MANITOU AMERICAS, INC.

One Gehl Way

P. O. Box 179
West Bend, WI 53095-0179 U.S.A

Website: www.us.manitou.com

For parts orders contact your Manitou dealer or call:

Manitou Americas Parts Department. 262-334-6653
Fax (254) 867--6504

MLT735 120 LSU

S6-E3
Operator Manual
Catalog No. 51900002
In. Rel. 04-2011

THIS OPERATOR’S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD
BY OPERATORS.
0 - ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

1 - OPERATING & SAFETY INSTRUCTION

2 - DESCRIPTION

3 - MAINTENANCE

4 - ATTACHMENT ENGAGEMENT

5 - ELECTRICAL & HYDRAULIC SCHEMATIC

RELEASE: 04/11 Initial Release

THE TEXTS AND ILLUSTRATIONS IN THIS DOCUMENT MUST NOT BE REPRODUCED EITHER WHOLLY OR IN PART.
Contents

ROUGH TERRAIN FORKLIFT TRUCK

GENERAL SAFETY STANDARDS

I
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 Manitou North America, Inc. if you have any ques-
tions concerning your forklift, its operation, service or parts. Keep both manuals in the literature box on the
forklift available for reference. If either manual becomes illegible or is missing, contact your dealer for replace-
ments immediately. This manual cannot cover every situation that might result in an accident. It is the respon-
sibility of the operator to always remain alert for potential hazards and be prepared to avoid them!

ADDITIONAL RECOMMENDED LITERATURE:

ANSI / ITSDF B56.6 is the national consensus standard for rough terrain forklift trucks. It contains rules about
forklift safety, maintenance, safe operation, training, and supervision. Forklift owners should learn this stan-
dard and make it available for their operators, service personnel, and supervisors. These standards can be
obtained, free of charge, from the Industrial Truck Standards Development Foundation (ITSDF) on their web-
site at www.itsdf.org. The following references are examples from the standard, addressing forklift operators:

A.) OPERATOR TRAINING QUALIFICATIONS

1.) The user shall ensure that operators understand that safe operation is the operator’s responsibility. The
user shall ensure that operators are knowledgeable of, and observe, all safety rules and practices.
2.) Create an effective operator training program centered around user company’s policies, operating condi-
tions, and rough terrain forklift trucks. The program should be presented completely to all new operators and
not be condensed for those claiming previous experience.
3.) Information on operator training is available from several sources, including rough terrain forklift truck man-
ufacturers, users, government agencies, etc.
4.) An operator training program should consist of the following:
a.) careful selection of the operator, considering physical qualifications, job attitude, and aptitude;
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.

B.) GENERAL SAFETY PRACTICES

1.) Rough terrain forklift trucks can cause injury if improperly used or maintained.
2.) Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to oper-
ate rough terrain forklift trucks. Unusual operating conditions may require additional safety precautions, train-
ing, and special operating instructions.
3.) Modifications and additions which affect capacity or safe operation shall not be preformed without the man-
ufacturer’s prior written approval. Where such authorization is granted, capacity, operation, and maintenance
instruction plates, tags, or decals shall be changed accordingly.
4.) If the rough terrain forklift truck is equipped with front end attachment(s) or optional forks, the user shall see
that the truck is marked to identify the forks or attachment(s), show the approximate weight of the truck and
fork or attachment combination, and show the capacity of the truck with forks or attachment(s) at maximum
elevation with load laterally centered.
5.) The user shall see that all nameplates and caution and instruction markings are in place and legible.
6.) The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity.

II
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

B.) GENERAL SAFETY PRACTICES (cont.)

7.) Where steering can be accomplished with either hand and the steering mechanism is of a type that pre-
vents road reactions from causing the handwheel to spin (power steering or equivalent), steering knobs may
be used. When used, steering knobs shall be of a type that can be engaged by the operator’s hand from the
top and shall be within the periphery of the steering handwheel.
8.) Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable
when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may con-
tribute to a condition of instability and defeat the purpose of the requirements.
9.) Users shall give consideration to special operating conditions. The amount of forward and rearward 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 exer-
cised by the operator.

C.) OPERATING SAFETY RULES AND PRACTICES

1.) Safe operation is the responsibility of the operator.
2.) This equipment can be dangerous if not used properly. The operator shall develop safe working habits and
also be aware of hazardous conditions in order to protect himself, other personnel, the rough terrain forklift
truck, and other material.
3.) The operator shall be familiar with the operation and function of all controls and instruments before under-
taking to operate the rough terrain forklift truck.
4.) Before operating any rough terrain forklift truck, truck operators shall have read and be familiar with the
operator’s manual for the particular truck being operated.
5.) Before starting to operate the rough terrain forklift truck:
a.) be in operating position and fasten seat belt;
b.) place directional controls in neutral;
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 attach-
ments.
10.) Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury
to personnel.
11.) Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck, whether
empty or loaded.
12.) Do not permit passengers to ride on rough terrain forklift trucks.
13.) Check clearance carefully before driving under electrical lines, bridges, etc.
14.) A rough terrain forklift truck is attended when the operator is less than 25 ft (7.6m) from the truck, which
remains in his view.
15.) A rough terrain forklift truck is unattended when the operator is 25ft (7.6m) or more from the truck, which
remains in his view, or whenever the operator leaves the truck and it is not in his view.
16.) Before leaving the operator’s position:
a.) bring rough terrain forklift truck to a complete stop;
b.) place directional controls in neutral;
c.) apply the parking brake;
d.) lower load-engaging means fully, unless supporting an occupied elevated platform;
e.) stop the engine;
f.) if the rough terrain forklift truck must be left on an incline, block the wheels;
g.) fully lower the load-engaging means.
17.) Maintain a safe distance from the edge of ramps, platforms, and other similar working surfaces.
18.) Do no move railroad cars or trailer with a rough terrain forklift truck.

III
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

19.) Do not use a rough terrain forklift truck for opening or closing railroad car doors.
20.) In areas classified as hazardous, use only rough terrain forklift trucks approved for use in those areas.
21.) Report all accidents involving personnel, building structures, and equipment to the supervisor or as
directed.
22.) Do not add to, or modify, the rough terrain forklift truck.
23.) Do not block access to fire aisles, stairways, and fire equipment.
24.) For rough terrain forklift trucks equipped with a differential lock, the lock should not be engaged when driv-
ing on the road or at high speeds or when turning. If the lock is engaged when turning, there could be loss of
steering control.
25.) Observe all traffic regulations including authorized speed limits. Under normal traffic conditions, keep to
the right, maintain a safe distance, based on speed of travel, from the truck ahead; and keep the truck under
control at all times.
26.) Yield the right-of-way to pedestrians and emergency vehicles such as ambulances and fire trucks.
27.) Do not pass another truck traveling in the same direction at intersections, blind spots, or at other danger-
ous locations.
28.) Slow down and sound the audible warning device(s) at cross-aisles and other locations where vision is
obstructed.
29.) Cross railroad tracks at an angle wherever possible. Do not park 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 ele-
vator, neutralize the controls, shut off engine, and set brakes. It is advisable that all other personnel leave the
elevator before truck is allowed to enter or leave.
40.) Avoid running over loose objects on the roadway surface.
41.) When negotiating turns, reduce speed to a safe level, and turn steering handwheel in a smooth sweeping
motion. Except when maneuvering at a very low speed, turn the steering handwheel at a moderate, even rate.
42.) Use special care when traveling without load, as the risk of lateral overturning is greater.
43.) Improper use of stabilizer controls (if so equipped) could cause rough terrain forklift truck upset. Always
lower the carriage before operating stabilizer controls.
44.) For rough terrain forklift trucks equipped with lateral leveling:
a.) Always level the frame before raising the boom or mast, with or without a load.
b.) Lateral leveling should not be used to position an elevated load; instead, lower the load and
reposition the rough terrain forklift truck.
45.) Handle only stable or safely arranged loads.
a.) When handling off-center loads which cannot be centered, operate with extra caution.
b.) Handle only loads within the capacity of the rough terrain forklift truck.
c.) Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity
with extra caution. Stability and maneuverability may be adversely affected.

IV
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

46.) When attachments are used, extra care shall be taken in securing, manipulating, positioning, and trans-
porting the load. Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks
when not handling a load.
47.) Completely engage the load with the load-engaging means. Fork length should be at least two-thirds of
load length. Where tilt is provided, carefully tilt the load backward to stabilize the load. Caution should be used
in tilting backward with high or segmented loads.
48.) Use extreme care when tilting load forward or backward, particularly when high tiering. Do not tilt forward
with load-engaging means elevated except to pick up or deposit a load over a rack or stack. When stacking
or tiering, use only enough backward tilt to stabilize the load.
49.) The handling of suspended loads by means of a crane arm (boom) or other device can introduce dynam-
ic forces affecting the stability of a rough terrain forklift truck. Grades and sudden starts, stops, and turns can
cause the load to swing and create a hazard if not externally stabilized. When handling suspended loads:
a.) do not exceed the truck manufacturer’s capacity of the rough terrain forklift truck as equipped
for handling suspended loads.
b.) only lift the load vertically and never drag it horizontally;
c.) transport the load with the bottom of the load and the mast as low as possible;
d.) with load elevated, maneuver the rough terrain forklift truck slowly and cautiously, and only to
the extent necessary to permit lowering to the transport position;
e.) use tag lines to restrain load swing whenever possible.
50.) At the beginning of each shift and before operating the rough terrain forklift truck, check its condition,
giving special attention to:
a.) tires and their inflation pressure
b.) warning devices
c.) lights
d.) lift and tilt systems, load-engaging means, chains, cables, and limit switches
e.) 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 opera-
tor shall not be on the rough terrain forklift
truck.
55.) Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced
before restarting engine.
56.) Do not use open flames when checking electrolyte level in storage batteries, liquid level in fuel tanks, or
the condition of LPG fuel lines and connectors.
57.) Do not lift personnel with the forklift. If the forklift must be used to lift people, precautions for the protec-
tion of the personnel must be taken (see ITSDF B56.6, chapter 5.15 Elevating Personnel).

V
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 miss-
ing, have them replaced immediately. Make sure all safety features provided by the original manufacturer are
in place and function properly. Do not operate a forklift with damaged, missing or unsafe components. Have
it repaired by authorized service personnel. Learn the functions of all controls, gauges, indicator lights, etc. on
the forklift. Know the speed/gear ranges, braking and steering capabilities, load ratings and clearances. When
referring to the location of forklift components, the terms “left”, “right”, “front”, and “rear” are related to the oper-
ator seated normally, facing forward in the operator’s seat. If you have any questions about the forklift, con-
sult your supervisor. Failure to fully understand or obey safety warnings can result in serious injury or death!

4.) WORK SITE KNOWLEDGE

Before operating on a work site, learn the rules for movement of people, forklifts and all other traffic. Check
the size, weight, and condition of the loads you will be expected to handle. Verify that they are properly
secured and safe to transport. Learn where the loads are to be placed, planning your route for a safe
approach, watching for hazardous conditions. Will a signal man be required to help place the load? Remove
any debris which may cause tire damage or rupture. Plan your route around problem areas or have them cor-
rected. Inform the supervisor of any unsafe conditions observed at the site. Examples of hazards: power
lines, cables, low clearance structures, garage doors, telephone pole guide lines, fencing, loose lumber, build-
ing materials, drop-offs, trenches, rough/soft spots, oil spills, deep mud, steep inclines, railroad tracks, curbs,
etc.. NEVER approach power lines, gas lines or other utilities with the forklift! Always verify that local,
state/provincial and federal regulations have been met. Report any accidents involving personnel, building
structures, and equipment to the supervisor immediately. Always remain alert - conditions are constantly
changing at the work site!

TECHNICAL SUPPORT
All data provided in this manual is subject to production changes, addition of new models, and improved prod-
uct designs. If a question arises regarding your forklift, please consult your dealer or Manitou-NA, 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
SAFETY DECALS

The purpose of this chapter is to introduce you to the safety messages, decals, and nameplates found on
your forklift truck. The decals are identified by name, part number, location, and a brief description. (The
forklift model logos, and other misc. decals not shown, can be found in your forklift parts manual.) The
decals illustrated may not be exactly the same as those installed on your forklift; installation of the decals
varies depending on the forklift model, series, decal updates, etc.. The size and location of some decals
limit the amount of information that can be placed upon it. For this reason, additional detailed information
not found on the decals is provided through-out this manual.

Every decal placed on the lift truck is important; they are constant reminders of safety and instructions that
should never be taken for granted. Even experienced operators can be seriously injured or killed by ignor-
ing, refusing to enforce, or forgetting to follow safe operating procedures! Do not assume you know all safe-
ty issues concerning the decals. Before operating the lift truck; learn the meaning(s) of the decals as
described in this manual. If any decal becomes illegible or missing, have it replaced immediately! Always
replace decals using the same decal part no., unless otherwise specified by the manufacturer. For replace-
ment decals not found in your parts manual, contact your nearest dealer. If you have any questions, contact
your supervisor or nearest dealer for advice before operating your forklift!

801011

Before Starting - 801011

(Boom equipped models). Location: on the brake fluid cover panel (to
the left and below the dash panel).

Safety Instructions - 420792

(Mast equipped models). Location: on or near the operator manual
storage case, and/or on the dash panel.

Instructions for the forklift operator; before operating the forklift.

Use of Seat Belt - 801012

(Boom equipped models). Location: to the right of the
operator, near the hydraulic control lever.

Instructs the operator to always wear the seat belt during

operations, and never jump from an over-turning forklift.

X
SAFETY DECALS

Emergency and Parking Brake - 801010

Location: near the park brake lever.

Identifies the Emergency/Parking Brake Lever.

Alarm Must Sound - 496162

Location: on the dash, in direct view of the operator.

The backup alarm must sound when the forklift is placed in reverse gear.

No Riders - 420732
Location: on the cab entrance(s), and on or near wheel fenders and engine
cover.

Informs: riders are not allowed on the forklift.

Clear of Raised Boom - 801006

(Boom equipped models). Location: on both sides
of the boom nose.

Keep away from unsupported boom.

Clear of Power Lines - 801007

(Boom equipped models). Location: on both sides
of the boom nose.

Keep away from power lines.

XI
SAFETY DECALS

Use of Frame Leveling - 801013

(Boom equipped models). Location: to the right of
the operator near the hydraulic control lever.

Frame leveling notice; load must be lowered.

Attachment and Boom Safety - 801009

(Boom equipped models). Location: on both sides of the
boom nose.

Important reminders of attachment and boom safety.

Hydraulic Coupling - 234805

Location: near the quick-disconnect adapters.

Stop the engine and release hydraulic pressure before changing

attachments.

Rotating Fan and Belt(s) - 801008

Location: on the radiator near the fan, and on any fan belt/pulley cover(s).

Keep hands and clothing away from rotating fan and belts.

XII
SAFETY DECALS

Gear Shift Pattern - 33460

(4-speed transmission models). Location: near the gear shift lever.

Identifies the gear shift pattern of the forklift transmission.

Steering Mode - 184276

(4 wheel steer equipped models). Location: near the steering mode selection lever.

Identifies the steering mode selection.

221322

Mineral Oil (Brake Reservoir) - 221322 or 234800 has

been replaced by 164091.
Location: near the brake fluid reservoir where applicable.

Refer to the Operator/Service Manual for the correct brake fluid

(mineral oil) to be used in the brake system.

234800

XIII
SAFETY DECALS

Hydraulic Oil - 234798 or 76573

Location: on the hydraulic tank or filler cap.

Identifies the hydraulic reservoir (tank) or filler cap.

Hydraulic Oil - 61024

Location: on the hydraulic tank.

Identifies the hydraulic reservoir (tank).

Anti-Freeze - 234799
Location: on the radiator, near the radiator filler cap.

Indicates required minimum to maximum anti-freeze protection (-220F to -400F).

Diesel Fuel - 161101

Location: on the fuel tank, near the filler cap.

Identifies the fuel tank, and use of diesel fuel.

No Step - 496735
Location: varies, depending on the forklift model.

Instructs personnel not to use the designated area as a step.

Do Not Tow - 494918

(Hydrostatic equipped models). Location: on the
dash, in view of the operator.

Towing the forklift will damage the transmission;

refer to the operator’s manual.

XIV
SAFETY DECALS

Attachment Warning - 421016

(Boom equipped models). Location: on the boom coupler,
near where the retaining shaft is installed.

Reminder to operator; install attachment retaining shaft and

safety pin before operations.

Hook Here - 24653

Location: at points provided on the forklift, where straps or chains may be attached to
secure the forklift to a trailer during transport.

Fork Safety - 426641

(Mast equipped models). Location: on the front and back side of the mast’s outer rails,
at eye level (4 required).

Instructs personnel not to travel beneath or upon the lift truck forks.

Pinch Point, Large, 2.5 x 4.5 in. - 426643

Pinch Point, Small, 1.5 x 2.75 in. - 426642
(Mast equipped models). Location: on the front and rear sides
of the mast cross bracing.

Keep fingers away from the mast

crossbracing.

HAND THROTTLE DANGER - 804784

(Boom equipped models, option). Location: Near the hand throttle mechanism.

Reminder to operator; set parking brake before operating hand throttle.

Disengage hand throttle before leaving the forklift.

XV
SAFETY DECALS

Acid in Battery - 801014

Location: in or near the battery
storage compartment.

Addresses battery hazards.

Jump Start Battery - 801015

Location: in or near the battery storage
compartment.

Jump start instructions.

Attachment Plate - 425995

Location: on the optional removeable forklift attachment.

Important manufacturer information about the attachment. Record this information for use
when contacting the maufacturer for parts and service.

Overhead Guard Data Plate - B6109

Location: attached to the overhead guard.

Overhead guard conformity.

496550 283688
Forklift Data Plate - 496550
(Boom equipped models)
Forklift Data Plate - 283688 MANITOU BF 44158 ANCENIS CEDEX FRANCE

MODELE MODELLO SERIE SERIE

MODEL MODELO SERIES SERIE

Location: within the operator’s compartment.

Année de fabrication N° de série Numero di serie
Year of manufacture Serial Nr Número de serie
Anno di fabbricazione
Año de fabricacion

Important forklift truck identification. Record Masse à vide

Unladen mass
Massa a vuoto
Masa en vacio

this information for use when contacting the Puissance ISO/TR14396

Power ISO/TR14396
Potenza ISO/TR14396
kg

manufacturer for parts and service. Potencia ISO/TR14396

kW
Numéro d'homologation
Homologation number
Numero d'omologazione
Contraseña homologacion

Effort vertical max. (sur accrochage remorque)

Vertical max. effort (on trailer hook)
Carico max. verticale (sul gancio di traino)
Esfuerzo vertical max. (sobre el gancho de remolque) Capacité maxi nominale
Nominal maximum capacity
daN Capacità maxi nominale
Capacidad máximo nominal

Pression des pneumatiques (Bar) kg

Tyre pressure (Bar)
Pressione per pneumatici (Bar)
Presion de los neumáticos (Bar) Effort de traction
Tractive effort
Avant Anteriore Arrière Posteriore Forza di traino
Front Adelante Rear Trasero Esfuerzo de traccion

daN

N°283688

XVI
CONTENTS

1 - OPERATING
AND SAFETY
INSTRUCTIONS

1-1
1-2
 TABLE OF CONTENTS

INSTRUCTIONS TO THE COMPANY MANAGER 1-4

THE SITE 1-4
THE OPERATOR 1-4
THE LIFT TRUCK 1-4
A - THE LIFT TRUCK’S SUITABILITY FOR THE JOB 1-4
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS 1-4
C - MODIFICATION OF THE LIFT TRUCK 1-5
D - FRENCH ROAD TRAFFIC RULES (or see current legislation in other countries) 1-5
THE INSTRUCTIONS 1-5
THE MAINTENANCE 1-5

INSTRUCTIONS FOR THE OPERATOR 1-6

PREAMBULE 1-6
GENERAL INSTRUCTIONS 1-6
A - OPERATOR’S MANUAL 1-6
B - AUTHORIZATION FOR USE IN FRANCE (or see current legislation in other countries) 1-6
C - MAINTENANCE 1-6
D - MODIFICATION OF THE LIFT TRUCK 1-6
E - LIFTING PEOPLE 1-7
OPERATING INSTRUCTIONS UNLADEN AND LADEN 1-8
A - BEFORE STARTING THE LIFT TRUCK 1-8
B - DRIVER’S OPERATING INSTRUCTIONS 1-8
C - ENVIRONMENT 1-9
D - VISIBILITY 1-9
E - STARTING THE LIFT TRUCK 1 - 10
F - DRIVING THE LIFT TRUCK 1 - 10
G - STOPPING THE LIFT TRUCK 1 - 11
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY (or see current legislation in other countries) 1 - 12
INSTRUCTIONS FOR HANDLING A LOAD 1 - 14
A - CHOICE OF ATTACHMENTS 1 - 14
B - MASS OF LOAD AND CENTRE OF GRAVITY 1 - 14
C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE 1 - 14
D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK 1 - 15
E - TAKING UP A LOAD ON THE GROUND 1 - 15
F - TAKING UP AND LAYING A HIGH LOAD ON TYRES 1 - 16
G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS 1 - 18
H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD 1 - 20
I - TRAVELLING WITH A SUSPENDED LOAD 1 - 20
PLATFORM OPERATING INSTRUCTIONS 1 - 21
A - AUTHORISATION FOR USE 1 - 21
B - SUITABILITY OF THE PLATFORM FOR THE JOB 1 - 21
C - PRECAUTIONS WHEN USING THE PLATFORM 1 - 21
D - USING THE PLATFORM 1 - 21
E - ENVIRONMENT 1 - 21
F - MAINTENANCE 1 - 22
INSTRUCTIONS FOR USING THE RADIO-CONTROL 1 - 23

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 - 24

GENERAL INSTRUCTIONS 1 - 24
MAINTENANCE 1 - 24
LUBRICANT AND FUEL LEVELS 1 - 24
HYDRAULIC 1 - 24
ELECTRICITY 1 - 24
WELDING 1 - 25
WASHING THE LIFT TRUCK 1 - 25

IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME 1 - 26

INTRODUCTION 1 - 26
PREPARING THE LIFT TRUCK 1 - 26
PROTECTING THE I.C. ENGINE 1 - 26
PROTECTING THE LIFT TRUCK 1 - 26
BRINGING THE LIFT TRUCK BACK INTO SERVICE 1 - 27

1-3
 INSTRUCTIONS TO THE COMPANY MANAGER

THE SITE
- Proper management of lift truck’s area of travel will reduce the risk of accidents:
. ground not unnecessarily uneven or obstructed,
. no excessive slopes,
. pedestrian traffic controlled, etc.

THE OPERATOR
- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment with respect to the use of lift trucks and must be carried permanently by the operator.
On the basis of experience, there are a number of possible situations in which operating the lift truck is contra-indicated. Such foreseeable abnormal
uses, the main ones being listed below, are strictly forbidden.
- The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any wish to put the machinery to any improper use.
- The reflex reactions of a person in the event of a malfunction, incident, fault, etc. during operation of the lift truck.
- Behaviour resulting from application of the «principle of least action» when performing a task.
- For certain machines, the foreseeable behaviour of such persons as: apprentices, teenagers, handicapped persons, trainees tempted to drive a
lift truck, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.
The person in charge of the equipment must take these criteria into account when assessing whether or not a person will makea suitable driver.

THE LIFT TRUCK

A - THE TRUCK’S SUITABILITY FOR THE JOB
- MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator’s
manual, in accordance to ASME B56.6 - 2002
- Before commissioning, the company manager must make sure that the lift truck is appropriate for the work to be done, and
perform certain tests (in accordance with current legislation).

B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS

- In addition to series equipment mounted on your lift truck, many options are available, such as: road lighting, stop lights, flashing
light, reverse lights, reverse buzzer alarm, front light, rear light, light at the jib head, etc… (as model of lift truck).
- The operator must take into account the operating conditions to define the lift truck’s signalling and lighting equipment.
Contact your dealer.
- Take into account climatic and atmospheric conditions of the site of utilisation.
. Protection against frost (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
. Adaptation of lubricants (ask your dealer for information).
. I.C. engine filtration (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).

For operation under average climatic conditions, i.e.: between - 15 °C and + 35 °C, 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.
- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are
solutions, consult your dealer.
Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated premises. It is prohibited
to use the lift truck in areas where there is a risk of fire or which are potentially explosive (e.g. Refineries, fuel or gas depots, stores of inflammable
products…). For use in these areas, specific equipment is available (ask your dealer for information).
- Our trucks comply with Directive 2004/108/EC concerning electromagnetic compatibility (EMC), and with the corresponding
harmonized norm EN 12895. Their proper operation is no longer guaranteed if they are used within areas in which the
electromagnetic fields exceed the limit specified by that norm (10 V/m).
- Directive 2002/44/EC requires company managers to not expose their employees to excessive vibration doses. There is no
recognized code of measurement for comparing the machines of different manufacturers. The actual doses received can therefore
be measured only under actual operating conditions at the user's premises.
- The following are some tips for minimizing these vibration doses:
• Select the most suitable lift truck and attachment for the intended use.
• Adapt the seat adjustment to the operator's weight (according to lift truck model) and maintain it in good condition, as
well as the cab suspension. Inflate the tires in accordance with recommendations.
• Ensure that the operators adapt their operating speed to suit the conditions on site.
• As far as possible, arrange the site in such a way as to provide a flat running surface and remove obstacles and harmful
potholes.

1-4
C - MODIFICATION OF THE LIFT TRUCK
- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.

D - FRENCH ROAD TRAFFIC RULES

(or see current legislation in other countries)
- Only one certificate of conformity is issued. It must be kept in a safe place.

THE INSTRUCTIONS
- The operator’s manual must always be in good condition and kept in the place provided on the lift truck and in the language used
by the operator.
- The operator’s manual and any plates or stickers which are no longer legible or are damaged, must be replaced immediately.

THE MAINTENANCE
- Maintenance or repairs other than those detailed in part: 3 - MAINTENANCE must be carried out by qualified personnel (consult
your dealer) and under the necessary safety conditions to maintain the health of the operator and any third party.
Your lift truck must be inspected periodically to ensure that it remains in compliance. The frequency of this inspection is defined by current legislation in
the country in which the lift truck is used.

1-5
 INSTRUCTIONS FOR THE OPERATOR

PREAMBLE
WHENEVER YOU SEE THIS SYMBOL IT MEANS:

WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK.
The risk of accident while using, servicing or repairing your lift truck can be restricted if you follow the safety instructions and safety measures detailed
in these instruction.
- Only the operations and manœuvres described in these operator’s manual must be performed. The manufacturer cannot predict
all possible risky situations. Consequently, the safety instructions given in the operator’s manual and on the lift truck itself are
not exhaustive.
- At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself
when you use it.
Failure to respect the safety and operating instructions, or the instructions for repairing or servicing your lift truck may lead to serious, even fatal
accident.

GENERAL INSTRUCTIONS
A - OPERATOR’S MANUAL
- Read the operator’s manual carefully.
- The operator’s manual must always be in good condition and in the place provided for it on the lift truck.
- You must report any plates and stickers which are no longer legible or which are damaged.

B - AUTHORISATION FOR USE IN FRANCE

(or see current legislation in other countries)
- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment with respect to the use of lift trucks and must be carried permanently by the operator.
- The operator is not competent to authorise the driving of the lift truck by another person.

C - MAINTENANCE
- The operator must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety
notice.
- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He must
keep the lift truck properly cleaned if this is among his responsibilities.
- The operator must carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- The operator must ensure tyres are adapted to the nature of the ground (see area of the contact surface of the tyres in the
chapter: 2 - DESCRIPTION: FRONT AND REAR TYRES). There are optional solutions, consult your dealer.
. SAND tyres.
. LAND tyres.
. Snow chains.
Do not use the lift truck if the tyres are incorrectly inflated, damaged or excessively worn, because this could put your own safety or that of others at
risk, or cause damage to the lift truck itself. The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer, excepting prior
authorisation.

D - MODIFICATION OF THE LIFT TRUCK

- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.

1-6
E - LIFTING PEOPLE
- The use of working equipment and load lifting attachments to lift people is:
• either forbidden
• or authorized exceptionally and under certain conditions (see current regulations
in the country in which the lift truck is used).
- The pictogram posted at the operator station reminds you that:
• Left-hand column
- It is forbidden to lift people, with any kind of attachment, using a non PLATFORM-
fitted lift truck.
• Right-hand column
- With a PLATFORM-fitted lift truck, people can only be lifted using platforms
designed by MANITOU for the purpose.
- MANITOU sells equipment specifically designed for lifting people (OPTION PLATFORM
lift truck, contact your dealer).

1-7
OPERATING INSTRUCTIONS UNLADEN AND LADEN
A - BEFORE STARTING THE LIFT TRUCK
- Carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Make sure the lights, indicators and windscreen wipers are working properly.
- Make sure the rear view mirrors are in good condition, clean and properly adjusted.
- Make sure the horn works.

B - DRIVER’S OPERATING INSTRUCTIONS

- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and
instruments before operating the lift truck.
- Wear clothes suited for driving the lift truck, avoid loose clothes.
- Make sure you have the appropriate protective equipment for the job to be done.
- Prolonged exposure to high noise levels may cause hearing problems. It is recommended to wear ear muffs to protect against
excessive noise.
- Always face the lift truck when getting into and leaving the driving seat and use the handle(s) provided for this purpose. Do not
jump out of the seat to get down.
- Always pay attention when using the lift truck. Do not listen to the radio or music using headphones or earphones.
- Never operate the lift truck when hands or feet are wet or soiled with greasy substances.
- For increased comfort, adjust the seat to your requirements and adopt the correct position in the driver’s cab.

Under no circumstances must the seat be adjusted while the lift truck is moving.
- The operator must always be in his normal position in the driver’s cab. It is prohibited to have arms or legs, or generally any part
of the body, protruding from the driver’s cab of the lift truck.
- The safety belt must be worn and adjusted to the operator’s size.
- The control units must never in any event be used for any other than their intended purposes (e.g. climbing onto or down from the
lift truck, portmanteau, etc.).
- If the control components are fitted with a forced operation (lever lock) device, it is forbidden to leave the cab without first putting
these controls in neutral.
- It is prohibited to carry passengers either on the lift truck or in the cab.

1-8
C - ENVIRONMENT
- Comply with site safety regulations.
- If you have to use the lift truck in a dark area or at night, make sure it is equipped with working lights.
- During handling operations, make sure that no one is in the way of the lift truck and its load.
- Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load.
- When using the lift truck on a transverse slope, before lifting the jib, follow the instructions given in the paragraph: INSTRUCTIONS
FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK.
- 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.

- Take into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passageway.
- 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 (wagon, lorry, 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 size 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.
- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.
- Make sure the ground is stable and firm under the wheels and/or stabilizers before lifting or removing the load. If necessary, add
sufficient wedging under the stabilizers.
- Make sure that the scaffolding, loading platform, pilings or ground is capable of bearing the load.
- Never stack loads on uneven ground, they may tip over.
If the load or the attachment must remain above a structure for a long time, there is the risk that it will rest on the structure because of the jib
descending owing to the oil in the cylinders cooling down.
To eliminate this risk:
- Regularly check the distance between the load or the attachment and the structure and readjust this if necessary.
- If possible use the lift truck at an oil temperature as close as possible to ambient temperature.
- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and
the aerial line.
You must consult your local electrical agency. You could be electrocuted or seriously injured if you operate or park the lift truck too close to power
cables.

In the event of high winds, 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.

D - VISIBILITY
- The safety of people within the lift truck’s working area, as well as that of the lift truck itself and the operator are depend on good
operator visibility of the lift truck’s immediate vicinity in all situations and at all times.
- This lift truck has been designed to allow good operator visibility (direct or indirect by means of rear-view mirrors) of the immediate
vicinity of the lift truck while traveling with no load and with the jib in the transport position.
- Special precautions must be taken if the size of the load restricts visibility towards the front:
- moving in reverse,
- site layout,
- assisted by a person directing the maneuver (while standing outside the truck’s area of travel), making sure to keep this
person clearly in view at all times.
- in any case, avoid reversing over long distances.
- Certain special accessories may require the truck to travel with the jib in the raised position. In such cases, visibility on the right
hand side is restricted, and special precautions must be taken:
- site layout,
- assisted by a person directing the maneuver (while standing outside the truck’s area of travel).
- If visibility of your road is inadequate, ask someone to assist by directing the maneuver (while standing outside the truck’s area
of travel), making sure to keep this person clearly in view at all times.
- Keep all components affecting visibility in a clean, properly adjusted state and in good working order (e.g. windscreens, windows,
windscreen wipers, windscreen washers, driving and work lights, rear-view mirrors).

