100% found this document useful (1 vote)
3K views148 pagesManitou MLT Manual
manitou manual
Uploaded by
Taras KutsykCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
100% found this document useful (1 vote)
3K views148 pagesManitou MLT Manual
manitou manual
Uploaded by
Taras KutsykCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 148
MANITOU
MANITOU NORTH AMERICA, INC.
6401 IMPERIAL DRIVE
WACO, TX 76712-6803
For Paris Ordors contact your Manitou North Amorica Dealer or cal
Manitou North America, Ine. Parts Dept. (800) 425-3727 or (254) 799-0232
Parts Dept. Fax (254) 867-8504 Website: www manitou-na.com
CALIFORNIA PROPOSITION 65 WARNING
Diasol Engine Exhaust and some of its constituents are known to the Stato of
Calitomia to cause cancer, birth defects or other reproductive harm,
MLT629T Series A
MLT633TLS Series A
MLT730TW(120)LS Series A
MT732T Series A
MT932 Series A
OPERATOR'S MANUAL
THIS OPERATOR'S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND
UNDERSTOOD BY USERS.
BATTESAS
R/t1-10 - INTRODUCTION TO SAFETY -
- ROUGH TERRAIN FORKLIFT TRUCK
GENERAL SAFETY STANDARDS -- - |
- SAFTETY MESSAGES - - - ----------------------- Vit
- SAFETY DECALS - - ---------------------------- VII
- TABLE OF CONTENTS - - ------------------------ XV ROUGH TERRAIN FORKLIFT TRUCK
GENERAL SAFETY STANDARDS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS
STUDY THE OPERATOR/SERVICE MANUALS
The information in this manual provides general instructions for the safe operation and maintenance of your
forkiift truck. This information is vital and must be clearly understood by the operator and serviceman. Study
this manual and the Rough Terrain Forklift Safety Manual (part no. 422494) thoroughly and carefully before
operating or servicing your forklift. Contact your dealer or Manitou North America, Inc. if you have any ques-
tions concerning your forklift, ts operation, service or paris. Keep both manuals in the literature box on the
forklift available for reference. If either manual becomes illegible or is missing, contact your dealer for repiace-
ments immediately. This manual cannot cover every situation that might result in an accident. Its the respon-
sibility of the operator to always remain alert for potential hazards and be prepared to avoid them!
ADDITIONAL RECOMMENDED LITERATURE:
ANSI / ITSDF B58.6 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-
sile at www.itsdf.org. The following references are examples from the standard, addressing forklift operators:
A.) OPERATOR TRAINING QUALIFICATIONS
11) The user shall ensure that operators understand that safe operation is the operator's responsibilty. The
user shall ensure that operators are knowledgeable of, and observe, all safety rules and practices,
2.) Create an effective operator training program centered around user company’s policies, operating condi-
tions, and rough terrain forklift trucks. The program should be presented completely to all new operators and
ot be condensed for those claiming previous experience.
3.) Information on operator training is available from several sources, including rough terrain forklift truck man-
Ufacturers, users, government agencies, etc.
4.) An operator training program should consist of the following:
‘.) careful selection of the operator, considering physical qualifications, job attitude, and aptitude;
b.) emphasis on safety of stock, equipment, operator, and other personnel;
.) citing of rules and why they were formulated;
4.) basic fundamentals of rough terrain forklift truck and component design as related to safety, ¢.g.,
in-lb (N-m) loading, mechanical limitations, center of gravity, stability, etc
¢.) introduction to equipment, control locations, and functions. Explain how they work when used
properly and problems when used improperly.
{.) 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.;
4g.) oral, written, and operational performance tests and evaluations during and at completion of the
h,) refresher courses, which may be condensed versions of the primary
course, and periodic “on job” operator evaluation;
i.) understanding of nameplate data and operator instructions and warning information appearing on
the rough terrain forklift truck.
