CONTENTS

MANITOU NORTH AMERICA, INC.

6401 IMPERIAL DRIVE
WACO,
WA CO, TX 76712-6803

For Parts Orders contact your Manitou North America Dealer or call:
Manitou North America, Inc. Parts Dept. (800) 425-3727 or (254) 799-0232

Parts Dept. Fax (254) 867-6504 Website: www.manitou-na.com

MLA 628 -120 LSU POWERSHIFT

Seri
Series
es 3-
3-E2
E2

OPERATOR'S MANUAL

THIS OPERATOR'S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.

547866AS
R11-10
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CONTENTS

- INTRO
INTRODUC
DUCTIO
TION
N T
TO
O SA
SAFET
FETY
Y - 

- ROUGH TERRAIN FORKLIFT TRUCK 

GENERA
GENERAL
L SAFETY
SAFETY STAND
STANDARD
ARDS
S - - - - - - - - - - - I 

- SAFTETY
SAFTETY MESSAGES
MESSAGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - V
VII 
II 

- SAFETY
SAFETY DECALS
DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII 
VIII 

- TABLE OF CONTENTS - 

- OPERATING
OPERATING AND SAFETY INSTRUCTIONS - - - - - - - - - - - - - 1 - 3

- DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3

- MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3

- PICKING UP THE ATTACHMENTS

TTACHMENTS - - - - - - - - - - - - - - - - - - - - 4 - 3

R05-05 

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CONTENTS

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CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK 

GENERAL SAFETY ST
STANDARDS 
ANDARDS 

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I
 

CONTENTS

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS 

STUDY THE OPERATOR/SERVICE MANUALS

The information in this manual provides general instructions for the safe operation and maintenance of your 
forklift truck. This information is vital and must be clearly understood by the operator and serviceman. Study
this manual and the Rough Terrain Forklift Safety Manual (part no. 422494) thoroughly and carefully before
operating or servicing your forklift. Contact your dealer or Manitou North America, Inc. if you have any ques-
tions concerning your forklift, its operation, service
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.
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
standard for rough terrain forklift
forklift trucks. It contains rules about
forklift safety,
safety, maintenance, safe operation, training, and supervision. Forklift owners should learn this stan-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.
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.
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
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
me chanical limitations, center of gravity
gravity,, stability,
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,
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
sha ll 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
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CONTENTS

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, im improper
proper operation, faulty maintenance, or poor housekeeping may 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 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.
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
injur y
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.

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III
 

CONTENTS

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
tru cks 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 lim
limits.
its. 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
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, w where
here 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,
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.

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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 fo forklift
rklift trucks equipped with attachments
attachments as part
partially
ially loaded trucks
when not handling a load.
47.) Completely engage the load with the the load-engaging means. Fork length should be at least two-thir two-thirds
ds 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 deposit a load over a rack or stack. When stacking
or tiering, use only enough backward tilt to stabilize the load.

49.) The handling

ic forces affecting of
thesuspended
stability of loads by terrain
a rough
rough means forklift
of a crane
truck.arm (boom)
Grades andor sudden
other device
starts,can
starts, introduce
stops, dynam-
and turns can
cause the load to swing and create create a hazard if not externally st stabilized.
abilized. 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).

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ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
 D.) SUSPENDED LOADS

 A jib or truss boom should ONLY

ONLY be used to lift and place loads when the machine is stationary and the frame
is level. Transporting suspended
suspended loads must ALWAALWAYSYS 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 tra
During transp
nsport
ort,, DO NOT rai
raise
se the
the load
load mor
more
e than
than 12
12 inche
inches
s (305
(305 mm)
mm) abov
above
e the
the groun
ground,
d, or
or raise
raise
the boom more than 45 degrees.

3. Only
Only li
lift
ft th
the
e lo
load
ad ve
vert
rtic
ical
ally
ly – NE
NEVER
VER dr
drag
ag it ho
hori
rizo
zont
ntal
ally
ly..

4. Use mul
multip
tiple
le picku
pickup
p point
points
s on the
the load
load when
when poss
possibl
ible.
e. Use
Use tagl
tagline
ines
s to rest
restrai
rain
n the
the load
load from
from swi
swingi
nging
ng
and rotating.

5. Start,, trave
Start travel,
l, turn
turn and
and stop
stop SLO
SLOWL
WLY
Y to pre
preven
ventt the
the load
load from
from swi
swingi
nging.
ng. DO NOT
NOT excee
exceed
d walkin
walking
g
speed.

6. Inspectt riggi
Inspec rigging
ng befo
before
re use.
use. Rig
Riggin
ging
g must
must be
be in goo
good
d condi
conditio
tion
n and
and in the U.S. com
comply
ply wit
with
h OSHA
OSHA
regulation §1910.184, “Slings,” or §1926.251, “Rigging equipment for material handling.”

7. Rig
Riggin
foreging
g equip
and equipmen
aft. ment
The t attach
attached
load ed must
center to the
to thenot
forks
forks mustt 24
mus
exceed be inches
secured
secured(610
such
such that itit cannot
that
mm). cannot mov
move
e either
either sid
sidewa
eways
ys or

8. DO NOT
NOT lift
lift the
the load
load wit
with
h anyon
anyone
e on the
the load
load,, riggi
rigging
ng or
or lift
lift equi
equipme
pment,
nt, and NEVE
NEVER
R lift
lift the
the load
load over
over
personnel.

9. Beware of the wind, which can cause suspended loads to swing, even with taglines.

10. DO NOT
NOT att
attemp
emptt to
to use
use fram
frame-l
e-leve
evelin
ling
g to
to compe
compensa
nsate
te for
for loa
load
d swing
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.
horizontally. In par ticular
ticular,, 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.
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 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 ofof the work site. They must have successfully completed
completed a training coarse in
accordance with the Powered Industrial Truck Standard
Standard (29 CFR 1910.178) as described by the Occupational
Safety and Health Administration
Administration (OSHA). They must be qualified as to their visual, hearing, physical,
physical, and
mental ability to operate the equipment
equipment safely.
safely. NEVER use drugs or alcohol
alcohol while operating a forklift! NEVER
operate or allow anyone to operate a forklift when mental alertness or coordination
coordination is impaired! An operator 
on prescription or over-the-counterhttps://www.forkliftpdfmanuals.com/
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
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,
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
performance and operation, a maintenance
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
function properly.
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.
model. Learn the locations
locations and meanings of of all safety decals. If any decals are illegible or miss-
ing, have them replaced immediately.
immediately. Make sure all safety features provided by the original manufacturer
manufacturer are
in place and function properly.
properly. Do not operate a forklift
forklift with damaged, missing or unsafeunsafe components. Have
it repaired by authorized service
service personnel. Learn the functions of all controls, gauges,
gauges, indicator lights, etc. on
the forklift. Know the speed/gear ranges,
ranges, braking and steering capabilities,
capabilities, load ratings and
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,
normally, facing forward in the operator’s seat. If you have any questions about the forklift, con-
sult your supervisor.
supervisor. Failure to fully understand or obey safety warnings
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.
traffic. Check
the size, weight, and condition of the loads you will be expected
expected to handle. Verify that they are properly
properly
secured and safe to transport.
transport. Learn where the loads are to be placed, placed, planning your route for a safe
approach, watching for hazardous conditions.
conditions. Will a signal man be required to help place the load?
load? Remove
any debris which may cause tire damage or rupture. Plan your route around problem problem areas or have them them cor-
rected. Inform the supervisor
supervisor of any unsafe
unsafe conditions
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,
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
regulations have been met. Report any accidents involving personnel, building building
structures, and equipment to the the supervisor immediately.
immediately. Always remain alert - conditions are constantly
constantly
changing at the work site!

TECHNICAL SUPPORT
 All data provided in this manual
manual is subject to production changes, addition
addition of new models, and improved
improved prod-
uct designs. If a question arises regarding your forklift, please consult your dealer or K-D Manitou, Inc. for the
latest information. When ordering service parts
parts or requesting technical information,
information, be prepared to quote
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
similar to those shown in the
examples below.

SAFETY ALERT SYMBOL

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

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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.
injury. May also alert unsafe practices.
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.
injury.

CALIFORNIA PROPOSITION 65 WARNING

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

WARNING: Battery posts, terminals and related accesories and related accessories
contain lead and lead compounds. Wash hands after handling.

 IX

CONTENTS

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,
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
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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).
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).
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

CONTENTS

SAFETY DECALS

Emergency and Parking Brake - 801010

Location: near the park brake lever.

Identifies the Emergency/Parking Brake Lever.

Alarm Must Sound - 496162

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

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

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 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

CONTENTS

SAFETY DECALS

Use
(Boomofequipped
Frame models).
Leveling
m - 801013
odels). 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).
models). Location: on both sides of the
boom nose.

Important reminders of attachment and boom safety.

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 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

CONTENTS

SAFETY
SAFETY DEC
DECALS
ALS

Gear Shift Pattern - 33460

(4-speed transmission
transmissi on 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.

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 221322

Mineral Oil (Brake Reservoir) - 221322 or 234800 has

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

Refer to the Operator/Service Man

Manual
ual for the correct brake fluid
(mineral oil) to be used in the brake system.

234800

XIII
XIII

CONTENTS

SAFETY
SAFETY DEC
DECALS
ALS

Hydraulic Oilhydraulic
Location: on the - 234798 oror76573
tank 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.
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0 0
 Indicates required minimum to maximum anti freeze protection ( 22 F to 40 F).

Diesel Fuel - 161101

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

Identifies the fuel tank, and use of diesel fuel.

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

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

Do Not Tow - 494918

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

Towing the forklift will damage the transmission;

refer to the operator’s manual.

XIV
XIV

CONTENTS

SAFETY
SAFETY DEC
DECALS
ALS

Attachment
(Boom equipped Warning
models). -Location:
421016on the boom coupler,
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:https://www.forkliftpdfmanuals.com/
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

CONTENTS

SAFETY DECALS

Acid in Battery - 801014

Location: in or near the battery
storage compartment.

 Addresses battery
battery hazards.

Jump Start Battery - 801015

Location: in or near the battery storage
compartment.

Jump start instructions.

Attachment Plate - 425995

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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   496538
Forklift Data Plate - 496550
(Boom equipped models)
Forklift Data Plate - 496538
(Mast equipped models)
Location: within the operator’s compartment.
compartment.

Important forklift
forklift truck identification.
identification. Record
this information for use when contacting the
manufacturer for parts and service.

XVI

CONTENTS

1 - OPERATING 
AND SAFETY 
INSTRUCTIONS 
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 1-1
 

CONTENTS

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 1-2
 

CONTENTS

TABLE OF CONTENTS 

I NSTR
NSTRUC
UCTIO
TIONS
NS TO TH
THE
E COMPA
OMPANY
NY MANA
MANAGE
GER 
R  1 - 4 

THE OPERATOR 1 - 4
THE LIFT TRUCK 1 - 4
A - THE LIFT TRUCK'S SUIT
SUITABILITY
ABILITY FOR THE JOB 1 - 4
B - ADAPTA
ADAPTATION
TION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS 1 - 4
C - MODIFICATION OF THE LIFT TRUCK  1 - 4
THE INSTRUCTIONS 1 - 5
THE MAINTENANCE 1 - 5

I NSTR
NSTRUC
UCTIO
TIONS
NS FOR
FOR THE
THE OPER
OPERAT
ATOR 
OR  1 - 6 

PREAMBLE 1-6
GENERAL INSTRUCTIONS 1-6
A - OPERATOR
OPERATOR'S'S MANUAL 1 - 6
B - AUTHORIZATION FOR USE 1 - 6
C - MAINTENANCE 1 - 6
D - MODIFICATION OF THE LIFT TRUCK  1 - 6
E - LIFTING PEOPLE 1 - 7
OPERATING
OPERATING INSTRUCTIONS UNLADEN AND LADEN 1 - 8
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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 HIGHWA
HIGHWAY
Y 1 - 12
INSTRUCTIONS FOR HANDLING A LOAD 1 - 14
A - CHOICE OF ATTACHMENTS 1 - 14
B - MASS OF LOAD AND CENTER OF GRAVITY 1 - 14

C
D -- TRANSVERSE
N/A ATTITUDE OF THE LIFT TRUCK  1
1 -- 14
15
E - TAKING UP A LOAD ON THE GROUND 1 - 16
F - TAKING UP AND LAYING A HIGH LOAD ON TIRES 1 - 17
INSTRUCTIONS FOR USE AS A LOADER 1 - 18
A - LOADING 1 - 18
B - FILLING 1 - 18

M 
A
AIN
INTEN
TENAN
ANCE
CE IN
INST
STRU
RUCT
CTIO
IONS
NS OF THE
THE LIFT TRU
TRUCK  1 - 20 

GENERAL INSTRUCTIONS 1 - 20
MAINTENANCE 1 - 20
LUBRICANT AND FUEL LEVELS 1 - 20
HYDRAULIC 1 - 20
ELECTRICITY 1 - 20
WELDING 1 - 21

WASHING THE LIFT TRUCK 1 - 21

I F THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME   1 - 22 

INTRODUCTION 1 - 22
PREPARING THE LIFT TRUCK 1 - 22
PROTECTING THE I.C. ENGINE 1 - 22
PROTECTING THE LIFT TRUCK 1 - 22
BRINGING THE LIFT TRUCK BACK INTO SERVICE 1 - 23

1-3

CONTENTS

INSTRUCTIONS TO THE COMPANY MANAGER 

T H
HE E OP
OPER
ERAT
ATOR 
OR 

- Only qualified, authorized personnel may 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.

WARNING

On the basis
On the basisof of
experience,
experience,there
there are numberofofpossible
number
are a number possible situations
situations in which
in which operating
operating the
the lift lift truck
truck is prohibited.
is unacceptable. Such
Such fore- 
foreseeable 
seeable abnormal
abnormal uses,
uses, the mainthe main
ones ones
being being
listed listed
below, arebelow,
strictlyare strictly forbidden.
forbidden.
- The foreseeable abnormal
- The foreseeable behavior
abnormal of neglect,
behaviour resultingbut notordinary
from intending to put
neglect, the
but machinery
does not resulttofrom
anyanyimproper
wish to use.
put the machinery to any 
improper
- The use.
reflex reactions
reflex of a person in the event of a malfunction, incident, fault, etc. during operation of the lift truck.
- The
- Behavior reflex reactions
resulting of a personofinthe
from application the"principle
event of a of
malfunction,
least action" incident,
whenfault, etc. during
performing operation of the lift truck.
a task.
- Behaviour
- For certain resulting
machines, thefrom application
foreseeable
foreseeable of the "principle
behavior of such of least action"
persons when performing
as unauthorized: a task. teenagers, handicapped per- 
apprentices,
- Fortrainees
sons and certain machines,
tempted tothe foreseeable
drive behaviour
a lift truck. of such persons
Truck drivers temptedasto: operate
apprentices, teenage
teenagers,
a truck rs, a
to win handicapped persons, trainees 
bet, in competition or for their 
own personal
tempted experience.
to drive a lift truck, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.
TheThe
person
personin in
charge
chargeofofthe
theequipment musttake
equipment must takethese
thesecriteria
criteria into
into account
account when
when assessing
assessing whether
whether or not or not a person
a person will 
will make a sui- 
make a suitable
table driver. driver.
dr iver.

T HE
HE LIFT TRUCK 
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A - THE LIFT 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,
manua l, with a STATIC test coefficient of 1.33 and a DYNAMIC test coefficient of 1, as specified
specified in harmoniz
harmonized
ed norm EN 1459
for variable range trucks.
- Before commissioning, the company manager must make sure that that the lift truck is appropriate for the work to be done, and per-
form certain tests (in accordance with current legislation).

B - ADAPTATI
ADAPTATION ON OF THE LIFT TRUCK TO STANDARD
STANDARD ENVIRONMENTAL CONDITIONS
- In addition
addition ttoo series eequipm
quipment
ent moun
mounted
ted on you
yourr lift truc
truck,
k, many o options
ptions a are
re avai
available,
lable, such as : road ligh
lighting,
ting, stop ligh
lights,
ts, fla-
shing light, rever
reverse
se lig
lights,
hts, rever
reverse
se bu
buzzer
zzer alarm, fron
frontt ligh
light,
t, rear light, light at tthe
he bo
boom
om he
head,
ad, etc.
- The operator must take into account the operating conditions to define the lift truck's signalling and lighting li ghting equipment. Contact
your dealer.
- Take into account climatic and atmospheric conditions of the site of utilzsation.
. Protection against frost (see : 3 - MAINTENANCE : LUBRIC LUBRICANTS
ANTS AND F FUEL).
UEL).
. Adaptation of lubricants (ask your dealer for information).
. I.C. engine filtration (see : 3 - MAINTENANCE
MAINTENANCE : FIL FILTERS
TERS CARTRIDGES AND BEL BELTS).
TS).

For operation under average climatic

climatic conditi
conditions,
ons, i.e. between -15 °C and + 35 °C (5° to 95°F), correct 
levels of lubricants in all the circuits are provided in production. For operation under more severe climatic 
For operation under average climatic conditions, i.e. : between -15 °C and + 35 °C, correct levels of lubricants in all the circuits are chec- 
IMPORTANT conditions, before starting up, it is necessary to drain all the circuits, then add the correct levels of lubri- 
ked in production. For operation under more severe climatic conditions, before starting up, it is necessary to drain all the circuits, then 
cants properly suited to the relevant ambient temperatures. It is the same for the cooling fluid (Contact 
ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures. It is the same for the cooling 
 your dealer for
for informat
information,
ion, if neces
necessary).
sary).
liquid.
- A lift truck
tr uck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are
solutions, consult your dealer
dealer..

Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and 
Your lift truck is designed for premises.
ventilated outdoor use It under normal atmospheric
is prohibited to use the liftconditions and indoor
truck in areas whereuse in suitably
there is a riskaerated
of fire and ventilated
or which premises.
are potentially 
ItWARNING
is prohibited to use the lift truck in areas where there is a risk of fire or which are a re potentially explosive (e.g. Refineries, fuel or gas depots,
stores of inflammableexplosive (i.e. refineries,
products…). fuel or gas depots, stores of inflammable products…). Fordealer
use inforthese areas, specific equip- 
ment is availableFor use
(ask in
your these
dealer areas, specific equipment
for information). is available (ask your information).

C - MODIFICATION OF THE LIFT TRUCK

- For your safety
safety and that of others, you must not change the structure and settings of the various components used used in your lift
truck (hydrau
(hydraulic
lic pres
pressure,
sure, calibr
calibrating
ating lim
limiters,
iters, I.C. e
engine
ngine sp
speed,
eed, addit
addition
ion of ext
extra
ra equip
equipment,
ment, additi
addition
on of cou
counterw
nterweight,
eight, unap-
proved attachments,
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.

1-4

CONTENTS

T H
HE E INSTRU
INSTRUCTI
CTIONS 
ONS 

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

T H
HE E MAIN
MAINTE
TENA
NANC
NCE 
E 

- 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 mustYour

be inspected periodically
lift truck must to ensure
be inspected that it remains
periodically in compliance.
to ensure Theinfrequency
that it remains of this
compliance. The inspection is this
frequency of defined by cur- 
inspection 
WARNING
rent legislation in the country in which the lift truck is used.
is defined by current legislation in the country in which the lift truck is used.

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 1-5

CONTENTS

INSTRUCTIONS FOR THE OPERATOR 

P 
REAMBLE 
REAMBLE 

The risk of accidentThe

while
riskusing, servicing
of accident or operating,
while repairing your lift truck
servicing can be restricted
or repairing if youcan
your lift truck follow the safety
be reduced instructions
if you follow theand safety
safety mea- 
ins- 
DANGER
sures detailed in these instruction.
tructions and safety measures detailed in this manual. Failure to respect the safety and operating instructions, or the 
instructions for repairing or servicing your lift truck can lead to serious injury or fatal accident.

- Only the operations and maneuvers described in these operator's manual may be performed. The manufacturer cannot predict
all possible risky situations. Consequently
Consequently,, the safety instructions given in the operator's manual and on the lift truck itself are
not all inclusive.
- At any
any time, as an oper
operator
ator,, you mus
mustt envis
envisage,
age, within re
reason,
ason, the pos
possible
sible ris
risk
k to yourse
yourself,
lf, to othe
others
rs or to the lift ttruck
ruck itse
itself 
lf 
when you use it.
G ENERAL
ENERAL INSTRUCTION
INSTRUCTIONS 
S 

A - OPERATOR'S MANUAL
- Read the operator's manual carefully
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 decals which are no longer legible or which are damaged.

B - AUTHORIZATION FOR USE

- Only qualified, authorized personnel may https://www.forkliftpdfmanuals.com/
use the lift truck. This authorization is given in writing by the appropriate person in the
company,, in charge of using the lift truck, and must be permanently carried by
company by the operator
operator..
 - The operator is not competent to authorize driving 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 safe-
ty notice.
- The operator is prohibited from carrying out any repairs or adjustments himself,
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 - DAIL DAILY
Y OR EVERY 10 HOURS SERVICE).
- The operator must ensure tires are adapted to the nature of the ground (see area of the contact surface of the tires in the chap-
ter : 2 - DESCRIPTION
DESCRIPTION : CHAR
CHARACTERISTICS).
ACTERISTICS). There are optional solutions, consult your dealer
dealer..
. SAND tires.
. LAND tires.
. Snow chains.

Do not use the lift Do notif operate

truck the tiresthe
arelift truck if the
incorrectly tires are
inflated, incorrectly
damaged inflated, damaged
or excessively or excessively
worn, because this couldworn, Bad own
put your tiressafety
can put
or your 
that 
DANGER
of others at risk, orsafety
causeordamage
that of to
others at risk,
the lift truckoritself.
causeThe
damage
fittingto
of the liftinflated
foam truck. The installation
tires of foam
is prohibited and isinflated tires is prohibited
not guaranteed and 
by the manu- 
is not guaranteed
facturer, excepting prior authorzsation. by the manufacturer (prior authorization is required).

D - MODIFICATION OF THE LIFT TRUCK

- For your safety
safety and that of others, you must not change the structure and settings of the various components used used in your lift
truck (hydrau
(hydraulic
lic pres
pressure,
sure, calibr
calibrating
ating lim
limiters,
iters, I.C. e
engine
ngine sp
speed,
eed, addit
addition
ion of ext
extra
ra equip
equipment,
ment, additi
addition
on of cou
counterw
nterweight,
eight, unap-
proved attachments,
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.

1-6

CONTENTS

E - LIFTING PEOPLE
- The use of working equipment and
and load lifting attachments to lift people
people is strictly 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 ORH ORH
- It is forbidden to lift peop
people,
le, with any kind of attach-
attach-
ment, using a non-
non-ORH
ORH lift truc
truck.
k.
• Right-hand column
- With an ORH lift truck, people can only be lifted using
platforms designed by MANITOU for the purpose.
- MANITOU sells equipment specifically designed for lifting people (OPTION
ORH lift truck, contact your dealer).

      1
      2
      6
      1
      4

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      2
      °
      N
 1-7

CONTENTS

O PERA
PERATI
TING
NG IN
INST
STRU
RUCT
CTIO
IONS
NS UNLA
UNLADE
DEN
N AND
AND LA
LADE
DEN 
N 

A - BEFORE STARTING THE LIFT TRUCK

- Carry out daily maintenance (see : 3 - MAINTENANCE : A - DAIL
DAILY
Y OR EVERY 10 HOURS SERVICE).
- Make sure the lights, indicators and windscreen wipers are working properly.
properly.
- Make sure the rear view mirrors are in good condition, clean and properly adjusted.
- Make sure the horn and backup alarm work properly.

B - DRIVER’S OPERATING
OPERATING INSTRUCTIONS
- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and ins-
truments before operating the lift truck.
- Wear clothes
clothes suited for driving the lift ttruck,
ruck, 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’
driver’s
s cab.

CAUTION
Under Undermust
no circumstances no circumstances should while
the seat be adjusted the seat
thebe
liftadjusted
truck is while the lift truck is moving.
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,
body, protruding from the driver’
driver’s https://www.forkliftpdfmanuals.com/
s cab of the lift truck.
- The safety belt must be worn and adjusted to the operator's size.
 - The control levers must never in any event be used for any other than their intended purposes (e.g. climbing onto or down from
the lift
lift truck, etc.)
etc.)..
- If the control components are fitted with a forced operation (lever
(lever lock) device, it is forbidden to leave the cab without first put-
ting these controls in neutral.
- It is prohibited to carry passengers either on the lift truck or in the cab.