1-9
E - STARTING THE LIFT TRUCK
SAFETY INSTRUCTIONS

The lift truck must only be started up or maneuvered when the operator is sitting in the driver’s cab, with his seat belt adjusted and fastened.
- Never try to start the lift truck by pushing or towing it. Such operation may cause severe damage to the transmission. If necessary,
to tow the lift truck in an emergency, the transmission must be placed in the neutral position (see: 3 - MAINTENANCE: G -
OCCASIONAL MAINTENANCE).
- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connecting
it. Connect at first the positive terminals before the negative terminals.
Failure to respect polarity between batteries can cause serious damage to the electrical circuit. The electrolyte in the battery may produce an explosive
gas. Avoid flames and generation of sparks close to the batteries. Never disconnect a battery while it is charging.
INSTRUCTIONS
- Check the closing and locking of the hood(s).
- Check that the cab door is closed.
- Check that the forward/reverse selector is in neutral.
- Turn the ignition key to the position I to activate the electrical system and the preheat.
- Whenever you switch on the lift truck, perform the automatic check on the longitudinal stability limiter and warning device system
(see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS). Do not use the lift truck if it does not conform to the regulations.
- Check the fuel level on the indicator.
- Turn the ignition key fully: the I.C. engine should then start. Release the ignition key and let the I.C. engine run at idle.
- Do not engage the starter motor for more than 15 seconds and carry out the preheating between unsuccessful attempts.
- Make sure all the signal lights on the control instrument panel are off.
- Check all control instruments when the I.C. engine is warm and at regular intervals during use, so as to quickly detect any faults
and to be able to correct them without any delay.
- If an instrument does not show the correct display, stop the I.C. engine and immediately carry out the necessary operations.

F - DRIVING THE LIFT TRUCK

SAFETY INSTRUCTIONS
Operators’ attention is drawn to the risks involved in using the lift truck, in particular:
- Risk of losing control.
- Risk of losing lateral and frontal stability of the lift truck.
The operator must remain in control of the lift truck.
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.
- Observe the company’s traffic regulations or, by default, the public highway code.
- Do not carry out operations which exceed the capacities of your lift truck or attachments.
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 300 mm from the ground, the jib retracted
and the carriage sloping backwards.
- Only carry loads which are balanced and properly anchored to avoid any risk of a load falling off.
- Ensure that palettes, cases, etc, are in good order and suitable for the load to be lifted.
- Familiarise yourself with the lift truck on the terrain where it will be used.
- Ensure that the service brakes are working properly.
- The loaded lift truck must not travel at speeds in excess of 12 km/h.
- Drive smoothly at an appropriate speed for the operating conditions (land configuration, load on the lift truck).
- Do not use the hydraulic jib controls when the lift truck is moving.
- Never change the steering mode whilst driving.
- Do not manoeuvre the lift truck with the jib 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.
- Take bends slowly.
- 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 selector from a stationary position and never do so abruptly.
- Do not drive with your foot on the brake pedal.
- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, so turn it gently and
not jerkily.
- Never leave the I.C. engine on when the lift truck is unattended.
- Do not leave the cab when the lift truck has a raised load.
- Look where you are going and always make sure you have good visibility along the route.

1-10
- Use the rear-view mirrors frequently.
- Drive round obstacles.
- Never drive on the edge of a ditch or steep slope.
- It is dangerous to use two lift trucks simultaneously to handle heavy or voluminous loads, since this operation requires particular
precautions to be taken. It must only be used exceptionally and after risk analysis.
- The ignition switch has an emergency stop mechanism in case of an operating anomaly occurring in the case of lift trucks not fitted
with a punch-operated cut-out.

INSTRUCTIONS
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 300 mm from the ground, the jib retracted
and the carriage sloping backwards.
- For lift trucks with gearboxes, use the recommended gear (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
- Select the steering mode appropriate for its use and/or working conditions (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS)
(as model of lift truck).
- Release the parking brake.
- Shift the forward/reverse selector to the selected direction of travel and accelerate gradually until the lift truck moves off.

G - STOPPING THE LIFT TRUCK

SAFETY INSTRUCTIONS
- Never leave the ignition key in the lift truck during the operator’s absence.
- When the lift truck is stationary, or if the operator has to leave his cab (even for a moment), place the forks or attachment on the
ground, apply the parking brake and place the forward/reverse selector 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 one meter 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 and lock all the lift truck accesses (doors, windows, cowls…).

INSTRUCTIONS
- Park the lift truck on flat ground or on an incline lower than 15 %.
- Set the forward/reverse selector to neutral.
- Apply the parking brake.
- For lift trucks with gearboxes, place the gear lever in neutral.
- Retract entirely the jib.
- Lower the forks or attachment to rest on the ground.
- When using an attachment with a grab or jaws, or a bucket with hydraulic opening, close the attachment fully.
- 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 I.C. engine and transmission. Do not forget this precaution, in the event of frequent stops
or warm stalling of the I.C. 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.
- Stop the I.C. engine with the ignition switch.
- Remove the ignition key.
- Lock all the accesses to the lift truck (doors, windows, cowls…).

1-11
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY
(or see current legislation in other countries)

SAFETY INSTRUCTIONS
- Operators driving on the public highway must comply with current highway code legislation.
- The lift truck must comply with current road legislation. If necessary, there are optional solutions. Contact your dealer.

INSTRUCTIONS
- Make sure the revolving light is in place, switch it on and verify its operation.
- Make sure the lights, indicators and windscreen wipers are working properly.
- Switch off the working headlights if the lift truck is fitted with them.
- Select the steering mode “HIGHWAY TRAFFIC” (as model of lift truck) (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
- Retract entirely the jib and put the attachment at 300 mm from the ground.
- Place the slope correctors in the central position, i.e. the transverse shaft of the axles parallel to the chassis (as model of lift truck).
- Lift up the stabilizers to the maximum and turn the blocks inwards (as model of lift truck).
Never move in neutral (forward/reverse selector or gear lever in neutral or transmission cut-off button pressed) to preserve the lift truck engine brake.
Failure to respect this instruction on a slope will lead to excessive speed which may make the lift truck uncontrollable (steering, brakes) and cause
serious mechanical damage.

1-12
DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT
- You must comply with current regulations in your country, covering the possibility of driving on the public highway with a front-
mounted attachment on your lift truck.
- If road legislation in your country authorizes circulation with a front-mounted attachment, you must at least:
• Protect and report any sharp and/or dangerous edges on the attachment (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION
ON THE RANGE: ATTACHMENT SHIELDS).
• The attachment must not be loaded.
• Make sure that the attachment does not mask the lighting range of the forward lights.
• Make sure that current legislation in your country does not require other obligations.

OPERATING THE LIFT TRUCK WITH A TRAILER

- For using a trailer, observe the regulations in force in your country (maximum travel speed, braking, maximum weight of trailer, etc.).
- Do not forget to connect the trailer’s electrical equipment to that of the lift truck.
- The trailer’s braking system must comply with current legislation.
- If pulling a trailer with assisted braking, the tractor lift truck must be equipped with a trailer braking mechanism. In this case, do
not forget to connect the trailer braking equipment to the lift truck.
- The vertical force on the towing hook must not exceed the maximum authorised by the manufacturer (consult the manufacturer’s
plate on your lift truck).
- The authorised gross vehicle weight must not exceed the maximum weight authorised by the manufacturer (see: 2 - DESCRIPTION:
CHARACTERISTICS).

IF NECESSARY, CONSULT YOUR DEALER.

1-13
INSTRUCTIONS FOR HANDLING A LOAD
A - CHOICE OF ATTACHMENTS
- Only attachments approved by MANITOU can be used on its lift trucks.
- Make sure the attachment is appropriate for the work to be done (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE).
- If the lift truck is equipped with the Single side-shift carriage OPTION (TSDL), use only the authorised attachments (see: 4 - ADAPTABLE
ATTACHMENTS IN OPTION ON THE RANGE).
- Make sure the attachment is correctly installed and locked onto the lift truck carriage.
- Make sure that your lift truck attachments work properly.
- Comply with the load chart limits for the lift truck for the attachment used.
- Do not exceed the rated capacity of the attachment.
- Never lift a load in a sling without the attachment provided for the purpose, as the sling risks to slip (see: INSTRUCTIONS FOR
HANDLING A LOAD: H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD).

B - MASS OF LOAD AND CENTRE OF GRAVITY B1

- Before taking up a load, you must know its mass and its centre of gravity.
- The load chart for your lift truck is valid for a load in which the longitudinal position of the
centre of gravity is 500 mm from the base of the forks (fig. B1). For a higher centre of
gravity, contact your dealer.
- For irregular loads, determine the transverse centre of gravity before any movement (fig. 500 mm

B2) and set it in the longitudinal axis of the lift truck.

It is forbidden to move a load heavier than the effective capacity defined on the lift truck load chart.

For loads with a moving centre of gravity (e.g. liquids), take account of the variations in the centre of
gravity in order to determine the load to be handled and be vigilant and take extra care to limit these
variations as far as possible.

B2

C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE

This device gives an indication of the longitudinal stability of the lift truck, and limits C
hydraulic movements in order to ensure this stability, at least under the following operating
conditions:
• when the lift truck is at a standstill, 1
• when the lift truck is on firm, stable and consolidated ground, 2
• when the lift truck is performing handling and placing operations.
3
- Move the jib very carefully when approaching the authorized load limit (see: 2 - DESCRIPTION:
INSTRUMENTS AND CONTROLS).
- Always watch this device during handling operations.
- In the event that "AGGRAVATING" hydraulic movements are cut-off, only perform
de-aggravating hydraulic movements in the following order (fig. C): if necessary, raise the
jib (1), retract the jib as far as possible (2) and lower the jib (3) to set down the load.
The instrument reading may be erroneous when the steering is at its maximum limit or the rear axle
oscillated to its limit. Before lifting a load, make sure that the lift truck is not in either of these
situations.

1-14
D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK D1
Depending on the model of lift truck

The transverse attitude is the transverse slope of the chassis with respect to the
horizontal.
Raising the jib reduces the lift truck’s lateral stability. The transverse attitude must be set
with the jib in down position as follows:

1 - LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TYRES

- Position the lift truck so that the bubble in the level is between the two lines (see: 2 -
DESCRIPTION: INSTRUMENTS AND CONTROLS).

2 - LIFT TRUCK WITH SLOPE CORRECTOR USED ON TYRES

- Correct the slope using the hydraulic control and verify the horizontality via the level. The D2
bubble in the level must be between the two lines (see: 2 - DESCRIPTION: INSTRUMENTS
AND CONTROLS).

3 - LIFT TRUCK USED ON STABILIZERS

- Set the two stabilizers on the ground and raise the two front wheels of the lift truck (fig. D1).
- Correct the slope using the stabilizers (fig. D2) and make sure the truck is horizontal
by checking the level. The bubble of the level must be between the two lines (see: 2
- DESCRIPTION: INSTRUMENTS AND CONTROLS). In this position, the two front wheels
must be off the ground.

E - TAKING UP A LOAD ON THE GROUND

- Approach the lift truck perpendicular to the load, with the jib retracted and the forks in a horizontal position (fig. E1).
- Adjust the fork spread and centering in connection with the load (fig. E2) (optional solutions
exist, consult your dealer). E1
- Never lift a load with a single fork.

Beware of the risks of trapping or squashing limbs when manually adjusting the forks.
- Move the lift truck forward slowly (1) and bring the forks to stop in front of the load (fig.
E3), if necessary, slightly lift the jib (2) while taking up the load.
- Bring the load into the transport position.
- Tilt the load far enough backwards to ensure stability (loss of load on braking or going
downhill).

FOR A NON-PALLETIZED LOAD

- Tilt the carriage (1) forwards and move the lift truck slowly forwards (2), to insert the fork
under the load (fig. E4) (block the load if necessary).
- Continue to move the lift truck forwards (2) tilting the carriage (3) (fig. E4) backwards to
position the load on the forks and check the load’s longitudinal and lateral stability. E2

E3 E4

1
2
2
1
3

1-15
F - TAKING UP AND LAYING A HIGH LOAD ON TYRES F1
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see:
INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK).
REMINDER: Make sure that the following operations can be performed with good visibility
2
(see: OPERATIONS INSTRUCTIONS UNLADEN AND LADEN: D - VISIBILITY).
1

TAKING UP A HIGH LOAD ON TYRES

- Ensure that the forks will easily pass under the load. 3
- Lift and extend the jib (1) (2) until the forks are level with the load, moving the lift truck (3)
forward if necessary (fig. F1), moving very slowly and carefully.
- Always think about keeping the distance necessary to fit the forks under the load, between
the pile and the lift truck (fig. F1) and use the shortest possible length of jib.
- Stop the forks in front of the load by alternately extending and retracting the jib (1) or, if
necessary, moving the lift truck forward (2) (fig. F2). Put the handbrake on and set the
forward/reverse selector to neutral. F2
- Slightly lift the load (1) and incline the carriage (2) backwards to stabilize the load (fig. F3).
- Tilt the load sufficiently backwards to ensure its stability.
1
- Watch the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR
HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE). If it is
overloaded, replace the load in the place from which it was taken.
- If possible lower the load without shifting the lift truck. Lift the jib (1) to release the load,
retract (2) and lower the jib (3) to bring the load into the transport position (fig. F4).
2
- If this is not possible, back up the lift truck (1), manoeuvring very gently and carefully to
release the load. Retract (2) and lower the jib (3) to bring the load into the transport position
(fig. F5).

F3
2

F4
1

F5

1-16
LAYING A HIGH LOAD ON TYRES F6
- Approach the load in the transport position in front of the pile (fig. F6).
- Put the handbrake on and set the forward/reverse selector to neutral.
- Lift and extend the jib (1) (2) until the load is above the pile, while keeping an eye on the
longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR HANDLING A
LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE). If necessary, move
the lift truck (3) forward (fig. F7), driving very slowly and carefully.
- Place the load in a horizontal position and lay it down on the pile by lowering and retracting
the jib (1) (2) in order to position the load correctly (fig. F8).
- If possible, release the fork by alternately retracting and raising the jib (1) (fig. F9). Then set
the forks into transport position.
- If this is not possible, reverse the lift truck (1) very slowly and carefully to release the
forks (fig. F10). Then set them into transport position.

F7

F8

F9

F10

1-17
G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS
Depending on the model of lift truck
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see: INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE
ATTITUDE OF THE LIFT TRUCK).
REMINDER: Make sure that the following operations can be performed with good visibility (see: OPERATIONS INSTRUCTIONS UNLADEN
AND LADEN: D - VISIBILITY).

USING THE STABILIZERS

The stabilizers are used to optimise the lift truck’s lifting performances (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).

POSITION THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION (UNLADEN AND LADEN) G1
- Set the forks in transport position in front of the elevation.
- Stay far enough away to have room for the jib to be raised.
- Put the handbrake on and put the gearshift lever into neutral.
- Set the two stabilizers on the ground and lift the two front wheels of the lift truck (fig. G1),
while maintaining its transverse stability.

RAISE THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION (UNLADEN AND LADEN)
- Raise both stabilizers fully and at the same time.

SETTING THE STABILIZERS WITH THE JIB UP (UNLADEN AND LADEN)

G2
This operation must be exceptional and performed with great care.
- Raise the jib and retract the telescopes completely.
- Set the lift truck in position in front of the elevation (fig. G2) moving very slowly and
carefully.
- Put the handbrake on and put the gearshift lever into neutral.
- Move the stabilizers very slowly and gradually as soon as they are close to the ground or
in contact with it.
- Lower the two stabilizers and lift the two front wheels of the lift truck (fig. G3). During this
operation, transverse attitude must be permanently maintained: the bubble in the level
must be kept between the two lines.

SETTING THE STABILIZERS WITH THE JIB UP (UNLADEN AND LADEN)

G3
This operation must be exceptional and performed with great care.
- Keep the jib up and retract the telescopes completely (fig. G3).
- Move the stabilizers very slowly and gradually as soon as they are in contact with the
ground and when they leave the ground. During this operation, the transverse attitude
must be permanently maintained: the bubble in the level must be kept between the two
lines.
- Raise both stabilizers completely.
- Release the parking brake and reverse the lift truck (1) very slowly and carefully, to
release it and lower the forks (2) into transport position (fig. G4).

G4

1-18
TAKING UP A HIGH LOAD ON STABILIZERS G5
- Make sure the forks will fit easily under the load.
- Check the position of the lift truck with respect to the load and make a test run, if
necessary, without taking the load.
- Raise and extend the jib (1) (2) until the forks are at the level of the load (fig. G5).
2
- Block the forks in front of the load by alternately using the controls to extend and lower 1
the jib (1) (fig. G6).
- Lift the load slightly (1) and tilt the carriage (2) backwards to stabilise the load (fig. G7).
- Monitor the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR
HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE). If it is
overloaded, set the load down in the place from where it was taken.
- If possible lower the load without moving the lift truck. Raise the jib (1) to release the load,
retract (2) and lower the jib (3) to set the load into transport position (fig. G8).

G6

G7 G8
2
1

2
1

LAYING A HIGH LOAD ON STABILIZERS

- Raise and extend the jib (1) (2) until the load is above the elevation (fig. G9), while G9
monitoring the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR
HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE).
- Position the load horizontally and release it by lowering and retracting the jib (1) (2) to 2
position the load correctly (fig. G10).
- Release the forks by alternating retracting and raising the jib (3) (fig. G11).
- If possible, set the jib in transport position without moving the lift truck. 1

G10 G11

1
3

1-19
H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD

WARNING: Failure to follow the above instructions may lead the lift truck to loose stability and overturn.

MUST be used with a lift truck equipped with an operational hydraulic movement cut-out device.

CONDITIONS OF USE
- The length of the sling or the chain shall be as short as possible to limit swinging of the load.
- Lift the load vertically along its axis, never by pulling sideways or lengthways.

HANDLING WITHOUT MOVING THE LIFT TRUCK

- Whether on stabilisers or on tyres, the lateral attitude must not exceed 1 % and the longitudinal attitude must not exceed 5%, the
bubble of the level must be held at “0”.
- Ensure that the wind speed is not higher than 10 m/s.
- Ensure that there is no one between the load and the lift truck.

I - TRAVELLING WITH A SUSPENDED LOAD

- Before moving, inspect the terrain in order to avoid excessive slopes and cross-falls, bumps and potholes, or soft ground.
- Ensure that the wind speed is not higher than 10 m/s.
- The lift truck must not travel at more than 0.4 m/s (1.5 km/h, i.e., one quarter walking speed).
- Drive and stop the lift truck gently and smoothly to minimise swinging of the load.
- Carry the load a few centimetres above the ground (max. 30 cm) the shortest possible jib length. Do not exceed the offset
indicated on the load chart. If the load begins to swing excessively, do not hesitate to stop and lower the jib to set down the
load.
- Before moving the lift truck, check the longitudinal stability limiter and warning device (see: 2 - DESCRIPTION: INSTRUMENTS AND
CONTROLS), only the green LEDs and possibly the yellow LEDs should be lit.
- During transport, the lift truck operator must be assisted by a person on the ground (standing a minimum of 3 m from the load),
who will limit swinging of the load using a bar or a rope. Ensure that this person is always clearly in view.
- The lateral attitude must not exceed 5%, the bubble in the level must be kept between the two “MAX.” marks
- The longitudinal attitude must not exceed 15%, with the load facing uphill, and 10%, with the load facing downhill.
- The jib angle must not exceed 45°.
- If the first red LED of the longitudinal stability limiter and warning device (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS)
comes on while travelling, gently bring the lift truck to a stop and stabilise the load. Retract the telescope to reduce the offset of
the load.

1-20
PLATFORM OPERATING INSTRUCTIONS
For PLATFORM-fitted lift trucks

Installation of the platform on the lift truck is only possible if the shields “operating the platform” of the lift truck and the platform are identical (see: 2
- DESCRIPTION: OPERATING THE PLATFORM).

A - AUTHORISATION FOR USE

- Operation of the platform requires further authorisation in addition to that of the lift truck.

B - SUITABILITY OF THE TRUCK FOR USE

- MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator’s
manual, with a STATIC test coefficient of 1.25 and a DYNAMIC test coefficient of 1.1, as specified in harmonised standard
EN 280 for “mobile elevating work platforms”.
- Before commissioning, the company manager must make sure that the platform is appropriate for the work to be done, and
perform certain tests (in accordance with current legislation).

C - PRECAUTIONS WHEN USING THE PLATFORM

- Wear clothes suited for operating the platform, avoid loose clothes.
- Never operate the platform when hands or feet are wet or soiled with greasy substances.
- Always pay attention when using the platform. Do not listen to the radio or music using headphones or earphones.
- For increased comfort, adopt the correct position at the platform’s operator station.
- The platform’s guard rail exempts the operator from wearing a safety harness under normal operating conditions. As a result, you
are responsible deciding whether to wear a safety harness.
- The controls must not be used for any other than their intended purpose (e.g. getting in and out of the lift truck, coat hanger etc.).
- Safety helmets must be worn.
- The operator must always be in the normal operator’s position. It is prohibited to have arms or legs, or generally any part of the
body, protruding from the basket.
- Ensure that any materials loaded onto the platform (pipes, cables, containers, etc.) cannot fall out. Do not pile these materials
to the point where it is necessary to step over them.

D - USING THE PLATFORM

- However experienced they may be, operators must acquaint themselves with the emplacement and operation of all control
instruments prior to operating the platform.
- Check before operating that the platform has been correctly assembled and locked onto the lift truck.
- Check before operating the platform that the access gate has been properly locked.
- The platform should be operated in an area free of any obstructions or danger when it is lowered to the ground.
- The operator using the platform must be aided on the ground by a person with adequate training.
- You should stay within the limits set out in the platform load chart.
- The lateral stresses are limited pressure (see: 2 - DESCRIPTION: CHARACTERISTICS).
- It is strictly forbidden to hand a load from the platform or the lift truck jib without a specially designed attachment (see: INSTRUCTIONS
FOR HANDLING A LOAD: H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD).
- The platform cannot be used as a crane or a lift for permanently transporting people or materials, nor as jacks or supports.
- The lift truck must not be moved with one (or more) person(s) in the platform.
- It is forbidden to transport people on the platform using the hydraulic controls in the lift truck’s driver’s cab (except in case of rescue).
- The operator must not get in or out of the platform when it is not on ground level (jib retracted and in the down position).
- The platform must not be fitted with attachments that increase the unit’s wind load.
- Do not use ladders or improvised structures in the platform to gain extra height.
- Do not climb onto the sides of the platform to gain extra height.

E - ENVIRONMENT DISTANCE ABOVE THE

NOMINAL VOLTAGE GROUND OR THE FLOOR
Operating the platform close to electricity cables is forbidden. Maintain the specified IN METRES
safe distances. 50 < U < 1000 2,30 M
1000 < U < 30000 2,50 M
30000 < U < 45000 2,60 M
45000 < U < 63000 2,80 M
63000 < U < 90000 3,00 M
90000 < U < 150000 3,40 M
150000 < U < 225000 4,00 M
225000 < U < 400000 5,30 M
400000 < U < 750000 7,90 M

1-21
 Operation of the platform is strictly forbidden in the event of wind speeds of over 45 km/h.
- The following scale is given for an empiric evaluation of the wind speed:

BEAUFORT scale (wind speed at a height of 10 m from flat ground)

Speed Speed Speed
Force Type of wind Effects on Land Sea condition
(knots) (kph) (m/s)
0 Calm 0-1 0-1 < 0,3 Smoke rises vertically. Sea like a mirror.
1 Light air 1-3 1-5 0,3 - 1,5 The wind bends the smoke. Ripples but without foam crests.
The wind can be felt on the face,
2 Light breeze 4-6 6 - 11 1,6 - 3,3 Small but evident wavelets.
shakes the leaves.
Gentle The wind continuously shakes the Large wavelets Perhaps scattered
3 7 - 10 12 - 19 3,4 - 5,4
breeze leaves and twigs. white horses.
Moderate The wind raises dust and scraps of Small waves. Fairly frequent white
4 11 - 16 20 - 28 5,5 - 7,9
breeze paper, shakes the twigs. horses.
Small waves form on inland waters.
5 Fresh breeze 17 - 21 29 - 38 8 - 10,7 Leafy shrubs sway. Moderate waves, many white
horses.
Shakes thick branches, metal wires
Strong Large waves begin to form, white
6 22 - 27 39 - 49 10,8 - 13,8 hum, it becomes difficult to keep an
breeze foam crests, probably spray.
umbrella open.
Sea heaps up and white foam blown
Whole trees sway, it is difficult to
7 Near gale 28 - 33 50 - 61 13,9 - 17,1 in streaks along the direction of the
walk against the wind.
wind.
Breaks the branches of trees, it is
Moderately high waves, crests begin
8 Gale 34 - 40 62 - 74 17,2 - 20,7 almost impossible to walk against
to break into spindrift.
the wind.
High waves. Dense foam along
Causes slight damage to buildings the direction of the wind. Crests of
9 Strong gale 41 - 47 75 - 88 20,8 - 24,4
(stacks, tiles, etc..). waves begin to roll over. Spray may
affect visibility.
Rare inland, uproots trees, causes Very high waves with long overhanging
10 Storm 48 - 55 89 - 102 24,5 - 28,4
considerable damage to buildings. crests. Visibility affected.
Exceptionally high waves that may
Violent Very rare, causes extensive
11 56 - 63 103 - 117 28,5 - 32,6 hide medium sized ships. Visibility
storm devastation.
affected.
The air is filled with foam and
spray. Sea completely white with
12 Hurricane 64 + 118 + 32,7 + Causes very serious catastrophes.
driving spray. Visibility very seriously
affected.

F - MAINTENANCE
Your platform must be periodically inspected to ensure its continued compliance. The inspection frequency is defined by the current legislation in the
country in which the platform is used.

1-22
INSTRUCTIONS FOR USING THE RADIO-CONTROL
For lift trucks with RC radio control

HOW TO USE THE RADIO-CONTROL

SAFETY INSTRUCTIONS
- This radio-control consists of electronic and mechanical safety elements. It cannot receive commands from another transmitter
because the internal encoding is unique to each radio-control.
If it is used improperly or incorrectly, there is a risk of danger to:
- The physical and mental health of the user or others.
- The lift truck and other neighbouring items.

Everyone working with this radio-control:

- Must be qualified in line with current regulations and therefore appropriately trained.
- Must follow this instruction manual as closely as possible.
- The system is used to control the lift truck remotely via radio waves. Commands are also transmitted if the lift truck is out of sight
(behind an obstacle or a building for example), this is why:
• After stopping the truck and removing the key button (only possible when it is stationary), always place the transmitter in
a safe, dry place.
• Before performing any installation, servicing or repair work, always switch off power sources (in particular, electric welding
devices and electric head units on hydraulic distributors must be disconnected at each section).
• Never remove or alter the safety devices (such as the hand-guard frame, key, emergency stop button, etc.).

Never drive the lift truck if it is not continuously and perfectly within view of the operator!
- Before leaving the transmitter, the operator must make sure that it cannot be used by an unauthorized third person: either by
removing the key button from the transmitter or locking it in an inaccessible place.
- The user must ensure that the instruction manual is accessible at all times and that operators have read and understood it.

INSTRUCTIONS
- Take up position in a stable place with no risk of slipping.
- Before using the transmitter, make sure there is nobody within the working area.
- Only use the transmitter with its carrying device or installed correctly on the platform.

When you remove the transmitter, remove the accumulator and key button so that it cannot be used accidentally or deliberately by anyone else.

PROTECTIVE DEVICES
- The lift truck will be immobilised within 450 milliseconds (approx. 0.5 second) at most:
• If the transmitter emergency stop button (50 milliseconds), or the one on the lift is pressed.
• If the transmission distance of the radio waves is exceeded.
• If the transmitter is faulty.
• If an interfering radio signal is received from elsewhere.
• If the accumulator is removed from its housing in the transmitter.
• If the accumulator reaches the end of its autonomy.
• If the transmitter is switched off by turning the key button to stop.
- These protective devices are provided for the safety of personnel and property and must never be altered, removed or bypassed
in any way whatsoever!
- The hand-guard frame prevents external action on a manipulator (if the transmitter falls, for example, or if the operator leans on
a guard-rail).
- An electronic safety device prevents radio transmission from being initiated if the manipulators are not mechanically and electrically
at rest and if the internal combustion engine speed selector is not set to idle.
In an emergency, press the transmitter emergency stop button immediately ; then follow the manual’s instructions (see: 2 - DESCRIPTION: INSTRUMENTS
AND CONTROLS).

1-23
 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

GENERAL INSTRUCTIONS
- Ensure the area is sufficiently ventilated before starting the lift truck.
- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie and protect your hair,
if necessary.
- Stop the I.C. engine and remove the ignition key, when an intervention is necessary.
- Read the operator’s manual carefully.
- Carry out all repairs immediately, even if the repairs concerned are minor.
- Repair all leaks immediately, even if the leak concerned is minor.
- Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.
- Be careful of the risk of burning and splashing (exhaust, radiator, I.C. engine, etc.).

MAINTENANCE
- Perform the periodic service (see: 3 - MAINTENANCE) to keep your lift truck in good working conditions. Failure to perform the periodic
service may cancel the contractual guarantee.

MAINTENANCE LOGBOOK
- The maintenance operations carried out in accordance with the recommendations given in part: 3 - MAINTENANCE and the other
inspection, servicing or repair operations or modifications performed on the lift truck or its attachments shall be recorded in a
maintenance logbook. The entry for each operation shall include details of the date of the works, the names of the individuals or
companies having performed them, the type of operation and its frequency, if applicable. The part numbers of any lift truck items
replaced shall also be indicated.

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

HYDRAULIC
- Any work on the load handling hydraulic circuit is forbidden except for the operations described in part: 3 - MAINTENANCE.
- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.
BALANCING VALVE: It is dangerous to change the setting and remove the balancing valves or safety valves which may be fitted to your lift truck cylinders.
These operations must only be performed by approved personnel (consult your dealer).

The HYDRAULIC ACCUMULATORS that may be fitted on your lift truck are pressurized units. Removing these accumulators and their pipework is a
dangerous operation and must only be performed by approved personnel (consult your dealer).

ELECTRICITY
- Do not short-circuit the starter relay to start the IC engine. If the forward/reverse selector is not in neutral and the parking brake is
not engaged, the lift truck may suddenly start to move.
- Do not drop metallic items on the battery.
- Disconnect the battery before working on the electrical circuit.

1-24
WELDING
- Disconnect the battery before any welding operations on the lift truck.
- 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.
- Never carry out welding or work which gives off heat on an assembled tyre. The heat would increase the pressure which could
cause the tyre to explode.
- If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing
irreparable damage to electronic components.

WASHING THE LIFT TRUCK

- Clean the lift truck or at least the area concerned before any intervention.
- Remember to close and lock all accesses to the lift truck (doors, windows, cowls…).
- During washing, avoid the articulations and electrical components and connections.
- 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 trace.

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

1-25
 IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME

INTRODUCTION
The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an
extended period.
For these operations, we recommend the use of a MANITOU protective product, reference 603726.
Instructions for using the product are given on the packaging.

Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership.

PREPARING THE LIFT TRUCK

- Clean the lift truck thoroughly.
- Check and repair any leakage of fuel, oil, water or air.
- Replace or repair any worn or damaged parts.
- Wash the painted surfaces of the lift truck in clear and cold water and wipe them.
- Touch up the paintwork if necessary.
- Shut down the lift truck (see: OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Make sure the jib cylinder rods are all in retracted position.
- Release the pressure in the hydraulic circuits.

PROTECTING THE I.C. ENGINE

- Fill the tank with fuel (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Empty and replace the cooling liquid (see: 3 - MAINTENANCE: F - EVERY 2000 HOURS SERVICE).
- Leave the I.C. engine running at idling speed for a few minutes, then switch off.
- Replace the I.C. engine oil and oil filter (see: 3 - MAINTENANCE: D - EVERY 500 HOURS SERVICE).
- Add the protective product to the engine oil.
- Run the I.C. engine for a short time so that the oil and cooling liquid circulate inside.
- Disconnect the battery and store it in a safe place away from the cold, after charging it to a maximum.
- Remove the injectors and spray the protective product into each cylinder for two seconds with the piston in low neutral position.
- Turn the crankshaft once slowly and refit the injectors (see I.C. engine REPAIR MANUAL).
- Remove the intake hose from the manifold or turbocharger and spray the protective product into the manifold or turbocharger.
- Cap the intake manifold or turbocharger hole with waterproof adhesive tape.
- Remove the exhaust pipe and spray the protective product into the exhaust manifold or turbocharger.
- Refit the exhaust pipe and block the outlet with waterproof adhesive tape.
NOTE: The spray time is noted on the product packaging and must be increased by 50 % for turbo engines.
- Open the filler plug, spray the protective product around the rocker arm shaft and refit the filler plug.
- Cap the fuel tank using waterproof adhesive tape.
- Remove the drive belts and store them in a safe place.
- Disconnect the engine cut-off solenoid on the injection pump and carefully insulate the connection.