B.) GENERAL SAFETY PRACTICES
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,) Ifthe rough terrain forklift truck is equipped with front end attachment(s) or optional forks, the user shall see
that the truck is marked to identify the forks or attachment(s), show the approximate weight of the truck and
fork or attachment combination, and show the capacity of the truck with forks or attachment(s) at maximum
elevation with load laterally centered.
5.) The user shall see that all nameplates and caution and instruction markings are in place and legible.
6.) The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity. ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont
B.) GENERAL SAFETY PRACTICES (cont.)
7.) Where steering can be accomplished with either hand and the steering mechanism is of a type that pre-
vents road reactions from causing the handwheel to spin (power steering or equivalent), steering knobs may
be used, When used, steering knobs shall be of a type that can be engaged by the operator's hand from the
top and shall be within the periphery of the steering handwheel.
8) Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable
when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may con-
tribute to a condition of instability and defeat the purpose of the requirements.
9.) Users shall give consideration to special operating conditions. The amount of forward and rearward ttt to
be used is governed by the application. Although the use of maximum rearward tit is allowable under certain
conditions, such as traveling with the load lowered, the stability of a rough terrain forkift truck as determined
by standardized tests does not encompass consideration for excessive tit 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 forkiit trucks equipped with attachments behave as partially loaded trucks even when operated
without a load on the attachment), dynamic and static forces, improper tite inflation, and the judgement exer-
cised by the operator.
C.) OPERATING SAFETY RULES AND PRACTICES
1.) Safe operation is the responsibilly of the operator.
2.) This equipment can be dangerous if not used property. 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 forkiit truck.
4.) Belore 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 forkiit truck:
a.) be in operating position and fasten seat belt;
b.) place directional controls in neutral;
©.) apply brakes
d,) start engine.
6.) Do not start or operate the rough terrain forklift truck, any of its functions, or attachments from any place
other than the designated operator's position.
7.) Keep hands and feet inside the operator's designated area or compartment. Do not put any part of the
body outside the operator compartment of the rough terrain forklift truck.
8) Never put any part of the body into the mast structure or between the mast and the rough terrain forklift
truck.
9.) Never put any part of the body within the reach mechanism of the rough terrain forklift truck or other attach-
ments.
10.) Understand rough terrain forklift imitations and operate the truck in a safe manner so as not to cause injury
to personnel.
411.) 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 25tt (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:
1) bring rough terrain forklift truck to a complete stop:
b.) place directional controls in neutral;
.) apply the parking brake;
1) lower load-engaging means fully, unless supporting an occupied elevated platform;
.) stop the engine;
1.) ifthe rough terrain forklift truck must be left on an incline, block the wheels;
4g.) fully lower the load-engaging means.
17.) Maintain a safe distance from the edge of ramps, platforms, and other similar working surfaces.
18.) Do no move railroad cars or trailer with a rough terrain forklift truck. ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont
C.) OPERATING SAFETY RULES AND PRACTICES (cont.)
19.) Do not use a rough terrain forkift truck for opening or closing railroad car doors.
20.) In areas classified as hazardous, use only rough terrain forklift trucks approved for use in those areas.
wolving personnel, building structures, and equipment to the supervisor or as
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 tetrain forkift trucks equipped with a differential lock, the lock should not be engaged when driv-
ing on the road or at high speeds or when turning, If the lock is engaged when turning, there could be loss of
steering control.
25,) Observe all traffic regulations including authorized speed limits. Under normal traffic conditions, keep to
the right, maintain a safe distance, based on speed of travel, from the truck ahead; and keep the truck under
control at all times.
26.) Yield the right-of-way to pedestrians and emergency vehicles such as ambulances and fire trucks
27.) Do not pass another truck traveling in the same direction at intersections, blind spots, or at other danger-
‘ous locations.
28.) Slow down and sound the audible warming device(s) at cross-aisles and other locations where vision is
obstructed.
29.) Cross railroad tracks at an angle wherever possible. Do not park closer than 6 ft (1.8m) to the nearest rail
of a railroad track.