1-8

CONTENTS

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
When using the lift truck on a transverse
transverse slope,
slope, befor
beforee lifting the boom, follow the ins
instructio
tructions
ns given in the paragr
paragraph
aph : INS-
TRUCTIONS FOR HANDLING A LOAD : D - TRANSVERSE ATTITUDE ATTITUDE OF THE LIFT TRUCK.
- Travelling
Travelling on a longitudinal slope :
• Drive and brake gently
gently..

• Moving without
without load : Forks or attachment facing down
downhill.
hill.

• Moving with load : Forks or attachment facing uphill.

- Tak
Take
e into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passagewa
passagewayy.
- Never move onto a loading platform without having first checked
checked :
• That it is suitably positioned and made fast.

• That
• the unit
That this to which
platform it is connected
connect
is prescribed for ed
the(wago
(wagon,
totaln, truck,ofetc.)
weight the wil
will
liftl truck
not shift.
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
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
loading bays, trenc
trenches,
hes, scaff
scaffolding,
olding, soft land and man manholes
holes..
https://www.forkliftpdfmanuals.com/
- 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
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
over..
If the loadmust
If the load or the attachment or theremain
attachment
above must remainfor
a structure above a structure
a long time, thereforisathe
period
riskof time,
that there
it will is on
rest thethe
riskstructure
that it will settle  of 
because
the boom descending upon the to
owing structure asthe
the oil in thecylinders
hydrauliccooling
oil in the cylinders cools.
down.
WARNING
To To: eliminate this risk : 
eliminate this risk
- Regularly check the - Regularly
distance check
betweenthethe
distance
load orbetween the load and
the attachment or the
theattachment
structure andandreadjust
the structure
this if and readjust as necessary.
necessary.
- If possible use the- lift
If possible
truck atuse thetemperature
an oil lift truck at as
an close
oil temperature
as possibleastoclose as possible
ambient to ambient temperature.
temperature.
- In the case of work near aerial lines, ensure that the safety distance is sufficient between
between the working area of the lift truck and
the aerial line.
You must consult your
You local
mustelectrical agency.
consult your localYou could be
electrical electrocuted
agency. or be
You could seriously injuredor
electrocuted if you operate
seriously or park
injured theoperate
if you lift truck
ortoo close 
park the 
DANGER
to power cables. lift truck too close to power lines.

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 
DANGER
catches During high winds do not attempt moving loads that may catch the wind or cause the fork lift to be unstable.
the wind badly.

D - VISIBILITY
- The safety of personnel within the lift truck's radius of operation as well as that of the lift truck and its operator
operator,, depends on the
operator having good visibility of the environment immediately around the lift truck, under all circumstances at all times.
- This lift truck was designed to provide the operator with good visibility (direct or indirect via rear-view mirrors) of the immediate
environment during movement with the lift truck empty and boom in transport position.
- If the volume of thethe load limits visibility ahead, particular precautions must be taken :
- move in reverse ;
- adjust the site layout ;
- be assisted by someone (outside the area of operations of the lift truck) who can direct movements, making sure that
this person is always in view.
- always avoid maneuvering too far in reverse.
- With certain specific attachments, lift truck moving operations may may need the boom to be in high position. In this case, visibility 
on the right is limited and particular precautions must be taken :
- adjust the site layout ;
- be assisted by someone (outside the area of operations of the lift truck) who can direct movements.
- In any situation where visibility of the route
route is inadequate, obtain the help of someone (outside the are
areaa of operations of the lift
truck) to direct movements, making sure that this person is always in view. view.
- Maintain all components
components used for visibility clean, well-adjusted, and in good working order : windscreen and windows, windscreen
wipers and washers
washers,, road and work lights
lights,, rear-view
rear-view mirror
mirrors.
s.

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CONTENTS

E - STARTING THE LIFT TRUCK

SAFETY NOTICE

The lift truck must The

only lift truck must
be started up orbe started orwhen
manoeuvred maneuvered only
the operator is when
sittingthe operator
in the driver’siscab,
sitting
withinhis
the driver’s
seat cab, his
belt adjusted seat 
and fas- 
WARNING belt fastened and properly adjusted.
tened.
- Never try to start the lift truck by pushing or towing it. Such operation may cause severe damage to the transmission. If neces-
sary,, to tow the lift truck in an emerge
sary emergency
ncy,, the trans
transmissio
mission
n must be placed in the neu
neutral
tral posit
position
ion (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 connec-
ting it. Connect at first the positive terminals before the negative terminals.
Failurebetween
Failure to respect polarity to respect polaritycan
batteries between
cause batteries can cause
serious damage serious
to the damage
electrical to the
circuit. Theelectrical circuit.
electrolyte in theThe electrolyte
battery in the 
may produce 
WARNING
an battery
explosive gas. Avoid may and
flames produce an explosive
generation gas.close
of sparks Avoidtoflames and generation
the batteries. of sparks close
Never disconnect to the
a battery batteries.
while Never disconnect 
it is charging.
a battery while it is charging.

INSTRUCTIONS
- Check the closing and locking of the hood(s).
- Make sure that the forward/reverse lever is in neutral.
- Turn the ignition key to the position I to activate the electrical system.
- Mak
Make e sure the signal lights on the instrument control panel and fuel level indicators are working properly (see : 2 - DESCRIP-
TION : INSTRUM
INSTRUMENTS
ENTS AND CONTRO
CONTROLS).
LS).
- Turn
Turn the ignition key to position II to preheat for 5 seconds and 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 for 5 seconds between unsuccessful
attempts.
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- 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 pro
blems and to be able to correct them without any delay.
- If an instrument does not show the correct display,
display, stop the I.C. engine and immediately carry out the necessary operations.

F - DRIVING THE LIFT TRUCK

SAFETY NOTICE
Operators'
Operators' attention is drawn attention
tto
o the risksis involved
drawn tointhe risksthe
using involved in using
lift truck,
lift the lift truck,
in particular :  in particular
particular : 
-
- Risk of losing control.Risk of losing control.
- Risk of losing lateral and frontal stability of the lift truck.
DANGER
The operator must remain- in Risk of losing
control lateral
of the and frontal
lift truck. stability
In the event of of
thethe
liftlift truck.
truck overturning, do not try to leave the cabin during the inci- 
The operator IS
dent. YOUR BEST PROTECTION must remainFASTENED
TO STAY in control IN
of THE
the lift truck. In the event of the lift truck overturning, do not try to leave the 
CABIN.
cab during the incident. YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB.

- Observe the company’s traffic regulations or, or, by default, the public highway c code.
ode.
- Do not carry out operations which exceed the capacities of your lift truck or attachments.
- Always drive
drive the lift truck with the forks or attachment tto o the transport position, i.e. at 12 in. from the ground, the boom retrac-
ted 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
that pallet
pallets,
s, cases
cases,, etc, are in good ordorder
er and suit
suitable
able for the loa
load
d to be lifted.
- Familiarize 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 7 mph.
- Drive smoothly at an appropriate speed for the operating conditions (land configuration, load on the lift truck).
- Do not use the hydraulic boom controls when the lift truck is moving.
- Do not maneuver the lift li ft truck with the boom iinn the raised position unless under exceptional circumstances and then with extre-
me caution, at very low speed and using gentle braking. Ensure tthat hat visibility is adequate.
- Take turns slowly.
- In all circumstances make sure you are in control of your speed.
- On damp, slipp
slippery
ery or uneven terrain,
terrain, drive slo
slowly
wly..
- Brake gently,
gently, never abruptly
abruptly..
- Only use the lift truck’s forward/r
forward/reverse
everse lever from a stationary position and never do so abruptly
abr uptly..
- Do not drive with your foot on the brake pedal.
- Always remember that hydrostatic ty type
pe steering is extremely sensitive to movement of the steering wheel, so turn it gently and
not abruptly.
- 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.

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CONTENTS

- Use the rear-view mirrors frequently.

- Drive around obstacles.
- Never drive on the edge of a ditch or steep slope.
- It is dangerous to use
use two lift trucks simultaneously to handle heavy
heavy or voluminous loads, since this operation requires particu-
lar 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
drive the lift truck with the forks or attachment tto
o the transport position, i.e. at 12 in. from the ground, the boom retrac-
ted and the carriage sloping backwards.
- For lift trucks with gearboxes, use the recommended gear (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS) CONTROLS)..
- Select the steering mode appropriate ffor or 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 lever to the selected direction of travel and accelerate gradually until the lift truck moves off.

G - STOPPING THE LIFT TRUCK

SAFETY NOTICE
- Never leave the ignition key in the lift truck during the operator's absence.
- When the lift truck
truck is stationary, or if the operator has to lea
leave
ve his cab (even for a moment), place the forks or attachment on
the ground, apply the parking brake and put tthe he forward/reverse lever
lever in neutral.
- Make sure that the lift truck
tr uck is not stopped in any position that will
wil l interfere with the traffic flow and at least 6 ft. from the track
of a railway.
- In the event of prolonged parking on a site, protect the lift truck from bad weather,
weather, particularly from frost (check the level of anti-
freeze),
freeze), close an
and
d lock all the lift truc
truck https://www.forkliftpdfmanuals.com/
k access
accesses
es (door
(doors,
s, windo
windows,
ws, cowls…
cowls…). ).
 INSTRUCTIONS
- Park the lift truck on flat ground
ground or on an incline lower than
than 15 %.
- Place the forward/reverse lever in neutral.
- Apply the parking brake.
- For lift trucks with gearboxes,
gearboxes, place the gear lever in neutral.
- Retract entirely the boom.
- Lower the forks or attachment to rest on the ground.
- When using an attachment
attachment with a grab or jaws
jaws,, or a bucket with h
hydraulic
ydraulic opening, close the attachment fufully.
lly.
- Before
Before stopping the lift truck after a long working period, allow the I.C. engine to idle for a few moments,
moments, to allow the coolant
liquid and oil to lower the temperature of the I.C.
I.C. engine and transmission. Do not forget this precaution,
precaution, in the event of frequent
stops or warm stalling of the I.C. engine, or else the temperature of certain parts
par ts will rise significantly due to the stopping of the
cooling system, with the risk o
off badly damaging s such
uch parts.
- Stop the I.C. engine with the ignition switch.
- Remove the ignition key.
- Lock all the accesses
accesses to the lift truck (doors,
(doors, windows,
windows, cowls
cowls…).
…).

1 - 11

CONTENTS

H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY

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.
dealer.

INSTRUCTIONS
- Make sure the revolving light is in place, switch it on and verify its operation.
- Check the good working order and cleanness of lights, indicators and windscreen wiper
wiper..
- Switch off the working headlights if the lift truck is fitted with them.
- Retract entirely the boom and put the attachment at 12 in. from the ground.
- For lift trucks
trucks with gear
gearboxes
boxes :
On the road, set off in 3rd gear and go into 4th (as per model of lift truck) when the conditions and state of the road allow. In
hilly areas, set off in 2nd gear and go into 3rd when the conditions and state of the road allow.
Never move in neutral
Do (gear reverser
not allow or gear
the lift trucklever in neutral
to coast or transmission
in neutral cut-off
(using either button pressed) to
the forward/reverse preserve
lever, the lift
gear shift truck
lever or engine brake.
transmission 
DANGER
Failure to respect this instruction
cut-off button). on a slopeonwill
Coasting lead to
a slope willexcessive speed which
lead to excessive may
speed make
which maythemake
lift truck uncontrollable
the lift (steering,
truck uncontrollable brakes) 
(steering,
and may cause severe mechanical
brakes) and maydamage.
cause serious mechanical damage.

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 1 - 12

CONTENTS

DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTA ATTACHMENT

CHMENT
- You
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 cou
country
ntry authorizes driving with a front-mounted attachment,
attachment, you must at least :
• Protect and flag any sharp and/or dangerous edges on the attachment (see : 4 - ADAPTABLE A ATTAC
TTACHMENTS
HMENTS IN OPTION
ON THE RANGE : A ATTACHMENT
TTACHMENT 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
For using a trailer
trailer,, observe the regulations in force in your country (maximum ttravel
ravel speed, braking, maximum weight of trailer
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 ttruck
ruck 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 maximum vertical pull on the trailer hook must not exceed 3370 ft/lb.
- The authorized maximum train weight must not exceed the maximum weight authorized by the manufacturer (consult the manu-
facturer’s
facturer’ s plate on your lift truck).
- For lift trucks
trucks with geagearboxes
rboxes :
When driving with a trailer,
trailer, set off in 2nd gear and go into 3rd when the conditions and state of the road allow.
allow. Do not exceed
4th gear to avoid overheating the internal combustion engine and the transmission.

IF NECESSARY,
NECESSARY, CONSULT Y
YOUR
OUR DEALER.
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 1 - 13

CONTENTS

I N
NSTR
STRUC
UCTI
TION
ONS
S FOR
FOR HAND
HANDLI
LING
NG A LOAD 
LOAD 

A - CHOICE OF ATTACHMENTS
- Only attachments approved by MANITOU can be used on its lift trucks.
- Make sure the attachment is appropriate for for the work to be done (see : 4 - ADAPTABLE
ATTACHMENTS
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. There are
optional solutions ; contact you
yourr dealer
dealer..

B - MASS OF LOAD AND CENTER OF GRAVITY B1

- Before taking up a load, you must know its mass and its center of gravity. gravity.
- The load chart
char t for your lift truck is valid for a load in which
whi ch the longitudinal position of the
center of gravity is 24 in. from the base of the forks (fig. B1). For a higher center of gra-
vity
vity,, contact your dealer
dealer..
24 IN.
500 mm
- B2)
For irregular loads,
and set it in thedetermine theaxis
longitudinal transverse center
of the lift truck.of gravity before
before any movement (fig.

It is forbidden to move a load heavier than the effective capacity defined on the lift truck load 
CAUTION
chart.
Do not attempt to move a load heavier than the effective capacity defined on the lift truck load 
chart. https://www.forkliftpdfmanuals.com/
 CAUTION
For loads with a moving center of gravity (e.g. liquids), take account of the variations in the cen- 
ter of gravity in order to determine the load to be handled and be vigilant and take extra care  B2
For to limitwith
loads wthese
ith a variations as far of
moving center as gravi
possible.
gravity
ty (i.e., liquids), take into accoun
accountt the variations 
of the center of gravity in order to determine the load to be handled (Consult your agent 
or dealer). Be vigilant and take extra care to limit these variations as much as possible.

C - LONGITUDINAL STABILITY
STABILITY ALARM C
- This device gives an indication of the lift
l ift truck's longitudinal stability. Move
Move the boom very 
carefully when approaching the autauthorized
horized load limit (see(see : 2 - DESCRIPTION : INSTRU-
MENTS AND CONTROLS).
- Always watch this device during handling operations. 2   1
- When the device is in alert mode, it is forbidden to perform so-called "AGGRAVATING"
"AGGRAVATING"
3
mo
movem
vement
ents,
s, the
these
se bein
beingg:
A - Extending the boom.
B - Lowering the boom.
- Perform movements to relieve aggravat
aggravation ion in the following order (fig. C) : if necessary,
raise the boom (1), retract the boom as far as poss possible
ible (2) and lower the boom (3) to
release 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

CONTENTS

D - TRANSVERSE (LEVEL) ATTITUDE OF THE LIFT TRUCK

(depending on the model of lift truck)

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

E1
E - TAKING UP A LOAD ON THE GROUND
- Direct the lift truck perpendicular to
to the load, with the boom retracted and the forks in a
horizontal position (fig. E1).
- Adjust the fork spread and centering in connection with the load (fig. E2) (optional solu-
tions exist,
exist, consult your dealer).
- Never lift a load with a single fork.

CAUTION
Beware of the risks of trapping or squashing limbs when manually adjusting the forks.

Beware of the risks of pinching or crushing fingers when manually adjusting the forks.

- Move the lift truck forward slowly (1) and bring the forks to rest in front of the load (fig.
E3), if necess
necessary
ary,, slight
slightly
ly lift the boom (2) while tak
taking
ing up the load.
- Bring the load into the transport position. E2
- Tilt the load far enough backwards to ensure stability (loss of load on braking or going
downhill).
https://www.forkliftpdfmanuals.com/
FOR A NON-PALLETIZED LOAD
 - Tilt the carriage (1) forwards and
and move the lift truck slowly forwards
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.

E3 E4

1
2

1
3

1 - 15

CONTENTS

F - TAKING UP AND LAYING A HIGH LOAD ON TIRES F1

You must not raise the boom if you have not checked the transverse attitude of the lift truck 
WARNING
(see : INSTRUCTIONS
INSTRUCTIONS FOR HANDLING
HANDLING A LOAD : D - TRANSVERSE
TRANSVERSE ATTITUDE
ATTITUDE OF THE LIFT 
TRUCK).
Do not raise the boom until you have first checked the level attitude of the lift truck (see : INS- 
TRUCTIONS FOR HANDLING A LOAD : D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK). 2

REMINDER : Make sure th

that
at the following operations can be performed with good visibility  3
(see : OPERA
OPERATIONS
TIONS INS
INSTRUCT
TRUCTIONS
IONS UNLA
UNLADEN
DEN AND LADEN : D - VISIBILIT
VISIBILITY).
Y).

TAKING UP A HIGH LOAD ON TIRES

- Ensure that the forks will easily pass under the load.
- Lift and extend the boom (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.
carefully.
- Always
Always think about keeping the distance necessary to fit the forks under the load, bet-
ween the pile and the lift truck (fig. F1) and use the shortest possible length of boom. F2
- Bring the forks
for ks in front of the load by alternately extending and retracting the boom (1) or,
if necessary, moving the lift truck forward (2) (fig. F2). Put the handbrake on and set the
reverse gear to neutral. 1
- 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.
2
- Watch
Watch the load, if it is overloaded, return the load to the place ffrom
rom which it was tak
taken.
en.
- If possible lower the load without shifting the lift truck. Lift the boom (1) to release the
load, retract (2) and lower the boom (3) to bring the load into the transport position (fig.
F4). https://www.forkliftpdfmanuals.com/
- If this is not possible, back up the lift truck (1), maneuvering very gently and care
carefully
fully to
 release the load. Retract (2) and lower the boom (3) to bring the load into the transport
position (fig. F5).
F3

F4

F5

1
3

1 - 16

CONTENTS

LAYING A HIGH LOAD ON TIRES F6

- Approach with the load in the transport position in front of the pile (fig. F6).

-- Put the handbrake

Lift and extend the on and(1)
boom set(2)
theuntil
(2) reversing
the loadlever to neutral.
is above the pile, while keeping an eye on
the load. If necessary,
necessary, move the lift truck ((3)
3) forward ((fig.
fig. F7), driving very slowly and care-
fully.
- Place the load in a horizontal position and lay it down on the pile by lowering and retrac-
ting the boom (1) (2) in order to position the load correctly (fig. F8).
- IIff possible, release the fork by alternately retracting and raising the boom (1) (fig. F9).
Then set the forks into transport position.
- IIff 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

1 3

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 F8

F9

F10

1 - 17

CONTENTS

INST
INSTR
RUC
UCTI
TION
ONS
S FOR USE
USE AS A LOADER 
ADER 

A1
A - LOADING
You must not lift the boom if you have not checked the lateral trim of the forklift truck (see: 
WARNING 2

INSTRUCTIONS FOR HANDLING A LOAD: D – LATERAL TRIM OF THE FORKLIFT TRUCK).   3

3
Do not raise the boom until you have first checked the level attitude of the lift truck (see : INS- 
TRUCTIONS FOR HANDLING A LOAD : D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK).
1

REMINDER: Make sure that the following operations can be performed with good visibility 
(see: OPERATING INSTRUCTIONS UNLADEN AND LADEN: D – VISIBILITY).
OPERATING

FILLING THE BUCKET

- Position the bottom of the bucket horizontally while scraping the ground (1) (fig. A1). A2
- Move forwards slowly (2) and raise the boom (3) while tilting the bucket backwards (3)
(fig. A1) to improve filling and lifting.
1
- Reverse the forklift truck (1) very gently and carefully to release the bucket. Lower the
2
boom (2) to transport position (fig.A2).

WARNING
Tilt Tilt the far
the bucket backwards bucket backwards
enough far any
to prevent enough to prevent
spillage any spillage
and ensure and ensure 
its stability (loss of 
product on braking).its stability (loss of product on braking).

LOADING A TRAILER
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- Approach the side of the trailer in transport position (fig. A3). A3
- Raise and extend the boom (1) (2) (fig. A4) until the bucket is over the trailer,
 Raise and extend the boom (1) (2) (fig. A4) until the bucket is over the trailer,
keeping an eye on the load. Move the forklift truck (3) forwards very gently and
carefully so that the load is tipped out into the center of the trailer. Put on the
handbrake and set the reverse lever to neutral.
- Slowly tip out the product (4).
- Tilt the bucket backwards (1) (fig. A5) and reverse the forklift truck (2) gently and
carefully.
- Retract (3) and lower the boom (4) into transpor t position (fig. A5).

4
A4

2   3

A5
1

B - FILLING
B1
- Position the bottom of the bucket horizontally while scraping the ground (1) (fig.
B1). 2
- Move slowly forwards (2) once the bucket
bucket is full, it will act as a levelling blade.
During movement, beware of trenches and land which has been recently dug and/ or 
During movement, beware of trenches and land which has been 
WARNING
filled in. 1
recently dug and/ or filled in.

1 - 18

CONTENTS

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 1 - 19

CONTENTS

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 

G ENERAL
ENERAL INSTRUCTION
INSTRUCTIONS 
S 

- Ensure the area is sufficiently ventilated before starting the lift truck.
- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jew jewelry
elry and loose clothes. Tie and protect your hair
hair,, if 
necessary.
- Stop the I.C. engine and remove the ignition key,
key, when an intervention is necessary.
- Read the operator's manual carefully
carefully..
- Carry out all repairs immediately, even if the repairs concerned are minor.
minor.
- Repair all leaks immediately, even if the leak concerned is minor.
minor.
- Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.
- Beware of the risk of burning and splashing
splashing (exhaus
(exhaust,
t, radiat
radiator
or,, I.C. engin
engine,
e, etc.)
etc.)..

M 
AINTENANCE 
AINTENANCE 

- 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.

L UBRI
BRICAN
ANT
T AN
AND
D FUEL
FUEL LEVE
LEVELS 
LS 
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 - 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.

H YDRAULIC 
YDRAULIC 

- Any work on the load handling hydraulic circuit is fo

forbidden
rbidden except for the operations
operations described in part : 3 - MAINTENANCE.
- Do not attempt to loosen unions, hoses or any hydhydraulic
raulic component with the circuit under pressure.
BALA
BALANCIN
NCING VALVE BALANCING
G VALVE VALVE
: For inspection, : For
see : 3inspection,
– MAINTEN see
MAINTENANCE
ANCE: 3: –DMAINTENANCE
- EVERY 500 HOURS : D - EVERY 500 HOURS
SERVICE. SERVICE.
It is dangerous toItchange
is dangerous to chan- 
the setting and 
WARNING
remove ge valves
the balancing the setting or remove
or safety valvesthe balancing
which may bevalves
fitted or
to safety
your liftvalves
truck which may These
cylinders. be fitted to your must
operations lift truck
onlycylinders. These 
be performed by 
approved personneloperations must
(consult your only be performed by approved personnel (consult your dealer).
dealer).

The HYDRAULIC ACCUMULATORS that may be fitted on your lift truck are pressurized units. Removing these accumulators and their pipe- 
The HYDRAULIC ACCUMULATORS which may be fitted on your lift truck, are under high pressure, it is dangerous to dis- 
WARNING
work is a dangerous operation and must only be performed by approved personnel (consult your dealer).
mantle them. This operation must only be performed by approved personnel (consult your dealer).

E LECTRICITY 
LECTRICITY 

- Do not short-circuit the star ter relay to start the IC engine. If the gear reverser is not in neutral and the parking brake is not enga-
ged, the lift truck ma
mayy suddenly s start
tart to move.
- Do not drop metallic items on the battery.
- Disconnect the battery before working on the electrical circuit.