PROTECTING THE LIFT TRUCK

- Set the lift truck on axle stands so that the tyres are not in contact with the ground and release the handbrake.
- Protect cylinder rods which will not be retracted, from corrosion.
- Wrap the tyres.
NOTE: If the lift truck is to be stored outdoors, cover it with a waterproof tarpaulin.

1-26
BRINGING THE LIFT TRUCK BACK INTO SERVICE
- Remove the waterproof adhesive tape from all the holes.
- Refit the intake hose.
- Refit and reconnect the battery.
- Remove the protection from the cylinder rods.
- Perform the daily service (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Put the handbrake on and remove the axle stands.
- Empty and replace the fuel and replace the fuel filter (see: 3 - MAINTENANCE: D - EVERY 500 HOURS SERVICE).
- Refit and set the tension in the drive belts (see: 3 - MAINTENANCE: C - EVERY 250 HOURS SERVICE).
- Turn the I.C. engine using the starter, to allow the oil pressure to rise.
- Reconnect the engine cut-off solenoid.
- Lubricate the lift truck completely (see: 3 - MAINTENANCE: SERVICING SCHEDULE).

Make sure the area is adequately ventilated before starting up the lift truck.
- Start up the lift truck, following the safety instructions and regulations (see: OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Run all the jib’s hydraulic movements, concentrating on the ends of travel for each cylinder.

1-27
1-28
CONTENTS

2 - DESCRIPTION

2-1
2-2
TABLE OF CONTENTS

IDENTIFICATION OF THE LIFT TRUCK 2-6

CHARACTERISTICS MLT 735 Turbo LSU Série 6-E 2-8

DIMENSIONS AND LOAD CHART MLT 735 -120 LSU Série 6-E 2-10

INSTRUMENTS AND CONTROLS 2-12

TOWING PIN AND HOOK 2-36

DESCRIPTION AND USE OF THE OPTIONS 2-40

2-3
 IDENTIFICATION OF THE LIFT TRUCK

As our policy is to promote a constant improvement of our products, our range of telescopic lift trucks may undergo certain
modifications, without obligation for us to advise our customers.

When you order parts, or when you require any technical information, always specify:

NOTE: For the owner’s convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time
of the delivery of the lift truck.

LIFT TRUCK MANUFACTURER’S PLATE (FIG. A) A

MANITOU BF - 44158 ANCENIS CEDEX FRANCE

- Model Type / Type / Tipo / Tipo / Typ

N° d'homologation / Homologation N° / N° di omologazione / N° de homologación / Homologatonsnummer

MANITOU BF 44158 ANCENIS CEDEX FRANCE
- Series N° d'identification / Identification N° / N° d'identificazione / N° de identificación / Identifizierungsnummer MODELE
MODEL
MODELLO
MODELO
SERIE
SERIES
SERIE
SERIE

- Serial Nr Masse totale admissible / Total permissible mass

Massa totale ammissibile / Peso total admisible / Zulässige Gesamtmasse

kg Année de fabrication N° de série Numero di serie

Serial Nr Número de serie

- Year of manufacture Masse maximale sur essieu AV / Maximum mass on front axle
Massa complessiva su assale anteriore / Peso máximo sobre eje delantero / Maximale Achslast vorne

kg
Year of manufacture
Anno di fabbricazione
Año de fabricacion

Masse maximale sur essieu AR / Maximum mass on rear axle Masse à vide Massa a vuoto
Massa complessiva su assale posteriore / Peso máximo sobre eje trasero / Maximale Achslast hinten Unladen mass Masa en vacio

kg Puissance ISO/TR14396
Power ISO/TR14396 kg
Potenza ISO/TR14396

For any further technical information regarding your lift truck refer to chapter: MASSE REMORQUABLE ADMISSIBLE / PERMISSIBLE TOWABLE MASS
MASSA RIMORCHIABILE AMMISSIBILE / PESO REMOLCABLE ADMISIBLE / ZULÄSSIGE ANHÄNGEMASSE

- Masse remorquable non freinée

- Towable mass with no braking
Potencia ISO/TR14396

kW
Numéro d'homologation
Homologation number
Numero d'omologazione
Contraseña homologacion

2 - DESCRIPTION: CHARACTERISTICS. kg
- Massa rimorchiabile non frenata
- Peso remolcable sin frenado Effort vertical max. (sur accrochage remorque)
- Nichtgebremste Anhängemasse Vertical max. effort (on trailer hook)
Carico max. verticale (sul gancio di traino)
- Masse remorquable avec freinage indépendant Esfuerzo vertical max. (sobre el gancho de remolque) Capacité maxi nominale
- Towable mass with independent braking Nominal maximum capacity
- Massa rimorchiabile con freno indipendente kg daN Capacità maxi nominale
- Peso remolcable con frenado independiente
- Anhängemasse mit unabhängiger Bremsung Capacidad máximo nominal

- Masse remorquable avec freinage à inertie Pression des pneumatiques (Bar) kg

- Towable mass with inertial braking Tyre pressure (Bar)
- Massa rimorchiabile con freno inerziale kg Pressione per pneumatici (Bar)
- Peso remolcable con frenado de inertia
- Anhängemasse bei Auflaubremsung Presion de los neumáticos (Bar) Effort de traction
Tractive effort
Avant Anteriore Arrière Posteriore Forza di traino
- Masse remorquable avec freinage assisté (Hydraul. ou pneumat.) Front Adelante Rear Trasero
- Towable mass with assisted braking (Hydraulic or pneumatic) Esfuerzo de traccion
- Massa rimorchiabile con servofreno (idraulico o pneumatico) kg
- Peso remolcable con frenado asistido (hydráulico o neumática)
- Anhängemasse bei Hilfskraftbremsung (hydraulisch oder pneumatisch) daN

N°283316 N°283688

B
I.C. ENGINE (FIG. B)
- I.C. engine Nr

C
GEAR BOX (FIG. C)
- Type
- MANITOU reference
- Serial Nr

D
ANGLE GEARBOX (FIG. D)
- Type
- MANITOU reference
- Serial Nr

2-6
FRONT AXLE (FIG. E) E

- Type
- Serial Nr
- MANITOU reference

REAR AXLE (FIG. F) F

- Type
- Serial Nr
- MANITOU reference

CAB (FIG. G) G

- Type
- Serial Nr

BOOM (FIG. H) H
- MANITOU reference
- Date of manufacture

PLATE MANUFACTURER OF THE ATTACHMENT (FIG. I) I

- Model
MANITOU BF

- Serial Nr 44158 ANCENIS CEDEX

FRANCE

MODELE
- Year of manufacture
N$ dans la série

Année fabrication

Masse à vide
kg
C d G / Tablier
A vide / En charge : mm

Cap. Nominale

Pression de service

AVERTISSEMENT : RESPECTEZ
LA CAPACITE DE L'ENSEMBLE
"CHARIOT ET EQUIPEMENT"

N$241415

2-7
CHARACTERISTICS
MLT 735 -120 LSU Série 6-E3

I.C. ENGINE
Type PERKINS 1104D-E44TA NJ38698
Fuel Diesel
Number of cylinders 4 in line
Suction Supercharged
Injection system Direct
Ignition sequence 1,3,4,2
Capacity cm3(cu/in) 4400(268.5)
Bore and stroke mm(in) 105 x 127(4 x 5)
Compression ratio 16,2:1
Nominal rating loaded rpm 2200
Rating slow unladen rpm 930
Max. rating unladen rpm 2360
Power ISO/TR 14396 cv- kW 124 - 91
Power SAE J 1995 cv- kW 124 - 91
Maximum torque ISO/TR 14396 Nm 490 to 1400 rpm
Air cleaner μm 3
Type of cooling By water
Fan Puller

TRANSMISSION
Gear box TURNER
Type Mechanical
Forward/reverse selector Electro-hydraulic
Torque converter SACHS
Number of forward speeds 4
Number of reverse speeds 4
Angle gear box TURNER
Front axle DANA
Differential Limited slip
Rear axle DANA
Differential Without locking
Drive wheels 4RM Permanent
Switch for 2/4 drive wheels No
Front tyres MICHELIN
Size 460-70 R24 159A8 TL
Pressure bar(psi) 3,4(49)
Rear tyres MICHELIN
Size 460-70 R24 159A8 TL
Pressure bar(psi) 3,4(49)

ELECTRIC CIRCUIT
Standard
Battery 12 V - 2 x 74 Ah - 2 x 680 A EN
Option
Alternator 12 V - 85 A
Type Denso Ai115
Starter 12 V - 4,2 kW
Type AZF

BRAKE CIRCUIT
Service brake Hydraulic power brake
Type of brake Multidisk brake immersed in oil
Type of control Foot-operated for the front and rear axles
Parking brake Mechanical
Type of brake Discon gear-box output
Type of control Manual

SOUND AND VIBRATION

Level of sound pressure in the driver’s cab LpA
dB 79
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment 106 (measured)
dB
(according to directive 2000/14/EC modified by directive 2005/88/EC) 107 (ensured)
Average weighted acceleration on driver’s body
m/s2
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the driver’s hand/arm system
m/s2(ft/s2) < 2,5(<8.2)
(according to standard ISO 5349-2)

2-8
HYDRAULIC CIRCUIT
Hydraulic pump
Type Variable volume pistons
1st casing
Capacity cm3(cu/in) 63(3.8)
Max. rating capacity unladen l/mn(gl/min) 149(39.4)
Flow rate at 1600 rpm l/mn(gl/min) 101(26.7)
Filtration
Return μm 15
Suction μm 125
Maximum service pressure bar (psi) 270 (3915)
Telescoping circuit bar (psi) 200/270 (2900/3316)
Lifting circuit bar (psi) 270/270 (3316)
Tilt circuit bar (psi) 190/270 (2756/3316
Attachment circuit bar (psi) 270 (3316)
Steering circuit bar (psi) 140 (2030)

HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device Electronic
Lifting motions (boom retracted)
Unladen lifting s - m/mn (ft/mn) 6,7 - 40,2 (41-132)
Laden lifting s - m/mn (ft/mn) 7,3 - 36,9 (24-121)
Unladen lowering s - m/mn (ft/mn) 4,8 - 56,1 (16-184)
Laden lowering s - m/mn (ft/mn) 4,6 - 58,5 (15-192)
Telescoping motions (boom raised)
Unladen extending s - m/mn (ft/mn) 7,1 - 22,2 (23-73)
Laden extending s - m/mn (ft/mn) 7,3 - 22,8 (24-75)
Unladen retracting s - m/mn (ft/mn) 5,7 - 28,4 (19-93)
Laden retracting s - m/mn (ft/mn) 5,5 - 29,5 (18-97)
Tilting movements
Unladen digging s - °/s 3,0 - 48,8
Forward tilting unladen s - °/s 2,35 - 62,3

SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen 1 km/h (mph) 5,3(3.3)
2 km/h (mph) 8,6(5.3)
3 km/h (mph) 18,2(11.3)
4 km/h (mph) 25,0(15.5)
Rear unladen 1 km/h (mph) 5,3(3.3)
2 km/h (mph) 8,6(5.3)
3 km/h (mph) 18,2(11.3)
4 km/h (mph) 25,0(15.5)
Standard attachment PFB
Weight of attachment (without fork) kg (lbs) 95 (209)
Weight of forks (each one) kg (lbs) 72,5 (160)
Rated capacity with standard attachment kg (lbs) 3500 (7716)
Tipping load at maximum reach on tyres kg (lbs) 1490 (3284)
Distance from the centre of gravity from the load to the lug of the forks mm (in) 500 (20)
Standard lifting height mm (in) 6860 (270)
Lift truck weight without attachment kg (lbs) 6860 (15124)
Lift truck weight with standard attachment
Unladen kg (lbs) 7100 (15653)
At rated load kg (lbs) 10600 (23369)
Weight per axle with standard attachment (transport position)
Front unladen kg (lbs) 3445 (7595)
Rear unladen kg (lbs) 3655 (8058)
Front rated load kg (lbs) 9370 (20657)
Rear rated load kg (lbs) 1230 (2712)
Weight per axle with standard attachment (boom extended)
Front rated load kg (lbs) 7630 (16821)
Rear rated load kg (lbs) 620 (1367)
Contact pressure on the ground for the whole surface of each
kg/cm2 -
stabilizer at maximum load when tilting
Drag strain on the coupling hook
Unladen (sliding) daN (lbf) 5465 (12286)
At rated load (transmission setting) daN (lbf) 7820 (17580)
Pull strain with open carrier (according to standard ISO 8313) daN (lbf) 3700 (8318)

2-9
 DIMENSIONS AND LOAD CHART

A mm (in.) 1200 (47.2)

B mm (in.) 2810 (110.6)
C mm (in.) 1192 (46.9)
C1 mm (in.) 1287 (50.7)
D mm (in.) 4791 (188.6)
D1 mm (in.) 4886 (192.4)
D2 mm (in.) 4165 (164.0)
E mm (in.) 5991 (235.8)
F mm (in.) 1935 (73.6)
F1 mm (in.) 1935 (73.6)
G mm (in.) 450 (17.7)
G1 mm (in.) 435 (17.1)
G2 mm (in.) 435 (17.1)
I mm (in.) 789 (31.1)
J mm (in.) 980 (34.1)
K mm (in.) 1260 (49.6)
L mm (in.) 45 (1.8)
N mm (in.) 1715 (67.5)
O mm (in.) 125 (4.9)
P2 (°) 38
P3 (°) 53
R mm (in.) 3685 (145)
S mm (in.) 7712 (303.6)
T mm (in.) 3575 (140.7)
U1 mm (in.) 2295 (90.4)
U2 mm (in.) 2545 (100.2)
V mm (in.) 4885 (192.3)
V1 mm (in.) 1310 (51.8)
V2 mm (in.) 3919 (154.3)
W mm (in.) 2402 (94.6)
Y (°) 12
Z (°) 133,7

2-10
INSTRUMENTS AND CONTROLS

25 24 27
8 38
7 4

20
29 27
15 18
25 17
9 6
28 19
26
10
14 25 18
1
13 6 38 15

2
17 19
22

MLT ... LSU ...

23
16 10
34
6
5
35

31
38

32
33
30 6
22
36
33
21
37

21

12

21

2-12
DESCRIPTION
1 - DRIVER’S SEAT
2 - SAFETY BELT
3 - CONTROL AND SIGNAL LIGHTS PANEL
4 - EMERGENCY STOP BUTTON
5 - EMERGENCY EXIT
6 - SWITCHES
7 - LIGHT SWITCH, HORN AND INDICATOR SWITCH
8 - FRONT AND REAR WINDSCREEN WIPER SWITCH
9 - IGNITION SWITCH
10 - FUSES AND RELAYS IN THE CAB
11 - FUSES AND RELAYS UNDER THE ENGINE HOOD (NOT ILLUSTRATED)
12 - DIAGNOSTIC SOCKET only for MLT ... -120 ...
13 - ACCELERATOR PEDAL
14 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
15 - GEAR LEVER AND TRANSMISSION CUT-OFF
16 - PARKING BRAKE LEVER
17 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
18 - STEERING SELECTION
19 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF
20 - FUNCTION FILES
21 - LEVEL INDICATORS
22 - HEATER CONTROL
22 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
23 - CAB FILTER VENTILATORS
24 - WINDSCREEN DEMISTER VENTS
25 - HEATING VENTS
26 - BRAKE FLUID RESERVOIR AND WINDSCREEN WASHER ACCESS PANEL
27 - STEERING WHEEL REGULATING HANDLE
28 - DOOR LOCK
29 - LOCKING HANDLE FOR UPPER HALF-DOOR
30 - UNLOCKING BUTTON FOR UPPER HALF DOOR
31 - HANDLE FOR REAR WINDOW OPENING
32 - DOCUMENT HOLDER
33 - SUN VISOR
34 - OVERHEAD LIGHT
35 - HOOK
36 - CIGAR LIGHTER
37 - ARMREST AND STORAGE
38 - CAR RADIO (OPTION)
39 - INSIDE REAR-VIEW MIRROR (OPTION) (NOT ILLUSTRATED)
40 - TOOL BOX (NOT ILLUSTRATED) except for MLT 1035 L Turbo LSU Série 6-E3
41 - NUMBER PLATE (NOT ILLUSTRATED)
42 - NUMBER PLATE LIGHTING (NOT ILLUSTRATED)
43 - REAR REFLECTORS (NOT ILLUSTRATED)
44 - FRONT LIGHTS (NOT ILLUSTRATED)
45 - REAR LIGHTS (NOT ILLUSTRATED)
46 - FLASHING LIGHT (NOT ILLUSTRATED)

NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver’s seat and looking
in front of him.

2-13
1 - DRIVER’S SEAT A

DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.

WEIGHT ADJUSTMENT (FIG. A)

It is advised that the weight be adjusted when the driver is not sitting in the cab.
- Refer to graduation 1 of the seat.
- Turn handle 2 depending on the driver’s weight.
NOTE: To avoid any health problems, it is recommended that the weight should be checked 2 1
and adjusted before starting up the lift truck.

SEAT HEIGHT ADJUSTMENT (FIG. B)

- Raise the seat to the desired position, until you hear the ratchet click. If you raise the seat
above the last notch (stop), the seat drops down to the lowest position.
B
SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C)
The back-rest angle of the seat may be adjusted to suit the individual.
- Press the left-hand button while pushing on the seat or relaxing pressure on the seat to
find a comfortable position.

SEAT DEPTH ADJUSTMENT (FIG. D)

The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired
position.

EXTENDING THE HEAD-REST (FIG. E)

- The height of the back-rest can be adjusted by pulling it upwards (the notches will click)
up to the stop.
- The head-rest can be removed by applying sufficient pressure to pull it off the stop. C

2-14
LUMBAR ADJUSTMENT (FIG. F) F
This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.

ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)

- Support the back-rest, pull the lever and position the back-rest to find the desired
position.

If you do not support the back-rest when making adjustments, it swings completely forwards.

LONGITUDINAL ADJUSTMENT (FIG. H)

- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
G
MAINTENANCE (FIG. I)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.

A rocking head-rest increases the risk of an accident !

Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a
small hidden area before using any fabric or plastic cleaner.

2-15
1 - BASIC PNEUMATIC DRIVER’S SEAT (OPTION) A

DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.

WEIGHT ADJUSTMENT (FIG. A)

It is advised that you adjust the seat according to your weight when sitting.
- Switch on lift truck ignition.
- Push or pull lever 1 until green appears in display 2 indicating correct adjustment according
to your weight.
NOTE: To avoid any health problems, it is recommended that the weight should be checked
and adjusted before starting up the lift truck.

SEAT HEIGHT ADJUSTMENT (FIG. B)

When weight adjustment has been carried out, you can then modify seat height.
- Keep the ignition on in the lift truck.
B
- Push or pull lever 1 until green appears and adjust the height of the seat while checking
that the green in display 2 remains visible.

To avoid causing any damage, do not activate the compressor for over 1 minute.

SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C)

The back-rest angle of the seat may be adjusted to suit the individual.
- Press the left-hand button while pushing on the seat or relaxing pressure on the seat to
find a comfortable position.

SEAT DEPTH ADJUSTMENT (FIG. D)

The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired
position.
C
EXTENDING THE HEAD-REST (FIG. E)
- The height of the back-rest can be adjusted by pulling it upwards (the notches will click)
up to the stop.
- The head-rest can be removed by applying sufficient pressure to pull it off the stop.

2-16
LUMBAR ADJUSTMENT (FIG. F) F
This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.

ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)

- Support the back-rest, pull the lever and position the back-rest to find the desired
position.

If you do not support the back-rest when making adjustments, it swings completely forwards.

HORIZONTAL SHOCK ABSORBER (FIG. H)

In certain conditions (e.g. driving with a trailer) it is advised that a horizontal shock absorber
be used. The driver’s seat is thus better able to absorb jerks in the direction of travel.
- Position 1: Horizontal shock absorber fitted. G
- Position 2: Horizontal shock absorber removed.

LONGITUDINAL ADJUSTMENT (FIG. I)

- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.

SERVICING (FIG. J)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.

A rocking head-rest increases the risk of an accident !

Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a H
small hidden area before using any fabric or plastic cleaner.

I J

2 - SAFETY BELT
- Sit correctly on the seat.
- Check that seat belt is not twisted.
- Place the seat belt at hip level.
- Attach the seat belt and check that it locks.
- Adjust the seat belt to your body shape without squeezing your hip and without over-slack.

In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.

2-17
3 - CONTROL AND SIGNAL LIGHTS PANEL

15
C1 C 10 RPM x 100 20 A1 A2 A3 A4
D A
5 25

12
0 30
9 3

CONTROL INSTRUMENTS

A - I.C. ENGINE WATER TEMPERATURE

Temperature zone:
A1 - Blue zone (0° - 50°) 122 °F Use the lift truck with moderation, wait for temperature to increase before normal operation.
A2 - Green zone (50° - 100°) 122 °F - 212 °F Use lift truck normally
A3 - White/red zone (100° - 105°) 212 °F - 221 °F Use lift truck with moderation, monitor the temperature.
A4 - Red zone (105° - 120°) 221 °F - 248 °F Stop the lift truck, look for the cause of overheating.

NOTE: Red indicator light comes on between zone A3 and A4.

B - HOUR METER AND REV COUNTER

C - FUEL LEVEL
Red zone C1 indicates that you are using the reserve supply and that time of use is limited.

D - CLOCK

SIGNAL LIGHTS
A permanently lit or flashing warning lamp, with the engine running, is the sign of an operating fault. The lighting of some lamps may be accompanied
by an audible signal. Do not ignore this warning, consult your dealer without delay.
If one of the warning lamps comes on while the lift truck is in motion, stop the lift truck under the safest possible conditions.
When activating the electrical system of the lift truck, all the red and orange lamps and the panel’s buzzer must light to indicate
their good working order. If one of the red lamps or the buzzer does not function, carry out the necessary repairs.

STOP

NOTE: only for: MLT ... -120 ...

ORANGE I.C. ENGINE PREHEATING INDICATOR LIGHT

Preheating is necessary. When the lift truck is switched on, the lamp comes on for 2 seconds and off as soon as preheating
is ended. Start the lift truck’s I.C. engine.

ORANGE I.C. ENGINE WARNING INDICATOR LIGHT

If the lamp comes on or flashes while the lift truck is in operation, a diagnostic fault has been detected. The lift truck will
operate in reduced mode. Consult your dealer without delay.

RED I.C. ENGINE STOPPED INDICATOR LIGHT

STOP
If the lamp comes on or flashes, when the lift truck is running, stop the I.C. engine immediately and consult your dealer.

RED STEERING SYSTEM OIL PRESSURE WARNING INDICATOR LIGHT

If the lamp comes on when the lift truck is running, stop the I.C. engine immediately and look for the cause (possible
leak, etc.).

STOP

NOTE: The indicator lights go off after engine preheating.

2-18
RED GEAR BOX OIL PRESSURE WARNING INDICATOR LIGHT

The lamp and buzzer come on when there is an abnormal drop in gear box pressure, in forward gear. Stop the I.C engine
and look for the cause (gear box oil level, possible leak, radiator, etc.).
NOTE: The signal light operates in forward travel conditions only, the signal should not be taken into account when the I.C.
engine is running at idle or is stopped.

RED CLUTCH PRESSURE WARNING INDICATOR LIGHT

The lamp and buzzer come on when there is an abnormal drop in pressure in the gear box. Stop the I.C engine and look for
the cause (gear box oil level, possible leak, radiator, etc.).
NOTE: Since this light only operates while driving, do not take the information into consideration when the lift truck has
stopped or is idling.

RED TRANSMISSION OIL TEMPERATURE FAULT NDICATOR LIGHT

The lamp and buzzer come on when the gearbox oil temperature is abnormally high. Stop the I.C engine and look for the
cause (gear box oil level, possible leak, radiator, etc.).

RED BRAKING OIL LEVEL WARNING INDICATOR LIGHT

If the lamp and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately and look for the cause
(braking oil level, possible leak, etc.). In the event of an abnormal dropping of the level, consult your dealer.

RED PARKING BRAKE LAMP

This lamp comes on when the parking brake is applied.

BATTERY CHARGE WARNING INDICATOR LIGHT

If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and look for the cause
(electric circuit, alternator belt, alternator, etc.).

RED I.C. ENGINE OIL PRESSURE WARNING INDICATOR LIGHT

If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and look for the cause
(engine oil level, possible leak, etc.).

RED I.C. ENGINE WATER TEMPERATURE WARNING INDICATOR LIGHT

If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and look for the cause
(coolant level, possible leak, radiator, etc.).

RED AIR FILTER OR HYDRAULIC RETURN FILTER CLOGGED INDICATOR LIGHT

The lamp and buzzer come on when the air filter cartridge or the hydraulic return oil filter cartridge is clogged up. Stop the
I.C. engine and carry out the necessary repairs (see cleaning and replacement requirements in chapter: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).

GREEN DIRECTION INDICATOR LAMP

GREEN SIDELIGHTS LAMP

GREEN LOW BEAM LAMP

BLUE MAIN BEAM LAMP

2-19
4- EMERGENCY STOP BUTTON
- In the event of danger, it lets you stop the I.C. Engine and thereby cut out all hydraulic
movements.
- Pull the button to disable it before restarting the lift truck.

Be ready for hydraulic movements suddenly stopping when you press this button.

5 - EMERGENCY EXIT
EMERGENCY HAMMER
Use the emergency hammer to break one of the windows in the event that it is impossible
to exit the cab by the door or by opening the rear window.

6 - SWITCHES
A B C D
NOTE: The location of the switches may vary depending on the options.

A - OPTION ELECTRICAL JIB PROVISION ELECTROVALVE AT JIB HEAD

See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
2
B - OPTIONAL BLUE FRONT AND REAR WORKING LIGHTS
1
C - WHEEL ALIGNMENT LAMPS
E F G H
D - WARNING LIGHTS

E - REAR FOG LIGHTS

F - SELF-CLEANING FAN OPTION

See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
H
G - STEERING SELECTION
2
H - TRANSMISSION CUT-OFF
1
The switch selects transmission cut-off to the service brake pedal or the hydraulic
controls lever.

NOTE: In all cases transmission cut-off can be activated using the GEAR lever. (except for
MLT... POWERSHIFT ...)
- Position 1: With the indicator light on, transmission cut-off is by means of the service MLT ... POWERSHIFT ...
brake pedal and the forward/neutral/reverse gear lever.
- Position 2: Indicator light off, transmission is cut-off from forward/neutral/reverse gear
selector.

USE OF TRANSMISSION CUT-OFF

Transmission cut-off to brake pedal (position 1).
• When loading.
Transmission cut-off to hydraulic controls lever (position 2).
• When driving.
• For inching and continuous stopping and starting (delicate handling). In order to optimise hydraulic movements, cut off
transmission to the hydraulic controls lever.
• Starting on a slope.

2-20
I - REVOLVING LIGHT

J - FRONT AND REAR WORKING LIGHTS

I J K L M
K - JIB HEAD LIGHT OPTION

L - OPTION

M - SIDE WINDSCREEN WIPER + ROOF WINDSCREEN WIPER OPTION

N/O - OPTION HYDRAULIC TOWING HOOK WITH SINGLE OR DUAL EFFECT REAR
HYDRAULIC PREDISPOSITION
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.

P - ATTACHMENT HYDRAULIC LOCKING DEVICE OPTION N O P Q R

See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.

Q - OPTION JIB SUSPENSION

See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.

R - NEUTRALIZATION OF HYDRAULIC MOVEMENTS

When driving on the road, it is highly recommended (mandatory in Germany) that you cut-off
all the hydraulic movements. The lamp shows when it is in use.

S - TILTING CORRECTOR
MLT 1035 L Turbo LSU Série 6-E3
See: 2 - DESCRIPTION: 20 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF.

MLT 1035 L Turbo LSU Série 6-E3

T - DISABLING 6TH GEAR

T U
See: 2 - DESCRIPTION: 16 - GEAR SELECTOR.

U - GEAR INDICATOR

See: 2 - DESCRIPTION: 16 - GEAR SELECTOR.

MLT ... POWERSHIFT ...

V - ATTACHMENT EASY HYDRAULIC CONNECTION OPTION

See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.

W - OPTION

2-21
7- LIGHT SWITCH, HORN AND INDICATOR SWITCH
The switch controls the visual and sound alarms.
A - All lights are off, the direction indicators do not flash. F E G
B - The right hand direction indicators flash. B
C - The left hand direction indicators flash.
D - The sidelights and the rear lights are on. A D G
E - The dipped headlights and the rear lights are on.
F - The main beam headlights and the rear lights are on. C
G - Headlight signal. A G

Pressing the switch sounds the horn.

NOTE: The positions D - E - F - G can be carried out without the ignition being on.

8 - FRONT AND REAR WINDSCREEN WIPER SWITCH

FRONT WINDSCREEN WIPER E
A - Front windscreen wiper off.
B - Front windscreen wiper low speed setting.
C - Front windscreen wiper high speed setting.
D - Front windscreen wiper intermittent setting. D A A F

REAR WINDSCREEN WIPER

D B B
E - Rear windscreen wiper off.
F - Rear windscreen wiper on.
D C C
NOTE: These functions will only work when the ignition is switched on.

9 - IGNITION SWITCH
MLT ... -120 ...
The key switch has five positions:
P - Ignition off, parking position.
O - Ignition switched off and I.C. engine stopped.
I - Ignition and pre-heating.
II - Not used.
III - The I.C. engine starts, return to position I as soon as the key is released.

MLT ... Turbo ...

The key switch has five positions:
P - Ignition off, parking position.
O - Ignition switched off and I.C. engine stopped.
I - Ignition on.
II - Heating.
III - The I.C. engine starts, return to position I as soon as the key is released.

2-22
10 - FUSES AND RELAYS IN THE CAB
- Lift up the fuse and relay access panel 1. 1

NOTE: A sticker on the inside of the access panel gives a clear display of the use of the
components described below.

Always replace a faulty fuse with another of equivalent rating. Never use a fuse that has been repaired.
F1 - Hydraulic control unit (7,5A). MLT … LSU
- OPTION.
F2 - Working tail light (15A).
F3 - Rear windscreen wiper (10A).
- Roof windscreen wiper (10A).
- Side windscreen wiper (10A).
F4 - Engine stop electrovalve (10A). MLT … Turbo LSU F32 F31
DIAG
- Engine stop electrovalve (15A). MLT 731 Turbo SPU
5A 25A
- Engine control unit (10A). MLT … -120 LSU K0 K1

F5 - Revolving light (7,5A). OPT.

F6 - Wheel alignment (5A).

K2 K3 K4
- OPTION.
F7 - Longitudinal stability limiter and warning device (7,5A).
- “Aggravating” hydraulic movement cut-off deactivation (7,5A). K5 K6
- OPTIONAL Blue front and rear working lights (15A).
F8 - Forward/neutral/reverse selector (15A). OPT.
- Transmission cut-off (15A). K7 K8 K9
- Reversing lights (15A).
- OPTION Reverse buzzer alarm (15A). OPT.
F9 - Control panel (5A). F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15
F10 - Sound alarm (10A). OPT. OPT. OPT.
OPT.
OPT. ECU
LSU HYD.
STOP

- Stop switch (10A). N$291213

10A max. 15A 10 A 15A max. 7.5A 7.5A max. 15A max. 15A 5A 10A 15A max. 10A 30A 25A max. 20A

F11 - OPTION Working lights on jib head (15A). F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30

F12 - Flashing unit (10A). OPT.

OPT.
OPT.
OPT. OPT.
F13 - Ventilation/heating (30A). 7,5A max. 15A max. 15A 15A 10A max. 10A 15A max. 7.5A 7.5A 7.5A 7.5A 15A 15A 15A 25A

F14 - Cigar lighter (10A).

