Manitou TMP25/HT TMP5500/HT VERTICAL LIFT MAST Operator Manual - PDF DOWNLOAD

CONTENTS

MANITOU NORTH AMERICA, INC. 6401 IMPERIAL DRIVE Waco, TX 76712--6803 For Parts Orders contact your Manitou North America Dealer or call: Manitou North America, Parts Dept. 800--425--3727 or (254) 799--0232 Parts Dept. Fax: (254) 867--6504

Website: www.manitou--na.com

CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust and some of its constituents are known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING! The specially designed TMP Forks must be replaced with Factory Approved Forks only!

Contact your Dealer or Manitou North America, Inc.

TMP25/HT TMP5500/HT

VERTICAL LIFT MAST

TMP25 S/N: 165123 THRU 751863 TMP5500 S/N: 165126 THRU 751863

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 801087EN R11--10

CONTENTS

CONTENTS

TMP 25 TMP 25 HT TMP 5500 (SHOWN BELOW) TMP 5500 HT

CALIFORNIA PROPOSITION 65 WARNING Engine Exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

WARNING Report faulty push--pull cables (throttle control cable, park brake cable, etc.) immediately!

Never adjust or modify the control cable(s) with the power on or the engine running, serious injury or death could result!

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

CONTENTS

CONTENTS

INTRODUCTION ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS STUDY THE OPERATOR/SERVICE MANUALS The information in this manual provides general instructions for the safe operation and maintenance of your forklift truck. This information is vital and must be clearly understood by the operator and serviceman. Study this manual and the Rough Terrain Forklift Safety Manual (part no. 422494) thoroughly and carefully before operating or servicing your forklift. Contact your dealer or K--D Manitou, Inc. if you have any questions concerning your forklift, its operation, service or parts. Keep both manuals in the literature box on the forklift available for reference. If either manual becomes illegible or is missing, contact your dealer for replacements immediately. This manual cannot cover every situation that might result in an accident. It is the responsibility of the operator to always remain alert for potential hazards and be prepared to avoid them!

ADDITIONAL RECOMMENDED LITERATURE: ASME 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 standard and make it available for their operators, service personnel, and supervisors. These standards can be obtained from the American Society of Mechanical Engineers (ASME), 345 East 47th St., United Engineering Center, New York, NY 10017. The following references are examples from the standard, addressing forklift operators: A.) OPERATOR TRAINING QUALIFICATIONS 1.) The user shall ensure that operators understand that safe operation is the operator’s responsibility.

The user shall ensure that operators are knowledgeable of, and observe, all safety rules and practices.

2.) Create an effective operator training program centered around user company’s policies, operating conditions, and rough terrain forklift trucks. The program should be presented completely to all new operators and not be condensed for those claiming previous experience.

3.) Information on operator training is available from several sources, including rough terrain forklift truck manufacturers, users, government agencies, etc.

4.) An operator training program should consist of the following: a.) careful selection of the operator, considering physical qualifications, job attitude, and aptitude; b.) emphasis on safety of stock, equipment, operator, and other personnel; c.) citing of rules and why they were formulated; d.) basic fundamentals of rough terrain forklift truck and component design as related to safety, e.g., in.--lb (N--m) loading, mechanical limitations, center of gravity, stability, etc.; e.) introduction to equipment, control locations, and functions. Explain how they work when used properly and problems when used improperly. f.) supervise practice on operating course remote from normal activity and designed to simulate actual operations, e.g., lumber stacking, elevating shingles to the roof, etc.; g.) oral, written, and operational performance tests and evaluations during and at completion of the course; h.) refresher courses, which may be condensed versions of the primary course, and periodic “on job” operator evaluation; i.) understanding of nameplate data and operator instructions and warning information appearing on the rough terrain forklift truck.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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 operate rough terrain forklift trucks. Unusual operating conditions may require additional safety precautions, training, and special operating instructions.

3.) Modifications and additions which affect capacity or safe operation shall not be preformed without the manufacturer’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.

7.) Where steering can be accomplished with either hand and the steering mechanism is of a type that prevents 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 contribute 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 exercised 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 undertaking 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.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

C.) OPERATING SAFETY RULES AND PRACTICES (cont.)

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 other attachments.

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.

19.) Do not use a rough terrain forklift truck for opening or closing railroad car doors.

20.) In areas classified as hazardous, use only rough terrain forklift trucks approved for use in those areas.

21.) Report all accidents involving personnel, building structures, and equipment to the supervisor or as directed.

22.) Do not add to, or modify, the rough terrain forklift truck.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

C.) OPERATING SAFETY RULES AND PRACTICES (cont.)

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 driving 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 dangerous locations.

28.) Slow down and sound the audible warning device(s) at cross--aisles and other locations where vision is obstructed.

29.) Cross railroad tracks at an angle wherever possible. Do not park closer than 6 ft (1.8m) to the nearest rail of a railroad track.

30.) Keep a clear view of the path of travel and observe other traffic, personnel, and safe clearances.

31.) If the load being carried obstructs forward view, travel with the load trailing.

32.) Ascend or descend grades slowly and with caution. a.) When ascending or descending grades in excess of 5%, loaded rough terrain forklift trucks should be driven with the load upgrade. b.) Unloaded rough terrain forklift trucks should be operated on all grades with the load--engaging means downgrade. c.) On all grades, the load and load--engaging means shall be tilted back, if applicable, and raised only as far as necessary to clear the road surface. d.) Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines; normally travel straight up or down.

33.) Under all travel conditions, operate the rough terrain forklift truck at a speed that will permit it to be brought to a stop in a safe manner.

34.) Travel with load--engaging means or load low and, where possible, tilted back. Do not elevate the load except during stacking.

35.) Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift load and/or overturn the rough terrain forklift truck.

36.) Do not indulge in stunt driving or horseplay.

37.) Slow down for wet and slippery surfaces.

38.) Before driving over a dockboard or bridge plate, be sure that it is properly secured. Drive carefully and slowly across the dockboard or bridge plate, and 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 elevator, 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.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

C.) OPERATING SAFETY RULES AND PRACTICES (cont.)

41.) When negotiating turns, reduce speed to a safe level, and turn steering handwheel in a smooth sweeping motion. Except when maneuvering at a very low speed, turn the steering handwheel at a moderate, even rate.

42.) Use special care when traveling without load, as the risk of lateral overturning is greater.

43.) Improper use of stabilizer controls (if so equipped) could cause rough terrain forklift truck upset. Always lower the carriage before operating stabilizer controls.

44.) For rough terrain forklift trucks equipped with lateral leveling: a.) Always level the frame before raising the boom or mast, with or without a load. b.) Lateral leveling should not be used to position an elevated load; instead, lower the load and reposition the rough terrain forklift truck.

45.) Handle only stable or safely arranged loads. a.) When handling off--center loads which cannot be centered, operate with extra caution. b.) Handle only loads within the capacity of the rough terrain forklift truck. c.) Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity with extra caution. Stability and maneuverability may be adversely affected.

46.) When attachments are used, extra care shall be taken in securing, manipulating, positioning, and transporting 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 dynamic forces affecting the stability of a rough terrain forklift truck. Grades and sudden starts, stops, and turns can cause the load to swing and create a hazard if not externally stabilized. When handling suspended loads: a.) do not exceed the truck manufacturer’s capacity of the rough terrain forklift truck as equipped for handling suspended loads. b.) only lift the load vertically and 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.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

C.) OPERATING SAFETY RULES AND PRACTICES (cont.)

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.) brakes f.) steering mechanism g.) fuel system(s) 51.) If the rough terrain forklift truck is found to be in need of repair or in any way unsafe, or if it contributes to an unsafe condition, the matter shall be reported immediately to the user’s designated authority, and the truck shall not be operated until it has been restored to safe operating condition.

52.) If during operation the rough terrain forklift truck becomes unsafe in any way, the matter shall be reported immediately to the user’s designated authority, and the truck shall not be operated until it has been restored to safe operating condition.

53.) Do not make repairs or adjustments unless specifically authorized to do so.

54.) When refueling, smoking in the area shall not be permitted, the engine shall be stopped, and the operator 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.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

vii

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

D.) SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level. Transporting suspended loads must ALWAYS be done slowly and cautiously, with the boom and load as low as possible. Use taglines to restrict loads from swinging, to avoid overturn.

The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards. Grades and sudden starts, stops and turns can cause the load to swing and create a hazard.

Guidelines for “Free Rigging / Suspended Loads” 1.

DO NOT exceed the rated capacity of the telescopic handler as equipped for handling suspended loads. The weight of the rigging must be included as part of the load.

2.

During transport, DO NOT raise the load more than 12 inches (305 mm) above the ground, or raise the boom more than 45 degrees.

3.

Only lift the load vertically – NEVER drag it horizontally.

4.

Use multiple pickup points on the load when possible. Use taglines to restrain the load from swinging and rotating.

5.

Start, travel, turn and stop SLOWLY to prevent the load from swinging. DO NOT exceed walking speed.

6.

Inspect rigging before use. Rigging must be in good condition and in the U.S. comply with OSHA regulation §1910.184, “Slings,” or §1926.251, “Rigging equipment for material handling.”

7.

Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft. The load center must not exceed 24 inches (610 mm).

8.

DO NOT lift the load with anyone on the load, rigging or lift equipment, and NEVER lift the load over personnel.

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.

WARNING U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in Construction) include requirements for employers that use powered industrial trucks ("forklifts") configured to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a hook (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(l).]

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 lbs. (907 kg), the employer must ensure that: a.) An accessible fire extinguisher is on the forklift; b.) Monthly and annual inspections are performed and documented, and records retained (three months for monthly, one year for annual); c.) 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 detailed description

VII

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

CONCLUSION: 1.) ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site. They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard (29 CFR 1910.178) as described by the Occupational Safety and Health Administration (OSHA). They must be qualified as to their visual, hearing, physical, and mental ability to operate the equipment safely. NEVER use drugs or alcohol while operating a forklift! NEVER operate or allow anyone to operate a forklift when mental alertness or coordination is impaired! An operator on prescription or over-the-counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the forklift.

2.) CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenance log, listing repairs requested and completed, for each forklift. Also, “lock out tag procedures” should be utilized. If the forklift 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 missing, have them replaced immediately. Make sure all safety features provided by the original manufacturer are in place and function properly. Do not operate a forklift with damaged, missing or unsafe components. Have it repaired by authorized service personnel. Learn the functions of all controls, gauges, indicator lights, etc. on the forklift. Know the speed/gear ranges, braking and steering capabilities, load ratings and clearances. When referring to the location of forklift components, the terms “left”, “right”, “front”, and “rear” are related to the operator seated normally, facing forward in the operator’s seat. If you have any questions about the forklift, consult 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 corrected. 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, building materials, drop-offs, trenches, rough/soft spots, oil spills, deep mud, steep inclines, railroad tracks, curbs, etc.. NEVER approach power lines, gas lines or other utilities with the forklift! Always verify that local, state/provincial and federal regulations have been met. Report any accidents involving 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 product designs. If a question arises regarding your forklift, please consult your dealer or K-D Manitou, Inc. for the latest information. When ordering service parts or requesting technical information, be prepared to quote the applicable Model/Serial Numbers.

VIII

SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Also, observe the safety messages places throughout this manual; providing special instructions, telling you when to take precautions and to identify potential hazards. The safety messages are highlighted and outlined in a box similar to those shown in the examples below.