30.) Keep a clear view of the path of travel and observe other traffic, personnel, and safe clearances.
81.) I the load being carried obstructs forward view, travel with the load trailing.
82.) Ascend or descend grades slowly and with caution.
‘.) When ascending or descending grades in excess of 5%, loaded rough terrain forklift trucks
should be driven with the load upgrade.
b.) Unloaded rough terrain forklift trucks should be operated on all grades with the load-engaging
means downgrade.
.) On all grades, the load and load-engaging means shall be titted back, if applicable, and raised
only as far as necessary to clear the road surface.
4.) Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines;
travel straight up or down.
33,) Under all travel conditions, operate the rough terrain forklift truck at a speed that will permit i to be brought
toa stop ina 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 overtum.
the rough terrain forklift truck.
36.) Do not indulge in stunt driving or horseplay.
87.) Slow down for wet and slippery surfaces.
38.) Before driving over a dockboard or bridge plate, be sure that itis property secured. Drive carefully and
slowly across the dockboard or bridge plate, and never exceed its rated capacity.
39.) Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so.
‘Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the ela-
valor, 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 tuns, reduce speed to a safe level, and turn steering handwheel in a smooth sweeping
motion. Except when maneuvering at a very low speed, tum 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 forkift 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 forkiit truck.
.) Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity
with extra caution. Stability and maneuverability may be adversely affected.
jormally
w 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 forklit 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 tiling 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 tioring, use only enough backward tilt o 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 creale a hazard if not externally stabilized. When handling suspended loads
1.) do not exceed the truck manufacturer's capacity of the rough terrain forklift truck as equipped
{or handling suspended loads.
b.) only lft the load vertically and never drag it horizontally;
cc) 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;
.) use tag lines to restrain load swing whenever possible.
50.) At the beginning of each shift and before operating the rough terrain forklift truck, check its condition,
giving special attention to:
a.) tires and their inflation pressure
b.) warning devices
.) lights
4.) lft and tilt systems, load-engaging means, chains, cables, and limit switches
e.) brakes
1.) 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.
552.) If during operation the rough terrain forkiit truck becomes unsafe in any way, the matter shall be reported
immediately to the user’s designated authority, and the truck shall not be operated until it has been restored to
‘safe operating condition.
'53.) Do not make repairs or adjustments unless specifically authorized to do so.
54.) When refueling, smoking in the area shall not be permitted, the engine shall be stopped, and the opera-
tor shall not be on the rough terrain forklift
‘ruck.
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 ines 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, chapier 5.15 Elevating Personnel). ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont)
D.) SUSPENDED LOADS
{jb 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 ather similar device can introduce dynamic
forces affecting the stability of the machine that are not considered in the stabiliy 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. DONOT exceed the rated capacity ofthe telescopic handler as equipped for handling suspended
loads. The weight ofthe rigging must be included as part ofthe load,
2. During transport, DO NOT raise the load more than 12 inches (305 mm) above the ground, or raise
the boom more than 45 degrees,
3. Onlylift 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. Star, 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 or
fore and aft, The load center must not exceed 24 inches (610 mm),
8 DONOTif the load with anyone on the load, rigging or lit equipment, and NEVER lif the load over
personnel
9, Beware of the wind, which can cause suspended loads to swing, even with taglines.
10. DONOT attempt to use frame-leveling to compensate for load swing
A WARNING
U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derticks in
Construction) Include requirements for employers that use powered Industrial trucks ("forklifts") configured
to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation
applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a
hhook (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: §1910.178(1).]
When 2 forklift / telescopic handler is configured and used for hoisting, the employer must ensure that:
1. Forklift lft 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 ts rated capacity and In accordance with the manufacturer's
Instructions.
rT 5. Operator and erew members have been trained in the safe use and operation of the equipment,
Including how to avold electrocution.