1 - 20

CONTENTS

W 
ELDING 

- 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.
alternator.
- Never carry out welding or work which gives off heat on an assembled tire. The heat would increase the pressure which could
cause the tire 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
causing irre-
parable damage to electronic components.

W 
ASHI
ASHING
NG 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,
necessary, prote
protect
ct against penet
penetratio
ration
n of wate
waterr, steam or cleaning agen
agents,
ts, compo
components
nents sus
susceptib
ceptible
le of being damaged,
damaged, parti-
cularly electrical components and connections and the injection pump.
- Clean the lift truck of any
any fuel, oil or grease trace.

FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT Y

YOUR
OUR DEALER.

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 1 - 21

CONTENTS

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

I NTRODUCTION 
NTRODUCTION 

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,
operations, we recommend the use of protective products.
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 dea- 
IMPORTANT
lership.
It is recommended that your dealer perform the following procedures for lift truck storage and returning it to service.

P 
REP
EPAR
ARIN
ING
G THE
THE LIF
IFT
T TRU
TRUCK 

- Clean the lift truck thoroughly.

- Check and repair
repair any leakage of fue
fuel,
l, oil, wate
waterr or air.
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 : OPERA
OPERATING
TING INSTRUCTIONS UNLADEN AND LADEN).
- Make sure the boom cylinder rods are all in retracted position.
- https://www.forkliftpdfmanuals.com/
Release the pressure in the hydraulic circuits.
 P 
R
ROTEC
OTECTIN
TING
G THE  I.C. ENGINE 

- Fill the tank with fuel (see : 3 - MAINTENANCE : A - DAIL

DAILY
Y OR EVERY 10 HOURS SERVICE).
- Empty and replace the cooling liquid (see : 3 - MAINTENANCE : F - EVER
EVERY Y 2000 HOURS SERVICE).
- Leave the I.C.
I.C. engine running at idling speed for a few minutes, then switch off.
- Replace the I.C. engine oil and oil filter (s
(see
ee : 3 - MAINTENANCE : D - EVER
EVERYY 500 HOURS SERVICE).
- Add a 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 a protective product into each cylinder for two seconds with the piston in low neutral position.
- Turn the crankshaft once slowly and install the injectors (see I.C. engine REPAIR MANUAL).
- Remove the intake hose from the manifold or turbocharger and spray a protective product into the manifold or turbocharger.
- Cap the intake manifold or turbocharger hole with waterproof adhesive tape.
- Remove the exhaust pipe and spray a protective product into the exhaust manifold or turbocharger.
- Install the exhaust pipe and block the outlet with waterproof adhesive tape.
NOTE : The spra
sprayy time is no
noted
ted on the p
product
roduct packaging and must be increased
increased by 50 % for turbo engines.
- Open the filler plug, spray a protective product around the rock
rocker
er arm shaft and install 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.

P 
ROTE
R OTECT
CTIN
ING
G THE
THE LIFT TRU
TRUCK 

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

1 - 22

CONTENTS

B RING
R INGIN
ING
G THE
THE LIFT TRUCK BACK INTO SER
ERV
VICE 

- Remove the waterproof adhesive tape from all the holes.

- Install the intake hose.
- Install and reconnect the battery.
- Remove the protection from the cylinder rods.
- Perform the daily service
service (see : 3 - MAINTENANCE : A - DAIL DAILY
Y OR EVERY 10 HOURS SERVICE).
- Put the handbrake on and remove the axle stands.
- Empty and replace the fuel and replace the fuel ffilterilter (see : 3 - MAINTENANCE : D - EVERY 500 HOUR
HOURSS SERVICE).
- Install and set the tension in the drive belts (s (see
ee : 3 - MAINTENANCE : C - EVERY 250 HOURHOURS
S SERVICE).
- Turn
Turn the I.C. engine using the starter
starter,, to allow the oil pressure to rise.
- Reconnect the engine cut-off solenoid.
- Lubricate the lift truck completely (s
(see
ee : 3 - MAINTENANCE : SERVI SERVICING
CING SCHEDULE).

WARNING Insure the area is adequately ventilated before starting the lift truck.
Make sure the area is adequately ventilated before starting up the lift truck.

- Start up the lift truck, following the safet

safetyy instructions and regulations (see : OPERA
OPERATING
TING INSTRUCTIONS UNLADEN AND LADEN).
- Run all the boom's hydraulic movements, concentrating on the ends of travel for each cylinder.
cylinder.

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 1 - 23

CONTENTS

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 1 - 24

CONTENTS

2 - DESCRIPTION 

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 2-1

CONTENTS

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 2-2

CONTENTS

TABLE OF CONTENTS 

I D
DENT
ENTIF
IFIC
ICAT
ATIO
ION
N OF THE
THE LIFT
LIFT TR
TRUC
UCK 
K  2 - 4 

C HARACTERISTICS 
HARACTERISTICS  2 - 6 

D IMEN
I MENSI
SION
ONS
S AN
AND
D LOAD
LOAD CHART  2 - 10 

I NSTRU
NSTRUME
MENT
NTS
S AND
AND CONTR
CONTROLS 
OLS  2 - 12 

T OWING PIN AND HO

HOOK 
OK  2 - 28 

D EESCR
SCRIP
IPTI
TION
ON AN
AND
D US
USE
E OF EL
ELEC
ECTR
TRIC
IC AN
AND
D HYDRA
YDRAUL
ULIC
IC OP
OPTI
TION
ONS 
S  2 - 30 

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 2-3

CONTENTS

IDENTIFICATION OF THE LIFT TRUCK 

As our policy is to promote a constant

constant improvement of our products, our range of telesco-
pic lift trucks may undergo certain modifications without prior notice.

When you order

order parts, or when you re
require
quire an
anyy technic
technical
al informa
information,
tion, alwa
always
ys spec
specify
ify :

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

A
P LATE
LATE MAN
ANU
UFAC
ACTU
TUR
RER OF TH
THE
E LIFT
LIFT TRUCK ( 
TRU FIG .
FIG  A)

- Model
- Series
- Serial No.
- Chassis No.
- Year of manufacture

For any further technical information regarding your lift truck refer to chapter : 2 - DES-
CRIPTION : CHARACTERISTICS.
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 I.C. ENGINE  ( 
F IG .
FIG  B)
B)
B
- I.C. engine No.

T RANSMISSION 
RANSMISSION  ( 
F IG . C)
FIG  C)

- Type
- MANITOU reference
- Serial No.

F RONT
RONT AXLE  ( 
F IG .
FIG  D)
C
- Type
- Serial No.
- MANITOU reference

2-4

CONTENTS

R EAR AXLE  ( 
FIG .
FIG  E)
E) E

- Type
- Serial No.
- MANITOU reference

C AB  ( FIG 
FIG . F)
F)

- Type
- Serial No.

F 
B O OM  ( 
OOM  FIG . G)
FIG 

- MANITOU reference
- Date of manufacture

P LLATE
ATE MA
MANU
NUFA
FACT
CTUR
URER
ER OF THE
THE ATTA
ATTACH
CHMENT  ( 
MENT  FIG .
FIG  H)
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- Model
 Model
- Serial No.
- Year of manufacture

2-5

CONTENTS

CHARACTERISTICS 

I.C. ENGINE 

- Type
MLA 628 -120 LSU POWERSHIFT Series 3-E2 PERKINS 1104C-44TA RJ81416

1104C-44TA
- Number of cylinders 4 in line
- Number of strokes 4
- Suction Turboc
urbocharge
harged,
d, cooled
- Injection system Direct
- Ignition sequence 1.3.4.2.
- Clearance of rocker valve (cold)
. Inlet 0,20 mm (0.008 in)
. Exhaust 0,45 mm (0.02 in)
- Capacity  4400 cm3 (269 in3)
- Bore 105 mm (4.1 in)
- Stroke 127 mm (5.0 in)
- Compression ratio 17,5/1
- Nominal rating loaded 2300 rpm
- Rating slow unladen 850 + 20 rpm
- Max. rating unladen
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2460 rpm
 Power ISO/TR 14396 124 cv/91 kw
- Maximum torque ISO/TR 14396 434 Nm à 1400 rpm (320 ft/lb)
- Air cleaner Sec 3 µ

C OOLING
OOLING CI
CIRC
RCUI
UIT 
T 

- Type By water
- Fan Puller
. Number of blades 10
. Diameter 508 mm (20 in)
- Thermostat
. Start opening 174 °F/183 °F 
. Full opening 200 °F 

T RANSMISSION 
RANSMISSION 

- Type DANA
- Torque converter DANA
- Gear box
. Gear shifting Electro-hydraulic
. Number of forward speeds 4
. Number of reverse speeds 3
- Gear reverser Electro-hydraulic

F RONT
RONT AXLE 

- Type DANA
- Limited slip differential 45 %
- Hub reducers Epicyclic

R EAR AXLE 

- Type DANA
- Limited slip differential 45 %
- Hub reducers Epicyclic

2-6

CONTENTS

B RAKE 
RAKE 

- Service brake Foot pedal. Hydraulic servo-brake,

servo-brake, applied on the front and rear wheels.
. Type Multidisc brake immersed in oil.
- Type of pump Gear pump.
. Capacity  4,8 cm3 (0.3 in3)
. Pressure 120 Bar (1740 psi)
. Max. rating capacity unladen 12 L/mn (3.2 gal/min)

- Filtration 10 µ
. Pollution abatement Mechanical hand lever applied on the the
the front wheels.
- Parking brake Multidisc brake immersed in oil.
. Type

E LECTRI
LECTRICC CIRC
CIRCUIT 
UIT 

- Earth Negative
- Battery  12 V - 110 Ah - 750 A EN
- Alternator 12 V - 75 A
. Type Denso A115i
. Tension regulator Incorporated into the alternator
- Starter 12 V - 3,0 kW
. Type https://www.forkliftpdfmanuals.com/
Denso E95RL
 2-7

CONTENTS

CHARACTERISTICS  MLA 628 -120

-120 LSU POWERS
POWERSHIFT
HIFT Series 3-E2 

with simple carriage 

F RON
R ONT AND REAR TI
TIR
RES 

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

DIMENSIONS PRESSURE TIRE LOAD
HARD
HARD GROU
GROUND
ND LI
LIGH
GHTT GROU
GROUND
ND HARD
HARD GROU
GROUND
ND LI
LIGH
GHTT GROU
GROUND
ND
FRONT UNLADEN 2976 LB KG/CM2 KG/CM2 CM2 CM2
15,5/80-24 SGI 10PR
3,3 BAR FRONT LADEN 8267 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS
(48 PSI) REAR UNLADEN 4409 LB KG/CM2 KG/CM2 CM2 CM2
GOODYEAR REAR LADEN 1874 LB KG/CM2 KG/CM2 CM2 CM2
FRONT UNLADEN 2976 LB 114 LB/IN2 38 LB/IN2 26 IN2 77 IN2
445/70R24 MPT IT510 151G
4,1 BAR FRONT LADEN 8267 LB 136 LB/IN2 45 LB/IN2 60 IN2 180 IN2
TUBELESS
(60 PSI) REAR UNLADEN 4409 LB 125 LB/IN2 41 LB/IN2 35 IN2 107 IN2
GOODYEAR REAR LADEN 1874 LB 103 LB/IN2 34 LB/IN2 18 IN2 54 IN2
FRONT UNLADEN 2976 LB 122 LB/IN2 31 LB/IN2 24 IN2 95 IN2
460/70R24 IT520 150A8
3,3 BAR FRONT LADEN 8267 LB 163 LB/IN2 43 LB/IN2 50 IN2 193 IN2
TUBELESS
(48 PSI) REAR UNLADEN 4409 LB 135 LB/IN2 33 LB/IN2 34 IN2 132 IN2
GOODYEAR REAR LADEN 1874 LB 121 LB/IN2 32 LB/IN2 16 IN2 59 IN2
FRONT UNLADEN 2976 LB 18 LB/IN2 17 LB/IN2 164 IN2 172 IN2
17,5LR24 XM27 145A8
3,2 BAR FRONT LADEN 8267 LB 39 LB/IN2 36 LB/IN2 209 IN2 230 IN2
TUBELESS
(47 PSI) REAR UNLADEN 4409 LB 25 LB/IN2 22 LB/IN2 178 IN2 196 IN2
MICHELIN REAR LADEN 1874 LB 12 LB/IN2 12 LB/IN2 153 IN2 160 IN2

19,5LR24 XM27 149A8 https://www.forkliftpdfmanuals.com/

FRONT UNLADEN 2976 LB KG/CM2 KG/CM2 CM2 CM2
3 BAR FRONT LADEN 8267 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS
 (44 PSI) REAR UNLADEN 4409 LB KG/CM2 KG/CM2 CM2 CM2
MICHELIN REAR LADEN 1874 LB KG/CM2 KG/CM2 CM2 CM2

IMPORTANT

When changing or replacing the tires and 

wheels; use only the manufacturer’s approved 
components as installed
installed at the factory
factory.. Any 
substitutes or modifications must first be
approved by the manufacturer.

H YDRAUL
YDRAULIC
IC CIRCU
CIRCUIT 
IT 

- Type of pump Variable displacement piston pump

. Capacity  63 cm3 (3.8 in3)
. Max. rating capacity unladen 155 L/mn (41 gal/min)
. Flow rate at 2300 rpm 145 L/mn (38 gal/min)
. Flow rate at 1600 rpm 101 L/mn (26.7 gal/min)
- Pressure
. Liftin
Lifting,
g, tilting, teles
telescoping,
coping, attac
attachment
hment circu
circuit
it 270 Bar (3915 psi)
. Steering circuit 175 Bar (2537 psi)
- Filtration
. Return 25 µ
. Suction 125 µ

2-8

CONTENTS

S PECIFICATIONS 
PECIFICATIONS  “ WITH
WITH SIM
SIMPLE
PLE CA
CARR
RRIAGE ” 
” 
IAGE 

- Level of sound pressure in the driver's cab LpA 73 dB

(accordngg to standard prEN 12053 : 1995)
(accordn

- Level of sound power in the LwA environment 107 dB

(according to directive 2000/14 CE guaranteed)

- Speed of movement of lift truck in standard configuration on horizontal

ground
(except particular conditions)
. Forward unladen 30 km/h (18.6 mph)
. Reverse unladen 20,9 km/h (13 mph)

- Standard lift height 5110 mm (201.2 in)

- Rated capacity with standard attachment 2500 kg (5512 lb)

- Load center 24 in.

- Weight of forks (each) 72 kg (159 lb)

- Lifting motions (boom retracted)

. Unladen lifting 6,5 s 34,9 m/mn (114.5 ft/min)
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. Laden lifting 6,9 s 32,9 m/mn (108 ft/min)
 . Unladen lowering 4,6 s 49,3 m/mn (162 ft/min)
. Laden lowering 4,6 s 49,3 m/mn (162 ft/min)

- Teles
Telescoping
coping motions (lifting boom)
. Unladen extending 3,9 s 21,5 m/mn (71 ft/min)
. Laden extending 4,1 s 20,5 m/mn (67 ft/min)
. Unladen retracting 2s 42 m/mn (138 ft/min)
. Laden retracting 2,2 s 38,2 m/mn (125 ft/min)

- Reverse tilt time unladen 3,6 s 44,7 °/s

- Forward tilt time unladen 2,5 s 64,3 °/s

- Lift truck weight with standard attachment
. Unladen 6730 kg (14837 lb)
. Rated load 9230 kg (20349 lb)

- Axle weight with attached equipment (transport position)

. Front unlalad
den 2740 kg (6041 lb)
rated load 7520 kg (16579 lb)
. Rear unladen 3990 kg (8796 lb)
rated load 1710 kg (3770 lb)

- Tensible strain at coupling hook

. Unladen 5800 daN (13038 ft/lb)
. Rated load 9400 daN (21131 ft/lb)

- Break out force with bucket 5800 daN (13038 ft/lb)

(according to standard iso 8313)

2-9

CONTENTS

DIMENSIONS AND LOAD CHART  MLA 628 -120

-120 LSU
LSU POWERSHIF
POWERSHIFT
T Series 3-E2 

with simple carriage 

      2
      1       U
      U

      N

       3

      2
      G       G
       Y

      L
B I F F1

A D W

V 
R 
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V   
1  
      V

      K

      O

A 1200 mm (47.2 in)

B 2500 mm (98.4 in)
C 1419 mm (55.9 in)
C1 1821 mm (71.7 in)
D 5394 mm (212.4 in)
E 6594 mm (259.6 in)
F  1770 mm (69.7 in)
F1 1770 mm (69.7 in)
G 455 mm (17.9 in)
G1 390 mm (15.4 in)
G2 460 mm (18.1 in)
I 1475 mm (58.1 in)
K 1260 mm (49.6 in)

L 45 mm (1.8 in)
N 2050 mm (80.7 in)
O 125 mm (4.9 in)
P2 42 °
P3 27 °
R 4005 mm (157.7 in)
U 44 °
U1 2645 mm (104.1 in)
U2 2860 mm (112.6 in)
V 4500 mm (177.2 in)
V1 2005 mm (78.9 in)
V2 4233 mm (166.7 in)
W 2225 mm (87.6 in)
Y 10 °
Z 151 °

2 - 10

CONTENTS

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 2 - 11

CONTENTS

INSTRUMENTS AND CONTROLS 

2
1

3
16

15

7
6 22

5
11
35
5
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 10
10

14

13

22

22
17
28 25 12

26
21
27

18

19
8 22
22
5

36

24

23

2 - 12

CONTENTS

D ESCRIPTION 
ESCRIPTION 

1 - DRIVER'S SEAT
2 - SAFETY BELT
3 - CONTROL AND SIGNAL LIGHTS PANEL
4 - N/A
5 - SWITCHES PANEL
6 - LIGHT SWITCH, HORN AND INDICATOR
INDICATOR SWITCH
7 - IGNITION SWITCH
8 - BATTERY CUT-OFF 
9 - WINDSCREEN WASHER TANK (NOT ILLUSTRATED)
10 - FUSES AND RELAY ACCESS PANEL
11 - FUSE AND RELAY
12 - ROOF LIGHT
13 - ACCELERA
ACCELERATOR
TOR PEDAL
14 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF 
15 - FORWARD/REVERSE LEVER AND GEAR SELECTOR
16 - PARKING BRAKE LEVER
17 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF 
18 - LOAD CHARTS FILE
19 - HEATER CONTROL
19 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
20 - CAB FILTER VENTILAT
VENTILATORS
ORS (NOT ILLUSTRATED)
ILLUSTRATED)
21 - WINDSCREEN DEMIST VENTS https://www.forkliftpdfmanuals.com/
22 - HEATING VENTS
 23 - DOOR LOCKS
24 - RELEASING BUTTONS FOR UPPER DOORS
25 - SIDE WINDOW OPENING HANDLES
26 - CIGAR LIGHTER
27 - ARM REST LIFTING HANDLE
28 - TOOL BOX AND DOCUMENT HOLDER
29 - FRONT LIGHTS (NOT ILLUSTRATED)
30 - REAR LIGHTS (NOT ILLUSTRATED)
31 - REVOL
REVOLVING
VING LIGHT (NOT ILLUSTRATED)
32 - FRONT WORKING TAIL LIGHT (NOT ILLUSTRATED)
33 - REAR WORKING TAIL
TAIL LIGHT (NOT ILLUSTRA
ILLUSTRATED)
TED)

34 - REAR REFLECTORS (NOT ILLUSTRATED)

35 - STEERING WHEEL REGULATING HANDLE
36 - DIAGNOSTIC CONNECTOR
37 - REAR ELECTRIC SOCKET (NOT ILLUSTRATED)

NOTE : All the terms such as : RIGHT, LEFT, FRON

FRONT
T, REA
REAR
R are meant for an observer seated
seated on driver'
driver's
s seat facing forward
forward..

2 - 13

CONTENTS

1 - D RIVER 
RIVER ' 
'S
  SEAT  ( 
STANDARD )
STANDARD  2

DESIGNED FOR MAXIMUM COMFORT,

COMFORT, THIS SEA
SEAT
T CAN BE ADJUSTED AS FOLLOWS.
5
1
FRONT TO BACK ADJUSTMENT OF THE ARMREST
- Pull lever 1 upwards.
- Slide the upper section of the seat until the arm rests comfortably on the armrest 2. 4 7
6
- Release the lever making sure it is locked.

FRONT TO BACK ADJUSTMENT OF THE SEAT

3
- Pull lever 3 upwards.
- Slide the entire seat to obtain a comfortable driving position.
- Release the lever making sure it is locked.

ADJUSTING SEAT FLEXIBILITY

- Turn
Turn the knob 4 according to driver's weight

ADJUSTING SEAT TILT

- Lean back against the back of the seat.
- Pull lever 5 and place
pl ace the seat in the desired position.

ADJUSTING THE LUMBAR REGION

- Set the pneumatic pressure in the back ofhttps://www.forkliftpdfmanuals.com/
the seat as required :
- Pump with the squeezer 6 to increase the pneumatic pressure.
 - Press the button 7 to reduce the pneumatic pressure.

1 - P NEUMAT
NEUMATIC
IC DRIVER ' 
'S
DRIVER    SEAT ( OPTION 
OPTION )

DESIGNED FOR MAXIMUM COMFORT,

COMFORT, THIS SEA
SEAT
T CAN BE ADJUSTED AS FOLLOWS.
4
WEIGHT AND SEAT HEIGHT ADJUSTMENT
3

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

SEAT HEIGHT ADJUSTMENT

When weight adjustment has been carried out, you can then modify seat height.
- Keep the ignition switched on.
- 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
IMPORTANT
To avoid causing any damage, do not activate the compressor for over 1 minute.
minute.

ADJUSTMENT OF THE ANGLE OF THE BACK-REST

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

If you do not supportIf the

youback-rest
do not support the back-rest
when making when making
adjustments, it swingsadjustments, it swings 
completely forwards.
CAUTION completely forwards.

LONGITUDINAL ADJUSTMENT
- Pull locking lever 1 towards the right.
- Slide the seat to the required position.
- Release the lever and be sure it returns to the lock position.

2 - 14

CONTENTS

2 - S AFET
FETY BELT 
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 Do
thenot
lift operate
truck bethe
used
liftiftruck
the seat belt
with a is defective.
defective seat belt (fixing, locking, cuts,
WARNING tears, etc.). Repair or replace the seat belt immediately.

B1 B1 B2 B3 B4
3 - C ONTR
O NTROL
OL AND SI
SIGN
GNAL
AL LIGH
LIGHTS
TS PANEL 

CONTROL INSTRUMENTS

A - HOURMETER AND REV COUNTER

B - I.C. ENGINE WATER TEMPERATURE

Temperature zone B1 - Blue zone (32°F - 122°F) C
B2 - Green zonehttps://www.forkliftpdfmanuals.com/
(122°F - 212°F)
B3 - Black/red zone (212°F - 221°F)
 B4 - Red zone (221°F - 248°F) B
NOTE : Red indicator light “J”
“J” comes on betw
between
een zone B3 and B4.
A

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

SIGNAL LIGHTS

When activating the electrical system of the lift truck, all the red lamps and the panel's buzzer must light to indicate their good
working order.
order. If one of the red lamps or the buzzer does not function, carry out the necessary repairs.
D - RED LAMP - HYDRAULIC RETURN FILTER CLOGGED
The lamp and buzzer come on when the hydraulic return oil filter cartridge is clogged up. Park the lift truck and carry out the
necessary
necessa ry repairs (see cleanin
cleaning
g and replacem
replacement
ent requirem
requirements
ents in chapt
chapter
er : 3 - MAINTENA
MAINTENANCE
NCE : FIL
FILTERS
TERS CA
CARTRIDGE
RTRIDGES S AND
BELTS).

E - RED TRANSMISSION OIL TEMPERATURE LAMP

The lamp and the buzzer come on when the converter oil tempe- L M N O
rature is abnormally high. Park the lift truck and look for the
cause of this overheating. H I J K

F - RED BRAKING OIL PRESSURE LAMP

If the lamp and the buzzer come on when the lift truck is running,
stop the I.C. engine immediately and investigate the cooling sys-
tem for the cause of the malfunction.
D E F G
G - RED PARKING BRAKE LAMP
This lamp comes on when the parking brake is applied.