SAFETY ALERT SYMBOL

NOTE or NOTICE Provides information, special instructions or references about the lift truck.

IMPORTANT Precautions which must be taken to avoid damage to the lift truck.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. May also alert unsafe practices.

WARNING Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury!

DANGER 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.

IX

CONTENTS

TABLE OF CONTENTS SECTION ONE - FORKLIFT OPERATION AND SAFETY 1- 1 - GENUINE SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 - GENERAL OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 3 - LOAD HANDLING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 7 - MOUNTING THE LIFT TRUCK TO THE FLATBED TRAILER . . . . . . . . . . . . . 1 -- 12 - MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK . . . . . . . . . . . . . . . . . 1 -- 15 - BEFORE STARTING UP A NEW LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 17 SECTION TWO - DESCRIPTION 2- 1 - IDENTIFICATION NAME PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3 - CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 5 - SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 9 - INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 14 SECTION THREE - SERVICING THE FORKLIFT 3- 1 - FILTER CARTRIDGES, SCREENS AND BELTS . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2 - LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3 - SERVICING SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4 - ALTERNATIVE TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 22 A - TOWING THE LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 22 B - FLATBED TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 22

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

CONTENTS

CONTENTS

SECTION ONE

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

CONTENTS

CONTENTS

FORKLIFT OPERATION AND SAFETY 1 - 1

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

1 -- 1

CONTENTS

GENUINE SPARE PARTS ALL SERVICING AND REPAIRS ON THE LIFT TRUCK MUST BE PERFORMED USING MANITOU ORIGINAL PARTS.

USING MODIFIED, ALTERED OR NON--ORIGINAL PARTS: -- Legally, of being liable in the event of an accident.

-- Mechanically, of causing breakdowns to occur or of reducing your lift truck’s service life.

PUTS YOU AT RISK

IMPORTANT Use of inferior parts or components not approved by the manufacturer may end contract warranty terms and cause the Dealer to withdraw the machine’s certificate of compliance.

BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS: YOU PROTECT YOURSELF

-- Any user installation of non--original parts is done at his own risk.

-- Any user who modifies his lift truck or has it modified by a service company, must consider that a new item of equipment has been brought onto the market and therefore takes liability for it.

-- Any user who copies original parts or has them copied is legally liable.

-- The certificate of compliance binds the manufacturer only for those parts procured under their control.

-- The manufacturer is not liable for user’s failure to perform scheduled maintenance.

THE MANUFACTURER BRINGS TO THE USER: YOU GET THE BENEFIT OF THE MANUFACTURER’S KNOW- HOW

---------

His know--how and skill.

Guaranteed quality work.

Original replacement parts.

Help with preventive maintenance.

Effective help with diagnosing problems.

Improved performance gained from feedback.

Training for operator/maintenance personnel.

The manufacturer knows how to perform the best maintenance.

ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY K- D MANITOU AND ITS DEALER NETWORK. You can obtain the list of dealers by phoning the Parts Department at: 800--425--3727

Modifications which affect capacity or safe operation of the forklift shall not be performed without manufacturer’s written approval. Where authorization is granted, capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

GENERAL OPERATING INSTRUCTIONS A -- DRIVER’S OPERATING INSTRUCTIONS -- Wear clothes suited for driving the lift truck, avoid loose fitting clothes!

-- Never operate the vehicle when hands or feet are wet or soiled with greasy substances.

-- When mounting the forklift, do not grab the steering wheel; always use the grab handle and step provided when climbing on or off the lift truck.

-- For increased comfort, adjust the driver’s seat as required.

-- The operator must always be seated normally when in the driver’s seat. It is prohibited to have arms, legs or any part of the body, extending from the cab of the lift truck.

-- Always remember to fasten your seat belt and adjust it properly before operating the fork lift.

-- If the forklift controls are fitted with a forced operation (lever lock) device, NEVER leave the cab without first putting these controls in neutral.

-- Never allow a passenger to travel on the lift truck or in the cab.

B -- BEFORE STARTING THE LIFT TRUCK -- If the lift truck is new, refer to: BEFORE STARTING A NEW LIFT TRUCK, at the end of this chapter.

-- Check the condition of the tires and tire pressures, see chapter 2: CHARACTERISTICS. -- Before starting the lift truck, check all fluid levels: -- Engine oil -- Hydraulic reservoir oil -- Cooling system -- Check for possible leaks: of oil, fuel or other fluids from the lift truck.

-- Check the latches on the hood or engine compartment.

-- The operator is advised to familiarize himself with the location and operation of all instruments and controls before operating the lift truck.

C -- STARTING THE LIFT TRUCK

WARNING Do not operate or drive the forklift unless properly seated, with seatbelt fastened!

IMPORTANT Never try to start the lift truck by pushing or towing it!

Pushing or towing the forklift can cause severe damage to the transmission!

See chapter: ALTERNATIVE TRANSPORT; A -- TOWING THE LIFT TRUCK STARTING INSTRUCTIONS: -- Verify that the park brake is engaged.

-- Make sure that the forward/reverse lever is in neutral.

-- Turn the ignition key to position I to activate the electrical system.

-- Check the level on the fuel gauge.

-- Turn the ignition key to position II to preheat for 15 seconds.

IMPORTANT Do not engage the starter motor for more than 15 seconds at a time. Wait 2 minutes between starting attempts, allowing the starter to cool. Engage the preheater for 10 seconds between starting attempts.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

GENERAL OPERATING INSTRUCTIONS (cont.)

-- Press the accelerator pedal and turn the ignition key fully : the engine should then start. Release the ignition key and let the engine run at idle.

-- Check all control instruments immediately after starting up, when the engine is warm and at regular intervals during use, so as to quickly detect any faults and to be able to correct them without any delay.

-- If an instrument does not show the correct display, stop the engine and immediately carry out the necessary operations.

D -- DRIVING THE LIFT TRUCK SAFETY NOTICE -- Always drive the lift truck with the forks or attachment at approximately 300 mm (12 in.) from the ground, i.e.

In the travel position.

-- Familiarize yourself with the lift truck on the terrain where it will be used.

-- Ensure that the service brakes and the sound alarm are working properly.

-- Drive according to, and at an appropriate speed for, the conditions and state of the terrain.

-- Slow down before executing a turn.

-- In all circumstances make sure you are in control of your speed.

-- On damp, slippery or uneven terrain, drive slowly.

-- Brake gently, never abruptly.

-- Only use the lift truck’s forward/reverse lever from a stationary position and never do so abruptly.

-- Do not drive with your foot on the brake pedal or with the parking brake on.

-- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, so turn it gently and not jerkily.

-- Do not allow the I.C. engine to idle needlessly for a long period.

-- Never leave the engine on when the lift truck is unattended.

-- Look in the direction of travel and always ensure you have good visibility of the route ahead.

-- When working at night, ensure that your lift truck is fitted with full beam lights. There are optional solutions, consult your agent or dealer.

-- Drive round obstacles.

-- Never move onto a loading platform without having first checked : . That it is suitably positioned and made fast. . That the unit to which it is connected (tractor, trailer, etc.) will not shift. . That this platform is prescribed for the total weight of the lift truck to be loaded. . That this platform is prescribed for the width of the lift truck.

-- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order.

WARNING Take extreme care when operating around platforms, trenches, recently dug and/or back--filled terrain!

-- The loaded lift truck must not travel at speeds in excess of 12 km/h (7 mph).

INSTRUCTIONS -- Check the transmission oil level.

-- Raise the forks or attachment to the travel position approximately 300 mm (12in.) from the ground.

-- Engage the gear required (where applicable).

-- Select the steering mode (where applicable).

-- Shift the forward/reverse lever to the selected direction of travel.

-- Release the parking brake and accelerate gradually until the lift truck moves off.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

GENERAL OPERATING INSTRUCTIONS (cont.)

E -- STOPPING THE LIFT TRUCK SAFETY NOTICE -- Before stopping the lift truck after a long working period, leave the I.C. engine idling for a few moments, to allow the coolant liquid and oil to lower the temperature of the engine and transmission.

IMPORTANT Do not forget this precaution, in the event of frequent stops of the engine, or else the temperature of certain parts will rise significantly due to the stopping of the cooling system, with the risk of badly damaging such parts.

-- Never leave the ignition key in the lift truck when the lift truck is unattended.

-- When the lift truck is stationary, place the forks or attachment on the ground, place the gear lever in neutral (where applicable), apply the parking brake and put the forward/reverse lever in neutral.

-- If the driver has to leave his cab, even for a moment, it is essential to place the gear lever in neutral (where applicable), apply the parking brake and put the forward/reverse lever in neutral.

-- Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at less than 6 ft. (1.8 m) from the track of a railway.

-- In the event of prolonged parking on a site, protect the lift truck from bad weather, particularly from frost (Check the level of antifreeze), close the rear window, lock the cab door and ensure that the hood is properly secured.

INSTRUCTIONS -- Park the lift truck on flat ground or on an incline lower than 15 %.

-- Release the accelerator pedal and stop the lift truck.

-- Place the forward/reverse lever in neutral.

-- Apply the parking brake.

-- Place the gear lever in neutral (where applicable).

-- Retract entirely the mast/boom.

-- Lower the forks or attachment to rest on the ground.

-- Stop the engine with the ignition switch.

-- Remove the pressure in the hydraulic circuits by using the hydraulic controls.

-- Remove the ignition key.

-- Check the closing and locking of door, rear window and hood (where applicable).

-- If required to park on an incline, park the forklift at right angles to the slope, set the parking brake and chock the wheels.

WARNING Before leaving your driver’s cabin, ensure that you have carried out all operations for stopping the lift truck, for your safety and the safety of others.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

GENERAL OPERATING INSTRUCTIONS (cont.)

F -- DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY (MOUNT--TYPE LIFT TRUCKS ARE NOT ALLOWED TO DRIVE ON PUBLIC HIGHWAYS) SAFETY INSTRUCTIONS -- When driving a lift truck on roads open to public traffic, observe the provisions of the Highway Code.

-- Lift truck drivers, driving on the public highway, must abide by the general provisions relative to highway traffic.

-- The lift truck must conform to the provisions of the Highway Code. If necessary, optional solutions exist, consult your dealer.

WARNING Transport of loads on some public highways is forbidden and attachments mounted on the lift truck must be fitted with equipment in accordance with local regulations or else dismounted.

INSTRUCTIONS (where applicable) -- Ensure that the flashing light is in position and that it is working.

-- Check the good working order and cleanness of lights, indicators and windscreen wiper.

-- Control the alignment of the wheels and select the steering mode HIGHWAY TRAFFIC. -- Check the adjustment of the rear view mirrors.

-- Ensure that the fuel level is sufficient.

-- Put the mast/boom in the retracted position and the attachment at 300 mm (12 in.) from the ground.

WARNING While on the road do not use the transmission cut--off to maintain engine braking on the lift truck.

G -- OPERATING THE LIFT TRUCK WITH A TRAILER ON A PUBLIC HIGHWAY -- For using a trailer, consult the regulations in force in your country (Maximum travel speed, braking, maximum weight of trailer, road lights, etc.).

-- Do not forget to connect the lift truck’s electrical equipment to that of the trailer (where applicable).

-- Do not use a non--braked trailer if the unit weight of a load exceeds that imposed by the highway code.

