused by the drying effect of the installation especially with high outside temperatures and high relative humidity For the air conditioning to perform properly the air intakes must not be blocked by frost snow or leaves When the facility is running at least one of the cab air grilles must be
121. particular this regulation applies to any rough terrain forklift e g telescopic handler equipped with a jib or truss boom with a hook with or without a winch or a hook assembly attached to the forks Note This regulation is in addition to the OSHA regulation that requires specific forklift operator training 81910 1 78 1 When a forklift telescopic handler is configured and used for hoisting the employer must ensure that 1 Forklift lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manufacturer s instructions VI 5 Operator and crew members have been trained in the safe use and operation of the equipment including how to avoid electrocution 6 During use no part of the equipment load line or load will be within the minimum clearance distance specified by OSHA 10 feet 3 0 m and more for lines rated over 50 kV of any energized power line and any taglines used are non conductive 7 In addition for lift equipment with a rated capacity greater than 2000 Ibs 907 kg the employer must ensure that a An accessible fire exti
122. r try to carry out a weld or any other operation by yourself this could provoke an explosion or a fire Place a container under drain plug 1 Fig E1 1 and unscrew the plug Remove cap 2 Fig E1 2 Let the fuel flow and clean with 10 litres 2 5 gal of clean fuel by filler port 3 Fig E1 2 Refit and tighten drain plug 1 Fig E1 1 Tightening torque 29 to 39 N m or 21 28 Fill the fuel tank with clean fuel See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE filtered through a strainer or a clean lint free cloth and refit the filler plug 2 Fig E1 2 Open the engine compartment Re prime the system by activating fuel feed pump 4 Fig E1 3 If necessary bleed the system See G1 FUEL SYSTEM in SECTION 3 MAINTENANCE E2 SAFETY DRY AIR FILTER CARTRIDGE CHANGE For the disassembly and reassembly of the cartridge see D3 DRY AIR FILTER CARTRIDGE in SECTION 3 MAINTENANCE Gently remove the dry air filter safety cartridge 1 Fig E2 taking care to avoid spilling the dust Clean the gasket surface on the filter with a damp clean lint free cloth Before mounting check the state of the new safety cartridge See FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE Introduce the cartridge into the filter axis and push it in pressing the edges and not the middle NOTE The schedule for changing the safety cartridge is given for reference only The safety cartridge must
123. raulic reservoir oil Cooling liquid Braking oil Also check for possible leakage of oil fuel or liquid from the lift truck Check the closing and locking of the hood Whatever his experience as a truck driver is the operator is advised to familiarize himself with the position and operation of all the controls and instruments before operating the lift truck C 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 OCCASIONAL MAINTENANCE in SECTION 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 carry out the preheating for 10 IMPORTANT seconds 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 en
124. ready to be started up Run the 1 C engine at idle for 5 minutes immediately IMPORTANT after bleeding the fuel feed circuit in order to ensure that the injection pump has been bled thoroughly NOTE If the I C engine functions correctly for a short time then stops or functions irregularly check for possible leaks in the low pressure circuit If in doubt contact your dealer G2 WHEEL CHANGE Use extreme caution when changing tires on the forklift especially when parked near the public highway Stop the lift truck if possible on even and hard ground For stopping and parking of the lift truck See DRIVING INSTRUCTIONS in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS Put the warning lights on Immobilize the lift truck in both directions on the axle opposite to the wheel to be changed Unlock the nuts of the wheel to be changed Place the jack under the flared axle tube as near as possible to the wheel and adjust the jack Fig G2 1 Lift the wheel until it comes off the ground and put in place the safety support under the axle Fig G2 2 Completely unscrew the wheel nuts and remove them Free the wheel by reciprocating movements and roll it to the side Slip the new wheel on the wheel hub Refit the nuts by hand if necessary grease them Remove the safety support and lower the lift truck with the jack Tighten the wheel nuts with a torque wrench See A DAILY OR EVERY