- OPTION.
F15 - Hydraulic movement control unit (20A).
F16 - Diagnostic socket (5A).
- OPTION.
F17 - OPTION CLEANFIX self-cleaning fan (10A).
- OPTION FINTRONIC anti-start system (10A).
- OPTION MODCOD / MODCLÉ Anti-theft system (10A).
- OPTION Rear hydraulic predisposition (10A).
- OPTION Two rear hydraulic predispositions (15A).
F18 - Front working lights (15A).
F19 - OPTION.
F20 - OPTION Pneumatic seat (10A).
- OPTION.
F21 - Front windscreen wiper and front windscreen washer (10A).
F22 - OPTION Jib suspension (10A).
- OPTION Electrical jib provision (5A).
- OPTION Head jib electrovalve (7,5A)
F23 - Right sidelight (7,5A).
- Dashboard lighting (7,5A).
F24 - Left sidelights (7,5A)
- Number plate lighting (7,5A).
F25 - Right indicators (7,5A).
F26 - Left indicators (7,5A).
F27 - Low beam (15A).
- Low beam indicator light (15A).
- Rear fog light (15A).
F28 - Main beam (15A).
- Main beam headlamp (15A).
F29 - Warning lights (15A).
- Roof light (15A).
- Anti-theft device provision (15A).
- Clock (15A).
- Rev counter (15A).
F30 - Lights, horn and indicator switch (25A).

2-23
 F31 - Starter (25A).
F32 - Diagnostic socket (5A).
- Hydraulic movement control unit (5A).

K0 - OPTION. K18 K17

K1 - Transmission cut-off relay. F32
F31
K2 - Transmission cut-off relay. except MLT ... POWERSHIFT ...
K3 - Reverse gear relay.
K4 - Forward gear relay. except MLT ... POWERSHIFT ...
K5 - Buzzer.
K6 - OPTION.
K7 - OPTION.
K8 - Safety system starting switch relay.
K9 - Flashing unit.
K17 - Indicator module relay.
F32 F31
K18 - Neutral security system switch relay. DIAG
SPU
5A 25A
K0 K1

OPT.

K2 K3 K4

K5 K6

OPT.

K7 K8 K9

OPT.

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15

OPT. OPT. OPT. OPT. ECU
LSU
STOP OPT. HYD.
10A max. 15A 10 A 15A max. 7.5A 7.5A max. 15A max. 15A 5A 10A 15A max. 10A 30A 25A max. 20A
N$291213

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
OPT.
OPT. OPT.
OPT. OPT.
7,5A max. 15A max. 15A 15A 10A max. 10A 15A max. 7.5A 7.5A 7.5A 7.5A 15A 15A 15A 25A

- Lift the lid 2 of the tool box for access to fuse.

F33 - Hydraulic control unit (1A). MLT … LSU

- Remove the les casings 3 and 4 of the hydraulic control for access to relays.
K10 - OPTION Jib suspension cut-off.
K11 - OPTION Jib suspension supply.

K11

F33
K10

2-24
11 - FUSES AND RELAYS UNDER THE ENGINE HOOD
Remove casing 1 and cover 2 for access to fuses and relays.

Always replace a faulty fuse with another of equivalent rating. Never use a fuse that has been repaired.

F40 - Key switch (40A). MLT … Turbo

- Key switch (80A). MLT … -120
F41 - Key switch (40A). MLT … Turbo 2
- Engine control unit (30A). MLT … -120 F42
F42 - Preheating I.C. engine (80A).
F40 K16
F43 - Alternator (80A). MLT … Turbo 1
- Alternator (100A). MLT … -120 F43
F47 - OPTION Fuel decongealant (15A). MLT … Turbo
F41
K15 - OPTION Diesel decongealant. MLT … Turbo
K16 - Engine preheating relay. MLT ... Turbo ...

1 F42 F43
K16

F41 F40

MLT ... 120 ...

12 - DIAGNOSTIC CONNECTOR
MLT 735 -120 LSU Série 6-E3

2-25
13 - ACCELERATOR PEDAL

14 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF

The pedal applies on the front and rear wheels by an hydraulic brake system, and allows the lift truck to be slowed down and
stopped. Depending on the position of the transmission cut-off switch, it enables the free travel to cut off transmission (see: 2
- DESCRIPTION: 5 - SWITCHES).

15 - GEAR LEVER AND TRANSMISSION CUT-OFF

4 2
1

In order to change speeds, it is necessary to cut the transmission by pressing the button 3 1
1 on the lever.
1st gear: to the right, backwards.
2nd gear: to the right, forwards.
3rd gear: to the left, backwards.
4th gear: to the left, forwards.

USING THE GEARS ON THE GEAR BOX

- On these lift trucks with a torque converter, it is not necessary to automatically start up in 1st speed and progress up the
gears.
The choice of transmission gear ratio should be made carefully according to the nature of the work being carried out. A poor choice may result in
the extremely rapid rise of the transmission oil temperature through excessive slipping of the converter, which could lead to serious damage to the
transmission (it is essential to stop and change the working conditions if the transmission oil temperature indicator light comes on). This poor choice may
also result in a reduction in the lift truck’s performance in forward gear. When the forward force increases, the forward speed in the r gear (for example,
in 3rd gear) may be lower than the forward speed that could be obtained with the r-1 gear (in 2nd instead of 3rd).

In general, we would advise you to use the following gears according to the nature of the work being carried out.
• ON THE ROAD:
Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it.
In hilly areas, set off in 2nd gear and go up to 3rd if the conditions and state of the road permit it.
• WITH A TRAILER ON THE ROAD:
Set off in 2nd gear and go up to 3rd if the conditions and state of the road permit it.
• HANDLING:
3rd gear.
2nd gear in restricted spaces.
• LOADING (reclaiming with bucket, manure fork, etc.):
2nd gear.
• EARTH MOVING:
1st gear.

2-26
15 - GEAR SELECTOR
2

The gear is selected by means of buttons 1 and 2. The selected gear is indicated on the
dial 3.
There are 6 forward and 3 reverse gears available.

NOTE: When reversing, the selected gear remains the same, except for the 4th, 5th and
6th gears in forward motion which become 3rd gear in reverse motion.

USING THE GEARS ON THE GEAR BOX

- On these lift trucks with a torque converter, it is not necessary to automatically start up
in 1st speed and progress up the gears.
The choice of transmission gear ratio should be made carefully according to the nature of the work being
carried out. A poor choice may result in the extremely rapid rise of the transmission oil temperature
through excessive slipping of the converter, which could lead to serious damage to the transmission 4
(it is essential to stop and change the working conditions if the transmission oil temperature indicator
light comes on). This poor choice may also result in a reduction in the lift truck’s performance in forward
gear. When the forward force increases, the forward speed in the r gear (for example, in 3rd gear) may 3
be lower than the forward speed that could be obtained with the r-1 gear (in 2nd instead of 3rd).

In general, we would advise you to use the following gears according to the nature of the
work being carried out.
• ON THE ROAD:
Set off in 4th gear and go up to 5th and 6th if the conditions and state of the road
permit it.
In hilly areas, set off in 3rd gear and go up to 4th and 5th (the use of 6th gear is prohibited) if the conditions and state of
the road permit it.
• WITH A TRAILER ON THE ROAD:
Set off in 2nd gear and go up through the gears to 5th if the conditions and state of the road permit it.
• HANDLING:
3rd, 4th or 5th gear (the use of the 6th gear is prohibited).
2nd gear in restricted spaces.
• LOADING (reclaiming with bucket, manure fork, etc.):
2nd gear.
• EARTH MOVING:
1st gear.

SWITCH FOR DISABLING 6TH GEAR

Switch 4 serves to enable or disable 6th gear and must be used when required for the task to be performed. When the lamp is
lit, 6th gear is disabled.
This device must be used during handling, when towing a trailer and in hilly areas, to reduce the risk of the gear box overheating. Disabling 6th gear also
guarantees that the speed limit will not be exceeded when towing a trailer.

16 - PARKING BRAKE LEVER

A
To prevent accidental loosening or release, the lever is fitted with safety locking.

- To apply the parking brake, pull the lever backwards (position A).
- To loosen the parking brake, release and push the lever forwards (position B).

2-27
17 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION A

FORWARD: Push the knob forward (position A). C

REVERSE: Pull the knob backwards (position B). B
NEUTRAL: The knob must be in the intermediate position to start the lift truck (position
C).

When operating this control, the lift truck should be travelling at slow speed and not accelerating.

NOTE: The reverse lights indicate that the lift truck is running in reverse motion. An
OPTIONAL audible reversing alarm can also be fitted.

SAFETY FOR MOVING THE LIFT TRUCK

Authorisation to move the lift truck is controlled by an electronic unit. The operator must
observe the following sequence to move the truck forwards or backwards:
1 - sit down correctly in the driver’s seat,
2 - release the parking brake,
3 - engage forward or reverse movement.
To stop the lift truck, he must observe the following sequence:
1 - Set the forward/reverse selector to neutral,
2 - engage the parking brake,
3 - get out of the lift truck.

NOTE: If the operator leaves the driving cab with forward or reverse engaged, a continuous alarm will sound. While this alarm
sounds, the operator can simply sit back in the seat and continue advancing or reversing.
If the alarm becomes discontinuous, the operator must sit back in the seat, put the forward/reverse selector back in
neutral and select forward or reverse if he wishes to continue moving.

18 - STEERING SELECTION
A
A - GREEN WHEEL ALIGNMENT LAMPS
These lamps come on to indicate the alignment of the wheels in relation to the lift truck. A1
Lamp A1 for the front wheels and lamp A2 for the rear wheels.
A2
Before selecting one of the three possible steering positions, bring all 4 wheels into alignment with
regards to the lift truck axle. Never change the steering mode whilst driving.

B - STEERING SELECTION LEVER

B1 - Front drive wheels (highway traffic). C

B2 - Front and rear drive wheels in opposite direction (short steering lock).

B3 - Front and rear drive wheels in the same direction (crab steering).
B3
B
C - SWITCH FOR ALIGNMENT OF THE WHEELS
This switch enables the use or not of the device for alignment of the wheels. The indicator
B1
light indicates its use.

CONTROL FOR ALIGNMENT OF THE WHEELS B2

- Connect the switch (signal light ON).
- Shift the steering selection lever B into position B2 (short steering lock).
- Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up.
- Shift the steering selection lever B into position B1 (highway traffic).
- Turn the steering wheel and bring the front wheels into alignment until lamp A1 lights
up.
Before driving on roads, it is necessary to check the alignment of the rear wheels and to drive in front
wheel steer. The control of the alignment of the rear wheels must be regularly done with the help of the
green lamps, while driving the lift truck. In case of anomalies, consult your dealer.

2-28
 19 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF
Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve. In the event of suspected malfunction, contact
your dealer. ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID.
Use the hydraulic controls carefully without jerking, to avoid accidents caused byshaking the lift truck.
NOTE: When driving on the road, it is highly recommended (mandatory in Germany) that you cut-off all the hydraulic movements
(see: 2 - DESCRIPTION 7 - SWITCHES).

NOTE: If necessary use the steering to reset the hydraulic

control steering accumulator.

A - Lifting and tilting control lever. C

B - Telescoping control button. D
C - Attachment control button.
B
D - Jib head electrovalve option control button.
LIFTING THE LOAD A
- The lever A backwards when lifting.

N°255968
- The lever A forwards when lowering.
TILT OF CARRIAGE
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Button B forwards for extending.
- Button B backwards for retracting.
ATTACHMENT
- The button C forwards or backwards.
OPTION ELECTRIC PREDISPOSITION ON ELECTROVALVE
JIB AT HEAD JIB
- Button D (see: 2 - DESCRIPTION: DESCRIPTION AND
USE OF ELECTRICAL AND HYDRAULIC OPTIONS).

TILTING CORRECTOR E
- Button E to the left to tilt the lift truck to the left.
- Button E to the right to tilt the lift truck to the right.
NOTE: Tilt can be corrected up to a carriage articulation axle height of 3m50 above the
ground, with the jib retracted.

2-29
20 - FUNCTION FILES
These files contain the description of the hydraulic controls and the load charts for the attachments used on the lift truck.

21 - LEVEL INDICATOR
Except for MLT 1035 L Turbo LSU Série 6-E3

Enables the operator to check that the lift truck is in the horizontal position.

21 - LEVEL INDICATORS
Only for MLT 1035 L Turbo LSU Série 6-E3
A
A - TILT INDICATOR
When the two marks are aligned, the chassis is parallel
with the front axle.

B - SPIRIT LEVEL
Enables the operator to check that the lift truck is in
the horizontal position. B

22 - HEATER CONTROL
B2 B1
A - HEATING FAN CONTROL
This 3-speed control regulates warm or cold air through the heating ventilators.

B - HEATING TEMPERATURE CONTROL B A

Allows the temperature inside the cab to be adjusted.
B1 - With the valve closed, the fan delivers fresh air.
B2 - With the valve opened completely, the fan delivers warm air.
The intermediate positions allow the temperature to be adjusted.

2-30
22 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)

The air conditioning only comes on when the forklift truck has been started up. When using your air
conditioning, you must work with the doors and windows closed.
In winter: So as to ensure correct operation and complete efficiency of the air conditioning unit, A B C
start up the compressor once a week, if only for a short spell, so as to lubricate the internal seals.
In cold weather: Warm the I.C. engine before switching on the compressor, so as to allow the
coolant that has collected in the liquid state at the lowest point of the compressor circuit to turn into
gas under the effect of the heat given off by the I.C. engine, as the compressor is liable to be damaged by coolant in the liquid state.

If your air conditioning does not seem to be working properly, have it examined by your dealer (see: 3 - MAINTENANCE: F - EVERY 2000 HOURS OF
SERVICE). Never try to repair any possible problems by yourself.

DESCRIPTION OF THE AIR CONDITIONING CONTROLS

A - Air conditioning system ON/OFF control switch with indicator lamp. Only works when control switch “C” set to 1, 2 or 3.
B - Air temperature control.
C - Air flow and fan speed control. When this control is set to “0” the air conditioning system will not work.

NOTE: Possible losses of water under the lift truck are due to condensate discharges caused by the drying effect of the
installation, especially with high outside temperatures and high relative humidity.
For the air conditioning to perform properly, the air intakes must not be blocked by frost, snow or leaves.
When the facility is running, at least one of the cab air grilles must be open so as to avoid any risk of freezing to the
evaporator.

HEATING MODE
The controls must be adjusted in the following way:
A - Control with signal light off.
B - At the required temperature.
C - To the desired position 1, 2 or 3.

CONDITIONED AIR MODE

The controls must be adjusted in the following way:
A - Control with signal light on.
B - At the required temperature.
C - To the desired position 1, 2 or 3.

DEMISTING MODE
The controls must be adjusted in the following way:
A - Control with signal light on.
B - At the required temperature.
C - To the desired position 1, 2 or 3.
NOTE: Direct the ventilators onto the cab’s windows for increased efficiency.

23 - CAB FILTER VENTILATORS

See: 3 - MAINTENANCE: D - EVERY 500 HOURS SERVICE.

24 - WINDSCREEN DEMISTER VENTS

For optimum effectiveness, close the heating ventilators.

25 - HEATING VENTS
These heating vents enable the air to be directed to the interior of the cabin and onto the side windows.

2-31
26 - BRAKING OIL AND WINDSCREEN WASHER TANK ACCESS PANEL
- Loosen screw 1 and lift up the braking oil and windscreen washer tank access panel
(see: 3 - MAINTENANCE: B - EVERY 50 HOURS OF SERVICE).

27 - STEERING WHEEL REGULATING HANDLE

This handle enables the angle and height of the steering wheel to be adjusted.

- Pull handle 1 to adjust the steering wheel.

- Push in handle 1 to lock the steering wheel in the desired position.

28 - DOOR LOCK
Two keys are provided with the lift truck to enable the cabin to be locked.

29 - LOCKING HANDLE FOR UPPER HALF-DOOR

30 - UNLOCKING BUTTON FOR UPPER HALF DOOR

31 - HANDLE FOR REAR WINDOW OPENING

EMERGENCY EXIT
Use the rear window as an emergency exit, in the event that it is impossible to leave the
cab by the door or by opening the windscreen.

NOTE: There is an OPTIONAL rear window stay.

2-32
32 - DOCUMENT HOLDER
Ensure that the operator’s manual is in its place in the document holder.

33 - SUN VISOR

34 - OVERHEAD LIGHT

35 - HOOK
35

36

36 - CIGAR LIGHTER
For 12 V appliance and max. amperage 10A.

2-33
37 - ARMREST AND STORAGE
- Lift the armrest 1 to access the storage.

38 - CAR RADIO (OPTION)

39 - INSIDE REAR-VIEW MIRROR (OPTION)

40 - TOOL BOX
Except for MLT 1035 L Turbo LSU Série 6-E3

41 - NUMBER PLATE

42 - NUMBER PLATE LIGHTING

42

43 43

43 - REAR REFLECTORS

2-34
44 - FRONT HEADLIGHTS
A - Left front indicator.
B - Left front dipped headlight. F B
C - Left front main beam.
D - Left front sidelight.
E - Right front indicator. E H D A
F - Right front dipped headlight.
G - Right front main beam. G C
H - Right front sidelight.

45 - REAR LIGHTS
A - Left rear indicator.
B - Left rear stoplight.
C - Left tail light. A B C D E F G H I H
D - Left rear reverse light.
E - Left rear fog light.
F - Right rear fog light.
G - Right rear reverse light.
H - Right tail light.
I - Right rear stoplight.
J - Right rear indicator.

46 - REVOLVING LIGHT
STANDARD
The revolving light pivots for space-saving on the lift truck and can be detached
to prevent theft.
- Loosen nut 1 and remove the revolving light.
- Protect mounting 2 with cap 3.
1
2
3

OPTIONAL AIR CONDITIONING

The magnetic revolving light must be clearly visible on the roof of the cab and plugged-in
to socket 1.

2-35
 TOWING PIN AND HOOK

Located at the rear of the lift truck, this device is used to attach a trailer. Its capacity is limited for each lift truck by the Authorized
Gross Vehicle Weight, tractive force and maximum vertical force on the coupling point.

- To use a trailer, see current regulations in your country (maximum running speed, braking, maximum weight of trailer, etc.).
- Verify the trailer’s condition before using it (tyre condition and pressures, electrical connection, hydraulic hose, brake system…).
Do not tow a trailer or attachment which is not in perfect working order. Using a trailer in poor condition may affect the lift truck’s steering and braking,
and hence safety.

If a third party helps in coupling or uncoupling the trailer, this person must be permanently visible to the driver and wait until the lift truck has stopped,
the handbrake is on and the I.C. engine is switched off before performing the operation.
NOTE: A rear-view mirror allows the lift truck to approach more closely to the trailer ring.

A - COUPLING FITTING
2
COUPLING AND UNCOUPLING THE TRAILER
- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- Put the handbrake on and switch off the I.C. engine.
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put clip 1 back in place.
When uncoupling, make sure that the trailer is supported independently.
1

B - REAR ELECTRIC SOCKET

- Connect the male plug to the female socket 1 on the lift truck and make sure the lights
of he trailer or the light bar are working properly.
1 - Rear left-hand indicator light. 1
2 - Rear fog lights.
3 - Earth.
4 - Rear right hand indicator light. 7 1
5 - Right rear light. 6 2
6 - Rear stop lights.
7 - Left rear light and number plate.
5 3
4

2-36
C - TRAILER BRAKE SYSTEM.
- Connect the brake hose to the provided brake unit 1 on the lift truck.
- Make sure the trailer brakes are working properly and test the effects of braking before
taking the trailer onto the public highway.

D - CHASSIS-MOUNTED FRONT TOWING HOOK

COUPLING AND UNCOUPLING THE TRAILER
- To couple the trailer, position the lift truck as close as possible to the trailer ring. 2
- Put the handbrake on and switch off the I.C. engine.
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put clip 1 back in place.
When uncoupling, make sure that the trailer is supported independently.
1

MLT 1035 L Turbo LSU Série 6-E3

E - COUPLING LADDER (OPTIONAL)

COUPLING AND UNCOUPLING THE TRAILER 6
- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- Put the handbrake on and switch off the I.C. engine. 4
ON THE FIXED PIN
- Remove pin 1, remove rod 2 and raise latch 3. 5
- Insert or remove the trailer ring, lower latch 3 and refit rod 2. 3
1
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put clip 1 back in place. 2
When uncoupling, make sure that the trailer is supported independently.
ON THE COUPLING LADDER
- Set the coupling fitting 4 according to the height of the trailer ring.

Do not forget to put rods and clip back in place.

- Remove the clip 5, lift the trailer pin 6 and place or remove the trailer ring.
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put clip 5 back in place.
When uncoupling, make sure that the trailer is supported independently.

2-37
F - HYDRAULIC TOWING HOOK (OPTION)

Never use the tow hook to raise the rear of the lift truck (when changing the rear wheel for example).

- Raise the hydraulic tow hook to release the hook lock 1 by pressing the upper part
of switch 2.
- Pull the knob 3, retain this position and press the lower part of switch 2 to lower the
tow hook.
1 1
- Release knob 3.
- Couple or uncouple the trailer.

When uncoupling, make sure that the trailer is supported independently.

- Raise the trailer hook by pressing the upper part of switch 2 and then lower the hook
to verify that the lock pin is in proper contact with hook 1 lock.

G - AUTOMATIC TRAILER HOOK (OPTION)

COUPLING THE TRAILER
- Remove the automatic towing pin using lever 1. 1
- Move the lift truck backwards so that the trailer ring slots into the automatic hook.
NOTE: The pin closes automatically when the trailer ring touches the end of the fitting.
The pin can be lowered by hand using lever 1.

UNCOUPLING THE TRAILER

When uncoupling, make sure that the trailer is supported independently.

- Remove the pin using lever 1 to uncouple the trailer.

2-38
2-39
DESCRIPTION AND USE OF THE OPTIONS

1 - BATTERY CUT-OFF
2 - REVERSE BUZZER ALARM
3 - PREHEATING ELEMENT
4 - CLEANFIX SELF-CLEANING FAN
5 - MODCOD ANTI-THEFT SYSTEM
6 - FINTRONIC ANTI-START SYSTEM
7 - MODCLÉ ANTI-START SYSTEM
8 - ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION
9 - JIB SUSPENSION
10 - ATTACHMENT EASY HYDRAULIC CONNECTION
11 - PROVISION FOR ELECTRICAL JIB
12 - JIB HEAD ELECTROVALVE
13 - HYDRAULIC ATTACHMENT LOCKING
14 - JIB HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING
15 - MACH2 QUICK-RELEASE COUPLER ON ACCESSORY CIRCUIT
16 - QUICK-RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT + HYDRAULIC ATTACHMENT LOCKING
17 - EXTERIOR DRAIN BACK
18 - LIFTING RING ON SINGLE CARRIAGE
19 - ANGULAR SECTOR ON JIB
20 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
21 - DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION + SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL
PREDISPOSITION
22 - HYDRAULIC TOWING HOOK + SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION

2-40
1 - BATTERY CUT-OFF

1
1

MLT ... -120 ... MLT ... Turbo ...

2 - REVERSE BUZZER ALARM

3 - PREHEATING ELEMENT
Enables the engine to be kept warm during prolonged periods of stoppage and thus
improves engine starting.

SUPPLY CHARACTERISTICS OF PREHEATING SYSTEM:

• Rated range of power: 220-240V; 50-60Hz
3
• Current consumed: 4,5A
• Equipment in class 1
• Equipment connectable only on feeder circuit TT or TN
• Category of insulation 2

ENVIRONMENTAL CONDITIONS FOR USE:

• Maximum ambient temperature for using preheating: +25°C
• Pollution level 2

CONDITIONS FOR CONNECTION AND USE OF PREHEATING:

- The preheating system should not be used for an external ambient temperature higher than + 25°C.
- It is essential that the power supply to the preheating system is:
• Effected with a cable that conforms to the installation standards in force and contains a protective earth conductor.
• Contains an appropriate sectioning system.
• Incorporate an appropriate safety system against short circuits (fuses or circuit breaker) and a differential circuit breaker
with 30 mA sensitivity.
- Only connect to and disconnect from the power supply while the unit is off and the I.C. engine is stopped.

4 - CLEANFIX SELF-CLEANING FAN

This system, operated by switch 1, cleans the radiator
core and the grille of the engine cover by reversing the B
air flow.

When in use, beware of the risk of projection into the eyes. 1

Position A: The indicator light is on, the fan

operates in self-cleaning mode for a A
few seconds once every 3 minutes.
Position B: The indicator light is off, the fan is
in normal operating mode.

2-41
5 - MODCOD ANTI-THEFT SYSTEM
OPERATION
- Switch on the lift truck: the red indicator 1 will flash.
- Enter your user code followed by “V” to validate: the green indicator 2 will come on. 2 1
- Start the lift truck within the next 60 seconds; otherwise the anti-theft system will
be reactivated and the red indicator 1 will flash.

NOTE: If you make a mistake when entering the code, press key “A” to cancel and
re-enter the code in full.
If you wait more than 5 seconds between key presses or do not complete entering
the code, the anti-theft system will be reactivated and the red indicator will flash.

6 - FINTRONIC ANTI-START SYSTEM

OPERATION
- Switch on the lift truck and set the black key A next to the antenna B (maximum 80 mm). C
- Wait a few seconds for red led C to go out before starting the lift truck.

NOTE: You can restart the lift truck within 20 seconds of stopping it: after this time,
the anti-start system reacts and led C flashes red.
B
A

7 - MODCLÉ ANTI-START SYSTEM

OPERATION
- Switch on lift truck ignition, red led 1 will flash.
- Apply key 2 to its base 3, and withdraw the moment the system emits a continuous beep,
and led 1 turns green.
- Start the lift truck within the next 20 seconds; otherwise the anti-theft system will 2 1
be reactivated and red led 1 will flash.

NOTE: You can restart the lift truck within 20 seconds of stopping it; after this time,
the anti-start system reacts and red led 1 flashes.

2-42
8 - ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION
This OPTION must only be used with an attachment requiring continuous hydraulic movement of type:
brush, supply bucket, mixer, spray… It is strictly forbidden in handling operations and at all other events
(winch, crane boom, crane boom with winch, hook, etc.). A

CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT

- Make sure the potentiometer C is set to 0%.
- Switch button A to the front or the back (depending on the type of attachment), press button
B and release button A. The red indicator 1, flashes to indicate that it is in operation.
- Set the required flowrate using potentiometer C.
- To stop continuous hydraulic movement of the attachment, move switch A forwards or
backwards or press button B. Indicator 1 goes out.
- Set potentiometer C to 0%.
Never leave the driver’s cab without resetting the potentiometer C to 0%. Before starting the lift truck,
make sure the potentiometer is set to 0%.
NOTE: If the operator leaves the driver’s cab, the continuous hydraulic movement will
automatically stop and must be restarted.

B C
1

9 - BOOM SUSPENSION
The boom is suspended to reduce shaking of the lift truck on rough ground (e.g. moving
straw in a field).
A
OPERATION
- Set the forks or attachment on the ground and relieve the front wheels a few centimetres
only. 1
- Press switch 1 set to position A, the visual indicator comes on indicating that boom
suspension is activated. B
- Press switch 1 set to position B, the visual indicator goes out indicating that boom
suspension is deactivated.
Boom suspension is active to a lifting height of 3m00 from the axis of articulation of the carriage with
respect to the ground with the boom retracted. When you move beyond this height or make another
hydraulic movement (tilting, telescoping, attachment), boom suspension is momentarily deactivated
and the visual indicator of switch 1 goes out.
- When the I.C. engine is off, boom suspension is automatically deactivated.

2-43
10 - ATTACHMENT EASY HYDRAULIC CONNECTION
For easily connecting and disconnecting the attachment.

OPERATION
- Press for two seconds on push-button 1 to release the attachment circuit hydraulic 1
pressure.
- Connect or disconnect the rapid connectors of the hydraulic attachment (see: 4 - OPTIONAL
ATTACHMENTS FOR USE WITH THE RANGE: PICKING UP THE ATTACHMENTS).

11 - PROVISION FOR ELECTRICAL JIB

Enables an electrical function to be used at the head A
of the jib foot.
3
2
ELECTRIC JIB FUNCTION CONTROL 1
- Set switch 1 to position B (indicator light on).
- Hold button 2 down and button 3 forwards
or backwards. B

NOTE: Set switch 1 to position A (indicator light

off) controls the hydraulic attachment line
(see: 2 - DESCRIPTION: 20 - HYDRAULIC AND
TRANSMISSION CUT-OFF CONTROLS).

12 - JIB HEAD ELECTROVALVE

L1
Enables use of two hydraulic functions on the attachment circuit.
L2
To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing L1
button 1 on the electrovalve.

ATTACHMENT LINE L1 CONTROL L2

- Set switch 2 to position A (indicator light off).
- Push button 3 forward or backward.
1
ATTACHMENT LINE L2 CONTROL
- Set switch 2 to position B (indicator light on).
- Hold button 4 down and push button 3 forwards or backwards.

A
3
4
2

2-44
13 - HYDRAULIC ATTACHMENT LOCKING
Enables the attachment to be locked onto the carriage and a hydraulic attachment to be
used by the same hydraulic circuit. A

ATTACHMENT LOCKING CONTROL

- Set valve 1 to position A and place switch 2 in position B (indicator light on).
B
- Push button 3 forward to lock the attachment and backward to release it. 1
After locking the attachment, return switch 2 to position A (indicator light off) to prevent accidental
release of the attachment.

HYDRAULIC ATTACHMENT CONTROL

- Set valve 1 to position B and press switch 2 in
position B (indicator light on).
- Push button 3 forward or backward.

3
2

14 - JIB HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING A

The addition of these two options on the attachment line allows two hydraulic functions 4
to be used and locks the attachment onto the carriage.
B
To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing L1
button 1 on the electrovalve.
ATTACHMENT LINE L1 CONTROL L1 L2
- Set switch 2 to position A (indicator light off).
- Push button 3 forward or backward. L2

ATTACHMENT LINE L2 CONTROL + HYDRAULIC ATTACHMENT LOCKING 1

LOCKING AN ATTACHMENT
- Set valve 4 to position A.
- Set switch 2 to position B (indicator light on).
- Hold button 5 down and push button 3 forward to lock
the attachment and backward to release it.
A
Once the attachment is locked, return valve 4 to position B
3
to prevent accidental release of the attachment. 5
2
HYDRAULIC ATTACHMENT
- Set switch 2 to position B (indicator light on).
- Hold button 5 down and push button 3 forwards B
or backwards.

2-45
15 - MACH2 QUICK-RELEASE COUPLERS ON ACCESSORY CIRCUIT
Enables the use of a hydraulic attachment fitted with MACH2 quick-release couplers. 1

CONNECTING A HYDRAULIC ATTACHMENT

- Lower lever 1 and valve 2 and connect the MACH2 quick-release couplers on the
attachment.
- Lift up lever 1 to lock the connection.
NOTE: A foolproofing device prevents the connection inversion.
2
DISCONNECTING A HYDRAULIC ATTACHMENT
- Lower lever 1 and disconnect the MACH2 quick-release couplers from the attachment.
- Lift up lever 1.

16 - MACH2 QUICK-RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT +

HYDRAULIC ATTACHMENT LOCKING
Enables the locking of the attachment on the carriage to be controlled and a hydraulic
attachment with MACH2 quick-release couplers to be used (see: 2 - DESCRIPTION:
14 - HYDRAULIC ATTACHMENT LOCKING and 15 - MACH2 QUICK-RELEASE COUPLERS
ON ATTACHMENT CIRCUIT).

17 - EXTERIOR DRAIN BACK

Enables connection of a hydraulic attachment for which drain-back is required.

2-46
18 - LIFTING RING ON SINGLE CARRIAGE
Kg
CONDITIONS OF USE
Kg Kg
Follow the instructions given in the instruction manual (see: 1 - OPERATING
AND SAFETY INSTRUCTIONS: INSTRUCTIONS FOR HANDLING LOADS).
- The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS,
but the angle of inclination of the carriage must be same as
when the forks are used in the horizontal position.

N°265284
- Do not change the angle of the carriage while using the Kg Kg Kg Kg Kg Kg

lifting ring.
- The lifting hook, the chains and slings shall have a minimum
capacity of 3000 kg with a factor of safety against breakage of 4.

Kg Kg Kg Kg

HANDLING WITH NO MOVEMENT OF THE LIFT TRUCK

- Whether on stabilisers or on tyres, the lateral attitude must not exceed 1 % and the
longitudinal attitude must not exceed 8,75 % (5°).
- The bubble of the level indicator must remain within the outer circle and be centred in the
longitudinal direction.

HANDLING WITH MOVEMENT OF THE LIFT TRUCK

- The lateral attitude must not exceed 8,75 % (5°). The bubble must remain within the
outer circle.

2-47
19 - ANGULAR SECTOR ON JIB
The angular sector displays the jib angle, and thus improves the reading of the load charts.

20 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION

Enables the use of a hydraulic attachment at the rear of the lift truck (e.g. a trailer with
hydraulic tipping).
1

SINGLE EFFECT HYDRAULIC CONTROL L1

- Press switch 1 downwards to supply the rear hydraulic attachment.

