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MHT 860-950 0:MHT 860 LT MS 0.qxd.qxd

1. 21 INTRODUCTION TO SAFETY 1 860 L 950 L Evaluzia INSTRUCTIONS FOR LIFT TRUCK MAINTENANCE MAINTENANCE INSTRUCTIONS A GENERAL INSTRUCTIONS Read and understand the instruction manual Switch off the combustion engine before carrying out any operation on the lift truck Wear clothing suitable for the lift truck maintenance operations and avoid jewellery and loose clothing Tie and protect your hair if neces sary Make sure the area 15 sufficiently ventilated before starting up the lift truck Pay special attention to disposal of consumables and worn parts ensuring this 15 done in maximum safety and in an eco friendly man ner Carry out the necessary repairs however minor immediately Repair leaks however minimum immediately Do not attempt to slacken the unions hose pipes or hydraulic compo nents with the circuit pressurized Modifying the adjustments and dismantling the balancing valves and safety valves sometimes fitted on the lift truck jacks can be dange rous A balancing valve must only be dismantled with the lift jack concerned deactivated and the pressure discharged from the hydrau lic circuit This operation must only be performed by authorized personnel Never smoke or expose the lift truck to naked flames with the fuel tank open or while it is being filled Take care as there is risk of burns Exhaust radiator
2. D SPECIFICATIONS CAPACITY DIMENSIONS DESCRIPTION ACCESSORY WEIGHT LEVEL NOMINAL MAXIMUM uem CBR 1500 1 2500 750 1190 L 15001 2500 1035 1141 426 800 Kg 21 INTRODUCTION TO SAFETY 5 860 L 950 L Zeclatiou AGRICULTURAL SHOVEL SPECIFICATIONS SPECIFICATIONS CAPACITY iud DESCRIPTION ce ACCESSORY WEIGHT LEVEL NOMINAL SER CBA 2000 L 2500 1550L 2005L 2150L 12500 us 469 mm 790 Kg 28 INTRODUCTION TO SAFETY 860 L 9501 Evolution 5 AGRICULTURAL SHOVEL SPECIFICATIONS SPECIFICATIONS CAPACITY ls ACCESSORY DESCRIPTION ce WEIGHT LEVEL NOMINAL MAXIMUM EVES CBA 3000 L 2500 2330 L 3003 32001 2500 1260 461 940 Kg 29 INTRODUCTION TO SAFETY 860 L Evolucion LOAD CHART WINCH 5 TON CUN 44 122 _ 731876 The capacity diagrams are only valid if the safety system is activated 30 INTRODUCTION TO SAFETY 860 L Evolution LOAD CHART Arm P 1200 T 9 sl Ve MN 736811 The capacity diagrams are only valid if the safety system 15 activated 31 INTRODUCTION TO SAFETY 860 L Evolucion LOAD CHART ARM WITH HOOK 50 RES The capacity diagrams are only valid if the safety system is activated 32 INT
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9. 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 c apply brakes d start engine 6 Do not start or operate the rough terrain forklift truck any of its functions or attachments from any place other than the designated operator s position 7 Keep hands and feet inside the operator s designated area or compartment Do not put any part of the body outside the operator compartment of the rough terrain forklift truck 8 Never put any part of the body into the mast structure or between the mast and the rough terrain forklift truck 9 Never put any part of the body within the reach mechanism of the rough terrain forklift truck or
10. 2 CHECK THE FRONT AND REAR AXLE DIFFE RENTIAL OIL LEVEL Position the lift truck on a level surface with the engine switched off Check the front axle differential oil level Remove plug 3 Fig 2 1 The oil level must reach the hole If necessary add oil through filler hole 4 Fig C2 1 see the LUBRI CANTS Table Repeat this operation for the rear axle differential Fig C2 2 C 3 CHECK THE FRONT AND REAR WHEEL REDUCTION GEAR OIL LEVEL Position the lift truck on a level surface with the engine switched off Check the level on the reduction gear of each front wheel Turn level 5 Fig to the horizontal position Remove the plug the oil level must reach the hole Add oil if necessary see LUBRICANTS Table Repeat the operation for each of the rear wheels INTRODUCTION TO SAFETY 3 860 L 9501 Zeclation 4 CHECK THE TRANSMISSION BOX OIL Position the lift truck on a horizontal surface with the combustion engine switched off Remove level plug 6 Fig C4 the oil must reach the level of the ope ning Top up with oil if necessary See the LUBRICANTS Table Refit and retighten level plug 6 Fig C4 5 CHECK THE BATTERY Check the electrolyte level in the battery if the battery specifications require it In high environmental temperatures check the level more frequently Maintenance Check connec
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12. du ON 7 f i 5 Q A ARR NS A O 22 40006 KOS 55550 AA a 2 X INTRODUCTION TO SAFETY 3 860 L 9501 Zeclatiou COMPULSORY REPORT 50 100 HOURS OF SERVICE WITHIN 3 MONTHS List of operations to be performed COMBUSTION ENGINE Change oil Replace oil filter Replace fuel filters Clean air filter Check seals injection supply Check cooling circuit Check belt tension Adjust valves HYDROSTATIC TRANSMISSION Replace intake filter Clean return filter depending on assembly Check oil level Check transmission control adjustment AXLES GEAR BOX Replace differential oil brakes casing Change reduction gear oil Grease pins articulations and commands Grease oscillation Change gear box oil HYDRAULIC CIRCUIT Replace return filter Check oil level Check seals BRAKING CIRCUIT Check working of service and parking brakes Check brake fluid level depending on assembly TELESCOPIC BOOM Grease the outriggers Grease all the trunnions Check locking of sliding pads MANISCOPIC SAFETYSYSTEM Check the working and adjustment if necessary ACCESSORIES OPTIONS Check the working CAB Check the dashboard and all the instruments Check controls heating and air conditioning if present ELECTRIC CIRCUIT Check battery level Check wor
13. Never try to carry out welding or other operations yourself this can result in an explosion or fire Place a container under drain plug 16 Fig E7 1 and unscrew the plug Remove filler plug 17 Fig E7 2 Let all the fuel flow out and rinse with 10 litres of clean fuel poured through the filler hole Refit and tighten drain plug 16 Fig E7 1 Fill the tank with clean fuel filtered through a suction rose or a clean cloth that does not leave residue then refit the filler plug 17 Fig E7 2 Before operating the starter motor run the suction pump for one minu te to bleed air from the filter Let the engine run in neutral for a few minutes at minimum speed 25 INTRODUCTION TO SAFETY 3 860 L 9501 Zeclation E 8 REPLACE THE ALTERNATOR BELT DRIVING SHAFT Position the lift truck on a level surface with the combustion engine swit ched off Unscrew the alternator fixing screws 18 and belt tightener lever retai ner bolt 19 Fig E8 through 2 or 3 turns of the thread and turn the alternator position to slacken the belt tension to remove it from the pul ley Replace the belt with a new one having identical features see Table FILTER ELEMENTS AND BELTS turn the alternator position to tigh ten the belt correctly Tighten the belt tightener retainer bolt 19 Fig E8 and alternator fixing screws 18 Fig E8 Check the belt tension again to mak
14. Boom equipped models option Location Near the hand throttle mechanism Reminder to operator set parking brake before operating hand throttle Disengage hand throttle before leaving the forklift A DANGER DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK OPERATE HAND THROTTLE ONLY WITH PARKING BRAKE SET FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH 804784 XV INTRODUCTION TO SAFETY SAFETY DECALS Acid in Battery 801014 Location in or near the battery storage Addresses battery hazards Jump Start Battery 801015 Location in or near the battery storage compartment Jump start instructions Attachment Plate 425995 DANGER EXPLOSION HAZARD Can cause blindness or severe injury Protect eyes Keep away from sparks flames and cigarettes exercise caution when using tools that can cause sparks Keep battery level and caps tight ACID POISON HAZARD Causes severe burns Contains sulfuric acid In event of contact flush with water and see a doctor Keep out of reach of children 801014 1 Wear eye Jg IMS 2 Bennecre ends of one cable to positive both batteries 7 3 Connect one end of remaining cable to negative terminal of good battery 4 Connect other end of cable to engine block or reliable chassis ground of vehicle being started DO NOT CONNECT TO BATTERY 5 To prevent damage to electrical components of vehicle b
15. INTRODUCTION TO SAFETY 4 860 L 950 L Evaluzia A O AS _ T H R1 25 N1 d dig d B t o 2 lt 5 lt 18 17 19 7 16 8 12 186X186 186 185 186 185 185 g m m x 2 i f c tn E 5 4 5 8 H 31 10 11 18 121 128 121 x121 d t 2 3 9 a j O sal 2 5 5 i 2 Y 1 1 1 X104 X133 X13 TIS Y133 Y134 lt 8197 ps ps 2 2 2 104 133 134 2 2 2 2 3 5 31 31 12 INTRODUCTION TO SAFETY 860 L 9501 Evolution 4 AA 366 5 364 T 7 7 1 T 70 070 7 A30 CAPACITY z seueaemocum REGULATION els 3 3 8 SAGELEC ELECTRONIC UNIT SWITCH CS QUEE DLE DEDE dd 3 HL 1 5 1 H L1 35 HA AAA E Mo 6 2 7 4 1 M N1 91 203 203 500203 E ES 11 T 2 2 q 2 gt 2 1 N 3 9 4 1 2 3 LL Hil ol xu x2 Y239 tsa RNI aq 5 31 31 2 mmm R N1 HL1 M N1 g MNI S N1 fs A X128 d 45 INTRODUCTION TO SAFETY 4 860 L 9501 Zeclation 5 4 8 1 55 H L1 i A365_____ RC2 ELECTRONI
16. N 211742 I N e INTRODUCTION TO SAFETY 2 950 L LOAD CHART 950 L Evolutcos LOAD CHART WITH FORKS N lt 2 860 L 950 L Evolution 2 INTRODUCTION TO SAFETY 2 860 L 9501 DESCRIPTION 1 Operator seat 2 Safety belt 3 Control instruments and indicator lights panel 4 Load status control and safety device Safety system exclusion key 5 Switches panel 6 Lights control lever horn and direction indicators 7 Anterior windscreen and rear window wiper washer control lever Key switch 9 Access guard to brakes oil tank windscreen wiper liquid tank 10 Brakes oil tank 11 Windscreen wiper liquid tank 12 Guard for access to fuses and relays 13 Accelerator pedal service brake and inching 14 Reversing control 15 Electro hydraulic movements controls 15a Decompression of optional circuit 16 Red emergency stop pushbutton 17 Description of controls and load diagrams 18 Level gauge 19 Heating controls 20 Air conditioning optional 21 Air inlet nozzles 22 Ceiling light 23 Sunshade optional 24 Tools and documents compartment 25 Cigarette lighter 26 Cab door closure 27 Upper half door lock 28 Rear window opening lever 29 Tow hook 30 Head lights 31 Tail lights 32 Rotary warning beacon 33 Steering wheel adjuster lever RECOMMENDA
17. 2 3 HYDRAULIC EXTENSION SWITCH OPTIONAL The switch has two or three positions depending on the machine setup It is used for switching the hydraulic control for making two or three hydraulic movements using the accessory S ROTARY BEACON SWITCH Two position switch for turning the rotary beacon light on off T FRONT AND REAR WORK LIGHTS SWITCH OPTIONAL Three position switch for turning the work lights On off U SWITCH FOR WORK LIGHT AT THE TOP OF THE BOOM OPTIONAL V SWITCH FOR DEFROSTING REAR WINDOW OPTIONAL Z SWITCH FOR ROOFTOP WINDOW WIPER OPTIONAL 18 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 LIGHTS HORN AND TURN INDICATOR LIGHTS CONTROL LEVER The lever commands visual and sound signals A Lights are switched off direction lights not working B RH direction lights working C LH direction lights working D Position lights On E Low beams and position lights On F High beams and position lights On G Flashing Press the tip of the lever to sound the horn 7 FRONT AND REAR WINDSCREEN WIPER SWITCH This switch controls the operation of the front and rear windscreen wipers A Front windscreen wiper off B Front windscreen wiper low speed setting C Front windscreen wiper high speed setting D Front windscreen wiper intermittent setting E Rear windscreen wiper off F Rear windscreen wiper on NOTE These functions will only work
18. 3 CLEAN THE RADIATOR GRILLES Check the radiator intercooler Fig B3 1 water Fig B3 2 oil Fig B3 3 for damaged fins corrosion dirt grease insects leaves oil or other debris The compressed air can cause accidents While using compressed air wear a protective device for the face and protective clothing The maximum pressure of the compressed air at the nozzle outlet must be 2 bar 30 PSI Direct the compressed air jets in the direction of the arrows Keep the air nozzle at a distance of about 6mm from the radiator fins Also use pressurized water to soften mud or solid debris The maximum water pressure must be less than 2 7 bar 40 PSI To remove oil and grease use a degreaser and steam Clean both sides of the radiator mass Wash the radiant mass with detergent and boiling water Rinse the radiant mass thoroughly with clean water After cleaning the radiator s start the engine keeping it running at minimum for about five minutes Bring the engine to maximum oper ating speed without load this operation helps to remove debris and to dry the radiant mass Gradually reduce the engine speed to the mini mum and stop it Use light to check behind the radiant mass to see if it is clean If necessary clean again Check to see if fins are damaged Bent fins can be straightened using a comb Check to make sure the following elements are in good condition weld ed parts mounting br
19. CAREFUL YOUR SAFETY AND THAT YOUR LIFT TRUCK ARE AT STAKE Abide by the data indicated on the load charts Never attempt to lift loads exceeding those permitted on the load charts enclosed with the machine Carry the load in a low position with the telescopic boom fully retracted Drive the truck at a speed suited to the ground conditions in question When driving the truck without load keep the telescopic boom low and fully retracted Never drive too fast or brake sharply with a load When the load 15 lifted check to make sure no one can hamper the operation and avoid incorrect manoeu Never attempt operations that are beyond capacity of the lift truck Pay attention to electric cables Never leave the truck parked with a raised load Never allow anyone to come near or walk under a load Always bear safety in mind and carry only well balanced loads Never leave the lift truck loaded with the parking brake engaged on slopes with gradient exceeding 15 For using a hoist or equipment with the load hanging from a hook Position the hoist perpendicular to the load to be lifted The hook without load must descend gradually gently since if released rapidly the rope will wind around the drum resulting in serious damage to the rope the limit stop etc If the rope starts twisting on the block unhook the fixed hook pull the rope and turn it in the opposite direc tion to eliminate the twis
20. Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so Approach elevators slowly and then enter squarely after the elevator car is properly leveled Once on the ele vator neutralize the controls shut off engine and set brakes It is advisable that all other personnel leave the elevator before truck is allowed to enter or leave 40 Avoid running over loose objects on the roadway surface 41 When negotiating turns reduce speed to a safe level and turn steering handwheel in a smooth sweeping motion Except when maneuvering at a very low speed turn the steering handwheel at a moderate even rate 42 Use special care when traveling without load as the risk of lateral overturning is greater 43 Improper use of stabilizer controls if so equipped could cause rough terrain forklift truck upset Always lower the carriage before operating stabilizer controls 44 For rough terrain forklift trucks equipped with lateral leveling a Always level the frame before raising the boom or mast with or without a load b Lateral leveling should not be used to position an elevated load instead lower the load and reposition the rough terrain forklift truck 45 Handle only stable or safely arranged loads a When handling off center loads which cannot be centered operate with extra caution b Handle only loads within the capacity of the rough terrain forklift truck c Handle loads exceeding the dimens
21. ape p 1 P 1200 1200 Kg 830 868 2944 1100 mm 2500 mm 165 Kg INTRODUCTION TO SAFETY 5 1200 SPECIFICATIONS 860 L 950 L HOOK ROTATION LUBRICATION WINCH RED GEAR DI AC 250 HOURS OIL AT 40 30 HOURS ACCESSORY HOOK DESCRIPTION CAPACITY ROPE HOOK LIMIT DISTANCE WEIGHT SPEED 5 1200 1200 Kg SPECIFICATIONS vem 23mimin IDRAULICO 830 868 2944 910mm 2450 mm 323 20 INTRODUCTION TO SAFETY 860 L 9501 Evolution 5 ARM WITH HOOK SPECIFICATIONS SPECIFICATIONS DIMENSIONS ACCESSORY HOOK DESCRIPTION CAPACITY mimi DISTANCE WEIGHT D PC 30 3000Kg 810 470 610 115 Kg 40 810 470 610 115 Kg 50 5000 Kg 810 470 610 175 mm 470 mm 115 Kg 21 INTRODUCTION TO SAFETY 5 860 L 950 L Zeclatiou ARM WITH HOOK SPECIFICATIONS SPECIFICATIONS DIMENSIONS ACCESSORY HOOK DESCRIPTION CAPACITY DISTANCE WEIGHT PC 60 6000 815 520 425 210 260 130 22 INTRODUCTION TO SAFETY 860 L 9501 Evolution Arm P 4000 SPECIFICATIONS 6 1200 4000 KG Q
22. 250 HOURS OF SERVICE in part 3 MAINTENANCE Check the various components of the electrical circuit the relative con nections and contacts CONTACT YOUR AGENT OR DEALER IF NECESSARY 25 22 DESCRIPTION INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 SPECIFICATIONS Engine E2 Type Number of cylinders Strokes Injection system Firing order Displacement Bore Stroke Compression ratio Rated speed Idle speed Power rating ISO TR 14396 Maximum torque Cooling System Type Intake fan No of blades Diameter Thermostat Complete opening Electrical System Earth Battery Alternator Voltage regulator Starting Brakes Type Service brake Parking brake PERKINS 1104D E44TA A A direct 1 3 4 2 4400 cm 105 mm 127 mm 16 2 1 2200 min 800 min 144 HP 106 kW 556 Nm 1400 min Water cooled 1760 min 7 550 mm 82 Negative 12v 140 Ah 12v 120A built into alternator 12 v Disk in oil bath Pedal operated acts on front and rear wheels Hydraulic with negative action acts on front axle service brakes INTRODUCTION TO SAFETY 2 Transmission Unit Type Type Gear No of forward gears No of reverse gears Reverser Hydraulic circuit Boom movements Type of pump Flow rate Pressure Steering circuit Type of pump Flow rate
23. Pressure Levelling circuit Type of pump Flow rate Pressure Cooling system 860 L 950 L Hydrostatic with continuous speed adjustment Variable displacement pump and engine with inching Hydraulic operation 2 2 Electrohydraulic with pistons 140 l min 275 bar Load sensing 140 l min 175 bar with gears 25 min 205 bar Water and hydraulic oil by means of fan with hydraulic motor Type of pump Flow rate Pressure Intercooler Electric fans Front and rear tyres Standard Type Operating pressure Optional Type Operating pressure with gears 25 min 175 bar 18x22 5 16PR MPT 06 TL 5 bar 445 65 R22 5 8 bar INTRODUCTION TO SAFETY 860 L Evolucion Specifications 860 Maximum speed Forwards Backwards without load 30 km h Forwards Backwards with load 10 km h Lifting speed without load with boom retracted 30 6 m min 9 8 sec Descent speed without load with boom retracted 38 5 m min 7 8 sec Extension speed without load 17 m min 11 3 sec Boom retraction speed without load 28 6 m min 6 7 sec Upward inclination time without load 33 sec 4 1 sec Downward inclination time without load 38 5 3 5 sec Fork dimensions length x width x thickness 1200 x 200 x 60 mm Max boom ext distance from fork 1750 mm Distance from centre of gravity 24 in Standard lifting height 81
24. applies to any rough terrain forklift e g telescopic handler equipped with a jib or truss boom with 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 178 1 When a forklift telescopic handler is configured and used for hoisting the employer must ensure that 1 Forklift lift equipment and rigging have been inspected each shift month and year and are in good safe condition and properly installed 2 An operator s manual and applicable load charts are on the forklift 3 Work zone ground conditions can support the equipment and load Any hazardous conditions in the work area have been identified and the operator notified 4 Equipment is being used within its rated capacity and in accordance with the manufacturer s instructions VI 5 Operator and crew members have been trained in the safe use and operation of the equipment including how to avoid electrocution 6 During use no part of the equipment load line or load will be within the minimum clearance distance specified by OSHA 10 feet 3 0 m and more for lines rated over 50 kV of any energized power line and any taglines used are non conductive 7 In addition for lift equipment with a rated capacity greater than 2000 Ibs 907 kg the employer must ensure that a An accessible fire extinguisher is on the forkli
25. combustion engi ne etc Disconnect the negative wire terminal of the battery before carrying out welding operations on the lift truck For electric welding on the lift truck place the negative welding gun on the part to be welded to prevent strong currents from passing through the alternator 22 INTRODUCTION TO SAFETY 860 L 9501 Evolution 1 MAINTENANCE Maintenance and maintaining the conformity of the lift truck are obligatory Carry out daily maintenance See Chapter A DAILY OR EVERY 10 HOURS OF SERVICE under 3 MAINTENANCE Do not operate the combustion engine without the air filter or if there is oil water or fuel leakage Wait for the combustion engine to cool down before removing the radiator cap Replace the filter cartridges See replacement frequency in Chapter FILTER ELEMENTS AND BELTS in 3 MAINTENANCE LEVELS Use the recommended lubricants Never use used lubricants Do not fill the fuel tank with the combustion engine running Refuelling operations must be carried out exclusively in the areas meant for the purpose D WASHING Clean the lift truck or at least the part concerned before every operation Remember to shut the cab door and the rear window During washing avoid wetting the electrical joints components and con nections If necessary protect components which run the risk of being damaged by water steam and deter