125. roper tire inflation and the judgement exer cised by the operator C OPERATING SAFETY RULES AND PRACTICES 1 Safe operation is the responsibility of the operator 2 This equipment can be dangerous if not used properly The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself other personnel the rough terrain forklift truck and other material 3 The operator shall be familiar with the operation and function of all controls and instruments before under taking to operate the rough terrain forklift truck 4 Before operating any rough terrain forklift truck truck operators shall have read and be familiar with the operator s manual for the particular truck being operated 5 Before starting to operate the rough terrain forklift truck a be in operating position and fasten seat belt b place directional controls in neutral apply brakes d start engine 6 Do not start or operate the rough terrain forklift truck any of its functions or attachments from any place other than the designated operator s position 7 Keep hands and feet inside the operator s designated area or compartment Do not put any part of the body outside the operator compartment of the rough terrain forklift truck 8 Never put any part of the body into the mast structure or between the mast and the rough terrain forklift truck 9 Never put any part of the body within the reach mechanism of
126. rting this truck If the operator s manual is missing a new instructions manual may be obtained through your local dealer or directly from K D Manitou Inc Waco Tx WHEN PARKING OR SERVICING Check truck for proper operation of all functions 1 Lower boom to the ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine Fasten seat belt FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 801011 Use of Seat Belt 801012 Boom equipped models Location to the right of the operator near the hydraulic control lever Instructs the operator to always wear the seat belt during operations and never jump from an over turning forklift A DANG Al days wear Seg operating machine Never jump from a tipping FORKLIFT SAFETY CONTENTS SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever Identifies the Emergency Parking Brake Lever Alarm Must Sound 496162 Location on the dash in direct view of the operator The backup alarm must sound when the forklift is placed in reverse gear No Riders 420732 Location on the cab entrance s and on or near wheel fenders and engine cover Informs riders are not allowed on the forklift Clear of Raised Boom 801006 Boom equipped models Location on both sides of the boom nose Keep away from unsupported boom
127. ry out the control within 5 minutes of the i c engine being stopped Remove the plastic cap 1 Fig A5 Remove the dipstick 2 Fig A5 Wipe the dipstick and check the correct level between the two MIN and MAX marks If necessary add oil See E3 TRANSMISSION OIL in SECTION 3 MAINTENANCE FORKLIFT SAFETY CONTENTS A6 TIRES PRESSURE AND WHEEL NUTS TORQUE CHECK Check the condition of the tires to detect cuts protrusions wear etc Check the torque load of the wheel nuts See fig A6 Non compliance with this instruction can cause damage and rupture to the wheel bolts and distortion to the wheels Check and adjust the tire pressures if necessary See CHARACTERISTICS in SECTION 2 DESCRIPTION Check that the air hose is correctly connected to the tire valve before inflating and keep all persons at a distance during inflation Respect the recommended tire pressures given 9 7 PADS CLEAN GREASE To be carried out every 10 hours during the first 50 hours service then once at 250 hours Extend the boom completely With a brush apply a coat of grease See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE on the 4 sides of the telescope s Fig A7 Telescope the boom several times in order to spread the coat of grease evenly Remove the surplus of grease Use a silicone spray lubricant when operating in an abrasive environment dust sand coal etc IMPORTANT
128. s determine the center of gravity in the transverse direction before handling Fig B For loads with a moving center of gravity e g 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 and be vigilant and take extra care to limit these variations as far as possible TAKING UP A LOAD ON THE GROUND Position the lift truck perpendicular to the load with the boom retracted and the forks in a horizontal position Fig C Adjust the fork spread and centering in connection with the load Fig D Optional solutions exist consult your dealer Beware of the risks of trapping or injuring limbs when manually adjusting the forks Always maintain an equal distance between the forks and the center of the carriage in order to keep the load completely stable Move the lift truck forward slowly 1 and bring the forks to stop in front of the load Fig E if necessary slightly lift the boom 2 while taking up the load Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 incline the carriage 2 backwards in the transport position Fig F CAUTION Tilt the load sufficiently backwards to ensure its stability loss of load on braking without upsetting the balance of the load in so doing 1 13 FORKLIFT SAFETY CONTENTS C TAKING UP A HIGH LOAD ON TIRES Under no circumstan