L1

DUAL EFFECT HYDRAULIC CONTROL L1

- Press switch 1 upwards or downwards to supply the rear hydraulic attachment.

L1 L1

2-48
21 - DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION + SINGLE
OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
Enables the use of a hydraulic attachment at the rear of the lift truck or another hydraulic
attachment at the rear of the lift truck. B 2

DUAL EFFECT L1 AND SINGLE EFFECT L2 REAR HYDRAULIC CONTROL

DUAL EFFECT ATTACHMENT L1
- Set switch 1 to position A (indicator light off).
- Press switch 2 upwards or downwards to supply the rear hydraulic attachment.
L2 L1 L1
SINGLE EFFECT ATTACHMENT L2
- Set switch 1 to position B (indicator light on).
- Press switch 2 downwards to supply the rear hydraulic attachment.

DUAL EFFECT L1 AND DUAL EFFECT L2 REAR HYDRAULIC CONTROL

DUAL EFFECT ATTACHMENT L1
- Set switch 1 to position A (indicator light off).
- Press switch 2 upwards or downwards to supply the rear hydraulic attachment.
L2 L2 L1 L1
DUAL EFFECT ATTACHMENT L2
- Set switch 1 to position B (indicator light on).
- Press switch 2 upwards or downwards to supply the rear hydraulic attachment.

2-49
22 - HYDRAULIC TOWING HOOK + SINGLE OR DUAL EFFECT REAR HYDRAULIC
CONTROL PREDISPOSITION
Enables the use of the trailer eye (see: 2 - DESCRIPTION: TRAILER PIN AND HOOK)
or a hydraulic attachment at the rear of the lift truck. B 2

HYDRAULIC TRAILER HOOK + SINGLE EFFECT REAR HYDRAULIC CONTROL L1

HYDRAULIC TRAILER HOOK

- Set switch 1 to position A (indicator light off).
- Press switch 2 upwards or downwards to use the hydraulic trailer hook (see: 2 - DESCRIPTION: L1
TRAILER PIN AND HOOK: F - HYDRAULIC TRAILER HOOK).

SINGLE EFFECT ATTACHMENT L2

- Set switch 1 to position B (indicator light on).
- Press switch 2 downwards to supply the rear hydraulic attachment.

HYDRAULIC TRAILER HOOK + DUAL EFFECT REAR HYDRAULIC CONTROL L1

HYDRAULIC TRAILER HOOK
- Set switch 1 to position A (indicator light off).
- Press switch 2 upwards or downwards to use the hydraulic trailer hook (see: 2 - DESCRIPTION:
TRAILER PIN AND HOOK: F - HYDRAULIC TRAILER HOOK).
L1 L1
DUAL EFFECT ATTACHMENT L2
- Set switch 1 to position B (indicator light on).
- Press switch 2 upwards or downwards to supply the rear hydraulic attachment.

2-50
2-51
CONTENTS

3 - MAINTENANCE

3-1
3-2
TABLE OF CONTENTS

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT 3-4

START-UP CHECKLIST 3-5

FILTERS CARTRIDGES AND BELTS 3-6

LUBRICANTS AND FUEL 3-8

SERVICING SCHEDULE 3-10

A - DAILY OR EVERY 10 HOURS SERVICE 3-12

B - EVERY 50 HOURS SERVICE 3-16

C - EVERY 250 HOURS SERVICE 3-22

D - EVERY 500 HOURS SERVICE 3-26

E - EVERY 1000 HOURS SERVICE 3-32

F - EVERY 2000 HOURS OF SERVICE 3-37

G - OCCASIONAL MAINTENANCE 3-39

3-3
 MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.

IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,

YOU RISK - Legally - to be held responsible in the event of an accident.

- Technically - to generate operating failure or shorten the life of the lift truck.

THE USE OF COUNTERFEIT PARTS OR COMPONENTS NOT APPROVED BY THE MANUFACTURER,

MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.

BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,

YOU BENEFIT Through its network, MANITOU provides the user with
EXPERTISE
- Know-how and competence.

- The guarantee of high-quality work.

- Original replacement components.

- Help with preventive maintenance.

- Efficient help with diagnosis.

- Improvements due to experience feedback.

- Operator training.

- Only the MANITOU network has detailed knowledge of the design of the lift truck and therefore the best
technical ability to provide maintenance.

ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
the dealer network list is available on manitou web site www.manitou.com

3-4
START-UP CHECKLIST
0 = OK 1 = Missing 2 = Incorrect

100 ENGINE 108 ATTACHMENTS

01 Air filter 01 Fitting on machine
02 Fuel tank 02 Hydraulic couplings
03 Fuel lines - Filter 109 CABIN/PROTECTOR/ELECTRIC CIRCUIT
04 Injection or carburetion system 01 Seat
05 Radiator and cooling system 02 Dashboard and radio
06 Belts 03 Sound and visual alarm/safety system
07 Hoses 04 Heating/Air conditioning
101 TRANSMISSION 05 Windscreen wiper/windscreen washer
01 Direction reversal system 06 Road horn
02 Gear shift 07 Reversing horn
03 Cut-off pedal 08 Road lights
04 Clutch 09 Additional lights
102 AXLES/TRANSFER GEAR BOX 10 Rotating beacon light
01 operation and seal 11 Battery
02 Stop settings 110 WHEEL
103 HYDRAULIC/HYDROSTATIC CIRCUIT 01 Rims
01 Tank 02 Tyre/Pressure
02 Pumps and couplings 111 SCREWS
03 Tightening of connections 112 FRAME AND BODYWORK
04 Lift cylinder(s) 113 PAINTING
05 Tilt cylinder(s) 114 GENERAL OPERATION
06 Attachment cylinder(s) 115 OPERATOR’S MANUAL
07 Telescope cylinder(s) 116 CUSTOMER INSTRUCTIONS
08 Compensation cylinder(s)
09 Steering cylinder(s)
10 Control Valve
11 Balancing valve
104 BRAKE SYSTEM
01 Service brake and parking brake operation
02 Brake fluid level
105 LUBRICATION AND GREASING
106 JIB/MANISCOPIC/MANIACCESS ASSEMBLY
01 Beam and telescope(s)
02 Skid
03 Hinges
04 Carriage
05 Forks
107 MAST ASSEMBLY
01 Fixed and mobile uprights
02 Carriage
03 Chains
04 Rollers
05 Forks

3-5
FILTERS CARTRIDGES AND BELTS

I.C. ENGINE

I.C. ENGINE OIL FILTER

ALTERNATOR BELT
Part number: 476954
Part number: 269138
Change: 500 H

DRY AIR FILTER CARTRIDGE

Part number: 563416 FAN BELT
Clean: 50 H* Part number: 257524
Change: 500 H*

SAFETY DRY AIR FILTER CARTRIDGE COMPRESSOR BELT

Part number: 563415 (OPTION AIR CONDITIONING)
Change: 1000 H* Part number: 244237

FUEL FILTER CYCLONIC PRE-FILTER

Part number: 747351 Part number: 224713
Change: 500 H Clean: 10 H

FUEL PRE-FILTER AUTOMATIC VACUUM-CLEANING PRE-FILTER

Part number: 747462 (OPTION)
Change: 500 H Part number: 226611

CLEANFIX COMPRESSOR FILTER (OPTION) AUTOMATIC VACUUM-CLEANING PRE-FILTER

Part number: 781443 (OPTION)
Change: 500 H Part number: 223510

*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.

TRANSMISSION

GEAR BOX OIL FILTER

Part number: 561749
Change: 500 H

HYDRAULIC

HYDRAULIC RETURN OIL FILTER CARTRIDGE SUCTION STRAINER FOR HYDRAULIC OIL TANK
Part number: 236094 Part number: 224726
Change: 500 H Clean: 1000 H

FILTER CAP FOR HYDRAULIC OIL TANK DISTRIBUTOR CONTROL HEAD FILTER
Part number: 62415 Part number: 254780
Change: 1000 H Change: 1000 H

CAB
CAB VENTILATION FILTER (WITH AIR CONDITIONING)
CAB VENTILATION FILTER (WITHOUT AIR CONDITIONING)
Part number: 282619
Part number: 282619
Clean: 50 H
Clean: 500 H
Change: 250 H

3-6
3-7
 LUBRICANTS AND FUEL
USE THE RECOMMENDED LUBRICANTS AND FUEL:
- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.
DIAGNOSTIC ANALYSIS OF OILS
If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, gear box and axle oils
may be requested depending on the rate of use.

(*) RECOMMENDED FUEL SPECIFICATION

Use a high-quality fuel to obtain optimal performance of the I.C. engine.
• N590 diesel fuel type - Auto/C0/C1/C2/C3/C4
• BS2869 Class A2
• ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA
• JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.

I.C. ENGINE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION

Shell: Rotella 15w40

I.C. ENGINE 11L(2.9 gl)
Citgo: C-600 15w40

Tulco 50/50 Premix Anti-freeze

COOLING CIRCUIT 18,5L(4.9 gl)

FUEL TANK 120L(31.7 gl) Diesel fuel (*)

TRANSMISSION
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION

Shell: Donax TG Dexron III

GEAR BOX 16,6L(4.4 gl)
Citgo: Transgard ATF Dexron III

Shell: Spirax DH 80w90

ANGLE GEAR BOX 2,2L(2.3qts) Citgo: Premium Gear MP 80w90

Shell: Rentinax Am
TRANSMISSION UNIVERSAL JOINT
Citgo: Lithoplex CM-2

BOOM
ORGANS TO BE LUBRICATED RECOMMENDATION
Shell: Rentinax Am
BOOM PADS
Citgo: Lithoplex CM-2

Shell: Rentinax Am
GREASING OF THE BOOM
Citgo: Lithoplex CM-2

3-8
HYDRAULIC
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION

Shell: Tellus T46

HYDRAULIC OIL TANK 135L(35.6 gl)
Citgo: Transgard THF Lo-Temp

BRAKE
ORGANS TO BE LUBRICATED RECOMMENDATION
Shell: Donax TG Dexron III
BRAKE CIRCUIT
Citgo: Transgard ATF Dexron III

CAB
ORGANS TO BE LUBRICATED RECOMMENDATION

Shell: Rentinax Am
CAB DOOR
Citgo: Lithoplex CM-2

WINDSCREEN WASHER TANK Windscreen washer fluid

FRONT AXLE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION

Shell: Donax TD
FRONT AXLE DIFFERENTIAL 8,1L(2.1 gl)
Citgo: Transgard (THF)

Shell: Spirax DH 80w90

FRONT WHEELS REDUCERS 0,8L(.8 qt) Citgo: Premium Gear MP 80w90

FRONT WHEELS REDUCERS PIVOTS Shell: Rentinax Am

FRONT AXLE OSCILLATION Citgo: Lithoplex CM-2

REAR AXLE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION

Shell: Donax TD
REAR AXLE DIFFERENTIAL 8,1L(2.1 gl)
Citgo: Transgard (THF)

Shell: Spirax DH 80w90

REAR WHEELS REDUCERS 0,8L(.8 qt) Citgo: Premium Gear MP 80w90

REAR WHEELS REDUCERS PIVOTS Shell: Rentinax Am

REAR AXLE OSCILLATION Citgo: Lithoplex CM-2

CHASSIS
ORGANS TO BE LUBRICATED RECOMMENDATION

Shell: Rentinax Am
TILTING CORRECTOR
Citgo: Lithoplex CM-2

3-9
 SERVICING SCHEDULE
(1): MANDATORY 500 HOUR OR 6 MONTH SERVICE
This service must be carried out after approximately the first 500 hours of operation or within the 6 months following the start-up of the machine
(whichever occurs first).

SERVICE OR 1 YEAR
EVERY 1000 HOURS

EVERY 2000 HOURS

EVERY 4000 HOURS

DAILY OR EVERY 10

EVERY 250 HOURS

EVERY 500 HOURS

EVERY 50 HOURS
HOURS SERVICE

OCCASIONALLY
SERVICE OR 6

SERVICE OR 2
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,

MONTHS
SERVICE

SERVICE

SERVICE
YEARS
PAGE
P = BLEED, R = REPLACE, V = DRAIN (1)

I.C. ENGINE
I.C. engine oil level 3-14 C C <<< <<< <<< <<< <<< <<<
Cooling liquid level 3-14 C C <<< <<< <<< <<< <<< <<<
Fuel level 3-15 C C <<< <<< <<< <<< <<< <<<
Fuel pre-filter 3-15 C C <<< <<< <<< <<< <<< <<<
Cyclonic pre-filter 3-15 N N <<< <<< <<< <<< <<< <<<
Dry air filter cartridge 3-20/31 R C/N <<< R <<< <<< <<<
Radiator cores 3-20 N N <<< <<< <<< <<< <<<
Condenser core (OPTION Air conditioning) 3-21 C/N C/N <<< <<< <<< <<< <<<
Fan belt tension 3-26 C/A C/A <<< <<< <<< <<<
Alternator/crankshaft belt tension 3-26 C/A C/A <<< <<< <<< <<<
Compressor belt tension (OPTION Air conditioning) 3-27 C/A C/A <<< <<< <<< <<<
I.C. engine oil 3-30 V V <<< <<< <<<
I.C. engine oil filter 3-30 R R <<< <<< <<<
Fuel pre-filter 3-31 R R <<< <<< <<<
Fuel filter 3-32 R R <<< <<< <<<
CLEANFIX compressor filter (OPTION) 3-33 R R <<< <<< <<<
Fuel tank 3-36 N <<< <<<
Safety dry air filter cartridge 3-36 R <<< <<<
I.C. engine silent blocks C** <<< <<<
I.C. engine rates C** <<< <<<
Valves clearances C** C** <<< <<<
Cooling liquid 3-42 V <<<
Radiator C** <<<
Water pump and the thermostat C** <<<
Alternator and the starter motor C** <<<
Turbocompressor C** <<<
Fuel system 3-44 P
TRANSMISSION
Gear box oil level 3-16 C C <<< <<< <<< <<< <<< <<<
Transmission universal joint 3-21 G G <<< <<< <<< <<< G/C**
Angle gear box oil level 3-28 C C <<< <<< <<< <<<
Gear box oil filter 3-33 R R <<< <<< <<<
Gear box oil 3-37 V V <<< <<<
Gear box sump strainer 3-37 N N <<< <<<
Angle gear box oil 3-39 V V <<< <<<
Silentblocks in the gear box C** <<< <<<
Gear box controls C** <<< <<<
Gear box pressures C** <<<
Converter pressure C** <<<
TYRES
Tyres pressure 3-16 C C <<< <<< <<< <<< <<< <<<
Wheel nuts torque 3-16 C C <<< <<< <<< <<< <<< <<<
Condition of wheels and tyres C** <<< <<<
Wheel 3-45 R
Boom
Boom pads 3-16 G* <<< <<< <<< <<< <<< <<<
Boom 3-22 G G <<< <<< <<< <<< <<<
Boom pads wear C** <<< <<<
Condition of boom unit C** <<<
Bearings and articulation rings C** <<<
HYDRAULIC
Hydraulic oil level 3-23 C C <<< <<< <<< <<< <<<
Hydraulic return oil filter cartridge 3-34 R R <<< <<< <<<
Hydraulic oil 3-39 V <<< <<<
Suction strainer for hydraulic oil tank 3-39 N <<< <<<
Filter cap for hydraulic oil tank 3-39 R <<< <<<
Distributor control head filter 3-39 R <<< <<<
Speeds of hydraulic movements C** <<< <<<
Hydraulic pump pipe filter (except ... LSU ...) N** <<< <<<
Condition of hoses and flexible pipes C** <<< <<<
Condition of cylinders (leakage, shafts) C** <<< <<<
Hydraulic circuit pressures C** <<<
Hydraulic circuit outputs C** <<<
Hydraulic oil tank N** <<<
3-10
 SERVICE OR 1 YEAR
EVERY 1000 HOURS

EVERY 2000 HOURS

EVERY 4000 HOURS

DAILY OR EVERY 10

EVERY 250 HOURS

EVERY 500 HOURS

EVERY 50 HOURS
HOURS SERVICE

OCCASIONALLY
SERVICE OR 6

SERVICE OR 2
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,

MONTHS
SERVICE

SERVICE

SERVICE
YEARS
PAGE
P = BLEED, R = REPLACE, V = DRAIN (1)

BRAKE
Brake oil level 3-23 C C <<< <<< <<< <<< <<<
Parking brake 3-28 C/A C/A <<< <<< <<< <<<
Parking brake lever mechanism 3-34 G G <<< <<< <<<
Parking brake mechanism on the transmission G** G** <<< <<< <<<
Brake oil V** <<< <<<
Brake system P** <<< <<<
Brake system pressure C** <<< <<<
Brake A** <<< <<<
STEERING
Steering C** <<<
Steering swivel joints C**
CAB
Windscreen washer liquid level 3-24 C C <<< <<< <<< <<< <<<
Cab door 3-24 G G <<< <<< <<< <<< <<<
Cab ventilation filter (OPTION Air conditioning) 3-24/28 R N R <<< <<< <<< <<<
Heating block non-return valve 3-28 N N <<< <<< <<< <<<
Cab ventilation filters 3-34 N N <<< <<< <<<
Seat belt 3-41 C <<< <<<
Condition of the rear view mirrors C** <<< <<<
Structure C** <<< <<<
Air conditioning (OPTION) 3-43 C <<<
ELECTRICITY
Longitudinal stability limiter and warning device 3-17/47 C <<< <<< <<< <<< <<< <<< XXX
Condition of wiring harness and cables C** <<< <<<
Lights and signals C** <<< <<<
Warning indicators C** <<< <<<
Front headlights 3-45 A
FRONT AXLE
Front wheels reducers pivots 3-25 G G <<< <<< <<< <<< G/C**
Front axle oscillation 3-25 G G <<< <<< <<< G/C** <<<
Front axle differential oil level 3-29 C C <<< <<< <<< <<<
Front wheels reducers oil level 3-29 C C <<< <<< <<< <<<
Front axle differential oil 3-35 V V <<< <<< <<<
Front wheels reducers oil 3-41 V V <<< <<<
Wear of front axle brake discs C**
Front wheels reducers universal joint C**
Front wheels reducers clearance C**
REAR AXLE
Rear wheels reducers pivots 3-25 G G <<< <<< <<< <<< G/C**
Rear axle oscillation 3-25 G G <<< <<< <<< G/C** <<<
Rear axle differential oil level 3-29 C C <<< <<< <<< <<<
Rear wheels reducers oil level 3-29 C C <<< <<< <<< <<<
Rear axle differential oil 3-35 V V <<< <<< <<<
Rear wheels reducers oil 3-41 V V <<< <<<
Wearing of rear axle brake discs C**
Rear wheels reducers universal joint C**
Rear wheels reducers clearance C**
CHASSIS
Tilting corrector 3-25 G G <<< <<< <<< <<< <<<
Structure C** <<< <<<
Bearings and articulation rings C** <<<
ATTACHMENTS
Forks wear C** C** <<< <<< <<<
Attachment carriage C** <<< <<<
Condition of attachments C** <<< <<<
LIFT TRUCK
Tow the lift truck 3-45 XXX
Sling the lift truck 3-46 XXX
Transport the lift truck on a platform 3-46 XXX

(*): Every 10 hours during the first 50 hours, then once at 250 hours.
(**): Consult your dealer.

3-11
 A - DAILY OR EVERY 10 HOURS SERVICE

A1 - I.C. ENGINE OIL LEVEL A1

CHECK

Place the lift truck on level ground with the I.C. engine stopped, and let the oil drain into 2
the sump.

- Open the I.C. engine bonnet.

- Remove the dipstick 1 (fig. A1).
- Clean the dipstick and check the correct level between the two notches.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port 2 1
(fig. A1).
- Check visually that there is no leakage or seepage of oil in the I.C. engine.
MLT ... Turbo ...

A1

MLT ... -120 ...

A2 - COOLING LIQUID LEVEL A2

CHECK
2

Place the lift truck on level ground with the I.C. engine stopped, and allow the I.C. engine
3
to cool.

- Open the I.C. engine bonnet.

- Check the correct level in the middle of gauge 1 (fig. A2).
- If necessary, add cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
- Slowly turn the cap of the radiator 2 (fig. A2) up to the safety stop. 1
- Allow the pressure and the steam to escape.
- Press down and turn the cap so as to release it.
- Add cooling liquid via filler port 3 (fig. A2) up to the middle of gauge 1 (fig. A2).
- Lubricate slightly the filler neck in order to facilitate the setting and the removal of the
radiator cap.
- Check visually that there is no leakage in the radiator and pipes.
To avoid any risk of spraying or burning, wait until the I.C. engine has cooled down before removing the cooling circuit filler plug. If the cooling liquid is
very hot, add only hot cooling liquid (80°C). In an emergency, you can use water as a cooling liquid, then change the cooling circuit liquid as soon as
possible (see: 3 - MAINTENANCE: F1 - COOLING LIQUID).

3-12
A3 - FUEL LEVEL A3
CHECK

Keep the fuel tank full, to reduce as much as possible any condensation due to the 1
atmospheric conditions.
2
- Remove cap 1 (fig. A3).
- Fill the fuel tank with clean fuel (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL), filtered
through a strainer or a clean, lint free cloth, through filler port 2 (fig. A3).
- Put the cap back 1 (fig. A3).
- Check visually that there is no leakage in the tank and pipes.
Never smoke or approach with a flame during filling operations or when the tank is open. Never refill
while I.C. engine is running.

The fuel tank is degassed via the filler plug. When changing it, always use an original part, with degassing
hole.
NOTE: A locking tank cap is available as an OPTION.

A4 - FUEL PRE-FILTER
CHECK A4/2
3

- Open the I.C. engine bonnet.

- Check for the presence of water in the pre-filter bowl 1 (fig. A4/2) and empty it out if
necessary. 1
- Place a receptacle under the drain plug 2 (fig. A4/2) and loosen it in two to three thread 2
turns.
- Allow the diesel fuel to flow out until it is free from impurities and water.
- Tighten the drain plug.
- Pressurise the circuit with the hand pump 3 (fig. A4/2).

A5 - CYCLONIC PREFILTER
CLEAN A5

The cleaning interval is given as a guide, however the pre-filter must be emptied as soon 1
as impurities reach the MAX. level on the tank. 2

- Loosen nut 1 (fig. A5), remove cover 2 (fig. A5) and empty the tank.
- Clean the pre-filter unit with a clean dry cloth and reassemble the unit.

When cleaning, take care not to let impurities into the dry air filter.

3-13
 A6
A6 - GEAR BOX OIL LEVEL
CHECK
1

Park the lift truck on level ground with the boom raised, the I.C. engine cold and stopped.
Carry out the control within 5 minutes of the I.C. engine being stopped.

- Remove the plastic cap 1 (fig. A6).

- Remove the dipstick 2 (fig. A6).
- Wipe the dipstick and check the correct level between the two MIN and MAX marks.
- If necessary, add oil (see: 3 - MAINTENANCE: E3 - GEAR BOX OIL).
- Check visually that there is no leakage or seepage of oil in the transmission.

A7 - TIRES PRESSURE AND WHEEL NUTS TORQUE

CHECK

- Check the condition of the tyres, to detect cuts, protuberances, wear, etc.
- Check the torque load of the wheel nuts. Non compliance with this instruction can cause damage and rupture to the wheel bolts
and distortion to the wheels.
Wheel nuts tightening torque
• Front tyres: 630 N.m (465 ft/lb) ± 15%
• Rear tyres: 630 N.m (465 ft/lb) ± 15%
- Check and adjust the tyre pressures if necessary (see: 2 - DESCRIPTION: FRONT AND REAR TYRES).

Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation. Respect the
recommended tyre pressures given.
NOTE: There is an OPTIONAL wheel toolkit and anti-puncture kit.

A8 - BOOM PADS A8
CLEAN - GREASE

To be carried out every 10 hours during the first 50 hours service, then once at 250
hours.

- Extend the boom completely.

- With a brush, apply a coat of grease (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) on
the 4 sides of the telescope(s) (fig. A8).
- Telescope the boom several times in order to spread the coat of grease evenly.
- Remove the surplus of grease.
If the lift truck is used in an abrasive environment (dust, sand, coal…) Use lubricating varnish (MANITOU
reference: 483536). In this respect, consult your dealer.

3-14
3-15
 B - EVERY 50 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

B1 - DRY AIR FILTER CARTRIDGE

CHECK - CLEAN

In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced.
If the clogging indicator light comes on, this operation must be carried out as quickly as possible (1 hour maximum). The cartridge must not be cleaned
more than seven times, after which the cartridge must be changed. Never use the lift truck without an air filter or with a damaged air filter.
- For the disassembly and reassembly of the cartridge, see: 3 - MAINTENANCE: D3 - DRY AIR FILTER CARTRIDGE.
- Clean the filter cartridge using a compressed air jet (max. pressure 3 bar) 45 psi directed from the top to the bottom and from the inside
towards the outside at a minimum distance of 30 mm from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.
Respect the safety distance of 30 mm between the air jet and the cartridge to avoid tearing or making a hole in the cartridge. The cartridge must not be blown
anywhere near the air filter box. Never clean the cartridge by tapping it against a hard surface. Your eyes must be protected during this intervention.
- Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU
reference: 479292).
- Check visually the outer condition of the air filter and its mounts. Verify the condition of the hoses and their mounts also.
Never clean the dry air filter cartridge by washing it in liquid. Do not clean by any means the safety cartridge located inside the filter cartridge,
change it for a new one if it is clogged or damaged.

B2 - RADIATOR CORES B2/1

CLEAN
In a polluting atmosphere, clean the radiator cores every day. Do not use a water jet or high-pressure
steam as this could damage the radiator fins.
- Open the I.C. engine bonnet.
- If necessary, clean the suction grid on the engine hood (fig. B2/1).
- Using a soft cloth, clean the radiator cores in order to remove as much dirt as possible.
- Clean the radiator cores using a compressed air jet aimed in the same direction as the
cooling air flow (fig. B2/2).
- Clean with the fan running for best results.

NOTE: There is an OPTIONAL self-cleaning fan.

B2/2

MLT ... -120 ...

3-16
B3 - CONDENSER CORE (OPTION AIR CONDITIONING) B3
CHECK - CLEAN
1
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure
steam as this could damage the condenser fins.
- Remove the protective grid 1 (fig. B3) and clean it if necessary.
- Visually check whether the condenser 2 (fig. B3) is clean and clean it if necessary.
- Clean the condenser using a compressed air jet aimed in the same direction as the air
flow (fig. B3).
2
NOTE: So as to enhance the cleaning, carry out this operation with the fans running.

B4 - TRANSMISSION UNIVERSAL JOINT B4/1 1

GREASE

- Clean and lubricate the following points with grease (see: 3 - MAINTENANCE: LUBRICANTS
AND FUEL) and remove the surplus of grease.

1 - Lubricators of the universal joint I.C. engine/Angle gear box (2 lubricators) (fig.
B4/1).
2 - Lubricators of the universal joint Transmission/Front axle (3 lubricators) (fig.
B4/2). 1
3 - Lubricators of the universal joint Transmission/Rear axle (3 lubricators) (fig.
B4/3).

B4/2

2 2
2

B4/3

3 3

3-17
B5 - BOOM
GREASE

To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week.

In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to 10 working hours or every day.
- Clean and lubricate the following points with grease (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) and remove the surplus of
grease.

1 - Lubricators of the boom axle (2 lubricators) (fig. B5/1). B5/1

2 - Lubricators of the carriage axle (2 lubricators) (fig. B5/2).
3 - Lubricator of the tilt cylinder foot axle (1 lubricator) (fig. B5/3).
4 - Lubricator of the tilt cylinder head axle (1 lubricator) (fig. B5/4).
5 - Lubricators of the carriage connecting rod axle (3 lubricators) (fig. B5/5). 1 1
6 - Lubricator of the lifting cylinder foot axle (1 lubricator) (fig. B5/6).
7 - Lubricator of the lifting cylinder head axle (1 lubricator) (fig. B5/7).
8 - Lubricator of the compensation cylinder foot axle (1 lubricator) (fig. B5/6).
9 - Lubricator of the compensation cylinder head axle (1 lubricator) (fig. B5/8).

B5/2 B5/3 B5/4

3 4

B5/5 B5/6 B5/7

5
5

6
8
5 7

B5/8

3-18
B6 - HYDRAULIC OIL LEVEL B6/1
CHECK

Place the lift truck on level ground with the I.C. engine stopped, and the boom retracted
and lowered as far as possible.

- Refer to gauge 1 (fig. B6/1).

- The oil level is correct when it is at the level of the red point. 1
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
- Remove cap 2 (fig. B6/2).
- Add oil by filler port 3 (fig. B6/2).

Use a clean funnel and clean the underside of the oil drum before filling.
- Put the cap back.
- Check visually that there is no leakage in the tank and pipes. B6/2

Always maintain the oil level at maximum as cooling depends on the oil flowing through
2
the tank.

B7 - BRAKE OIL LEVEL B7/1

CHECK
2
Place the lift truck on level ground.

- Loosen screw 1 (fig. B7/1) and remove the access panel for braking oil tank and
windscreen washer tank 2 (fig. B7/1).
- The level is correct when it is at the MAX. level in tank 3 (fig. B7/2)
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port.
1
- Pivot the tank 3 (fig. B7/2) to access the filler cap 4 (fig. B7/2).
- Check visually that there is no leakage in the tank and pipes.

If the braking oil level is abnormally low, consult your dealer.

B7/2

3-19
B8 - WINDSCREEN WASHER LIQUID LEVEL B8/1
CHECK
2
- Loosen screw 1 (fig. B8/1) and remove the access panel for braking oil tank and
windscreen washer tank 2 (fig. B8/1).
- Visually check the level.
- If necessary add windscreen washer liquid (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL) by filler port 3 (fig. B8/2).
1

B8/2

B9 - CAB DOOR B9
GREASE
1
- Clean and lubricate the points 1 (4 lubricators) (fig. B9) with grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL) and remove the surplus of grease.

B10 - CAB VENTILATION FILTER (OPTION AIR CONDITIONING) B10/1

CLEAN

- Unscrew the thumbscrew 1 (fig. B10/1) and remove protective guard back 2
(fig. B10/1).
- Lift out cabin ventilation filter 3 (fig. B10/2).
- Clean the filter using a compressed air jet. 2
- Check its condition and change if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS).
- Refit the filter and protective casing. 1

B10/2

3-20
B11 - FRONT AND REAR WHEEL REDUCER PIVOTS B11
GREASE

- Clean and lubricate the points 1 (8 lubricators) (fig. B11) with grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL) and remove the surplus of grease.
1

B12 - FRONT AXLE OSCILLATION B12

GREASE
MLT 1035 L Turbo LSU Série 6-E3
- Clean and lubricate the points 1 (2 lubricators) (fig. B12) with grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL) and remove the surplus of grease.

B13 - REAR AXLE OSCILLATION B13

GREASE

- Clean and lubricate the points 1 (2 lubricators) (fig. B13) with grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL) and remove the surplus of grease.

1
1

B14
B14 - TILTING CORRECTOR
GREASE
MLT 1035 L Turbo LSU Série 6-E3
- Clean and lubricate the following points with grease (see: 3 - MAINTENANCE: LUBRICANTS 1
AND FUEL) and remove the surplus of grease.

1 - Lubricator of the tilting corrector cylinder foot axle (1 lubricator) (fig. B14/1).
2 - Lubricator of the tilting corrector cylinder head axle (1 lubricator) (fig. B14/1). 2

3-21
 C - EVERY 250 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

C1 - FAN BELT TENSION C1/1

CHECK - ADJUST
2 3
- Open the I.C. engine bonnet.
- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Loosen screw 1 (fig. C1/1) on the tension pulley.
- Loosen lock nut 2 (fig. C1/1 and C1/2) and screw 3 (fig. C1/1 and C1/2). 1
- Tighten the screw 2 (fig. C1/1 and C1/2) until the belt is as close as possible to the
groove of the pulley 4 (fig. C1/1).
- Make a mark on the head of screw 3 (fig. C1/1 and C1/2) and tighten, turning it 5
times. 4
- Tighten the lock nut 2 (fig. C1/1 and C1/2).
- Retighten screw 1 (fig. C1/1) on the tension pulley.
When changing the fanbelt, tighten screw 3 (fig. C1/1 and C1/2) by one and a half turns, having allowed C1/2
the I.C. engine to idle for 30 minutes.
3

3-22
C2 - ALTERNATOR/CRANKSHAFT BELT TENSION C2/1
CHECK - ADJUST

For this operation, we advise you to use the MANITOU tension meter (fig. C2/1) reference
167418.

