INTRODUCTION TO SAFETY

MANITOU NORTH AMERICA, INC.

6401 IMPERIAL DRIVE
WACO, TX 76712-6803

For Parts Orders contact your Manitou North America Dealer or call:
Manitou North America, Inc. Parts Dept. (800) 425-3727 or (254) 799-0232
Parts Dept. Fax (254) 867-6504 Website: www.manitou-na.com

MLT 627 Turbo 20” COMPACT

MONO-ULTRA Series B-E2

OPERATOR'S MANUAL

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

547884AS
R11-10
INTRODUCTION TO SAFETY
INTRODUCTION TO SAFETY
INTRODUCTION TO SAFETY
INTRODUCTION TO SAFETY

- INTRODUCTION TO SAFETY -

- ROUGH TERRAIN FORKLIFT TRUCK

GENERAL SAFETY STANDARDS - - - - - - - - - - - I

- SAFTETY MESSAGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII

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

- TABLE OF CONTENTS -

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

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

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

- PICKING UP THE ATTACHMENTS - - - - - - - - - - - - - - - - - - - - 4 - 3

R05-05
INTRODUCTION TO SAFETY
INTRODUCTION TO SAFETY

ROUGH TERRAIN FORKLIFT TRUCK

GENERAL SAFETY STANDARDS

I
INTRODUCTION TO SAFETY

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

STUDY THE OPERATOR/SERVICE MANUALS

The information in this manual provides general instructions for the safe operation and maintenance of your
forklift truck. This information is vital and must be clearly understood by the operator and serviceman. Study
this manual and the Rough Terrain Forklift Safety Manual (part no. 422494) thoroughly and carefully before
operating or servicing your forklift. Contact your dealer or Manitou North America, Inc. if you have any ques-
tions concerning your forklift, its operation, service or parts. Keep both manuals in the literature box on the
forklift available for reference. If either manual becomes illegible or is missing, contact your dealer for replace-
ments immediately. This manual cannot cover every situation that might result in an accident. It is the respon-
sibility of the operator to always remain alert for potential hazards and be prepared to avoid them!

ADDITIONAL RECOMMENDED LITERATURE:

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

A.) OPERATOR TRAINING QUALIFICATIONS

1.) The user shall ensure that operators understand that safe operation is the operator’s responsibility. The
user shall ensure that operators are knowledgeable of, and observe, all safety rules and practices.
2.) Create an effective operator training program centered around user company’s policies, operating condi-
tions, and rough terrain forklift trucks. The program should be presented completely to all new operators and
not be condensed for those claiming previous experience.
3.) Information on operator training is available from several sources, including rough terrain forklift truck man-
ufacturers, users, government agencies, etc.
4.) An operator training program should consist of the following:
a.) careful selection of the operator, considering physical qualifications, job attitude, and aptitude;
b.) emphasis on safety of stock, equipment, operator, and other personnel;
c.) citing of rules and why they were formulated;
d.) basic fundamentals of rough terrain forklift truck and component design as related to safety, e.g.,
in.-lb (N-m) loading, mechanical limitations, center of gravity, stability, etc.;
e.) introduction to equipment, control locations, and functions. Explain how they work when used
properly and problems when used improperly.
f.) supervise practice on operating course remote from normal activity and designed to simulate
actual operations, e.g., lumber stacking, elevating shingles to the roof, etc.;
g.) oral, written, and operational performance tests and evaluations during and at completion of the
course;
h.) refresher courses, which may be condensed versions of the primary
course, and periodic “on job” operator evaluation;
i.) understanding of nameplate data and operator instructions and warning information appearing on
the rough terrain forklift truck.

B.) GENERAL SAFETY PRACTICES

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

II
INTRODUCTION TO SAFETY

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

B.) GENERAL SAFETY PRACTICES (cont.)

7.) Where steering can be accomplished with either hand and the steering mechanism is of a type that pre-
vents road reactions from causing the handwheel to spin (power steering or equivalent), steering knobs may
be used. When used, steering knobs shall be of a type that can be engaged by the operator’s hand from the
top and shall be within the periphery of the steering handwheel.
8.) Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable
when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may con-
tribute to a condition of instability and defeat the purpose of the requirements.
9.) Users shall give consideration to special operating conditions. The amount of forward and rearward tilt to
be used is governed by the application. Although the use of maximum rearward tilt is allowable under certain
conditions, such as traveling with the load lowered, the stability of a rough terrain forklift truck as determined
by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation
of trucks with excessive off-center loads.
10.) Some of the conditions which may affect stability are ground and floor conditions, grade, speed, loading
(rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operated
without a load on the attachment), dynamic and static forces, improper tire inflation, and the judgement exer-
cised by the operator.

C.) OPERATING SAFETY RULES AND PRACTICES

1.) Safe operation is the responsibility of the operator.
2.) This equipment can be dangerous if not used properly. The operator shall develop safe working habits and
also be aware of hazardous conditions in order to protect himself, other personnel, the rough terrain forklift
truck, and other material.
3.) The operator shall be familiar with the operation and function of all controls and instruments before under-
taking to operate the rough terrain forklift truck.
4.) Before operating any rough terrain forklift truck, truck operators shall have read and be familiar with the
operator’s manual for the particular truck being operated.
5.) Before starting to operate the rough terrain forklift truck:
a.) be in operating position and fasten seat belt;
b.) place directional controls in neutral;
c.) apply brakes;
d.) start engine.
6.) Do not start or operate the rough terrain forklift truck, any of its functions, or attachments from any place
other than the designated operator’s position.
7.) Keep hands and feet inside the operator’s designated area or compartment. Do not put any part of the
body outside the operator compartment of the rough terrain forklift truck.
8.) Never put any part of the body into the mast structure or between the mast and the rough terrain forklift
truck.
9.) Never put any part of the body within the reach mechanism of the rough terrain forklift truck or other attach-
ments.
10.) Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury
to personnel.
11.) Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck, whether
empty or loaded.
12.) Do not permit passengers to ride on rough terrain forklift trucks.
13.) Check clearance carefully before driving under electrical lines, bridges, etc.
14.) A rough terrain forklift truck is attended when the operator is less than 25 ft (7.6m) from the truck, which
remains in his view.
15.) A rough terrain forklift truck is unattended when the operator is 25ft (7.6m) or more from the truck, which
remains in his view, or whenever the operator leaves the truck and it is not in his view.
16.) Before leaving the operator’s position:
a.) bring rough terrain forklift truck to a complete stop;
b.) place directional controls in neutral;
c.) apply the parking brake;
d.) lower load-engaging means fully, unless supporting an occupied elevated platform;
e.) stop the engine;
f.) if the rough terrain forklift truck must be left on an incline, block the wheels;
g.) fully lower the load-engaging means.
17.) Maintain a safe distance from the edge of ramps, platforms, and other similar working surfaces.
18.) Do no move railroad cars or trailer with a rough terrain forklift truck.

III
INTRODUCTION TO SAFETY

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

19.) Do not use a rough terrain forklift truck for opening or closing railroad car doors.
20.) In areas classified as hazardous, use only rough terrain forklift trucks approved for use in those areas.
21.) Report all accidents involving personnel, building structures, and equipment to the supervisor or as
directed.
22.) Do not add to, or modify, the rough terrain forklift truck.
23.) Do not block access to fire aisles, stairways, and fire equipment.
24.) For rough terrain forklift trucks equipped with a differential lock, the lock should not be engaged when driv-
ing on the road or at high speeds or when turning. If the lock is engaged when turning, there could be loss of
steering control.
25.) Observe all traffic regulations including authorized speed limits. Under normal traffic conditions, keep to
the right, maintain a safe distance, based on speed of travel, from the truck ahead; and keep the truck under
control at all times.
26.) Yield the right-of-way to pedestrians and emergency vehicles such as ambulances and fire trucks.
27.) Do not pass another truck traveling in the same direction at intersections, blind spots, or at other danger-
ous locations.
28.) Slow down and sound the audible warning device(s) at cross-aisles and other locations where vision is
obstructed.
29.) Cross railroad tracks at an angle wherever possible. Do not park closer than 6 ft (1.8m) to the nearest rail
of a railroad track.
30.) Keep a clear view of the path of travel and observe other traffic, personnel, and safe clearances.
31.) If the load being carried obstructs forward view, travel with the load trailing.
32.) Ascend or descend grades slowly and with caution.
a.) When ascending or descending grades in excess of 5%, loaded rough terrain forklift trucks
should be driven with the load upgrade.
b.) Unloaded rough terrain forklift trucks should be operated on all grades with the load-engaging
means downgrade.
c.) On all grades, the load and load-engaging means shall be tilted back, if applicable, and raised
only as far as necessary to clear the road surface.
d.) Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines; normally
travel straight up or down.
33.) Under all travel conditions, operate the rough terrain forklift truck at a speed that will permit it to be brought
to a stop in a safe manner.
34.) Travel with load-engaging means or load low and, where possible, tilted back. Do not elevate the load
except during stacking.
35.) Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift load and/or overturn
the rough terrain forklift truck.
36.) Do not indulge in stunt driving or horseplay.
37.) Slow down for wet and slippery surfaces.
38.) Before driving over a dockboard or bridge plate, be sure that it is properly secured. Drive carefully and
slowly across the dockboard or bridge plate, and never exceed its rated capacity.
39.) Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so.
Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the ele-
vator, neutralize the controls, shut off engine, and set brakes. It is advisable that all other personnel leave the
elevator before truck is allowed to enter or leave.
40.) Avoid running over loose objects on the roadway surface.
41.) When negotiating turns, reduce speed to a safe level, and turn steering handwheel in a smooth sweeping
motion. Except when maneuvering at a very low speed, turn the steering handwheel at a moderate, even rate.
42.) Use special care when traveling without load, as the risk of lateral overturning is greater.
43.) Improper use of stabilizer controls (if so equipped) could cause rough terrain forklift truck upset. Always
lower the carriage before operating stabilizer controls.
44.) For rough terrain forklift trucks equipped with lateral leveling:
a.) Always level the frame before raising the boom or mast, with or without a load.
b.) Lateral leveling should not be used to position an elevated load; instead, lower the load and
reposition the rough terrain forklift truck.
45.) Handle only stable or safely arranged loads.
a.) When handling off-center loads which cannot be centered, operate with extra caution.
b.) Handle only loads within the capacity of the rough terrain forklift truck.
c.) Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity
with extra caution. Stability and maneuverability may be adversely affected.

IV
INTRODUCTION TO SAFETY

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

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

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

D.) SUSPENDED LOADS

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

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

Guidelines for “Free Rigging / Suspended Loads”

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

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

3. Only lift the load vertically – NEVER drag it horizontally.

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

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

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

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

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

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

10. DO NOT attempt to use frame-leveling to compensate for load swing.

WARNING
U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in
Construction) include requirements for employers that use powered industrial trucks ("forklifts") configured
to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation
applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a
hook (with or without a winch), or a hook assembly attached to the forks. [Note: This regulation is in
addition to the OSHA regulation that requires specific forklift operator training: §1910.178(l).]

When a forklift / telescopic handler is configured and used for hoisting, the employer must ensure that:

1. Forklift, lift equipment and rigging have been inspected (each shift, month and year) and are in
good, safe condition and properly installed.

2. An operator's manual and applicable load charts are on the forklift.

3. Work zone ground conditions can support the equipment and load. Any hazardous conditions in the
work area have been identified, and the operator notified.

4. Equipment is being used within its rated capacity and in accordance with the manufacturer's
instructions.
VI
5. Operator and crew members have been trained in the safe use and operation of the equipment,
including how to avoid electrocution.

6. During use, no part of the equipment, load line or load will be within the minimum clearance
distance specified by OSHA [10 feet (3.0 m), and more for lines rated over 50 kV] of any energized
power line, and any taglines used are non-conductive.

7. In addition, for lift equipment with a rated capacity greater than 2000 lbs. (907 kg), the employer
must ensure that:

a.) An accessible fire extinguisher is on the forklift;

b.) Monthly and annual inspections are performed and documented, and records retained (three
months for monthly, one year for annual);

c.) Before November 10, 2014, operators must have had the additional training and qualification /
certification required by OSHA regulations §1926.1427 and §1926.1430.

Note: Refer to the full text of the OSHA crane regulation (29 CFR Part 1926, Subpart CC) for a detailed
description

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

CONCLUSION:

1.) ATTEND OPERATOR TRAINING CLASSES

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

2.) CREATE A MAINTENANCE PROGRAM

OSHA recommends a maintenance log, listing repairs requested and completed, for each forklift. Also, “lock
out tag procedures” should be utilized. If the forklift malfunctions; park it safely, remove the key, tag “Do Not
Use”, and report the problem to the proper authority or authorized service personnel immediately.
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

2.) CREATE A MAINTENANCE PROGRAM (cont.)