6. During use, no part of the equipment, oad 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
ower line, and any taglines used are non-conductive
7. In-addition, for lift equipment with a rated capacity greater than 2000 bs. (907 kg), the employer
must ensure that:
4.) An accessible fire extinguisher Is on the forklifts
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 $1926.1427 and §1926.1430.
Note: Refer to the full text of the OSHA crane regulation (29 CFR Part 1926, Subpart CC) for a detalled
description
oa ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
CONCLUSIOT
4.) ATTEND OPERATOR TRAINING CLASSES
The forklit operator must clearly understand all instructions conceming 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 abilty to operate the equipment safely. NEVER use drugs or alcohol while operating a fork! NEVER.
‘operate or allow anyone to operate a forkift when montal 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 fork,
2.) CREATE A MAINTENANCE PROGRAM.
OSHA recommends a maintenance log, listing repairs requested and completed, for each forklift. Also, “lock
‘out tag procedures" should be utilized. Ifthe forklit 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 forklit 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 lit truck. After repair, 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 forklft model. Learn the locations and meanings of all safety decals. If any decais 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 forkit wth damaged, missing or unsafe components. Have
it repaired by authorized service personnel. Leam the functions of all controls, gauges, indicator lights, ete. on
the forklift. Know the speed!gear ranges, braking and steering capabilites, load ratings and clearances. When
referring o the location of forklit components, the terms “et, “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 forkitt, 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. Chock
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. Willa signal man be required to help place the load? Remove
‘any debris which may cause tre damage or rupture. Plan your route around problem areas or have them cor-
fected. Inform the supervisor of any unsafe concitions 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, crop-offs, trenches, roughisoft spots, oll spills, deep mud, steep inclines, railroad tracks, curbs,
‘te... NEVER approach power lines, gas lines or other utlties with the forklit! Always verify that loce
statelprovincial 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 ata provided in this manual is subject to production changes, addition of new modols, and improved prod-
Uuct designs. If 2 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.
vm SAFETY MESSAGES
NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL
HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Ao, observe
the safety messages places throughout this manual; providing special instructions, teling you when fo take precautions
‘and to identity potential hazards. The safely messages ara highlighted and outined in a box similar to those shown inthe
‘examples below.
SAFETY ALERT SYMBOL
A
NOTE or NOTICE
Provides information, spacial insracions or references about the it truck
IMPORTANT
Precauiions which must be taken o avoid damage ta the Ii ruck
A UuTION
Thalcates a potentaly hazardous siualion wich, nol avoided, may TeSull in Minor OF
moderato injury. May also alort unsafe practicas.
A WARNING
Tracts a potenialy hazardous sivalion which, W nol avoided, may result death or
‘soricus injury!
A DANGER
Tnicaies an inirineniy Razardous siualion wach, Ir nol avOWGEd, wil TeSUT i Gea OF
‘serious iniuy
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. SAFETY DECALS
The purpose of this chapter is to introduce you to the safety messages, decals, and nameplates found on
your forklift truck. The decals are identified by name, part number, location, and a brief description. (The
forklift model logos, and other misc. decals not shown, can be found in your forklift parts manual.) The
decals illustrated may not be exactly the same as those installed on your forklift; installation of the decals
varies depending on the forklift model, series, decal updates, etc.. The size and location of some decals
limit the amount of information that can be placed upon it. For this reason, additional detailed information
not found on the decals is provided through-out this manual
Every decal placed on the lift truck is important; they are constant reminders of safety and instructions that
should never be taken for granted. Even experienced operators can be seriously injured or killed by ignor-
19, 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; leam 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 neatest dealer for advice before operating your forklift!
801011
Before Starting - 801011
(Boom equipped models). Location: on the brake flu
the left and below the dash panel).
cover panel (to
__PEEORE STARTING OF OPERATES:
Safety Instructions - 420792 fed nd wand ey an opting
(Mast equipped models). Location: on or near the operator manual Seamer
storage case, andior on the dash panel. ela
Instructions for the forklift operator; before operating the forklift. Foss ot
Karp ts tc
por ne pare nt.