129. ssion cut off relay K3 Reverse gear relay K4 Forward gear relay K5 Buzzer K6 OPTION Electrovalve on boom head OPTION Electrical boom provision OPTION Electrovalve on boom head attachment 8 F14 hydraulic locking device 18 TE Ce K7 OPTION Hydraulic movements cut off K8 Safety system starting switch relay 7 K9 Flashing unit max 15A max max 10A m 15A max NOTE Replace a used fuse with a new fuse of the same quality and capacity Never reuse a repaired fuse F1 10A MAX Electric controls of hydraulic movements 7 5A OPTION Attachment hydraulic locking device 7 5A F2 15A MAX OPTION Working tail light 10A F3 10 MAX Rear windscreen wiper 7 54 OPTION Roof windscreen wiper 7 54 FORKLIFT SAFETY CONTENTS F4 10A MAX F5 10A MAX F6 7 5A MAX F7 15A MAX F8 15A MAX D D ns DE F9 10A MAX F10 15A MAX F11 15A MAX F12 10A MAX F13 35A MAX F14 25 MAX F15 25A MAX F16 10A MAX F17 15A MAX F18 F19 mE 15A MAX 15A MAX 10A MAX 10A MAX Ge F23 15A MAX 10A MAX D D D D D gt gt gt F24 10A MAX F25 10A MAX F26 10A MAX F27 15A MAX D D D ft St o F28 15A MAX F29 25A MAX F30 25A MAX F31
130. t DANGER A DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK OPERATE HAND THROTTLE ONLY WITH PARKING BRAKE SET FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH 804784 XV FORKLIFT SAFETY CONTENTS SAFETY DECALS Acid in Battery 801014 Location in or near the battery storage compartment A DANGER EXPLOSION HAZARD Can cause blindness or severe injury Protect eyes Keep away from sparks flames and cigarettes exercise caution when using tools that can cause sparks Keep battery level and caps tight Addresses battery hazards ACID POISON HAZARD Causes severe burns Contains sulfuric acid In event of contact flush with water and see a doctor Keep out of reach of children 801014 Jump Start Battery 801015 YTARNING a Wear eye protection 2 Connect ends of one cable to positive terminals of both batteries M Location In or near the battery storage 3 Connect one end of remaining cable to negative terminal of good battery 4 Connect other f of cable to engine block or reliable chassis ground of vehicle being started DO NOT CONNECT TO compartment 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 N A ET u ET Jump start instructions z IA SHENA AD Sp TE ELE Attachment Plate 425995 EN n Location
131. t legislation of the country in which the lift WARNING truck is being operated Maintenance or repairs other than those detailed in part 3 MAINTENANCE must be carried out by qualified personnel Consult your agent or dealer and under the necessary safety conditions to maintain the health of the operator and any third party 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 For operation under average climatic conditions i e between 15 C and 35 C 5 F to 95 F correct levels of lubricants in all the circuits are checked in production For operation under more IMPORTANT severe climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures lt is the same for the cooling liquid 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 e g refinery explosive atmosphere For use in these
132. t when making IMPORTANT adjustments it swings completely forwards LONGITUDINAL ADJUSTMENT FIG H Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position MAINTENANCE FIG 1 Dirt may adversely affect the correct functioning of the seat For this reason make sure your seat is always clean To clean or change the cushions simply remove them from the seat frame CAUTION A rocking head rest increases the risk of an accident Avoid wetting the cushion fabric when cleaning Check the resistance of the fabric on a small hidden area before using any fabric or plastic cleaner FORKLIFT SAFETY CONTENTS 2 SAFETY BELT 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 Fixing locking cuts tears etc Hepair or replace the seat belt immediately 3 CONTROL AND SIGNAL LIGHTS PANEL CONTROL INSTRUMENTS A HOURMETER AND REV COUNTER 1 C ENGINE WATER TEMPERATURE Temperature zone B1 Blue zone 0 50 C 32 122 F B2 Green zone 50 100 C 122 212 F B3 Black red zone 100 105 C 212 221 F B4 Red zone 105 120 C 221 248 F NOTE Red i