26. ELEMENTS AND BELTS LUBRICANTS MAINTENANCE SCHEDULE A Daily or every 10 hours of service Every 50 hours of service C Every 250 hours of service D Every 500 hours of service or yearly E Every 1000 hours of service or yearly F Every 2000 hours of operation or every 2 years G Occasional maintenance 4 ELECTRIC AND HYDRAULIC SYSTEM ELECTRICAL SYSTEM Starter motor Alternator Lighting Battery Fuse box and relay Fuse box and relay board Relays and diodes under cigarette lighter compartment Relays and fuses in engine compartment Wiring diagram HYDRAULIC SYSTEM Movements hydraulic system layout Steering and brakes hydraulic system layout Levelling and Fans hydraulic system layout Hydrostatic transmission system layout 5 OPTIONAL ACCESSORIES ADAPTABLE TO THE RANGE INTRODUCTION GENERAL RECOMMENDATIONS FOR USING THE LIFT TRUCK ACCESSORY WITHOUT HYDRAULIC SYSTEM AND MANUAL BLOCK ACCESSORY WITHOUT HYDRAULIC SYSTEM AND HYDRAULIC BLOCK OPT ACCESSORY WITH HYDRAULIC SYSTEM AND MANUAL BLOCK OPT ACCESSORY WITH HYDRAULIC SYSTEM AND HYDRAULIC BLOCK OPT USING THE FEM TYPE FORK HOLDER TECHNICAL SPECIFICATIONS OF ACCESSORIES LOAD CHART INTRODUCTION TO SAFETY 860 L 950 L INTRODUCTION Our telescopic lift trucks have been designed to ensure simple manoeuvres and easy maintenance Before starting up the lift truck for the first time the ope
27. OF THIS VEHICLE The backup alarm must sound when the forklift is placed in reverse gear No Riders 420732 Location on the cab entrance s and or near wheel fenders and engine cover CAUTION Informs riders are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 A DANGER Boom equipped models Location on both sides Stay cl f raised b of the boom nose ay clear of raised boom unless properly supported Operator may be crushed Keep away from unsupported boom between falling boom and main frame Failure to comply may result in serious injury or death Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose DANGER Keep machine at least 25 feet from overhead power lines Keep away from power lines Failure to comply may result in serious injury or death by electrocution 801007 XI INTRODUCTION TO SAFETY SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of the operator near the hydraulic control lever READ OPERATOR S MANUAL evel machine at around level betore Frame leveling notice load must be lowered Attachment and Boom Safety 801009 Boom equipped models Location on both sides of the boom nose ATTACHMENT AND BOOM SAFETY operating techniques can cause the machine to tip over Refer to machine load charts and operator s manual for p
28. X206 206 X206 X186 3185 186 185 H R1 1 31 H R1 1 41 2 a 8 5 V N1 31 4 AAA H L1 81 _ NE ___________ eee LBI 81 15 15 15 14 B V1 be L N1 61 5 K L 20 23 18 16 15 17 128 128 160 X160 X160 X160 X160 X160 6 105 m __ 10 1 5 8 1 8 s 353222 8 5 S 4 2 4 33 59 131 131 132 132 A201 PERKINS UNIT ACCELERATING PEDAL 2 2 X131 X132 2 2 15 31 31 31 ca ME TOU IMPIANTO ELETTRICO TAVOLA L 2 10 INTRODUCTION TO SAFETY 860 L 9501 Evolution 4 H1 10 1 gt Z N1 164 5168 5169 n M V1 SS 2181 9 1 oo e 5 61 2 y M N1 5 15 14 206 5X206 DENT La mm ASI S N1 Cl 9 1 C B1 pa 4 co Si ca X4 A UNIT F26 10A K12 86 87 87 um 415 KEY 1 03 Y ls o rn e c CEA E O EEN FRIAS TN E AAA 3 7 8 61 101 LIG1 10 1 7 81 d 5 5 z 5 0 E 5 2 3 20 15 14 5 6 135 135 121 X121 121 121 121 G R15 G RLA 81 m m 5 5 5 p 5 5 2 mmm
29. 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 telescopic handler as equipped for handl
30. available please contact your agent or dealer Do not use the lift truck in protected areas Such as Refineries explosive atmosphere Special optional equip men 15 available for use in such spaces Please contact your agent or dealer PLEASE CONTACT YOUR AGENT OR DEALER IF NECESSARY INTRODUCTION TO SAFETY 860 L 9501 Evolution 1 RECOMMENDATIONS FOR USING THE TRUCK LEVELLING DEVICE 860 LT 950 LT machines are provided with a device for levelling the chassis with respect to the ground and therefore raise the boom to the required height This device is used to correct the level by 8 to the right and 8 to the left IMPORTANT Using the device Level the machine before raising the boom using the spirit level provided as reference The levelling operation can only be carried out with the boom less than 2 metres above the ground If the machine is not level lower the boom again and repeat the levelling operation Take great care while moving the machine with the boom raised with or without load if possible carry out the load deposit operations with the machine stopped INTRODUCTION TO SAFETY 1 860 L 950 L Zeclatiou DRIVING INSTRUCTIONS A DRIVING SEAT Wear suitable clothing for driving the truck and avoid loose clothing Never d
31. 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 soeed that will permit it to be brought to a stop in a safe manner 34 Travel with load engaging means or load low and where possible tilted back Do not elevate the load except during stacking 35 Make starts stops turns or direction reversals in a smooth manner so as not to shift load and or overturn the rough terrain forklift truck 36 Do not indulge in stunt driving or horseplay 37 Slow down for wet and slippery surfaces 38 Before driving over a dockboard or bridge plate be sure that it is properly secured Drive carefully and slowly across the dockboard or bridge plate and never exceed its rated capacity 39
32. for leaks Check the level and add more liquid if necessary Dispose off the used liquid according to the regulations in force in the country of use The engine has no anticorrosion elements and must be kept filled throughout the year with a mixture with a minimum 25 content of anti frost TABLE F5 4 FREEZING POINT DEPENDING ON OF ANTIFREEZE Antifreeze Temperature MANITOU ANTIFREEZE 25 12 33 19 40 26 50 38 INTRODUCTION TO SAFETY 860 L 950 L Evolution 3 OCCASIONAL MAINTENANCE 1 CHANGING A WHEEL If the wheel needs replacement while travelling on the road proceed as described below If possible stop the lift truck on level compact ground Switch the lift truck off see 1 SAFETY INSTRUCTIONS AND REGU LATIONS INSTRUCTIONS FOR DRIVING WITH AND WITHOUT LOAD Turn the emergency lights On Apply wedges to block the lift truck in both directions on the axle oppo site the wheel to be replaced Slacken the bolts of the wheel to be replaced so that they can be remo ved without much effort Fit and adjust jack 1 fig G1 1 under the axle shaft as close as pos sible to the wheel Raise the wheel off the ground and position safety support 2 Fig G1 2 under the axle The use of a safety support is compulsory for carrying out this operation Unscrew the wheel bolts completely and remove them Remove the wheel us
33. low temperatures remove the battery from the truck and store it warm place until it is used INTRODUCTION TO SAFETY 860 L 9501 Evolution 4 HOLDER AND RELAYS BOARD The truck 15 provided with a fuse holder and relays board Fig B which protects the electric circuit This fuse holder and relays board is screwed on a base plate in the cab under the dashboard To change a fuse remove and replace with a new fuse having the same quality and calibration In case of a power failure check all the fuses and see if there has been a short circuit Never attempt to repair a blown fuse INTRODUCTION TO SAFETY 950 L Evolution MHT 860 L Y3HSV 13 00 E IBN 020481 SCATOLA FUSIBILI E RELE MATT 8601 25 01 2 E x INTRODUCTION TO SAFETY 860 L 9501 Evolution FUSE BLOCK AND RELAY BOARD Code F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 8 1 4 4 1 9 7 3 8 3 8 3 6 2 8 4 8 5 7 3 7 3 7 2 7 2 8 4 8 5 6 3 6 3 8 5 6 3 7 1 8 1 8 2 4 2 9 4 sl 3 3 7 2 6 2 2 5 6 2 4 4 7 2 4 5 3 3 8 1 3 2 3 2 5 3 8 2 5 4 8 2 3 4 8 5 8 3 4 3 5 3 4 2 8 4 Sheet Function 15A fuse main beams 10A fuse sensors power supp
34. lower boom 3 to bring the load to the transport position Fig K 19 INTRODUCTION TO SAFETY 1 860 L 950 L D DEPOSITING A LOAD AT A HEIGHT ON TYRES Do not deposit the load unless the lift truck 15 non a level surface See paragraph G HORIZONTALITY OF THE LIFT TRUCK in chapter HANDLING A LOAD Bring the load to the transport position in front of the stack Fig L Raise and extend boom 1 2 so that the load is above the stack moving lift truck 3 forwards if necessary Fig M gently and careful ly See paragraph E VISIBILITY in chapter HANDLING INSTRUC TIONS regarding visibility of the path Apply the parking brake and set the reverse gear lever in neutral Position the load horizontally and place it on the stack lower and retract boom 1 2 to position the load correctly Fig N Release the forks retracting and raising boom 3 alternately Fig N or if possible reversing the lift truck 3 See paragraph E VISIBI LITY in chapter HANDLING INSTRUCTIONS relative to visibility of the path Then bring the boom to the transport position E PICKING UP A LOAD WITHOUT PALLET Incline fork arm 1 forwards and extend boom 2 at the same time inclining fork arm 3 backwards to insert the forks under the load Fig O taking care to ensure the longitudinal and lateral stability of the load Wedge the load if necessary LOAD
35. 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 utilities w
36. oil see Table LUBRICANTS through and level hole 13 Fig 2 The level is correct when the oil reaches hole 13 Fig 2 Refit drain and level plug 13 Fig 2 and tighten it Repeat the operation for each of the rear wheel reduction gears Dispose off the used oil according to the regulations in force in the country of use 24 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 6 CHANGE THE TRANSMISSION BOX OIL The lift truck must be parked on a level horizontal surface with the combustion engine switched off and the gear oil still warm Place a container under plug 14 Fig 26 and let all the oil flow out D Remove level and filler plug 15 Fig 26 to make sure the tank 15 3 7 y 4 5 completely drained A ANT Screw plug 14 Fig M We Fill oil see Table LUBRICANTS through filler hole 15 Fig E6 Wo gt Check for leakage through drain plugs Dispose off the used oil according to the regulations in force in the country of use E 7 EMPTY AND CLEAN FUEL TANK During this operation avoid smoking or using a flame Position the lift truck on a level horizontal surface the combustion engine must be switched off Inspect the parts subject to leakage on the fuel circuit and the tank Contact your agent or dealer in case of leakage
37. the lift truck and is used for a trailer The capacity for each lift truck is limited by the total permitted carriage weight the pulling force and the maximum vertical force on the drawbolt These data are indicated on the manufacturer s plate affixed on every lift truck N B Optional solutions are available for towing for more information please contact your agent or dealer Travelling on roads with a trailer is only permitted for homologated tural tractors Check the braking system and trailer signalling system and connect these to the lift truck Reduce the lift truck speed Follow the road rules of the country of use Ensure that the split pin 15 fitted correctly on the hitch 30 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 27 INTRODUCTION TO SAFETY 2 860 L 950 L 31 REAR LIGHTS A Left rear indicator B Left rear stoplight Left tail light D Left rear reverse light E Left rear fog light F Right rear indicator G Right rear stoplight H Right tail light Right rear reverse light L Right rear fog light 32 ROTARY TOWER LIGHT The rotary tower light may be inclinded if necessary to reduce the lift truck dimensio
38. the rest of the travel produces the braking effect 14 gt REVERSING CONTROL The lift truck gear reversal must be done at low speeds without accelerating FORWARD Push the knob forward position C REVERSE Pull the knob backwards position NEUTRAL The knob must be in the intermediate position to start the lift truck position E NOTE The reversing lights indicate that the fork lift truck is moving in reverse reversing buzzer 15 also present If the forward reverse movement is not activated see point page 16 These indications must be followed for proper working of the transmission SAFETY FOR MOVING THE LIFT TRUCK Authorisation to move the lift truck is controlled by an electronic unit The operator must observe the following sequence to move the truck forwards or backwards 1 sit down correctly in the driver s seat 2 release the parking brake 3 engage forward or reverse movement To stop the lift truck he must observe the following sequence 1 set the reversing gear in neutral 2 engage the parking brake 3 get out of the lift truck NOTE the operator leaves the driver s seat for a short time with the for ward or reverse movement activated the vehicle will continue to move If the operator leaves the driving seat for a long period with the for ward or reverse movement activated the vehicle will set itself in idle mode the operator will have to return to the drive
39. the skin or the eyes Check to make sure the ignition key is turned off before carrying out maintenance or repairs on the fuel supply system since the pump will start supplying fuel if the engine is switched on Do not let impurities enter the fuel supply system Before disconnecting a union clean the surrounding surface carefully After disconnecting one of the components fit a suitable cover on all open unions Make sure the engine 15 stationary before carrying out maintenance or repairs on it After the engine is stopped before carrying out maintenance and repair operations on the fuel pipes wait for 60 seconds to allow pressure to be discharged Eliminate leaks if any from the supply system Replace the fuel piping that has leaks Place a suitable container under the fuel filter unit to collect the fuel that flows out Clean the outer surfaces of the fuel filter thoroughly Use a Suitable tool to dismantle the used fuel filter 11 Fig D5 from the engine Dispose off the used cartridge and the liquid contained in it in accor dance with the regulations in force in the country of use Make sure dirt cannot enter the new fuel filter see Table FILTER ELEMENTS AND BELTS Do not fill the new fuel filter before assembly Do not lubricate the sealing ring on the new fuel filter Insert the new filter Do not use a tool to insert the filter Tighten the filter manually Remove the container and dispo
40. the type of operations carried out in the vicinity of electric lines Do not let anyone approach the lift truck operating area or walk under a load For using the lift truck on sloping ground before raising the boom check to make sure the truck is horizontal Lift trucks provided with level correctors and or stabilisers can be used on transverse slopes as long as this inclination is corrected See paragraph G HORIZON TALITY OF LIFT TRUCK in the HANDLING A LOAD Chapter Moving on longitudinal slopes Move forward and brake gently Movement without load The fork arms and accessory facing downwards Movement with load The fork arms and accessory facing upwards Check to make sure the scaffolding loading surface or the stack can support the load Ensure the stability and compactness of the ground before depositing the load 15 INTRODUCTION TO SAFETY 1 860 L 950 L D HANDLING OPERATIONS Always observe the safety rules always transport loads balanced and placed correctly to avoid risk of tilting over Insert the forks all the way under the load and move to the transport position The forks 12 in off ground the boom completely retrac ted and the fork arms inclined backwards For obvious reasons of stability of the lift truck and good visibility move the lift truck only when the boom 15 in the transport position Move the lift truck with the boom raise
41. to start up the combustion engine always connect terminals having the same polarity Fig A Mount a battery having the same voltage as that on the truck If an outside charger is used always connect the wire of the char ger to the terminal of the battery and the wire of the charger to the terminal of the battery and earthing Never short circuit the alternator terminals or earth them Never invert the alternator connections on the battery Never dismantle or change an electric connection with the engine run ning In case of electric welding on the truck connect the negative cable of the welder directly to the part to be welded to prevent high voltage cur rent from passing through the alternator and then disconnect the batte INTRODUCTION TO SAFETY 4 860 L 950 L LIGHTING A fused bulb must be replaced immediately Never handle a new bulb with bare or dirty hands since traces of grease oil or sweat will evaporate when the bulb is heated and thus stain the reflector Never touch or try to polish the reflector Open the headlight only to change the bulb BATTERY The battery efficiency is proportional to the reduction in temperature and finally ceases at 40 F Never try to use the starter motor if the battery is exposed to a temperature around 20 F In such cases heat the battery by immersing it in warm water to a level of 2 in below the covers In case of very
42. to the regulations in force in the country of use 22 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 E 3 REPLACE HYDRAULIC OIL SUCTION FILTER CARTRIDGE Drain out the hydraulic oil tank see 2 Remove hydraulic oil filter cartridge holder flange 4 Fig E3 1 Remove the hydraulic oil suction filter cartridge 5 Fig 2 from the flange and replace it with a new one having identical features see Table FILTER ELEMENTS AND BELTS Dispose off the used filter according to the regulations in force in the country of use Refit hydraulic oil filter cartridge holder flange 4 Fig E3 1 ensuring the correct positioning Filling the tank Check to make sure the flanges with connecting tube 6 fig E3 3 are locked tight Fill theoil tank see Table OILS GREASE FLUIDS FUELS FIL TERS through filler hole 7 Fig E3 4 till the oil level reaches the marking on level indicator 8 Fig E3 5 Check for leakage from the flanges with connecting tube 6 fig E3 3 and flange 4 Fig E3 1 Refit the tank cap 7 fig E3 4 Use filtered uncontaminated oil It may sometimes be necessary to leave the combustion engine running at low speed for a few minutes to bleed the pumps inlet circuits if an air bubble has been formed during drainage If air bubbles persist consult your agent or dealer HUILE HYDRA QuE AYORA NIDRAULIK ACE
43. truck INTRODUCTION TO SAFETY 860 L 9501 Evolution C STARTING UP THE TRUCK The lift truck can only be started up or operated with the driver in the driver s seat with the seat belt on and adjusted SAFETY REGULATIONS Do not start the lift truck by towing or pushing it This operation can result in serious damage to the gears If the lift truck is to be towed turn the gear to neutral See Chapter H OCAS SIONAL MAINTENANCE in part 3 MAINTENANCE INSTRUCTIONS Check to make sure the reverse gear lever is in neutral Turn the ignition key to position to allow electric contact Check the fuel level on the indicator Turn the ignition key to position to allow preheating and wait for 15 seconds if the environmental conditions require it Do not run the starter motor for more than 15 seconds and allow preheating for 10 seconds between the various attempts made Press the accelerator and turn the ignition key all the way the engine must start Release the ignition key and let the engine run at low speed Before operating in very cold climatic conditions wait for the combu stion engine and the hydraulic systems to heat up correctly Observe all the control instruments immediately after start up with the engine hot to detect and solve problems rapidly if necessary If one of the instruments shows a fault switch the engine off and carry out the necessary operat
44. 00 mm Rated capacity with standard equipment 6000 kg Weight with standard equipment and forks 11580 kg Distribution of wt along axle with standard equipment Front axle no load 4400 kg Rear axle no load 7180 kg Weight loaded with standard equipment and forks 17580 kg Wt loaded with boom retracted and forks 20 cm off the ground Front axle kg Rear axle kg Towing capacity No load 9200 daN With load 10500 daN Vibrations Acceleration of upper limbs lt 2 5 m s Acceleration of body feet or seated part lt 0 5 m s Noise The noise level guaranteed LwA 105 dB in accordance with Directive 2000 14 CE modified by Directive 2005 88 CE Noise level in driving seat in accordance with EN 12053 LpA 80 8 dB INTRODUCTION TO SAFETY 2 Specifications 950 Maximum speed Forwards Backwards without load Forwards Backwards with load Lifting speed without load with boom retracted Descent speed without load with boom retracted Extension speed without load Boom retraction speed without load Upward inclination time without load Downward inclination time without load Fork dimensions length x width x thickness Max boom ext distance from fork Distance from centre of gravity Standard lifting height Rated capacity with standard equipment Weight with standard equipment and forks Distribution of wt along axle with standard equipment Front ax
45. 2 INTERCOOLER sin 2 SOLENOID VALVE X X a INVERSION KIT X103 125 2 3 5 NITOU IMPIANTO ELETTRICO TAVOLA MIA L 9 17 INTRODUCTION TO SAFETY 4 860 L 950 L A A E 4 ____ 225 PLATFORM CABLE os is m LIGl 35 25 1 ae ABI 5s AGI 2 p CBI 5 3 gt 1 23 22 n 85 B R1 85 G R1 85 E 85 85 L1 GSS e 8 5 51 85 GNI E 85 R G1 i ue Lus 1109 X110 2412412 2 Y110 pocos TRAILER X p X TRAILER BRAKE CONNECTOR VALVE KIT 109 110 2 2 2 n 2 95 31 ca ME TOU IMPIANTO ELETTRICO TAVOLA MAR L 10 18 INTRODUCTION TO SAFETY 860 L 950 L Evolution 4 HYDRAULIC SYSTEM UM NW AE 2 MOVEMENTS HYDRAULIC SYSTEM LAYOUT x poene ESL T gu gt Iesse SS PET 8 HHE ae o EN N 294 C gt A EN e H l del 19 INTRODUCTION TO SAFETY 4 LEGEND OF MOVEMENTS HYDRAULIC SYSTEM LAY OUT 20 Accumulator Relief and balancing valve Double relief valve Piloted relief valve Dist