H - RED ALTERNATOR
ALTERNATOR CHARGE LAMP
If the lamps E - F - H - I - J - K and the buz
buzzer
zer come on, when the lift truck is running, stop the I.C. engine immediately and check
the electrical circuit as well as the alternator belt.

I - RED I.C. ENGINE OIL PRESSURE LAMP

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

J - RED I.C. ENGINE WATER TEMPERATURE

TEMPERATURE LAMP
If the lamp and the buzzer come on when the lift truck is running , stop the I.C. engine immediately and investigate the cooling sys-
tem for the cause of the malfunction.

2 - 15

CONTENTS

K - RED LAMP - AIR FILTER OR HYDRAULIC RETURN FILTER CLOGGED

The lamp and buzzer come on when the air filter cartridge or the hydraulic return oil filter cartridge is clogged up. Park the li
lift
ft truck
and carry out the necessary repairs (see
(see cleaning and replacement
replacement requirements in chapter
chapter : 3 - MAINTENANCE
MAINTENANCE : FIL
FILTERS
TERS CAR-
CAR-
TRIDGES AND BELTS).

L - GREEN INDICATOR
INDICATOR LAMP

M - GREEN SIDELIGHTS LAMP

N - GREEN LOW BEAM LAMP

O - BLUE MAIN BEAM LAMP

4 - N/A

This device warns the operator that the lift truck is approaching the limit of longitudinal stability
stability.. However
However,, lateral stability can redu-
ce the load chart in the upper part, and this reduction is not detected by the longitudinal stability alarm.

The operator must always respect the lift truck load chart.

OPERATION
When the lift truck is switched on a controlhttps://www.forkliftpdfmanuals.com/
test is automatically carried out.
- Correct operation : All leds and the so
sound
und alarm function continuously for 2 seconds.
 - Faulty
Faulty opera
operation
tion : All leds and sound alarm function intermittently (park
(park the lift truck and consult your dealer,
dealer, never attempt a
repair yourself).

A - LEDS (VISUAL ALARM) (FIG. A)

A1 - 4 green leds : There is a large reserve of longitudinal stability.
A
A2 - 2 yellow leds : The lift truck is approaching the limit of longitudinal stability,
move carefully. A

A3 - 1 red led : The lift truck is very near at the limit of longitudinal stability. The A4
A3 C
alarm sounds simultaneously with a slow intermittent sound.
Move very carefully
carefully.. A2 B1
A4 - 1 red led : The lift truck is at the authorized limit of longitudinal stability
stability.. The A2
B
alarm sounds simultaneously with a speed intermittent sound. A1
Only make de-aggravating hydraulic movements in the following A1
order ; retract and raise the boom. A1
A1
B - SOUND ALARM SWITCH (FIG. A)
Used to switch off the sound alarm when using the lift truck with loading and ear th moving
buckets. When it is switched
switched off, the red led B1 indicates that the sound alarm has been
cut off and only the
the visual alarm is working. Under other operating conditions,
conditions, the sound
alarm must be switched on. B

C - TEST SWITCH (FIG. A)

Press the switch to verify at any time that the longitudinal stability alarm is working. D
NOTE : This test does not verify that the alarm is correctly set ; this must be checked at
every periodic service.
- Correct operation : All leds and the so
sound
und alarm function continuously
continuously..
- Faulty operation : All leds a
and
nd the sound alarm function intermittently (park the lift truck
and consult your dealer,
dealer, never attempt a repair yyourself).
ourself).

D - STRAIN GAUGE (FIG. B)

Disassembly or adjustment of the strain gauge is prohibited, this must only be done by spe- 
cially trained personnel, consult your dealer.

2 - 16

CONTENTS

5 - S WITC
WITCHE
HES
S PANE
PANEL 
L 

A - WORKING HEAD LIGHT

B - OPTION BOOM HEAD LIGHT

C - WORKING TAIL LIGHT

D - WARNING LIGHTS
A B C D
This switch enables the L.H. and R.H. Indicators to be switched on simultaneously
simultaneously,, with
the ignition off. The signal light
li ght indicates that the switch is being used.

E - OPTION REAR WINDOW DEFROSTING

F - FRONT WINDSCREEN WIPER

G - FRONT WINDSCREEN WASHER

H - OPTION

E F G
I - OPTION
- OPTION Electrovalve on boom head.
- OPTION Attachment hydraulic locking device.
- OPTION https://www.forkliftpdfmanuals.com/
Electrical boom provision.
- OPTION Electrovalve on boom head + attachment hydraulic locking de
device.
vice.
 See : 2 - DESCRIPTION : DESCRIPTION AND US
USE
E OF ELECTRIC AND HY
HYDRAULIC
DRAULIC OPTIONS.
H I J

J - TRANSMISSION CUT-OFF 
The switch selects transmission cut-off to the service
servi ce brake pedal or the hydraulic controls
lever.
Position A : Indicator light on, transmission cut-of
cut-offf to service brake pedal effected.
Position B : Indicator light off, transmission cut-off to hydraulic control lever eff
effected.
ected.

NOTE : T
Transmission
ransmission cut-off can only be carried out when the speed is less than 7 mph.
B
USE OF TRANSMISSION CUT-OFF 

Transmission cut-off to brake pedal (position A).

• When loading.
Transmision cut-off to hydraulic controls lever (position B).
• When driving. A
• For inching and continuous stopping and starting (delicate handling). In order
to optimize hydraulic movements,
movements, cut off transmission to the hydraulic controls
lever.
• Starting up on a slope.

K - OPTION
OPTION ROO
ROOF
F W
WIPE
IPER
R

L - REAR WINDSCREEN WIPER AND WINDSCREEN WASHER

K L M N
M - FLASHING LIGHT

N - KICK-DOWN
KICK-DOWN SWITCH
SWITCH <-> OPTION BOOM HEAD ELECTRO
ELECTROVAL
VALVE
VE
See : 2 - DESCRIPTION : 15 - FORWARD/REV
FORWARD/REVERSE
ERSE LEVER AND GEAR SELEC
SELECTOR.
TOR.

O - OPTION BOOM SUSPENSION O P Q

See : 2 - DESCRIPTION : DESCRIPTION AND US
USE
E OF ELECTRIC AND HY
HYDRAULIC
DRAULIC OPTIONS.

P - OPTION

Q - OPTION
- OPTION Dual effect hydraulic towing hook.
- OPTION Single or dual effect rear hydraulic predisposition.
See : 2 - DESCRIPTION : DESCRIPTION AND USE OF ELECTRIC AND HYDRAU HYDRAULIC
LIC OPTIONS.

2 - 17

CONTENTS

6 - L IIGHT
GHT SW
SWITCH , HO
ITCH  HORN
RN AN
AND
D IN
IND
DICAT
ICATOR
OR SW
SWIT
ITCH 
CH 

The switch controls the visual and sound alarms.

G A C
A - All lights are off,
off, the direction indicators do not flash.
B - The right hand direction indicators flash.
C - The left hand direction indicators flash. D
G
D - The sidelights and the rear lights are on. B
E - The dipped headlights and the rear lights are on.
F 
F - The main beam headlights and the rear lights are on. G D
G - Headlight signal.

Pressing the switch sounds the horn.

NOTE : The positions D - E - F - G can be carried out withou
withoutt the ignition being on.

7 - I GNITION
GNITION SW
SWIT
ITCH 
CH 

The key
key switch has ffive
ive posit
positions
ions :
P - Ignition off,
off, parking pos
position.
ition.
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.
https://www.forkliftpdfmanuals.com/
 8 - B A
ATTE
TTERY
RY CUT - 
CUT -O
  FF 
OFF 

9 - W IINDSC
NDSCREE
REEN
N WA
WASH
SHER
ER TA
TANK 
NK 

Located on the right side of the engine compartment.

See : 3 - MAINTENANCE : B - EVERY 50 HOURS S SERVICE.
ERVICE.

10 - F U
USESE AND RELAY ACC
ACCESS
ESS PANEL 

- Lift up the fuse and relay access panel 1.

2

NOTE : T
To
o access ffuses
uses F31, F32 and rela
relays
ys K8 to K17and K
K21,
21, you need to disassemble
the access panel 2. 1

2 - 18

CONTENTS

11 - F USE AND RELAY 

  . K10 K9 K12 K13
       2         T          U     A
       3          S
         I          S     3
       F         D          L

O P T.
T. O P T.
T.
A decal on the inside of the access panel gives a        1
       3
       F
    A
    0
    2
LSU TEST

clear display of the use of the components descri-        1

       1 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F 11
F1 F 12
F1 F 13
F1 F 14
F1 K5
bed below.        K
       0     .
             T
   x
   a
   m
ECU
O P T. O PT. O P T.
STOP

       3              P
    A O PT.
       F              O     5 STOP
    1
15A 5A 10A 10A 7.5A 7.5A 7.5A 7.5A 10A 10Amax 10Amax 7.5Amax 15A 15A
       9     A
       8        2
K0 - afety system starting switch relay.
relay.
    0
    2
       K        F
   x
F 15 F1 6 F1 7        8
    .    a
F 18 F1 9 F2 0 F 21
21 F2 2 F2 3 F 24
24 K2 K1
K1 - OPTION.
             T
   m
       2              P
    A
       F              O     5
    1

   x
O PT.

K2 - OPTION. K 14
14 K 15
15
5A 10A 10A
      7
       2
       F
    .
             T
             P
   a
   m
    A
             O     0
    1
15A 7.5A 15A 15A 25A 10A 15Amax

K3 - Reverse gear relay.        6

       2
    .
             T
             P
             O
   x
   a
   m
    A
       F     0
K4     1
K7 K6 K3 K0
K4 - Transmission cut-off relay. K16 K17       5
       2
    A
    0
    3
       F
K5 - Hydraulic return filter clogged. STOP STOP

K6 - Flashing unit. N° 244973

K7 - Buzzer
K8 - Front windscreen wiper.
K9 - OPTION Electrovalve on boom head.
- OPTION Electrovalve on boom head + attachment hydrau
hydraulic lic locking device.
K10 - OPTION Air conditioning.
K11 - Rear window defrosting
K12 - Electroproportional hydraulic control modules. MLA 628 -120 LSU POWERSHIFT Series 3-E2
K13 - Test relay.
K14 - OPTION Boom suspension relay
relay..
K15 - OPTION Boom suspension cut-off relay
relay..
K16 - OPTION Hydraulic movements cut-off. https://www.forkliftpdfmanuals.com/
K17 - OPTION
 K18 - Preheating I.C. engine.
K19 - Rear windscreen wiper.
K20 - Transmission cut-off relay module.
K21 - Gear reverser micro relay.
K22 - OPTION Cutting off "aggravating" hydraulic movements modules. MLA 628 -120 LSU POWERSHIFT Series 3-E2
K23 - OPTION Cutting off "aggravating" hydraulic movements. MLA 628 -120 LSU POWERSHIFT Series 3-E2
K24 - OPTION Diesel decongealant.

NOTA : Remplacer un fus

fusible
ible usagé par un fusible neuf de même qualité et capacité. Ne jamais réutiliser un fusible réparé.
réparé.

F1 - (15A MAX.)
MAX.) - Fr
Front
ont w working
orking head light (15A) (15A)..
F2 - (5A MAX
MAX.)
.) - Vari
Variabl
ablee d disp
isplac
laceme
ement nt piston
piston pump
pump (5A(5A).
). MLA 628 -120 LSU POWERSHIFT Series 3-E2
F3 - (10
(10A
A MA
MAX.)
X.) - Sou
Sound nd al alarm
arm ((10A
10A).).
- Stop switch (10A).
F4 - (10
(10A
A MAX
MAX.)
.) - Ciga
Cigarr ligh
lighter
ter ((10A
10A).).
F5 - (7,5A MMAX.)
AX.) - Left indi
indicators
cators ((7,5A)
7,5A)..
F6 - (10A MAX.)
MAX.) - Rig
Rightht ssideligh
idelights ts ((7,5A)
7,5A)..
- Fuel gauge lighting (7,5A).
- Hourmeter lighting (7,5A).
F7 - (10A MAX.)
MAX.) - Le
Leftft sidel
sidelights
ights (7,5
(7,5A).
A).
- OPTION Number plate lighting (7,5A).
F8 - (10
(10A
A MAX
MAX.)
.) - Fla
Flashi
shing
ng lig
light
ht (7(7,5A
,5A).).
F9 - (10
(10A
A MAX
MAX.)
.) - Wo
Workin
rkingg tail lilight
ght (1
(10A)
0A)..
F10 - (10A MAX.)
MAX.) - OPT
OPTIONION B Boom
oom h head
ead llight
ight ((10A).
10A).
F11 - (10A MAX.)
MAX.) - Ai
Airr co
conditio
nditioning
ning (7,5A
(7,5A). ).
- OPTION Electrovalve on boom head (10A).
- OPTION Electrovalve on boom boom head + attachment hydrau
hydraulic
lic locking device (10A).
F12 - (7,5A MA
MAX.)
X.) - OPTION Roof wind windscree
screen n wiper (7,5A
(7,5A).
).
F13 - (15
(15AA MAX
MAX.)
.) - Gear rreveeverse
rserr (15
(15A).
A).
- Transmission cut-off (15A).
F14 - (15A MAX.)
MAX.) - - Sto
Stop p engin
engine e elec
electrov
trovalve
alve ((15A).
15A).
- OPTION Hydraulic movements cut-off (10A).
F15 - (10
(10AA MAX
MAX.)
.) - Sign
Signal al lam
lamp p pan
panelel (5
(5A).
A).
- Fuel gauge (5A).
- Hourmeter (5A).
- Buzzer (5A).
F16 - (10A MAX.)
MAX.) - Indic
Indicators
ators p power
ower suppl
supplyy (10A
(10A).
).
F17 - (10A MAX.)
MAX.) - Front
Front windscreen
windscreen wiper (10A) (10A)..
- Front windscreen washer (10A).

2 - 19

CONTENTS

F18 - (15
(15A
A MA
MAX.)
X.) - Mai
Main
n be
beam
am ((15A
15A).
).
- Main beam lamp (15A).
F19 - (10
(10A
A MAX
MAX.)
.) - Righ
Rightt indi
indicat
cators
ors (7(7,5A
,5A).
).
F20 - (15
(15A
A MA
MAX.)
X.) - Low bea
beam m (1
(15A)
5A)..
F21 - (15A M
MAX.)
AX.) - Hazar
Hazard d warn
warning
ing light
lightss pow
powerer sup
supply
ply (15
(15A).
A).
- Roof light (15A).
F22 - (25A M
MAX.)
AX.) - Light s switch
witch ppower
ower s supply
upply,, horn and indica
indicators
tors (2
(25A).
5A).
F23 - (10A MAX.
MAX.)) - Rear
Rear windsc
windscreen
reen wiper (7,5 (7,5A).
A). F33
- Rear windscreen washer (7,5A).
F24 - (15A MAX.
MAX.)) - OPT
OPTION
ION P Pneuma
neumatic tic s
seat
eat ((15A)
15A)..
F25 - (30
(30A
A MA
MAX.)
X.) - Hea
Heatin
tingg (3
(30A)
0A)..
F2
F26
6 - (1
(10A
0A M
MAX
AX.)
.) - OP
OPTI
TION
ON
F27 - (10A M
MAX.)
AX.) - OPTIO
OPTION N Rear h hydrau
ydraulic
lic pro
provision
vision (10A)
(10A)..
- OPTION Dual effect hydraulic towing hook (10A).
F28 - (15A MAX.)
MAX.) - OPT
OPTION
ION B Boom
oom s suspen
uspensionsion (10A
(10A).
).
- OPTION
F29 - (20A MAX.)
MAX.) - OPTI
OPTION
ON Rea
Rearr windo
window w def
defrosti
rosting
ng (20
(20A).
A).
F30 - (15A MAX.)
MAX.) - OP
OPTION
TION 1 12V
2V ssocke
ockett (1
(15A).
5A).
- OPTION (+) permanent (15A).
F43
F41
F31 -- (20
F32 (20A
(5AA MA
MA
MAX.)
X.) -- Elec
MAX.)
X.) St
Starter
arter
Electro (20
(20A).
tropro A). onall hydr
proporti
portiona hydraul
aulic
ic con
contro
troll modu
modules
les (3
(3A)
A)..
1

MLA 628 -120 LSU POWERSHIFT Series 3-E2 F42

- OPTION Attachment hy hydraulic
draulic control forced operation (5A).
F44
https://www.forkliftpdfmanuals.com/
MLA 628 -120 LSU POWERSHIFT Series 3-E2
K18 K24
- OPTION Coupure des mouvements hydrauliques "aggravants" (5A).
 MLA 628 -120 LSU POWERSHIFT Series 3-E2
- OPTION Attachment hydraulic control forced operation + Cutting off 
"aggravating" hydraulic movements (5A).
MLA 628 -120 LSU POWERSHIFT Series 3-E2

Lift the lid of the tool box for access to F33 fuses.
F33 - (1A MAX MAX.)
.) - Diag
Diagnos
nostic
tic con
connec
nector
tor (1A
(1A).
). MLA 628 -120 LSU POWERSHIFT Series 3-E2

Remove cover 1 for access to fuses F41 to F44.

F41 - (40A MAX.)
MAX.) - Lift truck e
electri
lectrical
cal eq
equipmen
uipmentt (40
(40A).
A).
F42 - (80A MAX.)
MAX.) - Pre
Preheati
heating
ng I.I.C.
C. eengine
ngine (80A)
(80A)..
F43 - (80
(80A
A MAX
MAX.)
.) - Alt
Alterna
ernator
tor ((80A
80A).).
F44 - (15A MAX.)
MAX.) - OPTI
OPTIONON Dies
Diesel el dec
decongeal
ongealant
ant ((15A).
15A).

12 - R O
OOF
OF LIGH
LIGHT 
T 

13 - ACCE
CCELER
LERATO
ATOR
R PED
PEDAL 
AL 

14 - S EERVI
RVICE
CE BRAK
AKE
E PED
PEDAL AN
AND
D TR
TRAN
ANSM
SMIS
ISSION CUT - 
SION -O  FF 
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 stop-
ped. Depending on the position of the transmission cut-off switch, it enables the free travel to cut off transmission (see : 2 - DES-
CRIPTION : 5 - SWITCHES P PANEL).
ANEL).

2 - 20

CONTENTS

15 - F ORWARD 
 / R
ORWARD  REVE
EVERS
RSE
E LEVE
LEVER
R AND GEAR SELE
SELECT
CTOR 
OR 

DESCRIPTION LED
Colours Reverse lever
RED NEUTRAL
GREEN FORWARD GEAR
Forward YELLOW REVERSE GEAR

(Green) LED in forward gear

LED lights in "test" mode

(see repair manual)
Neutral
1 2 3 4 5 6 7 8
(Green) LED lights when
N T F N R the machine is stationary 

"T" LED lights in "test"

Reverse (Red) "N" neutral LED (lights mode (yellow) (see repair
when the reverse lever is in manual)
neutral)

FORWARD/ REVERSE LEVER https://www.forkliftpdfmanuals.com/

 When operating this control, the lift truck should be travelling
travelling at low speed and not acce-
lerating. A

During the directionDuring

change,the direction
depeding onchange, depeding
the original on the
selection the original
speed mayselection the speed 
also change (see  2
C 1
IMPORTANT may also change (see diagram A) it can be reset
diagram A) it can be reset using the button 2 or 4 (kick down see diagram using the button 2 or 4 
diagram B/kick up see dia- 
 gram
 gram C).
C). (kic
(kickk down see diagram
diagram B/kic
B/kickk up see diag
diagram
ram C)C)..
B

FORWARD : Push the lever forwards (P (Position

osition A).
REVERSE : Pull the lever backw
backwards
ards (Position BB).
).
NEUTRAL : To start the lift truck, the lever mus
mustt be in neut
neutral
ral (Position C).After starting the 4
4
lift truck, the 3nd gear is automatically select
selected
ed after a few seconds.
seconds.
NOTE : The reverse lights indicate that the lift truck is running in reverse motion. As well, MLA
MLA 62
6288 TTur
urbo
bo..
.... MLA
MLA 62
6288 -1
-120
20 LLSU
SU..
....
an OPTION sound alarm on reverse motion exists.

GEAR SELECTOR
A
The selected gear is indicated on display 1 by a signal light.
SPEED RATIO
FORWARD GEAR : The gears can be gradually increased from the 1st to the 4th by turning
FORWARD FORWARD REVERSE
the handle forwards or by a double pulse ((<
< 0.5 seconds) (kick up) on the button 2 and
decreased from the 4th to the 1st by turning the handle backwards or by a single pulse 1st 1st
(kick down) on the button 2 or 4.
2nd 2nd
REVERSE GEAR
GEAR : The gears can be gradually increased from the 1st to the 3rd by turning
the handle forwards or by a double pulse (< 0.5 seconds)(kick up) on the button 2 and 3rd 3rd
decreased from the 3rd to the 1st by turning the handle backwards or by a single pulse
(kick down) on the button 2 or 4.
4th

B C
kick down kick down kick up kick up
SPEED RATIO SPEED RATIO SPEED RATIO SPEED RATIO
FORWARD REVERSE REVERSE FORWARD FORWARD REVERSE REVERSE FORWARD
1st 1st 1st 1st 1st 1st 1st 1st

2nd 2nd 2nd 2nd 2nd 2nd 2nd 2nd

3rd 3rd 3rd 3rd 3rd 3rd 3rd 3rd

4th 4th 4th 4th

2 - 21

CONTENTS

KICK-DOWN SWITCH <-> BOOM HE

HEAD
AD ELECTROV
ELECTROVAL
ALVE
VE
B

Switch 3 selects kick-down with knob 4 on the hydraulic control lever or the solenoid valve
at the boom head OPTION. 3
.
Po
Posit
sition
ion A : The LED is off, enabling kick-down with knob 4 on the hydra hydraulic
ulic
A
control lever.
Position B : The LED is on, enabling operation of the solenoid valve at the boom
head with the hydraulic control lever
lever..

USING THE GEARS ON THE GEARBOX 4

- On these lift trucks with a torque converter,
converter, it is not necessary to automatically start up 4
in 1st speed and progress up the gears.
MLA
MLA 62
6288 TTur
urbo
bo..
.... MLA
MLA 62
6288 -1
-120
20 LLSU
SU..
....

IMPORTANT
The choice of gear ratio should be made carefully according to the nature of the work being carried out. A poor choice may result in the 
extremely
The choice rapidratio
of gear elevation
shouldof be
themade
transmission
according oilto
temperature
the nature through excebeing
excessive
of the work ssive carried
slippingout.
of the converter,
A poor choicewhich could lead
may quickly to serious
overheat dama - 
dama- 
the trans- 
 ge to
mission oilthe
the transmission
transmissi
through on (it slipping
excessive is essential
is essentof
ialthe
to torque
stop and
stop change the
change
converter, th e working
workiserious
causing ng conditions
conditions if the
damage tto
hethe
trans
transmissio
missionn oil temperatu
transmission. tem
It isperature
re indicator
indica
essential tor light
to stop light comes 
and chan- 
on). This poor choice may also result in a reduction in the lift truck's performance in forward speed. When the forward
ge to the correct gear if the transmission oil temperature indicator light comes on. An incorrect gear selection may also result in a reduction  force increases, the 
in the lift truck's
forward speedperformance
in the r gearin(for
forward speed.
example 3rd When
gear) the
mayforward force
be lower thanorthe
load increases,
forward speedthe forward
that could speed (for example
be obtained with the3rd
r-1gear)
gear may be 
(in 2nd 
instead of the 3rd).
slower than the forward speed that could be obtained with 2nd gear (instead of 3rd).

In general, we would advise you to use thehttps://www.forkliftpdfmanuals.com/

following gears according to the nature of the work being carried out.
• On the road : Set off in 4th gear if the conditions and state of the road permit it. In hilly areas, set off in 3rd gear and go up to
 4th 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 and then to 4th if the conditions and state of the road permit
it.
• Handling : 3rd or 4th gear
gear..
2nd gear in restricted spaces.
• Earth moving : 1st gear.
• Loading (reclaiming with buc
bucket,
ket, manure fork, etc.) : 2nd gear
gear..