- Open the I.C. engine bonnet.

- Unscrew the fastening screws 1 (fig. C2/2).
- Lay down the protective guard 2 (fig. C2/2).
- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE: C2/2
FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the crankshaft and of the alternator.
2
NEW BELT:
- At a pressure of 15 N ± 0.4 on strap 3 (fig. C2/3), the displacement must be about 3,7 mm.
BELT AFTER 20 HOURS OF OPERATION: 1
1
- At a pressure of 13 N ± 0.4 on strap 3 (fig. C2/3), the displacement must be about 3,7 mm.
1 1
- Carry out adjustments if necessary.
- Untighten screws 4 (fig. C2/3) by two to three thread turns.
- Swivel the alternator assembly so as to obtain the belt tension required.
- Retighten screws 4 (fig. C2/3) (tightening torque 22 N.m).
- Put the protective guard back 2 (fig. C2/2).

C2/3

3
If the alternator belt has to be changed, check the tension again after the first 20 hours of operation.
4
4

C3 - COMPRESSOR BELT TENSION (OPTION AIR CONDITIONING) C3/1

CHECK - ADJUST

- Open the I.C. engine bonnet. 2

- Unscrew the fastening screws 1 (fig. C3/1).
- Lay down the protective guard 2 (fig. C3/1).
- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE: 1
1
FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the crankshaft and of the compressor. 1 1
- Under a normal pressure exerted with the thumb (45 N), the belt should move approximately
10 mm.
- Carry out adjustments if necessary.
- Untighten screws 3 (fig. C3/2) with two to three thread turns.
- Swivel the compressor assembly so as to obtain the belt tension required.
- Retighten screws 3 (fig. C3/2).
- Put the protective guard back 2 (fig. C3/1). C3/2

If the compressor belt has to be changed, check the tension again after the first 20 hours of operation.
3

3-23
C4 - ANGLE GEAR BOX LEVEL C4
CHECK

Park the lift truck on level ground with the jib raised and the I.C. engine stopped. 1

- Remove level plug 1 (fig. C4).

- Wipe the dipstick and check the correct level between the MIN and MAX marks.
- If necessary, add oil (see: 3 - MAINTENANCE: E5 - ANGLE GEAR BOX OIL).

C5 - PARKING BRAKE C5
CHECK - ADJUST
A 1
Place the lift truck on level ground with the rated load in the transport position.
- Check braking by locking the parking brake in position A (fig. C5).
- Pull on the lift truck rear towing pin with a minimum force of 3500 daN. The wheels of the
lift truck must not rotate. B
- Carry out adjustments if necessary.
- Progressively tighten the end piece of the lever 1 (fig. C5) and recheck the braking.
- Repeat the operation until the correct braking adjustment is obtained.

C6/1
C6 - CAB VENTILATION FILTER (OPTION AIR CONDITIONING)
CHANGE

- Unscrew thumbscrew 1 (fig. C6/1) and remove protective guard back 2 (fig. C6/1).
- Lift out cabin ventilation filter 3 (fig. C6/2) and replace it with a new one
(see: 3 - MAINTENANCE: FILTERS AND BELTS). 2
- Refit the protective casing.

C6/2

C7 - HEATING BLOCK NON-RETURN VALVE C7

CLEAN

- Since non-return valve 1 (fig. C7) is located under the cab, it is possible for it to become
obstructed with spattered mud for example. Clean if necessary.

3-24
C8 - FRONT AND REAR DIFFERENTIAL OIL LEVEL C8
CHECK

Place the lift truck on level ground with the I.C. engine stopped.
2
- Remove level plug 1 (fig. C8). The oil should be flush with the edge of the hole.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port 2
(fig. C8). 1
- Replace and tighten the level plug 1 (fig. C8) (tightening torque 34 to 49 N.m).
- Repeat this operation for the rear axle differential.

C9 - FRONT AND REAR WHEELS REDUCERS OIL LEVEL C9

CHECK

Place the lift truck on level ground with the I.C. engine stopped.

- Check the level on each front wheel reducer.

- Place level plug 1 (fig. C9) in the horizontal position. 1
- Remove the level plug, the oil should be flush with the edge of the hole.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the same hole.
- Replace and tighten the level plug 1 (fig. C9) (tightening torque 34 to 49 N.m).
- Repeat this operation on each rear wheel reducer.

3-25
 D - EVERY 500 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

D1 - I.C. ENGINE OIL D1/1

DRAIN
D2 - I.C. ENGINE OIL FILTER
CHANGE 1

Place the lift truck on level ground, let the I.C. engine run at idle for a few minutes, then
stop the I.C. engine.

DRAINING THE OIL

- Open the I.C. engine bonnet. 2
- Remove access panel 1 (fig. D1/1).
- Place a container under drain plug 2 (fig. D1/1) and unscrew the plug 3 (fig. D1/2).
- Take drain hose 4 (fig. D1/3).
- Place the end of the drain hose in the container 2 (fig. D1/1) and screw fully the union on
draining port 5 (fig. D1/4). D1/2
- Remove filler cap 6 (fig. D1/5) in order to ensure that the oil is drained properly.

Dispose of the drain oil in an ecological manner. 7

REPLACEMENT OF THE FILTER

- Remove I.C. engine oil filter 7 (fig. D1/2); discard the filter and the filter seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly grease the new oil filter seal and refit the oil filter (see: 3 - MAINTENANCE: FILTERS 3
CARTRIDGES AND BELTS) on the filter bracket.

Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.

FILLING UP THE OIL

D1/3
- Loosen, clean and put back in place the drain hose
4 (fig. D1/3).
- Refit and tighten drain plug 3 (fig. D1/2).
- Refit access panel 1 (fig. D1/1).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS
4 4
AND FUEL) through filler port 8 (fig. D1/5).
- Wait a few minutes to allow the oil to flow into the
sump.
- Start the I.C. engine and let it run for a few minutes.
- Check for possible leaks at the drain plug and the
oil filter.
- Stop the I.C. engine, wait a few minutes and check
MLT ... Turbo ... MLT ... -120 ...
the level between the two notches on dipstick 9 (fig.
D1/5).
- Top up the level if necessary. D1/4

D1/5
6 6
8
8

9
9

MLT ... Turbo ... MLT ... -120 ...

3-26
D3 - DRY AIR FILTER CARTRIDGE D3
CHANGE
1
In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges, see:
3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS. Also, the checking and cleaning
periodicity of the cartridge must be reduced (up to 250 hours in a heavily laden dust
atmosphere and with pre-filtration).
Change the cartridge in a clean location, with the I.C. engine stopped. Never operate the lift truck with
the air filter removed or damaged. 2

- Open the I.C. engine bonnet.

- Loosen the bolts and remove cover 1 (fig. D3).
- Gently remove the cartridge 2 (fig. D3), taking care to avoid spilling the dust.
- Leave the safety cartridge in place.
- The following parts must be cleaned with a damp, clean lint-free cloth.
• The inside of the filter and cover.
• The inside of the filter inlet hose.
• The gasket surfaces in the filter and in the cover.
- Check pipes and connections between the air filter and the I.C. engine and the connection and state of the clogging indicator on
the filter.
- Before mounting check the state of the new cartridge (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.
- Reassemble the cover, guiding the valve downwards.

Make sure the electrical contact on the lift truck is cut, otherwise fuel will be released if the lift pump
is on.

D4 - FUEL PRE-FILTER D4
CHANGE

4
- Open the I.C. engine bonnet.
- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
3
the system. 1
- Place a container under the pre-filter and drain it using drain plug 1 (fig. D4).
2
- Disconnect the harness 2 (fig. D4).
- Unscrew locking screw 3 (fig. D4).
- Remove housing 4 (fig. D4) and discard cartridge 5 (fig. D4) as well as the seals of the
cartridge.
- Clean the inside of the pre-filter head and the housing, using a brush immersed in clean diesel oil.
- Refit the assembly with a new pre-filter and new seals (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Connect the harness
- Pressurise the circuit by means of the hand pump 6 (fig. D4).
- If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: G1 - FUEL SYSTEM).

3-27
D5 - FUEL FILTER
CHANGE D5/1
- Open the I.C. engine bonnet.
- Unscrew the fastening screws 1 (fig. D5/1). 1
- Remove the protective housing 2 (fig. D5/1).
- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
the system.
- Place a container under the fuel filter 3 (fig. D5/2). 4
- Unscrew the filter and discard it 2
- Refit a new fuel filter (see: 3 - MAINTENANCE: FILTERS AND BELTS) on its bracket.

1
1

D5/2
Tighten the fuel filter by hand pressure only and lock the filter in place by a quarter turn.
- Bleed the fuel system: work the hand pump 4 (fig. D5/4) 100 times to remove air from
the system.
- Remove the container from under the filter.
- Start up the I.C. engine and make sure there is no leakage.
- If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: G1 - FUEL SYSTEM).
3

3-28
D6 - CLEANFIX COMPRESSOR FILTER (OPTION) D6/1
CHANGE

- Open the I.C. engine bonnet.

- Remove compressor securing nut 1 (fig. D6/1). (MLT ... -120 ...)
- Remove clip 2 (fig. D6/2).
- Replace filter 3 (fig. D6/2) with a new one (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS) and correctly refit clip 2 (fig. D6/2).
- Refit the compressor securing nut. (MLT ... -120 ...)
1

D6/2

D7 - GEAR BOX OIL FILTER D7/1

CHANGE

- Remove the cover plate 1 (fig. D7/1).

- Unscrew and discard gear box oil filter 2 (fig. D7/2).
- Carefully clean the filter head with a clean, lint-free cloth.
- Slightly lubricate the new seal and fit the seal on the filter.
- Fill up the new gear box oil filter (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND
BELTS) with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
- Refit the filter, making sure that the seal is correctly positioned and tightened.
1
Tighten the gear box oil filter by hand pressure only and lock the filter in place by a quarter turn.
- Put back the cover plate 1 (fig. D7/1).
D7/2

3-29
D8 - HYDRAULIC RETURN OIL FILTER CARTRIDGE D8
CHANGE

Stop the I.C. engine and remove the pressure from the circuits by acting on the hydraulic
controls.
Thoroughly clean the outside of the filter and its surroundings before any intervention in order to prevent
any risk of polluting the hydraulic circuit.
1
- Place a container under hydraulic drain filter 1 (fig. D8).
- Unscrew the body of the filter.
- Remove the hydraulic return oil filter cartridge and fit new replacement cartridge
(see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Make sure that the cartridge is correctly positioned and refit the body of the filter.

Tighten the body of the filter by hand pressure only and lock the body of the filter in place by a quarter turn.

D9 - PARKING BRAKE LEVER MECHANISM D9

GREASE

- Clean and grease articulation axles 1 (fig. D9) with grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL).
1 1

1
1

D10 - CAB VENTILATION FILTER D10/1

CLEAN

- Unscrew thumbscrew 1 (fig. D10/1) remove protective guard back 2 (fig. D10/1).
- Lift out cabin ventilation filter 3 (fig. D10/2).
- Clean the filter using a compressed air jet.
- Check its condition and change if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES 2
AND BELTS).
- Refit the filter and protective casing.
1

D10/2

3-30
D11 - FRONT AND REAR AXLE DIFFERENTIAL OIL D11
DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the differential oil still
warm.
3
Dispose of the drain oil in an ecological manner. 2
- Place a container under drain plugs 1 (fig. D11) and unscrew the plugs.
- Remove level plug 2 (fig. D11) and filler plug 3 (fig. D11) in order to ensure proper
emptying. 1 1 1
- Refit and tighten drain plugs 1 (fig. D11) (tightening torque 34 to 49 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 3 (fig.
D11).
- The level is correct when the oil level is flush with the edge of port 2 (fig. D11).
- Check for any possible leaks at the drain plugs.
- Refit and tighten level cap 2 (fig. D11) (tightening torque 34 to 49 N.m) and filler port 3 (fig. D11) (tightening torque 34 to 49
N.m).
- Repeat this operation for the rear axle differential.

3-31
 E - EVERY 1000 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

E1 - FUEL TANK E1/1

CLEAN

While carrying out these operations, do not smoke or work near a flame.
Place the lift truck on level ground with the I.C. engine stopped.

- Inspect the parts susceptible to leaks in the fuel circuit and in the tank.
- In the event of a leak, contact your dealer. 1

Never try to carry out a weld or any other operation by yourself, this could provoke an explosion or a
fire.
- Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
- Remove filling plug 2 (fig. E1/2) in order to ensure that the oil is drained properly.
- Rinse out with ten litres of clean diesel through filler port 3 (fig. E1/2). E1/2
- Refit and tighten the drain plug (tightening torque 29 to 39 N.m).
- Fill the fuel tank with clean diesel filtered through the filler port.
- Refit the filling cap. 2
- If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: G1 - FUEL SYSTEM).
3

E2 - SAFETY DRY AIR FILTER CARTRIDGE E2

CHANGE

- For the disassembly and reassembly of the dry air filter cartridge, see: 3 - MAINTENANCE:
D3 - AIR FILTER CARTRIDGE.
- Gently remove the dry air filter safety cartridge 1 (fig. E2), taking care to avoid spilling
the dust.
1
- Clean the gasket surface on the filter with a damp, clean lint-free cloth.
- Before mounting, check the state of the new safety cartridge (see: 3 - MAINTENANCE:
FILTERS AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the
middle.

NOTE: The periodicity for changing the safety cartridge is given for information only. It must
be changed for every two changes of the dry air filter cartridge.

3-32
E3 - GEAR BOX OIL
DRAIN E3/1
E4 - GEAR BOX SUMP STRAINER
CLEAN

Place the lift truck on level ground with the I.C. engine stopped, the gear box oil still
1
warm.

DRAINING THE OIL

- Place a container under drain plug 1 (fig. E3/1) and under cover 2 (fig. E3/2) and unscrew
the drain plug.
- Remove cover plate 3 (fig. E3/3).
- Remove dipstick 4 (fig. E3/4) and unscrew filling plug 5 (fig. E3/4) in order to ensure that
the oil is drained properly.
E3/2

Dispose of the drain oil in an ecological manner.

2
CLEANING THE STRAINER
- Remove cover 2 (fig. E3/2) and set aside the O-ring joint and sealing washer.
- Allow the rest of the oil to drain away.
- Remove and clean the strainer using a compressed air jet.
- Clean the magnetic section on the plate.
- Refit the assembly and tighten up plate 2 (fig. E3/2) (tightening torque 18 to 31 N.m).

FILLING UP THE OIL

- Refit and tighten drain plug 1 (fig. E3/1) (tightening torque 34 to 54 N.m). E3/3
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 5 (fig. E3/4)
and refit the filler cap.
- Start the I.C. engine and let it run for a few minutes.
- Check any possible leaks from the drain plug or cover.
- Stop the I.C. engine, and within 5 minutes of the I.C. engine being stopped, check on the
dipstick 4 (fig. E3/4) the correct level between the two MIN and MAX. marks.
- Top up the level if necessary.
- Put back the cover plate 3 (fig. E3/3).

E3/4

3-33
E5 - ANGLE GEAR BOX OIL E5/1
DRAIN

Place the lift truck on level ground with the I.C. engine stopped, the angle gear box oil still
warm.

- Place a container under drain plug 1 (fig. E5/1) and unscrew the plug.
- Remove dipstick 2 (fig. E5/2) and unscrew filler cap 3 (fig. E5/2) in order to ensure that 1
the oil is drained properly.

Dispose of the drain oil in an ecological manner.

- Refit and tighten drain plug 1 (fig. E5/1) (tightening torque 20 to 29 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 3 (fig. E5/2)
and refit the filler cap.
- Check the correct level between the MINI and MAX. marks on dipstick 2 (fig. E5/2). E5/2
- Check for any possible leaks at the drain plug.

E6 - HYDRAULIC OIL E6/1

DRAIN
E7 - SUCTION OIL STRAINER FOR HYDRAULIC OIL TANK
CLEAN
E8 - FILTER CAP FOR HYDRAULIC OIL TANK
CHANGE
E9 - DISTRIBUTOR CONTROL HEAD FILTER
CHANGE
1
Place the lift truck on level ground with the I.C. engine stopped and telescope boom
retracted and lowered as far as possible. 1

Before any intervention, thoroughly clean the area surrounding the drain plugs and the suction cover on
the hydraulic tank.
E6/2
DRAINING THE OIL
- Place a container under drain plug 1 (fig. E6/1) and unscrew the plug. 2
- Remove filler cap 2 (fig. E6/2) in order to ensure that the oil is drained properly.
7
Dispose of the drain oil in an ecological manner.

CLEANING THE STRAINER

- Remove suction cover 3 (fig. E6/3).
- Remove and clean the strainer using a compressed air jet, check its condition and replace
if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Refit the strainer and tighten the suction cover 3 (fig. E6/3) (tightening torque 81 N.m)
making sure the seal is in the correct position.
E6/3

3-34
 REPLACING THE DISTRIBUTOR CONTROL HEAD FILTER
E6/4

4
5 5

5
6

- Remove the half clamp 4 (fig. E6/4).

- Undo the two couplings 5 (fig.E6/4) and replace the filter 6 (fig. E6/4).

Be careful to mount the filter 6 (fig. D6/4) in the same direction as the arrow.
E6/5
- Refit the half clamp 4 (fig. E6/4).

FILLING UP THE OIL

- Clean and refit drain plugs 1 (fig. E6/1) (tightening torque 29 to 39 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 7 (fig.
E6/2).
8

Use a clean container and funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 8 (fig. E6/5), the oil level should be at the level of the
red point.
- Check for any possible leaks at the drain plugs.
- Replace filler plug 2 (fig. E6/2) with a new filler plug (see: 3 - MAINTENANCE: FILTERS
CARTRIDGES AND BELTS).

HYDRAULIC CIRCUIT DECONTAMINATION

- Let the I.C. engine run (accelerator pedal at halfway travel) for 5 minutes without using anything on the lift truck, then for 5 more
minutes while using completely the hydraulic movements (except the steering system and the service brakes).
- Accelerate the I.C. engine at full speed for 1 minute, then activate the steering system and the service brakes.
- This operation makes a pollution abatement of the circuit possible through the hydraulic return oil filter.
This should be carried out by your dealer after each oil change.
The hydraulic oil used in the circuit must be at least equal in quality to class 8 (according to NAS 1638). Your dealer will be able
to clean the hydraulic circuit using an external unit and check the quality of the oil in order to ensure the long life of hydraulic
components and particularly of the main pump.

3-35
E10 - SEAT BELT
CHECK

SEAT BELT WITH TWO ANCHORING POINTS

- Check the following points:
• Fixing of the anchoring points on the seat.
• Cleanness of the strap and the locking mechanism.
• Triggering of the locking mechanism.
• Condition of the strap (cuts, curled edges).

REELED BELT WITH TWO ANCHORING POINTS

- Check the points listed above together with the following points:
• The correct winding of the belt.
• Condition of the reel guards.
• Roller locking mechanism when the strap is given a sharp tug.

NOTE: After an accident, replace the seat belt.

In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.

E11 - FRONT AND REAR WHEELS REDUCERS OIL E11

DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the reducers oil still
warm.
1
Dispose of the drain oil in an ecological manner. B

- Drain and change each front wheel reducer.

- Place drain plug 1 (fig. E11) in position A.
A
- Place a container under the drain plug and unscrew the plug.
- Let the oil drain fully.
- Place the drain port in position B, i.e. in a level port.
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by level port 1 (fig. E11).
- The level is correct when the oil level is flush with the edge of the hole.
- Refit and tighten the drain plug 1 (fig. E11) (tightening torque 34 to 49 N.m).
- Repeat this operation on each rear wheel reducer.

3-36
 F - EVERY 2000 HOURS OF SERVICE
Carry out the operations described previously as well as the following operations.

F1 - COOLING LIQUID F1/1

DRAIN

These operations are to be carried out if necessary or every two years at the beginning of
winter. Place the lift truck on level ground with the I.C. engine stopped and cold.

DRAINING THE LIQUID

- Open engine hood and lift the battery cover.
1
- Place a container under hose 1 (fig. F1/1) on the radiator and drain plug 2 (fig. F1/2) of
the engine block. Remove the hose and loosen the drain plug.
- Remove filling plug 3 (fig. F1/3) of the radiator.
- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.
- Check the condition of the hoses as well as the fastening devices and change the hoses
if necessary.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
F1/2
FILLING THE LIQUID
- Refit and tighten the hose 1 (fig. F1/1) and drain plug 2 (fig. F1/2) (tightening torque 40
N.m).
- Slowly fill up the circuit with cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL) to the middle of gauge 4 (fig. F1/3) through filler port 5 (fig. F1/3).
- Put back filling plug 3 (fig. F1/3).
- Run the I.C. engine at idle for a few minutes. 2
- Check for any possible leaks.
- Check the level and refill if necessary.

The I.C. engine does not contain any corrosion resistor and must be filled during the whole year with a
mixture containing 25% of ethylene glycol-based antifreeze.
F1/3
3

3-37
F2 - AIR CONDITIONING (OPTION)
CLEANING - INSPECTION

CLEANING CONDENSER AND EVAPORATOR COILS (*)

CLEANING CONDENSATE TRAY AND RELIEF VALVE (*)
COLLECTING COOLANT TO REPLACE FILTER-DRIER (*)
REFILLING WITH COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES (*)

NOTE: When opening the evaporator unit, remember to replace the cover seal.

(*): (CONSULT YOUR DEALER).

CAUTION: DO NOT ATTEMPT TO REPAIR ANY PROBLEMS YOURSELF. ALWAYS REFER TO YOUR DEALER WHEN REFILLING CIRCUITS, AS THEY HOLD THE
CORRECT SPARE PARTS, AS WELL AS HAVING THE NECESSARY TECHNICAL KNOWLEDGE AND TOOLS.
- Do not open the circuit under any circumstances as this would cause the coolant to be lost.
- The cooling circuit contains a gas which can be dangerous under certain conditions. This gas, coolant R 134a, is colourless,
odourless and heavier than air.
• If this gas is inhaled, take the victim into fresh air, give oxygen or artificial respiration if necessary and call a doctor.
• If the gas is in contact with the skin, wash it immediately under running water and remove any contaminated garments.
• If the gas is in contact with the eyes, rinse them in clear water for 15 minutes and call a doctor.
- The compressor has an oil level gauge (fig. F2). Never unscrew this gauge because it
F2
would depressurizes the installation. The oil level is only checked when changing the oil
in the circuit.

3-38
 G - OCCASIONAL MAINTENANCE

G1 - FUEL SYSTEM G1
BLEED

These operations are to be carried out only in the following cases:

• A component of the fuel system replaced.
• A drained tank.
• Running out of fuel.

Any contact with highly pressurized fuel risks presents a risk of percutaneous penetration or burns.
Spraying fuel under high pressure can cause a fire.
Failure to follow the inspection and maintenance instructions may result in serious injury.

Never work on the high pressure system. Failure to follow this instruction may result in serious damage to the engine.
The high pressure furl system must be adjusted and repaired only by approved and suitably trained technicians.

Ensure that the level of fuel in the tank is sufficient and bleed in the following order:
- Open the I.C. engine bonnet.
- Check the condition of the fuel system
- Operate the hand pump 1 (fig. G1) 50 times to remove air from the low pressure system.

- So the I.C. engine is ready to be started up.

- Turn the I.C. engine over slowly for 5 minutes immediately after bleeding the fuel feed circuit, in order to ensure that the injection
pump has been bled thoroughly.

NOTE: If the I.C. engine functions correctly for a short time then stops or functions irregularly, check for possible leaks in the low
pressure circuit. If in doubt, contact your dealer.

3-39
G2 - WHEEL G2/1
CHANGE

In the event of a wheel being changed on the public highway, make sure of the following points:
For this operation, we advise you to use the hydraulic jack MANITOU reference 505507 and
the safety support MANITOU reference 554772.

- Stop the lift truck, if possible on even and hard ground.

- To pass on stop of lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING
INSTRUCTIONS UNLADEN AND LADEN).
- Put the warning lights on.
- Immobilise the lift truck in both directions on the axle opposite to the wheel to be
changed.
- Unlock the nuts of the wheel to be changed.
- Place the jack under the flared axle tube, as near as possible to the wheel and adjust the G2/2
jack (fig. G2/1).
- Lift the wheel until it comes off the ground and put in place the safety support under the
axle (fig. G2/2).
- Completely unscrew the wheel nuts and remove them.
- Free the wheel by reciprocating movements and roll it to the side.
- Slip the new wheel on the wheel hub.
- Refit the nuts by hand, if necessary grease them.
- Remove the safety support and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see: 3 - MAINTENANCE: A - DAILY OR EVERY
10 HOURS SERVICE for tightening torque).

NOTE: There is an OPTIONAL wheel toolkit and anti-puncture kit.

G3 - FRONT HEADLAMPS G3
ADJUST
h2 = h1 - (l x 2 / 100)

RECOMMENDED SETTING
(as per standard ECE-76/756 76/761 ECE20) h1
Set to - 2% of the dipped beam in relation to the horizontal line of
the headlamp. +%
-%
-2%

ADJUSTING PROCEDURE h1
h2
- Place the lift truck unloaded and in the transport position and
perpendicular to a white wall on flat, level ground (fig. G3).
l
- Check the tyre pressures (see: 2 - DESCRIPTION:
CHARACTERISTICS).
- Place the forward/reverse selector in neutral and release the
parking brake.

CALCULATING THE HEIGHT OF THE DIPPED BEAM (H2)

• h1 = Height of the dipped beam in relation to the ground.
• h2 = Height of the adjusted beam.
•l = Distance between the dipped beam and the white wall.

G4 - LIFT TRUCK
TOW

Do not tow the lift truck at more than 25 km/h.

- Place the forward/reverse selector in neutral and the gear shift in neutral (according to model of lift truck).
- Release the parking brake.
- Put the warning lights on.
- If the I.C. engine is not running there will be no steering or braking assistance. Operate the steering and pedal slowly avoiding
sudden jerky movements.

3-40
G5 - LIFT TRUCK G5/1
SLING

- Take into account the position of the lift truck centre of gravity for lifting
(fig. G5/1).
A = 1450 mm B = 1110 mm MLT 634 . . .
A = 1345 mm B = 1215 mm MLT 731 T
A = 1485 mm B = 1325 mm MLT 735 T LSU
A = 1445 mm B = 1365 mm MLT 735 -120 LSU
A = 1450 mm B = 1360 mm MLT 735 -120 LSU PS
A= mm B= mm MLT 741 T LSU
A B
A = 1525 mm B = 1295 mm MLT 741 -120 LSU
A = 1535 mm B = 1275 mm MLT 741 -120 LSU PS
A = 1610 mm B = 1200 mm MLT 1035 LT LSU
- Place the hooks in the fastening
G5/2 G5/3
points provided (fig. G5/2 and
G5/3).

G6 - LIFT TRUCK ON A PLATFORM G6/1

TRANSPORT
Ensure that the safety instructions connected to the platform are respected before the loading of the lift
truck and that the driver of the means of transport is informed about the dimensions and the weight of
the lift truck (see: 2 - DESCRIPTION: CHARACTERISTICS).

Ensure that the platform has got dimensions and a load capacity sufficient for transporting the lift truck.
Check also the pressure on the contact surface allowable for the platform in connection with the lift
truck.

For lift trucks equipped with a turbo-charged I.C. engine, block off the exhaust outlet to avoid rotation of
the turbo shaft without lubrication when transporting the vehicle.
LOAD THE LIFT TRUCK
- Block the wheels of the platform.
- Fix the loading ramps so that you obtain an angle as little as possible to lift the lift G6/2
truck.
- Load the lift truck parallel to the platform.
- Stop the lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING INSTRUCTIONS
UNLADEN AND LADEN).

STOW THE LIFT TRUCK

- Fix the chocks to the platform at the front and at the back of each tyre (fig. G6/1).
- Fix also the chocks to the platform in the inside of each tyre (fig. G6/2).
- Secure the lift truck to the platform with sufficiently strong ropes. At the front of the lift
truck, attach the ropes to the fastening points 1 (fig. G6/3) and at the rear to the towing
pin 2 (fig. G6/4).
- Tighten the ropes (fig. G6/5).

G6/3 G6/4 G6/5

3-41
3-42
CONTENTS

4 - ENGANGING THE
ATTACHMENTS

4-1
4-2
TABLE OF CONTENTS

INTRODUCTION 4-5

PICKING UP THE ATTACHMENTS 4-6

4-3
4-4
 INTRODUCTION

- Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS.

- A wide range of attachments, specially designed and perfectly suitable for your lift truck is available and guaranteed by
MANITOU.

- The attachments are delivered with a load chart concerning your lift truck. The operator’s manual and the load chart should be
kept in the places provided in the lift truck. For standard attachments, their use is governed by the instructions contained on this
notice.

- Some particular uses require the adaptation of the attachment which is not provided in the price-listed options. Optional solutions
exist, consult your dealer.
All attachments with a suspended load (winch, crane jib, crane jib with winch, hook, etc.) MUST be used with a lift truck equipped with a hydraulic
movement cut-out device. In this case, the movement cut-out must be switched on and the transverse attitude perfectly horizontal.

Only attachments approved by MANITOU are to be used on our lift trucks (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE: TECHNICAL
SPECIFICATIONS OF ATTACHMENTS). The manufacturer’s liability will be denied in case of modification or of attachment adaptation carried out without
his knowing it.

Depending on their size, certain attachments may, when the boom is lowered and retracted, come into contact with the front tyres and cause damage
to them, if reverse tilt is activated in the forward tilt direction. TO REMOVE THIS RISK, EXTEND THE TELESCOPE TO A SUFFICIENT EXTENT FOR THE
PARTICULAR LIFT TRUCK AND ATTACHMENT SO THAT THIS CONTACT IS NOT POSSIBLE.

Maximum loads are defined by the capacity of a lift truck taking account of the attachment’s mass and centre of gravity. In the event of the attachment
having less capacity than the lift truck, never exceed this limit.

4-5
 PICKING UP THE ATTACHMENTS

A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE A

TAKING UP AN ATTACHMENT
- Ensure that the attachment is in a position facilitating the locking to the carriage. If it is
not correctly oriented, take the necessary precautions in order to move it safely.
- Check that the locking pin and the clip are in position in the bracket (fig. A).
- Place the lift truck with the boom fully lowered in front of and parallel to the attachment,
tilt the carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the boom, incline
the carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.

HAND LOCKING
- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D).
Do not forget to refit the clip. B

HAND RELEASING
- Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back
the locking pin and the clip in the bracket (fig. A).

LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.

4-6
B - HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE A

TAKING UP AN ATTACHMENT
- Ensure that the attachment is in a position facilitating the locking to the carriage. If it is
not correctly oriented, take the necessary precautions in order to move it safely.
- Check that the locking pin and the clip are in position in the bracket (fig. A).
- Place the lift truck with the boom fully lowered in front of and parallel to the attachment,
tilt the carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the boom, incline
the carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.

MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT

- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D).
B
Do not forget to refit the clip.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Remove the pressure of the hydraulic circuit by operating switch 1 (fig. E) on the distributor
lever backwards and forwards 4 or 5 times.
- Connect the rapid connectors according to the logic of the attachment’s hydraulic
movements.
Make sure that the rapid connectors are clean and protect the holes which are not used, with the caps
provided.

HAND RELEASING AND DISCONNECTING THE ATTACHMENT

- Proceed in the opposite order to that described in MANUAL LOCKING AND CONNECTION
OF THE ATTACHMENT while making sure you put the locking pin back into the bracket (fig. A).

LAYING AN ATTACHMENT C
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.