46. 712 800 433 3304 WWW Manitou na com TRUCK MODEL SERIAL NUMBER ____ CAES YEAR OF MFG TIRE PRESSURE FRONT BI TIRE PRESSURE REAR MN es FOR CAPACITIES REFER TO THE APPROPRIATE CHART OR CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DESIGN STANDARDS ANSI ASME 56 6 MANUFACTURED XVI 496538 MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 MAST MODEL mast 55 ATTACHMENTS S UNLADEN WEIGHT MM 95 YEAR OF mc A inches CAPACITY MM Les UP TO B a INCHES max CAPACITY MS ces AT MFH B INCHES TIRE PRESSURE FRONT TRE PRESSURE REAR ES 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 GROUND INTRODUCTION TO SAFETY 860 L 9501 Evolution 5 1 INSTRUCTIONS ORIGINAL SPARE PARTS AND EQUIPMENT OPERATING INSTRUCTIONS FOR THE FORK TRUCK Warnings General instructions Recommendations for using the lift truck Driving instructions Handling instructions Handling a load INSTRUCTIONS FOR LIFT TRUCK MAINTENANCE BEFORE STARTING UP A NEW LIFT TRUCK 2 DESCRIPTION FEATURES DIMENSIONS LOAD CHARTS CONTROL AND COMMAND INSTRUMENTS 3 MAINTENANCE FILTER
47. AFETY RULES AND PRACTICES cont 19 Do not use a rough terrain forklift truck for opening or closing railroad car doors 20 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 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 15 obstructed 29 Cross railroad tracks at an angle wherever possible Do not park closer than 6 ft 1 8m to the nearest rail of a railroad track 30 Keep a
48. C UNIT DIAGNOSI REXROTH o dl 5209 do bob brkbki i X365 gt gt 418 ele lalola fal lee 5 8 P 5 g 2 4 3 L N1 7 MY l HMM ea 1 5 o Mel 2 _ gt ME G0 5 CAV05 15 AAA 71 _ 15 21 14 5 61 25 L N1 2 3 Q9 15 15 228 F16 1 1 10 15 das P3al32 6 1 fi ill il 2 5 G R1 G R1 DIAGNOSTICK Es Hm 15 KEY 15 G0 5 CAV06 15 N0 5 06 71 71 15 R2 5 OPTIONAL SUPPLY 55 31 31 71 INTRODUCTION TO SAFETY 860 L 9501 Evolution 4 is T 1 xg x192 E EE E EE 1 HH po ibi Ti iP EES P175 5204 o v Y Y HEATING Al PANEL WITCH 2 2 2 2 of 8 a 7 3 8 bb a 2 52 gt g 175X175X175 X175 204 4 204 8204 32K 179X179 2 8 a gl 3 2 3 5 9 A A ee B G1 5 ss 1 61 5 gt T 15 15 4 F11 F12 7 5 7 5A e i 5 K181 86 87a 87 T 85 P 30 182 X182 X182 182 gt 2 ED AA Ed n 0 11 R1 TR __ E 1 1 LL LL
49. CLEAN AIR FILTER CARTRIDGE Release blocks 1 Fig 1 1 and remove cover 2 Fig B1 1 Remove cartridge 3 carefully Fig B1 2 to reduce dust dispersal to the minimum Do not remove the safety cartridge Clean the filter cartridge using a jet of compressed air always directing the jet outwards from inside Wipe the inside of the filter with a damp clean cloth that does not leave residue after covering the combustion engine inlet pipe Check the condition of the cartridge Cartridges that are no longer efficient must be replaced immediately Insert cartridge 3 Fig B1 2 in the filter rod pressing the cartridge around the edges not in the middle Refit cover 2 Fig B1 1 orienting the valve correctly for correct working of the valve do not exceed the inclination of approx 20 and tighten blocks 1 Fig B1 1 Never wash an air filter cartidge 2 CHECK THE HYDRAULIC OIL LEVEL Position the lift truck on a level surface with the combustion engine swit ched off and the telescopic boom retracted and lowered all the way down Check indicator 4 Fig B2 1 The oil level is correct when it is slightly below the maximum level A 1 NA Add oil if necessary see the LUBRICANTS Table through filler hole 5 Fig B2 2 Always keep the oil level maximum for optimum performance E INTRODUCTION TO SAFETY 3 860 L 9501 Zeclation
50. CTION TO SAFETY 3 860 L 950 L Zeclatiou EVERY 1000 HOURS OF SERVICE OR YEARLY E 1 REPLACE THE AIR FILTER SAFETY CARTIDGE Dismantle the air filter see operation D3 Remove cartridge 1 Fig E1 very carefully to reduce dust leakage to the minimum and dispose it according to the regulations in force in the country of use Wipe the inside of the filter with a damp clean cloth that does not leave residue protecting the combustion engine inlet pipe Never wash an air filter cartridge Fit a new cartridge 1 Fig having identical features see Table FILTER ELEMENTS AND BELTS in place of the one removed inser ting it on the filter rod pressing the cartridge around the edges not in the middle Refit the assembly see operation D3 2 DRAIN AND CHANGE THE HYDRAULIC OIL Before carrying out these operations make sure the lift truck 15 parked on a level surface with the engine switched off Place a container under the flanges with connecting tube 2 fig 2 1 To unscrew the 12 screws and to remove the flanges with connecting tube 2 fig E2 1 To hasten drainage remove filler plug 3 to let air in fig E2 2 When the tank is empty refit the flanges with connecting tube 2 fig E2 1 tightening the 12 fixing screws 12 and proceed with dismantling the hydraulic oil filter cartridge Suction side See operation E3 Dispose off the used oil according
51. D SAFETY DEVICE The load control and safety device makes it possible for the operator to know the condition of the lift truck in relation to the maximum permitted load WORKING When the lift truck electric contact is activated a test is carried out automatically Correct working the LEDs and alarm sound function continuously for 2 sec onds Defective working All the LEDs and alarm sound function intermittently Switch off the lift truck and contact your agent or dealer never attempt to carry out repairs yourself A LED VISUAL ALARM Fig 4 1 Fig 4 2 A1 4 green LEDs The lift truck is operating in complete safety A2 2 yellow LEDs The lift truck is approaching the maximum permitted load limit A3 1 red LED The lift truck has reached the maximum permitted load limit The alarm sound is activated simultaneously slowly and intermittently A4 2 red LED The lift truck is overloaded The alarm sound is activated slowly intermittently and rapidly Carry out the hydraulic movements in the following sequence retract and lower the boom When the A4 2 red LED switches on the hydraulic commands are blocked automatically Only boom retraction and inclination of the forks are permitted Do not turn key 4a to disconnect automatic blocking of the movements this must only be used in operating conditions using the shovel ALARM SWITCH Fig 4 1 Fig 4 2 Allows or inhibits use of the alar
52. HT D PF FLOTT L 1030 4999 Kg 1127 1130 456 Kg PF FLOTT L 1430 7500 1545 1325 270 300mm 565 Kg FORK SPECIFICATIONS CAPACITY DIMENSIONS WEIGHT pA BC 2 2500 Kg 150 60 1200 141 Kg 2 X 3750 Kg 200 60 1200 198 13 INTRODUCTION TO SAFETY 5 FORK HOLDER SPECIFICATIONS 860 L 9501 SPECIFICATIONS DESCRIPTION CAPACITY mm D PF FEM 3 1320 4999 Kg 1404 340 Kg PF FEM 4 1750 7500Kg 1800 850 Kg PF FEM 4 2000 7500 2050 870 320 200mm DIMENSIONS ACCESSORY WEIGHT 980 Kg FORK SPECIFICATIONS DESCRIPTION CAPACITY 3 2 X 2500 Kg 150 50 1200 104 50 FEM 4 2 3750 Kg 200 60 1200 DIMENSIONS rami WEIGHT 14 INTRODUCTION TO SAFETY 860 L 9501 Evolution FEM FORK HOLDER WITH TRANSFER DEVICE SPECIFICATIONS SPECIFICATIONS DIMENSIONS ACCESSORY DESCRIPTION CAPACITY WEIGHT D TDL FEM 3 1320 4999 1404 618 118 20mm 490 Kg TDL FEM 4 1750 7500 Kg 1800 755 140 200 mm 1130 Kg FORK SPECIFICATIONS DESCRIPTION CAPACITY DIMENSIONS mm WEIGHT F FEM3 2X2500Kg 150 50 1200 104 Kg 4 2 X 3750 Kg 200 60 1200 195 Kg 15 INTRODUCTI
53. IC BOOM ARTICULATION PIN 9 CLEAN AND GREASE QUICK RELEASE CULATION PIN B 10 CLEAN AND GREASE LIFT JACK BASE Fig B10 1 AND ROD 9 10 2 PINS 12 INTRODUCTION TO SAFETY 860 L 9501 Evolution B 11 CLEAN AND GREASE COMPENSATION JACK BASE Fig B11 1 AND ROD Fig B11 2 PINS 12 CLEAN AND GREASE SLEWING CYLINDER BASE Fig B12 1 AND ROD Fig B12 2 PINS 13 3 860 L 9501 Zeclatiou 13 CLEAN AND GREASE LEVELLING JACK BASE Fig B13 1 AND ROD Fig B13 2 PINS 14 CLEAN AND GREASE THE TWO FRONT AXLE OSCILLATION BUSHINGS Fig B14 1 Fig B14 2 B 15 CLEAN AND GREASE THE TWO REAR AXLE OSCILLATION BUSHINGS Fig B15 1 Fig B15 2 B 16 CLEAN AND GREASE CROSS JOURNALS AND CARDAN SHAFT Fig B16 1 Fig B16 2 14 INTRODUCTION TO SAFETY 860 L 950 L Evolution 3 EVERY 250 HOURS OF SERVICE 1 CHECK ALTERNATOR BELT TENSION DRI VING SHAFT The alternator belt tension must be adjusted in such a manner that when pressed normally with the thumb the belt must give by about 10 mm Fig C1 If the tension is not correct slacken screws 1 and 2 Fig C1 by 2 or 3 turns of the thread and rotate the alternate unit to obtain the required tension Retighten screws 1 and 2 Fig C1 Check the condition of the belt for signs of wear or cracks and replace it if necessary see operation No E8
54. INTRODUCTION TO SAFETY MANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DRIVE Waco 76712 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Email parts mna manitou com MHT860 EVOLUTION OPERATOR SERVICE MANUAL THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK IT MUST BE READ AND UNDERSTOOD BY THE LIFT TRUCK OPERATOR CATALOG 648434AS R11 10 INTRODUCTION TO SAFETY 860 L Evolution eet L Evolution Tarba INTRODUCTION TO SAFETY 950 L 950 Evolution Tarba INTRODUCTION TO SAFETY INTRODUCTION TO SAFETY ROUGH FORKLIFT TRUCK GENERAL SAFETY STANDARDS SAFETY MES SAFETY VIII TABLE OF CONTENTS see 6 see rete E E sees pes pa 1 INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS STUDY THE OPERATOR SERVICE MANUALS The information in this manual provides general instructions for the safe operation and maintenance of your forklift truck This information 15 vital and must be clearly understood by the operator and serviceman Study this manual and the Rough Terrain Forklift Safety Manual part no 422494 tho
55. ION TO SAFETY 1 860 L 9501 DRIVING THE TRUCK ON THE ROAD SAFETY REGULATIONS The general road traffic rules must be observed for driving a lift truck on roads The lift truck must conform to the general road safety rules applicable in the country of use Optional solutions are available if necessary Please contact your agent or dealer for more information It is forbidden to transport loads along roads and the accessories mounted on the lift truck must be fitted with equipment according to regulations or must be dismantled INSTRUCTIONS FOR DRIVING ALONG ROADS Check to make sure the flashing light is installed and in working order Low beams must also be used on roads and at times when the use of visual signals or lights is not obligatory Check the headlights direction lights and windscreen wipers to make sure they are clean and in working order Check the position of the rearview mirrors Check wheel alignment and select the ROAD TRAVEL steering mode Position the rear axle steering mechanical block Make sure there 15 sufficient fuel Fit all the accessories required for road travel depending on the model and the country Retract the boom and the accessory to about 12 in off the ground Level the machine with the chassis parallel to the ground using the inclination corrector Exclude the operating system commands by means of the swicht Se
56. ITE HIDRAUI 23 INTRODUCTION TO SAFETY 3 860 L 9501 Zeclatiou E 4 EMPTY AND CHANGE THE FRONT AND REAR AXLE DIFFERENTIAL OIL Park the lift truck on a level surface with the engine switched off and the differential oil still warm Drain out the front axle differential oil Place a container under plugs 9 Fig E4 and let the oil drain out Remove level plug 10 Fig E4 and filler plug 11 Fig F4 to ensure complete drainage and tighten plugs 9 Fig 4 Fill oil see Table LUBRICANTS through filler hole 711 Fig E4 The level is correct when the oil reaches the level hole 10 Fig E4 Check for leakage from the drain plugs Refit and tighten level plug 10 Fig E4 and refit plug 11 Fig E4 Repeat the operation for the rear axle differential Dispose off the used oil according to the regulations in force in the E4 country of use 5 EMPTY AND CHANGE THE FRONT AND REAR WHEEL REDUCTION GEAR OIL Park the lift truck on a level surface with the engine switched off and the differential oil still warm Drain each front wheel reduction gear Turn the and level plug 12 Fig E5 1 downwards to position A Place a container under the drain plug and unscrew the plug Let all the oil flow out Turn the drain and level hole to horizontal position Fig 25 2 1 in the level position Fill
57. NG Change the gas if the air is not as cool as required use 1 kg of 134 FREON in case of leakage or parts replacements change the oil using 60 g of special oil for Air Conditioning compressor 33 4e BLECTRIC AND FORAY LIG SYSTEM INTRODUCTION TO SAFETY 860 L 9501 Evolution 4 ELECTRIC SYSTEM STARTER MOTOR The starter motor is fitted to the left of the engine and it needs no maintenance apart from cleaning and tightening of the terminals Contact your agent or dealer if the starter motor does not work correct ly ALTERNATOR The alternator is mounted on the left of the engine The alternator and the regulator are designed to function in a system polarized in one direction only it is therefore necessary to take the following precau tions while working on the battery charge circuit as it can otherwise cause serious damage to the electrical equipment Do not activate the alternator with the circuit open but make sure all the terminals are tightened Do not dismantle the terminals on the back of the alternator with the combustion engine running as it can otherwise damage the alternator When installing a battery make sure the connections are polarized correctly The wire marked must be connected to the positive termi nal of the battery and the wire marked must be connected to the negative terminal of the battery and it must be earthed If a second battery is used
58. ON TO SAFETY 5 860 L 9501 WINCH 3 5 TON SPECIFICATIONS LUBRICATION HOOK ROTATION AT 40 250 5 30 HOURS SPECIFICATIONS DIMENSIONS CE DESCRIPTION CAPACITY ROPE HOOK LIMIT HOOK WEIGHT SPEED STOP 3000 Kg WITH 1500 Kg 10 mm 5000 Kg WITH 2500 Kg Y 12 mm WINCH 5 2 ROPES DIRECT x46m 18 m min HYDRAULIC 1070 1830 900 200 5 TON 420 Kg 16 INTRODUCTION TO SAFETY 860 L 9501 Evolution Arm P 600 SPECIFICATIONS SPECIFICATIONS DIMENSIONS ACCESSORY HOOK DESCRIPTION CAPACITY fain DISTANCE D 600 600 830 815 4027 1320 mm 3910 mm WEIGHT 210 Kg 17 INTRODUCTION TO SAFETY 5 860 L 950 L Arm PT 600 SPECIFICATIONS DESCRIPTION ROPE BLOCK WINCH RED GEAR HOOK ROTATION LUBRICATION OIL AT 40 30 HOURS DESCRIPTION PT 600 SPECIFICATIONS ACCESSORY HOOK CAPACITY ROPE HOOK LIMIT mm rem DISTANCE WEIGHT SPEED STOP 600 Kg m 45 m min IDRAULICO 830 815 4027 1170 mm 3840 mm 320 Kg 18 INTRODUCTION TO SAFETY 860 L 9501 Evolution Arm P 1200 SPECIFICATIONS SPECIFICATIONS DIMENSIONS ACCESSORY HOOK DESCRIPTION CAPACITY DISTANCE WEIGHT
59. R KNOB This knob is used to adjust the temperature inside the cab C The valve is closed the fan supplies cold air D The valve is completely open the fan supplies hot air The intermediate positions are used to adjust the temperature INTRODUCTION TO SAFETY 2 860 L 9501 Zeclatiou 20 AIR CONDITIONING OPTIONAL A COMPRESSOR SWITCH This switch has 2 positions AO Off indicator switched off A1 On compressor and indicator light switched on N B The lights indicates that the compressor is switched on ATTENTION The compressor can only be switched on with the fan knob turned to the B1 B2 or position If the fan knob is in the BO position the compressor will not switch on B Knob Adjusts the air flow in the supplementary air vents behind the driver s seat BO Off B1 1 speed B2 2 speed 3 sped Adjust the direction of the vents present behind the driver s seat C Fig 20 2 21 AIR VENTS These vents direct the ventilation inside the cab they are present in the upper part of the cab D Fig 21 1 and at the operator s feet E Fig 21 2 24 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 22 CEILING LIGHT The switch 15 built into the ceiling light It has two positions continuous lighting and Off 23 SUNSHADE OPTIONAL Front sunshade Adjust the height o
60. RESSURE RED INDICATOR LIGHT OPTIONAL If the indicator lights up during the working of the forklift truck switch off the engine immediately and contact your agent or dealer ENGINE FAULTS MONITORING TABLE i aa Descrizione dello stato della spia Stato del motore Quando si ruota il commutatore a chiave di avviamento ACCESA ACCESA Verifica della spia Ae Il motore ancora spento 8 entrambe le spie si accendono per 2 secondi SPENTA SPENTA Nessun guasto Nessun codice diagnostico attivo Il motore funziona normalmente Codice ACCESA SPENTA stato rilevato un codice diagnostico attivo Il motore funziona normalmente diagnostico attivo LAMPEGGIANTE SPENTA uno erprotezene de l funziona normalmente LAMPEGGIANTE LAMPEGGIANTE Riduzione della stato superato uno o dei valori di protezione del Il motore funziona normalmente ma a otenza e allarme motore potenza ridotta stato superato uno o dei valori di protezione del e ACCESA ACCESA Arresto del motore motore oppure stato rilevato un codice diagnostico attivo grave 14 ACCESA LAMPEGGIANTE Codice stato rilevato un codice diagnostico attivo grave ed motore funziona normalmente ma a diagnostico attivo stata avviata una riduzione della potenza del motore potenza ridotta INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 4 LOAD CONTROL AN
61. RODUCTION TO SAFETY 860 L Evolution LOAD CHART ARM WITH HOOK PC 60 a Jib 6T eQ o 8 2 06 Q q O N ON lt 3 m 3934 2 9 22 14 4 3 Coo 72415 y The capacity diagrams are only valid if the safety system 15 activated 33 INTRODUCTION TO SAFETY 860 L Evolucion LOAD CHART Arm P 4000 Wo 4 69 15 m _ 74590 The capacity diagrams are only valid if the safety system is activated 34 INTRODUCTION TO SAFETY 860 L Evolution LOAD CHART Arm P 4000 1200 m L sz ll 35 220022 741591 The capacity diagrams are only valid if the safety system 15 activated INTRODUCTION TO SAFETY 950 L 5 LOAD CHART Arm P 600 P 600 Rd The capacity diagrams are only valid if the safety system is activated 36 INTRODUCTION TO SAFETY 950 L Evolution LOAD CHART Arm PT 600 PT 600 US EE 5 7 277 Ju E A HB Y DN Sr AS _ 55 AR Y H ME The capacity diagrams are only valid if the safety system 15 activated INTRODUCTION TO SAFETY 5 950 L Evolution LOAD CHART Arm P 1200 The capacity diagrams are only valid if the safety system is activ
62. SAFETY CONTROL DEVICE Always observe the load status indicator during handling operations When the load status indicator enters alarm condition do not A Extend the boom B Lower the boom In the event of a load status indicator alarm carry out the the operations described below Fig 1 Retract the boom all the way 2 Raise the boom if necessary 3 Lower the boom to deposit the load The device reading may be false if the steering is turned all the way or if the rear axle oscillates all the way Before lifting a load always make sure the steering 15 not turned all the way and that the rear axle 15 not completely oscillated 20 INTRODUCTION TO SAFETY 860 L 9501 Evolution 1 G HORIZONTALITY OF THE LIFT TRUCK FORK LIFT TRUCK WITH LEVELLING Apart from the transverse slope of the ground other parameters can affect the horizontality of the lift truck The condition and pressure of the tyres Stability of the ground Load balance Strong wind and storm Correct the inclination by acting on the hydraulic control and check the levelling using the spirit level before raising the boom See chapter INSTRUMENTS AND CONTROLS in part 2 DESCRIPTION Before each movement check the conditions listed above and make sure the lift truck 15 perfectly horizontal check the spirit level
63. SLINGING THE TRUCK Take into consideration the position of the truck s centre of gravity for lifting Fig G3 1 Position the belts in the anchoring seats provided Fig G3 2 and Fig G3 3 MHT 860 L MHT 950 L A 1663 mm 1712 mm 1067 1018 mm 2785 2855 D 2405 mm D 2425 mm G Position of centre of gravity G Position of centre of gravity G3 1 INTRODUCTION TO SAFETY 3 860 L 9501 Zeclatiou 4 TRANSPORTING THE TRUCK ON A PLATFORM Check to ensure that the safety instructions regarding the transport platform are applied correctly before loading the lift truck on it and make sure the truck driver 15 familiar with the dimensional features and weight of the lift truck See Chapter TECHNICAL SPECIFICATIONS in part 2 DESCRIPTION Ensure that the dimensions and loading capacity of the platform are sufficient for transporting the lift truck Also check the contact pressure with the ground authorized for the platform with respect to the lift truck For lift trucks provided with a turbo compressed engine plug the exhaust to prevent rotation without lubrication of the turbo shaft when the convoy 15 in motion LOADING THE LIFT TRUCK Block the transport platform wheels Fix the platform loading ramp in such a manner as to obtain the smallest possible angle to allow the truck to climb on the platform Load the lift t
64. SPECIFICATIONS DESCRIPTION CAPACITY ACCESSORY HOOK DISTANCE WEIGHT D 4000 4000 830 467 2832 900 mm 710 mm 2710 mm 210 Kg 23 INTRODUCTION TO SAFETY 5 860 L 9501 MIXER BUCKET SPECIFICATIONS SPECIFICATIONS iu iu MIX 350 350 1120 HYDRAULIC 540 Kg MIX 500 5001 1570 1080 1120 HYDRAULIC 540 Kg MIX 750 750 L 1570 1080 1120 HYDRAULIC 540 Kg DESCRIPTION CAPACITY INLET OPENING WEIGHT 24 INTRODUCTION TO SAFETY 860 L 9501 Evolution BucKET FOR CONCRETE SPECIFICATIONS DESCRIPTION GL 400 GL 600 GL 800 GL 1500 SPECIFICATIONS DIMENSIONS LACE Lo 400 L 880 Kg 1200 1285 157 Kg 600 L 1320 Kg 1540 1435 1070 277 Kg 800 L 1760 Kg 1540 1635 1070 308 Kg 1500 L 330 Kg 1790 1745 1135 613 375 Kg 25 INTRODUCTION TO SAFETY 5 860 L 950 L Evaluzia SHOVEL FOR BUILDING CONSTRUCTION SPECIFICATIONS D SPECIFICATIONS CAPACITY DIMENSIONS DESCRIPTION ACCESSORY WEIGHT LEVEL NOMINAL MAXIMUM 1500 L 2500 10201 1336 17001 2500 1041 1272 404 mm 370 Kg 26 INTRODUCTION TO SAFETY 860 L 9501 Evolution RECLAIM SHOVEL SPECIFICATIONS