For the best forklift performance and operation, a maintenance program is required. Use the hour meter on
the instrument panel to keep maintenance properly scheduled (see SECTION TWO - “Servicing Schedule”).
For repairs on major components (engine, transmission, etc.), contact your nearest dealer for a Repair Manual.
Do not operate a forklift that is damaged or does not function properly. Only authorized personnel may make
repairs or adjustments to the lift truck. After repairs, the lift truck must be tested for safe operation before
returning to service.

3.) FORKLIFT KNOWLEDGE

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

4.) WORK SITE KNOWLEDGE

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

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

VIII
SAFETY MESSAGES

NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL

HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Also, observe
the safety messages places throughout this manual; providing special instructions, telling you when to take precautions
and to identify potential hazards. The safety messages are highlighted and outlined in a box similar to those shown in the
examples below.

SAFETY ALERT SYMBOL

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

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

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

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

DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.

CALIFORNIA PROPOSITION 65 WARNING

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

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

IX
INTRODUCTION TO SAFETY

SAFETY DECALS

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

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

801011

Before Starting - 801011

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

Safety Instructions - 420792

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

Instructions for the forklift operator; before operating the forklift.

Use of Seat Belt - 801012

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

Instructs the operator to always wear the seat belt during

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

X
INTRODUCTION TO SAFETY

SAFETY DECALS

Emergency and Parking Brake - 801010

Location: near the park brake lever.

Identifies the Emergency/Parking Brake Lever.

Alarm Must Sound - 496162

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

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

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

Informs: riders are not allowed on the forklift.

Clear of Raised Boom - 801006

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

Keep away from unsupported boom.

Clear of Power Lines - 801007

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

Keep away from power lines.

XI
INTRODUCTION TO SAFETY

SAFETY DECALS

Use of Frame Leveling - 801013

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

Frame leveling notice; load must be lowered.

Attachment and Boom Safety - 801009

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

Important reminders of attachment and boom safety.

Hydraulic Coupling - 234805

Location: near the quick-disconnect adapters.

Stop the engine and release hydraulic pressure before changing

attachments.

Rotating Fan and Belt(s) - 801008

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

Keep hands and clothing away from rotating fan and belts.

XII
INTRODUCTION TO SAFETY

SAFETY DECALS

Gear Shift Pattern - 33460

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

Identifies the gear shift pattern of the forklift transmission.

Steering Mode - 184276

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

Identifies the steering mode selection.

221322

Mineral Oil (Brake Reservoir) - 221322 or 234800 has

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

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

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

234800

XIII
INTRODUCTION TO SAFETY

SAFETY DECALS

Hydraulic Oil - 234798 or 76573

Location: on the hydraulic tank or filler cap.

Identifies the hydraulic reservoir (tank) or filler cap.

Hydraulic Oil - 61024

Location: on the hydraulic tank.

Identifies the hydraulic reservoir (tank).

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

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

Diesel Fuel - 161101

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

Identifies the fuel tank, and use of diesel fuel.

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

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

Do Not Tow - 494918

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

Towing the forklift will damage the transmission;

refer to the operator’s manual.

XIV
INTRODUCTION TO SAFETY

SAFETY DECALS

Attachment Warning - 421016

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

Reminder to operator; install attachment retaining shaft and

safety pin before operations.

Hook Here - 24653

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

Fork Safety - 426641

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

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

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

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

Keep fingers away from the mast

crossbracing.

HAND THROTTLE DANGER - 804784

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

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

Disengage hand throttle before leaving the forklift.

XV
INTRODUCTION TO SAFETY

SAFETY DECALS

Acid in Battery - 801014

Location: in or near the battery
storage compartment.

Addresses battery hazards.

Jump Start Battery - 801015

Location: in or near the battery storage
compartment.

Jump start instructions.

Attachment Plate - 425995

Location: on the optional removeable forklift attachment.

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

Overhead Guard Data Plate - B6109

Location: attached to the overhead guard.

Overhead guard conformity.

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

Important forklift truck identification. Record

this information for use when contacting the
manufacturer for parts and service.

XVI
INTRODUCTION TO SAFETY

1 - OPERATING
AND SAFETY
INSTRUCTIONS

1-1
INTRODUCTION TO SAFETY

1-2
INTRODUCTION TO SAFETY

TABLE OF CONTENTS

INSTRUCTIONS TO THE COMPANY MANAGER 1-4

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

INSTRUCTIONS FOR THE OPERATOR 1-6

PREAMBULE 1-6
GENERAL INSTRUCTIONS 1-6
A - OPERATOR'S MANUAL 1-6
B - AUTHORIZATION FOR USE 1-6
C - MAINTENANCE 1-6
D - MODIFICATION OF THE LIFT TRUCK 1-6
E - LIFTING PEOPLE 1-7
OPERATING INSTRUCTIONS UNLADEN AND LADEN 1-8
A - BEFORE STARTING THE LIFT TRUCK 1-8
B - DRIVER’S OPERATING INSTRUCTIONS 1-8
C - ENVIRONMENT 1-9
D - VISIBILITY 1-9
E - STARTING THE LIFT TRUCK 1 - 10
F - DRIVING THE LIFT TRUCK 1 - 10
G - STOPPING THE LIFT TRUCK 1 - 11
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY 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 - N/A
D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK 1 - 15
E - TAKING UP A LOAD ON THE GROUND 1 - 15
F - TAKING UP AND LAYING A HIGH LOAD ON TIRES 1 - 16

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 - 18

GENERAL INSTRUCTIONS 1 - 18
MAINTENANCE 1 - 18
LUBRICANT AND FUEL LEVELS 1 - 18
HYDRAULIC 1 - 18
ELECTRICITY 1 - 18
WELDING 1 - 19
WASHING THE LIFT TRUCK 1 - 19

IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME 1 - 20

INTRODUCTION 1 - 20
PREPARING THE LIFT TRUCK 1 - 20
PROTECTING THE I.C. ENGINE 1 - 20
PROTECTING THE LIFT TRUCK 1 - 20
BRINGING THE LIFT TRUCK BACK INTO SERVICE 1 - 21

1-3
INTRODUCTION TO SAFETY

INSTRUCTIONS TO THE COMPANY MANAGER

THE OPERATOR

- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment with respect to the use of lift trucks and must be carried permanently by the operator.
On the basis of experience, there are a number of possible situations in which operating the lift truck is unacceptable. Such foreseeable
WARNING
abnormal uses, the main ones being listed below, are strictly forbidden.
- The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any wish to put the machinery to any
On the basisuse.
improper of experience, there are a number of possible situations in which operating the lift truck is prohibited. Such fore-
seeable -abnormal uses, theofmain
The reflex reactions onesinbeing
a person listed
the event of below, are strictly
a malfunction, forbidden.
incident, fault, etc. during operation of the lift truck.
- The foreseeable
- Behaviour abnormal
resulting frombehavior of neglect,
application but not intending
of the "principle to putwhen
of least action" the machinery
performing atotask.
any improper use.
- The reflex reactions of a person in the event of a malfunction, incident, fault, etc. during operation
- For certain machines, the foreseeable behaviour of such persons as : apprentices, teenagers, handicapped of the liftpersons,
truck. trainees
- Behavior resulting from application of the "principle of least action" when performing a task.
tempted to drive a lift truck, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.
- ForThe
certain
personmachines,
in charge ofthetheforeseeable
equipment mustbehavior of such
take these persons
criteria as unauthorized:
into account apprentices,
when assessing whether teenagers,
or not a personhandicapped
will make aper-
sui-
sons and trainees
table driver. tempted to drive a lift truck. Truck drivers tempted to operate a truck to win a bet, in competition or for their
own personal experience.
The person in charge of the equipment must take these criteria into account when assessing whether or not a person will
make a suitable driver.

THE LIFT TRUCK

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

B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS

- In addition to series equipment mounted on your lift truck, many options are available, such as : road lighting, stop lights, fla-
shing light, reverse lights, reverse buzzer alarm, front light, rear light, light at the boom head, etc.
- The operator must take into account the operating conditions to define the lift truck's signalling and lighting equipment. Contact
your dealer.
- Take into account climatic and atmospheric conditions of the site of utilization.
. Protection against frost (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL).
. Adaptation of lubricants (ask your dealer for information).
. I.C. engine filtration (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
For operation under average climatic under
For operation conditions, i.e. : climatic
average between conditions,
-15 °C and +i.e.
35 between
°C, correct-15
levels of lubricants
°C and + 35 °Cin(5°all to
the95°F),
circuits are chec-
correct
ked in production. For operation
levels under more
of lubricants in allsevere climaticare
the circuits conditions,
providedbefore starting up,For
in production. it is necessaryunder
operation to drain
more all severe
the circuits, then
climatic
ensure correct levelsconditions,
IMPORTANT of lubricants using starting
before lubricants up,properly suited to to
it is necessary thedrain
relevant ambient
all the temperatures.
circuits, then add Ittheis correct
the same for the
levels cooling
of lubri-
liquid. cants properly suited to the relevant ambient temperatures. It is the same for the cooling fluid (Contact
your dealer for information, if necessary).

- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are
solutions, consult your dealer.
Your lift truck is designed
Your liftfor outdoor
truck use under
is designed for normal
outdooratmospheric conditions
use under normal and indoor
atmospheric use in suitably
conditions aerated
and indoor useand ventilated
in suitably premises.
aerated and
It is prohibited to use the lift truck
ventilated in areas
premises. It iswhere there is
prohibited toause
riskthe
of fire
lift or which
truck in are potentially
areas explosive
where there (e.g.ofRefineries,
is a risk fuelare
fire or which or gas depots,
potentially
WARNING explosive
stores of inflammable products…). For use in
(i.e. refineries, these
fuel areas,
or gas specific
depots, stores equipment is available
of inflammable (ask your
products…). Fordealer
use inforthese
information).
areas, specific equip-
ment is available (ask your dealer for information).

C - MODIFICATION OF THE LIFT TRUCK

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

1-4
INTRODUCTION TO SAFETY

THE INSTRUCTIONS

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

THE MAINTENANCE

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

1-5
INTRODUCTION TO SAFETY

INSTRUCTIONS FOR THE OPERATOR

PREAMBLE

The risk of accident while operating, servicing or repairing your lift truck can be reduced if you follow the safety ins-
DANGER tructions and safety measures detailed in this manual. Failure to respect the safety and operating instructions, or the
The risk of accidentinstructions
while using,forservicing
repairingororrepairing
servicingyour
yourliftlifttruck
truckcan
canbelead
restricted if you
to serious follow
injury the safety
or fatal instructions and safety mea-
accident.
sures detailed in these instruction.
- Only the operations and maneuvers described in this operator's manual must be performed. The manufacturer cannot predict all
possible risky situations. Consequently, the safety instructions given in the operator's manual and on the lift truck itself are not
all inclusive.
- At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself
when you use it.

GENERAL INSTRUCTIONS

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

B - AUTHORIZATION FOR USE

- Only qualified, authorized personnel may 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 the 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 notices.
- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He
must keep the lift truck properly cleaned if this is among his responsibilities.
- The operator must carry out daily maintenance (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).
- The operator must ensure tires are adapted to the nature of the ground (see area of the contact surface of the tires in the chap-
ter : 2 - DESCRIPTION : CHARACTERISTICS). There are optional solutions, consult your dealer.
. SAND tires.
. LAND tires.
. Snow chains.
Do not use the lift truck if the tires are incorrectly inflated, damaged or excessively worn, because this could put your own safety or that
Do not operate the lift truck if the tires are incorrectly inflated, damaged or excessively worn, Bad tires can put your
of others at risk, or cause damage to the lift truck itself. The fitting of foam inflated tires is prohibited and is not guaranteed by the manu-
DANGER safety or that of others at risk, or cause damage to the lift truck. The installation of foam inflated tires is prohibited and
facturer, excepting prior authorization.
is not guaranteed by the manufacturer (prior authorization is required).

D - MODIFICATION OF THE LIFT TRUCK

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

1-6
INTRODUCTION TO SAFETY

E - LIFTING PEOPLE
- The use of working equipment and load lifting attachments to lift people
is strictly forbidden.

1-7
INTRODUCTION TO SAFETY

OPERATING INSTRUCTIONS UNLADEN AND LADEN

A - BEFORE STARTING THE LIFT TRUCK

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

B - DRIVER’S OPERATING INSTRUCTIONS

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

CAUTION
Under Undermust
no circumstances no circumstances should the
the seat be adjusted seat
while thebe
liftadjusted while the lift truck is moving.
truck is moving.