16 - P ARKI
ARKING
NG BRAKE
RAKE LE
LEVE
VER 
R 
A

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

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

2 - 22

CONTENTS

17 - H Y
YDRA
DRAUL
ULIC
IC CONTR
CONTROLS
OLS AND
AND TR
TRAN
ANSM
SMIS
ISSI
SION CUT - 
-O
ON CUT    FF 
OFF 

WARNING
Do Do not
not attempt to alter theattempt to system
hydraulic alter thepressure
hydraulic
bysystem pressure
interfering by interfering
with the with the pressure
pressure regulating regulating
valve. In the valve.
event of In the malfunc- 
suspected event of 
suspected
tion, contact your dealer. ANY malfunction,
ALTERATION contact your dealer.
MAY RENDER ANY ALTERATION
THE WARRANTY MAYVOID.
NULL AND VOID THE WARRANTY.

WARNING
Use Use thecarefully
the hydraulic controls hydraulicwithout
controls carefully
jerking, to without sudden movements,
avoid accidents to avoid
caused by shaking theaccidents
lift truck.caused by shaking the lift truck.

MLA 628 -120 LSU POWERSHIFT Series 3-E2

NOTE : If necessary use the steering to reset the hydraulic
A
control steering accumulator
accumulator..
LIFTING OF THE LOAD
- The lever A backwards when lifting. B C
- The lever A forwards when lowering.
TILT OF THE CARRIAGE   L

  L

- The lever A to the left for reverse tilt. L

- The lever A to the right for forward tilt. D

TELESCOPING       8
      0
      7
      4

- The button B up for the extension.       4

      2
      °
      N
E

https://www.forkliftpdfmanuals.com/
- The button B down for the retraction.
ATTACHMENT
 - The button C up or down.
KICK-DOWN OR OPTION BOOM HEAD ELECTROV
ELECTROVALVE
ALVE
- Button D (see : 2 - DESCRIPTION : 5 - SWITCHES P
PANEL).
ANEL).
TRANSMISSION CUT-OFF 
- Button E (see : 2 - DESCRIPTION
DESCRIPTION : 5 - SWITCHES P
PANEL).
ANEL).

18 - L O
OADAD CHA
HAR
RTS FI
FILE 
LE 

This file includes the description of the hydraulic controls and the load charts of the attachments used on the lift truck.

19 - H EEATE
ATER
R CON
CONTRO
TROL 
L 
B A

A - HEATING FAN CONTROL

This 3-speed control regulates warm or cold air through the heating ventilators.

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

2 - 23

CONTENTS

19 - AIR COND
CONDITI
ITION
ONIN
ING
G CONT
CONTROLS  ( 
ROLS  OPTI
OPTION
ON AIR COND
CONDITI
ITION
ONING )
ING 

The air conditioning only comes on when the forklift truck IMPORTANT
has been started up. When using your air conditioning, you must work with the 
doors and windows closed.
The air conditioning Inoperates
winter :only
So aswhile the lift correct
to ensure truck engine is running.
operation During use,
and complete keep the
efficiency doors
of the and windowsunit,
air conditioning closed.
start up the compressor 
In the winter : To ensure correct operation and efficiency of
once a week, if only for a short spell, so as to lubricate the internal seals. the air conditioning unit, run the compressor once a week, for a few 
minutes, to lubricateInthe internal seals.
cold weather : Warm the I.C. engine before switching on the compressor, so as to allow the coolant that has collected 
In cold
in the liquid weather
state at the: lowest
Warm the I.C.ofengine
point before switching
the compressor onturn
circuit to the compressor,
into gas under this
thewill allow
effect ofthe
thecoolant thatoff
heat given hasbycollected in the 
the I.C. engine,
liquidas
state at the lowest point of the compressor circuit to turn into
the compressor is liable to be damaged by coolant in the liquid state.gas by the heat given off by the I.C. engine (otherwise the compressor is 
liable to be damaged by pumping coolant in the liquid state when operated).

If your air conditioning does not seem to be working properly, have it examined by your dealer (see : 3 - MAINTENAN- 
If your air conditioning does not seem to be working regularly, have it examined by your dealer (see : 3 - MAINTENANCE : H - EVERY TWO 
WARNING CE : H - EVERY TWO YEARS "OPTION AIR CONDITIONING"). The air conditioning system is under high pressure,
YEARS "OPTION AIR CONDITIONING").
CONDITIONING"). Never try to repair any anomalies yourself.
repairs must be made by a professional airconditioning repairman.

DESCRIPTION OF THE AIR CONDITIONING CONTROLS

C B D
A - Control with signal light indicating start-up and cutout of the air conditioning
system,
syste m, if cont
control
rol "D" is in p
positio
osition
n 1, 2 or 3.
B - Heating air temperature control.
C - Conditioned air temperature control.
D - Air flow setting and fan speed control. In position "0" the air conditioning sys-
A
tem no longer functions. https://www.forkliftpdfmanuals.com/
 IMPORTANT
NOTE : Possible losses of water under the forklift truck are due to condensate discharges caused by the drying effect of the ins-
Possibletallation,
losses ofespecially
water underwiththe forklift
high truck
outside are due res
temperatu
temperatures to condensate discharges
and high relative caused
humidity.
humidity . by the drying effect of the installation,
especially
Forwith
the high outside temperatures
air conditioning to performand high, relative
properly
properly, humidity.must no
the air intakes nott be blocked by frost, snow or leaves.
For the When
air conditioning
conditionin g to perform properly, the air intakes must not be blocked
the facility is running, at least one of the cab air grilles must be open by
by frost, snow
so as or leaves.
leaves.
to avoid any risk of freezing to the
When the unit is
evaporator. running, at least one of the cab air g
grilles
rilles must be open so as to avoid freezing-up the evaporator.
evaporator.

HEATING MODE
The controls must be adjusted in the following way : C B D
A - Control with signal light off.
B - At the required temperature.
C - At the end of travel to the left.
D - At the required temperat
temperature
ure 1, 2 or 3.
A
CONDITIONED AIR MODE
The controls must be adjusted in the following way : C B D
A - Control with signal light on.
B - At the end of travel to the left.
C - At the required temperature.
D - At the required temperat
temperature
ure 1, 2 or 3.
A
DEMISTING MODE
The controls must be adjusted in the following way :
C B D
A - Control with signal light on.
B - At the required temperature.
C - At the required temperature.
D - At the required temperat
temperature
ure 1, 2 or 3.
A

20 - C AB FI
FILT
LTER
ER VE
VENT
NTIL
ILAT
ATOR
ORS 
S 

See : 3 - MAINTENANCE : D - EVERY 500 HOURS SE

SERVICE.
RVICE.

21 - W INDSCR
INDSCREE
EEN
N DEMI
DEMIST
ST VENTS 
VENTS 

For optimum effectiveness, close the heating ventilators.

22 - H EATI
EATING
NG VEN
VENTS 
TS 

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

2 - 24

CONTENTS

23 - D OORS
O ORS LO
LOCK
CKS 
S 

Two keys are provided with the lift truck to enable the cabin to be locked.

24 - R EELEA
LEASI
SING
NG BU
BUTT
TTON
ONS
S FOR UPPER DO
DOOR
ORS 
S 

25 - S IDE
I DE WIN
WINDOW OP
OPEN
ENIN
ING
G HA
HAND
NDLE
LES 
S 

26 - C IGAR
IGAR LIG
LIGHTE
HTER 
R 

27 - ARM REST
EST LI
LIFT
FTIING HAND
HANDLE 
LE 

28 - T OOL
O OL BOX AND DOCUM
CUMENT
ENT HO
HOLD
LDER 
ER 
Ensure that the operator's manual is in its place in the document holder.

https://www.forkliftpdfmanuals.com/
29 - FRO
RONT
NT LIGH
LIGHTS
TS
 29 F R
RONT
ONT LIGH
LIGHTS 
TS 

A - Left front indicator. G C

B - Left front dipped headlight.
C - Left front main beam.
D - Left front sidelight. E H D A
E - Right front indicator.
F - Right front dipped headlight.
G - Right front main beam.
F  B
H - Right front sidelight.

30 - R EAR LIGH
LIGHTS 
TS 

A - Left rear indicator.

B - Left rear stoplight.
C - Left tail light. A B/C D E F/G H
D - Left rear reverse light.
E - Right rear reverse light.
F - Right tail light.
G - Right rear stoplight.
H - Right rear indicator
indicator..

31 - R EVOLVI
EVOLVING
NG LIG
LIGHT 
HT 

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.

2 - 25

CONTENTS

32 - F R
RONT
ONT WO
WORK
RKIN
ING
G TAIL LIGH
LIGHT 
T 

33 - R EAR WO
WORK
RKIN
ING
G TAIL LIGH
LIGHT 
T 

https://www.forkliftpdfmanuals.com/
 34 - R EAR
EAR REF
REFLEC
LECTOR
TORS 
S 

35 - S TEER
TEERIN
ING
G WH
WHEE
EEL
L REGU
REGULA
LATI
TING
NG HAND
HANDLE 
LE 

This handle enables the angle and height of the steering wheel to be adjusted.
1
B
- Turn handle 1 towards A to loosen and adjust steering wheel.
- Turn handle 1 towards B to lock steering wheel in the position required.

37 - D IAGNOSTI
IAGNOSTIC
C CONN
CONNECTOR 
ECTOR 

2 - 26

CONTENTS

37 - R EAR EL
ELEC
ECTR
TRIC
IC SO
SOCK
CKET 
ET 

Enables power supply connection for a trailer (see : 2 - DESCRIPTION : TOWING PIN AND
HOOK) or signalling
signall ing bar.
A - Left rear indicator.
C - Earth.
D - Right rear indicator
indicator..
A
E - Right tail light.
F - Rear stoplight. F 
G - Left tail light. G
E
C
D

https://www.forkliftpdfmanuals.com/
 2 - 27

CONTENTS

TOWING PIN AND HOOK 

Located at the rear of the lift truck, this device is used to attach a trailer.
trailer. Its capacity is limited for each lift truck by the
gross vehicle weight, tractive effort and maximum vertical force on the coupling point. This information is given on the manufac-manufac-
turer's plate fixed to each lift truck (see : 2 - DESCRIPTION : IDENTIFICATION OF THE LIFT TRUCK).

- To
To use a trailer
trailer,, see current regulations in your country (maximum running speed, braking, maximum weight of trailer trailer,, etc.).
- Verify the
the trailer's condition bef
before
ore using it (tire condition and pressure
pressures,
s, electrical connection, hydraulic hose, braking system…).
Do not tow a trailerDo
or not tow a trailer
accessory whichoris accessory which
not in perfect is not order.
working in proper working
Using order.
a trailer Using
in poor a trailermay
condition in poor condition
effect may effect
the lift truck's the 
steering 
WARNING lift truck's steering, braking, and safety.
and braking, and hence safety.

If a third party helpsIf in

a third partyorhelps
coupling in coupling
uncoupling or uncoupling
the trailer, the trailer,
this person must be they must be continually
permanently visible
visible to the to the
driver and driver until the
wait until the lift
lift truck 
truck 
WARNING is parked and the I.C. engine is turned off.
has stopped, the handbrake is on and the I.C. engine is switched off before performing the operation.
NOTE : There is an OPTIONAL rear-view mirror which allows the lift truck to be directed more closely to the trailer ring.

A - T OWIN
OWINGG PIN  ( 
PIN  STANDARD )
STANDARD  https://www.forkliftpdfmanuals.com/
 COUPLING AND UNCOUPLING THE TRAILER
-TTo
o couple the trailer,
trailer, position the lift truck as close as possible to the trailer ring.
- Put the handbrake on and switch off the I.C. engine. 2
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.
Risk
Be careful not to get of crushed
your fingersororcrushed
fingers caught hands! during
Keep hands and fingers clear while cou- 
this operation.
Do not forget
WARNING to pling
put clipthe
1 trailer!
back in The safety
place. clip 1 must be installed after coupling. Before 
uncoupling,
When uncoupling, make make
sure that thesure theistrailer
trailer is blocked
supported in place and independently 
independently.
supported.

B - H Y
YDRA
DRAUL
ULIC
IC TRAI
TRAILE
LER
R HOOK  ( 
HOOK  OPTION )
OPTION 

NOTE : The rear-view mirror OPTION is mandatory with the hydraulic trailer tow hook.

- 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.
- Release knob 3.
- Couple or uncouple the trailer.

WARNING When uncoupling, make sure that the trailer is supported independently.
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 hook 4 lock is in proper
contact with hook 1 lock.
Never use the tow hook to raise the rear of the lift truck (when changing 
WARNING the rear wheel for example).
Never use the tow hook to raise the rear of the lift truck.

4 3
1

2 - 28

CONTENTS

C - E LECTRI
LECTRICAL
CAL CONNECTION  ( 
CONNECTION  STANDARD )
STANDARD 

- Connect the male plug to the female socket 1 on the lift truck and make sure the trailer
lights work properly
properly..
1

D - C O
ONNE
NNECT
CTIN
ING
G TH
THE
E BRA
RAKI
KING
NG SYSTEM  ( 
SYSTEM  OPTION )
OPTION 

- Connect the brake hose to the provided brake unit 2 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
highway..

https://www.forkliftpdfmanuals.com/
 2 - 29

CONTENTS

DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 

1 - R EVERSE
EVERSE BUZZ ER  ( 
BUZZER  BACKUP ) ALARM 
BACKUP 

2 - N UMBE
UMBER
R PLAT
PLATE 
E 

3 - N UMBE
UMBER
R PL
PLAT
ATE
E LIG
LIGHT
HTIN
ING 
G  3 2 3
https://www.forkliftpdfmanuals.com/
 4 - P REHEAT
REHEATIN
ING
G ROD 

Enables the motor unit to be kept warm during prolonged periods of stoppage and thus,
ensures the improved start-up of the I.C. engine.

SUPPLY CHARACTERISTICS OF PREHEATING SYSTEM :

• Rated range of power : 110-120V ; 50-60Hz
• Current consumed : 4,5A
• Equipment in class 1
• Category of insulation 2

ENVIRONMENTAL CONDITIONS IN USE :

ENVIRONMENTAL
• Maximum ambient temperature for using preheating : 77° F 
• Pollution level 2

CONDITIONS FOR CONNECTION AND USE OF PREHEA PREHEATING

TING :
- The preheating system should not be used for an external ambient temperature higher than 77° F.
- 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.

• Incorporates
ker with 30mAansensitivity.
appropriate safety system against short circuits (fuses or circuit breaker) and a differential circuit brea-
- Only connect to and disconnect from the power supply while the unit is off and the I.C. engine is stopped.

5 - E LECTR
LECTRIC
IC SOCKET  12V 
SOCKET 

2 - 30

CONTENTS

6 - E LECTR
LECTRIC
ICAL
AL BO
BOOM
OM PRO
PROVIS
VISION 
ION 

Enables an electrical function to be used at the head of the boom.

FUNCTIONING
MLA 628 -120 LSU POWERSHIFT Series 3-E2
- Hold button 1 down and move button 2 up or down.
NOTE : Switch 3 enables the function controlled by  3
button 1 to be locked. Indicator 4 lights up to 2
show when it is in use. 4

7 - H Y
YDRA
DRAUL
ULIC
IC AT
ATTA
TACH
CHME
MENT
NT LOCKING  https://www.forkliftpdfmanuals.com/
LOCKING 
 Enables attachment locking to be controlled on the carriage and the use of a hydraulic
attachment on the same hydraulic circuit (see : 4 - ADAPTA
ADAPTABLE
BLE ATTACHMENTS
ATTACHMENTS IN OPTION
ON THE RANGE : PICKING UP THE A ATTA
TTACHMENTS).
CHMENTS).

8 - B OOM
OOM HEAD
HEAD EL
ELEC
ECTR
TROV
OVAL
ALVE 
VE 

Enables use of two hydraulic functions on the attachment circuit.

To make connectionToofmake
the rapid connectors
connection easier,
to the decompress
connectors thedecompress
easier, hydraulic circuit by pres- 
the hydraulic 
IMPORTANT
sing button 1 on thecircuit
electrovalve.
by pressing button 1 on the electrovalve.

2 - 31

CONTENTS

FUNCTIONING
MLA 628 -120 LSU POWERSHIFT Series 3-E2
- Butt
Button
on 1 not engaged, button 2 controls a h hydraulic
ydraulic
function.
- Hold butto
button n 1 down, butto
button
n 2 contr
controls
ols anothe
anotherr 3
hydraulic function. 2
NOTE : Switch 3 enables the hydraulic function
4
controlled by button 1 to be locked. Indicator 4
lights up to show when it is in use.

9 - B OOM
OOM HEAD
HEAD ELEC
ELECTR
TROV
OVALVE  + PRE
ALVE  PREARR
ARRANG
ANGED
ED HYD
HYDRAU
RAULIC
LIC ATT
ATTAC
ACHM
HMENT
ENT LOCKING 

The addition of these two options enables the combining of several hydraulic functions.

https://www.forkliftpdfmanuals.com/
 10 - P R
REAR
EARRA
RANG
NGED
ED TR
TRAI
AILE
LER
R LOCKING 
LOCKING 

Enables the hydraulic connection of a braked trailer (see : 2 - DESCRIPTION : TOWING PIN
AND HOOK).

2 - 32

CONTENTS

11 - D UAL
UAL EF
EFFE
FEC
CT REA
EAR
R HYDR
HYDRAU
AULI
LIC
C CONT
CONTRO
ROL
L PR
PRED
EDISP
ISPOS
OSIT
ITIO
ION 
N 

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

FUNCTIONING
- Switch 1 controls this predisposition.

https://www.forkliftpdfmanuals.com/ 1
 12 - B OOM
OOM SUS
SUSPEN
PENSIO
SION 
N 

The boom is suspended to reduce shaking of the lift truck on rough ground (e.g. moving
straw in a field).

FUNCTIONING
- Set the forks or attachment on the ground and relieve some of the load from the front A2
wheels.
- Press switch A set to position A1, the visual indicator comes on indicating that boom sus- A

pension is activated.
- Press switch A set to position A2,
A2, the visual indicator goes out indicating that boom sus
sus-- A1

pension is deactivated.

IMPORTANT
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 
Boom retracted. When
suspension you move
is active to abeyond this height
lifting height of 9.8orfeet
make another
from hydraulic
the axis movement
of articulation (tilting,
of the telescoping,
carriage attachment),
with respect boomwith
to the ground suspension
the boomis 
momentarily deactivated and the visual indicator of switch A goes out.
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 A goes out.

- When the I.C. engine

engine is off, boom suspension is automatically deactivated.

2 - 33

CONTENTS

13 - ATT
TTAC
ACHM
HMEN
ENT
T HY
HYDR
DRAU
AULIC
LIC CON
CONTRO
TROL
L FO
FORC
RCED
ED OP
OPER
ERATI
ATION 
ON 
MLA 628 -120 LSU POWERSHIFT Series 3-E2

This OPTION must only be used with an attachment requiring continuous 

This OPTION must only be used with an :attachment requiring
bucket,continuous hydraulic movement 
WARNING hydraulic movement brush, supply mixer, spray… It is strictly for-  A
of type : brush, supply bucket, mixer, spray… It is strictly forbidden in handling operations
bidden in handling operations and all other operations (winch, crane boom, and 
at all others events crane
(winch, crane
boom boom,
with crane
winch, boom
hook, with winch, hook, etc.).
etc.).

CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT ATTACHMENT

- Make sure
sure the potentiometer C is set to 0 %.
- Switch button A up or down (depending on the ttype ype 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
stop continuous hydraulic movement o off the attachment, switch button A up or down or
press button B. Indicator 1 goes out.
- Set potentiom
potentiometer
eter C to 0 %.
C
Nevercab
Never leave the driver's leave the driver's
without resetting cabthe
without resetting Cthe
potentiometer
potentiometer to potentiometer C to 0 the 
0 %. Before starting t%.
he 
WARNING Before starting the lift truck, make sure the
the potentiometer is set to 0 %.
lift truck, make sure the potentiometer is set to 0 %.

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B
 1

2 - 34

CONTENTS

3 - MAINTENANCE 
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 3-1

CONTENTS

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 3-2

CONTENTS

TABLE OF CONTENTS 

MANITOU ORIG
ORIGIN
INAL
AL SPA
SPARE PA
PART
RTS
S AN
AND
D EQUI
EQUIPM
PMEN
ENT 
T  3 - 5 

F IILTE
LTERS
RS CART
CARTRI
RIDG
DGES
ES AND BELT
BELTS 
S  3 - 7 

L UBRI
U BRICA
CANT
NTS
S AN
AND
D FUEL 
FUEL  3 - 8 

S EERVI
RVICI
CING
NG SCHEDU
SCHEDULE 
LE  3 - 10 

A - D AILY OR EVERY  10 HOUR

HOURS
S SE
SERV
RVIC
ICE 
E  3 - 12 

B - E VERY 
VERY  50 HOURS
HOURS SERV
SERVIC
ICE 
E  3 - 16 
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 C - E VERY 
VERY  250 HOURS
HOURS SE
SERV
RVIC
ICE 
E  3 - 22 

D - E VERY 
VERY  500 HOURS
HOURS SE
SERV
RVIC
ICE 
E  3 - 24 

E - E VERY 
VERY  1000 HOURS
HOURS SERV
SERVIC
ICE 
E  3 - 30 

F - E VERY 
VERY  2000 HOURS
HOURS SERV
SERVIC
ICE 
E  3 - 34 

G - O CCASIONA
CCASIONAL
L MAIN
MAINTEN
TENANCE 
ANCE  3 - 36 

H - E VERY TWO YEARS  ( 

OPTIO
OPTION
N AIR CONDIT
CONDITIONING )
IONING  3 - 40 

3-3

CONTENTS

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 3-4

CONTENTS

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT 

OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.

I F 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.

B Y USIN
USING
G ORIG NAL  MANITOU PART
ORIGIINAL  PARTS
S FOR
FOR MAIN
MAINTE
TENA
NANC
NCE
E OP
OPER
ERAT
ATIONS ,
IONS 

YOU BENEFIT  THROUGH ITS NETWORK, MANITOU PROVIDES THE USER WITH
EXPERTISE 
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- 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

EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.

3-5

CONTENTS

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 3-6

CONTENTS

FILTERS CARTRIDGES AND BELTS 

MLA 628 -120 LSU POWERSHIFT Series 3-E2

I.C. ENGINE

I.C. ENGINE OIL FILTER

ALTERNATOR BELT
Part number
number : 476
476954
954
Part number
number : 773
773722
722
Change
Cha nge : 500 H

DRY AIR FILTER CARTRIDGE

Part number
number : 563
563416
416
Clean
Clean : 50 H*
Change
Cha nge : 500 H
H*
*

SAFETY DRY AIR FIL

FILTER
TER CARTRIDGE CYCLONIC PRE-FILTER
Part number
number : 563
563415
415 Part number
number : 224
224713
713
Change
Cha nge : 1000 H
H*
* Clean
Clean : 1
10
0 H

FUEL FILTER CARTRIDGE https://www.forkliftpdfmanuals.com/

Part number
number : 605
605013
013
 Change
Change : 500 H

* : This schedule is given ffor

or information only (see : 3 - MAINTENANCE : SERVICING
SERVICING SCHEDULE) for cleaning and changing.

TRANSMISSION

TRANSMISSION OIL FILTER

Part number
number : 550
550145
145
Change
Cha nge : 500 H

HYDRAULICS

HYDRAULIC RETURN OIL FILTER CARTRIDGE SUCTION STRAINER FOR HYDRAULIC OIL TANK 
Part number
number : 485
485696
696 Part number
number : 224
224726
726
Change
Cha nge : 500 H Clean
Clean : 10
1000
00 H

FILTER CAP FOR HYDRAULIC OIL TANK 

Part number
number : 62
62415
415
Change
Cha nge : 100
1000
0H

BRAKE

BRAKING PRESSURE OIL FIL

FILTER
TER CARTRIDGE
Part number
number : 705
705922
922
Change
Cha nge : 500 H

CAB
CAB VENTILATION FILTER (WITH AIR CONDITIONING)
CAB VENTILATION FILTER (WITHOUT AIR CONDITIONING)
Part number
number : 603747 ((Qty:
Qty: 1)
Part number
number : 603747 ((Qty:
Qty: 2)
Clean
Clean : 5
50
0 H
Clean
Clean : 50
500
0 H
Change
Cha nge : 250 H

3-7

CONTENTS

LUBRICANTS AND FUEL 

- For topping up, oils may not be miscible.