65. TIONS However experienced the driver may be in this field he must become fully familiar with the location and function of all the instruments and controls before operating the lift truck When the contact key 15 turned without switching on the diesel engine an instruments test 15 carried out auto matically all the indicators light up and the buzzer starts sounding These stop when the diesel engine 15 switched on Check all instruments on board immediately after having started the truck when the engine has warmed up and at regular intervals during use This will help identify faults immediately and proceed with prompt remedies If an instrument fails to give the right indication switch off the engine and take the necessary measures to restore correct operation Using the lift truck without due regard for the above recommendations could be dangerous 10 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 1 DRIVER S SEAT STANDARD THE SEAT CAN BE ADJUSTED IN DIFFERENT WAYS TO MAKE MORE COMFORTABLE ADJUSTING THE WEIGHT Adjust the weight with the seat empty Take notch A of the seat as reference Turn knob according to the weight NOTE To avoid health problems before starting up the lift truck check the weight and adjust if necessary ADJUSTING THE HEIGHT Bring the seat to the required position until it clicks into place If the seat is raised beyond the last click it r
66. To deactivate the indicators press the switch again INDICATOR LIGHTS On inserting the electric contact of the fork lift truck all the red indicator lights and the buzzer of the panel must switch on thereby indicating that they are working correctly If one of these does not work carry out the necessary repairs O INDICATOR LIGHT NOT USED INDICATOR LIGHT NOT USED BRAKES FLUID LEVEL RED INDICATOR LIGHT If the indicator and buzzer switch on while the forklift truck is in operation switch the engine off immediately and check the brakes fluid level If the level is relatively low contact your agent or dealer PARKING BRAKE RED INDICATOR LIGHT indicator lights up indicating that the parking brake has been activated ALTERNATOR ENERGIZATION RED INDICATOR LIGHT If the indicator and buzzer switch on while the forklift truck is in operation switch the I C engine off immediately and check the electrical system and the alternator belt 13 INTRODUCTION TO SAFETY 2 860 L 950 L ENGINE OIL PRESSURE RED INDICATOR LIGHT If the indicator buzzer switch on while the forklift truck is in operation switch the engine off immediately and look for the cause of the problem see engine crank casing oil level ENGINE OIL TEMPERATURE RED INDICATOR LIGHT If the indicator and buzzer switch on while the forklift truck is in operation switch the engine off immediate
67. UCTION TO SAFETY 4 860 L 9501 Evaluzia LEGEND LEVELLING AND FANS HYDRAULIC SYS TEM LAYOUT E C L Levelling control solenoid valve F A Intake filter F R Exhaust filter M 1 engine M V R A Water radiator fan motor M V R O Oil radiator fan motor P V D Double fan pump R Oil tank V L Levelling cylinder 24 INTRODUCTION TO SAFETY 860 L 9501 Evolution If1OAV I WALSAS NOISSINSNV4AL 1 25 INTRODUCTION TO SAFETY 4 LEGEND HYDROSTATIC TRANSMISSION SYSTEM LAYOUT EEM EFS 26 Manipulator exclusion solenoid valve Parking brake solenoid valve Intake filter Exhaust filter engine Hydrostatic motor Brake pump Hydrostatic pump G connection of hydrostatic pump Radiator Oil tank Slow fast speed selector valve 860 L 950 L 92 OPTIONAL ACCESSORIES AVAILABLE INTRODUCTION TO SAFETY 860 L 9501 Evolution 5 INTRODUCTION The manufacturer provides you with a large range of perfectly adaptable accessories with guarantee for your lift truck The accessories are delivered together with a load chart relative to your lift truck The instruction booklet and load chart must be kept in the lift truck The use of possible accessories depends on the instructions in t
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69. a single fork arm Never lift a slung load by a single fork arm or using a plank For more information regarding the optional solutions available please contact your agent or dealer the accessory is not used keep it horizontal on the ground Prop unstable accessories properly Check to make sure the hydraulic quick release couplings of the accessory circuit are clean and protected Before each change of accessory operated hydraulically prevent dete rioration of the quick release hydraulic couplings by switching off the turn the contact key to position 1 drain pressure from the circuit by means of the knob C ENVIRONMENTAL OPERATING CONDITIONS Check to make sure there 15 adequate lighting Take care while lifting a load making sure there is nothing or no one that can be an obstacle to the operations being carried out correctly and avoid false movements If work is being carried out near overhead electric lines make sure the safety distance between the operating area and the power line is suf ficient Contact your local power supply Company for information 14 INTRODUCTION TO SAFETY 860 L 9501 Evolution You run the risk of being electrocuted or seriously injured if you work or park the lift truck very close to electric cables It is therefore impor tant to make sure the safety rules applied at the work site conform to the local regulations applicable for
70. ackets piping connections clamps and gaskets Carry out repairs if necessary 4 CHECK BRAKE CIRCUIT OIL LEVEL Position the truck on a flat level surface with the engine switched off Remove the guard for access to the brake oil tank The oil level in the tank must be at the maximum level Add oil if necessary through the filler hole 6 Fig B4 see the LUBRICANTS Table In case of abnormal drop in level consult your agent or dealer 10 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 5 CLEAN AND GREASE TELESCOPIC BOOM PADS This operation must be carried out every 50 hours up to the first 250 hours of service and then every 1000 hours of service subsequently Extend the boom completely Using a brush apply a layer of grease see 3 MAINTENANCE LUBRI CANTS AND FUEL on all four sides of the telescopic boom fig B3 Extend and retract the boom a number of times to distribute the grease uniformly Remove excess grease Must be done every week if the lift truck has not completed 50 hours of weekly service If used intensively in extremely dusty and oxidising environments reduce this frequency to 10 HOURS of service or daily 6 CLEAN AND GREASE CAB DOOR PINS 7 CLEAN AND GREASE FRONT AND REAR WHEEL PIVOT PINS 11 INTRODUCTION TO SAFETY 3 860 L 9501 Zeclatiou 8 CLEAN AND GREASE THE TELESCOP
71. all be freed of all responsibility Periodic checks are compulsory to keep the lift truck in state of conformity The checking frequency 15 defined by the regulations applicable in the country of use Maintenance or repairs not included in part 3 MAINTENANCE must be carried out by qualified personnel Contact your agent or dea ler for more information in compliance with the safety conditions to guarantee your own Safety and that of others ENVIRONMENTAL OPERATING CONDITIONS Equip the lift truck with an extinguisher if it is used in a place devoid of extinguishing means For information regarding the optional solu tions available please contact your agent or dealer Always take into account the climatic and atmospheric conditions of the place in which the machine 15 used Lubricant is filled at the factory using lubricants suitable for average cli matic conditions i e 15 to 35 For use in more severe ditions before starting up the truck drain out the lubricant and fill with lubricants suitable for operation at these temperatures The same applies to the cooling liquid Please contact your agent or Dealer for more information Protection from frost See Chapter LUBRICANTS AND FUELS in part 3 MAINTENANCE Use of suitable lubricants Please contact your agent or Dealer for more information Engine filters Lights Work light For more information regarding the options
72. and blocked perfectly on the fork holder Fig C MANUAL BLOCK Take the check pin on the support and block the accessory Remember to fit the split pin Fig D MANUAL RELEASE Repeat the MANUAL BLOCK procedure in reverse order taking care to refit the check pin in the support on the chassis REMOVING AND PLACING THE ACCESSORY Repeat the ACCESSORY PICKUP procedure in reverse order taking care to place it in a safe position on compact level ground INTRODUCTION TO SAFETY 860 L 9501 Evolution 5 ADJUSTING THE OPENING OF THE FORKS Raise the lever of the forks check pin Fig A Move the forks manually to the required operating width Lower the check pin rod Fig B and move the forks until they are inserted in the locking notch present on the fork carriage Fig C When lifting loads with the lift truck first check to make sure the fork check pin 15 inserted in the notch present on the fork carriage PERIODIC INSPECTION OF THE FORKS Check the thickness at the fork heel to make sure it is not less than 90 of the original thickness which for forks with constant section corresponds to the shoulder thickness see 150 standard 5057 Check for permanent deformation or alignment defects if any in con formity to 150 standard 5057 The difference in height of the tips must be less than 3 of the length of the horizontal part of the fork The permanent deformations must be checked by
73. ansmission This precaution must be strictly observed in case of frequent stopping of the combustion engine Never leave the ignition key in the lift truck in the absence of the driver When the fork lift truck is stopped lower the fork or accessory to the ground set the reverse gear lever in neutral and apply the parking brake the driver needs to leave his seat even momentarily the reverse gear lever must be turned to the neutral position and the parking brake must be applied Make sure the lift truck is parked in such a manner that it does not obstacle movements and 15 at least one metre away from railway lines the lift truck is to be left parked for long periods protect it from bad weather particularly frost Check the antifreeze level close the rear window lock the cab door and the engine hood INSTRUCTIONS FOR STOPPING THE LIFT TRUCK Park the lift truck on level ground or a slope less than 15 Set the reverse gear lever in the neutral position Apply the parking brake Retract the boom completely Lower the fork arms or accessory to the ground completely level Switch the combustion engine off Remove the ignition key Check to make sure the door rear window and engine hood are locked Before leaving the driver s seat make sure all the operations for stop ping the lift truck have been carried out correctly to ensure your own safety and that of others 11 INTRODUCT
74. ated 38 INTRODUCTION TO SAFETY 950 L Evolution LOAD CHART ARM WITH HOOK PC 30 zn The capacity diagrams are only valid if the safety system is activated 39 INTRODUCTION TO SAFETY 5 950 L Evolution LOAD CHART ARM WITH HOOK PC 40 KAT 689284 The capacity diagrams are only valid if the safety system is activated 40 INTRODUCTION TO SAFETY 950 L Evolution LOAD CHART ARM WITH HOOK 50 10 1 2 M 1 68778 The capacity diagrams are only valid if the safety system is activated 41 INTRODUCTION TO SAFETY 5 950 L Evolution LOAD CHART Arm P 4000 CUN 5 5 1 9 __ 708581 The capacity diagrams are only valid if the safety system is activated 42 INTRODUCTION TO SAFETY 950 L Evolution LOAD CHART Arm P 4000 a 1200 EEES H 1000 Kg The capacity diagrams are only valid if the safety system is activated 43
75. ating a person s driving attitude Become familiar with the telescopic lift truck on the terrain where it will be used Carry the load in a low position with the telescopic arms fully retrac ted Set the fork arms perpendicular to the load to be lifted Drive the truck at a speed suited to the ground conditions in question Never drive too fast or brake sharply with a load When picking up a load check that the ground is as even as possi ble Never attempt operations that are beyond the capacity of the lift truck Never lift a load that is heavier than the truck capacity and never increase the size of the counterweight Drive around obstructions Be careful when there are electric cables ditches freshly dug soil or recently filled excavations Never leave the engine running when the truck is unattended Use the parking brake to deposit a difficult load or on sloping ground Never ever leave the truck parked with a raised load Never authorize anyone to come near or walk under a load Always bear safety in mind and only carry well balanced loads Never lift a load by a single fork arm Drive carefully and with prompt reflexes When the lift truck is not being used lower the fork arms to the ground and engage the hand brake Never leave the ignition keys in the truck whilst the driver is absent INTRODUCTION TO SAFETY 1 860 L 950 L Never leave the truck
76. ations applicable in the country of use necessary place the spacer block on the lift cylinder The front dimensions of the fittings must be marked on the three sides by means of alternate red and white retroreflecting stripes 10 cm high inclined at 45 follow the indications specific to each fitting IF NECESSARY CONTACT YOUR AGENT OR DEALER 13 INTRODUCTION TO SAFETY 1 860 L 950 L HANDLING INSTRUCTIONS A GENERAL INFORMATION Check the lift truck accessories to make sure they are in working order Do not carry out operations which exceed the capacity of the lift truck or the accessory Do not increase the counterweight whatever the accessory used Do not transport or lift persons using the lift truck unless the vehicle 15 equipped for the purpose and is accompanied by a conformity certifi cate regarding lifting passengers Avoid travelling long distances in reverse gear Carry out slow gradual movements for raising and lowering the tele scopic boom even without load ACCESSORY Check to make sure the accessory is installed and locked correctly on support Comply with the load diagram limits Check to make sure the pallets crates etc are in good condition and suitable for the load to be lifted Keep the fork arms perpendicular to the load to be lifted taking into account the position of the load s centre of gravity Never lift a load using
77. ator itself depending on the type of lift truck in your possession For more information refer to the relevant pages in the lift truck Operation and Maintenance Manual Remember to carry out decompression of the optional circuit each time a supplementary accessory 15 to be connected to or disconnected from the lift truck this will make it easier to connect and disconnect the quick release couplings at the top of the boom REMOVING AND PLACING THE ACCESSORY Repeat the ACCESSORY PICKUP operation in reverse order taking care to place it in a safe position on compact level ground INTRODUCTION TO SAFETY 5 860 L 950 L Zeclation USING THE FEM TYPE FORK HOLDER PICKING UP THE ACCESSORY Check to make sure the accessory is in a position to facilitate con nection of the quick release coupling If it is not oriented correctly take the precautions necessary to shift it to maximum safety condi tions Check to make sure the check pin is inserted in the support provided on the chassis Position the lift truck with the boom lowered in front and parallel to the accessory and incline the quick release coupling forwards Fig A Bring the quick release coupling under the accessory coupling tube raise the boom slightly and incline the coupling backwards to posi tion the accessory Fig B Disengage the accessory from the ground to facilitate blockage Check to make sure that the safety screw is present
78. by 164091 JA BREMSFLUESSIGKEIT _ Location near the brake fluid reservoir where applicable LIQUIDO DE FRENO gt LIQUIDO FRENI Utiliser IMPERATIVEMENT de l huile min rale IMPERATIVE to use mineral oil Verwenden Sie UNBEDINGT Mineral l Usar IMPERATIVAMENTE de aceite mineral Utilizzare IMPERATIVAMENTE oli olio minerale Refer to the Operator Service Manual for the correct brake fluid mineral oil to be used in the brake system IMPERATIVE to use MINERAL OIL Recommendation ATF DEXRON N SHELL _ 164091 234800 n 234800 XIII SAFETY DECALS Hydraulic Oil 234798 or 76573 Location on the hydraulic tank or filler cap Identifies the hydraulic reservoir tank or filler cap 234798 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAULIC OIL Identifies the hydraulic reservoir tank HYDRAULIK OL ACEITE HIDRAULICO 0110 IDRAULICO N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap Indicates required minimum to maximum anti freeze protection 22 F to 40 F Diesel Fuel 161101 Location on the fuel tank near the filler cap Identifies the fuel tank and use of diesel fuel No Step 496735 Location varies depending forklift model Instructs personnel not to use the designated area as a step NO STEP Do Not Tow 494918 Hydrostatic equipp
79. c steering A2 Front steering wheels Road travel A3 Front and rear steering wheels in the same direction crab steer Ing Wheel alignment procedure Press the steering mode selection switch on 1 turn the steering wheel until the rear wheels are aligned press the steering mode selec tion switch on A2 and turn the steering wheel until the front wheels are aligned When the front and rear wheels are aligned one of the three steering modes mentioned above can be selected The wheels coordination may be lost with use carry out realignment of the wheels every 20 hours of service by following the procedure described above CONCENTRIC STEERING GREEN LIGHT The green light indicates that concentric steering is selected LATERAL OR CRAB STEERING GREEN INDICATOR LIGHT The green light indicates that lateral or crab steering is selected D SAFETY SYSTEM DISENABLED RED INDICATOR LIGHT The red indicator light indicates that key 4a page 15 is turned to position 0 and the safety system is disen abled In this condition with the system excluded there is nothing to prevent the truck from tilting over or overload E FANS ROTATION INVERSION TIMED CONTROL SWITCH OPTIONAL The 3 position switch can by activated to invert the rotation of the water cooler fan and intercooler radiator in the engine compartment after a few seconds In this situation the direction of fan rotation is alte
80. 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 hand from the top and shall be within the periphery of the steering handwheel 8 Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable when properly operated However improper operation faulty maintenance or poor housekeeping may con tribute to a condition of instability and defeat the purpose of the requirements 9 Users shall give consideration to special operating conditions The amount of forward and rearward tilt to be used is governed by the application Although the use of maximum rearward tilt is allowable under certain conditions such as traveling with the load lowered the stability of a rough terrain forklift truck as determined by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation of trucks with excessive off center loads 10 Some of the conditions which may affect stability are ground and floor conditions grade speed loading rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment dynamic and static forces improper tire inflation and the judgement
81. checking the angle or diagonal between the fork tip and shoulder Visually check the forks to make sure there are no cracks near the heel or the fork hook In case of doubt proceed with penetrant liquid testing Repairs if any are only permitted is carried out in conformity with the indications of ISO standard 5057 and documented accord ingly INTRODUCTION TO SAFETY 5 860 L 950 L Zeclatiou DISASSEMBLING THE FORKS Remove the fork safety screw from the fork holder Fig A Shift the fork manually towards the centre of the fork holder lift it manually by the tip and position it slightly away from the centre on the side rest ing it on the lower guide Fig B Lower the boom and slew it for wards to rest the forks on the ground and detach them from the fork holder upper guide Fig C DANGER Take great care to prevent the forks from falling to the side 10 INTRODUCTION TO SAFETY 860 L 950 L Evolution 5 ASSEMBLING THE FORKS Position the lift truck in such a manner that the forks are in front aligned longitudinally to the truck Fig A Incline the fork holder forwards push against the forks and then hook them in the upper guide by slewing the boom backwards and raising it Fig B With the forks raised off the ground move them manually towards the centre of the fork holder to insert them in the lower guide and then move them outwar
82. ct the filter and its gasket Wipe the filter support with a clean cloth Lubricate the new gasket lightly Fit a new filter having identical specifications FILTER ELEMENTS AND BELTS Tighten the oil filter manually and turn it through a quarter of a turn to lock it in place Dispose off the filter and used oil according to the regulations in force in the country of use Filling the engine oil pan Refit and tighten drain plug 1 Fig D2 1 Fill oil as shown in the Table LUBRICANTS through filler hole 2 Fig D2 2 Wait for a few minutes to allow the oil to flow down into the pan Start up the engine and leave it running for a few minutes Check for leakage from the drain hole and the oil filter Stop the engine wait for a few minutes and check the level using rod 4 Fig D2 3 Top up if necessary INTRODUCTION TO SAFETY 3 860 L 9501 Evaluzia 3 REPLACE THE AIR FILTER CARTRIDGE The air used for combustion of the fuel is purified by a dry air filter never use the lift truck with the air filter dismantled or damaged Release blocks 5 Fig D3 1 and remove cover 6 Fig D3 1 Remove cartridge 7 Fig B3 2 very carefully to reduce dust leakage to the minimum and dispose it according to the regulations in force in the country of use Do not remove the safety cartridge Wipe the inside of the filter with a damp clean cloth that does not leav