- The operator must always be in his normal position in the driver’s cab. It is prohibited to have arms or legs, or generally any part
of the body, protruding from the driver’s cab of the lift truck.
- The safety belt must be worn and adjusted to the operator's size.
- The control levers must never be used for any other than their intended purposes (e.g. climbing onto or down from the lift truck,
etc.).
- If the control components are fitted with a forced operation (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
INTRODUCTION TO SAFETY

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

• Moving without load : Forks or attachment facing downhill.

• Moving with load : Forks or attachment facing uphill.

- Take into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passageway.
- Never move onto a loading platform without having first checked :
• That it is suitably positioned and made fast.
• That the unit to which it is connected (wagon, truck, etc.) will not shift.
• That this platform is prescribed for the total weight of the lift truck to be loaded.
• That this platform is prescribed for the size of the lift truck.
- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the lift
truck to be loaded and without having checked that they are in sound working order.
- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.
- Make sure the ground is stable and firm under the wheels and/or stabilizers before lifting or removing the load. If necessary, add
sufficient wedging under the stabilizers.
- Make sure that the scaffolding, loading platform, pilings or ground is capable of bearing the load.
- Never stack loads on uneven ground, they may tip over.
If the loadmust
If the load or the attachment or theremain
attachment
above must remainfor
a structure above a structure
a long forisathe
time, there period
riskofthat
time, there
it will restis on
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
betweenthethedistance
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 the working area of the lift truck and
the aerial line.
You must consult your
You local
mustelectrical agency.
consult your local You could agency.
electrical be electrocuted or be
You could seriously injuredorif seriously
electrocuted you operate or park
injured theoperate
if you lift truck
or too
parkclose
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
- Maintain permanently good visibility throughout the route. In reverse, either look directly behind you or use the panoramic rear-
view mirrors. In any case, avoid reversing over long distances.
- Visibility may be reduced on the right-hand side when the boom is raised, so before lifting the boom make sure that the move-
ment can be made in complete safety.
- If the visibility in forward motion is not sufficient because of the bulkiness of the load, drive in reverse motion. This maneuver
must remain exceptional and for short distances.
- Ensure you have good visibility (clean windows, adequate lighting, correctly adjusted rear view mirrors, etc.).
- If visibility of your road is inadequate, ask someone to help, standing outside the area in which the truck will be moving, and
make sure you always have a good view of this person.

1-9
INTRODUCTION TO SAFETY

E - STARTING THE LIFT TRUCK

SAFETY NOTICE
The lift truck must only be started
The lift up orbe
truck must manoeuvred
started orwhen the operator
maneuvered onlyis when
sittingthe
in the driver’siscab,
operator withinhis
sitting seat
the belt adjusted
driver’s cab, hisand fas-
seat
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 emergency, the transmission must be placed in the neutral position (see : 3 - MAINTENANCE : G
- OCCASIONAL MAINTENANCE).
- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when 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.
- Make sure the signal lights on the instrument control panel and fuel level indicators are working properly (see : 2 - DESCRIP-
TION : INSTRUMENTS AND CONTROLS).
- 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.
- 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, stop the I.C. engine and immediately carry out the necessary operations.

F - DRIVING THE LIFT TRUCK

SAFETY NOTICE
Operators' attentionOperators'
is drawn toattention is involved
the risks drawn tointhe risksthe
using involved in using
lift truck, the lift truck,
in particular : in particular :
- Risk of losing control.
- Risk of losing control.
DANGER
- Risk of losing lateral- Risk of losing
and frontal lateral ofand
stability thefrontal stability
lift truck. The of the liftmust
operator truck.remain in control of the lift truck.
In the event of the The operator
lift truck must remain
overturning, do notin try
control of the
to leave theliftcabin
truck. In the
during theevent of theYOUR
incident. lift truck
BESToverturning,
PROTECTION do IS
notTOtrySTAY
to leave the
FASTE-
NED IN THE CABIN.cab during the incident. YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB.

- Observe the company’s traffic regulations or, by default, the public highway code.
- Do not carry out operations which exceed the capacities of your lift truck or attachments.
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 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 palettes, cases, etc, are in good order and suitable for the load 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 truck with the boom in the raised position unless under exceptional circumstances and then with extre-
me caution, at very low speed and using gentle braking. Ensure that visibility is adequate.
- Take bends slowly.
- In all circumstances make sure you are in control of your speed.
- On damp, slippery or uneven terrain, drive slowly.
- Brake gently, never abruptly.
- Only use the lift truck’s forward/reverse lever from a stationary position and never do so abruptly.
- Do not drive with your foot on the brake pedal.
- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, so turn it gently and
not 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.

1 - 10
INTRODUCTION TO SAFETY

- 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 two lift trucks simultaneously to handle heavy or bulky loads, since this operation requires particular pre-
cautions to be taken. It must only be used exceptionally and after risk analysis.
- The ignition switch has an emergency stop mechanism in case of an operating anomaly occurring in the case of lift trucks not
fitted with a punch-operated cut-out.

INSTRUCTIONS
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 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).
- Select the steering mode appropriate for its use and/or working conditions (see : 2 - DESCRIPTION : INSTRUMENTS AND
CONTROLS) (as model of lift truck).
- Release the parking brake.
- Shift the forward/reverse 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 is stationary, or if the operator has to leave his cab (even for a moment), place the forks or attachment on
the ground, apply the parking brake and put the forward/reverse lever in neutral.
- Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at 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, particularly from frost (check the level of anti-
freeze), close and lock all the lift truck accesses (doors, windows, cowls…).

INSTRUCTIONS
- Park the lift truck on flat ground or on an incline lower than 15 %.
- Place the forward/reverse lever in neutral.
- Apply the parking brake.
- For lift trucks with 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 with a grab or jaws, or a bucket with hydraulic opening, close the attachment fully.
- Before stopping the lift truck after a long working period, allow the I.C. engine to idle for a few moments, to allow the coolant
liquid and oil to lower the temperature of the I.C. engine and transmission. Do not forget this precaution, in the event of frequent
stops or warm stalling of the I.C. engine, otherwise the temperature of certain parts will rise significantly due to the stopping of
the cooling system, with the risk of badly damaging such parts.
- Stop the I.C. engine with the ignition switch.
- Remove the ignition key.
- Lock all the accesses to the lift truck (doors, windows, cowls…).

1 - 11
INTRODUCTION TO SAFETY

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.

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.
- Switch off the working headlights if the lift truck is fitted with them.
- Select the steering mode "HIGHWAY TRAFFIC" (as model of lift truck) (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).
- Retract entirely the boom and put the attachment at 12 in. from the ground.
- Place the stabilizers in the central position, i.e. the transverse shaft of the axles parallel to the chassis (as model of lift truck).
- Lift up the stabilizers to the maximum and turn the blocks inwards (as model of lift truck).
- For lift trucks with gearboxes :
On the road, set off in 3rd gear and go into 4th (as 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.
Do (gear
Never move in neutral not allow the lift
reverser trucklever
or gear to coast in neutral
in neutral (using either
or transmission the forward/reverse
cut-off button pressed) lever, gear shift
to preserve lever
the lift or transmission
truck engine brake.
DANGER
Failure cut-off
to respect this button). on
instruction Coasting
a slopeonwill
a slope willexcessive
lead to lead to excessive speed
speed which maywhich
makemaythemake the lift
lift truck truck uncontrollable
uncontrollable (steering,
(steering, brakes)
and may cause severebrakes) and maydamage.
mechanical cause serious mechanical damage.

1 - 12
INTRODUCTION TO SAFETY

DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT

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

OPERATING THE LIFT TRUCK WITH A TRAILER

- For using a trailer, observe the regulations in force in your country (maximum travel speed, braking, maximum weight of trailer,
etc.).
- Do not forget to connect the trailer’s electrical equipment to that of the lift truck.
- The trailer's braking system must comply with current legislation.
- If pulling a trailer with assisted braking, the lift truck must be equipped with a trailer braking mechanism. In this case, do not for-
get to connect the trailer braking equipment to the lift truck.
- The maximum vertical pull on the trailer hook must not exceed 3372 ft/lbs.
- The authorized maximum train weight must not exceed the maximum weight authorized by the manufacturer (consult the manu-
facturer’s plate on your lift truck).
- For lift trucks with gearboxes :
When driving with a trailer, set off in 2nd gear and go into 3rd when the conditions and state of the road allow. Do not exceed
4th gear to avoid overheating the internal combustion engine and the transmission.

IF NECESSARY, CONSULT YOUR DEALER.

1 - 13
INTRODUCTION TO SAFETY

INSTRUCTIONS FOR HANDLING A LOAD

A - CHOICE OF ATTACHMENTS
- Only attachments approved by MANITOU can be used on its lift trucks.
- Make sure the attachment is appropriate for the work to be done (see : 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE).
- 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 your dealer.

B - MASS OF LOAD AND CENTER OF GRAVITY

- Before taking up a load, you must know its mass and its center of gravity.
B1
- The load chart for your lift truck is valid for a load in which 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, contact your dealer.
- For irregular loads, determine the transverse center of gravity before any movement (fig.
B2) and set it in the longitudinal axis of the lift truck. 24 in.
500 mm

It is forbidden to move a load heavier than the effective capacity defined on the lift truck load
chart.
CAUTION
Do not attempt to move a load heavier than the effective capacity defined on the lift truck load
chart.

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
For loads
to limitwith a variations
these moving center
as far of
as gravity
possible.(i.e., liquids), take into account the variations B2
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 - N/A
- This device gives an indication of the lift truck's longitudinal stability. Move the boom very
carefully when approaching the authorized load limit (see : 2 - DESCRIPTION : INSTRU- C
MENTS AND CONTROLS).
- Always watch this device during handling operations.
- When the device is in alert mode, it is forbidden to perform so-called "AGGRAVATING"
1
movements, these being : 2
A - Extending the boom.
3
B - Lowering the boom.
- Perform movements to relieve aggravation in the following order (fig. C) : if necessary,
raise the boom (1), retract the boom as far as possible (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
INTRODUCTION TO SAFETY

D - TRANSVERSE (LEVEL) ATTITUDE OF THE LIFT TRUCK D1

(depending on the model of lift truck)

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

1 - LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TIRES

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

2 - LIFT TRUCK WITH SLOPE CORRECTOR USED ON TIRES

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

3 - LIFT TRUCK USED ON STABILIZERS

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

E - TAKING UP A LOAD ON THE GROUND E1

- Direct the lift truck perpendicular 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, 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 necessary, slightly lift the boom (2) while taking up the load.
- Bring the load into the transport position.
- Tilt the load far enough backwards to ensure stability (loss of load on braking or going E2
downhill).

FOR A NON-PALLETIZED LOAD

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

E3 E4

1
2
2

3 1

1 - 15
INTRODUCTION TO SAFETY

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 FOR HANDLING A LOAD : D - TRANSVERSE ATTITUDE OF THE LIFT
TRUCK).
Do not raise the boom until you have first checked the level attitude of the lift truck (see : INS-
2
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 : OPERATIONS INSTRUCTIONS UNLADEN AND LADEN : D - VISIBILITY). 3

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.
- 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
- Stop the forks 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
1
reverse gear to neutral.
- 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.
- Watch the load, if it is overloaded, replace the load in the place from which it was taken.
2
- 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).
- If this is not possible, back up the lift truck (1), maneuvering very gently and carefully to
release the load. Retract (2) and lower the boom (3) to bring the load into the transport
position (fig. F5).
F3
2

F4
1

F5

1 - 16
INTRODUCTION TO SAFETY

LAYING A HIGH LOAD ON TIRES F6

- Direct the load in the transport position in front of the pile (fig. F6).
- Put the handbrake on and set the reversing lever to neutral.
- Lift and extend the boom (1) (2) until the load is above the pile, while keeping an eye on
the load. If necessary, move the lift truck (3) forward (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).
- If possible, release the fork by alternately retracting and raising the boom (1) (fig. F9).
Then set the forks into transport position.
- If this is not possible, reverse the lift truck (1) very slowly and carefully to release the
forks (fig. F10). Then set them into transport position.

F7

F8

F9

F10

1 - 17
INTRODUCTION TO SAFETY

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

GENERAL INSTRUCTIONS

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

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

LUBRICANT AND FUEL LEVELS

- Use the recommended lubricants (never use contaminated lubricants).

- Do not fill the fuel tank when the I.C. engine is running.
- Only fill up the fuel tank in areas specified for this purpose.
- Do not fill the fuel tank to the maximum level.
- Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.

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

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

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

1 - 18
INTRODUCTION TO SAFETY

WELDING
- Disconnect the battery before any welding operations on the lift truck.
- When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being
welded, so as to avoid high tension current passing through the alternator.
- Never carry out welding or work which gives off heat on an assembled 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 irre-
parable damage to electronic components.