SAFETY INSTRUCTIONS
1. Read ang understand operator's manual betore you operate
this truck. the operators manual Is missing, a new
‘manual may be obiained through your local dealer
(oF directly trom K-D Manitou, ine. Waco, Te
‘ceron eos pi, re say
mance
\WHEN PARKING OR SERVICING:
2 he aoe
2, Check truck for proper operation of al functions.
3. Fasten seat-ett. a
Use of Seat Belt - 801012
(Boom equipped models). Location: to the right of the
operator, near the hydraulic control lever.
INNS
Instructs the operator to always wear the seat belt during
operations, and never jump from an over-tuming forklift. “Kx SAFETY DECALS
Emergency and Parking Brake - 801010
Location: near the park brake lever.
Identifies the Emergency/Parking Brake Lever.
Alarm Must Sound - 496162
Location: on the dash, in direct view of the operator.
EMERGENCY STOPPING
AND PARI
The backup alarm must sound when the forklift is placed in reverse gear.
No Riders - 420732
Location: on the cab entrance(s), and on or near wheel fenders and engine
cover.
Informs: riders are not allowed on the forklift.
Clear of Raised Boom - 801006
(Boom equipped models). Location: on both sides
of the boom nose.
Keep away from unsupported boom.
Clear of Power Lines - 801007
(Boom equipped models). Location: on both sides
of the boon nose.
Keep away from power lines.
5
ee
THIS VEHICLES
EQUIPPED WITH A BACK UP
ALARM. WHEN BACKING, THE
ALARM
MUST
‘THE OPERATOR
FOR THE
‘THIS:
IG BRAKE
SOUND
AIS RESPONSIBLE
‘SAFE USE OF
VEHICLE.
A CAUTION
NO
RIDERS
TNs
aa
reat
ci
oer
x
$y wo
Wye)
ee ei
reat
coed
Ce
fret) SAFETY DECALS
Use of Frame Leveling - 801013
(Boom equipped models). Location: to the right of my DANGER
the operator near the hydraulic control lever. err
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:
Important reminders of attachment and boom safety imachneotpovr, Feferte nective ed
{hart ane operator's manual or proper
‘parating techniques.
Fofer to operator's manual fer proper
Never use this machine asa mani
“Attachment must be propery locked tothe
‘carrier befor raising boom.
Use onty approved atachments on this
machin,
Do not work under raises boom or atachments
unless supported.
FAILURE TO FOLLOW ANY OF THE ABOVE
INSTRUCTIONS GAN CAUSE SERIOUS INJURY
"TO THE OPERATOR OR OTHER PERSONS.
Hydraulic Coupling - 234805
Location: near the quick-disconnect adapters. t
Gace) 2 =f
‘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).. ween
Keep hands and clothing away from rotating fan and belts. plogaedcelbss|
Raa
eu
ENP a)
aan
Saat
Ie
em
xi SAFETY DECALS
Gear Shift Pattern - 33460
(4-speed transmission models). Location: near the gear shift lever.
Identifies the gear shift pattem of the forklift transmission.
(4.wheel steer equipped models). Location: near the steering mode selection lever.
Steering Mode - 184276 bi
Identifies the steering mode selection. n
221322
ATTENTION = —_ CUIDADO.
ACHTUNG _ATTENZIONE
LIQUIDE DE FREIN
BRAKE LIQUID
BREMSFLUESSIGKEIT
LIQUIDO DE FRENO
LIQUIDO FRENI
Utiiser MPERATIVEMENT de huile minérale
IMPERATIVE to use mineral oil
‘Verwenden Sie UNBEDINGT MineraiOl
Usar IMPERATIVAMENTE de aveite mineral
Utllzzare IMPERATIVAMENTE olio minerale
LHMS =
Mineral Oil (Brake Reservoir) - 221322 or 234800
Location: attached to the brake fluid reservoir.
Refer to the Operator/Service Manual for the correct brake fluid
(mineral oil) to be used in the brake system.