83. d off and cold Do not drain the coolant liquid when the engine 15 hot and the coolant 15 under pressure since there 15 risk of a dangerous jet of boiling hot liquid being thrown out Position the forklift truck on a horizontal surface stop the engine and leave it to cool Place a container under the rubber hose pipe 1 fig F5 1 of the radi ator and drainage plug 2 fig F5 2 of the engine block Remove the rubber hose pipe 1 fig F5 1 and slacken the drainage plug 2 fig F5 2 Remove the filler plug 3 Fig F5 3 of the radiator Drain out the cooling circuit completely ensuring that the openings are not obstructed Check the condition of the hose pipes and their fittings replace them if necessary Clean the system with clean water and use a detergent product if nec essary To avoid damage caused by frost ensure that all the coolant liquid is removed from the engine This is important in case the system Is drained after being rinsed with water or in case a very weak anti freeze solution is used to protect the system from frost Refit and tighten the rubber hose pipe 1 Fig F5 1 and the drainage plug 2 fig F5 2 tightening torque 40 Nm Prepare the cooling liquid see Table 5 4 Fill the cooling system slowly up to 12 mm below the filler neck Refit the filler plug 3 Fig F5 3 Leave the engine running at minimum speed for a few minutes Check
84. d only in exceptional cases and operate with great care at very low speeds and by braking very gen Make sure visibility is good and have someone else guide you if necessary Keep the load stable when the lift truck is moving Never move too fast and avoid braking suddenly with a load During handling operations drive the lift truck at very low speeds Supervise the load especially on bends and in particular if it is bulky sling must be used for unstable loads Handle loads carefully at low speeds without jerks especially while lifting to great heights and with considerable jerks In case of strong winds or a storm avoid movements that may be potentially dangerous for the stability of the lift truck and the load Do not change direction suddenly and at high speeds If the lift truck tilts over do not try to get out of the cab during the acci dent ALWAYS DRIVE WITH THE SAFETY BELT ON STAY INSIDE THE CAB WITH THE SAFETY BELT ON AS THIS IS THE BEST WAY TO PROTECT YOURSELF Use the parking brake to deposit or raise a difficult load or on sloping ground Never ever leave the truck parked with a raised load Never leave the truck whether empty or with load with the parking brake applied on a slope exceeding 15 16 INTRODUCTION TO SAFETY 860 L 9501 Evolution E VISIBILITY Always ensure good visibility of the path both direct and indirect with panoramic r
85. d or killed by ignor ing refusing to enforce or forgetting to follow safe operating procedures Do not assume you know all safe ty issues concerning the decals Before operating the lift truck learn the meaning s of the decals as described in this manual If any decal becomes illegible or missing have it replaced immediately Always replace decals using the same decal part no unless otherwise specified by the manufacturer For replace ment decals not found in your parts manual contact your nearest dealer If you have any questions contact your Supervisor or nearest dealer for advice before operating your forklift 801011 Before Starting 801011 Boom equipped models Location on the brake fluid cover panel to the left and below the dash panel EFORE STARTING OR OPERATING Safety Instructions 420792 Rend and understand all safety and operating Mast equipped models Location on or near the operator manual storage case and or on the dash panel Clear the area of bystanders Locate and know operations of controls Instructions for the forklift operator before operating the forklift Fasten seat Keep all shields in place Operate only from operator s seat Carry load as low as posalble avoid steep slopes and drive slowly on rough terrain to avold machine overturn SAFETY INSTRUCTIONS Read and understand operator s manual before you operate this truck the operator s manua
86. dealer For uneven loads determine the centre of gravity transversally before making each movement Fig B ale Sua BAT For loads with mobile centre of gravity for example liquids take into account the variations in centre of gravity to determine the load to be lif ted contact your agent or dealer and take great care to limit these variations as far as possible PICKING UP A LOAD FROM THE GROUND Bring the lift truck perpendicularly close to the load with the boom retracted and the forks horizontal Fig C Adjust the difference and centring of the forks with respect to the load Fig D For information regarding the optional solutions available plea se contact your agent or dealer Pay attention to pinching or crushing of the limbs during manual adju stment of the forks Always maintain the same distance between the forks and central axis of the plant to ensure perfect load stability Move lift truck 1 forwards slowly and bring the forks against load Fig E raise boom 2 slightly if necessary while picking up the load Apply the parking brake and set the reverse gear lever in the neutral position Raise load 1 carefully incline fork arms 2 backwards in the transport position Fig F Incline the load backwards sufficently to ensure stability load lost during braking taking care to maintain the balance 18 INTRODUCTION TO SAFETY 860 L 9501 Evol
87. ds to the required operating width Fig C making sure that they are inserted correctly in the upper and lower guides Fit the fork safety screw in the fork holder blocking it by means of the lock nut Fig D 11 INTRODUCTION TO SAFETY 5 860 L 950 L Zeclation TECHNICAL SPECIFICATIONS OF ACCESSORIES DESCRIPTION NAME PFFLOTT L 1030 PFFLOTT L 1430 PF FEM 3 1320 Floating fork holder 4999 kg Floating fork holder 7500 kg Fem fork holder 4999 kg PF FEM 4 1750 Fem fork holder 7500 kg PF FEM 4 2000 Fem fork holder 7500 kg F FEM 3 Fem forks 2500 kg F FEM 4 Fem forks 3750 kg ARGANO 3T 3 Ton Winch ARGANO 5T 5 Ton Winch P 600 Arm P 600 PC 40 Arm with hook PC 50 Arm with hook PC 60 Arm with hook P 4000 Arm MIX 350 Mixer bucket MIX 500 Mixer bucket GL 400 Bucket for concrete GL 600 Bucket for concrete GL 800 Bucket for concrete GL 1500 Bucket for concrete CBC 1500 L2500 Shovel for building construction CBR 1500 L2500 Reclaim shovel CBA 2000 L2500 Agricultural shovel CBA 3000 L2500 Agricultural shovel 860 INTRODUCTION TO SAFETY 860 L 9501 Evolution FLOATING FORK HOLDER SPECIFICATIONS eo Y SPECIFICATIONS DIMENSIONS ACCESSORY DESCRIPTION CAPACITY iin WEIG
88. e residue Never wash an air filter cartridge Fit a new cartridge 7 Fig D3 2 having identical features see Table FILTER ELEMENTS AND BELTS inserting it on the filter rod pres sing the cartridge along the edges not in the middle Refit cover 6 Fig D3 1 orienting the valve correctly for correct working of the valve do not exceed an inclination of approx 20 and tighten the blocks 5 Fig D3 1 D 4 REPLACE ENGINE BASE VENT CARTRIDGE Make sure the engine is stopped before carrying out maintenance or repairs on it To access the engine base vent cartridge remove the intercooler radia tor partitions 8 and 9 Fig D4 1 using 10 mm hex wrench Place a container under the vent cartridge 10 Fig 04 2 Using a suitable tool remove the engine base vent cartridge 10 Fig 04 2 Lubricate the O ring of the new cartridge with clean engine oil Insert the new cartridge see Table FILTER ELEMENTS AND BELTS and screw it in manually by applying a torque not greater than 12 Nm Dispose off the used cartridge and oil contained in it in accordance with the regulations in force in the country of use 18 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 5 REPLACE THE FUEL FILTER CARTRIDGE The combustible materials of certain engine components such as the seals can be extermely dangerous if burnt Never allow such material to come in contact with
89. e Chapter INSTRUMENTS AND CONTROLS in part 2 DESCRIPTION on page 18 The vehicle can only be used without load on roads Do not transport company personnel as passengers on the vehicle Do not set the reverse gear in neutral while driving on roads to have the lift truck engine brake always ready for use 12 INTRODUCTION TO SAFETY 860 L 9501 Evolution G DRIVING THE LIFT TRUCK WITH TRAILER ON ROADS For using a trailer observe the regulations applicable in the country of use maximum permitted speed braking system maximum trailer weight etc Remember to connect the lift truck electrical system to that of the trailer Do not use a trailer if the unit weight of the load 15 greater than that permitted by road rules Do not use braked trailer if the lift truck is devoid of a trailer braking system Remember to connect the lift truck braking system to that of the trai ler The permitted total carriage road weight must not exceed the maxi mum limit authorized by the manufacturer See lift truck manufactu rer s plate DRIVING THE LIFT TRUCK WITH A FRONT ACCESSORY ROADS For driving the truck with an accessory on roads consult the regula tions applicable in the country of use The accessory must not exceed the maximum width of the lift truck Do not block the area illuminated by the front headlights Fit the covers on the accessories installed consult the regul
90. e sure it is correct It is advisable to check the belt tension again after 20 hours of opera tion following replacement see operation No C1 E 9 REPLACE TRANSMISSION HYDRAULIC OIL FILLER AND VENT PLUG Unscrew the transmission hydraulic oil filler and vent plug 20 Fig E9 in the back of the cab and replace it with a new one having identical features see Table FILTER ELEMENTS AND BELTS Fit the new transmission hydraulic oil filler and vent plug and tighten it manually E 10 CHECK THE TELESCOPIC BOOM PADS FOR WEAR For these operations contact your agent or dealer E 11 CHECK THE ENGINE VALVES CLEARANCE This operation must be carried out after the first 500 hours of operation and periodically every 1000 hours of operation For these operations contact your agent or dealer 26 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 EVERY 2000 HOURS OF OPERATION OR EVERY 2 YEARS 1 CHECK THE ALTERNATOR AND STARTER MOTOR 2 CHECK THE TURBO COMPRESSOR 3 CHECK THE RADIATOR 4 CHECK WATER PUMP AND THERMOSTAT FOR THESE OPERATIONS CONSULT YOUR AGENT OR DEALER 27 INTRODUCTION TO SAFETY 3 860 L 950 L Evaluzia F 5 REPLACE COOLING CIRCUIT LIQUID This series of operations must be carried out whenever it 15 necessary or at least once every two years before the winter Position the fork lift truck on level ground with the engine switche
91. ear view mirrors to check for the presence of a person animal holes obstacles change in slope etc There is possible of the visibility being reduced on the right side when the boom 15 raised therefore ensure good visibility of the path before raising the boom and starting movements f visibility in front is not sufficient owing to the size of the load move in reverse This is an exceptional operation and must only be used for very short distances Ensure good visibility Clean windows sufficient lighting rearview mir ror adjusted etc The lift truck signals and lights must be suitable for the conditions of use Standard machine lighting is not sufficient for use in poorly lit areas or at night Various options are available in addition to the stan dard equipment mounted on the lift truck Please contact your agent or dealer for more information CONTACT YOUR AGENT OR DEALER IF NECESSARY 17 INTRODUCTION TO SAFETY 1 860 L 950 L Zeclatiou HANDLING A LOAD A WEIGHT OF THE LOAD AND THE CENTRE OF GRAVITY Do not raise or transport a load heavier than the rated capacity of the lift truck or accessory The weight of the load and the centre of gravity must be known before lifting the load The load chart relative to your lift truck is valid for a load for which the centre of gravity is 24 in from the fork heel Fig A For a centre of gravity that is farther away contact your agent or
92. eave residue Fit a new filter having identical features see Table FILTER ELEMENTS AND BELTS using only your hands making sure the gasket 15 tioned correctly after lubricating it Start up the lift truck and check for leaks Check the working efficiency of the filter on indicator 27 Fig 07 D 8 REPLACE HYDRAULIC OIL FILTERS EXHAUST Using a box wrench dismantle the two hydraulic oil filters 28 Fig 08 and discard them together with the gaskets Wipe the filter supports with a clean cloth that does not leave residue Fit the new filters having identical features see Table FILTER ELE MENTS AND BELTS using only your hands making sure the gasket is positioned correctly after lubricating it Start up the lift truck and check for leaks D 9 REPLACE THE TRANSMISSION AND HYDRAULIC OIL TANK VENT FILTER Slacken vent 29 Fig D9 on the back of the cab and replace it with a new one having identical features see Table Filter elements and belts Fit the new vent tightening it manually D 10 REPLACE THE CAB VENTILATION FILTER CARTRIDGE Remove guard 30 Fig D10 Remove cab ventilation filter 31 Fig D10 Clean the filter using a jet of compressed air Check thje condition of the filter and if necessary replace the cartridge with a new one having identical features see Table FILTER ELE MENTS AND BELTS Refit the filter and guard INTRODU
93. ed models Location on the dash in view of the operator A WARNING PPED WITH Towing the forklift will damage the transmission VEHICLE EGET HYDROSTATIC TRANSMISSION DO NOT ATTEMPT refer to the operator s manual TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494910 XIV INTRODUCTION TO SAFETY SAFETY DECALS om sipped me Loto WARNING NEM Boom equipped models Location on the boom coupler N near where the retaining is installed THE ATTACHMENT RETAINING SHAFT MUST BE IN PLACE AND SECURED WITH THE SAFETY SNAP PIN BEFORE TRUCK OPERATION Reminder to operator install attachment retaining shaft and safety pin before operations 421016 gt ya 24653 Fork Safety 426641 Mast equipped models Location on the front and back side of the mast s outer rails at eye level 4 required Hook Here 24653 Location at points provided on the forklift where straps or chains may be attached to secure the forklift to a trailer during transport ____ 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 Keep fingers away from the mast KEEP FINGERS crossbracing CLEAR OF CROSSBRACING HAND THROTTLE DANGER 804784
94. eing started make certain that Location on the optional removeable forklift attachment Important manufacturer information about the attachment when contacting the maufacturer for parts and service Overhead Guard Data Plate B6109 Location attached to the overhead guard Overhead guard conformity Forklift Data Plate 496550 Boom equipped models Forklift Data Plate 496538 Mast equipped models Location within the operator s compartment Important forklift truck identification Record this information for use when contacting the manufacturer for parts and service Record this information for use the engine is at idle speed prior to disconnecting jumper cables MANITOU NORTH AR A INC 01 IMPERIA pn TX 76 BR am com MODEL NUMBER SERIAL NUMBER YEAR MANUFACTURE COUNTRY OF MANUFACTURE UNL ADEN WEIGHT LB HORIZONTAL CENTER GRAVITY IN OPERATING PRESSURE PSI This attachment affects the capacity of the lift truck Check the operator service Manual or load chart for net capacity with this attachment If the load chart is not available contact the factory 425995 THIS OVERHEAD GUARD CONFORMS ANSI DESIGN RECOMMENDATION HAS PASSED AN IMPACT TEST OF THIS GUARD FT LBS DO NOT REMOVE THIS OWERHEAD GUARD 496550 MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76
95. eir dimensions and with the boom lowered and retracted run the risk of inter fering with the front tyres and damaging them if the accessory is inclinded downwards TO ELIMINATE THIS RISK EXTEND THE TELESCOPIC BOOM TO A SUFFICIENT LENGTH ACCORDING TO THE FORK LIFT TRUCK AND ACCESSORY SO THAT THERE IS NO INTERFERENCE The maximum loads are defined by the lift truck capacity also taking into account the weight and centre of gra vity of the accessory lf the accessory capacity is lower than that of the lift truck never exceed this limit Before starting up operation with an accessory on the lift truck ensure the capacity of the machine and safety system calibration concerning the accessory used INTRODUCTION TO SAFETY 5 860 L 950 L Zeclation ACCESSORY WITHOUT HYDRAULIC SYSTEM AND MANUAL BLOCK PICKING UP THE ACCESSORY Check to make sure the accessory is in a position to facilitate con nection of the quick release coupling If it is not oriented correctly take the necessary precautions to shift it to the maximum safety con ditions Check to make sure the check pin is inserted in its support on the chassis Position the lift truck with the boom lowered in front and parallel to the accessory and incline the quick release coupling forwards Fig A Bring the quick release coupling under the accessory coupling tube raise the boom slightly and incline the coupling backwards to posi tion the accessory F
96. en Never refuel with the engine running If the tank has been empty for a while or the vehicle has run dry without fuel run the priming pump 6 Fig 4 until the glass cup fills up 7 Fig A4 Switch the engine on and check for leaks INTRODUCTION TO SAFETY 3 860 L 950 L Zeclatiou 5 CLEAN THE CYCLONIC PREFILTER The cleaning frequency given here 15 purely indicative the prefilter must however be cleaned as soon as the impurities reach the MAX level visi ble on cup 8 Fig A5 Slacken nut 9 Fig 5 remove cover 10 Fig 5 and cup 8 Fig A5 Wipe the prefilter with a clean dry cloth and refit it While cleaning take special care to prevent impurities from entering the dry air filter A 6 CHECK TYRE PRESSURE AND LOCKING OF WHEEL NUTS Check the tyre pressure and adjust if necessary see the WHEEL NUTS Specifications Chapter TIGHTENING TORQUE Check the tyres for cuts protruberances wear etc Check the locking of the wheel bolts see TABLE Fig pies ps ba Follow these warnings to avoid rupture as it can result in accidents A 7 CHECK THE TELESCOPIC BOOM PADS Remove the telescopic boom completely and make sure the telescopic boom pads are greased correctly if greasing is required see point B5 INTRODUCTION TO SAFETY 860 L 950 L Evolution 3 EVERY 50 HOURS OF SERVICE 1
97. er D3 Replace air filter cartridge A D4 Change the motor base vent cartridge D5 Replace fule filter cartridge D6 Change cartridge of the fuel filter with water condenser D7 Replace transmission oil filter D8 Replace hydraulic oil filters exhaust D9 Replace the hydraulic and transmission oil vent filter D10 Replace cab ventilation filter A INTRODUCTION TO SAFETY 860 L 9501 Evolution E EVERY 1000 HOURS OF SERVICE OR YEARLY 1 Replace air filter safety cartidge E2 Drain and change hydraulic oil 3 Replace hydraulic oil suction filter cartridge E4 Drain and change front and rear axle differential oil E5 Drain and change front and rear wheels reduction gear oil E6 Change transmission box oil E7 Drain and clean fuel tank 8 Replace alternator belt engine shaft E9 Replace transmission hydraulic oil filler and vent plug E10 Check telescopic boom pads for wear E11 Check engine valves clearance Y F EVERY 2000 HOURS OF OPERATION OR EVERY 2 YEARS O F1 Check alternator and starter motor F2 Check turbo compressor F3 Check radiator F4 Check water pump and thermostat F5 Change cooling circuit liquid OCCASIONAL MAINTENANCE G1 Changing a wheel G2 Towing the fork lift truck G3 Slinging the fork lift truck G4 Transporting the fork lift truck on a platform G5 Adjusting head lights G6 Air c
98. erfectly Avoid wetting the cushions while cleaning them First check the fabric to make sure it is resistant to normal detergents for plastic fabrics and materi als by testing in a concealed area 2 SEAT BELTS Sit correctly in the seat Check to make sure the seat belt is not twisted Wear the belt around the waist and not the stomach Fasten the seat belt and check to make sure it is secured properly Adjust the belt to your body and avoid pressing against the hip Never use the fork lift truck with the seat belt damaged under any circum stances whatsoever Fixing blocking seams straps etc Repair or replace the seat belt immediately 12 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 3 CONTROL INSTRUMENTS AND INDICATOR LIGHTS PANEL MANITOU M Oe ee _ gt po CONTROL INSTRUMENTS A SPEEDOMETER AND REVOLUTION COUNTER ENGINE WATER TEMPERATURE Temperature zones B1 Blue zone 0 50 B2 Green zone 50 100 B3 Black red zone 100 105 B4 Red zone 105 120 NOTE The red indicator lights up between the B3 and B54 zones C FUEL LEVEL INDICATOR The red zone C1 indicates that the fuel tank is in reserve and wont last long D CLOCK DIAL EMERGENCY LIGHTS SWITCH Pressing this switch will activate all the direction indicators simultaneously