WASHING THE LIFT TRUCK

- Clean the lift truck or at least the area concerned before any intervention.
- Remember to close and lock all accesses to the lift truck (doors, windows, cowls…).
- During washing, avoid the articulations and electrical components and connections.
- If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged, parti-
cularly electrical components and connections and the injection pump.
- Clean the lift truck of any fuel, oil or grease trace.

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

1 - 19
INTRODUCTION TO SAFETY

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

INTRODUCTION
The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an
extended period.
For these operations, we recommend the use of protective products.
Instructions for using the products 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.

PREPARING THE LIFT TRUCK

- Clean the lift truck thoroughly.

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

PROTECTING THE I.C. ENGINE

- Fill the tank with fuel (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).
- Empty and replace the cooling liquid (see : 3 - MAINTENANCE : F - EVERY 2000 HOURS SERVICE).
- Leave the I.C. engine running at idle speed for a few minutes, then switch off.
- Replace the I.C. engine oil and oil filter (see : 3 - MAINTENANCE : D - EVERY 500 HOURS SERVICE).
- Add 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 spray time is noted on the product packaging and must be increased by 50 % for turbo engines.
- Open the filler plug, spray a protective product around the rocker 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.

PROTECTING THE LIFT 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 outdoors, cover it with a waterproof tarpaulin.

1 - 20
INTRODUCTION TO SAFETY

BRINGING THE LIFT TRUCK BACK INTO SERVICE

- 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 (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).
- Put the handbrake on and remove the axle stands.
- Empty and replace the fuel and replace the fuel filter (see : 3 - MAINTENANCE : D - EVERY 500 HOURS SERVICE).
- Install and set the tension in the drive belts (see : 3 - MAINTENANCE : C - EVERY 250 HOURS SERVICE).
- Turn the I.C. engine using the starter, to allow the oil pressure to rise.
- Reconnect the engine cut-off solenoid.
- Lubricate the lift truck completely (see : 3 - MAINTENANCE : SERVICING SCHEDULE).

WARNING
Make sure the areaInsure the areaventilated
is adequately is adequately ventilated
before starting before
up the starting the lift truck.
lift truck.

- Start up the lift truck, following the safety instructions and regulations (see : OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Run all the boom's hydraulic movements, concentrating on the ends of travel for each cylinder.

1 - 21
INTRODUCTION TO SAFETY

1 - 22
INTRODUCTION TO SAFETY

2 - DESCRIPTION

2-1
INTRODUCTION TO SAFETY

2-2
INTRODUCTION TO SAFETY

TABLE OF CONTENTS

IDENTIFICATION OF THE LIFT TRUCK 2-4

CHARACTERISTICS 2-6

DIMENSIONS AND LOAD CHART 2 - 10

INSTRUMENTS AND CONTROLS 2 - 12

TOWING PIN AND HOOK 2 - 28

DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 2 - 32

2-3
INTRODUCTION TO SAFETY

IDENTIFICATION OF THE LIFT TRUCK

As our policy is to promote a constant improvement of our products, our range of telesco-
pic lift trucks may undergo certain modifications, without prior notice.

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

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

A
PLATE MANUFACTURER OF THE LIFT TRUCK (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.

I.C. ENGINE (FIG. B)

B
- I.C. engine No

TRANSMISSION (FIG. C)
- Type
- MANITOU reference
- Serial No

FRONT AXLE (FIG. D)

C
- Type
- Serial No
- MANITOU reference

2-4
INTRODUCTION TO SAFETY

REAR AXLE (FIG. E) E

- Type
- Serial No
- MANITOU reference

CAB (FIG. F)
- Type
- Serial No

F
BOOM (FIG. G)
- MANITOU reference
- Date of manufacture

PLATE MANUFACTURER OF THE ATTACHMENT (FIG. H)

- Model
- Serial No
- Year of manufacture

2-5
INTRODUCTION TO SAFETY

CHARACTERISTICS

I.C. ENGINE

- Type
MLT 627 Turbo COMPACT MONO-ULTRA Series B-E2 PERKINS 1104C-44T RE38173

1104C-44T
- Number of cylinders 4 in line
- Number of strokes 4
- Suction Turbocharged
- 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 (0.018 in)
- Capacity 4400 cm3 (268.5 in2)
- Bore 105 mm (4.1 in)
- Stroke 127 mm (5.0 in)
- Compression ratio 17,5/1
- Nominal rating loaded 2200 rpm
- Rating slow unladen 850 ± 10 rpm
- Max. rating unladen 2355 rpm
- Power ISO/TR 14396 101 cv/74,5 kw
- Maximum torque ISO/TR 14396 412 Nm to 1400 rpm (303.9 ft/lb)
- Air cleaner Dry 3 µ

COOLING CIRCUIT

- Type By water
- Fan Puller
. Number of blades 10
. Diameter 508 mm (19.9 in)
- Thermostat
. Start opening 174 °F/183 °F
. Full opening 199°F

TRANSMISSION
- Type TURNER POWERTRAIN SYSTEMS
- Torque converter SACHS
- Gear box
. Number of forward speeds 4
. Number of reverse speeds 4
- Gear reverser Electro-hydraulic

FRONT AXLE

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

2-6
INTRODUCTION TO SAFETY

REAR AXLE

- Type DANA
- Hub reducers Epicyclic

BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front and rear wheels.
. Type Multidisc brake immersed in oil.
- Parking brake Mechanical hand lever applied on the front wheels.
. Type Multidisc brake immersed in oil.

ELECTRIC CIRCUIT

- 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 Denso E95RL

2-7
INTRODUCTION TO SAFETY

CHARACTERISTICS MLT 627 Turbo (20”) COMPACT MONO-ULTRA

Series B-E2

FRONT AND REAR TIRES

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

DIMENSIONS PRESSURE TIRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
400/70-20 T37 150B 14PR FRONT UNLADEN 6803 LB KG/CM2 KG/CM2 CM2 CM2
2,75 BAR FRONT LADEN 18712 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS
(40 PSI) REAR UNLADEN 7533 LB KG/CM2 KG/CM2 CM2 CM2
DUNLOP REAR LADEN 2429 LB KG/CM2 KG/CM2 CM2 CM2
425/75R20 XM27 167A2/155B FRONT UNLADEN 6803 LB KG/CM2 KG/CM2 CM2 CM2
2,6 BAR FRONT LADEN 18712 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS
(38 PSI) REAR UNLADEN 7533 LB KG/CM2 KG/CM2 CM2 CM2
MICHELIN REAR LADEN 2429 LB KG/CM2 KG/CM2 CM2 CM2
400/70R20 XM37 153A8/150B FRONT UNLADEN 6803 LB KG/CM2 KG/CM2 CM2 CM2
2,1 BAR FRONT LADEN 18712 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS
(31 PSI) REAR UNLADEN 7533 LB KG/CM2 KG/CM2 CM2 CM2
MICHELIN REAR LADEN 2429 LB KG/CM2 KG/CM2 CM2 CM2
405/70R20 XM27 155A2/143B FRONT UNLADEN 6803 LB KG/CM2 KG/CM2 CM2 CM2
3,6 BAR FRONT LADEN 18712 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS (52 PSI) REAR UNLADEN 7533 LB KG/CM2 KG/CM2 CM2 CM2
MICHELIN REAR LADEN 2429 LB KG/CM2 KG/CM2 CM2 CM2
15R22,5 XF FRONT UNLADEN 6803 LB KG/CM2 KG/CM2 CM2 CM2
3,4 BAR FRONT LADEN 18712 LB KG/CM2 KG/CM2 CM2 CM2
TUBELESS (49 PSI) REAR UNLADEN 7533 LB KG/CM2 KG/CM2 CM2 CM2
MICHELIN REAR LADEN 2429 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 at the factory. Any
substitutes or modifications must first be
approved by the manufacturer.

2-8
INTRODUCTION TO SAFETY

HYDRAULIC CIRCUIT

- Type of pump Gear pump with flow divider

. Capacity 41 cm3 (2.5 in3)
. Max. rating capacity unladen 97 L/mn (25.6 gal/min)
. Flow rate at 2300 rpm 94 L/mn (24.8 gal/min)
. Flow rate at 1600 rpm 66 L/mn (17.4 gal/min)
- Pressure
. Lifting, tilting, telescoping, attachment circuit 260 Bar (3770 psi)
. Steering circuit 140 Bar (2030 psi)
- Filtration
. Return 10 µ
. Suction 125 µ

SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA 79 dB
(accordng to standard prEN 12053 : 1995)

- Level of sound power in the LwA environment 106 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 29 km/h (18 mph)
. Reverse unladen 29 km/h (18 mph)

- Standard lift height 5500 mm (216.5 in)

- Rated capacity with standard attachment 2700 kg (5952 lb)

- Load center 24 in.

- Weight of forks (each) 72 kg (160 lb)

- Lifting motions (boom retracted)

. Unladen lifting 6,8 s 33,9 m/mn (111 ft/min)
. Laden lifting 7,1 s 32,5 m/mn (107 ft/min)
. Unladen lowering 4,8 s 48,0 m/mn (157 ft/min)
. Laden lowering 4,7 s 49,0 m/mn (160 ft/min)

- Telescoping motions (lifting boom)

. Unladen extending 4,5 s 24,0 m/mn (79 ft/min)
. Laden extending 4,6 s 23,4 m/mn (77 ft/min)
. Unladen retracting 2,2 s 48,0 m/mn (157 ft/min)
. Laden retracting 2,2 s 48,0 m/mn (157 ft/min)

- Reverse tilt time unladen 3,3 s 46,7 °/s

- Forward tilt time unladen 2,7 s 57,1 °/s

- Lift truck weight with standard attachment

. Unladen 5935 kg (13084 lb)
. Rated load 8635 kg (19037 lb)

- Axle weight with attached equipment (transport position)

. Front unladen 2795 kg (6162 lb)
rated load 7670 kg (16909 lb)
. Rear unladen 3140 kg (6923 lb)
rated load 965 kg (2127 lb)

- Tensible strain at coupling hook

. Unladen 4700 daN (10566 ft/lb)
. Rated load 7100 daN (15961 ft/lb)

- Break out force with bucket 4260 daN (9576 ft/lb)

(according to standard iso 8313)

2-9
INTRODUCTION TO SAFETY

DIMENSIONS AND LOAD CHART MLT 627 Turbo (20”) COMPACT MONO-ULTRA
Series B-E2

A 1200 mm (47.2 in)

B 2520 mm (99.1 in)
C 1307 mm (51.5 in)
C1 1260 mm (49.6 in)
D 4687 mm (184.5 in)
D1 4640 mm (182.7 in)
D2 3870 mm (152.4 in)
E 5887 mm (231.8 in)
F 1600 mm (63.0 in)
F1 1600 mm (63.0 in)
G 400 mm (15.7 in)
G1 365 mm (14.4 in)
G2 365 mm (14.4 in)
I 860 mm (33.9 in)
J 866 mm (34.1 in)
K 1260 mm (49.6 in)
L 45 mm (1.8 in)
N 1455 mm (57.3 in)
O 125 mm (4.9 in)
P2 41 °
P3 39 °
R 3250 mm (128.0 in)
S 7352 mm (289.4 in)
T 3280 mm (129.1 in)
U1 2060 mm (81.1 in)
U2 2320 mm (91.3 in)
V 4680 mm (184.3 in)
V1 1400 mm (55.1 in)
V2 3585 mm (141.1 in)
W 2010 mm (79.1 in)
Y 11,8 °
Z 142,3 °
2 - 10
INTRODUCTION TO SAFETY

2 - 11
INTRODUCTION TO SAFETY

INSTRUMENTS AND CONTROLS

3 24 24

25

25 5

6
17 21

20
27
7
26

35

8
36
1 25

11

MLT 627 . . . MONO-ULTRA Series B-E2

19 9
18 22
1
16

10

22

23

11

14
25
12

15
13

29

30

28
34

2 - 12
INTRODUCTION TO SAFETY

DESCRIPTION
1 - DRIVER'S SEAT
2 - SAFETY BELT
3 - CONTROL AND SIGNAL LIGHTS PANEL
4 - N/A - OMITTED
5 - SWITCHES PANEL
6 - LIGHT SWITCH, HORN AND INDICATOR SWITCH
7 - IGNITION SWITCH
8 - BRAKING OIL TANK AND WINDSCREEN WASHER ACCESS PANEL
9 - BRAKING OIL TANK
10 - WINDSCREEN WASHER TANK
11 - FUSES AND RELAY ACCESS PANEL
12 - FUSE AND RELAY
13 - ROOF LIGHT
14 - ACCELERATOR PEDAL
15 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
16 - GEAR LEVER AND TRANSMISSION CUT-OFF
17 - FORWARD/REVERSE LEVER
18 - PARKING BRAKE LEVER
19 - STEERING SELECTION
20 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF
21 - LOAD CHARTS FILE
22 - HEATER CONTROL
22 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
23 - CAB FILTER VENTILATORS
24 - WINDSCREEN DEMIST VENTS
25 - HEATING VENTS
26 - DOOR LOCK
27 - LOCKING HANDLE FOR UPPER HALF DOOR
28 - RELEASING BUTTON FOR UPPER HALF DOOR
29 - HANDLE FOR REAR WINDOW OPENING
30 - DOCUMENT HOLDER
31 - FRONT LIGHTS (NOT ILLUSTRATED)
32 - REAR LIGHTS (NOT ILLUSTRATED)
33 - FLASHING LIGHT (NOT ILLUSTRATED)
34 - SPIRIT LEVEL
35 - STEERING WHEEL REGULATING HANDLE
36 - ARM-REST

NOTE : All the terms such as : RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver's seat and facing forward.