4-7
4-8
Contents

Electrical schematic diagram F1

Pages

POSITION OF CONNECTORS ON DIAGRAMS . . . . . . . . . . . . . . . . . . . . . .F3

POSITION OF COMPONENTS ON DIAGRAMS. . . . . . . . . . . . . . . . . . . . . .F9
POSITION OF FUSES AND RELAYS ON DIAGRAMS . . . . . . . . . . . . . . . . .F15
POSITION OF SPLICES ON DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . .F16

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F17

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 F2 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3
80

80-02-M171EN (21/12/2010)
 Electrical schematic diagram F3
MLT 735 -120 LSU Serie 6-E3

POSITION OF CONNECTORS ON DIAGRAMS

Connectors
Position on diagram Hydraulic
Wiring harness Name
Item Designation correspon-
type component 1 2 3 4 dence
MAIN X01 TRANSMISSION CUT-OFF ON GEAR LEVER 26B

MAIN X02 SEAT SWITCH POWER SUPPLY 25D

MAIN X03 SEAT SWITCH INFORMATION 25D

MAIN X04 POWER SUPPLY TO OPTIONS 36C

MAIN X08 TRANSMISSION FLUID THERMOSTAT (PS: on PS gear box) 18E

MAIN X09 FORWARD SOLENOID 21B

MAIN X10 REVERSE MOTION SOLENOID 21B

MAIN X11 PNEUMATIC SEAT 27B

MAIN X12 HAND BRAKE CONNECTOR 27B

MAIN X13 FRONT RIGHT HEADLIGHT 13A

MAIN X14 HORN 18E

MAIN X15 FRONT WHEEL ALIGNMENT 34B

MAIN X16 RIGHT REAR LIGHT 15A

MAIN X17 LEFT REAR LIGHT 14A

MAIN X18 NUMBER PLATE LIGHT 17A

MAIN X19 REAR TRAILER CONNECTOR 16B

MAIN X20 REVERSING SOUND ALARM 16A

MAIN X21 REAR WHEEL ALIGNMENT 35B

MAIN X22 CLOGGING HYDRAULIC FILTER 18E

CONTROL VALVE X23 HYDRAULIC CUT-OFF EV / VS 32A

MAIN / ENG X24 MAIN HARNESS / ENGINE HARNESS INTERFACE 2D

MAIN X25 OPTION WORKING HEAD LIGHTS ON JIB 46B

MAIN X26 CAB UPPER HARNESS 42E

80
MAIN X27 CAB LOUDSPEAKER HARNESS 45B

CONTROL VALVE X28 TELESCOPE RETRACTION EV 31A

CONTROL VALVE X29 TELESCOPE EXTENSION EV 31A

MAIN X30 HEATING / VENTILATION 19B

MAIN X31 AIR CONDITIONING OPTION 19C

MAIN X32 CIGARETTE LIGHTER CONNECTOR 23C

MAIN X33 HYDR MVT NEUTRALISATION SWITCH 31C

CONTROL VALVE X34 ATTACHMENT MINUS DIRECTION EV 30A

CONTROL VALVE X35 ATTACHMENT PLUS DIRECTION EV 30A

MAIN X36 JSM 32G

MAIN X37 PLATE POWER CONNECTOR 11F

MAIN X38 PLATE FAULT INDICATOR LAMP CONNECTOR 18F

MAIN X39 LIGHTING HARNESS 12F

MAIN X40 IGNITION SAFETY / WHEEL ALIGNMENT / BRAKE FLUID JAR 9F

MAIN X41 OPTION AND CEILING LIGHT POWER SUPPLY 8F

MAIN X42 FUSE HOLDER PLATE 23F

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 F4 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

Connectors
Position on diagram Hydraulic
Wiring harness Name
Item Designation correspon-
type component 1 2 3 4 dence
MAIN X44 RELAYS / HYDR MVT CUT-OFF / TRANSMISSION CUT-OUT / EV 19F

MAIN X45 FUSE AND RELAY HOLDER PLATE POWER SUPPLY AND EARTH 7F

MAIN X46 HELLA K17 MINI RELAY HOLDER 11C

MAIN X47 STARTER ATOFUSE HOLDER 1E

MAIN X48 DIAG CONNECTOR ATOFUSE HOLDER 7C

MAIN X49 REAR FOG LIGHT SWITCH 18A

MAIN X50 FRONT WHEEL ALIGNMENT INDICATOR LAMP 34A

MAIN X51 REAR WHEEL ALIGNMENT INDICATOR LAMP 35A

MAIN X52 WHEEL ALIGNMENT SWITCH 35C

MAIN X53 CAR RADIO LOUDSPEAKER OUTPUT 5F

MAIN X54 4-WAY KEY SWITCH 2F

MAIN X55 6-WAY KEY SWITCH 3F

MAIN X56 SPU CN1-A 29F

MAIN X57 SPU CN1-B 32F

MAIN X58 LLMI SAFETY MODULE 33B

MAIN X59 CLOCK 7A

MAIN X60 CLOCK LIGHT 7A

MAIN X61 TRANSMISSION CUT-OFF SWITCH 25B

MAIN X68 HOUR METER REV COUNTER MODULE 9A

MAIN X70 FRONT WINDSCREEN WASHER PUMP 40F

MAIN X71 BRAKE PEDAL TRANSMISSION CUT-OFF SWITCH 26B

MAIN X72A BRAKE FLUID LEVEL 12C

MAIN X72B BRAKE FLUID LEVEL 12C

80

MAIN X73A STOP SWITCH 11A

MAIN X73B STOP SWITCH 11A

MAIN X74 FRONT LEFT-HAND LIGHT 12A

MAIN X75 TUV SIDELIGHT CONTROL BY WORKING LIGHT ON JIB 13G

MAIN X76A CAB LEFT-HAND EARTH 1A

MAIN X76B CAB LEFT-HAND EARTH 1A

MAIN X77 FRONT WINDSCREEN WIPER 41F

MAIN X79 WIPER STALK SWITCH 40G

MAIN X80 WIPER RESET 42G

MAIN X81 STEERING FAULT INDICATOR LAMP 14E

MAIN X82 STEERING FAULT PRESSURE SWITCH 13A

MAIN X83 DASHBOARD INDICATOR LAMPS (4 way) 14E

MAIN X87 CONTROL VALVE HARNESS INTERFACE 30D

MAIN X89 ENGINE WATER TEMPERATURE MODULE 10A

MAIN X90 FUEL LEVEL MODULE 7A

MAIN X91 CIGARETTE LIGHTER LIGHT 23C

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 Electrical schematic diagram F5
MLT 735 -120 LSU Serie 6-E3

Connectors
Position on diagram Hydraulic
Wiring harness Name
Item Designation correspon-
type component 1 2 3 4 dence
CONTROL VALVE X92 PROPORTIONAL EV ON JIB LOWERING / VRD-VRP 31A
MAIN / CONT
X93 TILTING CUT-OFF EV / VCI 32A
VALVE
OPT X94 JIB HEAD ELECTROVALVE 34B

MAIN X95 HELLA K12-K18 MINI RELAY HOLDER 22B

OPT (MT) X96 REAR 7-PIN SOCKET ELECTRIC CONNECTOR 16A

MAIN X97 JIB HEAD ELECTRICAL PROVISION OR JIB HEAD EV 34B

MAIN X98 TRANSMISSION FLUID PRESSURE SWITCH (PS: ON PS GEAR BOX) 19E

MAIN X99 VISHAY GAUGE CONNECTOR 29B

MAIN X100 JIB ANGLE SENSOR EN15000 30G

CABLE X101 MID-CHASSIS EARTH / ENGINE 2A

MAIN X102A FUSE HOLDER POWER SUPPLY BY 30 THK 36E

MAIN X102B 1A FUSE HOLDER FOR MICROPHONE RC2-20 POWER SUPPLY 37E

MAIN X103 JIB HEAD CONNECTOR OR JIB HEAD EV SWITCH 35C

MAIN X104 LSU PUMP 39E

MAIN / CONT
X105 CONTROL VALVE HARNESS EARTH CONNECTION 1A
VALVE
MAIN X106 REAR CHASSIS EARTH 1A

MAIN X107 CAB REAR EARTH 1A

CABLE X108 FRONT CHASSIS EARTH ON CAB BRACKET 26A

MAIN X109 LSU ECU / REXTROTH 35F

MAIN X112 FORCED OPERATION PUSH BUTTON 28G

MAIN X113 FORCED OPERATION POTENTIOMETER 29G

MAIN X114 EMERGENCY STOP 26F

80
MAIN X115 DIAGNOSTIC 34F

MAIN X116 EASY CONNECT SYSTEM SWITCH 28A

MAIN X117 ATTACHMENT LOCKING SWITCH 32C

MAIN X118 ANTI-THEFT MODULE PROVISION 24F

MAIN X119 OVERRIDE SWITCH 33C

MAIN X121 CANLINK MODULE 9C

CABLE X126 ENGINE EARTH (ALTERNATOR CABLE) 1A

MAIN X134 JIB RETRACTION SENSOR 31G

OPT X135 OPTION CAB RIGHT-HAND EARTH 1A

CAB X136 FRONT WORKING HEAD LIGHT INTERCONNECTION 43B

CAB X138A LEFT LOUDSPEAKER 45B

CAB X138B LEFT LOUDSPEAKER 45B

CAB X139A RIGHT LOUDSPEAKER 45B

CAB X139B RIGHT LOUDSPEAKER 45B

CAB X140 LEFT FRONT WORKING LIGHT 43B

CAB X141 RIGHT FRONT WORKING LIGHT 43B

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 F6 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

Connectors
Position on diagram Hydraulic
Wiring harness Name
Item Designation correspon-
type component 1 2 3 4 dence
CAB X142 REAR WINDSCREEN WIPER 41B

CAB X143 SIDE WINDSCREEN WIPER 40B

CAB X144 ROOF WINDSCREEN WIPER 41B

CAB X145A ROTATING BEACON LIGHT 42B

CAB X145B ROTATING BEACON LIGHT 42B

CAB X146 LEFT REAR WORKING LIGHT 44B

CAB X147 RIGHT REAR WORKING LIGHT 44B

CAB X148A ROOF LIGHT 44B

CAB X148B ROOF LIGHT 44B

CAB X148C ROOF LIGHT 44B

CAB X149 ROOF / SIDE WINDSCREEN WIPER SWITCH 41C

CAB X150 REVOLVING LIGHT SWITCH 42C

CAB X151 WORKING LIGHT SWITCH 43C

CAB X152 JIB-MOUNTED WORKING LIGHT SWITCH 45C

CAB X153 DEFROSTING SWITCH 45C

CAB X154A REAR DEFROST 44D

CAB X154B REAR DEFROST 44C

ENGINE ECM X158 ENGINE ECM J2 6B

ENGINE ECM X159 ECM CONNECTOR DIAGNOSTIC CONNECTOR 6B

ENGINE CABLE X160 BATTERY FUSE BOX BF1 1C

ENGINE X161 STARTER SOLENOID 1B

ENGINE X165 FUEL GAUGE 2A

ENGINE X166A AIR FILTER CLOGGING 3A

80

ENGINE X166B AIR FILTER CLOGGING 3A

ENGINE X167 PREHEAT 2B

ENGINE X168 ENGINE EARTH 1A

ENGINE X171 PRE-HEATING RELAY 2C

ENGINE X172 PRE-HEATING / ALTERNATOR POWER FUSES 2C

ENGINE X173 EQUIPMENT POWER FUSES (MLT) - ECM FUSE (MT) 2D

ENGINE X174 CLOCK EARTH 1B

CABLE X176 ENGINE EARTH 2A

ENGINE X177 ENGINE ECM J1 4B

ENGINE X178 PRESENCE OF WATER IN DIESEL FUEL 3A

ENGINE X179 ACCELERATOR POTENTIOMETER 4A

HOLDER PLATE X180 INDICATOR LAMP HARNESS CONNECTOR E 15F

HOLDER PLATE X181 INDICATOR LAMP HARNESS CONNECTOR F 17F

HOLDER PLATE X182 DASHBOARD INDICATOR LAMPS (4 way) 14E

HOLDER PLATE X183 DASHBOARD INDICATOR LAMPS (16 way) 15E

HOLDER PLATE X184 BATTERY CHARGE INDICATOR LAMP 17E

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 Electrical schematic diagram F7
MLT 735 -120 LSU Serie 6-E3

Connectors
Position on diagram Hydraulic
Wiring harness Name
Item Designation correspon-
type component 1 2 3 4 dence
HOLDER PLATE X185 STEERING FAULT INDICATOR LAMP 15E

HOLDER PLATE X187 WARNING SWITCH 17G

HOLDER PLATE X188 LIGHTING STALK SWITCH 11G

HOLDER PLATE X189 AWAITING STALK SWITCH-PLATE TUV DIODE 10G

HOLDER PLATE X190 AWAITING PLATE-STALK SWITCH TUV DIODE 10G

HOLDER PLATE X191 AWAITING PLATE-WORKING LIGHTS TUV DIODE 11G

HOLDER PLATE X192 CAR RADIO POWER SUPPLY 7F

OPT X200A BATTERY CUT OFF 1B

OPT X200B BATTERY CUT OFF 1A

OPT X202 BLUE HEADLIGHT SWITCH 38B

AGGRAVATING MVT CUT-OFF POWER SUPPLY ON NON
OPT X203 36C
EN15000 VERSION
OPT X204 AIR-CONDITIONING HIGH PRESSURE SENSOR 19B

OPT X205 REMOTE AIR-CONDITIONING module 19B

OPT X206 REMOTE AIR-CONDITIONING module 20B

OPT X207 AIR-CONDITIONING COMPRESSOR 20A

OPT X208 AIR-CONDITIONING FAN MOTOR 1 20A

OPT X209 AIR-CONDITIONING FAN MOTOR 2 20A

OPT X210 LEFT-HAND JIB WORKING LIGHT 46B

OPT X211 RIGHT-HAND JIB WORKING LIGHT 46B

OPT X212 CLEANFIX SWITCH 39B

OPT X213 CLEANFIX 38A

OPT X216 REAR HYDRAULIC SELECTOR SWITCH 37B

OPT X217 REAR HYDRAULIC CONTROL SWITCH 36B

80
OPT X218 SELECTOR EV 37A

OPT X219 REAR HYDRAULIC EV 1 35A

OPT X220 REAR HYDRAULIC EV 2 36A

OPT X221 REAR HYDRAULIC PROVISION STANDBY CONNECTOR 36C

OPT X222 JIB SUSPENSION SWITCH 39E

OPT X223 JIB SUSPENSION EV 1 37C

OPT X224 JIB SUSPENSION EV 2 37C

OPT X225 JIB SUSPENSION VALVE PRESSURE SWITCH 38D

OPT X226 JIB POSITION SENSOR 38E

OPT X227 JIB SUSPENSION CUT-OFF RELAY 38C

OPT X228 JIB SUSPENSION POWER SUPPLY RELAY 38C

OPT X229 JIB SUSPENSION REVERSE TILT PRESSURE SWITCH 37D

OPT X230 NC T.S. REVERSE TILT MVT DETECTION PRESSURE SWITCH 37D

OPT X231 NC T.S. REVERSE TILT MVT DETECTION PRESSURE SWITCH 37D

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 F8 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

Connectors
Position on diagram Hydraulic
Wiring harness Name
Item Designation correspon-
type component 1 2 3 4 dence
OPT X232 NC JIB LOWERING MVT DETECTION PRESSURE SWITCH 38D

OPT X233 NC JIB LOWERING MVT DETECTION PRESSURE SWITCH 38D

OPT X234 NC T.S. DUMPING MVT DETECTION PRESSURE SWITCH 38D

OPT X235 NC T.S. DUMPING MVT DETECTION PRESSURE SWITCH 25G

OPT X236 FINTRONIC ANTI-START UNIT 25G

OPT X238 PRE-HEATING ROD 1B

OPT X239 ANTI-THEFT UNIT 25G

ENGINE D+ ALTERNATOR D+ 2C

ENGINE B+ ALTERNATOR B+ 2C
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 Electrical schematic diagram F9
MLT 735 -120 LSU Serie 6-E3

POSITION OF COMPONENTS ON DIAGRAMS

Components
Position on diagram Hydraulic
Item Designation
1 2 3 4 correspondence

A1 ANTI-THEFT UNIT 26G

A2 INSTRUMENT PANEL 17D

A3 SPU MODULE 30F

A4 LSU PROPORTIONAL PUMP ECU 35F

A5 LONGITUDINAL SECURITY MODULE (LLMI) 33B

A6 AIR CONDITIONING MODULE 20B

A7 CAR RADIO 6G

A8 HEATING / VENTILATION PANEL 19B

A9 CLEANFIX MODULE 38A

A10 FINTRONIC ANTI-START UNIT 24G

A11 FINTRONIC ANTENNA 25G

A12 JSM (JOYSTICK SWITCH AND MOVE) 32G

A13 DIGICODE 26G

A14 MODCLÉ 27G

A15 HOLDER PLATE 23G

A19 ENGINE ECM 4B

A20 CANLINK MODULE 8C

BF1 PRE-HEATER POWER FUSE AND RELAY BOX 1D

B1 REVERSING SOUND ALARM 16A

B2 HORN 18E

B4 WATER IN DIESEL SENSOR 2A

B6 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH 3A

B7 HYDRAULIC FILTER CLOGGING PRESSURE SWITCH 18E

80
B8 STEERING FAULT PRESSURE SWITCH 13A

B9 FRONT WHEEL ALIGNMENT SENSOR 34B

B10 REAR WHEEL ALIGNMENT SENSOR 35B

B11 STOP SWITCH PRESSURE SWITCH 11A

B12 REVERSE TILT / JIB SUSPENSION MVT DETECTION PRESSURE SWITCH 37D

B13 LOWERING / JIB SUSPENSION MVT DETECTION PRESSURE SWITCH 37D

B14 DUMPING / JIB SUSPENSION MVT DETECTION PRESSURE SWITCH 38D

B15 AIR INTAKE PRESSURE SENSOR 4C

B16 FUEL PRESSURE SENSOR 5C

B17 ENGINE OIL PRESSURE SENSOR 5C

B18 COOLANT LIQUID TEMPERATURE SENSOR 4B

B19 AIR INTAKE TEMPERATURE SENSOR 4A

B20 STRAIN GAUGE 29A

B21 FORCED OPERATION POTENTIOMETER 29G

B23 JIB ANGLE POTENTIOMETER 30G

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 F10 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

Components
Position on diagram Hydraulic
Item Designation
1 2 3 4 correspondence

B24 ACCELERATOR TPS POTENTIOMETER 4A

B25 JIB SUSPENSION CYLINDER VALVE PRESSURE SWITCH 38D

B27 RIGHT LOUDSPEAKER 45A

B28 LEFT LOUDSPEAKER 45A

B29 PRIMARY SPEED SENSOR 5A

B30 SECONDARY SPEED SENSOR 5A

B46 AIR-CONDITIONING HIGH PRESSURE SENSOR 19B

B69 TRANSMISSION FLUID PRESSURE SENSOR 19A

B70 TRANSMISSION FLUID TEMPERATURE SENSOR 18A

E1 LEFT FRONT LIGHT 12A

E2 RIGHT FRONT LIGHT 12A

E3 LEFT REAR LIGHT 14A

E4 RIGHT REAR LIGHT 15A

E5 LEFT-HAND TRAILER LIGHT 16A

E6 RIGHT-HAND TRAILER LIGHT 16A

E7 REAR NUMBER PLATE LIGHT 17A

E8 WHEEL ALIGNMENT INDICATOR LAMPS 34A

E12 RIGHT FRONT WORKING LIGHT 43A

E13 LEFT FRONT WORKING LIGHT 43A

E14 ROOF LIGHT 44A

E15 ROTATING BEACON LIGHT 42A

E16 LEFT REAR WORKING LIGHT 43A

E17 RIGHT REAR WORKING LIGHT 44A

80

E18 LEFT-HAND JIB WORKING LIGHT 45A

E19 RIGHT-HAND JIB WORKING LIGHT 46A

E20 FRONT LEFT-HAND BLUE LIGHT 37B

E21 RIGHT FRONT BLUE LIGHT 38B

E22 LEFT FRONT BLUE LIGHT 38B

E23 RIGHT REAR BLUE LIGHT 38B

F46 THERMAL CIRCUIT-BREAKER 20C

G1 12V - 74AH - 680A BATTERY 1B

G2 ALTERNATOR 12V / 85 A 2C
14A
H1 RIGHT AND LEFT REAR FOG LIGHT
15A
14A
H2 RIGHT AND LEFT REAR POSITION LIGHT
15A
14A
H3 RIGHT AND LEFT REAR STOP LIGHT
15A
H4 LEFT REAR DIRECTION INDICATOR LIGHT 14A

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 Electrical schematic diagram F11
MLT 735 -120 LSU Serie 6-E3

Components
Position on diagram Hydraulic
Item Designation
1 2 3 4 correspondence

14A
H5 RIGHT AND LEFT REAR REVERSING LIGHT
15A
H6 RIGHT REAR DIRECTION INDICATOR LIGHT 15A
12A
H7 RIGHT AND LEFT FRONT POSITION LIGHTS
13A
12A
H8 RIGHT AND LEFT DIPPED BEAM LIGHT
13A
12A
H9 RIGHT AND LEFT MAIN BEAM LIGHT
13A
H10 RIGHT FRONT DIRECTION INDICATOR LIGHT 13A

H11 LEFT FRONT DIRECTION INDICATOR LIGHT 12A

H13 FRONT WHEEL ALIGNMENT LIGHT 35A

H14 REAR WHEEL ALIGNMENT LIGHT 35A

H15 CLOCK LIGHT 7A

H20 PREHEATING 14E

H21 ENGINE POLLUTION 14E

H22 FAULT STOP ENGINE IMMEDIATELY 14E

H23 STEERING FAULT 15E

H24 TRANSMISSION OIL PRESSURE 15E

H25 TRANSMISSION OIL TEMPERATURE 15E

H26 BRAKE FLUID LEVEL 15E

H27 PARKING BRAKE 16E

H28 BATTERY CHARGE 16E

H29 ENGINE OIL PRESSURE 16E

H30 ENGINE COOLANT TEMPERATURE 16E

80
H31 AIR FILTER CLOGGING 16E

H32 DIRECTION INDICATORS 17E

H33 SIDE LIGHTS 17E

H34 DIPPED BEAM HEADLIGHTS 17E

H35 MAIN BEAM HEADLIGHTS 17E

H36 FINTRONIC INDICATOR LAMP 25G

K0 FAST SPEED RELAY 19G

K1 NC TRANSMISSION CUT-OFF RELAY 20G

K2 NO TRANSMISSION CUT-OFF RELAY 20G

K3 REVERSE GEAR RELAY 21G

K4 FORWARD GEAR RELAY 21G

K5 MACHINE FAULT ALARM 17G

K6 SLOW SPEED RELAY 22G

K7 FREE 22G

K8 ANTI-START RELAY 23G

K9 FLASHING / WARNING UNIT 16G

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 F12 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

Components
Position on diagram Hydraulic
Item Designation
1 2 3 4 correspondence

K10 JIB SUSPENSION CUT-OFF RELAY 38C

K11 JIB SUSPENSION POWER SUPPLY RELAY 39C

K16 PREHEATER RELAY 1C

K17 MODULE RELAY LIGHTS 11C

K18 NEUTRAL SAFETY RELAY 22A

M1 STARTER 1B

M3 FRONT WINDSCREEN WIPER MOTOR 41E

M4 REAR WINDSCREEN WIPER MOTOR 41A

M5 ROOF WINDSCREEN WIPER MOTOR 41A

M6 SIDE WINDSCREEN WIPER MOTOR 40A

M7 FRONT WINDSCREEN WASHER PUMP 40E

M10 AIR-CONDITIONING COMPRESSOR 20A

M11 CLEANFIX COMPRESSOR 38A

M12 AIR-CONDITIONING FAN MOTOR 1 20A

M13 AIR-CONDITIONING FAN MOTOR 2 20A

M15 PNEUMATIC SEAT COMPRESSOR 28A

M16 VENTILATION MOTOR-FAN 19A

P1 HOUR METER / REV COUNTER 9A

P2 FUEL LEVEL 8A

P3 ENGINE COOLANT TEMPERATURE 10A

P4 WATCH 7A

R1 PREHEATING RESISTANCES 2B

R2 FUEL LEVEL SENSOR 2A

80

R3 REAR DEFROSTER 44D

R4 RESISTANCE 120 OHM 1/2 W 4C

R6 PREHEATING ELEMENT 1A

S1 BATTERY CUT OFF 1A

S2 KEY SWITCH 2F

S4 WIPER SWITCH 43G

S5 LIGHT SWITCH 10G

S7 CIGARETTE LIGHTER 23B

S10 JIB HEAD ELECTROVALVE REEL 34B

S11 BRAKE LIQUID LEVEL CONTACT 11C

S12 REVOLVING LIGHT SWITCH 42C

S13 WARNING SWITCH 17G

S14 EASY CONNECT SYSTEM SWITCH 27A

S15 BLUE HEADLIGHT SWITCH 38B

S16 REAR WINDOW DE-FROST SWITCH 45C

80-02-M171EN (21/12/2010)
 Electrical schematic diagram F13
MLT 735 -120 LSU Serie 6-E3

Components
Position on diagram Hydraulic
Item Designation
1 2 3 4 correspondence

S18 REAR HYDRAULIC CONTROL SWITCH 36B

S19 HAND BRAKE SWITCH 27A

S20 BRAKE PEDAL SWITCH 26A

S21 GEAR LEVEL SWITCH 26A

S22 REAR HYDRAULIC SELECTOR SWITCH 37B

S23 JIB SUSPENSION SWITCH 39E

S24 JIB POSITION SENSOR 37E

S27 OVERRIDE SWITCH 33C

S28 ATTACHMENT LOCKING SWITCH 32C

S29 JIB ELECTRICAL CONNECTOR / JIB HEAD EV SWITCH 35C

S30 TRANSMISSION CUT-OFF SWITCH 25B

S31 WHEEL ALIGNMENT SWITCH 35C

S32 REAR FOG LIGHT SWITCH 18B

S33 MOVEMENT NEUTRALISATION SWITCH 31C

S34 TELESCOPE RETRACTED POSITION SWITCH 31G

S35 CLEANFIX SWITCH 39B

S36 PUSH BUTTON + FORCED OPERATION INDICATOR LAMP 29G

S44 PNEUMATIC SEAT SWITCH 28B

S46 DRIVER PRESENCE SWITCH 25C

S50 EMERGENCY STOP BUTTON 26F

S54 JIB WORKING LIGHT SWITCH 46C

S115 ROOF-SIDE WINDSCREEN WIPER SWITCH 41C

S139 FRONT AND REAR WORKING LIGHT SWITCH 43C

80
V1 DIODE P600 J - REVERSING LIGHTS 15C
12G
V2 6A 300V DIODE - TUV
13G
V3 1A 1000V DIODE - AIR FILTER CLOGGING 8D

V4 1A 1000V DIODE - SAFETY RELAY / REVERSE GEAR 22B

V5 1A 1000V DIODE - SAFETY RELAY / FORWARD GEAR 22B

V6 DIODE P600J 6A / 600V - JIB SUSPENSION HARNESS 38D

V7 DIODE P600J 6A / 600V - JIB SUSPENSION HARNESS 39D

V9 DIODE 10D

Y3 FORWARD ELECTROVALVE 21A

Y4 REVERSE ELECTROVALVE 21A

Y5 CLEANFIX ELECTROVALVE 39A

Y6 LSU PUMP ELECTROVALVE 39E

Y7 TILTING CUT-OFF ELECTROVALVE / VCI 32A

Y10 JIB SUSPENSION SOLENOID VALVE 1 37C

Y11 JIB SUSPENSION SOLENOID VALVE 2 37C

(21/12/2010) 80-02-M171EN
 F14 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

Components
Position on diagram Hydraulic
Item Designation
1 2 3 4 correspondence

Y12 HEAD JIB ELECTROVALVE 34A

Y15 TELESCOPE EXTEND PROPORTIONAL SOLENOID VALVE 31A

Y16 TELESCOPE RETRACT PROPORTIONAL SOLENOID VALVE 31A

Y17 ATTACHMENT POS DIRECTION PROPORTIONAL ELECTROVALVE 30A

Y18 ATTACHMENT NEG DIRECTION PROPORTIONAL ELECTROVALVE 30A

Y19 JIB LOWERING PROPORTIONAL EV / VRD-VRP 31A

Y20 HYDRAULIC CUT-OFF ELECTROVALVE / VS 32A

Y21 SELECTION ELECTROVALVE 36A

Y22 REAR HYDRAULIC ELECTROVALVE 1 35A

Y23 REAR HYDRAULIC ELECTROVALVE 2 36A

Y30 ELECTRONIC INJECTOR 1 5C

Y31 ELECTRONIC INJECTOR 2 5C

Y32 ELECTRONIC INJECTOR 3 6C

Y33 ELECTRONIC INJECTOR 4 6C

Y34 INJECTION PUMP SOLENOID 6C

Y35 DISCHARGE ELECTRONIC VALVE 5A

80

80-02-M171EN (21/12/2010)
 Electrical schematic diagram F15
MLT 735 -120 LSU Serie 6-E3

POSITION OF FUSES AND RELAYS ON DIAGRAMS

Fuses and relays
Position on diagram
Item Current Designation
1 2 3 4

F1 7,5 A LSU + AS OPTION 13G

F2 15 A REAR WORKING LIGHTS 8G

F3 10 A REAR WINDSCREEN WIPER + ROOF / SIDE WINDOW WIPER 9G

F4 15 A Max ENGINE STOP EV OR ENGINE ECM 9G

F5 7,5 A ROTATING BEACON LIGHT 8G

F6 5A WHEEL ALIGNMENTS + AS OPTION 10G

F7 7,5 A LLMI + OVERRIDE SWITCH + SENSORS + BLUE LIGHT OPT (15A) 13G

F8 15 A RELAYS K2/K3/K4 + TRANSMISSION CUT-OFF + JSM / FNR 13G

F9 5A DASHBOARD MODULE + INDICATOR LAMPS 10G

F10 10 A HORN + STOP SWITCH 10G

F11 15 A JIB WORKING LIGHTS 10G

F12 10 A DIRECTION INDICATORS 13G

F13 30 A VENTILATION 11G

F14 10 A CIGARETTE LIGHTER 11G

F15 20 A SPU 11G

F16 5A DIAGNOSTIC CONNECTION 8G

F17 15 A Max CLEANFIX + REAR HYDRAULICS + ANTI-THEFT 8G

F18 15 A FRONT WORKING LIGHTS 8G

F19 15 A REAR WINDOW DEFROSTER 9G

F20 10 A PNEUMATIC SEAT + AS OPTION 8G

F21 10 A FRONT WINDSCREEN WIPER + WASHER 10G

F22 10 A Max JIB SUSPENSION + JIB ELECTRICAL PROVISION + JIB HEAD EV 10G

F23 7,5 A RIGHT SIDELIGHT + MODULE LIGHTING 12G

80
F24 7,5 A LEFT SIDELIGHT + REAR PLATE LIGHTING 12G

F25 7,5 A RIGHT INDICATOR LIGHTS 13G

F26 7,5 A LEFT INDICATOR LIGHTS 13G

F27 15 A DIPPED HEADLIGHT + FOG LIGHT 12G

F28 15 A HEADLIGHTS 12G

F29 15 A WARNING + CEILING LIGHT + ANTI-THEFT + CLOCK + REV COUNTER 8G

F30 25 A LIGHTING STALK SWITCH 11G

F31 25 A STARTER 1E

F32 5A DIAGNOSTIC CONNECTOR + SPU 7C

F33 1A LSU POTENTIOMETER 36E

F40 80 A IGNITION SWITCH 1D

F41 30 A ENGINE ECM 1D

F42 80 A PREHEATING 1C

F43 100 A ALTERNATOR 1C

(21/12/2010) 80-02-M171EN
 F16 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3

POSITION OF SPLICES ON DIAGRAMS

Position on diagram
Item Designation
1 2 3 4
EP02 EARTH 27B
EP03 RIGHT SIDELIGHT POWER SUPPLY 16C
EP04 JSM / K1 POWER SUPPLY 25E
EP06 FORWARD GEAR NEUTRAL CONTROL 22B
EP07 REVERSE GEAR NEUTRAL CONTROL 22B
EP08 FOG LIGHT POWER SUPPLY 16B
EP09 LEFT REAR SIDELIGHT POWER SUPPLY 14C
EP10 REVERSING LIGHT DIODE 15C
EP11 RIGHT REAR DIRECTION INDICATOR POWER SUPPLY 15B
EP12 NEUTRAL CONTROL 22B
EP13 REVERSING LIGHT DIODE 15C
EP14 LEFT REAR DIRECTION INDICATOR POWER SUPPLY 14B
EP15 STOP LIGHT POWER SUPPLY 14B
EP16 DASHBOARD MODULE EARTH 9B
EP17 DASHBOARD MODULE INDICATOR LAMP 9B
EP19 10D
EP20 10D
EP21 GROUND CAN B 9D
EP23 FORWARD CONTROL 33G
EP24 REVERSE CONTROL 33G
EP25 CAN A EARTH 33E
EP26 ROLLER 1 32G
EP27 ROLLER 2 33G
EP28 SPU ANA EARTH 29G
EP29 ANA POWER SUPPLY 30G
EP30 LSU POWER SUPPLY or LSU EARTH 36F
EP33 DIAG CAN EARTH 34F
EP34 AIR FILTER CLOGGING DIODE 8C
80