99. eturns to the lower position ADJUSTING THE INCLINATION The seat inclination can be adjusted to suit individual needs Press the LH button and simultaneously push or release the seat to get the correct position ADJUSTING THE DEPTH The seat depth can be adjusted to suit individual needs Press the RH button and push the seat forwards or backwards to get the correct position BACKREST EXTENSION The height of the backrest extension can be adjusted by raising it until it clicks to a stop you can hear the clicks The backrest extension can be removed by pulling it beyond the last stop notch LUMBAR ADJUSTMENT This helps to improve comfort and makes it possible for the driver to move freely in the seat Turn the knob to the right or the left to adjust the height and depth of thelum bar support INTRODUCTION TO SAFETY 2 860 L 9501 ADJUSTING THE BACKREST With your back against the backrest pull the lever and move the backrest to the required position If the backrest is not held in place during the adjustment it will forwards completely LONGITUDINAL ADJUSTMENT Insert the locking lever in the required position Once blocked the seat will not move CLEANING Dirt can affect proper working of the seat It must therefore be kept clean To clean or change the cushions just remove them from the seat frame Risks of accident increase when the back rest is not locked p
100. f the sunshade pulling handle A downwards Fig 23 1 Press lever B Fig 23 1 to the RH to rewind the shade Rooftop sunshade Pull the sunshade backwards locking it in the hooks provided C Fig 23 2 24 TOOLS AND DOCUMENTS COMPARTMENT In the back of the driver s seat there is a documents compartment A make sure the instruction manual is always present in it NOTE A water tight document holder is also available as OPTIONAL Cover can be lifted to access the tool compartment 25 2 860 L MHT 950 L Evolution 25 CIGARETTE LIGHTER The cigarette lighter is present to the RH of the driver 29 DOOR LOCK Outer lock A Fig 26 To open the door grip the handle and pull outwards The lift truck is provided with two keys for locking the cab Inner lock Fig 26 To open the door grip the handle and pull it inwards 277 HALF DOOR LOCK Closed position To open press lock A Fig 27 1 downwards To close pull handle B Fig 27 1 inwards Open position Push the door towards the cab to lock key Fig 27 2 To release press knob D Fig 27 3 or use lever E Fig 27 2 26 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 23 REAR WINDOW OPENING LEVER To open the rear window pull lever A clockwise to the right and push the glass 29 HITCH The hitch is present on the rear part of
101. filter 22 Fig D6 3 Do not use a tool to insert the filter Tighten the filter manually Insert the new sealing ring 20 Fig D6 3 on fixing screw 23 Fig D6 3 Insert the new sealing ring 21 Fig D6 3 on glass cup 24 Fig D6 3 Align the glass cup 24 Fig 06 3 with filter 22 Fig D6 3 Insert fixing screw 23 Fig D6 3 Remove the container and dispose off the liquid in accordance with the regulations applicable in the country of use Manual priming pump on fuel filter with water separator To bleed air from the supply system proceed as follows Make sure the supply system is in good working condition Activate priming pump 25 Fig D6 1 until it is blocked The supply system must now be primed and the engine must be able to start up Activate the starter motor Once the engine starts up let it run at minimum speed without load for at least five minutes immediately after having bled the air from the supply system Note This will ensure that no air is present in the supply system 20 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 D 7 REPLACE TRANSMISSION OIL FILTER Using a collar wrench remove the transmission oil filter 26 Fig 07 and dispose it off together with the gasket in accordance with the regu lations in force in the country of use Wipe the filter support with a clean cloth that does not l
102. ft b Monthly and annual inspections are performed and documented and records retained three months for monthly one year for annual Before November 10 2014 operators must have had the additional training and qualification certification required by OSHA regulations 81926 1427 and 81926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a detailed description VII ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont CONCLUSION 1 ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard 29 CFR 1910 178 as described by the Occupational Safety and Health Administration OSHA They must be qualified as to their visual hearing physical and mental ability to operate the equipment safely NEVER use drugs or alcohol while operating a forkliftl NEVER operate or allow anyone to operate forklift when mental alertness or coordination is impaired An operator on prescription or over the counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the forklift 2 CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenance log listing repairs
103. g information appearing 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 INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont B GENERAL SAFETY PRACTICES cont 7 Where steering
104. gents especially the electric components and con nections and the injection pump Clean the lift truck to remove all traces of fuel oil and grease FOR ALL OPERATIONS THAT ARE NOT INCLUDED UNDER SCHEDU LED MAINTENANCE CONTACT YOUR AGENT OR DEALER 23 INTRODUCTION TO SAFETY 1 860 L 9501 BEFORE STARTING UP NEW LIFT TRUCK INTRODUCTION Our lift trucks are designed to ensure the driver simple manoeuvres and easy maintenance However before starting up the truck for the first time the user must have read and understood this manual which 15 prepared to provide all the information concerning driving and maintenance By complying with these indications the user will be able to get the best performan ces from his vehicle Before using the lift truck the user must become familiar with the posi tion and functions of the various instruments and controls Never start up a lift truck without having made the following inspec tions GREASING Check the various lubrication points and different levels consult MAINTENANCE SCHEDULE under 3 MAINTENANCE and proceed with topping up if necessary The trucks are delivered filled with lubricant at the factory using lubri cant suitable for average user conditions i e 15 C to 35 C For use in extreme conditions before start up drain and fill with fresh lubricant using the lubricant suitable for such temperatures The same applies t
105. his Manual Certain specific uses require adaptation of accessories not included as optionals in the list Other solutions are available for more information please contact your agent or dealer Only accessories that are homologated and certified by the manufacturer be used on your lift trucks The manufacturer shall not be liable for unauthorized modifications or use of accessories Manitou assures oneself about the employement s capacity of this machine in normal conditions of working foreseen in the user s manual with a static test coefficient of 1 33 and a dynamic test coefficient of 1 in the harmonized rules 1459 for the truck with variable capacity and EN 1726 1 for the forklift Do not use interchangeable accessories not originally included in the machine supply For subsequent requests for implementation of machine functions using other accessories before starting up the machine the user must request inspection for suitability for use by an authorized MANITOU technician who will check the correct working and updating of the documentation necessary for using the new accessory It is only after this inspection that a new CE conformity certificate will be issued for the machine indicating only the new accessories installed INTRODUCTION TO SAFETY 5 860 L 950 L RECOMMENDATIONS FOR USING THE LIFT TRUCK REMEMBER THAT THIS SYMBOL MEANS ATTENTION
106. ig B Disengage the accessory from the ground to facilitate blocking MANUAL BLOCK Take the check pin on the support and block the accessory Fig C Remember to fit the split pin MANUAL RELEASE Repeat the MANUAL BLOCK operation in reverse taking care to refit the check pin in the support on the chassis REMOVING AND PLACING THE ACCESSORY Repeat the ACCESSORY PICKUP operation in reverse order taking care to place it in a safe position on compact level ground INTRODUCTION TO SAFETY 860 L 950 L Evolution 5 ACCESSORY WITHOUT HYDRAULIC SYSTEM HYDRAULIC BLOCK OPTION PICKING UP THE ACCESSORY Check to make sure the accessory is in a position to facilitate con nection of the quick release coupling If it is not oriented correctly take the precautions necessary to shift it to maximum safety condi tions Check to make sure the blocking jack rods are retracted Position the lift truck with the boom lowered in front and parallel to the accessory and incline the quick release coupling forwards Fig A Bring the quick release coupling under the accessory coupling tube raise the boom slightly and incline the coupling backwards to posi tion the accessory Fig B Disengage the accessory from the ground to facilitate blockage HYDRAULIC BLOCK AND RELEASE OPTION Blocking and releasing an accessory is done by means of an optio nal command command which can be activated by mean
107. ing 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 raise the boom more than 45 degrees J 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 particular this regulation
108. ing to and fro movements and turn it on the side Place the new wheel on the hub Screw the bolts manually lubricating with grease if necessary Remove the safety support and lower the lift truck by means of the jack Tighten the wheel bolts completely using a dynamometric wrench see MAINTENANCE A DAILY OR EVERY 10 HOURS OF SERVICE for tightening torque 29 INTRODUCTION TO SAFETY 3 860 L 9501 Zeclatiou 2 TOWING THE TRUCK Towing must be done at very low speeds for short distances Set the reverse gear lever in neutral Disengage the parking brake Switch on the emergency lights Position the gear in neutral manually a disconnect and plug the hydraulic hoses 1 Fig G2 1 from the slow fast gear box cylinder b lever on rod 2 Fig G2 1 of the gear box to pull it out and bring it to the neutral position intermediate position between the two successive clicks Deactivate the negative brake a screw nuts with lock nuts 3 Fig G2 2 on the two sides of the front axle box until they rest against the piston b then rotate through one turn Attention The opposite screws must be tightened to the same extent In the absence of hydraulic servo assistance of direction and brakes act slowly but firmly on these two commands Avoid sudden jerky movements 30 INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 G 3
109. ion K181 7 5 Air conditioner enable relay K182 7 4 Diodes FUSES AND RELAY IN ENGINE COMPARTMENT To access the fuses and relays placed in the engine compartment slacken the six screws spanner 10 mm Fig D and remove the plate Fig E Code Sheet Function F144 1 3 30A fuse Perkins power F146 1 3 fuse ignition input FG1 1 1 50A fuse electric fan relay FG2 1 1 40A fuse spark plugs relay FG3 1 1 50A fuse electro mechanical control unit FG4 1 1 30A fuse start up panel relay FG5 1 1 50A fuse services relay FG6 1 1 30A fuse heating FG7 1 2 30A fuse optional power supply 1 2 30A fuse start up panel relay K142 1 2 Start up relay K143 1 3 Perkins control unit power supply relay K145 1 3 Electric fans relay K147 1 5 Preheating relay K148 1 4 Services relay JosseJdujoo yeas c A 2 19x90S 9 LH YIJMS 30014 7 6SN juBi epis S 8 DELH UBBJOSPUIM IN JosseJduio ON ZZ juBi epis HI 8 6ZLH Bulao asryyol 014 v7 41 1461 ajejd esueor 8 ZCVH YOL 9 8 63 Jauonipuos Jezzng y 8 OZ LH Ajddns youms 1461 98N1 VOL y 8 94 epis juo HH Z8 80LH ejes Bunesyald SL 2719 860 dns jewod
110. ions immediately INTRODUCTION TO SAFETY 1 860 L 9501 D DRIVING THE LIFT TRUCK SAFETY RULES Always carry out lift truck movements with the fork arms or accessory about 12 in off the ground e in the transport position Practice driving the lift truck on terrain where work is to be carried out Check the service brakes and horn to make sure they are in perfect working order Drive correctly at a speed suitable for the conditions and type of ter rain Slow down before turning Have complete control over the lift truck and its speed under all cir cumstances Drive slowly over damp slippery or uneven ground Brake gradually avoiding sudden braking Use the lift truck reverse gear only with the machine stopped to avoid sudden movements Always remember that a hydraulic steering is very sensitive to driving wheel movements therefore steer gradually without jerks Never leave the engine running if the driver is not in the seat Always look in the direction of movement and maintain correct visibili ty of the path Use the side rearview mirrors frequently and check their condition cleaning and adjustment Do not use the truck in dark or poorly lit places At night ensure that the lift truck is fitted with work lights For more information regarding the options available contact your agent or dea ler Drive around obstacles Do not position yourself on a
111. ions used to establish rough terrain forklift truck capacity with extra caution Stability and maneuverability may be adversely affected IV INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 46 When attachments are used extra care shall be taken in securing manipulating positioning and trans porting the load Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks when not handling a load 47 Completely engage the load with the load engaging means Fork length should be at least two thirds of load length Where tilt is provided carefully tilt the load backward to stabilize the load Caution should be used in tilting backward with high or segmented loads 48 Use extreme care when tilting load forward or backward particularly when high tiering Do not tilt forward with load engaging means elevated except to pick up or deposit a load over a rack or stack When stacking or tiering use only enough backward tilt to stabilize the load 49 The handling of suspended loads by means of a crane arm boom or other device can introduce dynam ic forces affecting the stability of a rough terrain forklift truck Grades and sudden starts stops and turns can cause the load to swing and create a hazard if not externally stabilized When handling suspended loads a do not exceed the truck manufacturer s capacity of the rough te
112. ith the forklift Always verify that local state provincial and federal regulations have been met Report any accidents involving personnel building structures and equipment to the supervisor immediately Always remain alert conditions are constantly changing at the work site TECHNICAL SUPPORT All data provided in this manual is subject to production changes addition of new models and improved prod uct designs If a question arises regarding your forklift please consult your dealer or K D Manitou Inc for the latest information When ordering service parts or requesting technical information be prepared to quote the applicable Model Serial Numbers VIII SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL SHOWN BELOW IT IDENTIFIES POTENTIAL HAZARDS WHICH IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH Also observe the safety messages places throughout this manual providing special instructions telling you when to take precautions and to identify potential hazards The safety messages are highlighted and outlined in a box similar to those shown in the examples below SAFETY ALERT SYMBOL Provides information special instructions or references about the lift truck IMPORTANT Precautions which must be taken to avoid damage to the lift truck Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury May also alert unsafe practices Indicates a po
113. jeoipui sapos y jo uonisoduioo y SI NOJO JO 3JON LAIOIA 2 AIV N MOTIAA 9 3534 IN ANId S 3N 18 MNHVO 1 JLIHM 8 AJYUO H 3019 54 AO piougjos jeuonJuodoud Z s 06 12401404014 ZELA 4 OCLA peeds 1524 VELA peeds CELA piouajos Bullaa s ZELA Bullea s 72 LELA PIOUSJOS 490 Q S OJJUOD 66 LLLA prouajos HI VOL OLLA Duije e OL 60 plougjos Ayloeded JapuljAD 7 Lv YOLA CVC plougios COLA JOJOBUUOD jun 298 19 X JOJ99UUO09 sisouDeip u10Jxe GOCX Jojoeuuoo Jesuepuo LOX Jojoeuuoo 09 X JOJ99UUO9 19205 sisouDeip qao 092 Jojoeuuoo ssed q UOISIAOId 5 S 9GCX JOJ93UUO9 uoisiAOJd 5 d 9GZX JOJ99UUO9 S OJeoIpu JOJOBUUOD UB JOJ99UU09 jun 9 20 21
114. k engine oil level A2 Check cooling circuit filling A3 Check fuel level A4 Check and drain the fuel filter with water separator 5 Clean the cyclonic filter Check tyre pressure and locking of wheel nuts A7 Check telescopic boom pads EVERY 50 HOURS OF SERVICE B1 Clean air filter cartridge 4 B2 Check hydraulic oil level B3 Clean radiator grilles 4 Check brake circuit oil level B5 Clean and grease telescopic boom pads Clean and grease cab door B7 Clean and grease front and rear wheels pivot pins M B8 Clean and grease telescopic boom articulation pin M B9 Clean and grease quick release articulation pin M B10 Clean and grease lift jack base and rod pins M B11 Clean and grease compensation jack base and rod pins M B12 Clean and grease slewing jack base and rod pins M B13 Clean and grease levelling jack base and rod pins M B14 Clean and grease two front axle oscillation bushings M B15 Clean and grease two rear axle oscillation bushings M B16 Clean and grease cross journals and cardan shaft I C EVERY 250 HOURS OF SERVICE C1 Check alternator belt tension driving shaft C2 Check front and rear axle differential oil level C3 Check front and rear wheels reduction gear oil level C4 Check transmission box oil C5 Check battery D EVERY 500 HOURS OF SERVICE OR YEARLY e D1 Drain and change engine oil D2 Replace engine oil filt
115. king of lights WHEELS Check tightening of wheels Check tyre pressure GENERAL MACHINE LUBRICATION WORKING OF THE MACHINE Hydraulic function with rated load Road test steering and braking INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 LUBRICANTS PARTS TO BE LUBRICATED RECOMMENDED PRODUCT Shell Rotella 15w40 Rear wheels reduction gear Shell Spirax DH80w90 Front wheels reduction gear Citgo Prem Gear MP 80w90 Front axle differential Shell Donax TD Gear box Citgo Trans Trac Hyd FL THF Rear axle differential P Shell Tellus T46 Hydraulic oil tank Citgo Transgard THF Lo Temp Braki TT Shell Donax TG Dexron Citgo Transgard ATF Dexron III anti Shell Rentinax Am General lubrication Citgo Lithoplex CM 2 Greasing telescopic Shell Rentinax Am boom Citgo Lithoplex CM 2 Cooling circuit Fuel tank FEATURES OF FUEL Use good quality fuel to obtain the best performance out of the engine FEATURES OF THE RECOMMENDED FUEL e DERV in accordance with EN590 BS2869 Class A2 ASTM 0975 91 Class 2D e JIS K2204 1992 Degrees 1 2 3 and Special Degree 3 The hydrostatic transmisson filter hydraulic filter oil and engine filter must be replaced after the first 50 hours of service to guarantee safety INTRODUCTION TO SAFETY 3 860 L 950 L Zeclation MAINTENANCE SCHEDULE A DAILY OR EVERY 10 HOURS OF SERVICE A1 Chec
116. l is missing a new Refer lo operator s manual for Jump starting instructions manual may be obtained through your local dealer Er gt WHEN PARKING OR SERVICING or directly from Manitou Inc Waco Tx Check truck for proper operation of all functions Fasten seat belt di XT 1 Lower boom to the ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 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 LAS Al T fas V ee i operating machine Never jump from a Tipping m 1m machine ll T Faire t IT IE SERIAS Y T INTRODUCTION TO SAFETY SAFETY DECALS Emergency and Parking Brake 801010 Location near the park brake lever EMERGENCY STOPPING Identifies the Emergency Parking Brake Lever AND PARKING BRAKE 4 THIS VEHICLE 15 EQUIPPED WITH A BACK UP Alarm Must Sound 496162 ALARM WHEN BACKING THE Location on the dash in direct view of the operator ALARM MUST SOUND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE
117. le no load Rear axle no load Weight loaded with standard equipment and forks Wt loaded with boom retracted and forks 20 cm off the ground Front axle Rear axle Towing capacity No load With load Vibrations Acceleration of upper limbs Acceleration of body feet or seated part Noise The noise level guaranteed 950 L 30 km h 10 km h 30 6 m min 10 8 sec 38 5 m min 8 6 sec 17 m min 12 7 sec 28 6 m min 7 5 sec 33 sec 4 1 sec 38 5 3 5 sec 1200 x 150 x 50 mm 1320 mm 24 in 8800 mm 5000 kg 10650 kg 3970 kg 6680 kg 15650 kg kg 8500 daN 10500 daN lt 2 5 m s lt 0 5 m s LwA 105 dB in accordance with Directive 2000 14 CE modified by Directive 2005 88 CE Noise level in driving seat in accordance with EN 12053 LpA 80 8 dB INTRODUCTION TO SAFETY 860 L Evolution 2 DIMENSIONS 860 L Evolatioe DOZZP 000 9 gt lt lt lt 4 O INTRODUCTION TO SAFETY 2 950 L DIMENSIONS 950 L 2 N I zx Oo lt 000 gt lt lt lt lt 4 O OO INTRODUCTION TO SAFETY 860 L Evolution 2 LOAD CHART 860 L Seclation LOAD CHART WITH FORKS
118. les of professional skil Is C ROUTINE MAINTENANCE f the user finds that his lift truck does not work correctly or does not comply with the safety regulations he must inform the person in char ge immediately he driver must not carry out repairs or make adjustments himself unless he has been trained for the tasks He must keep the lift truck for which he is responsible in perfect condition Daily maintenance must be carried out see Chapter A DAILY OR EVERY 10 HOURS OF SERVICE in part 3 MAINTENANCE The tyres must be checked to make sure they are suitable for the type of terrain See surface of tyres in contact with the ground Chapter SPECIFICATIONS in part 2 DESCRIPTION Tyres may be of different types Tyres for SAND Tyres for AGRICULTURAL TERRAIN Snow chains Other options are available for more information contact your agent or dealer Do not use worn or damaged tyres Do not use tyres inflated with polyurethane foam it is not guaranteed by the manufacturer except without authorization INTRODUCTION TO SAFETY 1 860 L 9501 Zeclatiou For your safety and that of others avoid modifying the structure or making adjustments to the various lift truck components hydraulic pressure calibration of the limiters engine speed supplementary too ling assembly etc The same applies to deactivation or modification of safety systems In such cases the manufacturer sh