-- Do not use a non--braked trailer without braking equipment for the trailer on the lift truck (where applicable).

-- Do not forget to connect the lift truck’s braking equipment to that of the trailer (where applicable).

-- The maximum vertical pull on the trailer hook must not exceed 1500 daN (3370 lbs) (where applicable).

-- The authorized total towed weight (A.T.T.W.) must not exceed the maximum weight authorized by the manufacturer (Consult the manufacturer’s plate on your lift truck).

H -- OPERATING THE LIFT TRUCK WITH A FRONT--END ATTACHMENT ON A PUBLIC HIGHWAY -- For driving with an attachment, check the regulations currently applicable in your area, some technical changes may be necessary to meet regulations.

-- The attachment must not exceed the overall width of the lift truck.

-- The length of the entire unit must not exceed the overall length of 6 meters (20 ft).

-- Do not mask the lighting range of the front headlights.

-- Set the attachment’s shields in place or disassemble the attachment (where applicable).

IF NECESSARY, CONSULT YOUR DEALER.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

LOAD HANDLING INSTRUCTIONS A -- GENERAL -- Do not attempt to perform operations which exceed the capacities of your lift truck or attachments.

-- Before lifting a load; check the size, weight, and condition of the load.

-- If the load is not properly marked, check with your supervisor for verification of weight. Divide the load into smaller units if necessary.

-- Note the center of gravity of the load; where to place the forks for stable transport.

-- Verify that the load is properly wrapped or banded and safe to transport. Check the condition of the pallet or skid, does it need to be replaced? If the load is of loose materials or is poorly wrapped, it must be made secure.

-- Secure the load (utilize the backrest when necessary) so that it will not shift or fall during transport.

-- It is prohibited to increase the counterweight value in any way.

-- It is strictly prohibited to carry or to lift personnel with the lift truck, unless the vehicle is specially equipped for this purpose and has the corresponding certificate of conformance for lifting personnel.

-- Never lift a load with a single fork.

-- Never lift a sling load with a single fork or with the carriage. Consult your dealer for optional solutions.

B -- ATTACHMENTS -- Ensure your lift truck’s attachments function correctly.

-- Ensure that the attachment is correctly fitted and locked to its frame.

-- Adhere to the limits on the load chart for the lift truck and/or attachment.

-- Ensure that quick--fit hydraulic connections on the attachment system are clean and protected.

IMPORTANT Before changing an attachment with hydraulic function, and in order to avoid damaging the quick--fit connections: -- Place the attachment in the closed position, flat on the ground (For unstable attachments, ensure they are secured using wedges or blocks).

-- Remove pressure from the attachment hydraulic system using the hydraulic controls.

C -- ENVIRONMENT -- Take care when raising the load that no object or person is in the way of mast or lift truck movements.

-- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and the aerial line.

DANGER You must consult your local electrical agency.

You could be electrocuted or seriously injured if you operate or park the lift truck too close to power cables. You are strongly advised to ensure that the safety rules on the site conform to the local regulations in force regarding all types of work carried out close to power cables.

-- Do not allow personnel to come near the working area of the lift truck or pass beneath an elevated load.

-- When using the lift truck on a slope, before raising the forks, ensure that the lift truck is level and stable.

-- Travelling on a longitudinal slope: -- Drive and brake gently.

-- Moving without load: Forks or attachment facing downhill.

-- Moving with load: Forks or attachment facing uphill.

-- Ensure that the loading platform or pile is capable of bearing the weight.

-- Ensure the stability and solidity of the ground before depositing a load.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

LOAD HANDLING INSTRUCTIONS (cont.)

D -- HANDLING -- Always consider safety and only transport balanced and correctly secured loads to avoid any risk of tipping.

-- Fully engage forks under the load and transport it in the low position, approximately 300 mm (12 in) from the ground, the mast retracted to the maximum and sloping backwards.

-- For obvious reasons regarding the lift truck’s stability and clear visibility of the surrounding environment, only move the lift truck when the mast is in the travel position, forks approximately 300 mm (12 in) from the ground.

-- Do not maneuver the lift truck with the mast in the raised position unless under exceptional circumstances and then with extreme caution, at very low speed and using gentle braking. Ensure that visibility is adequate and get another person to guide you along if necessary.

-- Never shift the position of the load while the lift truck is in motion.

-- The simultaneous use of two lift trucks to handle heavy or bulky loads is a dangerous maneuver, requiring specific precautions to be taken. This should only be done in exceptional circumstances and in the presence of a handling manager.

-- Never drive too fast or brake abruptly when carrying a load.

-- Check the load, particularly when turning corners and especially if it is very bulky.

-- Secure unstable loads.

-- Handle loads with caution, at slow speed, without sudden jerks when moving them at significant heights and mast extension.

WARNING In the event of high winds or storms, do not carry out handling work that jeopardizes the stability of the lift truck and its load, particularly if the load catches the wind badly.

-- Do not change direction sharply and at high speed.

DANGER In the event of the lift truck overturning, do not try to leave the cabin during the incident.

YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN. -- Apply the parking brake when lifting or depositing a difficult load or when on an incline.

-- Do not stop the lift truck with the load in an elevated position.

-- Do not leave a laden lift truck with the parking brake applied on an incline which exceeds 15%.

E -- VISIBILITY -- If the visibility in forward motion is not sufficient because of the bulkiness of the load, drive in reverse motion. This maneuver must remain exceptional and for short distances.

-- Ensure you have good visibility (Clean windows, adequate lighting, correctly adjusted rear view mirror, etc., where applicable).

IF NECESSARY, CONSULT YOUR DEALER.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

LOAD HANDLING INSTRUCTIONS (cont.)

CHECK THE RECEIVING AND PLACEMENT AREAS Before lifting or placing a load, check the area; will the area support the lift truck and load? Insure the terrain will properly support the lift truck’s stabilizers (use suitable wood or metal to properly support the stabilizers on soft terrain).

WARNING

The stabilizers must be fully lowered when lifting or placing a load!

FIG. 1

FORK ADJUSTMENT Safely park the forklift, with the forks raised slightly. Unlock the fork locking pins (where applicable) and position the forks as wide as the load allows. Keep the forks the same distance from the center of the carriage. Secure the fork locking pins (where applicable).

FIG. 2

LIFTING A LOAD FROM GROUND LEVEL 1.) Approach the load slowly, with mast fully extended, aligning the forklift and forks with the load. Stop the forklift before engaging the load. Using the control levers, align the forks to the correct height and angle (fig. 1).

2.) Move forward slowly, until the forks are fully engaged and the load is against the backrest. Lower the stabilizers. Raise the forks to lift the load. Tilt the mast back, placing the load against the backrest (fig. 2). (If required; safely park the forklift and secure the load

FIG. 3

to the backrest.) Retract the mast fully. Raise or lower the forks to transport position, side--shift the mast to center the load as needed.

Raise the stabilizers (fig. 3). Check traffic; drive or back away slowly, watch your direction of travel and the stability of the load. Travel with caution at all times!

PLACING A LOAD AT GROUND LEVEL 1.) Approach the receiving area slowly, stop the forklift to raise/lower or side--shift the load as needed. When the lift truck is properly aligned, lower the stabilizers. Fully extend the mast forward. Lower the forks and tilt the mast forward to place the load.

2.) Raise the stabilizers and prepare to back away. Before backing, insure the forks have properly disengaged the load, and that the load is stable. Check traffic and back away cautiously, assuring the forks remain clear of the load upon exit. When the forks have cleared the load; stop the forklift, raise/lower the forks and side--shift the mast to center. Check traffic, proceed with caution at all times!

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

LOAD HANDLING INSTRUCTIONS (cont.)

FIG. 1A LIFTING AN ELEVATED LOAD

WARNING

Never lift a load from a scaffold or deposit a load on one! Never side-shift an elevated load! Never travel with an elevated load!

An elevated load requires special handling, be extra cautious!

FIG. 2A

Before unloading a truck or trailer, make sure its wheels have been chocked to prevent movement during operations.

1.) Approach the loading area slowly with forks lowered, aligning the forklift with the load. Stop the forklift, with the mast fully extended, raise the forks to the height of the load. Using the control levers, align the forks to the correct height and angle (fig. 1A).

2.) Move forward slowly, making adjustments as needed, until the forks are fully engaged and the load is against the backrest. Apply the park brake and place the forward/reverse lever into neutral. Lower the stabilizers.

FIG. 3A

Raise the forks just enough to lift the load. Tilt the mast back slightly, with the heaviest part of the load against the backrest (fig. 2A).

3.) Retract the mast back fully. Lower the load to transport position. Side-shift the mast to center the load as needed. Raise the stabilizers (fig.

3A). Check traffic, release the park brake, place the forklift into reverse, and cautiously back the forklift. (Park the forklift if securing the load to the backrest is required.) Watch your direction of travel and the stability of the load.

Travel with caution at all times!

FIG. 1B PLACING AN ELEVATED LOAD An elevated load requires special handling, be extra cautious!

Before loading a truck or trailer, make sure its wheels have been chocked to prevent movement during operations.

1.) Approach the loading area slowly, aligning the forklift and the load.

When the load is properly aligned, set the park brake and lower the stabilizers. Place the forward/reverse lever in neutral (fig. 1B).

3

2.) Raise the load high enough to clear the stack or platform. Align the forks to the correct angle and height for load placement. Extend the mast forward slowly, making adjustments as needed (fig. 2B), until the load is properly aligned. Lower the load into a stable position.

3.) Raise the stabilizers slowly. Make required adjustments to the forks to properly clear the load. Check traffic, release the park brake, place the forklift into reverse, and back the forklift slowly. After clearing the load, lower the forks and side--shift the mast to center as needed. Check traffic; drive or back away slowly. Travel with caution at all times!

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

1 -- 10

FIG. 2B

2 1

CONTENTS

LOAD HANDLING INSTRUCTIONS (cont.)

WIDE LOADS A wide load is one that will not fit between the front wheels and forklift frame during transport.

1.) Approach the load slowly, aligning the lift truck and forks with the load’s center of gravity. When the forks are fully engaged, set the park brake and lower the stabilizers.

2.) Place the forward/reverse lever in neutral. Raise the forks to lift the load. Tilt the mast back, placing the load against the backrest. (If required; safely park the forklift and secure the load to the backrest.) Raise the load enough to clear the tires, and fully retract the mast. Raise or lower the forks keeping the load off the frame, side--shift the mast to center the load as needed.

3.) Raise the stabilizers. Check traffic; release the park brake, drive or back away slowly, watch your direction of travel and the stability of the load. Travel with caution at all times!

DOUBLE--FORK A LOAD The forklift capacity is reduced when the forks do not fully engage a load. On occasion it may be necessary to move or re--position a load before the forks can be fully engaged, this is called “Double Forking”. With the lift truck properly positioned, raise the load slightly, bring the load forward by retracting the mast. Lower the load into a stable position, extend the mast forward to fully engage the load. Never attempt to lift or “double fork” an unstable load!

DIFF--LOCK OPERATION

WARNING Ensure the forklift is traveling in a straight line BEFORE engaging the diff--lock!

Do not engage the diff--lock while turning corners!