- For oil changes, MANITOU oils are perfectly appropriate.

DIAGNOSTIC ANALYSIS
ANALYSIS OF OILS
If a service or maintenance
maintenance contract has been organized with the dealer
dealer,, a diagnostic analysis of engine, transmission and axle
oils may be requested depending on the rate of use.

(*) FUEL CHARACTERISTICS

Use a high-quality fuel to obtain optimal performance of the I.C. engine.

CHARACTERISTICS OF RECOMMENDED FUEL :

 Types of diesel N590 - Auto/C0/C1/C2/C3/C4
• BS2869 Class A2
• ASTM D975 - 91 Class 2D
• JIS K2204
K2204 (1992
(1992)) Grades 1
1,, 2, 3 and Spe
Special
cial Gra
Grade
de 3.

I.C. ENGINE
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 COMPONENT CAPACITY RECOMMENDATION

8,5 Liters Shell:: Rotel

Shell Rotella
la 15w40
I.C. ENGINE
(2.2 gal) Citgo: C-600 1
Citgo: 15w40
5w40

Tulco 50/50 Premix Anti-

freeze
COOLING CIRCUIT 20 Liters

FUEL TANK 117 Liters (30.9 gal) Diesel fuel (*)

TRANSMISSION
COMPONENT CAPACITY RECOMMENDATION

Shell: Donax T
TG
G Dexron III
16 Liters
TRANSMISSION Citgo: Transgard A
ATF
TF Dexron
(4.2 gal)
III

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

BOOM
COMPONENT RECOMMENDATION

Shell: Renti
Rentinax
nax Am
BOOM PADS
Citgo: Lithoplex
Citgo: Lithoplex CM-2

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

3-8

CONTENTS

HYDRAULICS

COMPONENT CAPACITY RECOMMENDATION

Shell: Tellus T46
130 Liters
HYDRAULIC OIL TANK  Citgo:
Citgo: Tran
ransgar
sgard
d THF Lo-
(34.3 gal)
Temp

BRAKE
COMPONENT RECOMMENDATION
Shell: Donax T
Shell: TG
G Dexron III
BRAKE CIRCUIT
Citgo: Transgard A
ATF
TF Dexron III

CAB
COMPONENT RECOMMENDATION

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

WINDSCREEN WASHER TANK https://www.forkliftpdfmanuals.com/

Windscreen washer fluid
 FRONT AXLE
COMPONENT CAPACITY RECOMMENDATION
Shell: Donax TD
6,8 Liters
FRONT AXLE DIFFERENTIAL* Citgo: Transgard T
Tractor
ractor Hyd
(1.8 gal)
Fluid

Shell: Spira
Spirax
x DH80w90
0,75 Liter
FRONT WHEELS REDUCERS Citgo:: Premium
Citgo Premium Gear MP
(0.8 qts)
80w90

REAR AXLE
COMPONENT CAPACITY RECOMMENDATION
Shell: Donax TD
6,9 Liters
REAR AXLE DIFFERENTIAL* Citgo: Transgard T
Tractor
ractor Hyd
(1.8 gal)
Fluid

Shell: Spira
Spirax
x DH80w90
0,75 Liter
REAR WHEELS REDUCERS Citgo: Premium
Citgo: Premium Gear MP
(0.8 qts)
80w90

Shell: Renti
Rentinax
nax Am
REAR AXLE OSCILLA
OSCILLATION
TION
Citgo: Lithoplex
Citgo: Lithoplex CM-2

CHASSIS
COMPONENT RECOMMENDATION

Shell: Renti
Rentinax
nax Am
ARTICULATION
ARTICULATION OF THE CHASSIS
Citgo: Lithoplex
Citgo: Lithoplex CM-2

Shell: Renti
Rentinax
nax Am
STEERING CYLINDER
Citgo: Lithoplex
Citgo: Lithoplex CM-2

* First
First 200
200 h
hrs:
rs: Use Manito
Manitou
u Sp
Special
ecial Immers
Immersed
ed B
Brake
rakes
s 549 Lubrica
Lubricant.
nt. (5 ga
gal.
l. drum, p/n: 54560
545608)
8)

3-9

CONTENTS

SERVICING SCHEDULE 

A = AJUS
AJUST
T N = CL
CLEA
EANN After Day 1 year 1 year
C = CH
CHEC
ECKK P = BL
BLEE
EED
D the first or 50 250 or or 2000 4000
D = DESC
DESCAL
ALE
E R = CHAN
CHANGE
GE 50 10 hours hours 500 1000 hours hours
G = GREA
GREASE
SE V = DRAIN/
DRAIN/CHA
CHANGE
NGE hours hours hours hours

I.C. ENGINE
I.C. engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Cooling liquid level
l evel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Cyclonic
Cyclo nic prefil
prefilter
ter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . N R
Radiator core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Condenser core (OPTION Air conditioning) . . . . . . . . . . . . N
Alternator/crankshaft belt tension . . . . . . . . . . . . . . . . . . A A
Compressor belt tension (OPTION Air conditioning) . . . . . . A
I.C. engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V V
I.C. engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R R
Fuel filter car tridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R R
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
fil ter cartridge . . . . . . . . .https://www.forkliftpdfmanuals.com/
Safety dry air filter . .. . . . .. . . . . . R
I.C. engine silent blocks . . . . . . . . . . . . . . . . . . . . . . . . . C**
 I.C. engine rates . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . C**
Valves clearances . . . . . . . . . . . . . . . . .. . . . .. . . . . .. C** C**
Cooling liquid . . . . . . . . . . . . . . . . . ..... . ..... . .... V
Radiator . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . N/D**
Water pump and the thermostat . . . . . .. . . . .. . . . . .. . C**
Alternator and the starter
star ter motor . . . . . .. . . . .. . . . . .. . C**
Turbocompressor . . . . . . . . . . . . . . ..... . ..... . .... C**
Bleed the fuel system . . . . . . . . . . . ..... . ..... . ....

TRANSMISSION
Transmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Transmission universal joint . . . . . . . . . . . . . . . . . . . . . . G G/C**
Transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . R R

Transmission
Transmission silent
oil . . .blocks
. . . . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. V V
C**
Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Transmission pressures . . . . . . . . . . . . . . . . . . . . . . . . . C**
Converter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**

TIRES
Tires pressure . . . . . . . . . . . . . .... . . .... . . .... . . . C
Wheel nuts torque . . . . . . . . . . .... . . .... . . .... . . . C
Condition of wheels and tires . . . . .. . . . . .. . . . .. . . . . C**
Change a wheel . . . . . . . . . . . . .... . . .... . . .... . . .

BOOM
Boom pads . . . . . . . . . . . . . . . . ...... ...... . ..... G*
Boom . . . . . . . . . . . . . . . . . . . . ...... ...... . ..... G
Boom pads wear . . . . . . . . . . . . . . . . .. . . . .. . . . . .. . C**
Condition of boom unit . . . . . . . . ...... ...... . ..... C**
Bearings and articulation rings . . . . .. . . . . .. . . . . .. . . C**

HYDRAULICS
Hydraulic oil level
l evel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Hydraulic return oil filter cartridge . . . . . . . . . . . . . . . . . . R R
Balancing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C C
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Suction strainer for hydraulic oil tank . . . . . . . . . . . . . . . . N
Filter cap for hydrau
hydraulic
lic oil tank . . . . . . . . . . . . . . . . . . . . R
Speeds of hydraulic movements . . . . . . . . . . . . . . . . . . . C**
Hydraulic pump pipe filter . . . . . . . . . . . . . . . . . . . . . . . . N**
Condition
Condi tion of hose
hoses s and flexib
flexibles
les pipes . . . . . . . . . . . . . . C**
Condition
Condi tion of cylind
cylinders
ers (leaka
(leakage,
ge, shaf
shafts)
ts) . . . . . . . . . . . . . . C**
Hydraulic circuit pressures . . . . . . . . . . . . . . . . . . . . . . . C**
Hydraulic circuit outputs . . . . . . . . . . . . . . . . . . . . . . . . . C**
Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N**

3 - 10

CONTENTS

A = AJUS
AJUST
T N = CL
CLEA
EANN After Day 1 year 1 year
C = CH
CHEC
ECKK P = BL
BLEE
EED
D the first or 50 250 or or 2000 4000
D = DESC
DESCAL
ALE
E R = CHAN
CHANGE
GE 50 10 hours hours 500 1000 hours hours
G = GREA
GREASE
SE V = DRAIN/
DRAIN/CHA
CHANGE
NGE hours hours hours hours

BRAKE
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C/A
Parking brake lever mechanism . . . . . . . . . . . . . . . . . . . . G
Braking pressure oil filter cartridge
car tridge . . . . . . . . . . . . . . . . . R R
Brake oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V**
Brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P**
Brake circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A**

STEERING
Steering
Steering cylind
cylinder
er . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
Steering swivel joints . . . . . . . . . . . . . . . . . . . . . . . . . . . C**

CAB
Windscreen washer liquid level . . . . . . . . . . . . . . . . . . . . C
Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
Cab ventilation filter (OPTION Air conditioning) . . . . . . . . . N R
Cab ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Seat belt . . . . . . . . . . . . . . . . . . . . . . .https://www.forkliftpdfmanuals.com/
............. C
Condition of the rear view mirrors
mirror s . . . . . . . . . . . . . . . . . . C**
 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
OPTION Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICITY
Battery
Battery electroly
electrolyte
te level . . . . . . . . . . . . . . ..... ...... C
Battery electrolyte density . . . . . . . . . . . . . ..... ...... C
Condition of wiring harness and cables . . . . .. . . . . .. . . C**
Lights and signals . . . . . . . . . . . . . . . . . . . . . .. . . . . .. C**
Warning indicators . . . . . . . . . . . . . . . . . . ..... ...... C**
Adjust the front headlamps . . . . . . . . . . . . ..... ......

FRONT AXLE
Front axle differential oil level . . . . . .. . . . .. . . . . .. . . . C
Front wheels reducers oil level . . . . . .. . . . .. . . . . .. . . C
Front axle differential oil . . . . . . . .................. V V
Front wheels reducers oil . . . . . . . . . . .. . . . .. . . . . .. . V V
Wearing of front axle brake discs . . . . . .. . . . .. . . . . .. C**
Front wheels reducers clearance . .................. C**

REAR AXLE
Rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . G G/C**
Rear axle differential oil level . . . . . . . . . . . . . . . . . . . . . C
Rear wheels reducers oil level . . . . . . . . . . . . . . . . . . . . . C
Rear axle differential oil . . . . . . . . . . . . . . . . . . . . . . . . . V V
Rear wheels
wheels reduce
reducers
rs oil . . . . . . . . . . . . . . . . . . . . . . . . V V
Wearing of rear axle brake discs . . . . . . . . . . . . . . . . . . . C**
Rear wheels reducers clearance . . . . . . . . . . . . . . . . . . . C**

CHASSIS
Articulation axles of the chassis . . . . . . . . . . . . . . . . . . . G G/C**
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Bearings and articulation rings . . . . . . . . . . . . . . . . . . . . C**

ATTACHMENTS
Forks wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Attachment carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Condition of attachments . . . . . . . . . . . . . . . . . . . . . . . . C**

LIFT TRUCK
Tow the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sling the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport the lift tr
truck
uck on a platform . . . . . . . . . . . . . . . .

(*) : Every 10 hours during

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

3 - 11

CONTENTS

A - DAILY OR EVERY 10 HOURS SERVICE 

A1 - I.C. ENGI
ENGINE
NE OIL
OIL LE
LEVE
VEL 
L  A1
CHECK 

Park the lift truck on level ground with the I.C. engine stopped, and let the oil drain into the
sump.
1
- Open the I.C. engine cover. 2
- Remove the dipstick 1 (fig. A1).
- Wipe the dipstick and check the correct level at the upper mark.
- If necessary,
necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the filler port
2 (fig. A1).
- Check visually that there is no leakage or seepage of oil in the I.C. engine.

A2 - C OOLI
O OLING
NG LIQU
LIQUID
ID LEVE
LEVEL 
L  A2
CHECK 
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Park the lift truck on level ground with the I.C.
I.C. engine stopped, and allow the I.C. engine
 to cool.
2
- Open the I.C. engine cover.
1
- The liquid must be situated half way up the expansion pan 1 (fig. A2).
- If necessary,
necessary, add cooling liquid (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the
filler port 2 (fig. A2).

To avoid risk of spraying or burning, wait until the I.C. engine has cooled 
To avoid any risk of spraying or burning, wait until the I.C. engine has cooled down before 
down before removing the radiator cap. If the cooling liquid is very hot,
ho t, add 
WARNING
removing the cooling circuit filler plug. If the cooling liquid is very hot, add only hot cooling liq- 
only hot cooling liquid. In an emergency, you can use water as a cooling liq- 
uid (80°C). In an emergency, you can use water as a cooling liquid, then change the cooling cir- 
uid, then change the cooling circuit
circuit liquid as soon as possible (see : 3 - 
cuit liquid as soon as possible (see : 3 - MAINTENANCE : F1 - COOLING LIQUID).
MAINTENANCE : F1 - COOLING LIQUID LIQUID). ).

A3 - F UEL
U EL LE
LEVE
VEL 
L  A3
CHECK 

Keep the fuel

fuel tank near full, to reduce as much as possible any condens
condensation
ation due to
1
atmospheric conditions.
2
- Open the I.C. engine cover.
- Remove cap 1 (fig. A3).
- Fill the fuel
fuel tan
tank
k with clea
clean
n fuel (s
(see
ee : 3 - MAIN
MAINTENANC
TENANCE E : LUBR
LUBRICANTS
ICANTS AND FUEL ), fil-
tered through a strainer or a clean
clean,, lint free cloth, through filler p
port
ort 2 (fig. A3).
- Put the cap back 1 (fig. A3).
- Check visually that there is no leakage in the tank and pipes.

Never smoke
Never smoke or approach or approach
with a flame with aoperations
during filling flame during
d uring filling the
or when operations or when
tank is open. the 
Never 
WARNING
tank
refill while I.C. engine is is open. Never refill while the I.C. engine is running.
running.
The fuel tank is vented via the filler plug. When changing it, always use an 
WARNING original part, with vented hole.
The fuel tank is degassed via the filler plug. When changing it, with degassing hole.

3 - 12

CONTENTS

A4 - C YCLONIC
YCLONIC PREF
PREFIL
ILTE
TER 
R  A4

CLEAN 
1
The cleaning interval is given as a guide, however the prefilter
prefilter must be emptied as soon
2
as impurities reach the MAXI level on the tank.

- Loosen nut 1 (fig.

(fig. A4), remove cover 2 ((fig.
fig. A4) and empty the tank.
- Clean the prefilter unit with a clean dry cloth and reassemble the unit.

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

A5 - T RANS
R ANSMI
MISS
SSIO
ION
N OIL
OIL LE
LEVE
VEL 
L  A5/1
CHECK 
3
Park the lift truck on level ground with the engine cold and at idle.

- For the minimum oil level, remove the screw 1 (fig. A5/1) and and check that the oil flushes
the port.
- If necessary
necessary,, add oil https://www.forkliftpdfmanuals.com/
- Remove the cover
cover plate 2 (fig. A5/2) and a
add
dd oil (see : 3 - MAINTENANCE : LUBRICANTS
 AND FUEL) by the filler port 3 (fig. A5/1).
4

NOTE : COLD LEVEL (b(betwe

etween
en 59°F and 68°
68°F)
F) 1

The oil must be at its minimum, at the level of the screw

screw 1 (fig. A5/1)
HOT LEVEL (between 180°F and 200°F)
The oil must be at the level of the screw 4 (fig. A5/1).
A5/2

A6 - T IRES PR
PRE
ESSUR
URE
E AND WHEEL NU
NUTS
TS TORQ
RQU
UE 
CHECK 

- Chec
Check
k the cond
condition
ition of tthe
he tires
tires,, to detec
detectt cuts, wear
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
Front tires : 465 ft/ft/lb
lb
• Rear tires : 465 ft ft/lb
/lb
- Check and adjust the tire pressures if necessary (see : 2 - DESCRIPTION : CHARACTERISTICS
CHARACTERISTICS).
).

Check that the air hose

Checkis that
correctly connected
the air to the tire
hose is correctly valve before
connected inflating
to the and before
tire valve keep all personsand
inflating at a distance
keep during at
all persons inflation. Respect 
a distance dur- 
WARNING
the recommended tireing pressures given. the recommended tire pressures given.
inflation. Respect

3 - 13

CONTENTS

A7 - B OOM
O OM PADS  A7

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. A7).
- Telescope
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 lift
If the an truck
abrasive environment
is used (dust, environment
in an abrasive sand, coal…)(dust,
Use lubricating varnish 
sand, coal…) Use 
IMPORTANT
(MANITOU
(MANITOU reference
referencelubricating
: 483536). In thiscontact
varnish, respect,your
consult your dealer.
dealer.

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 3 - 14

CONTENTS

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 3 - 15

CONTENTS

B - EVERY 50 HOURS SERVICE 

Carry out the operations described previously as well as the following operations.

B1 - D RY AIR FI
FILT
LTE
ER CART
CARTRI
RIDG
DGE 
E 
CHECK - CLEAN 

In case of use in a heavily

heavily dust laden atmosphere, there are pre-filtration cartridges (see : 3 - MAINTENANCE : FI
FILTERS
LTERS CAR-
TRIDGES AND BELTS).
BELTS). Also, the checking and cleaning schedule of the cartridge must be reduced.

If thelight
If the clogging indicator clogging indicator
comes on, thislight comesmust
operation on, this operation
be carried outmust be carried
as quickly out as quickly
as possible (1 houras possible (1
maximum). Thehour maximum).
cartridge
If the clogging indicator light comes on, this operation must be carried out as quickly as possible (1 hour maximum). The cartridge must must 
IMPORTANT
not be cleaned moreThe cartridge
than must not
seven times, bewhich
after cleaned
themore than must
cartridge sevenbe
times, after which the cartridge must be changed.
changed.
- For the disassembly and reassembly of the cartridge,
cartridge, see : 3 - MAINTENANCE : D3 - DRY AIR FILTER CARTRIDGE.
CARTRIDGE.
- Clean the filter cartridge using a compressed air jet (max. pressure 40 psi) directed from the top to the bottom and from the
inside towards the outside at a distance no less than 1 in. from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.

Respect the safetyAvoid tearing

distance ormm
of 30 making a hole
between theinair
theje
jetcartridge. The cartridge
t and the cartridge must
to avoid not beorblown
tearing anywhere
making a hole innear
the the air filter
cartridge. Thebox. Never 
cartridge 
IMPORTANT
must not be blown clean the cartridge
anywhere near the by https://www.forkliftpdfmanuals.com/
air tapping it against
filter box. a hard
Never clean surface.
the Your
cartridge by eyes must
tapping be protected
it against a hardduring this intervention.
surface.
- Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant.
 - Check visually the outer condition of the air filter and its mounts. Verify the condition of the hoses and their mounts also.
Do not clean the dryDo
airnot
filter cartridge
clean the drybyair
washing it in liquid.
filter cartridge Do not clean
by washing by any
in liquid. Domeans the safety
not clean cartridge
the safety located
cartridge inside
located the filter
inside car- 
the filter 
IMPORTANT
tridge, change it forcartridge,
a new onechange
if it is itdirty ornew
for a damaged.
one if it is dirty or damaged.

B2 - R ADIA
ADIATO
TOR
R COR
CORE 
E 
CLEAN 

In a heavy dust atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure steam as this 
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 radi- 
IMPORTANT
ator fins. could damage the radiator fins.

- Open the I.C. engine cover.

- In order to prevent
prevent the radiator becoming clogged, clean the radiator with a compressed air jet directed
directed from inside to outside.
This is the only way to clean the core of debris.
- If necessary, clean the suction grid on the engine cover.
cover.

B3/1
B3 - C ONDEN
O NDENSER
SER CORE  ( 
CORE  OPTI
OPTION
ON AIR CON
CONDIT
DITIONING )
IONING 
CLEAN  1

In a heavy dust atmosphere, clean the radiator core every day. Do not use 
IMPORTANT
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high- 
a water jet or high-pressure steam as this could damage the radiator fins.
pressure steam as this could damage the radiator fins.
- Open the I.C. engine cover. 1

- Loosen the knurled screws 1 (fig. B3/1) and swing around the filter and condenser unit.
- Clean the core with a blast of compressed air aimed from the inside towards the outside
(fig. B3/2). This is the most effective way of removing the impurities.

B3/2

3 - 16

CONTENTS

B4 - B OOM 
OOM 

GREASE 
To be carried out weekly
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 
In the event of prolonged use in an extremely dusty or oxidizing atmosphere, reduce this interval to 10 working hours or every day.
IMPORTANT or every day.

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

1 - Lubricators of the boom axle (2 lubricators) (fig. B4/1).

2 - Lubricators of the carriage axle (2 lubricators) (fig. B4/2).
3 - Lubricator of the tilt cylinder foot axle (1 lubricator) (fig. B4/3).
4 - Lubricator of the tilt cylinder head axle (1 lubricator) (fig. B4/4).
5 - Lubricators of the carriage connecting rod axle (3 lubricators) (fig. B4/2 and B4/4).
6 - Lubricator of the lifting cylinder foot axle (1 lubricator) (fig. B4/5).
7 - Lubricator of the lifting cylinder head axle (1 lubricator) (fig. B4/6).
8 - Lubricator of the compensation cylinder foot axle (1 lubricator) (fig. B4/5).
9 - Lubricator of the compensation cylinder head axle (1 lubricator) (fig. B4/6).

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B4/1 B4/2 B4/3
 1 1
5
3

2 2

B4/4 B4/5 B4/6

4
5 7
9

B5 - H YDRA
Y DRAUL
ULIC
IC OIL
OIL LE
LEVE
VEL 
L  B5
CHECK 
2 3

Park the lift truck on level ground with the I.C.

I.C. engine stopped, and the boom retracted and
lowered as far as possible.

- Refer to gauge 1 (fig. B5).

- The oil level is correct when it is at the level of the red point.
- If necessary,
necessary, add oil (see : 3 - MAINTE
MAINTENANCE
NANCE : LUBRIC
LUBRICANTS
ANTS AND FUEL)
FUEL)..
- Remove cap 2 (fig. B5).
1
- Add oil by filler port 3 (fig. B5).

IMPORTANT Use a clean funnel and clean the oil nozzle before filling.
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.

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

3 - 17

CONTENTS

B6 - W IINDS
NDSCR
CREE
EEN
N WA
WASH
SHER
ER LI
LIQU
QUID
ID LE
LEVE
VEL 
L  B6

CHECK 
1
- Open the I.C. engine cover.
- Check visually the level.
- If necessary
necessary add windscreen washer liquid (see : 3 - MAINTENANCE : LUBRICANTS AND
FUEL) by filler port 1 (fig. B6).

B7 - C AB DO
DOOR 
OR  B7
GREASE 

Clean and lubricate the points 1 (4 lubricators) (fig. B7) with grease (see : 3 - MAINTE-

NANCE : LUBRICANTS AND FUEL) and rremove

emove the surplus grease. 1

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1
 B8 - C AB VENT
VENTIL
ILAT
ATIO
ION
N FI
FILTER  ( 
LTER  OP
OPTI
TION
ON AIR CONDIT
CONDITIONING )
IONING  B8
CLEAN 

- Lift up protective casing 1 (fig. B8).

- Lift out cabin ventilation filter 2 (fig. B8). 1
- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS).
- Install the filter and protective casing.
2

B9 - B A
ATTE
TTERY
RY EL
ELEC
ECTR
TROLY
OLYTE
TE LEVEL 
LEVEL  B9
CHECK 
1
Check the electrolyte level in each cell of the battery.
If the lift truck is working in a high
high temperature environment, check the level more fre
fre--
quently than every 50 hours service.

- Open the I.C. engine cover.