133. the following sequence continued on next page FORKLIFT SAFETY CONTENTS G7 EMERGENCY JUMP STARTING continued STEP 1 Clamp the positive jumper cable to the good battery s positive terminal STEP 2 Clamp the other end of the positive cable to the dead battery s positive terminal STEP 3 Clamp the negative jumper cable to the good battery s negative terminal STEP 4 Clamp the other end of the negative cable to a solid metel point on the frame or engine ground at least 18 inches away from the battery Keep the clamps away from the engine fan and belts GOOD BATTERY DEAD BATTERY Jumper Vehicle STEP 2 JUMPER CABLES O STEP 3 TO GROUND STEP 3 x GROUND ENGINE BLOCK OR FRAME Start the engine on the jumper vehicle and allow it to run at high idle for about 5 minutes Start the forklift Make sure that the engines in both vehicles are at low idle before disconnecting the jumper cables Remove the cables in reverse order of installation Remove the negative cable from the forklift frame or engine ground Remove the negative cable from the jumper vehicle Remove the positive cable from the forklift Remove the positive cable from the jumper vehicle If the forklift fails to start after several attempts seek assistance from a qualified mechanic or contact your nearest dealer FORKLIFT SAFETY CONTENTS H EVERY TWO YEARS OPTION AIR CONDITIONING H1 CLEANING THE COND
134. 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 tracks curbs etc NEVER approach power lines gas lines or other util
135. 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 ROUGH TERRAIN FORKLIFT TRUCK GENERAL SA
136. tial to stop and change the working conditions if the transmission oil temperature indicator light comes on This poor choice may also result in a reduction in the lift truck s performance in forward speed When the forward force increases the forward speed in the r gear for example 3 gear may be lower than the forward speed that could be obtained with the r 1 gear in 2 instead of the 3 In general we would advise you to use the following gears according to the nature of the work being carried out On the road Set off in 3 gear and go up to 4 if the conditions and state of the road permit it In hilly areas set off in 2 gear and go up to 3 if the conditions and state of the road permit it e With a trailer on the road Set off in 2 gear and go up to 3 if the conditions and state of the road permit it e Handling 3 gear 2 gear in restricted spaces e Earth moving 1 gear Loading reclaiming with bucket manure fork etc 2 gear FORKLIFT SAFETY CONTENTS 18 FORWARD REVERSE LEVER When operating this control the lift truck should be travelling at slow speed and not accelerating When the reverser is in the neutral position a mechanical lock prevents an accidental shifting movement FORWARD Lift slightly and push the lever forwards Position A HEVERSE Lift slightly and pull the lever backwards Position B NEUTRAL To start the lift truck the lever must be in neutral Position C NOTE T
137. tions and state of the road allow H OPERATING THE LIFT TRUCK WITH A FRONT END ATTACHMENT ON A PUBLIC HIGHWAY For driving with an attachment check the regulations currently applicable in your country The attachment must not exceed the overall width of the lift truck The length of the entire unit must not exceed the overall length by 6 m 19 68 ft Do not mask the lighting range of the front headlamps Set the attachments shields in place or disassemble the attachment 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 t is strictly prohibited to carry or to lift up persons using the lift truck unless the vehicle is specially equipped for this purpose and has the corresponding certificate of conformance for lifting people Avoid 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
138. to be recharged 1 280 The density should not vary more than 0 025 units between cells 1 290 1 300 Check the electrolyte density in each battery cell using a hydrometer Do not carry out this check immediately after topping up with distilled water C 18 10 0 10 20 30 40 Recharge the battery for at least an hour before checking the battery F 0 14 32 50 68 86 104 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 a naked flame Work in a well ventilated area n 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 D11 FRONT AND REAR AXLE DIFFERENTIAL OIL DRAIN Place the lift truck on level ground with the engine stopped and the differential oil still warm IMPORTANT Dispose the drain oil in an ecological manner Place a container under drain plugs 1 Fig D11 and unscrew the plugs Remove level plug 2 Fig D11 and filler plug 3 Fig D11 in order to ensure that the oil is drained properly Refit and tighten drain plugs 1 Fig D11 Tightening torque 34 to 49 N m or 25 36 ft Ibs Fill up with oil See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE by filler port 3 Fig D11 The level is correct when the oil level is flush with the edge of port 2 Fig D11