Under normal operating conditions the fork lift utilizes independent all--wheel drive. However, in some slippery conditions (such as mud, loose gravel or a wet concrete incline) one or more wheels may slip or spin free, causing a loss of traction. To maintain traction, the diff--lock can be engaged, causing all 3 wheels to turn at the same speed. Before engaging the diff--lock be aware that the fork lift must be traveling in a straight line!

The diff--lock may be engaged while the forklift is stopped or in motion, after the rear steer wheel has been aligned with the front wheels. Press and hold the diff--lock switch for continuous use, release the switch to disengage the diff--lock. Additional engine speed is usually required when using the diff--lock. Improper use of the diff--lock on non--slippery surfaces causes excessive tire wear and may over--heat the powertrain!

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

MOUNTING THE LIFT TRUCK TO THE FLATBED TRAILER

1 2

CAUTION When loading the lift truck onto or off of the flatbed trailer: Always operate the control levers slowly and carefully!

Abrupt maneuvers can harm the operator and damage the lift truck.

ALWAYS WEAR THE SEATBELT DURING FORKLIFT OPERATIONS! LEVER 1: controls mast tilting and side--shifting.

LEVER 2: controls raising/lowering of the carriage and mast extension/retraction.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

MOUNTING THE LIFT TRUCK TO THE FLATBED TRAILER (cont.)

1A

A -- MOUNTING THE LIFT TRUCK

WARNING The mounting kit for the TMP must be supplied or approved in writing by K--D Manitou, Inc..

-- Set the parking brake on the tractor/trailer and chock the tires.

-- Approach the trailer with the lift truck’s mast extended forward.

-- Raise and align the lift truck’s forks with the trailer’s fork supports .

-- Move the lift truck forward, fully inserting the forks.

-- Raise the rear tire by tilting the carriage back; pull Lever 1 back.

-- Raise the lift truck by lowering the carriage; push Lever 2 forward (Fig.1A).

1B

-- Retract the mast, placing the tires on the supports (Fig. 1B).

-- Turn the engine off and remove the key.

-- TMP25/HT MODELS ONLY -- Slide the operator’s seat “A” fully forward (Fig. 1C). Lift and rotate the seat guard “B”, locking it into transport position as shown.

-- Attach the transport chains.

-- Work the control levers to release hydraulic pressure, allowing the lift truck to be supported by the transport chains. Insure both transport chains are tight and properly support the lift truck.

WARNING The lift truck must be supported by the transport chains and NOT the forks during transport!

1C

-- Connect the trailer lighting cable into the socket provided (Fig. 1D).

1D

B

A

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CONTENTS

MOUNTING THE LIFT TRUCK TO THE FLATBED TRAILER (cont.)

2 -- UNLOADING THE LIFT TRUCK

1A

-- Set the parking brake on the tractor/trailer and chock the tires.

-- Disconnect the trailer’s lighting cable.

-- On TMP25/HT MODELS -- rotate and lock the seat guard into operating position, adjust the operator’s seat as required.

-- Start the lift truck’s engine, lower and tilt the mast to place slack in the transport chains. Insure the steer tire is turned in the proper direction (Fig. 1C).

-- Turn the engine off and remove the transport chains (Fig. 1A).

-- Start the engine and extend the mast until the lift truck’s front tires clear the wheel pads/supports. (Fig. 1B).

-- Lower the lift truck to the ground by raising the forks.

1B

-- Tilt the mast forward to lower the steer wheel.

-- Back slowly, adjusting the forks as needed to clear the fork supports.

1C

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK A -- GENERAL -- Read the operator’s manual carefully and ensure you understand it.

-- Stop the I.C. engine, when an intervention is necessary.

-- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewelry and loose clothes. Tie and protect your hair, if necessary.

-- Ensure the area is sufficiently ventilated before starting the lift truck.

IMPORTANT Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.

-- Carry out all repairs immediately, even if the repairs concerned are minor.

-- Repair all leaks immediately, even if the leak concerned is minor.

-- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.

WARNING The handling and removal of the balancing valves which may be fitted to the cylinders of your lift truck can be dangerous. A balancing valve must only be removed when the cylinder concerned is at rest and the hydraulic circuit is depressurized.

This operation can only be carried out by authorized staff.

-- Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.

-- Take care not to burn yourself (Exhaust, radiator, I.C. engine, etc.).

-- Disconnect the negative cable terminal (--) from the top of the battery before working on the electrical circuit or on the lift truck (e.g. : Welding).

-- Do not drop metallic items on the battery.

-- When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being welded, so as to avoid high tension current passing through the alternator.

B -- MAINTENANCE -- The maintenance and the keeping in compliance of the lift truck are compulsory.

-- Carry out daily maintenance (See SECTION 3; chapter A -- DAILY OR EVERY 10 HOURS SERVICE).

-- Do not run the engine without air filter, or with oil, water or fuel leaks.

-- Change the filter cartridges (See SECTION 3; chapter FILTERS, CARTRIDGES AND BELTS).

C -- LEVELS -- Use the recommended lubricants (Never use contaminated lubricants).

-- Do not fill the fuel tank when the I.C. engine is running.

-- Only fill up the fuel tank in areas specified for this purpose.

-- Do not fill the fuel tank to the maximum level.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK (cont.)

D -- WASHING -- Clean the lift truck or at least the area concerned before any intervention.

-- Remember to close the door and the rear window of the cab (where applicable).

-- During washing, avoid the articulations and electrical components and connections.

IMPORTANT If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged, particularly electrical components and connections and the injection pump.

-- Clean the lift truck of any fuel, oil or grease excess.

FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT YOUR DEALER.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

BEFORE STARTING UP A NEW LIFT TRUCK INTRODUCTION -- Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the mechanic.

-- However, before commencing to operate the lift truck, the user should carefully read and understand the various chapters of this manual which has been provided to solve driving and maintenance problems. By following these instructions the user will be able to take full advantage of the versatility of this lift truck.

-- The operator must familiarize himself with the positions and functions of all the controls and instruments before operating the lift truck.

IMPORTANT Do not attempt to start a new lift truck before the following checks have been carried out :

LUBRICATION -- Check that all the correct grades of oils and greases that are required are available and topped up if necessary; see SECTION 3; SERVICING SCHEDULE.

IMPORTANT For operation under average climatic conditions, i.e. : --150C to +350C (50F to 950F), correct levels of lubricants in all the circuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessary to drain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures. It is the same for the cooling liquid (Contact your dealer for information, if necessary).

DRY AIR FILTER -- Ensure that the air filter is undamaged and not blocked.

-- Tighten the fastening devices if necessary.

IMPORTANT Never run the engine with the air filter removed or damaged.

COOLING SYSTEM -- Do not start the lift truck without checking the radiator coolant level or if the fan belt is damaged or broken.

HYDRAULIC SYSTEM -- Check for any oil leaks on the hoses, connections and unions. If necessary, tighten or repair the defective connections.

-- Also check that the tank oil level is correct.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

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CONTENTS

BEFORE STARTING UP A NEW LIFT TRUCK (cont.)

TIRES -- Make sure that the wheel nuts are correctly tightened (See SECTION 3; chapter A -- DAILY OR EVERY 10 HOURS SERVICE) and that the tire pressures are correct (See SECTION 2; chapter CHARACTERISTICS).

FUEL SYSTEM -- Check that all fuel lines are secured.

-- If necessary drain the fuel filter and bleed the fuel system of air.

ELECTRICAL CIRCUIT -- Check the level and the density of the electrolyte in the battery (See SECTION 3; chapter B -- EVERY 50 HOURS SERVICE).

-- Check the components of the electrical system, the connections and fastening devices.

IF NECESSARY, CONSULT YOUR DEALER.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

1 -- 18

CONTENTS

SECTION TWO

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

CONTENTS

CONTENTS

DESCRIPTION

2- 1

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 1

CONTENTS

DESCRIPTION TMP 25 TMP 25 HT TMP 5500 (SHOWN BELOW) TMP 5500 HT

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 2

CONTENTS

IDENTIFICATION NAME PLATES A All data provided in this manual is subject to production variations, release of new models and improved product designs. If a question arises regarding your lift truck, please consult your Manitou dealer.

When ordering parts or requiring any technical information, be prepared to specify:

MANUFACTURER OF THE LIFT TRUCK (FIG. --------

Truck Model: Attachments: Unladen Weight: Year of MFG: Tire Pressure Front: Tire Pressure Rear: Manufactured in:

ENGINE I.D. (FIG.

A)

S.N.: S.N.:

B

LBS PSI PSI

B)

-- Engine No.

C

TRANSMISSION [HYDROSTATIC PUMP] (FIG.

C)

-- Transmission type -- MANITOU parts No. -- Serial No.

D

FRONT WHEEL REDUCER (FIG.

D)

-- Type -- Code -- Serial No

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2 -- 3

CONTENTS

IDENTIFICATION NAME PLATES (cont.)

REAR WHEEL REDUCER (FiG. E)

E

-- Type -- Code -- Serial No.

F

FRAME IDENTIFICATION (FIG. F) -- Frame Identification No. On the frame, near the front left tire.

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2 -- 4

CONTENTS

CHARACTERISTICS ENGINE ----------------

Type Number of cylinders Number of strokes Injection system Firing order Capacity Bore Stroke Compression ratio Nominal running speed Idle speed Full speed Power Maximum torque Air cleaner

LISTER -- PETTER LPWS 4 4 4 Indirect 1.3.4.2.

1860 cc (113 cu.in.)

86 mm (3.39 in) 80 mm (3.15 in) 22:1 2800 rpm 950 rpm 3000 rpm 38.9 HP 96.6 Nm (855 ft.lb.) at 2000 rpm 3 microns

HYDRAULIC OIL COOLING CIRCUIT (OPTIONAL) -- Type -- Fan Number of blades -- Thermostat activated -- Fuse

By air Puller 6 20 Amp

ENGINE COOLING CIRCUIT -- Type -- Fan Number of blades Diameter -- Thermostat Start opening Full opening

By water Puller 6 381 mm (15 in) 710C (1600F) 850C (1850F)

ELECTRIC CIRCUIT ------

Ground Battery Alternator Regulator Starter

Negative 12 V -- Cold Cranking Amps 630 @ 00F 14 V -- 45 A built--in alternator 12 V

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2 -- 5

CONTENTS

CHARACTERISTICS (cont.)

HYDROSTATIC TRANSMISSION TMP25/HT & TMP5500/HT HYDROSTATIC PUMP -- Type -- Gear reverser

A4VG 56 DA variable displacement pump with automatic power governor Electromagnetic 12V

-- Inching starter

Hydraulic through outside valve TH 7

MAIN PUMP -- Displacement

-- Flow rate at 3,000 rpm

MAX MIN

56 cm3/r (3.14 cu.in./rev.)

0

MAX MIN

168 I/min (44.38 gal/min) 0

-- Working pressure

450 bar (6525 psi)

BOOSTPUMP -- Cubic capacity -- Flow rate at 3,000 rpm

-- Boost pressure Max. rpm

MAX MIN

11 cm3/r (0.67 cu.in./rev.)

33 I/min (8.7 gal/min) 0 29 bar (420.5 psi)

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2 -- 6

CONTENTS

CHARACTERISTICS (cont.)