- Remove caps 1 (fig. B9) from each cell of the battery.
- The level is correct when it is 1/2 in. above the top of the plates in the battery.
- If necessary,
necessary, top up the cells with clean distilled water that has been stored in a glass
container.
- Clean and dry caps 1 (fig. B9) and install.
- Check the terminal connections and lightly smear them with petroleum jelly to prevent the
formation of corrosion.

Handling and servicing a battery can be dangerous, take the following precau- 
Handling and servicing a battery can be dangerous, take take the following precautions : 
tion
tions
s : 
- Wear protective goggles. Keep the battery horizontal.
- Wear protective goggles.
- Never smoke or work near a naked flame.- Work in a well-ventilated area.
- Keep the battery horizontal.
WARNING
- In the event of electrolyte being spilled onto the skin or splashed in the eyes,
- Never smoke or work near an open flame.
rinse thoroughly with cold water for 15 minutes and call a doctor.
- Work in a well-ventilated area.
- In the event of electrolyte being spilled onto the skin or splashed in the 
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.

3 - 18

CONTENTS

B10 - R EAR AXL

XLE
E OSC
OSCILL
ILLATI
ATION 
ON  B10

GREASE 
Clean and lubricate the points 1 (2 lubricators) (fig. B10) with grease (see : 3 - MAINTE-
NANCE : LUBRICANTS AND FUEL) and rremove
emove the surplus grease.

B11 - T RANSMI
RANSMISSI
SSION
ON UNIVE
UNIVERS
RSAL
AL JOI
JOINT 
NT  B11/1
GREASE 

Clean and lubricate the following points with grease (see : 3 - MAINTENANCE : LUBRI-

CANTS AND FUEL) and remove the surplus grease.

- Remove access panel 1 (fig. B11/1).
https://www.forkliftpdfmanuals.com/ 1
2 - Lubricators of the universal joint Transmission/Front axle (4 lubricators) (fig.
 2 Lubricators of the universal joint Transmission/Front axle (4 lubricators) (fig.
B11/2).
3 - Lubricators of the universal joint Transmission/Rear axle (3 lubricators) (fig.
B11/3).

B11/2

2 2 2

B11/3

3
3

B12 - ARTIC
RTICUL
ULAT
ATIO
ION
N AX
AXLE
LES
S OF THE
THE CHAS
CHASSI
SIS 
S  B12
GREASE
1
1
Clean and lubricate the following points with grease (see : 3 - MAINTENANCE : LUBRI-
CANTS AND FUEL) and remove the surplus grease.

1 - Lubricators
Lubricators of the articulation axl
axles
es of the chassis
chassis (3 lubricato
lubricators)
rs) (fig B12)
B12)..

3 - 19

CONTENTS

B13 - S TEERIN
TEERING
G CYLINDE
CYLINDER 
R  B13/1

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

- Remove access panel 1 (fig. B13/1).

1

2 - Lubricators of the head axles of the steering cylinder (2 lubricators) (fig.

B13/2).
3 - Lubricators of the foot axles of the steering cylinder (2 lubricators) (fig.
B13/3).

B13/2

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 B13/3

3 - 20

CONTENTS

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 3 - 21

CONTENTS

C - EVERY 250 HOURS SERVICE 

Carry out the operations described previously as well as the following operations.

C1 - ALTERNATOR 
 / C
CRAN
RANKS
KSHA
HAFT
FT BE
BELT
LT TENSIO
TENSION 
N  C1
CHECK - ADJUST 
- Open the I.C. engine cover. 1
-- Check the belt for signs of wear and cracks and change if necessary (see : 3 - MAINTE-
NANCE : FILTER
FILTERSS CARTRIDGES AND BELTS
BELTS).
).
- Check the belt tension between the pulleys of the crankshaft and of the alternator.
- Under a normal pressure exerted with the thumb (10 ft/lb), the tension should be approx-
imately 3/8 in.
- Carry out adjustments if necessary.
- Loosen screws 1 (fig. C1) by two to three thread turns.
- Swivel the alternator assembly so as to obtain the belt tension required. 1
- Retighten screws 1 (fig. C1)(tightening torque 16 ft/lb). 1

If the alternator beltIfhas

IMPORTANT theto
alternator belt check
be changed, has tothe
be tension
changed, check
again thethe
after tension again
first 20 after
hours the 
of oper- 
ation. first 20 hours of operation.

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 C2 - C OMPR
O MPRES
ESSO
SOR
R BELT
BELT TENS
TENSION  ( 
ION  OPTIO
OPTION
N AIR CONDIT
CONDITIONING )
IONING  C2
CHECK - ADJUST  1

- Open the I.C. engine cover.

- Check the belt for signs of wear and cracks and change if necessary (see : 3 - MAINTE-
NANCE : FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the crankshaft and of the compressor
compressor..
- Under a normal pressure exerted with the thumb (10 ft/lb), the tension should be approx-
imately 3/8 in. 1
- Carry out adjustments if necessary.
- Loosen screws 1 (fig. C2) by two to three thread turns.
- Swivel the compressor assembly so as to obtain the belt tension required.
- Retighten screws 1 (fig. C2).
If the compressor belt hasalternator
If the to be changed,
belt hascheck
to be the tensioncheck
changed, againthe
after the first
tension 20after
again hoursthe 
of 
IMPORTANT
operation. first 20 hours of operation.

C3 - P ARKING
ARKING BR
BRAK
AKE 
E  C3/1
CHECK - ADJUST 

A
Park the lift truck on a slope less than 15 % with the rated load in the transport position. 5

- Check the tightening adjustment by locking the parking

par king brake in position A (fig.
(fig . C3/1).
- The adjustment is correct when the lift truck is held stationary on a slope. B
- Carry out adjustments if necessary.

ADJUSTMENT OF THE PARKING BRAKE CABLE ON THE FRONT AXLE

- Press
Press and release the brake p
pedal,
edal, then release the parking brake, putting it in pos
position
ition
B (fig. C3/1).
- Remove the cover plate 1 (fig. C3/2).
- Unscrew nuts 2 (fig. C3/3).
- Adjust the cable by loosening nu
nuts
ts 2 (fig. C3/3), until a clearance of 0.06 in. betw
between
een
cams 3 (fig. C3/3) and stops 4 (fig. C3/3) is obtained. C3/2

The adjustment of Make

the stops performed
adjustments by to
only the manufacturer
the stops noted.must not be
DO NOT modified
MAKE under any 
ADJUSTMENTS  1
WARNING
circumstances. TO THE DRIVE AXLE FACTORY
FACTORY SETTINGS! (CONTACT YOUR DEALER.
DEALER.) ) 
ADJUSTMENT OF THE PARKING BRAKE
- Leave the parking brake in position B (fig. C3/1).
- Progressively tighten the end piece of the lever 5 (fig. C3/1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.

3 - 22

CONTENTS

C3/3

3 3
4 4

2 2

C4 - C AB VENT
VENTIL
ILAT
ATIO
ION
N FI
FILTER  ( 
LTER  OP
OPTI
TION
ON AIR CONDIT
CONDITIONING )
IONING 
C4
CHANGE 

- Lift up protective casing 1 (fig. C4).

- Lift out cabin ventilation filter 2 (fig. C4) and fit new replacement filter (see : 3 - MAIN-
TENANCE : FILTERS CARTRIDGES AND BELTS). 1

- Install the protective casing.

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 2

C5
C5 - F RONT
R ONT AND REAR AXLE DIFF
FFE
EREN
RENTI
TIA
AL OIL
OIL LE
LEVE
VEL 
L 
CHECK 

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

- Remove level plug 1 (fig. C5). The oil should be flush with the edge of the hole. 2

- If necessary,
necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the filler port
1
2 (fig. C5).
- Replace and tighten the level plug 1 (fig. C5) (tightening torque 32 ft/lb).
- Repeat this operation for the rear axle differential.

C6 - F RONT AND REAR WHEELS REDUC

EDUCE
ERS OIL LEVE
VEL 
L 
C6
CHECK 

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

- Check the level on each front wheel reducer.

reducer.
- Place level plug 1 (fig. C6) in the horizontal position. 1
- Remove the level
level plug ; the oil should be flus
flush
h 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. C6) (tightening torque 32 ft/lb).
- Repeat the same operation on each rear wheel reducer.
reducer.

3 - 23

CONTENTS

D - EVERY 500 HOURS SERVICE 

Carry out the operations described previously as well as the following operations.

D1 - I.C. ENGI
ENGINE
NE OIL 
OIL  D1/1
DRAIN 
D2 - I.C. ENGI
ENGINE
NE OIL
OIL FILTER 
CHANGE 

Park the lift truck

truck on level ground
ground,, let the I.C. en
engine
gine run at idle for a few minute
minutes,
s, then
stop the I.C. engine.

DRAINING THE OIL 1

- Open the I.C. engine cover.
- Remove access panel 1 (fig. D1/1).
- Place a container under drain plugs 2 (fig. D1/2) and under the oil filter 3 (fig. D1/2).

-- Unscrew the drain

Remove filler cap 4plugs 2 (fig. D1/2).
(fig. D1/3) in order to ensure that the oil is drained properly.
D1/2
IMPORTANT Dispose of the drain oilhttps://www.forkliftpdfmanuals.com/
in an ecological manner.
Dispose of the drain oil in an ecological manner.
 REPLACEMENT OF THE FILT FILTERER 3

- Remove I.C.
I.C. engine oil filter 3 (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 install the oil filter (see : 3 - MAINTENANCE : FIL-
TERS CARTRIDGES AND BELTS) on the filter bracket.
2 2
Tighten the oil filter by hand pressure only and lock the filter in place by a
IMPORTANT
Tighten the oil filterquarter
by handturn.
pressure only and lock the filter in place by a quarter turn.

FILLING UP THE OIL

- Install and tighten drain plugs 2 (fig. D1/2).
- Install access panel 1 (fig. D1/1). D1/3
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 5 (fig.
D1/3).
- Wait a few minutes to allow the oil to flow into the sump.
4
- 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. 6
- Stop the I.C. engine, wait a few minutes and check the level between the two notches on 5
dipstick 6 (fig. D1/3).
- Top up the level if necessary.

3 - 24

CONTENTS

D3 - D RY AIR FILT

FILTER
ER CART
CARTRI
RIDG
DGE 
E  D3

CHANGE 
1
In case of use in a hea
heavily
vily dust laden atmosphere, there are pre-filtration cartridges, see 2
: 3 - MAINTENANCE : FILTERS
FILTERS CARTRIDGES AND BELBELTS.
TS. Also, the checking and cleaning
schedule of the cartridge must be reduced (up to 250 hours in a heavily laden dust atmos-
phere and with pre-filtration).
Change
Change the cartridge clthe
eancartridge
in a clean location,inwith
a clean location,
the I.C. enginewith the I.C.
stopped. engine
Never runstopped. Never 
the I.C. engine 
IMPORTANT run the or
with the air filter removed I.C.damaged.
engine with the air filter removed or damaged.
- Open the I.C. engine cover.
- Loosen the bolts and remove cover 1 (fig. D3).
- Gently remove the cartridge 2 (fig. D3), taking care to avoid s spilling
pilling the dust.
- Leave the safety cartridge in place.
- The following parts must be cleaned with a damp, damp, clean lint-free cloth.
• The inside of the filter and cover
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 installing check the state of the new cartridge (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter axishttps://www.forkliftpdfmanuals.com/
and push it in, pressing the edges and not the middle.
- Reassemble the cover
cover,, guiding the valve downwards.
 D4 - F U
UELEL FI
FILT
LTER
ER CA
CART
RTRI
RIDG
DGE 
E  D4/1
CHANGE 

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

- Open the I.C. engine cover.

2
- Carefully
Carefully clean the outside of the filter and its holder,
holder, to prevent dust from getting into
the system.
- Place a container under the filter and drain it via drain plug 1 (fig. D4/1).
- Loosen the body of filter 2 (fig. D4/1).
- Remove the filter cartridge by pressing the cartridge
car tridge 3 (fig. D4/2) down against the pres-
1
sure of the spring and turn it to the left to extract it.
- Insert a new cartridge (see : 3 - MAINTENANCE : FILTERS FILTERS CARTRIDGES AND BEL BELTS),
TS), by 
pressing the cartridge 3 (fig. D4/2) down against the pressure of the spring and turn it
to the right to lock it into the body of the filter. D4/2
- Place the new seal 4 (fig. D4/2) onto the body of the filter and lubricate the contact sur-
face using clean engine oil.
- Install the body of the filter onto its holder,
holder, hand-tighten it only and lock it with a quarter-
turn.
- Close drain plug 1 (fig. D4/1) and remove the container. 4
3
- Before
Before starting the I.C. engine, leave the ignition on for one minute on the lift truck, to
give the lift pump time to pump air from the filter.
- Start up the I.C. engine and make sure there is no leakage.

D5 - T R
RANSM
ANSMISS
ISSION
ION OIL FI
FILT
LTER 
ER 
D5
CHANGE 
1

- Remove the cover plate 1 (fig. D5).

- Unscrew and discard the transmission oil filter 2 (fig. D5).
- Carefully clean the filter
filter head with a clean, lint-free cloth.
- Slightly lubricate the new seal and fit the seal on the filter. 2
- Install the new transmission oil filter (see : 3 - MAINTENANCE : FILTERS CARTR
CARTRIDGES
IDGES AND
BELTS),
BELTS ), making sure that the seal is correctly positioned and tightened.
Tighten the transmission
Tightenoilthe
filter by hand pressure
transmission oil filteronly and lock
by hand the filter
pressure only in place
and lockby a quar- 
the filter 
IMPORTANT
ter turn. in place by a quarter turn.
- Install the cover plate 1 (fig. D5).

3 - 25

CONTENTS

D6 - H YDRA
Y DRAUL
ULIC
IC RETU
RETURN
RN OIL
OIL FI
FILT
LTE
ER CART
CARTRI
RIDG
DGE 
E  D6
1
CHANGE 

Stop the I.C. engine and remove the pressure from the circuits by acting on the hydraulic
controls.
Thoroughly clean the outside of
Thoroughly the filter
clean and its of
the outside surroundings before
the filter and any intervention
its surroundings in order 
before any  2
IMPORTANT
to prevent any risk intervention,
of polluting the hydraulic
to prevent circuit.
risk of polluting the hydraulic circuit.
- Open the I.C. engine cover.
- Unscrew the locking screws of the cover 1 (fig. D6).
- Remove
Remove the hyd
hydraulic
raulic return oil filter cartridge 2 (fig. D6), and fit new replacement car-
car-
tridge (See chapter : FILTERS CARTRIDGES AND BELTS BELTS in paragraph : 3 - MAINTENANCE).
- Make sure that the cartridge is correctly positioned and install cover 1 (fig. D6).

D7 - B ALANCI
ALANCING
NG VA
VALV
LVE 
E 
CHECK 

To bethe
Park performed
lift truckafter the first 50
on horizontal hoursput
ground, of operation and then
the handbrake every
on and set500
the hours.
reverse gear to neutral.

ROLE OF BALANCING VALVES

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 - The balancing valves protect the user from any risk due to a fall in hydraulic pressure or an exploding hose during hydraulic oper-
ations.
Keep everyone wellKeep
awayeveryone
during these
well inspections.
away during these inspections. In all cases, the balancing val
valve(s)
ve(s) concerned must be repaired 
repaired 
InDANGER
all cases, the balancing valve(s)
or replaced concerned
if hydraulic must be
movement repaired after
continues or replaced
the I.C.ifengine
hydraulic
hasmovement continues
been switched after use
off. Never the I.C. engine
the lift truckhas 
with
been switched off. aNever use the
defective lift truck
balancing with a defective balancing valve.
valve.

TESTING EACH HYDRAULIC MOVEMENT

LIFTING CIRCUIT :
- Start up the lift truck and raise the boom by about 45°.
- With the I.C. engine running at mid- speed,
speed, lower the boom. While the boom is being low
lowered,
ered, switch off the I.C. engine; move-
ment should slow down as the I.C. engine speed falls and stop when the I.C. engine stops.

TELESCOPING CIRCUIT :
- Start up the lift truck and raise the boom as far as it will go, extending the telescope(s) completely
completely..
- With the I.C. engine running at mid- speed, retract the telescope(s
telescope(s).
). When retracting the boom, switch off the I.
I.C.
C. engine; move-
ment should slow down as the I.C. engine speed falls and stop when the I.C. engine stops.

TILT CIRCUIT :
- Place the nominal load on the forks,
forks, anchor it correctly to prevent it from falling off during the test.
- Start up the lift truck and tilt the carriage backwards,
backwards, lifting the boom sufficiently to allow the carriage to tilt.
- With the I.C. engine running at mid-speed, tilt the carriage forwards. While it is tilting, switch off the I.C. engine; movement should
slow down as the I.C. engine speed falls and stop when the I.C. engine stops.

D8 - P A
ARKI
RKING
NG BR
BRAK
AKE
E LEVE
LEVER
R ME
MECH
CHAN
ANIS
ISM 
M  D8
GREASE 

- Clean and grease articulation axles 1 (fig. D8) with grease ((see
see : 3 - MAINTENANCE :
LUBRICANTS AND FUEL).

1
1

3 - 26

CONTENTS

D9 - BRAK
BRAKIN
ING
G PRES
PRESSU
SURE
RE OIL
OIL FI
FILT
LTER
ER CART
CARTRI
RIDG
DGE 
E  D9/1

CHANGE 

Stop the I.C. engine and remove the pressure from the circuits by acting on the hydraulic
controls.
Thoroughly
Thoroughly clean the clean
outside of the outside
the filter and its of the filter and
surroundings its surroundings
before before
any intervention any 
in order 
IMPORTANT
to prevent any risk intervention, to prevent
of polluting the risk
hydraulic of polluting the hydraulic circuit.
circuit.
1
- Remove the shroud 1 (fig. D9/1).
- Place a container under the braking pressure oil filter.
- Unscrew the body of the filter 2 (fig. D9/2).
- Remove the braking press
pressure
ure oil filter cartridge, and fit n
new
ew replacement cartridge (see :
3 - MAINTENANCE : FIL FILTERS
TERS CARTRIDGES AND B BELTS)
ELTS)..
- Make sure that the cartridge and gaskets are correctly positioned and install the body of 
the filter 2 (fig. D9/2).
D9/2
Tighten the body of Tighten
the filterthe
by body
hand of the filter
pressure onlybyand
hand pressure
lock the bodyonly andfilter
of the lockinthe body
place byof 
a 
IMPORTANT
quarter turn. the filter in place by a quarter turn.

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2
 D10 - C AB VENT
VENTIL
ILAT
ATIO
ION
N FI
FILT
LTER 
ER  D10
CLEAN 

- Lift up protective casing 1 (fig. D10).

- Lift out cabin ventilation filters 2 (fig. D10). 1
- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS).
- Install the filters and protective casing.
2

D11 - B A
ATTE
TTERY
RY ELE
ELECT
CTROL
ROLYT
YTE
E DE
DENSI
NSITY 
TY  D11
1.240
CHECK 
1.250

The electrolyte density varies depending on

on the temperature concerned, but a minimum of  1.260
1260 at 61°F must be maintained. In the s shaded
haded area (fig. D11), the battery is in a nor- 1.270
mal charge condition. Readings above this zone indicate that the battery needs to be
1.280
recharged.
The density should not vary more than 0.025 units between cells. 1.290

1.300
- Check the electrolyte density in each battery cell using a hydrometer.
- Do not carry out this check immediately after topping up with distilled water
water.. Recharge the C -18 -10 0 10 20 30 40
°

battery for at least an hour before checking the battery electrolyte density. F  0 14 32 50 68 86 104
°

Handling and servicing a battery can be dangerous, take the following precau- 
Handling and servicing
tions :  a battery can be dangerous, take
tions take the following precautions : 
- Wear protective goggles.
- Wear protective goggles.
- Keep the battery horizontal.
- Keep the battery horizontal.
WARNING
- Never smoke or work nearsmoke
- Never a naked
or flame.
work near an open flame.
- Work in a well-ventilated
- Work area.
in a well-ventilated area.
- In the event of electrolyte beingof
- In the event spilled onto the
electrolyte skin
being or splashed
spilled in skin
onto the the eyes,
or splashed in the 
rinse thoroughly with coldrinse
eyes, water for 15 minutes
thoroughly andwater
with cold call afor
doctor.
15 minutes and call a doctor.

3 - 27

CONTENTS

D12 - F RONT
R ONT AND REAR AXLE DIFFE
FER
RENTI
NTIAL OIL 
OIL  D12/1

DRAIN 
3
Park the lift truck on level ground with the I.C. engine stopped and the differential oil still
warm.

IMPORTANT Dispose of the drain oil in an ecological manner.

Dispose the drain oil in an ecological manner.
2
- Place a container under drain plugs 1 (fig. D12/1) and unscrew the plugs.
- Remove level plug 2 (fig. D12/1) and filler plug 3 (fig. D12/1) in order to ensure that the
oil is drained properly
properly..
1
- Install and tighten drain plugs 1 (fig. D12/1) (tightening torque 32 ft/lb).
1 1
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 3 (fig.
D12/1).
- The level is correct when the oil level is flush with the edge of port 2 (fig. D12/1).
D12/2
- Check for any possible leaks at the drain plugs.
- Install and tighten level plug 2 (fig. D12/1) (tightening torque 32 ft/lb) and filler plug 3
(fig. D12/1) (tightening torque 32 ft/lb). 3

- Repeat this operation for the rear axle differential (fig. D12/2).

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2
 1
1 1

3 - 28

CONTENTS

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 3 - 29

CONTENTS

E - EVERY 1000 HOURS SERVICE 

Carry out the operations described previously as well as the following operations.

E1 - F UEL
U EL TANK  E1/1
CLEAN 

WARNING While carrying out these operations, do not smoke or work near a flame.
While carrying out these operations, do not smoke or work near a flame.
Park 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.
1
- In the event of a leak, contact your dealer
dealer..
Never try to carry out a weld
Never or any
perform other operation
welding on the fuelbysystem,
yourself,this
thiscould
couldcause
provoke an explosion 
an explosion or 
WARNING a fire.
or a fire.
- Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
- Remove cap 2 (fig. E1/2).
- Let the fuel flow and flush with 2 gal.of clean fuel by filler port 3 (fig. E1/2).
- Install and tighten drain plug 1 (fig. E1/1)https://www.forkliftpdfmanuals.com/
(tightening torque 26 ft/lb). E1/2
- Fill the fuel tank with clean
clean fuel (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) fil-
fil-
 tered through a strainer or a clean, lint-free cloth and install the filler plug 2 (fig. E1/2).
- If necessary
necessary,, bleed th
the
e fuel cir
circuit
cuit (s
(see
ee : 3 - MAINTEN
MAINTENANCE
ANCE : G1 - FUEL SYS SYSTEM).
TEM). 2

E2 - S AFETY DRY
DRY AIR FILT
FILTE
ER CART
CARTRI
RIDG
DGE 
E  E2
CHANGE 
1
- For the disassembly and reassembly of the cartridge, see : 3 - MAINTENANCE : D3 - DRY
AIR FILTER CARTRIDGE.
- Gently remove the dry air filter safety cartridge 1 (fig. E2), taking care to avoid s
spilling
pilling the
dust.
- Clean the gasket surface on the filter with a damp, clean lint-free cloth.
- Before installing check the state of the new safety cartridge (see : 3 - MAINTENANCE :
FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter
filter axis and push it in, pressing the edges and not the
middle.

NOTE : The schedule for changing the safety cartridge is given for reference only.
only. The safe-
ty cartridge must be changed for every two changes of the air filter cartridge.

E3 - T RAN
RANSMI
SMISSI
SSION
ON OIL  E3/1
DRAIN 

Park the lift truck on level ground with the I.C. engine stopped, the transmission oil still
warm.

DRAINING THE OIL

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

IMPORTANT Dispose
Dispose the drain oil of the drainmanner.
in an ecological oil in an ecological manner.

3 - 30

CONTENTS

FILLING UP THE OIL E3/2

- Install and tighten drain plug 1 (fig. E3/1) (tightening torque 32 ft/lb).
- Fi
Fill
ll up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 4 (fig. E3/4)
and install the plug.
- Check oil nivel (see : 3 - MAINTENANCE : A5 - CHECK THE TRANSMI
TRANSMISSION
SSION OIL LEVEL).