2 - 13
INTRODUCTION TO SAFETY

1 - DRIVER'S SEAT A

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

WEIGHT ADJUSTMENT (FIG. A)

It is advised that the weight be adjusted when the driver is not sitting in the cab.
- Refer to graduation 1 of the seat.
- Turn handle 2 according to the driver’s weight.
2 1
NOTE : To 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 (FIG. B)

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

2 - 14
INTRODUCTION TO SAFETY

SEAT DEPTH ADJUSTMENT (FIG. D) D

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

EXTENDING THE HEAD-REST (FIG. E)

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

LUMBAR ADJUSTMENT (FIG. F)

This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.

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

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

If you do not support the back-rest

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

LONGITUDINAL ADJUSTMENT (FIG. H)

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

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

ACAUTION
rocking head-restA increases
rocking head-rest increases
the risk of the risk
an accident ! of an accident! F

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

2 - SAFETY BELT

- Sit correctly on the seat.

- Check that seat belt is not twisted.
- Place the seat belt at hip level.
- Attach the seat belt and check that it locks. G
- Adjust the seat belt to your body shape without squeezing your hip and without over-slack.
Do not
In no event should the operate
lift truck be the
usedliftif truck withbelt
the seat a defective seat(fixing,
is defective belt (fixing, locking,
locking, cuts,
cuts, tears,
WARNING tears,the
etc.). Repair or replace etc.).
seatRepair or replace the seat belt immediately.
belt immediately.

H I

2 - 15
INTRODUCTION TO SAFETY

3 - CONTROL AND SIGNAL LIGHTS PANEL

B1 B2 B3 B4 C1

CONTROL INSTRUMENTS

A - HOURMETER AND REV COUNTER

B
B - I.C. ENGINE WATER TEMPERATURE
Temperature zone B1 - Blue zone (32°F - 122°F)
B2 - Green zone (122°F - 212°F)
B3 - Black/red zone (212°F - 221°F) A
C
B4 - Red zone (221°F - 248°F)
NOTE : Red indicator light “J” comes on between zone B3 and B4.

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

SIGNAL LIGHTS
H I J K
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. If one of the red lamps or the buz-
zer does not function, carry out the necessary repairs. L M N O

D - RED TRANSMISSION OIL PRESSURE LAMP

The lamp and the buzzer come on when the pressure in the transmission, when driving for-
ward, is abnormally low. Park the lift truck and look for the cause (insufficient transmission
oil level, internal leak in the transmission, etc.).
NOTE : The signal light operates in forward travel conditions only, the signal should not be
taken into account when the I.C. engine is running at idle or is stopped.

E - RED TRANSMISSION OIL TEMPERATURE LAMP

The lamp and the buzzer come on when the converter oil temperature is abnormally high. Park the lift truck and look for the cause
of this overheating.

F - RED BRAKING OIL LEVEL LAMP

If the lamp and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately and check the braking oil level.
In the event of an abnormal dropping of the level, consult your dealer.

G - RED PARKING BRAKE LAMP

This lamp comes on when the parking brake is applied.

H - RED ALTERNATOR CHARGE LAMP

If the lamps E - F - H - I - J - K and the buzzer 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 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 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.

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 lift truck
and carry out the necessary repairs (see cleaning and replacement requirements in chapter : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS).

2 - 16
INTRODUCTION TO SAFETY

L - GREEN 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. 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 control test is automatically carried out.
- Correct operation : All leds and the sound alarm function continuously for 2 seconds.
- Faulty operation : All leds and sound alarm function intermittently (stop the lift truck and consult your dealer, never attempt a
repair yourself).

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

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,
A4
move carefully. C
A3
A3 - 1 red led : The lift truck is very near at the limit of longitudinal stability. The
alarm sounds simultaneously with a slow intermittent sound. A2
B1
Move very carefully. A2
B
A4 - 1 red led : The lift truck is at the authorized limit of longitudinal stability. The A1
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

B - SOUND ALARM SWITCH (FIG. A)

Used to switch off the sound alarm when using the lift truck with loading and earth moving
buckets. When it is switched off, the red led B1 indicates that the sound alarm has been
cut off and only the visual alarm is working. Under other operating conditions, the sound B
alarm must be switched on.

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 sound alarm function continuously.
- Faulty operation : All leds and the sound alarm function intermittently (stop the lift truck
and consult your dealer, never attempt a repair yourself).

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 - 17
INTRODUCTION TO SAFETY

5 - SWITCHES PANEL
A B G H C I
The location of the switches may vary depending on the options.

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

B - FLASHING LIGHT

C - REAR FOG LIGHT

D E F J

D - FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER

This switch, when set on on the "intermediate" position, the windscreen wiper to be ope-
rated and the "down" position and simultaneously pressed, the windscreen-washer to be operated.

E - REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER

NOTE : The rear windscreen wiper is operated with this switch only ; to do so, the switch
located on the rear windscreen wiper motor must remain in Position 1. 0
E1
I

F - TRANSMISSION CUT-OFF
The switch selects transmission cut-off to the service brake pedal or the hydraulic controls B
lever.
Position A : Indicator light on, transmission cut-off to service brake pedal effec-
ted.
Position B : Indicator light off, transmission cut-off to hydraulic control lever effec-
ted. A

NOTE : In all cases transmission cut-off can be effected using the gear lever.

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.
• For inching and continuous stopping and starting (delicate handling). In order to optimize
hydraulic movements, cut off transmission to the hydraulic controls lever.

N°238780
• Starting up on a slope.

G - OPTION WORKING HEAD LIGHT

H - OPTION WORKING TAIL LIGHT

I - OPTION
- OPTION Boom head light.
- OPTION Blue front working light.

J - OPTION REAR WINDOW DEFROSTING

K - OPTION
- OPTION Electrovalve on boom head.
- OPTION Electrical boom provision.
- OPTION Electrovalve on boom head + attachment hydraulic locking device.
See : 2 - DESCRIPTION : DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS. K L M

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

M - OPTION

2 - 18
INTRODUCTION TO SAFETY

6 - LIGHT SWITCH, HORN AND INDICATOR SWITCH

The switch controls the visual and sound alarms.

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

Pressing the switch sounds the horn.

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

7 - IGNITION SWITCH

The key switch has five positions :

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

8 - BRAKING OIL TANK AND WINDSCREEN WASHER ACCESS PANEL

- Loosen screw 1 and lift up the brake fluid and windscreen washer access panel.

9 - BRAKING OIL TANK

See : 3 - MAINTENANCE : B - EVERY 50 HOURS SERVICE. 9

10 - WINDSCREEN WASHER TANK

10
See : 3 - MAINTENANCE : B - EVERY 50 HOURS SERVICE.

2 - 19
INTRODUCTION TO SAFETY

11 - FUSE AND RELAY ACCESS PANEL

- Lift up the fuse and relay access panel 11.

11

12 - FUSE AND RELAY F32 F31

DIST.
LSU
3A 20A
A decal on the inside of the access panel gives a clear display of the use of the K0 K1

components described below. OPT. OPT.

K2 K3 K4
K0 - OPTION Air conditioning.
K1 - Relay cutting transmission to hydraulic controls.
K2 - Transmission cut-off relay. K5 K6
K3 - Reverse gear relay.
OPT.
K4 - Forward gear relay.
K5 - Buzzer. K7 K8 K9
K6 - OPTION Electrovalve on boom head.
- OPTION Electrical boom provision. OPT.
- OPTION Electrovalve on boom head + attachment hydraulic locking devi- F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15
ce. OPT.
OPT. STOP

OPT.
OPT. OPT.
OPT. OPT.
K7 - OPTION Hydraulic movements cut-off. N°243543
10A max. 15A 7.5A 10A 7.5A 5A 10A 15A 5A 15A 15A max. 10A 30A 25A max. 25A max.

K8 - Safety system starting switch relay. F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
OPT.
K9 - Flashing unit. OPT.
OPT.
OPT. OPT. OPT.

K10 - OPTION. 10A max. 15A max. 15A 15A max. 10A max. 10A 15A max. 7.5A 7.5A 7.5A 7.5A 15A 15A 15A 25A

K16 - Preheating I.C. engine relay.

K17 - Control panel lighting relay.
K18 - OPTION Diesel decongealant.

NOTE : Replace a usedNOTE

fuse: with
Replace a used
a new fuse
fuse of thewith
samea new fuseand
quality of capacity.
the sameNever
qualityreuse
and
IMPORTANT
a repaired fuse. capacity. Never reuse a repaired fuse.
K10

F1 - (10A MAX.) - Electric controls of hydraulic movements (7,5A). F31

F2 - (15A MAX.) - OPTION Working tail light (10A).
F3 - (10A MAX.) - Rear windscreen wiper (7,5A).
- OPTION Roof windscreen wiper (7,5A).
F4 - (10A MAX.) - Stop I.C. engine electrovalve (7,5A).
F5 - (10A MAX.) - Flashing light (7,5A).
F6 - (7,5A MAX.) - Alignment of the wheels (5A).
F7 - (15A MAX.) - OPTION Hydraulic movements cut-off (10A).

K16

K17

F44

K18

2 - 20
INTRODUCTION TO SAFETY

F8 - (15A MAX.) - Gear reverser (15A).

- Transmission cut-off (15A).
- Reverse lights (15A).
- Reverse buzzer alarm (15A).
F9 - (10A MAX.) - Control instruments panel (5A).
F10 - (15A MAX.) - Sound alarm (15A).
- Stop switch (15A).
F11 - (15A MAX.) - OPTION Boom head light (10A).
- OPTION Blue front and rear working lights (10A).
F12 - (10A MAX.) - Indicator power supply (10A).
F13 - (35A MAX.) - Heating (30A).
F14 - (25A MAX.) - OPTION.
F15 - (25A MAX.) - OPTION.
F16 - (10A MAX.) - OPTION Air conditioning (7,5A).
F17 - (15A MAX.) - OPTION Electrovalve on boom head (10A).
- OPTION Electrovalve on boom head + attachment hydraulic locking device (10A).
- OPTION Electrical boom provision (10A).
- OPTION Anti-theft device provision (10A).
- OPTION Anti-theft system (10A).
- OPTION Anti-start system (10A).
F18 - (15A MAX.) - OPTION Front working head light (15A).
F19 - (15A MAX.) - OPTION Rear window defrosting (15A).
F20 - (10A MAX.) - OPTION Pneumatic seat (10A).
- OPTION Blue front and rear working lights (10A).
F21 - (10A MAX.) - Front windscreen wiper and windscreen washer (10A).
F22 - (15A MAX.) - OPTION Boom suspension (10A).
F23 - (10A MAX.) - Right sidelight (7,5A).
- Sidelight indicator light (7,5A).
- Control panel lighting (7,5A).
- OPTION Number plate lighting (7,5A).
F24 - (10A MAX.) - Left sidelights (7,5A).
F25 - (10A MAX.) - Right indicators (7,5A).
F26 - (10A MAX.) - Left indicators (7,5A).
F27 - (15A MAX.) - Low beam (15A).
- Low beam indicator light (15A).
- Rear fog light (15A).
F28 - (15A MAX.) - Main beam (15A).
- Main beam lamp (15A).
F29 - (25A MAX.) - Hazard warning lights power supply (15A).
- Roof light (15A).
- OPTION (+)permanent (15A).
F30 - (25A MAX.) - Light switch power supply, horn and indicators (25A).
F31 - (20A MAX.) - Starter (20A). F43
F42

- Remove cap 1 for access to fuses F40 to F43.