234800
vs ©
xi SAFETY DECALS
Hydraulic Oil - 234798 or 76573
Location: on the hydraulic tank or filler cap.
Identifies the hydraulic reservoir (tank) or filler cap.
Hydraulic Oil - 61024
Location: on the hydraulic tank
Identifies the hydraulic reservoir (tank),
Anti-Freeze - 234799
Location: on the radiator, near the radiator filler cap.
Indicates required minimum to maximum anti-freeze protection (-229F 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 on the forklift model
HUILE HYDRAULIQUE
HYDRAULIC OIL
HYDRAULIK OL
ACEITE HIDRAULICO |
OLIOIDRAULICO 3}
-30°C | -40°C
-22°F | -40°F
NOTICE
Instructs personnel not to use the designated area as a step,
Do Not Tow - 494918
(Hydrostatic equipped models). Location: on the
dash, in view of the operator.
Towing the forklift will damage the transmission;
refer to the operator's manual
NO STEP
4 WARNING
THIS VEHICLE IS EQUIPPED WITH A
HYDROSTATIC TRANSMISSION. DO NOT ATTEMPT
TO PUSH OR TOW, TRANSMISSION DAMAGE WILL|
OCCUR. SEE OPERATOR'S MANUAL.
xv SAFETY DECALS
Attachment Warning - 421016
near where the retaining shaft is installed.
Reminder to operator: install attachment retaining shaft and
safety pin before operations.
TRUCK OPERATION.
Hook Here - 24653
Location: at points provided on the forklift, where straps or chains may be attached to
secure the forklift to a trailer during transport
Fork Safety - 426641
(Mast equipped models). Location: on the front and back side of the mast's outer rails.
at eye level (4 required).
Instructs personnel not to travel beneath or upon the lift truck forks.
Pinch Point, Large, 2.5 x 4.5 in. - 426643
Pinch Point, Small, 1.5 x 2.75 in. - 426642
(Mast equipped models). Location: on the front and rear sides
of the mast cross bracing
| AWARNING|
Keep fingers away from the mast HE acon
crossbracing ICLEAR OF
ICROSSBRACING
HAND THROTTLE DANGER - 804784
(Boom equipped models, option). Location: Near the hand throttle mechanism.
Reminder to operator: set parking brake before operating hand throttle.
Disengage hand throttle before leaving the forklift
A DANGER A
DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK.
OPERATE HAND THROTTUE ONLY WITH PARIN® BRAKE SET,
FAILURE TO COMPLY MAY RESULT IN SERIOUS [NJURY OR DEATH.
xv
THE ATTACHMENT RETAINING SHAFT
MUST BE IN PLACE AND SECURED
WITH THE SAFETY SNAP PIN BEFORE
018
[ AWARNING| SAFETY DECALS
Acid in Battery - 801014
Location: in or near the battery
storage compariment
Addresses battery hazards.
Reid
Jump Start Battery - 801015 Gece Ni)
Location: in or near the battery storage fe eg on
‘compartment,
Jump start instructions.
Attachment Plate - 425995
Location: on the optional removeable forklift attachment.
Important manufacturer information about the attachment, Record this information for use
when contacting the maufacturer for parts and service.
Overhead Guard Data Plate - B6109
Location: attached to the overhead guard.
HS eo ees ea
‘Overhead guard conformity. was Passe aN INFACT test or[_ "JF. us.