E3/3 E3/4

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 E4 - H YDRA
YDRAUL
ULIC
IC OI
OIL 
L  E4/1
DRAIN 
E5 - S UCTI
U CTION
ON STR
TRA
AINER
NER FOR HYD
HYDRAU
RAULIC
LIC OIL
OIL TANK 
CLEAN 
E6 - F ILT
LTER
ER CAP FOR HYD
HYDRAU
RAULIC
LIC OIL
OIL TANK 
CHANGE 

Park the lift truck on level ground with the I.C. engine stopped and telescope boom retract- 1
ed and lowered as far as possible.
Before any intervention,
Beforethoroughly clean thethoroughly
any intervention, area surrounding thearea
clean the drainsurrounding
plugs and the
thesuction 
drain 
IMPORTANT
cover on the hydraulic
plugstank.
and the suction cover on the hydraulic tank.

DRAINING THE OIL

- Place a container under drain plugs 1 (fig. E4/1) and unscrew the plug. E4/2
- Remove filler cap 2 (fig. E4/2) in order to ensure that the oil is drained properly. 4
2
IMPORTANT Dispose of the drain oil in an ecological manner.
Dispose the drain oil in an ecological manner.

CLEANING THE STRAINER

- Remove suction cover 3 (fig. E4/3).
- Remove and clean the strainer using a compressed
compressed air jet, check its condition and
replace if necessary (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS). 5
- Install the strainer and tighten the suction cover 3 (fig.
(fig . E4/3) (Tightening torque 60 ft/lb)
making sure the seal is in the correct position.

FILLING UP THE OIL

- Clean and install drain plug 1 (fig. E4/1) (tightening torque 26 ft/lb).
E4/3
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 4 (fig.
E4/2).
Use a clean container and funnel, and clean the underside of the oil nozzle 
IMPORTANT
Use a clean container andfilling.
before funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 5 (fig. E4/4) ; the oil level should be at the level of the
red point.
- Check for any possible leaks at the drain plug.
- Replace filler plug 2 (fig. E4/2) with a new filler plug (see : 3 - MAINTENANCE : FILTERS 3
CARTRIDGES AND BELTS)
BELTS)..

3 - 31

CONTENTS

POLLUTION ABATEMENT OF THE HYDRAULIC CIRCUIT

MLA 628 -120 LSU POWERSHIFT Series 3-E2

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
i n order to ensure the long life of hydraulic com-
ponents and particularly of the main pump.

E7 - S EAT BELT 
BELT 
CHECK 

SEAT BELT
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 (cut
(cuts,
s, curled edges).

REELED SEAT BELT WITH TWO ANCHORING POINTS

- Check the points listed above together with the following points :
https://www.forkliftpdfmanuals.com/
• 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.

Under no circumstances
Under should you use theshould
no circumstances lift truck
youif use
the the
seatlift
belt is faulty
truck (fixing,
if the seat locking 
belt is dam- 
WARNING aged! Repair or replace the seat belt immediately! 

E8 - F RON
ONT
T AND REAR WHEEL
ELS
S RE
RED
DUC
UCE
ERS OIL  E8
DRAIN 

Park the lift truck on level ground with the I.C. engine stopped and the reducers oil still
warm.
1

IMPORTANT Dispose of the drain oil in an ecological manner. B

Dispose the drain oil in an ecological manner.
- Drain and change each front wheel reducer reducer..
- Place drain plug 1 (fig. E8) in position A.
- Place a container under the drain plug and unscrew the plug.
- Let the oil drain fully.
A
- Place the drain
drain port in position B
B,, i.e. in a level po
port.
rt.
- Fi
Fill
ll up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by by level port 1 (fig. E10).
- The level is correct when the oil level is flush with the edge of the hole.
- Install and tighten the drain plug 1 (fig. E8) (tightening torque 32 ft/lb).
- Repeat this operation on each rear wheel reducer reducer..

3 - 32

CONTENTS

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 3 - 33

CONTENTS

F - EVERY 2000 HOURS SERVICE 

Carry out the operations described previously as well as the following operations.

F1 - C OOLIN
O OLING
G LIQU
LIQUID 
ID  F1/1

These operations are to be carried out if necessary or every two years at the beginning of 
winter. Park the lift truck on level ground with the I.C. engine stopped and cold.
1
DRAINING THE LIQUID
- Open the I.C. engine cover.
- Place a container under drain plug 1 (fig. F1/1) of the radiator and drain plug 2 (fig. F1/2)
of the I.C. engine block and unscrew the plugs.
- Remove filler cap 3 (fig. F1/3) of the expansion pan 4 (fig. F1/3).
- 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
necessar y.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
https://www.forkliftpdfmanuals.com/ F1/2
 FILLING THE LIQUID
- Tighten the drain valve 2 (fig. F1/2) and drain plug 3 (fig. F1/3) (tightening torque 30
ft/lb).
- Slowly fill up the cooling circuit (see
(see : 3 - MAINTENANCE : LUBRICANTS AND F FUEL)
UEL) to half 
way up the expansion pan 5 (fig. F1/4). 2
- Install filler cap 4 (fig. F1/4).
- Run the I.C. engine at idle for a few minutes.
- Check for any possible leaks.
- Check the level and refill if necessary.
The I.C. engine does
Tonot contain
pervent any corrosion
corrosion resistor
the I.C. engineand must system
cooling be filled must
duringbe
the whole
filled year 
with a
IMPORTANT
with a mixture containing
minimum 25 mixture
25 % of ethylene
mixture of 25 %glycol-based antifreeze. antifreeze.
ethylene glycol-based

F1/3

3 - 34

CONTENTS

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 3 - 35

CONTENTS

G - OCCASIONAL MAINTENANCE 

G1 - F UEL
U EL SYST
SYSTEM 
EM 
G1/1
BLEED 
1
These operations are to be carried out only in the following cases
cases :
• A component of the fuel system replaced.
• A drained tank.
• Running out of fuel.

Ensure that the level of fuel in the tank is suff

sufficient
icient and bleed in the following order :

- Open the I.C. engine cover.

- Remove the muffler 1 (fig. G1/1).
- Put the ignition on for three minutes on the lift truck, to give the lift pump time to pump
air from the filter.

- Switch off the ignition with the ignition key. G1/2

BLEEDING THE INJECTORS https://www.forkliftpdfmanuals.com/
- Remove the injectors cover 2 (fig. G1/2).
 - Loosen high pressure connectors 3 (fig. G1/3) of all the injectors. 2

- Activate the starter until the diesel fuel flows out free of air at high pressure connectors
3 (fig. G1/3).
Do not motor
Do not engage the starter engageon
the starter motor
a continual onfor
basis a continual
more thanbasis for moreand
30 seconds than
let30
it sec- 
cool 
IMPORTANT onds
between unsuccessful and let it cool between unsuccessful attempts.
attempts.
- Tighten the connection while the diesel fuel is flowing out (tightening torque 22 ft/lb).

- Install the muffler 1 (fig. G1/1).

- The I.C. engine is then ready to be started up.
- Turn the I.C. engine over slowly for 5 minutes immediately after bleeding the fuel feed cir-
cuit, in order to ensure that the injection pump has been bled thoroughly.
thoroughly. G1/3

NOTE : If the I.C. en

engine
gine functions correctly for a short time then stops or functions irreg-
ularly, check for pos
possible
sible leaks in th
the
e low pressure circuit. If in doubt, contact your 3
dealer. 3

3
3

3 - 36

CONTENTS

G2 - W HEEL 
HEEL  G2/1

CHANGE 
In the
In the event of a wheel event
being of a wheel
changed being
on the changed
public onmake
highway, the public highway,
sure of make sure
the following of 
o f : 
points
WARNING the following points 

For this operation we advise you to use an approved hydraulic jack and safety support (con-
tact your dealer).

- Park the lift truck, if possible on even and h

hard
ard ground.
- Put the warning lights on.
- Immobilize the lift truck in both directions on the axle opposite to the wheel to be
changed.
- Unlock the nuts of the wheel to be changed.
- Place the jack under the flared axle tube, as near as possible to the wheel and adjust the
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. https://www.forkliftpdfmanuals.com/
- Install the nuts by hand, if necessary grease the
them.
m.
 - Remove the safety support and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see : 3 - MAINTENANCE : A - DAIL
DAILY
Y OR EVERY
10 HOURS SERVICE for tightening torque).

G3 - L IFT TRUC
TRUCK 
K 
TOW 
TOW 

IMPORTANT Do not tow the lift truck at more than 15 mph.

Do not tow the lift truck at more than 25 km/h.
- Put the forward/reverse lever and the gear shift in neutral (as model of lift truck).
- Release the parking brake.
- Put the warning lights on.
- If the I.C. engine is not running there will be no steering or braking assistance. Operate the steering and pedal slowly avoiding
sudden abrupt movements.

G4 - L IFT TRUC
TRUCK 
K 
G4/1
SLING 

- Take into account the position of the lift truck gravity center for lift-
ing (fig. G4/1).
A = 58. 3 i n. B = 40. 2 i n.
- Place the hooks in the fastening points provided (fig. G4/2 and
G4/3).

A B

G4/2 G4/3

3 - 37

CONTENTS

G5 - L IFT TRUCK ON A PLATFORM  G5/1

TRANSPORT 

Ensure
Ensure that the safety that the safety
instructions connectedinstructions for the platform
to the platform are followed
are respected beforebefore load- 
the loading 
ofWARNING
the lift truck anding thethe
that lift driver
truck and that
of the the driver
means of transport
of transport is informed
is informed about about the dimen- 
the dimensions 
and the weight of thesions
lift and
truck weight
(see :of2 the lift truck.
- DESCRIPTION : CHARACTER
CHARACTERISTIC
ISTICS).
S).

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

For lift
For lift trucks equipped trucks
with equipped with
a turbo-charged a turbo-charged
I.C. engine, I.C. exhaust
block off the engine, outlet
block to
offavoid 
the 
IMPORTANT exhaust outlet to avoid rotation of the turbo shaft without
rotation of the turbo shaft without lubrication when transporting the vehicle. lubrication when 
transporting the vehicle.

LOAD THE LIFT TRUCK G5/2

- Block the wheels of the platform.
- Fix the loading ramps so that you obtain an angle as little
li ttle as possible to lift the lift truck.
- Load the lift truck parallel to the platform.
- Park the lift truck (see : 1 - OPERATING AND SAFETY INSTRUCTIONS
INSTRUCTIONS : DRIVING INSTRUC-
TIONS UNLADEN AND LADEN).
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 STOW THE LIFT TRUCK
- Fix the chocks to the platform at the front and at the back of each tire (fig. G5/1).
- Fix also the chocks to the platform in the inside of each tire (fig. G5/2).
- Stow the lift truck on the platform with enough resisting straps/chains. At the front of the
lift truck, on the fa
fastening
stening points 1 (fig. G5/3) and at the bac
back,
k, on the towing pin 2 (fig.
G5/4).
- Tighten the straps/chains (fig. G5/5).
G5/3

G5/4 G5/5

3 - 38

CONTENTS

G6 - F RONT
RONT HEADLA
HEADLAMPS 
MPS  G6

ADJUST 
h2 = h1 - (l x 2 / 100)

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

-%
-2    
  
ADJUSTING PROCEDURE h1 %    
h2
- Park the lift truck unloaded and in the transport position and
perpendicular to a white wall on fflat,
lat, level ground (f
(fig.
ig. G6).
l
- Check the tire pressures
pressures (see : 2 - DESCRIPTION : CHARACTER-
ISTICS).
- Put the gear reverser lever in neutral and release the parking brake.

CALCULATING THE HEIGHT OF THE DIPPED BEAM (H2)

• h1
h1 = He
Heig
ight
ht of th
the
e dip
dippe
ped
d b
bea
eam
m iin
n rrel
elat
ation
ion to th
the
e g
gro
roun
und.
d.

• lh2
• h2 = Di
= Hesta
igahnce
Dist t o
ncof
ef b
th
thewad
bet
etwaee
djn
eenustthe
the
ed dip
b
be
die
pamd. b
ped
pe bea
eam
maand
nd th
the
e w
whi
hite
te wall.
all.
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 3 - 39

CONTENTS

H - EVERY TWO YEARS (OPTION AIR CONDITIONING)

WARNING : NEVER DO
TRYNOT ATTEMPT
TO REPAIR REPAIRS.
ANY ONLY
ANOMALIES A QUALIFIED
YOURSELF.
YOURSELF AIR CONDITIONING
. TO RECHARGE SERVICEMAN
A CIRCUIT, SHOULDYOUR
ALWAYS CONTACT MAKE REPAIRS.
DEALER WHOCONTACT 
HAS THE 
WARNING YOUR DEALER.
APPROPRIATE SPARE PARTS, TECHNICAL TRAINING AND NECESSARY 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.

Do not open the cooling circuit under any circumstances, this will cause the coolant to be lost. The cool-
• If this gas is inhaled,circuit
ing contains
take the a gas
victim into freshwhich c
can
anoxygen
air, give be dangerous under
or artificial certain
respiration conditions.
if necessary andThis
call gas, coolant R 134a, is
a doctor.
colorless,
• If the gas is in contact with odorless and hea
the skin, wash heavier
vier than air
it immediately air.
.
under running water and remove any contaminated garments.
WARNING
• If the gas is in contact with the eyes, rinse them in clear water for 15 minutes and call a doctor.
If the 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 gar- 
ments.• If the gas is in contact with the eyes, rinse them in clear water for 15 minutes and call a doctor.

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- The charger has an oil level gauge; never unscrew this gauge because it would depres-
 surise the installation. The oil level is only checked when changing the oil in the circuit.

H1 - C LE
LEAN
ANIN
ING
G THE
THE CON
CONDE
DENS
NSER
ER AN
AND
D EVAPO
VAPORA
RATO
TOR
R COILS  (*)
COILS 

H2 - C LEAN
L EANIN
ING
G TH
THE
E HOTW
HOTWEL
ELL
L AND TH
THE
E PR
PRES
ESSU
SURE LIEF VALVE  (*)
RE RELIE

H3 - C OLLE
O LLECT
CTIN
ING
G TH
THE
E COOL
COOLAN
ANT
T TO REPLACE THE FILTER -- DRIER 
PLA D  RIER  (*)

H4 - R ELOA
E LOADI
DING
NG COOL
COOLAN
ANT
T AN
AND
D CHEC
CHECKI
KING
NG THE
THE THER
THERMO
MOST
STAT
ATIC
IC CONT
CONTRO
ROL
L AN
AND
D PR
PRES
ESSU
SURE
RE SWIT
SWITCHES  (*)
CHES 

(*) : (CONSULT YOUR DEALER).

3 - 40

CONTENTS

4 - PICKING UP
THE ATTACHMENTS https://www.forkliftpdfmanuals.com/
 THE ATTACHMENTS 

4-1

CONTENTS

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 4-2

CONTENTS

TABLE OF CONTENTS 

I NTRODUCTION 
NTRODUCTION  4 - 5 

P IICKI
CKING
NG UP TH
THE
E AT
ATTA
TACH
CHME
MENT
NTS 
S  4 - 6 

A - ATTACHMENT
ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE 4-6

B - ATTACHMENT
ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE (OPTION) 4-7

C - HYDRAULIC ATT
ATTACHMENT
ACHMENT AND HAND LOCKING DEVICE 4-8

D - HYDRAULIC ATT
ATTACHMENT
ACHMENT AND HYDRAULIC LOCKING DEVICE (OPTION) 4-9

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 4-3

CONTENTS

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 4-4

CONTENTS

INTRODUCTION 

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

- A wide range of attachments, specially designed and perfectly suitable for your lift truck is ava
available
ilable 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 solu-
tions exist, consult your dealer
dealer..
Only attachments approved by MANITOU are to be used on our lift trucks (see : 4 - ADAPTABLE ATTACHMEN ATTACHMENTS TS IN OPTION ON THE RANGE : 
IMPORTANT
TECHNICAL SPECIFICATIONS
SPECIFICATIONS OF ATTACHMENTS). The manufacturer's liability will be denied in case of modification or of attachment adap- 
tation carried out without
Only attachments approved by his knowing
MANITOU are it.to be used on our lift trucks. The manufacturer's liability will be voided in case of modification(s) 
without prior written permission.
Depending on their size, certain attachments may, when the boom is lowered and retracted, come into contact with the front tires and 
Maximum loads are defined by the capacity of a lift truck taking into account the attachment’s mass and center of gravity. In the event of the 
cause
attachment
FICIENTdamage
having
EXTENT toFOR
lessthem, if reverse
capacity
THE tilt lift
than the
PARTICULAR is activated
truck,
LIFT in the
never
TRUCK forward
exceed
AND tilt direction.
its limit.
ATTACHMENT TO REMOVE
SO THAT THIS RISK,
THIS CONTACT IS NOTEXTEND THE TELESCOPE TO A SUF- 
POSSIBLE.
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Maximum loads are defined by the capacity of a lift truck taking account of the attachment’s mass and center of gravity. In the event of 
 WARNING
the attachment having less capacity than the lift truck, never exceed this limit.

Depending on their size, certain attachments (when the boom is lowered and/or retracted, or the tilt is activated) may come into contact with
the front tires and cause damage to them. TO AVOID TIRE DAMAGE, EXTEND THE TELESCOPE TO A SUFFICIENT DISTANCE TO AVOID DAMAGING 
THE TIRES! 

4-5

CONTENTS

PICKING UP THE ATTACHMENTS 

A - ATT
TTAC
ACHM
HMEN
ENT
T WI
WITH
THOU
OUT
T HYDR
HYDRAU
AULI
LICS
CS AN
AND
D HAND
HAND LO
LOCK
CKIN
ING
G DEVI
DEVICE 
CE  A

TAKING UP AN ATTACHMENT
- Ensure that the attachment is oriented for locking to the carriage. If it is not correctly 
oriented, take the necessary precautions in or order
der to move it safely.
safely.
- Check that the locking pin and the clip are in position in the bracket (fig. A).
- Park the lift truck with the boom lowered
lowered in front of and parallel
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 install the clip. B

HAND RELEASING
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 - Proceed in the reverse order of paragraph HAND LOCKING while making sure you install
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
ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.

4-6

CONTENTS

B - ATTAC
TTACHM
HMEN
ENT
T WI
WITH
THOU
OUT
T HYDR
HYDRAU
AULI
LICS
CS AN
AND
D HYDR
HYDRAU
AULI
LIC
C LO
LOCK
CKIN
ING
G DEVICE  ( 
DEVICE  OPTION ) A
MLA 628 -120 LSU POWERSHIFT Series 3-E2

TAKING UP AN ATTACHMENT
- Ensure that the attachment is oriented for locking to the carriage. If it is not correctly 
oriented, take the necessary precautions in or order
der to move it safely.
safely.
- Check that the rods on the locking cylinder are retracted (fig. A).
- Park the lift truck with the boom lowered
lowered in front of and parallel
parallel to the attachment, tilt the
carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the boom, incline
the carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.

HYDRAULIC LOCKING B
- Put the valve in position A (fig.
(fig. D), the hydraulic circuit of the attachment locking open.
- Switch button 1 (fig. E) of the distributor lever up to completely lock the attachment on
the carriage.

- Close the valve in position

position B (fig. D), the hydraulic circuit of the a
attachment
ttachment locking clo-
sed.
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Always close the valve in position
Always B (fig.
close the valveD)inafter the locking
position o
off the
B (fig. D) afterattachment,
locking thein order to avoid 
attachment, to 
 WARNING
accidental unlocking andaccidental
avoid use the attachment
unlocking! safety.

HYDRAULIC RELEASING
- Put the valve in position A (fig.
(fig. D), the hydraulic circuit of the attachment locking open.
- Switch button 1 (fig. E) of the distributor lever down to completely release the attachment.

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

INACTIVATE THE HYDRAULIC RELEASE CONTROL

INACTIVATE
You can change an attachment without lea leaving
ving the control post, by cutting the electricity 
supply to the hydraulic control.
- Leave the valve in position A (fig. D).
- Use switch 2 (fig. F) to cut the electricity supply to the hydraulic control. The circuit is out
of action when indicator 3 (fig. F) is on.
Always cut the electrical power to the circuit using switch 3 (fig. F) after each change of attach- 
Always cut the electrical power to the circuit using switch 3 (fig. F) after 
WARNING
ment to avoid involuntary release and use the attachment in complete safety.
each change of attachment to avoid involuntary release! 

D
A

E F 

4-7

CONTENTS

C - H YDRA
Y DRAUL
ULIC
IC ATTAC
TTACHM
HMEN
ENT
T AN
AND
D HAND
HAND LO
LOCK
CKIN
ING
G DEVI
DEVICE 
CE  A
MLA 628 -120 LSU POWERSHIFT Series 3-E2

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

HAND LOCKING AND CONNECTING THE ATTACHMENT ATTACHMENT

- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D). B
Do not forget to install the clip.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Release the pressure from the attachment hydraulic circuit by pressing button 1 (fig. E)
on the distributor lever up and down 4 or 5 times.
- Connect the rapid connectors according to the logic of the attachment’s hydraulic move-
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ments.
 Make sure that theMake
rapid sure
connectors
that theare clean
rapid and protect the
(quick-release) holes which
connectors are are notand
clean used, with 
protec- 
IMPORTANT
the caps provided. ted with the caps provided when not in use.

HAND RELEASING AND DISCONNECTING THE ATTA ATTACHMENT

CHMENT
- Proceed in the reverse order of paragraph HAND LOCKING AND CONNECTING THE
ATTACHMENT
ATT ACHMENT while making sure you iinstall
nstall the locking pin and the clip in the bracket (fig.
A).
C
LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT
ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.

4-8

CONTENTS

D - H YDRA
YDRAUL
ULIC
IC AT
ATTA
TACH
CHME
MENT
NT AN
AND
D HYDR
HYDRAU
AULI
LIC
C LOC
LOCKIN
KING
G DEVICE  ( 
DEVICE  OPTION )
OPTION  A
MLA 628 -120 LSU POWERSHIFT Series 3-E2

TAKING UP AN ATTACHMENT
- Ensure that the attachment is oriented for locking to the carriage. If it is not correctly 
oriented, take the necessary precautions in or order
der to move it safely.
safely.
- Check that the rods on the locking cylinder are retracted (fig. A).
- Park the lift truck with the boom lowered
lowered in front of and parallel
parallel to the attachment, tilt the
carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the boom, incline
the carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.

HYDRAULIC LOCKING AND CONNECTING THE ATTA ATTACHMENT

CHMENT
- Put the valve in position A (fig.
(fig. D), the hydraulic circuit of the attachment locking open. B
- Switch button 1 (fig. E) of the distributor lever up to completely lock the attachment on
the carriage.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Release the pressure from the attachment hydraulic circuit by pressing button 1 (fig. E)
on the distributor lever up and down 4 or 5 times.
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- Connect the rapid connectors according to the logic of the attachment’s hydraulic move-
 ments.
Make sure that theMake
rapid sure that theare
connectors rapid (quick-release)
clean connectors
and protect the are are
holes which clean
notand protec- 
used, with 
IMPORTANT
the caps provided. ted with the caps provided when not in use.
- Close the valve in position
position B (fig. D), the hydraulic circuit of the a
attachment
ttachment locking clo-
sed.
Always close the valve in position
Always B (fig.
close the valveD)inafter the locking
position o
off the
B (fig. D) afterattachment,
locking thein order to avoid 
attachment, to 
WARNING
accidental unlocking and use the attachment
avoid accidental unlocking!  safety.
C

HYDRAULIC RELEASING AND DISCONNECTING THE ATTA ATTACHMENT

CHMENT
- Close the attachment.
- Put the valve in position A (fig.
(fig. D), the hydraulic circuit of the attachment locking open.
- Switch button 1 (fig. E) of the distributor lever down to completely release the attachment.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Release the pressure from the attachment hydraulic circuit by pressing button 1 (fig. E)
on the distributor lever up and down 4 or 5 times.
- Disconnect the rapid connectors of the attachment.
Make sure that theMake
rapid sure
connectors
that theare clean
rapid and protect the
(quick-release) holes which
connectors are are notand
clean used, with 
protec- 
IMPORTANT
the caps provided. ted with the caps provided when not in use.

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

4-9

CONTENTS

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 4 - 10

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