WHEEL REDUCERS (HYDRAULIC MOTORS) EXCEPT TMP25HT & TMP5500HT REAR WHEEL -- Type

MSE02 POCLAIN Motor wheel with brakes, fixed displacement 400 cm3/r (24.5 cu.in./rev) 420 bar (6090 psi)

-- Cubic capacity -- Working pressure

WHEEL REDUCER (HYDRAULIC MOTOR) TMP25HT & TMP5500HT REAR WHEEL ONLY -- Type -- Cubic capacity -- Working pressure

MSE05 POCLAIN Motor wheel (TMP HT Model only) 750 cm3/r (45.8 cu.in./rev) 420 bar (6090 psi)

BRAKE -- Type -- Inching Pedal -- Parking brakes

Multidisc brake immersed in oil (on both front wheel motors) Hydrostatic Negative braking; electrically controlled at the dashboard, applied to the front wheels through hydraulic pressure break.

FRONT & REAR TIRES

(TMP25HT & TMP5500HT)

OTR -- MUD SHARK 31 -- 15.50 -- 15 N.H.S. 10 PLY RATE, TUBELESS

FRONT & REAR TIRES

3.15 bar (45 psi)

(TMP25 & TMP5500)

OTR -- WIDE WALL 10 -- 16.50 N.H.S. 10 PLY RATE, TUBELESS

3.8 bar (55 psi)

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2 -- 7

CONTENTS

CHARACTERISTICS (cont.)

HYDRAULIC CIRCUIT TMP5500/HT & TMP25/HT -- Lifting, tilting, telescoping travel circuit, stabilizers Type of pump Flow rate at full speed Pressure

Gear Pump (18cc) 54 l/mn (14.3 gpm) 170 Bar (2465 psi)

-- Steering direction Provided by flow distributor (Load sensing) Pressure

120 Bar (1740 psi)

-- Filtration

Hydraulic Filter, Tank mounted:

Hydrostatic type -- single element (12 microns) closed--loop, anti--cavitation breather filter (40 microns)

Hydraulic Tank Cap:

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2 -- 8

CONTENTS

SPECIFICATIONS TMP25/HT

TMP5500/HT

-- Travel speed of the lift truck Forward, unloaded Forward, with rated load Reverse, unloaded Reverse, with rated load

18.2 km/h (11.3 mph) 15.8 km/h (9.8 mph) 16.9 km/h (10.5 mph) 14.8 km/h (9.2 mph)

18.2 km/h (11.3 mph) 15.8 km/h (9.8 mph) 16.9 km/h (10.5 mph) 14.8 km/h (9.2 mph)

-- Standard lift height

3150 mm (124 in)

3150 mm (124 in)

-- Rated capacity with standard attachment

2500 kg (5500 lbs)

2500 kg (5500 lbs)

-- Load center

500 mm (20 in)

600 mm (24 in)

-- Weight of forks (each)

74 kg (162.5 lbs)

74 kg (162.5 lbs)

-- Lifting motions Unloaded lifting Rated load lifting Unloaded lowering Rated load lowering

10 sec.

13 sec.

7 sec.

6 sec.

10 sec 13 sec 7 sec 6 sec

-- Extending the Mast Extending the Mast Retracting the Mast

7 sec.

5 sec.

7 sec 5 sec

-- Back tilt time unloaded -- Back tilt time loaded

0.8 sec.

2 sec.

0.8 sec 2 sec.

-- Forward tilt time unloaded -- Forward tilt time loaded

0.8 sec.

0.6 sec.

0.8 sec 0.6 sec

-- Lift truck weight with standard ITA carriage Unloaded (no forks) With rated load (plus 72” forks)

2,644 kg (5,828 lbs) 5,225 kg (11,520 lbs)

2,722 kg (6,000 lbs) 5,416 kg (11,940 lbs)

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2 -- 9

CONTENTS

SPECIFICATIONS (TMP25/HT) -- DIMENSIONS

Z Y D H1

H

N

U G1

G F W

B

C

TMP 25 (in)

K

R

T

V

S

B

1803.4 (71)

1803.4 (71)

C D

381 (15) 2667 (105)

381 (15) 2667 (105)

F G

2159 (85) 190.5 (7.5)

2159 (85) 190.5 (7.5)

G1

355.6 (14)

355.6 (14)

H H1

1828.8 (72) 3911.6 (154)

1828.8 (72) 3911.6 (154)

K N

1524 (60) 1422.4 (56)

1524 (60) 1422.4 (56)

R S

---

1809.75 (71.25) 2298.7 (90.5)

T U

2197.1 (86.5) 1879.6 (74)

2197.1 (86.5) 1879.6 (74)

V W

-2578.1 (101.5)

2006.6 (79) 2578.1 (101.5)

Y Z

100 80

100 80

Extension 965 (38)

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2 -- 10

TMP 25 HT (in)

CONTENTS

SPECIFICATIONS (TMP5500/HT) -- DIMENSIONS

O

Z

Y D H1

H

N

U G1

G F W

C

K

R

T

V

S

B

TMP 5500 (in)

TMP 5500 HT (in)

B

1924 (75.75)

1924 (75.75)

C D

377.8 (14.88) 2806.7 (110.5)

377.8 (14.88) 2806.7 (110 .5)

F G

2108.2 (83) 190.5 (7.5)

2108.2 (83) 190.5 (7.5)

G1

365.1 (14.38)

365.1 (14.38)

H H1

1831.9 (72) 4019.5 (158)

1831.9 (72) 4019.5 (158)

K N

1524 (60) 1423.9 (56)

1524 (60) 1423.9 (56)

O R

1765 (69.5) 1994 (78.5)

1765 (69.5) --

SR SL

4267.2 (168) 3810 (150)

---

T U

3251.2 (128) 1905 (75)

3251.2 (128) 1905 (75)

V W

2120.9 (83.5) 2374.9 (93.5)

-2374.9 (93.5)

Y Z

100 80

100 80

Extension 965 (38)

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2 -- 11

CONTENTS

SPECIFICATIONS LOAD CHARTS TMP 25 / HT

CAPACITY (Kg)

MAST EXTENDED STABILIZER UP

CAPACITY (Kg)

MAST EXTENDED STABILIZER DOWN

LIFT (METERS)

LIFT (METERS)

LIFT (METERS)

LOAD CHART FOR TMP25 AND TMP25HT @ LOAD CENTER OF 500mm (20”)

CAPACITY (Kg)

MAST RETRACTED STABILIZER UP 801180

TMP 5500 / HT LOAD CHART FOR TMP5500 AND TMP5500HT @ LOAD CENTER OF 600mm (24”)

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 12

CONTENTS

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 13

CONTENTS

INSTRUMENTS AND CONTROLS

12

13

6

13

13

4

3 2

15 7

11

10

5 1

9 8

14

14

14

14

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 14

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

DESCRIPTION 1 -- DRIVER’S SEAT AND SEAT BELT 2 -- ACCESSORY LIGHT PANEL 3 -- FUEL LEVEL GAUGE AND HOURMETER 4 -- SWITCH PANEL 5 -- DIFF. LOCK 6 -- HEADLIGHT LEVER SWITCH AND HORN 7 -- IGNITION SWITCH 8 -- FUSES 9 -- TAIL LIGHT CONNECTORS FOR TRACTOR TRAILER 10 -- ACCELERATOR PEDAL 11 -- INCHING / TRANS. DUMP PEDAL 12 -- FORWARD/REVERSE LEVER 13 -- HYDRAULIC CONTROL LEVERS 14 -- TAIL LIGHTS 15 -- DOCUMENT STORAGE

NOTE: All terms such as: RIGHT, LEFT, FRONT, and REAR are for reference as observed by the operator seated in the driver’s seat and facing forward.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 15

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

1 -- DRIVER’S SEAT & SAFETY BELT The seat can be adjusted as follows: 1

FORWARD/REVERSE ADJUSTMENT -- Pull locking lever 1 towards the right.

-- Slide the seat to the desired position.

-- Release the lever, insuring it returns to a locked position.

SEAT SUSPENSION ADJUSTMENT

2

-- Position the lever 2 according to the driver’s weight: Position A: light weight driver.

Position B: middle weight driver.

Position C: heavy weight driver.

3

ADJUSTMENT OF THE BACK--REST ANGLE -- Turn the lever 3 to incline the back--rest into the desired position between 50 and --200.

SAFETY BELT -- Push back on the lever 4 to wind or unwind the safety belt.

-- Always wear the safety belt while operating the lift truck!

2 -- ACCESSORY LIGHT PANEL 4 -- When activating the ignition on the lift truck, all panel lamps should light to indicate good working order. If a panel lamp is not working, make the necessary repairs.

A -- Engine oil pressure light.

B -- Water temperature light.

C -- Hydrostatic transmission oil filter restriction light.

D -- Air filter restriction light.

E -- not used.

F -- Alternator charge light.

G -- Park Brake Indicator H -- not used I -- not used J -- Engine preheat light.

A B

C

F G H

A -- ENGINE OIL PRESSURE LIGHT If the light or buzzer come on during lift truck operation, stop the engine immediately (check oil level in engine crankcase).

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 16

D E

I

J

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

2 -- ACCESSORY LIGHT PANEL (cont.)

B -- WATER TEMPERATURE LIGHT If this light comes on during operation of the lift truck, stop the engine immediately and allow it to cool. Inspect the cooling system for problems.

C -- HYDROSTATIC TRANSMISSION OIL FILTER RESTRICTION LIGHT This light warns of a plugged or damaged oil filter cartridge. Stop the truck and change the filter (See SECTION 3; chapter -- FILTERS, CARTRIDGES AND BELTS).

Note: This light may activate in cold weather until the hydraulic oil reaches its proper working temperature.

D -- AIR FILTER RESTRICTION LIGHT This light warns of a plugged or damaged air filter cartridge. Stop the truck and repair the filter (See SECTION 3; chapter -- FILTERS, CARTRIDGES AND BELTS) F -- ALTERNATOR CHARGE LIGHT This light warns of a faulty alternator/electrical circuit or loose alternator belt. Stop operation of the truck and make the necessary repairs.

G -- PARK BRAKE INDICATOR This light indicates that the Park Brake is engaged. See the following page for engaging/disengaging the Park Brake. DO NOT drive the Lift Truck with the Park Brake engaged!

J -- ENGINE PREHEATING LIGHT This light shows operation of the engine preheating element, it goes out when the engine is started.

3 -- FUEL LEVEL GAUGE AND HOURMETER A -- HOURMETER Shows the number of hours the lift truck has operated. Use the hourmeter as a guide for scheduling maintenance.

A

B -- FUEL LEVEL GAUGE Indicates the amount of fuel in the fuel tank. If the tank is allowed to run dry, the engine may need air bled out of the fuel system (see SECTION 3; chapter I -- OCCASIONAL MAINTENANCE; paragraph I1 -- BLEEDING THE FUEL SYSTEM).

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2 -- 17

B

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

4 -- SWITCH PANEL

A

B

A -- PARKING BRAKE SWITCH This switch applies the parking brake. The Red Light indicates the Parking Brake is engaged. See also, the Accessory Light Panel on the previous pages, Item “G” -- Park Brake Indicator.

B -- (OPTIONAL ACCESSORY SWITCH LOCATION) C -- (OPTIONAL CARRIAGE ROTATOR ACCESSORY) This switch activates the optional carriage rotator. The carriage rotator is operated using the Hydraulic Control Lever C (see Hydraulic Control Levers on the following pages). The Blue Light indicates the switch is active.

5 -- DIFFERENTIAL (DIFF.) LOCK This switch drives all 3 wheels simultaneously. It may be used when operating in muddy or slippery conditions.