EP35 CAN H 33E

EP36 CAN L 33E
EP37 AIR FILTER CLOGGING DIODE 8D
EP38 SPU POWER SUPPLY 29F
EP42 ECM POWER SUPPLY 3C
EP43 ECM POWER SUPPLY 3A
EP44 CAN L 4B
EP45 CAN H 4C
EP46 B4 B6 POWER SUPPLY 3A
EP48 CONT AP POWER SUPPLY 3C
EP50 FRONT WORKING LIGHT POWER SUPPLY 43B
EP51 FRONT WORKING LIGHT EARTH 43B
EP52 CAB HARNESS EARTH 43C
EP53 LEFT-HAND LIGHT HP EARTH 44B
EP54 RIGHT REAR WORKING LIGHT POWER SUPPLY 44B
EP55 LEFT REAR WORKING LIGHT POWER SUPPLY 43B
EP56 REVOLVING LIGHT POWER SUPPLY 42B
EP57 WINDSCREEN WIPER POWER SUPPLY 41B
80-02-M171EN (21/12/2010)
 Electrical schematic diagram F17
MLT 735 -120 LSU Serie 6-E3

DETAIL CAN A et B
210 496
241 EP 28 3 NOIR
459 LUMBERG
460
495 0935 253 105 X99
462 2 ROUGE CABLE 3
1
5
2

4 3 JAUGE
X58-3 490 493 4 BLANC
LLMI CABLE 2 EP 35 494
X58-4 491 5 BLEU
EP 25
1 DRAIN

260 X57-1
486 EP 36 CABLE 5 X57-2 SPU
X115-14 264
X115-6
CABLE 1
485 492
X57-28
X57-11
PRISE
DIAG 495
CANLINK
X56-21 SPU
489
X115-5 EP 33 X107

X121-8

X121-5
FAISCEAU
X115-11
CABLE 7 CABLE 6 X24-C6 MOTEUR
X115-3 X24-C5 (vers ECM)
EP 21 X24-C7

X109-39 ECU RC2-2

CABLE 8 X109-40
X109-24

526
X115-12 X109-51
525

80
X115-13 X109-50

EP 36 CAN LOW
EP 35 CAN HIGH
EP 21 DRAIN
EP 25 DRAIN
EP 28 MASSE ANALOGIQUE
EP 33 MASSE CAN

(21/12/2010) 80-02-M171EN
 80
F18

A
E
G

B
D

C
Masse Châssis

1
Masse Cabine

3
20 mm

617
Masse Moteur

X238
X161

R6
2
X160

M1
10 mm

M
X126

1
X47
F31

80-02-M171EN
82 4 mm

70 mm
86 30

1
15

X200A

X200B
G1
2
70 mm 70 mm

F43
F42
F40

F41

K16
BF1
X168 25 mm

S1
85 87

4 mm

70 mm
X24
1 2 5 3 B A B A 617 14

70 mm

G1

X174 609
10 mm

X171
X176

B1

X173
16

645
627
620
629

629
608 16

631

X172
X54
S2

noir
X101 63

A1
12

628 noir
606 12

649
2

16 mm
C8
611 7 7

3
X168 621 noir 7 mm 64

A8
603 13 13

4
92

|
627 7 mm

2
C1
30 30 17 17
621

7 mm

620
82

B+

N
2

R2
3~
7

X167
18

R1
607 601 601 92

M
U
8

1
A6

D+
W
9

X165
G2645
25

5
607

noir
A7
6

B4
650 650 SWG 9 GND prech 628

1
50a 19 19 54 15 58

44
57
10

67
68
65
66
648 646 612 612 20 26F
ap cont X114-5

2
B3

40
X55
649 batt (+) 656

3
7
B2

EP48
657

ECM
batt (+)

O P

X178
B4
batt (+) 658 631 7 mm

B6

15
batt (+) 659

X166B

P
648

3
B7

16

B6
EP42
643 643 642 642 572
SWG 11 prech

38
63
C2
644 647 613 613 19 19E
SWG RET phm X38-3

35
A4

62
noir 637 615 615 573
batt (-) stop

1
60
C3

EP46
noir 638 614 614 6
batt (-) pollut

X166A
59
C4
X168 636 noir 7 mm 636 noir 639 batt (-)

3
EP45
noir 640 660 661 661 305
batt (-) CAN H
Electrical schematic diagram

9
20
C5

EP43
noir 641 663 662 CABLE 662 306
batt (-) CAN L

X179
10
21
C6
652 652 8V 100mA

+
5

B24
43
C7

EP44
R4

IVS
653 653 noir 609 267 noir

-
SWG 8 CAN GND

6
45
A2

4
22
X177-J1
651 651 0V

-
2
A19
33
654 654 AIN ACT7 5V

4
54
46
B15

ANALOG
+
655 655 5V 200mA masse

1
41
38

T
pression
adm air

55

B18
T
5V

48

B19
B16
alim masse

37
A3

40
pression
T∞ ADM AIR combust

42
A5

51
T∞ LIQUIDE 5V
refroidiss

43
47
B17
vitesse
secondaire masse

53
39
pression

B29
huile mot
8V

5
56

10

B30
45B noir 252
X27-1

C
8

Y30
vitesse
X53

primaire masse 45B 251

X27-3

52
35

Y35
7

soupape
d charge injecteur 1

17
57
6

Y31
masse masse
CABLE 6

44
34
5

J1939 + injecteur 2

24
58
4

Y32
J1939 - masse

23
33
3

CDL - injecteur 3 45B noir 254

X27-2

20
59
2

Y33
CDL + masse 45B 253

8
X27-4

21
1

batt - injecteur 4

45
64
A7

Y34
batt + masse

6
8

18
26
J H G F E D C B A sol pompe
7

injection

25

X159
PRISE DIAGNOSTIC ECM
6

X168 604 noir noir 604 11

5

X158-J2
B5

X168 605 noir 4 mm noir 605 10

4

B8

X76A 10 noir 4 mm
3

X76B 11 noir
2
1
X192

9
X59
267 noir
63

6
12
266

3
1
F32
X45 - K

151 151

7
1

X60
265 487 35F 64
X115-16
2

H15
P4
189 28F
X56-07
3

X48

X76A 69 noir noir 69

4

68
5

X90
142 67
Battery

1
6

70 noir 66
Ground

2
7

Ground 65

3
8

n.c.

4
25 43E 88 F2
signal X26-7

5
1

F17
X41- A

127 36C 160

illumination X4-2
6

8
signal
2

43E 86 F18
Warning led - X26-5
7
3

36C 158 F20

warning led + X4-8
8
4

P2
V3
EP34
EP37

18E 18E F5
21 571 17 42E 87
X38-1 X38-7 X26-6
5

221
6
7

F29
X107 569 noir noir 569 266
6

A20

306
1

35F 488 F16

308
8

noir

X115-1
7

305
X68

221
70

Battery 307 36C 159

5

120 ohms

X4-1
1
8

220 noir 91 noir noir 91 40F F3

Ground 85
X79-1
2
3
9

43E 135 F19

Sensor (-)
265

127

X26-11
EP21

570 570
140 noir
10

EP16

90 F4
10

Ignition 36C 157

2

X4-7
4

15
CANLINK
11

Sensor (+) 24 24 25F 214

RPMx100
20

X118-5
5
9

9
30
25
12

219 89 26 143
Illumination
6
4
13

X121

Service (TX)
126

7
EP17

Service (Rx)
8

P1

15
9
X40- B

14
3

40F F21
80
X89

81 X79-3
1

Battery
F22
1

36C
CABLE 7

156
140 noir X4-6
2

Ground 142
F9
2

90
0 1
57/58

Ground
F11
3
2

36C 149
X4-4
6

n.c.
F6
4
56a

35B 58
26 X52-5
7

signal
10
5

36C 161
126 X4-3
56b

illumination
30

signal 81
Warning led -
12

F10
7

57
54s
L

V9

warning led +
8
S5 L

P3

73
0

11
54d

EP19

EP20

224
R

10

55
31
49

18
13

62 43E 105
X26-10
25F
K17

215
85

74 X118-1
1

F15
1

29F 188
224
30

X56-1
2

497
3
5

86 87 87a

31F 183
1 5 4

X57-9
P
3

57
X73A

B11

F14
4

11

31F 182
233 noir X57-8
4

4 98
5

F13
4 mm 84
X46

1 7 5 6 8 9 3 4 2
222
X188

X73B

X76B 222 noir

X76A 56 noir 56 F30

X37-D

N
« 1/4 »

S11

X76A 54 noir 40F noir 43 55

X70-2

54
Fus Therm 2A

F27
X72A

X72B

52 52
3

2
X39- C

F28
53 53
E1 AV GA
X189

50 110
5

12

F24
51 1
V2

H8 H9 H7 H11

50
1

6
X74

89
13

F23
X190

X76A 111 noir 107

6

111 114
1
12

109 109
9

F26
110 51
E2 AV DR
3
10

107 3
4
11

F25
108 108
X191

H8 H9 H7 H10

F1
115
8

13
X13

F7
V2

F8
4 mm

F12
6
573
572

4
62

3
307
308
7 mm

1
noir 233
143
497

115
114
84

98
X75
208 43E

Masse Cabine
Masse Moteur
Masse Châssis
X26-14

14
7

9
3
1

15
17
13
11
4

8
2

16
18
12
14
10
F

A
E

B
D
G

(21/12/2010)
MLT 735 -120 LSU Serie 6-E3
 Electrical schematic diagram F19
MLT 735 -120 LSU Serie 6-E3 « 2/4 »

S13
1 0 2 8 5 10

6 3 1 7
X187
SWF 525 192
G +
SWF 586 371 S2 G
1
2 A15
3 K5
85
BUZZEUR
87
K0 2 5 4 K1 2 5 4 K2 2 5 K3 2 5 K4 2 5 K6 2 5 4 K7 2 5 K8 2 5
87a 86
K9 85 87 87a 85 87 87a 85 87 85 87 85 87 85 87 87a 85 87 85 87
4 85 CENTRALE 87
CLIGNOTANTE
5

3.5 sec 2 0.5

86 30 86 30 86 30 86 30 86 30 86 30 86 30 86 30
6 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3

Tempo
7
8
9
10
11
F 13
12 F
14
15
16
17
18
X180 - E X38 - I
5 8 1 6 2 3 7 4 6 7 4 5 3 2 8 1 4 2 7 5 1 3 6 19 6 20 7 8 9 21 10 18 4 5 16 15 1 11 2 17 14 12 13 3 5 1 2 3 4
X81-X185 X181-F X44 - G X42-H

150

148

197

213

197

155

163

166

167
202

205

205

455

236

232
17

21

19
22

34

99

33

45
312

212
X184

noir

218
226
8C
8D

3D
8

5
27

X121-6
EP37

X24-A4

30G

33G

33G
36C

36C

EP29

EP23

EP24
X4-5

X4-9
X182 noir
X83 X183
E E
572

573

71

31
38

29

24

22

34

28

33

27

26

25

23

72

30

32
62
6

X14 X08 X22 X98 236

150

202
33

9
17 18 19 20 16 10 6 7 8 9 5 1 2 3 4 11 12 13 14 15
572 1 2 1 1 166
Tempo 1.5s

573 218
6
T P
62
H20 H21 H22 H23 H24 H25 H26 H27 H28 H29 H30 H31 H32 H33 H34 H35
B2 B70 P
B69
B7 148

A2 45
84 4 mm

98
D 497 497 D
143

7 mm
308 308
307 CABLE 7 CABLE 7 307
233 noir

EP13 5

7 mm
V1
C 123 EP10 239 noir 112 C

80
112
122

247 noir 101

EP9

100
98
1 1 246
X32 X91

153

154

164
249 1 2
F46
118

114 114
EP3 100
X31 A B C

orange
violet

rose
244 136
245

EP11 S7

268

269
115 115 248
3 3 EP14 250 X204 X205 EP6 EP7
255
EP8 144
1 2 1 2 3 4 5 6

A6
120

4 mm
145 V4 V5
B B46
HP
EP12
B
144

X30
136

164

154

153
77A

X49
83

84

RT7sec RT7sec noir noir 38

X19 S320 A B C D E F R1
243
235

250

249

256

247

235

245

248

233 noir
1 1 9 228

212

213
269
230

268
230
38
EP15 3 1 7 2 8 6 5 4
X95

231
A8

228

226
4

jaune/vert
4 117
X206 C B A
X10 1 2 X09 1 2 2 1 5 4 3
239
312

marron

bleu

bleu
vert
rouge
blanc
jaune

bleu
noir

vert

X82 X17 X16 X96 X20 X18 5 10

K18
118

116

117

121
313

124

123

120

125
145

122
255

244

237

238

246

BP
4 mm

1 2 1 2 3 4 5 6 7 7 6 5 4 3 2 1 3 1 7 2 6 5 4 1 2 2 1 1 5 4
SWF 525 005 77A X207 X208 X209 86 87 87a
143

STOP STOP + 1 2 1 2 1
131
130

0
SWF 586 374 S6 2

4 mm
P B1 3
Y4 Y3 85
2
30
3
35C

B8 H2 H5 H4 H3 H1 H1 H3 H6 H5 H2 C
MARCHE MARCHE
X103-10

E4 AR DR
STOP
E3 AR GA
STOP
A A
313 noir

124 noir

M10 M12 M13 ARRIERE AVANT

243 noir

noir

83 noir
125 noir

noir

noir

noir
9 noir

E7 M16
X76A 130

X76B 101
X106 237
X106 238

E5 E6
X76B

X76A
X106

X106
X106

X105

X176
Masse Moteur
Masse Cabine Masse Cabine
Masse Châssis Masse Châssis

13 14 15 16 17 18 19 20 21 22 23

(21/12/2010) 80-02-M171EN
 80
F20

A
E

B
D
G

C
Masse Châssis
Masse Cabine

45
38
307
308
497
228
236

218
166
148

112
X76B 216 noir noir 216

24
12

80-02-M171EN
12

X118
11
11

10
10
41

CABLE 7
OPTION

9
ANTIVOL

9
499

1
8
8

+
A10
X76B 40 noir 236

7
7

0
S30
X236
X107 40 noir 225

SWF 525 110

6
6
4
49 9F

SWF 586 372 S3

214

1
X41-12

166
A11

X02
41

5
5
8

S46

5
X76A 129 noir 133 259 259 39 39

4
4

77D
12
129 noir

X61
7 2
X105 60

EP4
3
3

6
242
211

8
2

25
2
H36

X03
X76A 132 noir 132 77D 11E 215
X37-1

9
1

10
X135
X239
X235

X118 X118
(-) batt

X71
1

12
12

S20
49
A13

D tection 1

1
9
2

133 11
D tection 2

2
3

10
10

S50
Com C3
9
4
4

139
Com C2

X01
X114
8
6
5

2
1
228
Com C1

26
7
3
6

1
2
206 225 DEM
NC C1

4
A1

6
5
7

499 1
NC C2

2
5
8
8

S21
2
3D 20 EVM
X24-B3 NC C3
5
4
7
9

X135 10 mm 497 1 Blocage

Electrical schematic diagram

3
11

2
10

X108 498 SPU

(+) apr s contact
6
2
2
11
A14

(+) batt

S19
1
1
12

146

1
203 noir

2
45

3
113 noir

27
4
noir 203

113

X12
38 noir

CABLE 7
X76A 258 noir noir 258 47 noir

262
EP2

1
X11
262 noir

C
2

S44
263

M15
X106 466 noir

X106 467 noir

28
ECS

+
0
7C 189
479 X48-2 12VP
7

SWF 525 010

1

5
X76B 480 noir 480 60 IN TOR 1
17

206 IN TOR 10

SWF 586 373 S17 noir

S36

75C
X112

S14
15

277 146 noir 460

X116
IN TOR 2

9
1

10
noir 496

23

479 IN TOR IN TOR 461 461

13 3
2

10
22

498

X76B 186 noir noir 186 463

GND
3

20

X76B 185 noir noir 185 noir noir 462

GND
4

26

61 61 W UP IN
EP38
13

X99
EP28 459

210
241

29
1
180
181

CAN H 493 blanc 11E 188 noir 459

X37-2 12VB
2

4
1

CABLE 3
CN1-A / X56

CABLE CAN
4 L 458

R120
494 bleu
3

B20
ALIM 495 rouge 495 OUT SENSOR 457
1

2
21

MASSE 496 noir

X44-13

3
457

noir 471
X113

OUT LS 22
4
B21

22E 455
EP29

204 IN TOR 12

X35
X87
16

Y17
178 178 178 178 OUTPWM 7

1
3

ACCES +
14
484
483
469

195 179 179 179 OUTPWM 8

X100

2
4
2

X105 195 noir noir 191 191 noir noir 191 OUT LS 12 468
2

30
7
6

noir 44 44 noir noir 44 464 464

OUT LS 11 IN1ANA

X34
3

8
5
25

Y18
179 478 IN TOR 4 noir 466

ACCES -
1

1
11

194 469
A3
5

2
8

X105 194 noir 176 176 176 IN ANA 465 465

OUTPWM 5 2
6

1
29

177 177 177 OUTPWM 6 noir 467

X29
4

2
5
B23

Y15
176 196 196 196 OUTPWM 4

TELES
SORTIE
1
5
6

192 42 42 42 OUTPWM 1
2
6
7
CN1-A / X56

X105 192 noir 234 IN TOR 169

OUT TOR 1 14
32
12

168
1

IN ANA 3
+

X28
18

Y16
177 181

TELES
12VD
S330

1
4

RENTREE

31
SWF 525 110

193 180 458

204

12VD IN ANA 5
X134

2
3

SWF 586 374 S3

13

X105 193 noir noir 112 148 OUTPWM 463 483

5

OUTPWM 10
1

17
33

2 481
IN TOR 5 481
75B

X92
4

7 2

X33
15

Y19
CABLE 7

196 11E 183 482 482

S34

12VC IN TOR 6
6

X37-3
VRD
noir
3

1
9
23

191 noir 11E 182 210 484

X37-3 12VC AGND
2

2
8
31

128
9

10

190
SPU

217

X23
1

Y20
+

42
VS
noir

1
0
S28

44 noir
CABLE 3
X36

CN1-B / X57

SWF 525 005

CN1-B / X57

2
BP5

456 456 IN TOR IN TOR 240 240

SWF 586 374 S4

11
1

16
9

32
A12

190
19
12

X93
10

Y7
169

234 172
R1

noir
75A

VCI
X117
2

217

264 173
9

10
D+ D-

2
EP26

277

X105 264 noir 168

6

X76B 187 noir noir 187 GND 174

4

34
EP27
D+ D-

171 175
IN TOR 15
5

X58

171
24
R2

GND 31 170 170

IN ANA 4
7

1
16

ALIM 12V 79 GND CAN 1 noir 241

1

2
493
28

EP35

CAN H 490 490 260 260 CAN 1 H 242

8

3
1

494

CAN L 491
CABLE 2 CABLE 2 491 261 CABLE 5 261 CAN 1 L
120 ohms

33
4
2

A5 / LLMI
EP23

476
1

492 492 476 36

+

IN TOR 8
11

CAN 1 120
EP36
11
22

477 477 37
S270

IN TOR 9
12

14

485
486

SWF 525 010

478
SWF 586 371 S3

218
1
EP25

X76A 30 noir
EP24167

noir 31
X119
23E
232 23E

77C
F N R

noir 30 79
9
X42-3
X42-4

10
X115

471 noir 486

77C

2
14

472 CABLE 1 485

« 3/4 »

1
1

EVTDF
2

Y12
X94
X97

S10
9

34
EP33

X107 489 noir noir 489 noir 311

5

47 noir
_
7

B9

46 308
+

310
B
11

CABLE 7
E8

48 307
+
3

309
A

X50 1
1

48
X40-7

X15
+
8

H13
2
S310

28 noir
10E

71
_
ou

27
46

C
10
PRISE DIAGNOSTIC

B10
SWF 525 005

7C
1

27 487
X48-2
noir
+
SWF 525 024 SWF

B
16

71
1

SWF 586 373 S14

5

29 58 8F 488
S290

X41-7
1

2
A
472

29 526
X21
+ 525 005

77E

1
X52

H14
SWF 586 374 S4 SWF 586 373 S3
12

32 noir
5

32 77E 475 525

9

35
10
13

X51

28 noir 536
X103

X105
77B
15

CABLE 8

134 noir 134 77B

9

10

18A noir 131

X49-10
310
309
526
525
536

128

475
263
211

Masse Cabine
Masse Châssis

36

(21/12/2010)
F

A
E

B
D
G

C
MLT 735 -120 LSU Serie 6-E3
 Electrical schematic diagram F21
MLT 735 -120 LSU Serie 6-E3 « 4/4 »

0 1 0

S4 F
G G

X79 1 2 3 4 5 6 7 8 9 X80 1 2

104

103
85
99

80

59

96

78

94
97

95
10E
9F
X41-9

X40-1
A4
GND RXTX+GND CAN

ALIM C RC2-2

ALIM C RC2-2
ECU RC2-2/21
ALIM RC2-2

ALIM RC2-2

GND RC2-2

GND RC2-2
FLASH C

RX/RS232

PWM1-A1
TX/RS232

CAN H

CAN L

F X109 F

X72B
52 50 51 24 40 39 1 27 41 42 31 2 28
310

531
536

525

526

309

532

529

530

527

533

534

noir 12B
43

59

94

95

78

96

93
536 521
X70 X77

X41-10
EP30

X41-5

X41-1

X41-3

X37-1
2 3 5 6 4 1

X4-4
529

530

525

X75
2 1
520

11E

14G
36C
8F

8F

8F

9F
521

527

528
526
M 3 2
X102A X102B X104 1 2

199 noir

200 noir

201 noir
+perm vit 1
309 2
raz
M X26

103

104

105

135

162

102

208
99

87

88

86
310 CABLE 8 1
- 1 2 3 8 9 6 13 12 4 7 5 10 11 15 16 14 17
M7
F33

M3 6

711

noir 710
723

724

702

noir 709

noir 708

732

728

743

750

756

755

736
E S24 S23 X222 Y6 E
1 0 2 1 7 2 8 9

2 1 X226 3 6 10

SWF 525 212

+
SWF 586 373 S12

noir

noir
211 X229 X230 X233 X234
X225 1 2
128 X231 X232
263
D P P P P
D

735

736
B12 B13 B14 B25 V7
717 703 733 751 758

753
714
718
X152

720

704

730

729
735

737

753

755
S115 X149 X150 X153
3 7 4 8 9
S12 1
S139 X154A S160 S540
2 1 0 9 0
V6 1 0 1 2 1 7 2 8 9 1 1 9 1 1 7 2 8 9
10E X26-15
X44-17
X41-8

X41-2

43E X40-8

22E X40-6

X40-2

X44-12
X41-11

X41-4

R3
10E
8F
9F

10E

noir

noir

noir

noir
22E
9F

8F

5 10 5 10 5 6 10
X224 1 2 X223 1 2 X227 2 1 3 5 X228 2 1 3 5
1 5 2 6 10 3 4 10
X151
211

161
159

160

162
149
155

156

157

158

163
128
520
475

263

SWF 525 243 SWF 525 005 X154B SWF 525 005 SWF 525 110

721
715

719

noir 701
SWF 525 053

noir 722

702

728

732

noir 734

750

noir 752

756

noir 759
+ 717 + 703 733 + 751 + 757 758
+

754
X4 1 2 3 4 5 6 7 8 9 86 30 86 30 SWF 586 373 S9

710 noir

709 noir

708 noir
475
SWF 586 373 S8 SWF 586 372 S4 SWF 586 374 S2 SWF 586 373 S2

noir
85 87 85 87
C X221
Y11 Y10 734 noir C

80
K10 K11 noir
noir
701
722
754
752
noir
noir
noir 725 759 noir
noir 726 740 noir
noir 727 707 noir
731 noir
X203 EP52

X53-8

X53-7

X53-2

X53-1
714
X136

5F

5F

6F

6F
731

730
715
X202 X212 2 1
S150

252 noir

254 noir
S350 716 711

707 noir
EP57

251

253
1 9 1 9

noir 766

765
1 1 713
X27

712
1 3 2 4
noir 706 749 noir
X217 X216
S18 S22 EP53

744

745

noir 746

747
764 748 noir
EP51
B B
5 10 5 10

704
1 0 2 1 7 2 8 9 1 0 1 9

742

noir
737
noir 762
738
EP56 EP55

765
SWF 525 005 SWF 525 005 EP54

102

106
noir

noir

noir

noir
+ + 763
SWF 586 375 S1 SWF 586 373 S10
EP50 X25 1 2

746

747
3 4 10

744
5

745
10

705 0.75 mm

706 0.75 mm

762 0.75 mm

761 0.75 mm

764 0.75 mm

763 0.75 mm

741 0.75 mm

742 0.75 mm

739 0.75 mm

740 0.75 mm

748 noir

749 noir

X138B
X148C

X139B
X148B

X148A

X138A

X139A
725 noir

726 noir

727 noir
SWF 525 058 SWF+525 005
E20 E21

743
+ E22 E23 X145A X145B X141 X147 X210 X211
719

716

718

712

721

713
720

723

724
SWF 586 373 S6 SWF 586 373
X143 3 1 2 4 X144 3 1 2 4 X142 3 1 2 4 2 1 2 1 1 2 1 2 1 2 1 2
1 4 3 2 X213 X140 X146
X219 X220 X218
1 2 1 2 1 2 1
+perm vit
2 1
+perm vit
2 1
+perm vit
2
E13 E12
raz
M raz
M raz
M M
3
-
3
-
3
- E16 E17
A C
M6 4
M5 4
M4 4 E14 A
AV AV AR AR B28 B27 E18 E19
noir
noir
noir

528 noir

533 noir

534 noir

93 noir

106 noir

201 noir

200 noir

199 noir
Y22 Y23 Y21 Y5 LAT TOIT AR E15 GA DR GA DR
X135

A9
X135

M11

X76B
X76B
X76B
X76A
X135

X135

X135

X107
X107
X107

X106
Masse Cabine
Masse Châssis

35 36 37 38 39 40 41 42 43 44 45 46

(21/12/2010) 80-02-M171EN
 F22 Electrical schematic diagram
MLT 735 -120 LSU Serie 6-E3
80

80-02-M171EN (21/12/2010)
Contents

Hydraulic schematic diagrams G1

pages

– Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G2
– Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G5

70

(07/02/2011) 70-02-M171EN
 G2 Hydraulic schematic diagrams

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
AC Accumulator O27, G36
CA Suction strainer S15
CSP Counterbalance valve I29
CR(O) Trailer hook (option) C16, C19, C25
D Control Valve Q37
EE Inlet section S25
EA(O) Attachment component (option) S30
EL Lifting component S36
EI Tilt component S28
EA Attachment component S34
ET Telescoping component S32
EF Closing component S38
EVAA(O) Rear attachment electrovalve (option) C16, C18, C21,
C23
EVP(O) Pilot electrovalve (option) Q22
EVTDF(O) Jib head electrovalve (option) C36, C38
FDAV Front disc brake I3
FDAR Rear disc brake I22
FEMS EMS head filter M39
FR Return filter Q17
M Engine I18
Idle speed 930 rpm
Nominal loaded speed 2200 rpm
70

Full speed unladen 2360 rpm

MA Manipulator O40
MC Master cylinder A3
N Level S12
P Hydraulic pump G18
PAAV Front attachment plug C31
PAAV (O) AV1 Front attachment plug (option) Hydraulic locking C34
PAAV (O) AV2 Front attachment plug (option) Jib head electrovalve C36
PAAV (O) AV3 Front attachment plug (option) Jib head electrovalve and hydraulic
C39
locking
PAAR(O) AR1 Rear attachment plug (option) single-effect C28
PAAR(O) AR2 Rear attachment plug (option)dual effect C27
PAAR(O) AR3 Rear attachment plug (option) hydraulic hook C25
PAAR(O) AR4 Rear attachment plug (option) dual + single rear provision C23
PAAR(O) AR5 Rear attachment plug (option) 2 dual rear provisions C21
PAAR(O) AR6 Rear attachment plug (option) towing hook + dual rear provision C19
PAAR(O) AR7 Rear attachment plug (option) towing hook + rear single provision C16
PCR Cooling circuit pump Q12
PD Steering pump C11
PFR Trailer brake plug integrated in the VAFR E4
PP Pressure port O25
PRES Pressure sensitive switch E12

70-02-M171EN (07/02/2011)
 Hydraulic schematic diagrams G3

MLT 735 -120 LSU Serie 6-E3

HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
PRES(O) Pressure sensitive switch (option) G34
PRF(O) Leakage return plug (option) K13
R Hydraulic tank S12
RH Oil cooler Q14
RLF Brake fluid tank C3
SC Circuit selector E8
SCFR Trailer brake circuit selector E7
SD 3 position steering selector C9
Position 1 : short steering
Position 2 : front wheel steering
Position 3 : crab steering
VC Compensating cylinder (MLT 735) I26 100x50 c310
Compensating cylinder (MLT 741) 110x55 c310
VI Tilting cylinder (MLT 735) G26 130x65 c380
Tilting cylinder (MLT 741) 140x70 c388
VDAV Front steering cylinder I4
VDAR Rear steering cylinder I21
VL Lifting cylinder (MLT 735) E35, G39 140x70 c720
Lifting cylinder (MLT 741) 150x70 c716
VT Telescoping cylinder (MLT 735) G30 70x50 c2700
Telescoping cylinder (MLT 741) 75x55 c2700
VAFR Trailer brake valve E3
VVT(O) Carriage locking cylinder (option) C34, A39 60x45 c183

70
VAI(O) Isolation valve (option) C33, C38
VS Safety valve Q25
VRP Pressure control valve Q36
VASF Jib suspension valve I35
VCI Inclination cut-off valve. O35

NOTE : 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine
speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.

(07/02/2011) 70-02-M171EN
 G4 Hydraulic schematic diagrams

MLT 735 120 LSU Serie 6-E3

70

70-02-M171EN (07/02/2011)
 Hydraulic schematic diagrams G5

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

A OPTION AV-3 A
MA
Ø 0.9 VCD VVT (O)
B L N A B T 2 OPTION AR-3 OPTION AR-2 OPTION AR-1
3 1
MC OPTION AV-1 OPTION AV-2

VAI (O)
3 2 1
AV AR PAAR (O) PAAR (O) C2
CR (O) VVT (O)
B1 C2 C2 PAAV
RLF SD PAAV (O)
3 2 1
C4 Vers V2 du CSD C4 Vers V2 du CSD C4 Vers V2 du CSD Ø 0.9 C2 PAAV (O)
P P C2
de DEVERS de DEVERS de DEVERS
R L VAI (O) C4 C4
C 200b 200b PD Vers V1 du CSD Vers V1 du CSD Vers V1 du CSD C2 CSD C1 PAAV PAAV C
de DEVERS de DEVERS de DEVERS
C3 C1 C3 C1 C3 C1 PAAV C3 C1 C3 C1

P
200 cm3/tr EVAA (O) EVAA (O) EVAA (O) V2 V1 EVTDF (O) EVTDF (O)
T P2 P1 P2 P1 P2 P1 P2 P1 P2 P1
Y SC
V1 V2 LS
VAFR SCFR 140b PRES
N LS V1 V2 S 7.5 b
OPTION CRC
E PFR E
B S T P VT2
VL

VI C1 C2
CSP
VL
PRES
X

1 2
G C1 C2 V1 V2 G

3
C1 C2
30b
B
VT1 1.5 L
CSP
P V1 V2 AC C1 C2
45 cm3/tr M CSP
ES.AV

ES.AR
C1 C2
L L1 L2 S VC 320b+15/0

I 30b+6/0 I
VASF (O)
T V1 V2
FDAV VDAV VDAR V1 V2
V1 V2
FDAR

0.7 L

70
C1 C2 13 b
K CSP K
35b
BA
PRF(O) U
V1 V2
45±5B

P1
T

FEMS
M 10 μm M

P T
0.32 L MA
100 b
Ø1

AC VCI
PP 1 2 3 4

O O

M LS D b B1 A1 b B2 A2 B3 A3 B4 A4 b B5 A5
DLS D
b
FR b

6b P
5b
Q Q
RH
PCR 3 2 Tdd VS
VRP 23 bar
14 cm3/tr
1 4 a a
b
14 V
LS
15 μm absolu
EVP
B A B B
270 b T T T

N T EE 190b 280b
EI 200 bar
T
280 bar

CA ECD ET EA EL EF
Niveau moyen: 110L 125 μm a a a Pr Tpr
absolu Gicleur Ø 0.8 mm
S S

R Capacité 135 litres Réserve direction 12 litres

(07/02/2011) 70-02-M171EN
 G6 Hydraulic schematic diagrams
70

70-02-M171EN (07/02/2011)