119. loaded with the hand brake engaged on slopes exceeding a 15 gradient When lifting a load take care to make sure there is no obstacle to the movements and avoid making false movements Comply with the values given in the load curves Never transport passengers on the lift truck At every tool change to avoid damaging the hydraulic connections stop the combustion engine turn the key contact to position discharge pressure from the circuit by means of the knob Check to make sure these connections are always clean INTRODUCTION TO SAFETY 860 L 9501 Evolution GENERAL INSTRUCTIONS A INSTRUCTION MANUAL Read the Instruction Manual carefully and understand it The Instruction Manual must always be kept in its place in the lift truck and it must be in the driver s language Observe the safety regulations and the instructions described for the lift truck Replace all rating plates and stickers that become illegible or dama ged B DRIVING PERMIT Comply with the legislation applicable in the country of use Only specially trained qualified personnel can use the lift truck The lift truck can only be used with a driver s permit issued by the Manger of the factory where the vehicle is used The driver must always carry the driving permit while on duty The driver must not entrust another person to drive the lift truck The use of the lift truck must conform to the ru
120. loading bridge unless you have checked to ensure that is positioned and fixed correctly the means to which it is connected wagon truck etc cannot move the bridge can handle the total weight of the lift truck and its load if any the width of the bridge is suitable for the lift truck Never enter a gangway a flatbed or hoists without first ensuring that these are suitable for the lift truck weight and dimensions and its load if any and are in good condition Pay special attention to loading wharfs trenches scaffolding freshly dug ground or filled excavations The road speed of the lift truck with load must never exceed 10 km h under any circumstances whatsoever INSTRUCTIONS FOR MOVEMENT Check the transmission oil level Position the fork arms or accessory in the transport position i e about 12 in off the ground Engage the selected gear See Chapter INSTRUMENTS AND CON TROLS in part 2 DESCRIPTION Select the required steering mode Set the reverse gear lever in the required position Release the parking brake and accelerate slowly to allow the lift truck to move 10 INTRODUCTION TO SAFETY 860 L 9501 Evolution E STOPPING THE LIFT TRUCK SAFETY REGULATIONS Before stopping the lift truck after a heavy job leave the combustion engine running for a few moments at minimum speed to let the cooling liquid and oil lower the temperature of the engine and tr
121. ly 15A fuse work lights 7 5A fuse rotary beacon switch power supply 5A fuse RH position light 5A fuse LH position light 5A fuse RC2 diagnostics power supply 10A fuse light switch power supply 10A fuse warning 10A fuse ceiling light 7 5A fuse front windscreen wiper switch 7 5A fuse rear windscreen wiper switch 7 5A fuse seat compressor power supply fuse indicator lights and instruments 7 5A fuse stop micro switch 10A fuse optional power supply 10A fuse bucket switch power supply 7 5A fuse warning 15A fuse boom work lights switch 25 fuse heating 15A fuse dipped beams 15A fuse buzzer 7 5A fuse operating mode switch power supply 7 5A fuse anti tilting device 10A fuse operation micro switch power supply 10A fuse emergency mushroom shaped button 10A fuse air conditioning 10A fuse ARB control unit power supply fuse optional 7 5A fuse RC2 control unit power supply Relay with diode Air conditioning relay Relay with diode Running enable relay Main beams relay Reverse movement relay Forwards movement relay Anti tilting relay Buzzer relay ARB forcing key power supply relay Dipped beams relay Neutral position relay Trailer brake relay Stop micro switch relay Speed change relay Sagelet relay Working mode control unit relay Warning relay INTRODUCTION TO SAFETY 4 860 L 950 L Evaluzia RELAY AND DIODES UNDER CIGARETTE LIGHTER Code Sheet Funct
122. ly and check the cooling circuit for the cause of the problem AIR FILTER CLOGGED RED INDICATOR LIGHT The indicator and buzzer switch on when the air filter cartridge is clogged Switch off the forklift truck and carry out the necessary repairs see the cleaning and replacement schedules in Chapter 3 MAINTENANCE FILTER ELE MENTS AND BELTS DIRECTION INDICATORS GREEN INDICATOR LIGHT POSITION LIGHTS GREEN INDICATOR LIGHT This indicator lights up when the position lights are working DIPPED HEADLIGHTS GREEN INDICATOR LIGHT This indicator lights up when the dipped headlights are switched on This indicator lights up when the main beams are working ENGINE PRE HEATING YELLOW INDICATOR LIGHT OPTIONAL This indicator lights up during preheating of the engine in case of temperatures below 0 Wait for the indicator to switch off completely before starting up the engine ENGINE PROBLEM YELLOW INDICATOR LIGHT If the indicator lights up during the working of the forklift truck consult I C engine faults Monitoring Table contact your agent or dealer ENGINE PROBLEM STOP RED INDICATOR LIGHT If the indicator lights up during the working of the forklift truck consult the engine faults Monitoring Table switch off the engine if necessary and contact your agent or dealer 9 e gt MAIN BEAMS BLUE INDICATOR LIGHT HYDROSTATIC POWER STEERING OIL P
123. m sound If it is not used the red indicator light B1 indicates that the alarm sound is deactivated and only the visual alarm is working TEST INDICATOR Fig 4 1 Press the switch at any time to check the correct working of the load status indicator device Correct operation All the LEDs and alarm sound function in continuous mode Defective operation All the LEDs and alarm sound function intermittently Switch off the lift truck and contact your agent or dealer never attempt to carry out repairs yourself STRAIN GAUGE Fig 4 3 Disassembly or adjustment of the strain gauge is prohibited this must only be done by specially trained personnel consult your dealer SAFETY SYSTEM INHIBIT KEY Fig 4 4 This key has two positions 1 0 In position 1 the safety system is enabled In position 0 the safety system is disenabled and a red LED 5D pag 16 lights up ATTENTION The safety system can be inhibited only when operating with a shovel by turning key 4a With the system inhibited there is nothing to prevent tilting or overloading of the lift truck 15 INTRODUCTION TO SAFETY 2 860 L 9501 Zeclatiou 5 a SWITCHES PANEL A DIRECTION SELECTION SWITCH Before selecting one of the three steering options align the four wheels in relation to the forklift truck axis A1 Front and rear steering wheels in opposite directions Short or concentri
124. mmand refer to the pages concerning the commands in the Use and maintenance manual Connect the quick release couplings according to the description of the accessory s hydraulic movements Keep the quick release couplings clean and plug unused holes for pro tection REMOVING AND PLACING THE ACCESSORY Repeat the ACCESSORY PICKUP operation in reverse order taking care to place it in a safe position on compact level ground INTRODUCTION TO SAFETY 860 L 950 L Evolution 5 ACCESSORY WITH HYDRAULIC SYSTEM AND HYDRAULIC BLOCK OPTION PICKING UP THE ACCESSORY Check to make sure the accessory is in a position to facilitate con nection of the quick release coupling If it is not oriented correctly take the precautions necessary to shift it to maximum safety condi tions Check to make sure the blocking jack rods are retracted Position the lift truck with the boom lowered in front and parallel to the accessory and incline the quick release coupling forwards Fig A Bring the quick release coupling under the accessory connection tube raise the boom slightly and incline the coupling backwards to position the accessory Fig B Disengage the accessory from the ground to facilitate blockage HYDRAULIC BLOCK AND RELEASE OPTION Blocking and releasing an accessory is done by means of an optio nal command command which can be activated by means of a spe cial pushbutton or the manipul
125. ne off and turn ignition key 8 to position 2 Rotate roller forwards and backwards pushbutton D Fig 15 1 pressed red indicator light On see point page 18 When the operation is complete the optional is depressurized it will therefore be easier to connect disconnect the quick release couplings on the top of the boom N B The operations must be carried out immediately after the combustion engine is switched off and not for more than 3 sec onds for each command 22 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 16 EMERGENCY STOP RED PUSHBUTTON This pushbutton stops the engine NOTE PRESS THE BUTTON ONLY IN CASE OF EXTREME NEED TO STOP THE ENGINE To stop the engine press the red pushbutton A To re enable the switching on of the engine turn the red pushbutton A clockwise 17 LOAD CHART FILE This file includes the description of the hydraulic controls and the load charts of the attachments used on the lift truck 118 SPIRIT LEVEL It is situated at the top inside the cab in front of the operator and 15 used for levelling operations to check the inclination of the lift truck with respect to the ground see point 5R page 18 Levelling control pushbutton 19 HEATING CONTROLS A FAN KNOB This 3 speed knob is used to supply cold hot air to the diffusers B TEMPERATURE REGULATO
126. ns it can also be dismantled to avoid theft Unscrew nut A and remove the rotary tower light Protect support with cover C 33 STEERING WHEEL ADJUSTMENT LEVER This lever is used for adjusting the inclination and height of the steering wheel Pull lever A Fig 33 1 to slacken and adjust the steering wheel Fig 33 2 Push lever A Fig 33 1 to lock the steering wheel in the selected position 28 MAINT SNANG INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 FILTER ELEMENTS AND BELTS Ir 1 Engine filter 476 954 Replace Every 500 H 2 Air filter cartridge 775 479 Clean Every 500 H 3 Transmission oil filter 485 695 Replace Every 500 H 4 Fuel pre filter cartridge with water separator 745 032 Check Every 500 H 5 Fuel filter cartridge 747 351 Replace Every 900 H 6 Engine base vent cartridge 743 204 Every 500 H 7 Hydraulic oil filter cartridge exhaust 673 203 Replace Every 500 H 8 Hydraulic oil tank vent 448 269 Clean Every 500 H 9 Hydraulic oil tank venting plug 659 917 Every 1000 H 10 Hydraulic oil filter cartridge intake 513 752 Every 1000 H 11 Safety air filter cartridge A 775 480 Every 1000 H 12 Cyclone pre filter 773 433 13 Engine belt 503 965 Every 1000 H 14 Cab ventilation filter cartridge 225 052 Every 500 extremely dusty environments reduce the interval and make replacements sooner Sos
127. ns will free the the manu facturer of all responsibility THE MANUFACTURER MUST PROVIDE THE USER WITH His know how and skill Guarantee of the quality of all the jobs done Original spare parts Preventive maintenance service Effective diagnostics service Improvements due to exchange of experiences Training of personnel concerned Only the manufacturer understands the truck design in detail and the refore the best technological capacity to ensure maintenance INTRODUCTION TO SAFETY 1 860 L 9501 INSTRUCTIONS FOR THE LIFT TRUCK DRIVER WARNINGS REMEMBER THAT THIS SYMBOL MEANS ATTENTION BE CAREFUL YOUR SAFETY AND THAT OF YOUR TRUCK IS AT STAKE Most accidents linked to the use maintenance and repair of the lift truck are due to failure to apply and observe the elementary safety regu lations Identifying all the risks you are exposed to and taking all the necessary precautions will help avoid these accidents All the operations or movements not described in the instruction Manual must be avoided anyone using another method must first of all ensure his own safety and that of others and the good working order of the lift truck Since it is impossible to foresee all hazard situations the manufactu 5 instructions and safety regulations regarding the lift truck included in this Manual cannot be considered as complete Failure to observe the safe
128. ns with out any obligation for us to give advance warning to our customers Type cabine MANTTOU P150 REST Constructeur 1 2 7552 INSTRUCTIONS INTRODUCTION TO SAFETY 860 L 950 L Evolution 1 ORIGINAL SPARE PARTS AND TOOLING ALWAYS USE ORIGINAL PARTS FOR MAINTENANCE OF YOUR LIFT TRUCK BY AUTHORIZING THE USE OF NON ORIGINAL PARTS YOU RUN THE RISK of becoming legally involved in case of an accident of becoming technically involved for causing operating problems to the life of the truck If the manufacturer uses counterfeit parts or components that homologated this can put an end to the warrantee according to the terms of the contract and induce the manufacturer to withdraw the Certificate of Conformity USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS WILL PROTECT YOU LEGALLY The user who looks for alternate suppliers does so at his own risk The user who modifies or gets third parties to modify the lift truck must be aware of the fact that a new item is issued on the market and this also involves his responsibility The user who copies or has copies made of original parts exposes him self to legal risk The Certificate of Conformity implies the manufacturer s responsibility only for the parts selected or processed under his control The practical maintenance conditions are fixed by the manufacturer Failure by the user to respect these conditio
129. o cooling liquids Contact your agent or dealer for more information DRY AIR FILTER Make sure the filter is in good condition and not fouled Tighten the bolts if necessary Never use the lift truck without its air filter or if the filter is damaged COOLING CIRCUIT Never start the truck without checking the cooling liquid level HYDRAULIC CIRCUIT Check to make sure there is no oil leakage on the connections hose pipes pipes and unions Tighten or check the defective connections if necessary Check the oil level in the tank 24 INTRODUCTION TO SAFETY 860 L 9501 Evolution 1 BRAKING SYSTEM Check to make sure there 15 no oil leakage on the connections hose pipes pipes and unions Tighten or check the defective connections if necessary Check the oil level in the tank Use only the recommended types of oil as otherwise there 15 risk of damaging the braking system see Chapter on LUBRICANTS in part 3 MAINTENANCE WHEELS AND TYRES Check to make sure the wheel nuts are tightened correctly See Chapter A DAILY OR EVERY 10 HOURS OF SERVICE in part 3 MAINTENANCE and check the tyre pressure See chapter SPECIFI CATIONS in part 2 DESCRIPTION FUELLING SYSTEM Check to ensure that the fuel lines are sealed tight f necessary drain the fuel filter and fuel feed system ELECTRICAL CIRCUIT Check the level of electrolyte in the battery See chapter B EVERY
130. onditioning For these operations consult your agent or dealer O To be performed once a year if the lift truck has not completed the required number of operating hours A In extremely dusty environments reduce the interval and make replacements sooner Every 50 hours up to the first 250 hours and periodically every 1000 hours of service case of use in extremely dusty or oxidising environments redu ce this frequency to 10 hours of operation or daily After the first 500 hours of operation and periodically every 1000 hours of operation INTRODUCTION TO SAFETY 3 860 L 950 L Zeclation A DAILY OR EVERY 10 HOURS OF SERVICE A 1 CHECK ENGINE OIL LEVEL Before checking the oil level make sure the combustion engine is swit ched off and the lift truck is parked on a level horizontal surface For precise indications wait a few minutes after the engine stops to allow the oil to flow into the crankcase Remove dipstick 1 Fig A1 1 clean it and check the oil level Top up through the filler hole 72 Fig A1 2 if necessary A 2 CHECK COOLING CIRCUIT FILLING Refer to point F5 for the cooling circuit filling procedure If necessary add cooling fluid during maintenance and let the engine cool down before proceeding Remove the filler plug carefully as there is serious risk of coolant splashing out if the system is still pressurized and the liquid itself is still ho
131. other attach ments 10 Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury to personnel 11 Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck whether empty or loaded 12 Do not permit passengers to ride on rough terrain forklift trucks 13 Check clearance carefully before driving under electrical lines bridges etc 14 A rough terrain forklift truck is attended when the operator is less than 25 ft 7 6m from the truck which remains in his view 15 A rough terrain forklift truck is unattended when the operator is 25ft 7 6m or more from the truck which remains in his view or whenever the operator leaves the truck and it is not in his view 16 Before leaving the operator s position a bring rough terrain forklift truck to a complete stop b place directional controls in neutral c apply the parking brake d lower load engaging means fully unless supporting an occupied elevated platform e stop the engine f if the rough terrain forklift truck must be left on an incline block the wheels g fully lower the load engaging means 17 Maintain a safe distance from the edge of ramps platforms and other similar working surfaces 18 Do no move railroad cars or trailer with a rough terrain forklift truck INTRODUCTION TO SAFETY ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING S
132. ound 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 15 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 basic fundamentals of rough terrain forklift truck and component design as related to safety e g in lb loading mechanical limitations center of gravity stability etc e introduction to equipment control locations and functions Explain how they work when used properly and problems when used improperly f supervise practice on operating course remote from normal activity and designed to simulate actual operations e g lumber stacking elevating shingles to the roof etc g oral written and operational performance tests and evaluations during and at completion of the course h refresher courses which may be condensed versions of the primary course and periodic on job operator evaluation i understanding of nameplate data and operator instructions and warnin
133. r s seat restore the inverter to idle and activate the forward or reverse movement to continue with the movement 21 INTRODUCTION TO SAFETY 2 860 L 950 L Zeclatiou 15 ELECTRO HYDRAULIC CONTROLS The truck has a multi purpose single lever manipulator with pro portional electro hydraulic control to the right of the operator and is provided with two rollers A and Fig 15 To enable the movements at least one of the two enable pushbut tons C Fig 15 1 must be kept pressed to raise the load pull the lever backwards Fig 15 2 to lower the load push the lever forwards Fig 15 2 to incline the forks downwards push the lever to the right Fig 15 2 to incline the forks upwards push the lever to the left Fig 15 2 to extend the boom rotate roller A forwards Fig 15 2 to retract the boom rotate roller A backwards Fig 16 2 to use the optional command rotate roller B forwards or back wards Fig 15 2 pushbutton D Fig 15 1 pressed and red indi cator light On see point 50 page 18 Do not attempt to modify the hydraulic pressure of the system In case of problems contact your agent or dealer MANIPULATIONS WILL INVALIDATE THE WARRANTEE 15 A DECOMPRESSION OF OPTIONAL CIRCUIT This operation must be carried out each time a lift truck supple mentary accessory is to be connected or disconnected 1 Switch the combustion engi
134. rator must read and understand the various topics discussed in this Manual these instructions are meant to provide all the information required for plant conduction and maintenance The operator must follow these instruc tions to get the best out of his telescopic lift truck The terms right and left front and rear used in this Manual refer to positions as seen by the operator normally in the driver s seat Always state the following information when ordering spare parts or requesting technical information TOU MANITOU HORTH AMERICA INC IMPERIAL DA WACO TX 76712 800 432 1304 Wer cdm Manufacturer s data plate FIG A Model Series Serial No Chassis No Year of manufacture On internal combustion engine FIG B Engine No On hydrostatic pump FIG C MANITOU reference No Serial No INTRODUCTION TO SAFETY 860 L 9501 Evolution On hydrostatic engine FIG D MANITOU reference No Serial No On front axle FIG E Axle type and model Serial No of front axle On rear axle FIG F Axle type and model Serial No of rear axle On cab FIG G Cab No ER 3 an 55 Write all these numbers immediately in the empty spaces provided Since the MANITOU policy 15 ongoing improvement of our products our range of telescopic lift trucks may be subject to modificatio