-- The switch must be held down with the foot continuously for operation.

-- Release the switch to discontinue its use.

Refer to: SECTION 1; chapter -- LOAD HANDLING INSTRUCTIONS; paragraph -- DIFF--LOCK OPERATION.

6 -- HEADLIGHT SWITCHING LEVER & HORN Located on the steering column’s right side.

For the use of 6 headlights; 3 white headlights and 3 red headlights.

-- Lever in position A: all headlights off.

-- Lever in position B: white headlights on.

-- Lever in position C: red headlights on.

B

Push the lever in, toward the steering column, to sound the horn.

A

C

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2 -- 18

C

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

7 -- IGNITION SWITCH P

The key switch has five positions 1 -- “P” -- Ignition off, parking position, key removeable.

2 -- “0” -- Ignition switched off and engine stopped, key not removeable.

3 -- “I” -- Ignition on.

4 -- “II” -- Engine Pre--Heating.

5 -- “III” -- Engine starter position, release key when engine starts.

8 -- FUSES 1 2 3 4 5 6 7 8 9

----------

Fuel level gauge + hourmeter (10 amp) (OPTION) (10 amp) Horn (10 amp) Accessory light panel (10 amp) Parkbrake solenoid valve block assembly (10 amp) Reverse gear + reverse horn + reverse light (10 amp) Diff. lock (10 amp) Headlight switch. (10 amp) Oil Cooler Fan (10 amp)

NOTE: Replace blown fuses with new fuses only, use same quality and capacity. Never re--use a repaired fuse.

9 -- TAIL LIGHT CONNECTOR FOR

TRAILER LIGHTS

The flatbed trailer’s operating lights plug into this outlet during transport.

10 -- ACCELERATOR PEDAL Depress this pedal to increase power or speed while driving the lift truck.

Release the pedal to return to idle speed.

11 -- INCHING / TRANSMISSION DUMP PEDAL This pedal disengages the hydrostatic transmission, providing hydrostatic braking effort.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 19

O I II III

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

12 -- FORWARD/REVERSE LEVER (Fig. 1)

Fig. 1

Bring the lift truck to a complete stop before shifting the forward/ reverse lever.

B

NEUTRAL: To start the truck the lever must be in neutral (Position A).

FORWARD: Lift and push the lever upward (Position B).

REVERSE: Lift and pull the lever downward (Position C). This position also activates the backup alarm and backup light.

A

C

13 -- HYDRAULIC CONTROL LEVERS (Fig. 2) LEVER A: TILTING AND SIDE--SHIFTING THE MAST -- move the lever back to tilt the mast back.

-- move the lever forward to tilt the mast forward.

-- move the lever left to side--shift the mast left.

-- move the lever right to side--shift the mast right.

Fig. 2

A

LEVER B: RAISING / LOWERING THE CARRIAGE AND EXTENDING / RETRACTING THE MAST -- move the lever back to raise the forks.

-- move the lever forward to lower the forks.

-- move the lever left to extend the mast out.

-- move the lever right to retract the mast.

LEVER C: FRONT WHEEL STABILIZERS OR THE OPTIONAL CARRIAGE ROTATOR -- move the lever forward to lower the stabilizers.

-- move the lever back to raise the stabilizers.

OPTIONAL CARRIAGE ROTATOR (Engage the Rotator Switch, see Switch Panel on previous pages) -- move the lever forward to rotate the carriage left -- move the lever back to rotate the carriage right

IMPORTANT Do not alter the hydraulic system pressure setting.

If the hydraulic system malfunctions, contact your dealer.

ANY ALTERATION MAY VOID THE WARRANTY.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 20

B C

CONTENTS

INSTRUMENTS AND CONTROLS (cont.)

14 -- TAIL LIGHTS These tail lights operate only when connected to the tractor trailer’s lights, while in transport. Properly connected, they function as standard trailer lights: turn signals, brake lights, and running lights (backup lights optional).

TMP5500/HT MODELS

TMP25/HT MODELS

15 -- DOCUMENT STORAGE The Operator’s Manual is to be stored in this compartment, always available for reference.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 21

CONTENTS

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

2 -- 22

CONTENTS

SECTION THREE

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

CONTENTS

CONTENTS

SERVICING THE FORKLIFT

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 1

3- 1

CONTENTS

FILTERS, CARTRIDGES AND BELTS

6 3 1

2

4

5

7

8 10

9 DESIGNATION 1 2 3 4 5

PART NUMBER

------

Engine oil filter 549 798 Air filter cartridge 551 017 Fuel filter cartridge 549 797 Safety (inner) air filter cartridge 551 018 Hydrostatic transmission oil filter cartridge 800 741 TMP25 S/N: 165123 & 165125 TMP5500 S/N: 165126 & 165128 5 -- Hydrostatic transmission oil filter cartridge 800 814 TMP25/HT S/N: 165124, and 165127 & above TMP5500/HT S/N: 165130 & above 6 -- Suction Strainer, hydraulic oil return 19 911 7 -- Hydraulic tank breather cap 800 741 8 -- Alternator belt / Fan / Crankshaft 800 336 9 -- Air intake pre--filter (Turbo II) 494 313 10 -- Oil Cooler Screen 800 139

CLEAN

50

CHANGE 200 Hours 400 400 800 800

800

800 800 1600 as required if damaged

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3 -- 2

CONTENTS

LUBRICANTS

ITEM

CAPACITY

SUGGESTED

PACKAGING

P/N:

I.C. ENGINE

5.6 Liters (1.5 gal)

Oil MANITOU MOTOR SAE 15W/40

5 L. (1.32 gal) 25 L. (6.6 gal) 56 L. (14.8 gal) 215 L. (56.7 gal)

485 297 161 584 490 013 485 165

40 Liters (10.5 gal)

Oil MANITOU HYDRAULIC ISO 46

25 L. (6.6 gal) 56 L. (14.8 gal) 215 L. (56.7 gal)

161 588 453 265 485 227

Grease SHELL RETINAX HD

Cartridge, 14 oz.

161 589

Grease SHELL RETINAX HDM

Cartridge, 14 oz.

Tub, 2.2 lbs.

499 236 161 590

Grease SHELL RETINAX HD

Cartridge, 14 oz.

161 589

2 L. (0.5 gal) 5 L. (1.32 gal) 20 L. (5.3 gal) 210 L. (55.4 gal)

473 076 470 077 470 078 470 079

HYDRAULIC OIL TANK

GENERAL GREASING

MAST CARRIER THRUST PADS GREASING OF THE STABILIZERS

COOLING CIRCUIT

8 Liters (2.1 gal)

Antifreeze --300C (--220F)

FUELTANK

40 Liters (10.5 gal)

Diesel fuel

MAST CHAINS

as required

30 Wt. non--detergent Motor Oil

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3 -- 3

CONTENTS

SERVICING SCHEDULE AFTER THE FIRST 50 HOURS SERVICE Cl -- Change the engine oil.

C2 -- Change the engine oil filter.

D2 -- Change the fuel filter cartridge.

D3 -- Change the hydraulic return oil filter cartridges.

3 3 3 3

-----

11 11 13 13

Al -- Check the engine oil level.

A2 -- Check the radiator fluid level.

A3 -- Check the fuel level.

A4 -- Check the tire pressure and lug nut torque.

3 3 3 3

-----

7 7 7 8

GREASE POINTS: A5 -- Grease the mast side--shift.

A6 -- Grease the mast carrier thrust pad channels.

A7 -- Grease the mast roller channels.

3 -- 8 3 -- 8 3 -- 8

A - EVERY DAY OR EVERY 10 HOURS SERVICE

-- Check the tension on the mast chains.

-- Lightly oil mast chains.

3 -- 8 3 -- 8

B - EVERY 50 HOURS SERVICE Bl -- Clean the air filter cartridge (or every 25 hours when working in very dusty conditions).

B2 -- Check the hydraulic oil level.

B3 -- Check the battery.

B4 -- Clean the radiator, oil cooler, and screens.

3 3 3 3

-----

9 9 9 10

GREASE POINTS: B5 -- Grease fitting on the rear wheel pivot.

-- Grease fitting on the steering cylinder.

B6 -- Grease fittings on the stabilizers.

3 -- 10 3 -- 10 3 -- 10

C - EVERY 200 HOURS SERVICE Cl -- Change the engine oil.

C2 -- Change the engine oil filter.

C3 -- Check and adjust the alternator belt tension.

C4 -- Inspect the Hydraulic Tank Breather Cap

3 3 3 3

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 4

-----

11 11 12 12

CONTENTS

SERVICING SCHEDULE (cont.)

D - EVERY 400 HOURS SERVICE Or once a year if the lift truck has not reached 400 hours service.

Dl -- Change the air filter cartridge.

D2 -- Change the fuel filter cartridge.

D3 -- Change the hydraulic return oil filter cartridge.

D4 -- Check the forks for wear (Consult your dealer).

3 3 3 3

-----

13 13 13 13

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

----------------

14 14 15 16 16 17 17 17 17 17 17 17 17 17 17

E - EVERY 800 HOURS SERVICE Or once a year if the lift truck has not reached 800 hours service.

El -- Change the hydraulic oil.

E2 -- Replace the hydraulic tank breather cap.

E3 -- Change the radiator fluid.

E4 -- Drain and clean the fuel tank.

E5 -- Clean and lubricate the pivot wheel housing.

E6 -- Change the air filter safety cartridge.

E7/1 -- Check wear on the mast carrier thrust pads (Consult your dealer).

E7/2 -- Check wear on the mast rollers (Consult your dealer).

E8 -- Check the brake adjustment (Consult your dealer).

E9 -- Check the engine mounts (Consult your dealer).

E10 -- Check the engine (Consult your dealer).

E11 -- Check the carriage (Consult your dealer).

E12 -- Check the condition of the wheels and tires (Consult your dealer).

E13 -- Check the hydraulic movement speeds (Consult your dealer).

E14 -- Check the carriage attachments (Consult your dealer).

F - EVERY 1600 HOURS SERVICE Fl -- Change the alternator belt.

3 -- 18

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 5

CONTENTS

SERVICING SCHEDULE (cont.)

G - EVERY 2400 HOURS SERVICE Gl -- Check the hydraulic circuit pressures and discharge rates (Consult your dealer).

G2 -- Check the hydrostatic transmission circuit pressures (Consult your dealer).

G3 -- Check and adjust the governing start r.p.m. of the hydrostatic transmission (Consult your dealer) G4 -- Insure transmission cut--off hydraulic valves are in good working order (Consult your dealer) G5 -- Check the steering system (Consult your dealer).

G6 -- Clean the hydraulic oil tank (Consult your dealer).

G7 -- Check the engine fuel injectors (Consult your dealer).

G8 -- Check and clean the radiator (Consult your dealer).

G9 -- Check the water pump and the thermostat (Consult your dealer).

G10 -- Check the mast and mast carrier assemblies (Consult your dealer).

3 3 3 3 3 3 3 3 3 3

-----------

18 18 18 18 18 18 18 18 18 18

3 3 3 3

-----

19 19 19 19

H - EVERY 4800 HOURS SERVICE Hl -- Check the brake disc wear on the front wheel motors (Consult your dealer).

H2 -- Check the rear wheel motor pivot (Consult your dealer).

H3 -- Check the steering ball joints (Consult your dealer).