139. turer s approved components as installed at the factory Any substitutes or modifications must first be approved by the manufacturer Gear pump with flow divider 43 77 cm 17 23 cu in 105 L mn 27 75 gal mn 250 Bar 3625 psi 105 L mn 27 75 gal mn 140 Bar 2030 psi 105 L mn 27 75 gal mn 40 Bar 580 psi 20 Micron 125 Micron FORKLIFT SAFETY CONTENTS SPECIFICATIONS Level of sound pressure in the driver s cab According to standard prEN 12053 1995 Travel speed of the lift truck Forward Reverse Standard lift height Rated capacity with standard attachment Load center Weight of forks Each Lifting motions Boom retracted Unladen lifting Load lifting Unladen lowering Load lowering Telescoping motions Lifting boom Unladen extending Laden extending Unladen retracting Laden retracting Reverse tilt time unladen Forward tilt time unladen Lift truck weight with standard attachment Unladen Rated load Axle weight with attached equipment Transport position Front unladen Rated load Rear unladen Rated load Tensible strain at coupling hook Unladen Rated load Break out force with bucket According to standard ISO 8313 81 dBA 25 km h 15 5 mph 25 km h 15 5 mph 6050 mm 238 in 2900 kg 6000 Ib 610 mm 24 in 72 kg 158 Ib 5 65 45 2 m mn 6 55 39 m mn 41s 61 8 m mn 3 8 66 7 m mn 4 9 25 7 m mn 5 365 23 7
140. ty C C C C Load status indicator device Cc c C Condition of wiring harness and cables Ce Lights and signals C c C Warning indicators Ce CU Adjust the front headlamps AXLES Front wheels reducers pivots G G G G G C Rear wheels reducers pivots G G G G G C Rear axle oscillation G G G G C G C Transmission universal joint G G G G G G C Front axle differential oil level C C C C C Rear axle differential oil level C C C C C Front wheels reducers oil level C C C C C Rear wheels reducers oil level C C C C C Front axle differential oil V V V V V Rear axle differential oil V V V V V Front wheels reducers oil V V V V Rear wheels reducers oil V V V V ateen series Moats oun dE EE CU CF Wearing of front axle brake discs Wearing of rear axle brake discs Front wheels reducers universal joint Rear wheels reducers universal joint Steering swivel joints C Front wheels reducers clearance Rear wheels reducers clearance CHASSIS SIC RR C c Bearings
141. ugh 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 rules and practices 2 Cre
142. ulic predispositions 20 OIL COOLER OPTION Oil Cooler Option for forklift with air conditioning option must verify Oil Cooler Option for forklift without air conditioning option must verify 21 CONTINUOUS RUNNING AUXILARY LINE For use on continuous running hydraulic equipment e silage cutter etc With the toggle switch control the direction of continuous hydraulic flow forward or reverse Toggle the switch to center to turn hydraulics off Option availability varies according to model country FORKLIFT SAFETY CONTENTS MAINTENANCE FORKLIFT SAFETY CONTENTS FORKLIFT SAFETY CONTENTS MLT 629 633 730 S rie A MT 732 932 S rie A MT 732 Turbo S rie A NS FA NS 2 Kam 4 N N N N S DESIGNATION PART NUMBER CLEAN CHANGE 1 Engine oil filter MLT 629 730 MT 732 932 S rie 133755 500 H MT 732 Turbo S rie A 476954 500 H 2 Dry air filter cartridge 50H 3 Safety dry air filter cartridge 4 Transmission oil filter 5 Fuel filter cartridge 6 Hydraulic return oil filter cartridge 629 MT 732 turbo 932 S rie A Up to machine Nr 166043 563483 From machine Nr 166044 236095 6 Hydraulic return oil filter cartridge 633 730 turbo S rie Up to machine Nr 164449 563482 From machine Nr 164450 236094 7 Suction strainer for hydraulic oil tank 9 Alternator belt 10 Fan belt Up to mac
143. vior 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 of the equipment must take these criteria into account when assessing whether or not a person will make a suitable driver FORKLIFT SAFETY CONTENTS GENERAL INSTRUCTIONS A DRIVER S OPERATING INSTRUCTIONS Read the operator s manual carefully making sure you understand it The operator s manual must always be kept in the lift truck in the place provided and in the language understood by the operator Respect the safety notices and instructions given on the lift truck It is mandatory to replace all plates or stickers which are no longer legible or which have become worn or damaged AUTHORIZATION TO OPERATE Or refer to the legislation for each particular country Only qualified personnel may use the lift truck Its use is subject to authorization to operate being given by the appropriate manager in the user establishment The 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

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