F40 - (40A MAX.) - Lift truck electrical equipment (40A).
F41 - (40A MAX.) - Lift truck electrical equipment (40A). 1
F42 - (80A MAX.) - Preheating I.C. engine (80A).
F43 - (80A MAX.) - Alternator (80A). F40
F41

F44 - (15A MAX.) - OPTION Diesel decongealant (15A).

2 - 21
INTRODUCTION TO SAFETY

13 - ROOF LIGHT

14 - ACCELERATOR PEDAL

15 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF

The pedal applies on the front and rear wheels by an hydraulic brake system, and allows the lift truck to be slowed down and 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 PANEL).

16 - GEAR LEVER AND TRANSMISSION CUT-OFF

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

4
USING THE GEARS ON THE GEARBOX
- On these lift trucks with a torque converter, it is not necessary to automatically start up
in 1st speed and progress up the gears.

The choice of gear ratio should be made carefully according IMPORTANT

to the nature of the work being carried out. A poor choice may result in the
extremely rapid elevation of the transmission oil temperature
The choice of gear ratio should be made according to the nature of the work through excessive
being slipping of the
carried out. converter,
A poor choicewhich
may could
quicklylead to serious
overheat dama-
the trans-
ge to the transmission (it is essential to stop and change the working conditions if the transmission oil temperature
mission oil through excessive slipping of the torque converter, causing serious damage to the transmission. It is essential to stop and chan- indicator light comes
ge toon).
theThis poorgear
correct choice may
if the also result inoilatemperature
transmission reduction in indicator
the lift truck's performance
light comes on. Aninincorrect
forward gear
speed. When the
selection mayforward force in
also result increases, the
a reduction
forward speed in the r gear (for example 3rd gear) may be lower than the forward speed that could be obtained with
in the lift truck's performance in forward speed. When the forward force or load increases, the forward speed (for example 3rd gear) may be the r-1 gear (in 2nd
instead
slower of the
than the 3rd). speed that could be obtained with 2nd gear (instead of 3rd).
forward

In general, we would advise you to use the following gears according to the nature of the work being carried out.
• On the road : Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it. In hilly areas, set off in 2nd
gear and go up to 3rd if the conditions and state of the road permit it.
• With a trailer on the road : Set off in 2nd gear and go up to 3rd if the conditions and state of the road permit it.
• Handling : 3rd gear.
2nd gear in restricted spaces.
• Earth moving : 1st gear.
• Loading (reclaiming with bucket, manure fork, etc.) : 2nd gear.

17 - FORWARD/REVERSE LEVER
A
When operating this control, the lift truck should be travelling at slow speed and not acce-
lerating. When the reverser is in the neutral position a mechanical lock prevents an acci-
dental shifting movement. C

FORWARD : Lift slightly and push the lever forwards (position A).
REVERSE : Lift slightly and pull the lever backwards (position B). B
NEUTRAL : To start the lift truck, the lever must be in neutral (position C).

NOTE : The backup alarm indicates that must

the lift truckwhen
is running in in
reverse motion.
WARNING The backup alarm sound running reverse.

2 - 22
INTRODUCTION TO SAFETY

18 - PARKING BRAKE LEVER

To prevent accidental loosening or release, the lever is fitted with safety locking.
A
- To apply the parking brake, pull the lever backwards (position A).
- To loosen the parking brake, release and push the lever forwards (position B). B

19 - STEERING SELECTION
A
Before selecting one of the three possible steering positions, bring the 4 wheels into ali- A3 A1 A2
gnment, i.e., in the straight ahead position.

A - STEERING SELECTION LEVER

A1 - Front wheel steer (highway traffic). B1

C B
A2 - Front and rear wheels steer in opposite direction (4 wheel steer).
B2

A3 - Front and rear wheels steer in the same direction (crab steer).

B - GREEN LAMPS FOR ALIGNMENT OF THE WHEELS

These lamps come on to indicate the alignment of the wheels, in relation to the axle of the lift truck. The lamp B1 for the front
wheels and the lamp B2 for the rear wheels.

C - SWITCH FOR ALIGNMENT OF THE WHEELS

This switch enables the use or not of the device for alignment of the wheels. The indicator light indicates its use.

WHEEL ALIGNMENT PROCEDURE

- Engage the switch (signal light ON).
- Shift the distributor control lever for steering selection A in position A2 (4 wheel steering).
- Turn the steering wheel and bring the rear wheels into alignment until the lamp B2 is on.
- Shift the distributor control lever for steering selection A in position A1 (highway traffic).
- Turn the steering wheel and bring the front wheels into alignment until the lamp B1 is on.

Before
Before driving on roads, it driving on public
is necessary roads,the
to check it isalignment
necessaryoftothe
setrear
thewheels
alignment
andoftothe rearin wheels
drive and to
front wheel driveThe
steer. in front wheel
control steer.
of the ali-
WARNING
gnment Long distance
of the rear wheels must betravel requires
regularly periodically
done with the helpstopping the lift
of the green truckwhile
lamps, to check thethe
driving rear
liftwheel’s
truck. Inalignment (using theconsult
case of anomalies, green
your dealer. lamps). In case of anomalies, consult your dealer.

2 - 23
INTRODUCTION TO SAFETY

20 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF

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

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

NOTE : If necessary use the steering to reset the hydraulic

control steering accumulator. A
LIFTING OF THE LOAD
B D
- The lever A backwards when lifting.
- The lever A forwards when lowering.
C E
TILT OF THE CARRIAGE
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Press button B for the extension.
G

N°226111
- Press button C for the retraction.
ATTACHMENT F
- Press buttons D or E.
OPTION BOOM HEAD ELECTROVALVE
- Button F (see : 2 - DESCRIPTION : DESCRIPTION AND USE OF ELECTRIC AND
HYDRAULIC OPTIONS).
TRANSMISSION CUT-OFF
- Button G (see : 2 - DESCRIPTION : 5 - SWITCHES PANEL).

21 - LOAD CHARTS FILE

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

2 - 24
INTRODUCTION TO SAFETY

22 - HEATER CONTROL A

A - HEATING FAN CONTROL

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

B - HEATING TEMPERATURE CONTROL

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

B2

22 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)

The air conditioning only comes on when the forklift truckIMPORTANT has been started up. When using your air conditioning, you must work with the
doors and windows closed.
The air conditioning In operates
winter : only
So as while the liftcorrect
to ensure truck engine is running.
operation During use,
and complete keep of
efficiency thethe
doors and windowsunit,
air conditioning closed.
start up the compressor
In the winter
once a week, if only :forToaensure correct
short spell, so operation and efficiency
as to lubricate of the
the internal air conditioning unit, run the compressor once a week, for a few
seals.
minutes, to lubricateInthe coldinternal
weather seals.
: Warm the I.C. engine before switching on the compressor, so as to allow the coolant that has collected
in the liquid state at the lowestthe
In cold weather : Warm I.C.ofengine
point before switching
the compressor onturn
circuit to the compressor,
into gas underthisthewill allowofthe
effect thecoolant thatoff
heat given hasbycollected in the
the I.C. engine,
liquidas
state
the at the lowestispoint
compressor liableoftothe
becompressor
damaged bycircuit
coolantto in
turn
theinto gasstate.
liquid 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
If your air conditioning airnot
does conditioning
seem to bedoes not seem
working to behave
regularly, working properly,by
it examined have
yourit dealer
examined
(seeby: 3your dealer (see : 3: H- MAINTENAN-
- MAINTENANCE - EVERY TWO
WARNING
YEARS "OPTION AIRCECONDITIONING").
: H - EVERY TWONever
YEARStry"OPTION
to repairAIR
anyCONDITIONING"). The air conditioning system is under high pressure,
anomalies yourself.
repairs must be made by a professional airconditioning repairman.
DESCRIPTION OF THE AIR CONDITIONING CONTROLS
A - Control with signal light indicating start-up and cutout of B
the air conditioning system, if control "C" is in position
1, 2 or 3.
B - Heating air temperature control.
C - Air flow setting and fan speed control. In position "0"
C A
the air conditioning system no longer functions.

NOTE : Possible losses of water under the forklift truck IMPORTANT

are due to condensate discharges caused by the drying effect of the ins-
tallation, especially with high outside temperatures and high relative
Possible losses of water under the forklift truck are due to condensate humidity.
discharges caused by the drying effect of the installation,
For the air conditioning to perform properly, the air intakes
especially with high outside temperatures and high relative humidity. must not be blocked by frost, snow or leaves.
For the When the facilitytoisperform
air conditioning running,properly,
at leastthe
oneair
ofintakes
the cabmust
air grilles
not bemust be open
blocked so as
by frost, to avoid
snow any risk of freezing to the
or leaves.
evaporator.
When the unit is running, at least one of the cab air grilles must be open so as to avoid freezing-up the evaporator.

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

CONDITIONED AIR MODE

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

DEMISTING (DEFROST) MODE

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

C A

2 - 25
INTRODUCTION TO SAFETY

23 - CAB FILTER VENTILATORS

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

24 - WINDSCREEN DEMIST (DEFROST) VENTS

For optimum effectiveness, close the heating ventilators.

25 - HEATING VENTS

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

26 - DOOR LOCK

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

27 - LOCKING HANDLE FOR UPPER HALF DOOR

28 - RELEASING BUTTON FOR UPPER HALF DOOR

29 - HANDLE FOR REAR WINDOW OPENING

EMERGENCY EXIT 29
Use the rear window as an emergency exit, if it is impossible to leave the cab by the door.

30 - DOCUMENT HOLDER

Ensure that the operator's manual is in its place in the document holder. 30

NOTE : There is an OPTIONAL document holder net.

31 - FRONT LIGHTS

A - Left front indicator.

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

32 - REAR LIGHTS

A - Left rear indicator.

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

2 - 26
INTRODUCTION TO SAFETY

33 - REVOLVING LIGHT

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.
3 1

34 - SPIRIT LEVEL

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

34

35 - STEERING WHEEL REGULATING HANDLE

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

- Turn handle 1 towards A to loosen and adjust steering wheel.

- Turn handle 1 towards B to lock steering wheel in the position required.
A

B
36 - ARM-REST 1

The arm-rest can be adjusted in height.

- Loosen screws 1 and adjusting arm-rest in the height required.
- Retighten screws 1.

36

1 1

1 1

2 - 27
INTRODUCTION TO SAFETY

TOWING PIN AND HOOK

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

- To use a trailer, see current regulations in your country (maximum running speed, braking, maximum weight of trailer, etc.).
- Verify the trailer's condition before using it (tire condition and pressures, electrical connection, hydraulic hose, braking system…).

Do not tow a trailerDoor 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
effectcondition may effect
the lift truck's the
steering
WARNING lift truck's
and braking, and hence steering, braking, and safety.
safety.

If a third party helpsIf in coupling

a third partyorhelps
uncoupling the trailer,
in coupling this person
or uncoupling must be
the trailer, permanently
they visible to the
must be continually driver
visible anddriver
to the wait until
until the lift truck
truck
WARNING
has stopped, the handbrake
is parked isandon the
andI.C.
theengine
I.C. engine is switched
is turned off. 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 - TOWING PIN (STANDARD)

COUPLING AND UNCOUPLING THE TRAILER 2

- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- Put the handbrake on and switch off the I.C. engine.
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.

Risk of crushed fingers or hands! Keep hands and fingers clear while cou-
Be careful not to get your fingers caught or crushed during this operation.
WARNING pling the trailer! The safety clip 1 must be installed after coupling. Before
Do not forget to put clip 1 back in place.
uncoupling, make sure the trailer is blocked in place and independently 1
When uncoupling, make sure that the trailer is supported independently.
supported.

B - PROJECTING HOOK (OPTION)

COUPLING AND UNCOUPLING THE TRAILER

- To couple the trailer, position the lift truck as close as possible to the trailer ring. 2
- Put the handbrake on and switch off the I.C. engine.
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.

Risk of crushed fingers or hands! Keep hands and fingers clear while cou-
Be careful not to get your
pling thefingers
trailer!caught or crushed
The safety clip 1 during
must bethis operation.
installed after coupling. Before
WARNING
Do not forget to putuncoupling,
clip 1 backmake
in place.
sure the trailer is blocked in place and independently 1
When uncoupling, make sure that the trailer is supported independently.
supported.

2 - 28
INTRODUCTION TO SAFETY

C - COUPLING LADDER (OPTION) 4

COUPLING AND UNCOUPLING THE TRAILER

- To couple the trailer, position the lift truck as close as possible to the trailer ring.
6
- Put the handbrake on and switch off the I.C. engine.
ON THE FIXED PIN 5
- Remove pin 1, remove rod 2 and raise latch 3.
- Insert or remove the trailer ring, lower latch 3 and install rod 2. 3

Risk of crushed fingers or hands! Keep hands and fingers clear while cou- 2
Be careful not to get your
pling thefingers
trailer!caught or crushed
The safety clip 1 during
must bethis operation.
installed after coupling. Before 1
WARNING
Do not forget to putuncoupling,
clip 1 backmake
in place.
sure the trailer is blocked in place and independently
When uncoupling, make sure that the trailer is supported independently.
supported.