496550
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.
xv TABLE OF CONTENTS
OPERATING AND SAFETY INSTRUCTIONS 1-1
~ ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS 1-3
~ DRIVER'S OPERATING INSTRUCTIONS 1-4
* CAUTION 14
+ GENERAL INSTRUCTIONS 1-5
+ OPERATING INSTRUCTIONS 1-7
“+ HANDLING INSTRUCTIONS wn
+ LOAD HANDLING 4-13
~ MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1-16
~ BEFORE STARTING UP A NEW LIFT TRUCK 1-18
2 - DESCRIPTION 2-1
— IDENTIFICATION OF THE LIFT TRUCK 2-4
~ CHARACTERISTICS
NLT 629 Turbo Série A 2-6and2-8
IMLT 633 LS Turbo Série A 2-6and2-12
LT 730 LS Turbo Séeo A 2-6and2-16
INT 732 Turbo Série A 2-6and2-20
INT 932 Serie A 2-6and2-24
~ DIMENSIONS AND LOAD CHART
IMLT 629 LS Turbo Série A 2-10
NLT 633 LS Turbo Série A 2-14
MLT 730 LS Turbo Série A 2-18
IMT 732 Turbo Sexo A 2-22
INT 982 Série A 2-26
~ INSTRUMENTS AND CONTROLS 2-28
~ DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 2-45
3 - MAINTENANCE 3-1
~ FILTERS CARTRIDGES AND BELTS 3-3
~ LUBRICANTS AND FUEL 3-4
~ SERVICING SCHEDULE 3-6
~ A- DAILY OR EVERY 10 HOURS SEVICE 3-8
~ B- EVERY 50 HOURS SERVICE 3-11
~ C- EVERY 250 HOURS SERVICE 3-18
~ D- EVERY 500 HOURS SERVICE 3-22
~ E- EVERY 1000 HOURS SERVICE 3-28
~ F - EVERY 2000 HOURS SERVICE 3-33
~ G- OCCASIONAL MAINTENANCE 3-34
~ H- EVERY TWO YEARS (OPTION AIR CONDITIONING) 3-40
4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE 4-1
~ INTRODUCTION 403
~ PICKING UP THE ATTACHMENTS 45
xv 1 - OPERATING
AND SAFETY
INSTRUCTIONS ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS
ALL MAINTENANCE ON OUR LIFT TRUCKS MUST BE CARRIED OUT USING ORIGINAL PARTS.
BY ALLOWING NON-ORIGINAL PARTS TO BE USED,
YOU RUN THE RISK - Legally, of being liable in the event of an accident,
«Technically, of causing broakdowns to occur or of reducing your lit truck's service ite.
Using counterfeit paris or compononis nat approved by the manufacturer
IMPORTANT ‘may put an end to contract warranty terms and lead
the maker to witharaw the lit truck's certificate of compliance.
BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS,
YOU ARE LEGALLY — - Any user who procures parts from another quarter does so at his own risk.
COVERING
YOURSELF - Any user who modifies his lit truck or has it modified by a service company, must consider
that a new item of equipment has been brought onto the market and therefore takes liability
fort
- Any user who copies original parts or has them copied is taking a risk from the legal viewpoint.
= The certificate of compliance only binds the maker for parts chosen or produced under the
maker's control
+ The practicalities of maintenance terms are set out by the maker. The maker is in no way
liable in the event of the user not complying with such terms.
YOU GET THE THE MANUFACTURER BRINGS TO THE USER,
BENEFIT OF THE
MANUFACTURER'S. - His know-how and sill
KNOW-HOW
= Guaranteed quality work.
Original replacoment parts
- Help wth preventive maintenance.
- Effective help with diagnesing faut.
Enhancements gained trom fedback.
- Training for operating stat.
- Only the manufacturer knows the details of the lift truck design and therefore has the best
technological capability to carry out maintenance. DRIVER'S OPERATING INSTRUCTIONS
WARNING
WHENEVER YOU SEE THIS SYMBOL IN MEANS:
WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK.
|- Most accidents connected with the use, maintenance and repair of the lift truck are due to non application of the basic
safely instructions. By being aware of the risks to which you are exposed and by taking the necessary preventive
‘measures, you should be able to avoid accidents occurring
Any operation or maneuver not described in the instructions is prohibited, however, any person who does use another
‘method must first ensure that he is not putting himsel, another person or the lit truck in danger.
- The manulacturer is not ablo to anticipate all possible risk situations. Therefore the sataly instructions and notices|