135. reen light indicates that fast speed is selected N OPERATING MODE Activating the two position switch will activate the operating system concerned to work slowly and accurately The switch can also be turned on with the lift truck in motion 17 INTRODUCTION TO SAFETY 2 860 L 950 L Evaluzia O OPTIONAL DISCONNECT SWITCH accessories hydraulic block The two position switch is used for activating or deactivating the optional With the switch pressed in pos 01 red indicator light On the Optional accessories hydraulic block function is activated With the switch pressed in pos 02 red indicator light Off the Optional accessories hydraulic block function is deactivated STOPPING HYDRAULIC MOVEMENTS While travelling on roads it is advisable compulsory in Italy and Germany to stop all hydraulic movements The indicator lights up when the movements are being used Q LEVELLING CONTROL PUSHBUTTON The pushbutton has two positions it controls the truck level correction movements to the right and left pressing the button in position 01 will level the truck on the left pressing the button in position Q2 will level the truck on the right Verify the correct levelling using the sprit level placed in the cab see point 17 on page 23 Spirit level N B The levelling operation is not possible when the telescopic boom is inclined beyond approx 30 from the ground R
136. 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 the functions
137. ributor Manipulator exclusion solenoid valve Parking brake solenoid valve Anti tilting solenoid valve Intake filter Exhaust filter Manipulator Gear pump Optional socket Brake pump G connection of hydrostatic pump Oil tank Lift cylinder Inclination cylinder Compensation cylinder Slow fast selector valve Extension cylinder 860 L 950 L INTRODUCTION TO SAFETY 860 L 9501 Evolution 4 A ee a M a a mi EN 8 Q D ME Cp m D3 XE licor oo EEA E 4 STEERING AND BRAKES HYDRAULIC SYSTEM LAYOUT VSL 21 4 INTRODUCTION TO SAFETY 860 L 950 L LEGEND STEERING AND BRAKES HYDRAULIC SYS TEM LAYOUT C F S Parking brake cylinder CS Steering cylinder D Distributor D 3 Steering distributor EFS Parking brake solenoid valve F A Intake filter FDAR Rear axle brake disks FDAV Front axle brake disks F R Exhaust filter Gear pump P D Hydraulic powered steering Pl Connection to hydrostatic pump PI connection of hydrostatic pump R Oil tank S Brake oil tank VCLR Slow fast control cylinder VSLR Slow fast selector valve 22 INTRODUCTION TO SAFETY 860 L 9501 Evolution SNOUWOIIN WALSAS SNVI GNV DNITTIAT 1 23 INTROD
138. rive with hands or footwear wet or dirty with grease For greater comfort adjust the driver s seat and assume a correct posi tion Always maintain the normal driving position Do not put your arms or legs in general any part of the body out side the lift truck driving seat Always fasten the seat belt The controls must never be used for purposes other than those for which they are meant For example Getting into and out of the lift truck hang clothing etc When the control instruments are provided with a forced operation device lever lock it is forbidden to leave the driver s seat without set ting these commands in neutral Never allow passengers on the lift truck or in the driver s seat BEFORE STARTING THE LIFT TRUCK If the lift truck is new refer to Chapter BEFORE STARTING UP ANEW LIFT TRUCK in part 1 SAFETY INSTRUCTIONS AND REGULA TIONS Check the condition and pressure of the tyres See Chapter SPECI FICATIONS in part 2 DESCRIPTION Before startup check the various levels Combustion engine oil Hydraulic tank oil Gear oil Cooling liquid Brake fluid Also check the lift truck for oil fuel and liquid leakage Ensure correct closure and locking of the engine hood Whatever his level of experience as a lift truck operator the user must familiarize himself with the position and use of the instruments and controls before starting up the lift
139. rnated periodically E2 lights up to indicate that the system is activated When the switch is pressed E2 green light On the fan rotation inversion function is activated When the switch is pressed E3 green light Off the fan rotation inversion function is deactivated When the switch is in position E4 the fan rotation inversion function is forced When the switch is released the fan rotation inversion timed control is reset The switch can also be activated with the forklift truck running IMPORTANT When the forklift truck is travelling on roads the fan rotation inversion system must be deactivated switch pressed in position E3 TRANSMISSION RESET PUSHBUTTON LIGHT ON During normal use the pushbutton light is On For more detailed information regarding its working see point SPEED SELECTOR SLOW FAST 16 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 G FRONT WHEELS ALIGNMENT GREEN INDICATOR LIGHT Indicates alignment of the front wheels with respect to the vehicle axis When the wheels are aligned the indicator lights up See point wheels alignment procedure REAR WHEELS ALIGNMENT YELLOW INDICATOR LIGHT Indicates alignment of the rear wheels with respect to the vehicle axis When the wheels are aligned the indicator lights up See point A wheels alignment procedure PARKING BRAKE SWITCH Two position luminous s
140. roper operating techniques Important reminders of attachment and boom safety Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as 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 Hydraulic Coupling 234805 Location near the quick disconnect adapters Stop the engine and release hydraulic pressure before changing attachments Rotating Fan and Belt s 801008 Location on the radiator near the fan and on any fan belt pulley cover s KEEP HANDS Keep hands and clothing away from rotating fan and belts AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 XII INTRODUCTION TO SAFETY SAFETY DECALS Gear Shift Pattern 33460 4 speed transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift transmission R47 FEL Steering Mode 184276 4 wheel steer equipped models Location near the steering mode selection lever Identifies the steering mode selection 221322 ATTENTION CUIDADO ACHTUNG _ATTENZIONE Mineral Oil Brake Reservoir 221322 or 234800 has a been replaced
141. roughly 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 is missing contact your dealer for replace ments immediately This manual cannot cover every situation that might result in an accident It is the respon sibility of the operator to always remain alert for potential hazards and be prepared to avoid them ADDITIONAL RECOMMENDED LITERATURE ANSI ITSDF B56 6 is the national consensus standard for rough terrain forklift trucks It contains rules about forklift safety maintenance safe operation training and supervision Forklift owners should learn this stan dard and make it available for their operators service personnel and supervisors These standards can be obtained free of charge from the Industrial Truck Standards Development Foundation ITSDF on their web site at www itsdf org The following references are examples from the standard addressing forklift operators A OPERATOR TRAINING QUALIFICATIONS 1 The user shall ensure that operators understand that safe operation is the operator s responsibility The user shall ensure that operators are knowledgeable of and observe all safety rules and practices 2 Create an effective operator training program centered ar
142. rrain 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 When refueling smoking in the
143. ruck parallel to the platform Switch off the lift truck see chapter DRIVING INSTRUCTIONS in part 1 SAFETY INSTRUCTIONS AND REGULATIONS SLINGING THE LIFT TRUCK Fix the wedges in front and at the back of each tyre Fig G4 1 Also fix wedges on the inner sides of each tyre Fig G4 2 Fix the lift truck on the platform with sufficiently resistant ropes on the front of the lift truck at the anchoring points 1 Fig G4 3 and on the rear part in the tow pin 2 Fig G4 4 Tighten the ropes Fig G4 5 y 5 MO 2 SD WP INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 G 5 ADJUST THE HEADLIGHTS RECOMMENDATIONS FOR THE ADJUSTMENTS In accordance with standards ECE 76 756 76 761 20 Adjust the low beam by 2 with respect to the horizontal axis of the headlight ADJUSTMENT PROCEDURE Set the lift truck without load in the transport position perpendicular to a white wall on level horizontal ground Fig G5 Check the tyre pressure See chapter A5 CHECK TYRE PRESSU RE AND LOCKING OF WHEEL NUTS in part 3 MAINTENANCE Turn the reverse gear to neutral and apply the parking brake CALCULATING THE HEIGHT OF THE LOW BEAM LIGHTS h2 h1 Height of low beam light with respect to the ground h2 Height of adjusted beam Distance between low beam lights and the white wall h2 h1 I x 2 100 G 6 AIR CONDITIONI
144. s of a spe cial pushbutton or the manipulator itself depending on the type of lift truck in your possession For more information refer to the lift truck Use and Maintenance Manual REMOVING AND PLACING THE ACCESSORY Repeat the ACCESSORY PICKUP operation in reverse order taking care to place it in a safe position on compact level ground INTRODUCTION TO SAFETY 5 860 L 950 L ACCESSORY WITH HYDRAULIC SYSTEM AND MANUAL BLOCK OPTION PICKING UP THE ACCESSORY Check to make sure the accessory is in a position to facilitate con nection of the quick release coupling If it is not oriented correctly take the necessary precautions to shift it to the maximum safety con ditions Check to make sure the check pin is inserted in its support on the chassis Position the lift truck with the boom lowered in front and parallel to the accessory and incline the quick release coupling forwards Fig A Bring the quick release coupling under the accessory coupling tube raise the boom slightly and incline the coupling backwards to posi tion the accessory Fig B Disengage the accessory from the ground to facilitate blockage MANUAL BLOCKING AND CONNECTION OF THE ACCESSORY Take the check pin on the support and block the accessory Fig C Remember to fit the split pin Switch off the combustion engine Suppress the pressure in the accessory hydraulic circuit by means of the optional co
145. se off the liquid in accordance with the regulations applicable in the country of use Refit the two intercooler radiator partitions 12 and 13 Fig 05 2 using a 10 mm hex wrench 19 INTRODUCTION TO SAFETY 3 860 L 9501 D 6 REPLACE THE FUEL FILTER CARTRIDGE WITH WATER SEPARATOR Place a suitable container under the fuel filter with water separator 14 Fig 06 1 to collect the liquid that flows out Clean the outer surfaces of the filter thoroughly Install a suitable tube on outlet 15 Fig D6 2 Open drainage outlet 16 Fig 06 2 and let the liquid drain out com pletely into the container Close the drainage opening 16 Fig 06 2 tightening it only manually and remove tube 15 Fig D6 2 Slacken screw 17 Fig D6 2 holding the glass cup 18 steady Fig D6 2 Remove the glass cup 18 Fig D6 2 from cartridge 19 Fig D6 2 Use a suitable tool to remove cartridge 19 Fig D6 2 Dispose off the used cartridge 19 Fig D6 2 and the old gaskets 20 21 Fig 06 3 according to the regulations in force in the country of use Clean the glass 18 Fig 06 2 using a clean cloth that does not leave residues Make sure dirt cannot enter the new fuel filter see Table FILTER ELEMENTS AND BELTS Do not lubricate the sealing ring on the new fuel filter Insert the new
146. t The cooling liquid added in the maintenance phase must be the same as that originally used for filling the circuit INTRODUCTION TO SAFETY 860 L 9501 Evolution 3 A 3 CHECK FUEL LEVEL Position the lift truck on a horizontal surface with the combustion engi ne switched off To reduce the condensate due to atmospheric conditions to a minimum keep the fuel tank filled as far as possible Remove plug 3 Fig A3 Fill the tank with fuel oil through the filler plug taking care to avoid impurities entering the tank Refit plug 3 Fig A3 Do not smoke or approach the machine during fuelling operations or with the tank open Never carry out fuelling operations with the combu stion engine running A 4 CHECK AND DRAIN THE FUEL FILTER WITH WATER TRAP Make sure the engine is stationary before carrying out maintenance or repairs on it Place a suitable container under the condensate trap to collect the fuel that flows out Wipe the fuel that leaks out Install a suitable tube on outlet 4 Fig A4 Open drainage outlet 5 Fig 4 Let the liquid flow out into the container Close drainage outlet 5 Fig A4 tightening it only manually Remove the tube and dispose off the drained liquid in accordance with the regulations applicable in the country of use Do not smoke near or approach the machine with the flame while filling the tank or when the tank 15 op
147. tentially 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 INTRODUCTION TO SAFETY SAFETY DECALS The purpose of this chapter 15 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 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 injure
148. ting and then rehook Handle the control level gently to avoid jerking the load and eventual winding of the rope around the drum Lift the load vertically avoiding oscillation and oblique lifting Check the rope daily and replace it immediately if it is worn damaged or even just one string is broken see ISO 4309 consult your dealer Check the working of the hydraulic ascent descent limit stops daily and the braking with load applied Lubricate rotating parts of the hook with oil periodically Check the rope winding around the drum periodically The following accessories are not meant for lifting systems or for transferring persons Before using the hoist or any other equipment that hangs the load by a hook inform the inspection authori ties responsible ISPEL in your area for Italy only Remember to ask for an inspection by your local health authorities every year for Italy only It is forbidden to lift hanging loads using fork accessories or other supports not meant for this function Contact your agent or dealer INTRODUCTION TO SAFETY 860 L 9501 Evolution 5 Before you start using the hoist on the lift truck ensure the compatibility of the machine and its safety system with the type of hoist required ATTENTION Non conforming calibration of the safety system can be very hazardous for your safety therefore contact your dealer immediately in case of doubt Certain accessories owing to th
149. ting terminals 7 Fig C5 Check the electrolyte level regularly and if necessary top up with demineralized or distilled water never add sulphuric acid strictly fol low the indications on the battery If the voltage at the battery poles is less than 12 3 V recharge the bat tery Disconnect the battery if the truck is to remain unused for long periods Charging the battery Remove the caps 8 Fig C5 if possible Only direct current must be used for recharging the battery Connect the positive wire of the battery charger to the positive pole of the battery and the negative wire of the battery charger to the negative pole of the battery Charge using a current 1 10 of the battery s rated capacity Ah When charging is complete switch off the battery charger before disconnecting the battery Check the electrolyte level 16 INTRODUCTION TO SAFETY 860 L 950 L Evolution 3 EVERY 500 HOURS OF SERVICE OR YEARLY D 1 DRAIN OUT AND CHANGE COMBUSTION ENGINE OIL D 2 REPLACE THE ENGINE OIL FILTER Position the lift truck on a level surface let the engine run at minimum speed for a few minutes and then switch it off Emptying the engine oil pan Place a container under drain plug 1 Fig D2 1 and unscrew the plug Remove filler plug 2 Fig 02 2 to facilitate drainage Replacing the filter Remove oil filter 3 Fig D2 1 reje
150. ty regulations and use maintenance and repair instructions can result in serious accidents sometimes even death Draws the user s attention to the possible risks of driving at speeds exceeding those imposed by road travel restrictions especially Risk of losing control on bad roads Increased braking space The user must always be in a position to control the lift truck and therefore Adapt the speed to every situation to ensure his own Safety that of others and his materials Judge the braking space constantly INTRODUCTION TO SAFETY 860 L 9501 Evolution Experience shows that there may be certain contraindications for the use of the lift truck These abnormal uses the main ones are indica ted subsequently are strictly forbidden Expected abnormal working resulting from routine negligence but not due to intentional incorrect use of material Reflected behavior of a person in case of defective functioning acci dent breakdown etc while using the lift truck Behaviour resulting from application of law of minimum stress while carrying out a function For certain machines the expected behaviour of certain persons such as apprentists adolescents disabled persons beginners tempted to drive a lift truck operators tempted to place bets regar ding the use competition or personal experience The person responsible for the material must take these criteria into account while evalu
151. uby Jajem Jajuno9 Jana any 42915 joued dund any Jadim 5 UB 911199 9 19 009 19 U UB 19 009 19 U euondo Jeuonipuoo CN XE LO SE P CO xE IA 10 10 SE 10 SE lt 00 0 00 EX CX LX 8 5 9965 7965 2665 8605 2665 CECS LECS 0225 2165 9125 2165 CLES LLES 6005 8005 7005 2815 2415 0415 6915 8915 2915 9915 2015 715 v8va LOLH LEcW 96 LIN 9G LIN VIN Of INTRODUCTION TO SAFETY 860 L 9501 Evolution P231 P234 P230 FUELLEVEL WATER TEMP INSTRUMENT INSTRUMENT CAPACITOR WATCH L4 SIL SIL E vu M Eia 90 ri T 15 54 JH ab 0 n TOME X360 K360 G L1 2 8 _ al al Bl al 4 9 61 21 1322514 C N1 21 EN s O O R1 d 8 1 Ee N1 4 1 21 4 L 23 a_i 5 1 T y y TL 1 _ 7 81 21 q AGI 33 1044
152. ution 1 PICKING UP A LOAD FROM HEIGHTS ON TYRES Do not pick up a load unless the lift truck 15 on level ground See para graph G HORIZONTALITY OF THE LIFT TRUCK in Chapter HANDLING A LOAD Check to make sure the forks pass easily under the load Raise and extend boom 1 2 to position the forks level with the load If necessary move lift truck 3 Fig G forwards gently and carefully See paragraph E VISIBILITY in Chapter HANDLING INSTRUC TIONS relative to path visibility Always maintain the necessary distance to insert the fork under the load between the stack and lift truck Fig G using the minimum pos sible length of the boom Bring the forks against the load Fig H Apply the parking brake and set the reverse gear lever in neutral Lift load 1 slightly and incline fork arm 2 backwards to stabilize load Fig 1 Incline the load backwards sufficently to ensure stability load lost during braking taking care to maintain the balance If possible lower the load without moving the lift truck Raise boom 1 to move the load away retract 2 and lower boom 3 to bring the load to the transport position Fig J this is not possible move the lift truck backwards Move very gently and carefully See paragraph E VISIBILITY in Chapter HANDLING INSTRUCTIONS concerning visibility of the path move lift truck 1 away from the load retract 2 and
153. when the ignition is switched on KEY SWITCH The key switch has 4 positions O Electric contact and switching off the combustion engine Electric contact Start up and return to position I as soon as the key is released Before starting up the engine make sure the forwards backwards selec tor is in the idle position and that the emergency stop button is released 19 INTRODUCTION TO SAFETY 2 860 L 950 L Evaluzia 9 GUARD FOR ACCESS BRAKE FLUID AND WINDSCREEN WASHER LIQUID TANKS Slacken screw A and remove the guard to access the brake fluid and wind screen washer liquid tanks 410 gt BRAKES FLUID TANK 11 WINDSCREEN WASHER LIQUID TANK To the operator s LH Remove cap B make sure the container is always full Liquid to be used water detergent use anti freeze in winter 12 GUARD FOR ACCESS TO FUSES AND RELAYS Release and pull block C to remove the guard for access to the fuses and relays 20 INTRODUCTION TO SAFETY 860 L 9501 Evolution 2 19 ACCELERATOR PEDAL SERVICE BRAKE AND INCHING PEDALS Pedal A is used to change the lift truck speed by acting on the combustion engine rpm Pedal B acts on the front wheels and makes it possible to slow down and block the lift truck The brake pedal in the first 20 mm of travel works as the inching pedal allowing precise slow movements and during
154. witch with safety block The parking brake acts on the front axle To release the brake press the pushbutton in position I1 To lock the brake press the pushbutton in position I2 To release the brake from I2 to I1 while pressing the switch act on safety lock I3 J REAR FOG LIGHT SWITCH Two position luminous switch K SPEED SELECTOR SLOW FAST The machine can run at two speeds Slow for work site Fast for road travel To change the speed follow the instructions given below stop the forklift truck movement completely keep the i c engine running at minimum speed position the reverse gear in idle see point 15 on page 22 push the brake pedal all the way and press the slow fast pushbutton until the respective lights 1 or light up If the forward reverse movement is not activated follow the instruc tions given below position the reverse switch as required Forwards Reverse discharge pressure from the brake pedal Press the TRANSMISSION RESET pushbutton to obtain the connection in the required direction f the vehicle does not move start accelerating the internal combustion engine slowly and gradually until the truck starts moving These indications must be followed for proper working of the transmission L SLOW SPEED GREEN INDICATOR LIGHT The green light indicates that slow speed is selected M FAST SPEED GREEN INDICATOR LIGHT The g

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