ON THE COUPLING LADDER

- Set the coupling fitting 4 according to the height of the trailer ring.

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

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

D - N/A

2 - 29
INTRODUCTION TO SAFETY

E - HYDRAULIC TRAILER HOOK (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 1 1
hook.
- Release knob 3.
- Couple or uncouple the trailer.

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

- Raise the trailer hook by pressing the upper part of switch 2 and then lower the hook to
verify that the lock pin is in proper contact with hook 1 lock.
Never use the tow Never
hook to raise
use the the
towrear
hookoftotheraise
lift truck (when
the rear changing
of the lift truckthe(when
rear wheel for
changing
WARNING the rear wheel for example).
example).

F - ELECTRICAL CONNECTION (OPTION)

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

2
G - CONNECTING THE BRAKING SYSTEM (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.

2 - 30
INTRODUCTION TO SAFETY

2 - 31
INTRODUCTION TO SAFETY

DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS

1 - REAR ELECTRIC SOCKET

Enables power supply connection for a trailer (see : 2 - DESCRIPTION : TOWING PIN AND
HOOK) or signalling bar. 1
A - Left rear indicator.
C - Earth.
D - Right rear indicator.
E - Right tail light. A
F - Rear stoplight.
G - Left tail light. F
G
E
C
D

2 - BATTERY CUT-OFF

3 - REVERSE BUZZER ALARM

4 - NUMBER PLATE

5
4

5 - NUMBER PLATE LIGHTING

2 - 32
INTRODUCTION TO SAFETY

6 - PREHEATING 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
• Equipment connectable only on feeder circuit TT or TN
• Category of insulation 2

ENVIRONMENTAL CONDITIONS IN USE :

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

CONDITIONS FOR CONNECTION AND USE OF PREHEATING :

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

7 - DIGICODE ANTI-THEFT SYSTEM

OPERATION
- Switch on the forklift truck : LED A flashes red.
- Enter your user code followed by "VAL": LED A goes out. A
- The entry of each figure in your code is confirmed by LED A lighting up green. If you make
an error, press the “ANN” key and re-enter your code completely.
- Start the forklift truck within the next 30 seconds ; otherwise the anti-theft system will
react and LED A flashes red.
NOTE : You can restart the forklift truck within 12 seconds of stopping it : after this time,
the anti-theft system reacts and LED A flashes red.

8 - FINTRONIC ANTI-START SYSTEM

- Switch on the forklift truck and set the black key A next to the antenna B (maximum
C
80 mm).
- Wait a few seconds for red LED C to go out before starting the forklift truck.
NOTE : You can restart the forklift truck within 20 seconds of stopping it : after this time,
the anti-start system reacts and LED C flashes red.

2 - 33
INTRODUCTION TO SAFETY

9 - ELECTRICAL BOOM PROVISION

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

FUNCTIONING

- Hold button 1 down and switch on button 2 or 3. 2

NOTE : Switch 4 enables the function controlled by
button 1 to be locked. Indicator 5 lights up to 3
show when it is in use.
4

10 - EXTERIOR DRAIN-BACK

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

11 - HYDRAULIC ATTACHMENT LOCKING

Enables attachment locking to be controlled on the carriage and the use of a hydraulic
attachment on the same hydraulic circuit (see : 4 - ADAPTABLE ATTACHMENTS IN OPTION
ON THE RANGE : PICKING UP THE ATTACHMENTS).

2 - 34
INTRODUCTION TO SAFETY

12 - BOOM HEAD ELECTROVALVE

Enables use of two hydraulic functions on the attachment circuit.

To make connection of the rapidthe
Decompress connectors
hydraulic easier, decompress
circuit by the hydraulic
pressing button circuit
1 on the by pres-
electrovalve
CAUTION
sing button 1 on the electrovalve.
before attemping to make connections.

FUNCTIONING

- Button 1 not engaged, buttons 2 and 3 control a 2

hydraulic function.
- Hold button 1 down, buttons 2 and 3 control another 3
hydraulic function.
NOTE : Switch 4 enables the hydraulic function 4
controlled by button 1 to be locked. Indicator 5
lights up to show when it is in use.
5

13 - BOOM HEAD ELECTROVALVE + PREARRANGED HYDRAULIC ATTACHMENT LOC-

KING

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

2 - 35
INTRODUCTION TO SAFETY

14 - N/A

15 - N/A

16 - PREARRANGED TRAILER LOCKING

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

17 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION

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 the function.

2 - 36
INTRODUCTION TO SAFETY

3 - MAINTENANCE

3-1
INTRODUCTION TO SAFETY

3-2
INTRODUCTION TO SAFETY

TABLE OF CONTENTS

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT 3-5

FILTERS CARTRIDGES AND BELTS 3-6

LUBRICANTS AND FUEL 3-8

SERVICING SCHEDULE 3 - 10

A - DAILY OR EVERY 10 HOURS SERVICE 3 - 12

B - EVERY 50 HOURS SERVICE 3 - 14

C - EVERY 250 HOURS SERVICE 3 - 20

D - EVERY 500 HOURS SERVICE 3 - 24

E - EVERY 1000 HOURS SERVICE 3 - 30

F - EVERY 2000 HOURS SERVICE 3 - 34

G - OCCASIONAL MAINTENANCE 3 - 36

H - EVERY TWO YEARS (OPTION AIR CONDITIONING) 3 - 40

3-3
INTRODUCTION TO SAFETY

3-4
INTRODUCTION TO SAFETY

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.

IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,

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

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

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

MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.

BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,

YOU BENEFIT THROUGH ITS NETWORK, MANITOU PROVIDES THE USER WITH
EXPERTISE
- Know-how and competence.

- The guarantee of high-quality work.

- Original replacement components.

- Help with preventive maintenance.

- Efficient help with diagnosis.

- Improvements due to experience feedback.

- Operator training.

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

ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.

3-5
INTRODUCTION TO SAFETY

FILTERS CARTRIDGES AND BELTS

I.C. ENGINE

I.C. ENGINE OIL FILTER

ALTERNATOR BELT
Part number : 476954
Part number : 605041
Change : 500 H

DRY AIR FILTER CARTRIDGE

FAN/COMPRESSEUR BELT
Part number : 563416
(OPTION AIR CONDITIONING)
Clean : 50 H*
Part number : 249202
Change : 500 H*

SAFETY DRY AIR FILTER CARTRIDGE COMPRESSOR/ALTERNATOR BELT

Part number : 563415 (OPTION AIR CONDITIONING)
Change : 1000 H* Part number : 231803

FUEL FILTER CARTRIDGE CYCLONIC PRE-FILTER

Part number : 605013 Part number : 224713
Change : 500 H Clean : 10 H

AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION)

Part number : 235797

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

TRANSMISSION

TRANSMISSION OIL FILTER

Part number : 561749
Change : 500 H

HYDRAULICS

HYDRAULIC RETURN OIL FILTER CARTRIDGE SUCTION STRAINER FOR HYDRAULIC OIL TANK
Part number : 221174 Part number : 224726
Change : 500 H Clean : 1000 H

FILTER CAP FOR HYDRAULIC OIL TANK

Part number : 62415
Change : 1000 H

CAB
CAB VENTILATION FILTER (WITH AIR CONDITIONING)
CAB VENTILATION FILTER (WITHOUT AIR CONDITIONING)
Part number : 601645
Part number : 601645
Clean : 50 H
Clean : 500 H
Change : 250 H

3-6
INTRODUCTION TO SAFETY

3-7
INTRODUCTION TO SAFETY

LUBRICANTS AND FUEL

USE THE RECOMMENDED LUBRICANTS AND FUEL :

- For topping up, oils may not be mixed.

DIAGNOSTIC ANALYSIS OF OILS

If a service or maintenance contract has been organized with the 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 (1992) Grades 1, 2, 3 and Special Grade 3.

I.C. ENGINE
COMPONENT CAPACITY RECOMMENDATION

8,5 Liters Shell: Rotella 15w40

I.C. ENGINE Citgo: C-600 15w40
(2.25 gal)

Tulco 50/50 Premix

Anti-freeze
18 Liters
COOLING CIRCUIT
(4.75 gal)

FUEL TANK 104 Liter (27.5 gal) Diesel fuel (*)

TRANSMISSION
COMPONENT CAPACITY RECOMMENDATION

14,5 Liters Shell: Donax TG Dexron III

TRANSMISSION
(3.8 gal) Citgo: Transgard ATF Dexron III

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

BOOM
COMPONENT RECOMMENDATION

BOOM PADS Shell: Rentinax Am

Citgo: Lithoplex CM-2

GREASING OF THE BOOM Shell: Rentinax Am

Citgo: Lithoplex CM-2

HYDRAULICS
COMPONENT CAPACITY RECOMMENDATION

135 Liters Shell: Tellus T46

HYDRAULIC OIL TANK Citgo: Transgard THF Lo-Temp
(35.7 gal)

3-8
INTRODUCTION TO SAFETY

BRAKE
COMPONENT RECOMMENDATION

BRAKE CIRCUIT Shell: Donax TG Dexron III

Citgo: Transgard ATF Dexron III

CAB
COMPONENT RECOMMENDATION

CAB DOOR Shell: Rentinax Am

Citgo: Lithoplex CM-2

WINDSCREEN WASHER TANK Windscreen washer fluid

FRONT AXLE
COMPONENT CAPACITY RECOMMENDATION

0,60 Liter Shell: Spirax DH 80w90

TRANSFER BOX Citgo: Premium Gear MP
(0.6 qt) 80w90

Shell: Donax TD
5,50 Liters
FRONT AXLE DIFFERENTIAL* Citgo: Transgard Tractor Hyd
(1.5 gal)
Fluid

0,75 Liter Shell: Spirax DH 80w90

FRONT WHEELS REDUCERS Citgo: Premium Gear MP
(0.8 qt) 80w90

FRONT WHEELS REDUCERS PIVOTS Shell: Rentinax Am

Citgo: Lithoplex CM-2

REAR AXLE
COMPONENT CAPACITY RECOMMENDATION
Shell: Donax TD
6,35 Liters
REAR AXLE DIFFERENTIAL* Citgo: Transgard Tractor Hyd
(1.7 gal)
Fluid

0,75 Liter Shell: Spirax DH 80w90

REAR WHEELS REDUCERS Citgo: Premium Gear MP
(0.8 qt) 80w90

REAR WHEELS REDUCERS PIVOTS Shell: Rentinax Am

Citgo: Lithoplex CM-2

Shell: Rentinax Am
REAR AXLE OSCILLATION Citgo: Lithoplex CM-2

* First 200 hrs: Manitou Special Immersed Brakes 549. (5 gal. drum, part number - 545608)

3-9
INTRODUCTION TO SAFETY

SERVICING SCHEDULE

A = AJUST N = CLEAN After Day 1 year 1 year

C = CHECK P = BLEED the first or 50 250 or or 2000 4000
D = DESCALE R = CHANGE 50 10 hours hours 500 1000 hours hours
G = GREASE V = DRAIN/CHANGE hours hours hours hours

I.C. ENGINE
I.C. engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Cooling liquid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Cyclonic prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . N R
Radiator core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Condenser core (OPTION Air conditioning) . . . . . . . . . . . . N
Alternator/crankshaft belt tension . . . . . . . . . . . . . . . . . . A A
Compressor belts tension (OPTION Air conditioning) . . . . . A
I.C. engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V V
I.C. engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R R
Fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R R
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Safety dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . . 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 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 oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V V
Transmission housing strainer . . . . . . . . . . . . . . . . . . . . . N
Transmission silent blocks . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 hydraulic oil tank . . . . . . . . . . . . . . . . . . . . R
Speeds of hydraulic movements . . . . . . . . . . . . . . . . . . . C**
Hydraulic pump pipe filter . . . . . . . . . . . . . . . . . . . . . . . N**
Condition of hoses and flexibles pipes . . . . . . . . . . . . . . C**
Condition of cylinders (leakage, shafts) . . . . . . . . . . . . . . C**
Hydraulic circuit pressures . . . . . . . . . . . . . . . . . . . . . . . C**
Hydraulic circuit outputs . . . . . . . . . . . . . . . . . . . . . . . . . C**
Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N**

BRAKE
Brake oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C/A
Parking brake lever mechanism . . . . . . . . . . . . . . . . . . . . G
Brake oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V**
Brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P**
Brake circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A**