H4 -- Check the alternator and the starter motor (Consult your dealer).

I - OCCASIONAL MAINTENANCE I1 -- Bleeding the fuel system.

I2 -- Changing the wheels.

3 -- 20 3 -- 20

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 6

CONTENTS

A - EVERYDAY OR EVERY 10 HOURS SERVICE A1 - CHECK THE ENGINE OIL LEVEL

A1/1

CAUTION 1

Do not touch the muffler, it may be extremely hot!

Place the truck on level ground, stop the engine, and allow the oil to settle.

-- Open the engine compartment.

-- Remove the dipstick 1 (Fig. A1/1).

-- Clean the dipstick and check the oil level, it should be between the marks.

Add oil through the filler port 2 (Fig. A1/2) (See SECTION 3; LUBRICANTS).

A1/2

A2 - CHECK THE RADIATOR FLUID LEVEL CAUTION NEVER OPEN A HOT RADIATOR CAP! Do not add cold fluid to a hot radiator, allow the radiator to cool.

Place the truck on level ground, stop the engine, and allow the engine and radiator to cool.

-- Open the engine compartment.

-- Slowly turn the radiator cap 1 (Fig. A2) counterclockwise to the safety stop.

-- Allow any pressure to escape before turning the cap further.

-- Push down and turn the cap to remove it.

-- Add fluid until 1/2” below the filler port 2 (Fig. A2).

-- Lubricate the filler neck occasionally to prevent corrosion.

2

A2

1

A3 - CHECK THE FUEL LEVEL

2

CAUTION Never smoke or approach the lift truck with an open flame while refueling. Never refuel while the engine is running.

Turn the ignition key to “on” and check the fuel level gauge on the dash.

Turn the key off. When refueling: -- Remove the fuel cap 1 (Fig. A3).

-- Fill the fuel tank with clean diesel fuel only. If necessary, filter the fuel through a lint free cloth.

-- Wipe away any spilt fuel and replace the cap.

-- Keep the fuel tank near full when possible, this will help reduce condensation and oxidation inside the tank.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 7

A3

1

CONTENTS

A - EVERYDAY OR EVERY 10 HOURS SERVICE (cont.)

A4 - CHECK THE TIRE PRESSURE AND LUG NUTS -- Check/adjust the tire pressure. (See SECTION 2; chapter CHARACTERISTICS).

-- Check the tires for wear, cuts, punctures, etc..

-- Check all wheel lug nuts for torque (Fig. A4).

Loose lug nuts can damage or break the wheel bolts and damage the wheels.

A4 WHEEL TORQUES FRONT WHEEL

87--108 ft.lbs 118--146 Nm

REAR WHEEL

87--108 ft/lbs 118--146 Nm

GREASE POINTS Clean and lubricate the following locations with grease (See SECTION 3; chapter LUBRICANTS), remove any surplus.

A5

A6

GREASE THE MAST SIDE SHIFT (1) and TILT CYLINDERS. Six places. Also, add a thin film of lubricant to the exposed chrome surfaces.

A5

1

LIGHTLY BRUSH OIL ON THE MAST CHAINS (2) Use 30 Wt. non--detergent motor oil.

CHECK TENSION ON MAST CHAINS (2), ALLOW NO FREE PLAY

A6

2

IMPORTANT When operating in extremely dirty environments (dust, sand, etc.) use a dry lubrication. Consult your dealer.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 8

CONTENTS

B - EVERY 50 HOURS SERVICE B1

Bl - CLEAN THE AIR FILTER CARTRIDGE In extremely dirty conditions clean at every 25 hours of service (see SECTION 3; chapter FILTERS, CARTRIDGES AND BELTS).

-- Open the engine compartment.

-- Loosen the cover nut 1 (Fig. B1), and remove cover 2.

-- Remove the wingnut 3 (Fig. B1) and air filter cartridge 4.

-- Leave the safety cartridge in place.

-- Inspect the air filter cartridge, replace the cartridge if damaged.

-- Clean the filter cartridge with low air pressure, directed from the inside out only.

4

2 1 3

IMPORTANT Clean the air filter cartridge carefully, if damaged, it must be replaced!

-- Wipe the inside of the air filter housing with a clean cloth.

-- Reassemble the cartridge and cover.

B2

IMPORTANT Do not wash the air filter cartridge.

Do not clean the inner safety cartridge, if dirty or damaged, it must be replaced.

1

B2 - CHECK THE HYDRAULIC OIL LEVEL Secure the lift truck on level ground, forks lowered, park brake on and engine stopped.

-- Check the oil level sight glass on the hydraulic tank.

-- The oil level must be between the upper and lower marks.

-- Add oil if necessary (See SECTION 3; chapter LUBRICANTS).

-- Add oil through the filler port 1 (Fig. B2).

The proper oil level must be maintained, it is critical in cooling the hydraulic system.

B3

B3 - CHECK THE BATTERY The battery is self--contained and maintenance free.

-- Open the battery compartment.

-- Check that the battery is properly secured.

-- Check the terminal connections, add a light coat of grease to prevent corrosion.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 9

CONTENTS

B - EVERY 50 HOURS SERVICE (cont.)

B4/1

B4 - CLEAN THE RADIATOR, OIL COOLER & SCREENS B4/1 -- On the back side of the engine compartment; remove, inspect and clean the oil cooler screen. Replace the screen after cleaning the oil cooler.

B4/2 -- Open the engine compartment.

Inspect the oil cooler. Clean the oil cooler with compressed air directed through the fan side of the cooler. The compressed air should flow freely through the cooler.

B4/3 -- Clean the radiator with compressed air, directed through the fan side of the radiator. The compressed air should flow freely through the radiator. Inspect the radiator frequently, especially when operating in dusty conditions.

B4/2

GREASE POINTS Clean and lubricate the following fittings with grease, removing any excess (See SECTION 3; chapter LUBRICANTS):

B5 -

B4/3

GREASE FITTING (1) ON THE REAR WHEEL PIVOT. -- GREASE FITTING (2) ON THE STEERING CYLINDER.

B6 -

GREASE FITTING (1) ON THE STABILIZERS. (2 places)

B5

B6

1 2

1

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 10

CONTENTS

C - EVERY 200 HOURS SERVICE C1/1

Cl - CHANGE THE ENGINE OIL C2 - CHANGE THE ENGINE OIL FILTER Allow the engine to run at idle for a few minutes to warm the oil. Park the lift truck on a level grade.

CAUTION The engine oil is HOT, protect yourself against spills!

Dispose of oil and filter in accordance with local regulations.

C1/2 DRAINING THE ENGINE OIL -- Open the engine compartment.

-- Place an oil drain pan under the engine oil drain plug and remove the oil drain plug (Fig. C1/1).

-- Remove the oil filler cap (Fig. C1/2), allowing the oil to vent and drain properly.

CHANGING THE OIL FILTER -----

Remove the engine oil filter (Fig. C2/1); discard the filter and seal.

Clean the filter housing with a clean, lint--free cloth.

Lightly lubricate the new seal.

Install a new filter and hand tighten.

C2/1

IMPORTANT When installing the oil filter, hand tighten only .

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 11

CONTENTS

C - EVERY 200 HOURS SERVICE (cont.)

C2/2 FILLING THE CRANKCASE WITH OIL -- Install the drain plug (Fig. C1/1).

-- Add oil (See SECTION 3; chapter LUBRICANTS) through the filler port (Fig. C1/2), and re--install the filler plug -- Start the engine, allowing it to idle for a few minutes.

-- Check for leaks at the drain plug and oil filter.

-- Stop the engine and allow the oil to settle a few minutes before checking the dipstick (Fig. C2/2).

-- Add oil if necessary, do not overfill.

C3 - CHECK AND ADJUST THE ALTERNATOR BELT

C3

-- Open the engine compartment.

-- Check the alternator belt; if worn or damaged, replace it.

-- Check the belt tension between the crankshaft and alternator pulleys.

There should be approx. 3/8 in. of belt tension.

-- Make adjustments if necessary.

-- Loosen the bolts 1 (Fig. C3) a few turns.

-- Rotate the alternator as needed to adjust the belt tension.

-- Tighten the bolts 1 (Fig. C3) and re--check the tension.

1

1

C4 - INSPECT THE HYDRAULIC TANK BREATHER CAP -- Remove and inspect the breather cap (Fig. C4); the foam filter within the cap must be dirt and debris free. If the filter shows any signs of deterioration or contains any debris, replace it immediately.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 12

C4

CONTENTS

D - EVERY 400 HOURS SERVICE D1

D1 - CHANGE THE AIR FILTER CARTRIDGE Do not operate the lift truck with the air filter cartridge removed or

2

damaged.

-------

3

Open the engine compartment.

Loosen the knob 1 (Fig. D1) and remove the cover 2.

Remove the wingnut 3 (Fig. D1) and discard the filter cartridge 4.

Unless damaged, the safety cartridge remains in place.

Clean inside the housing with a clean, damp lint free cloth.

Install a new air filter cartridge and the cover.

1

When operating in extremely dusty conditions, install an air pre--cleaner (see SECTION 3; chapter FILTERS, CARTRIDGES AND BELTS).

4

D2 1

D2 - CHANGE THE FUEL FILTER CARTRIDGE -- Open the engine compartment.

-- Carefully clean the exterior of the filter and bracket to prevent debris from entering the fuel system.

-- Loosen the locking bolt 1 (Fig. D2).

-- Remove and discard the cartridge 2 (Fig. D2) and seals.

-- Clean inside the filter head with a brush and clean diesel fuel.

-- Install a new cartridge and seals, tighten the locking bolt.

If necessary, bleed the fuel system (see SECTION 3; chapter I -- OCCASIONAL MAINTENANCE; paragraph I1 -- BLEEDING THE FUEL SYSTEM).

2

D3

1

D3 - CHANGE THE HYDRAULIC OIL FILTER CARTRIDGE 2

D4 - CHECK THE FORKS FOR WEAR/DAMAGE (CONSULT YOUR DEALER)

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 13

CONTENTS

E - EVERY 800 HOURS SERVICE FLUSHING THE HYDRAULIC CIRCUIT -- With the park brake on and the transmission in neutral, run the engine at half throttle for 5 minutes. Next, with the engine at half throttle, operate all of the hydraulic circuits (except the steering system and the service brakes) for 5 minutes.

-- Now accelerate the engine at full throttle for 1 minute, activating the steering system and the inching pedal (do not drive the lift truck while performing this operation).

-- This operation flushes any debris into the hydraulic return oil filter.

E1 - CHANGING THE HYDRAULIC OIL Secure the lift truck on level ground; with the mast retracted, the forks lowered and the engine stopped.

DRAINING THE OIL

E1/1

CAUTION The hydraulic oil may be HOT, protect yourself against spills!

Dispose of oil and filter in accordance with local regulations.

1

IMPORTANT It is critical that no debris enters the hydraulic system!

Keep the filler area clean.

E1/2 -- Place a container under the drain port 1 (Fig. E1/1) and remove the drain plug.

-- Remove the filler cap 2 (Fig. E1/2) and return filter cartridge 3, allowing the oil to vent and drain properly.

FILLING WITH OIL (Before filling, see E2- CLEAN THE SUCTION STRAINER, next paragragh) -- Install the drain plug 1 (Fig. E1/1), torque to 25 ft.lbs.

-- Fill with oil (See SECTION 3; chapter LUBRICANTS) through the filler port 4 (Fig. E1/2).

-- Check the oil level using the dipstick 5 (Fig. E1/2) or sight glass (Fig. E1/3) provided, ensure the oil level is be between the marks indicated.

-- Check for leaks at the drain plug.

-- Place the cartridge 3 and filler cap 2 (Fig. E1/2) into position, and hand tighten.

2 5 3 4

E1/3

IMPORTANT If air becomes trapped in the hydraulic system while changing the oil, it may become necessary to bleed the system, consult your dealer.

E2 - CLEAN THE SUCTION STRAINER IN THE HYDRAULIC OIL TANK

-- Remove the access panel at the rear of the hydraulic tank.

-- Remove and clean the suction strainer, checking for damages.

-- Replace the strainer if it is damaged in any way. Install the strainer.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 14

CONTENTS

E - EVERY 800 HOURS SERVICE (cont.)

E3

E3 - REPLACE THE HYDRAULIC TANK BREATHER CAP -- Remove and replace the breather cap (Fig. E3) with a new one.

E4 - CHANGING THE RADIATOR FLUID

E4/1

A 50% mix of anti--freeze and water is recommended. Replace the fluid annually, flushing the entire system.

Secure the truck on level ground with the engine stopped and cold.

1

DRAINING THE RADIATOR -- Open the engine compartment.

-- Place a container under the radiator drain plug 1 (Fig. E4/1).

-- Remove the radiator cap 2 (Fig. E4/2) and drain plug.

-- Allow the system to drain. Debris in the fluid may indicate corrosion, make the necessary repairs or replace the radiator (consult your dealer).

-- Inspect the hoses and hose clamps for damage, replace if necessary.

-- Flush the system with clean water or a flushing agent as needed.

E4/2

FILLING THE RADIATOR -----

2

Install the drain plug 1 (Fig. E4/1).

Mix the radiator fluid, 50% clean water and 50% anti--freeze.

Add the mixture to within 1/2 in. below the filler port 3 (Fig. E4/2).

Install the radiator cap 2 (Fig. E4/2).

-- Allow the engine to run at idle for two minutes, checking the cooling system for leaks.

-- Stop the engine. When the radiator is cool, check and adjust the fluid level.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 15

3

CONTENTS

E - EVERY 800 HOURS SERVICE (cont.)

E4/1

E4 - DRAIN AND CLEAN THE FUEL TANK WARNING Do not smoke or work near a flame when handling fuel!

Avoid risk of fire or explosion, do not perform welding on or near the lift truck!

-- Secure the truck on level ground with the engine stopped.

1

E4/2

-- Inspect the entire fuel system for leaks.

-- If a fuel leak is found, contact your dealer.

-- Place a container under the drain port 1 (Fig. E4/1) and remove the drain plug.

2

CAUTION Protect yourself against fuel spills!

-- Remove the fuel cap 2 (Fig. E4/2).

-- Allow the fuel to drain, rinse the fuel tank with clean fuel (approx. 2

E4/3

gal.) through the filler port.

-- Install the drain plug 1 (Fig. E4/1), torque to 25 ft.lbs.

-- Fill the fuel tank with clean fuel (filtered through a strainer or lint--free cloth) and replace the fuel cap 2 (Fig. E4/2).

-- Re--prime the system by pumping the fuel feed pump 3 (Fig. E4/3) -- If necessary, bleed the fuel system (see SECTION 3; chapter I -- OCCASIONAL MAINTENANCE; paragraph I1 -- BLEEDING THE FUEL SYSTEM).

3

E5

E5 - CLEAN AND LUBRICATE THE PIVOT WHEEL HOUSING -- Clean the grease fitting 1 (Fig. E5).

-- Fill with grease (See SECTION 3; chapter LUBRICANTS).

-- Remove any excess.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 16

1

CONTENTS

E - EVERY 800 HOURS SERVICE (cont.)

E6 - CHANGE THE AIR FILTER SAFETY CARTRIDGE

E6

-- Remove the air filter cartridge (See chapter: D1).

-- Replace the air filter safety cartridge 1 (Fig. E6) with a new one.

-- Reassemble the entire unit (See chapter: D1).

1

E7/1 - CHECK FOR WEAR ON THE MAST CARRIER THRUST PADS (CONSULT YOUR DEALER) E7/2 - CHECK FOR WEAR ON THE MAST ROLLERS (CONSULT YOUR DEALER) E8 - CHECK THE BRAKE ADJUSTMENT (CONSULT YOUR DEALER) E9 - CHECK THE ENGINE MOUNTS (CONSULT YOUR DEALER) E10 - CHECK THE ENGINE (CONSULT YOUR DEALER) E11 - CHECK THE CARRIAGE (CONSULT YOUR DEALER) E12 - CHECK THE WHEELS AND TIRES (CONSULT YOUR DEALER) E13 - CHECK THE HYDRAULIC MOVEMENTS (CONSULT YOUR DEALER) E14 - CHECK THE CARRIAGE ATTACHMENTS (CONSULT YOUR DEALER)

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 17

CONTENTS

F - EVERY 1600 HOURS SERVICE Fl - CHANGE THE ALTERNATOR BELT (CONSULT YOUR DEALER)

G - EVERY 2400 HOURS SERVICE Gl - CHECK THE HYDRAULIC CIRCUIT PRESSURES AND DISCHARGE RATES (CONSULT YOUR DEALER)

G2 - CHECK THE HYDROSTATIC TRANSMISSION CIRCUIT PRESSURES (CONSULT YOUR DEALER)

G3 - CHECK AND ADJUST THE GOVERNING START R.P.M. OF THE HYDROSTATIC TRANSMISSION (CONSULT YOUR DEALER)

G4 - MAKE SURE THE TRANSMISSION CUT- OFF HYDRAULIC VALVES ARE IN GOOD WORKING ORDER (CONSULT YOUR DEALER)

G5 - CHECK THE STEERING SYSTEM (CONSULT YOUR DEALER) G6 - CLEAN THE HYDRAULIC OIL TANK (CONSULT YOUR DEALER) G7 - CHECK THE FUEL INJECTORS (CONSULT YOUR DEALER) G8 - CHECK AND SCALE THE RADIATOR (CONSULT YOUR DEALER) G9 - CHECK THE WATER PUMP AND THERMOSTAT (CONSULT YOUR DEALER) G10 - CHECK THE MAST & MAST CARRIER ASSEMBLIES (CONSULT YOUR DEALER)

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 18

CONTENTS

H - EVERY 4800 HOURS SERVICE H1 - CHECK THE BRAKE DISC WEAR ON THE FRONT WHEEL MOTORS (CONSULT YOUR DEALER)

H2 - CHECK THE REAR WHEEL MOTOR PIVOT (CONSULT YOUR DEALER) H3 - CHECK THE STEERING BALL JOINTS (CONSULT YOUR DEALER) H4 - CHECK THE ALTERNATOR AND STARTER MOTOR (CONSULT YOUR DEALER)

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 19

CONTENTS

I - OCCASIONAL MAINTENANCE I1/1

I1 - BLEEDING THE FUEL SYSTEM

1

Bleeding the fuel system may be necessary after the following: -- changing or draining a component of the fuel system -- draining the fuel tank -- running the fuel tank dry Make sure the fuel level is sufficient. Turn the ignition key to the ”on” position (do not start the engine), this allows the fuel to flow to the engine.

-- Open the engine compartment.

-- Loosen the bleed screw 1 (Fig. I1/1).

-- Pump the fuel lift pump 2 until airless fuel drains from the bleed screw.

-- Tighten the bleed screw 1 (Fig. I1/1) while fuel is flowing out.

NOTE: If the fuel lift pump lever will not operate, turn the crankshaft one revolution.

2

I1/2 3

BLEEDING THE INJECTION NOZZLES -- Loosen the tube connections 3 (Fig. I1/2) on the injection nozzles, just enough to allow fuel and air to escape.

-- Operate the starter motor until airless fuel drains from all tube connections 3 (Fig. I1/2).

-- Tighten the connections while operating the starter. NOTE: If the engine starts running during this process; finish tightening the connections quickly, and then stop the engine.

-- Clean the engine compartment of all spilt fuel before running the engine!

I2 - CHANGING THE WHEELS

3 3 3

I2

-- Secure the lift truck on level, solid ground.

-- Stop the engine and apply the park brake.

FRONT WHEEL -- Chock both sides of the wheel opposite to the wheel to be changed.

-- Loosen the lug nuts on the wheel to be changed.

-- Place a block under the stabilizer 1 of the wheel to be changed (Fig. I2).

-- Lower the stabilizers.

-- Remove the wheel lug nuts.

-- Remove the wheel and roll it aside.

-- Place the new wheel onto the wheel hub.

-- Lubricate the lug nuts, installing them all hand tight.

-- Lift the stabilizers.

-- Remove the block 1 (Fig. I2).

-- Torque the nuts from 87 to 108 ft. lbs (118 -- 146 Nm).

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 20

1

CONTENTS

I - OCCASIONAL MAINTENANCE (cont.)

I3 REAR WHEEL -----------

Block both sides of the front wheels.

Loosen the lug nuts on the rear wheel.

Place a jack under the rear pivot 1 (Fig. I3).

Raise the wheel until it clears the ground.

Remove the lug nuts.

Remove the wheel and roll it aside.

Place the new wheel onto the wheel hub.

Lubricate the lug nuts, installing them all hand tight.

Lower the wheel and remove the jack.

Torque the lug nuts from 87 to 108 ft. lbs (118 -- 146 Nm).

1

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 21

CONTENTS

ALTERNATIVE TRANSPORT A/1

A - TOWING THE LIFT TRUCK -- Locate the high pressure relief valve on the back side of the hydrostatic pump, behind the steer tire (Fig. A/1). Also find the additional valve located on the opposite side. Loosen the lock nuts on both valves (Item 1, Fig. A/2).

-- BEFORE adjusting, note measurement “X” on the adjustment screws (Fig. A/2).

-- Tighten the screws (Item 2, Fig. A/2) until flush with the lock nut.

-- After towing, reposition the valves to the previous “X” position.

IMPORTANT Tow the lift truck very slowly; do not exceed 3 mph (5 km/h) or a towing distance of over 328 ft (100 m).

A/2 2

B - FLATBED TRANSPORTING X CAUTION All safety precautions regarding the trailer must be observed and the driver informed of the weight and dimensions of the lift truck. (See chapter: CHARACTERISTICS).

IMPORTANT

1

B/1

The trailer must be certified to carry the over--all weight, size, and weight distribution of the lift truck.

LOAD THE LIFT TRUCK -- Block the wheels of the trailer (Fig. B/1).

WARNING The lift truck must be backed onto the trailer using reverse (see Fig. B/1).

-- Load the lift truck parallel to the trailer.

-- Park the lift truck.

-- For transport purposes, retract the mast fully, and lower the forks.

SECURE THE LIFT TRUCK -- Block the front and rear of each tire on the lift truck (Fig. B/2).

-- Secure the lift truck on the trailer with proper capacity straps; at the front of the lift truck on the spars and at the rear on the eye hooks provided under the bumper (Fig. B/2).

-- Insure the straps are adequately secured.

NOTICE! STUDY THE ENTIRE MANUAL BEFORE OPERATING THE LIFT TRUCK!

3 -- 22

B/2