3 - 10
INTRODUCTION TO SAFETY

A = AJUST N = CLEAN After Day 1 year 1 year

C = CHECK P = BLEED the first or 50 250 or or 2000 4000
D = DESCALE R = CHANGE 50 10 hours hours 500 1000 hours hours
G = GREASE V = DRAIN/CHANGE hours hours hours hours

STEERING
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Condition of the rear view mirrors . . . . . . . . . . . . . . . . . . C**
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
OPTION Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICITY
Battery electrolyte 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 wheels reducers pivots . . . . . . . . . . . . . . . . . . . . . . G G/C**
Transfer box oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Front axle differential oil level . . . . . . . . . . . . . . . . . . . . . C
Front wheels reducers oil level . . . . . . . . . . . . . . . . . . . . C
Transfer box oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Front axle differential oil . . . . . . . . . . . . . . . . . . . . . . . . . V V
Front wheels reducers oil . . . . . . . . . . . . . . . . . . . . . . . . V V
Wearing of front axle brake discs . . . . . . . . . . . . . . . . . . C**
Front wheels reducers universal joint . . . . . . . . . . . . . . . . C**
Front wheels reducers clearance . . . . . . . . . . . . . . . . . . . C**
Bearings clearance of the transfer box . . . . . . . . . . . . . . C**

REAR AXLE
Rear wheels reducers pivots . . . . . . . . . . . . . . . . . . . . . . G G/C**
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 reducers oil . . . . . . . . . . . . . . . . . . . . . . . . V V
Wearing of rear axle brake discs . . . . . . . . . . . . . . . . . . . C**
Rear wheels reducers universal joint . . . . . . . . . . . . . . . . C**
Rear wheels reducers clearance . . . . . . . . . . . . . . . . . . . C**

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

3 - 11
INTRODUCTION TO SAFETY

A - DAILY OR EVERY 10 HOURS SERVICE

A1 - I.C. ENGINE OIL LEVEL A1/1

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

A1/2

A2 - COOLING LIQUID LEVEL

CHECK A2

Park the lift truck on level ground with the I.C. engine stopped, and allow the I.C. engine
to cool.
2

- Open the I.C. engine cover.

- Check the correct level in the middle of expansion chamber 1 (fig. A2). 1
- If necessary, add cooling liquid (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the
filler port 2 (fig. A2).
- Check visually that there is no leakage in the radiator and pipes.
To avoid any risk of To avoid or
spraying risk of spraying
burning, or burning,
wait until the I.C.wait
engine until
hasthe I.C. engine
cooled has cooled
down before remo-
down before removing the radiator cap. If the cooling liquid is
ving the cooling circuit filler plug. If the cooling liquid is very hot, add only hot cooling very hot,liquid
add
WARNING only hot
(80°C). In an emergency, youcooling
can useliquid.
waterInasana cooling
emergency,
liquid,you
thencanchange
use water as a cooling
the cooling circuit
liquid, then
liquid as soon as possible (seechange the cooling circuit
: 3 - MAINTENANCE : F1 - liquid
COOLINGas soon as possible (see : 3 -
LIQUID).
MAINTENANCE : F1 - COOLING LIQUID).

A3 - FUEL LEVEL A3
CHECK
1
Keep the fuel tank near full, to reduce condensation due to the atmospheric conditions.
2
- Open the side cover.
- Remove cap 1 (fig. A3).
- Fill the fuel tank with clean fuel (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL), filte-
red through a strainer or a clean, lint free cloth, through filler port 2 (fig. A3).
- Put the cap back 1 (fig. A3).
- Check visually that there is no leakage in the tank and pipes.

Never smoke or approach with a flame during filling operations or when the
WARNING tank is open. Never refill while the I.C. engine is running.

The fuel tank is vented via the filler plug. When changing it, always use an
WARNING original part, with vented hole.

3 - 12
INTRODUCTION TO SAFETY

A4 - CYCLONIC PREFILTER A4
CLEAN
1
The cleaning interval is given as a guide, however the prefilter must be emptied as soon 2
as impurities reach the MAXI level on the tank.

- Loosen nut 1 (fig. A4), remove cover 2 (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 lettake care not
impurities intotothe
let dry
impurities
air filter.into the dry air filter.

A5 - TRANSMISSION OIL LEVEL A5

CHECK

Park the lift truck on level ground with the boom raised, the I.C. engine cold and stopped.
Carry out the control within 5 minutes of the I.C. engine being stopped. 1

2
- Remove the plastic cap 1 (fig. A5).
- Remove the dipstick 2 (fig. A5).
- Wipe the dipstick and check the correct level between the two MIN and MAX marks.
- If necessary, add oil (see : 3 - MAINTENANCE : E3 - TRANSMISSION OIL).
- Check visually that there is no leakage or seepage of oil in the transmission.

A6 - TIRES PRESSURE AND WHEEL NUTS TORQUE

CHECK

- Check the condition of the tires, to detect any damages, cuts, 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 tires : 465 ft/lb
• Rear tires : 465 ft/lb
- Check and adjust the tire pressures if necessary (see : 2 - DESCRIPTION : CHARACTERISTICS).

Check that the air hose

Check is that
correctly
the airconnected to the tire
hose is correctly valve before
connected to theinflating andbefore
tire valve keep inflating
all persons
andatkeep
a distance during
all persons at inflation.
a distanceRespect
during
WARNING
the recommended tire pressures
inflation. given.
Respect the recommended tire pressures given.

A7
A7 - BOOM PADS
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 the boom several times in order to spread the coat of grease evenly.
- Remove the surplus of grease.

If the lift truck is used in an abrasive environment (dust, sand, coal…) Use lubricating varnish
IMPORTANT
(MANITOU referenceIf:the lift truckInisthis
483536). used in an abrasive
respect, consult environment
your dealer. (dust, sand, coal…), use
a dry graphite lubricate. Contact your dealer.

3 - 13
INTRODUCTION TO SAFETY

B - EVERY 50 HOURS SERVICE

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

B1 - DRY AIR FILTER CARTRIDGE

CHECK - CLEAN

In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS). Also, the checking and cleaning schedule of the cartridge must be reduced.
If the clogging indicator
If thelight comes
clogging on, thislight
indicator operation
comes must be carried
on, this outmust
operation as quickly as possible
be carried (1 houras
out as quickly maximum). Thehour
possible (1 cartridge must
maximum).
IMPORTANT
not be cleaned moreThe than seven times,
cartridge after
must not bewhich themore
cleaned cartridge
than must
sevenbetimes,
changed.
after which the cartridge must be changed.
- For the disassembly and reassembly of the cartridge, see : 3 - MAINTENANCE : D3 - DRY AIR FILTER CARTRIDGE.
- Clean the filter cartridge using a compressed air jet (max. pressure 40 psi) directed from the top to the bottom and from the insi-
de towards the outside at a 1 in. distance or more from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.
Respect the safetyAvoid
IMPORTANT tearing
distance or mm
of 30 making a holethe
between in air
thejet
cartridge.
and the The cartridge
cartridge musttearing
to avoid not be or
blown anywhere
making a holenear
in thethe air filter The
cartridge. box.cartrid-
Never
clean the cartridge by tapping it against a hard surface. Your eyes must be protected during this intervention.
ge must not be blown anywhere near the air filter box. Never clean the cartridge by tapping it against a hard 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.
Do not clean the dryDoairnot
filter cartridge
clean the drybyairwashing it in liquid.
filter cartridge Do not clean
by washing by any
in liquid. Domeans the the
not clean safety cartridge
safety located
cartridge inside
located the filter
inside car-
the filter
IMPORTANT
tridge, change it forcartridge,
a new onechange
if it is itdirty
for aornew
damaged.
one if it is dirty or damaged.

B2 - RADIATOR CORE
CLEAN
In a heavy dust atmosphere, clean the radiator core every day. Do not use
IMPORTANT a water jet or high-pressure steam as this could damage the radiator fins.

- Open the I.C. engine cover.

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

B3 - CONDENSER CORE (OPTION AIR CONDITIONING) B3/1

CLEAN
1
In a heavy
In a polluting atmosphere, dustthe
clean atmosphere, clean
radiator core theday.
every radiator coreuse
Do not every day. Do
a water jet not use
or high-
IMPORTANT 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.
- Loosen the knurled screw 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 - 14
INTRODUCTION TO SAFETY

B4 - BOOM B4/1
GREASE

To be carried out weekly, if the lift truck has been operated for less than 50 hours during
the week.
1
In the event of prolonged use in an extremely dusty or oxidising atmos-
In the event of prolonged use in an extremely dusty or oxidizing atmosphere, reduce this inter-
IMPORTANT phere,
val to 10 working hours or reduce this interval to 10 working hours or every day.
every day.
Clean and lubricate the following points with grease (see : 3 - MAINTENANCE : LUBRI-
CANTS AND FUEL) and remove the surplus of grease.

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

2 2

B4/3 B4/4 B4/5

3 4

B4/6 B4/7 B4/8

6 9
8
7

3 - 15
INTRODUCTION TO SAFETY

B5 - HYDRAULIC OIL LEVEL B5/1

CHECK

Park the lift truck on level ground with the I.C. engine stopped, and the boom retracted and
lowered as far as possible. 1

- Refer to gauge 1 (fig. B5/1).

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

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.
B5/2
- Put the cap back.
- Check visually that there is no leakage in the tank and pipes.
2
Always maintain the oil level at maximum as cooling depends on the oil flowing through the
tank. 3

B6 - BRAKE OIL LEVEL B6/1

CHECK

Park the lift truck on level ground. 2

- Loosen screw 1 (fig. B6/1) and remove the access panel for braking oil tank and wind-
screen washer tank 2 (fig. B6/1).
- The level is correct when it is at the MAXI level on the tank.
1
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the filler port
3 (fig. B6/2).
- Check visually that there is no leakage in the tank and pipes.

WARNING If the braking oil level is abnormally low, consult your dealer.
If the braking oil level is abnormally low, consult your dealer.
B6/2

3 - 16
INTRODUCTION TO SAFETY

B7 - WINDSCREEN WASHER LIQUID LEVEL B7/1

CHECK

- Loosen screw 1 (fig. B7/1) and remove the access panel for braking oil tank and wind- 2
screen washer tank 2 (fig. B7/1).
- Check visually the level.
- If necessary add windscreen washer liquid (see : 3 - MAINTENANCE : LUBRICANTS AND
FUEL) by filler port 3 (fig. B7/2).
1

B7/2

B8
B8 - CAB DOOR
GREASE 1

Clean and lubricate the points 1 (4 lubricators) (fig. B8) with grease (see : 3 - MAINTE-
NANCE : LUBRICANTS AND FUEL) and remove the surplus grease.

B9 - CAB VENTILATION FILTER (OPTION AIR CONDITIONING) B9

CLEAN

- Lift up protective casing 1 (fig. B9).

- Lift out cabin ventilation filter 2 (fig. B9).
2
- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS). 1
- Install the filter and protective casing.

3 - 17
INTRODUCTION TO SAFETY

B10 - BATTERY ELECTROLYTE LEVEL B10/1

CHECK

Check the electrolyte level in each cell of the battery.

If the lift truck is working in a high temperature environment, check the level more fre- 1
quently.

- Open the side cover.

- Disassemble the fastening plate 1 (fig. B10/1).
- Remove caps 2 (fig. B10/2) 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, top up the cells with clean distilled water that has been stored in a glass
container.
- Clean and dry caps 2 (fig. B10/2) and install.
- Check the terminal connections and lightly smear them with petroleum jelly to prevent cor- B10/2
rosion.
- Reassemble the fastening plate 1 (fig. B10/1).
2
Handling and servicing
Handlingaandbattery can be
servicing dangerous,
a battery take
can be the following
dangerous, takeprecautions : precau-
the following
- Wear protective
tions : goggles.
- Keep the battery horizontal.
- Wear protective goggles.
- Never smoke or work the
- Keep nearbattery
a naked flame.
horizontal.
WARNING
- Work in a well-ventilated area.or work near an open flame.
- Never smoke
- In the event of- electrolyte being spilled onto
Work in a well-ventilated area.the skin or splashed in the eyes, rinse tho-
roughly with cold
- In water for 15
the event of minutes andbeing
electrolyte call aspilled
doctor.onto the skin or splashed in the
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.

B11 - FRONT AND REAR WHEELS REDUCERS PIVOTS B11

GREASE

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

B12 - REAR AXLE OSCILLATION B12

GREASE

Clean and lubricate the points 1 (2 lubricators) (fig. B12) with grease (see : 3 - MAINTE-
NANCE : LUBRICANTS AND FUEL) and remove the surplus grease.
1

3 - 18
INTRODUCTION TO SAFETY

B13 - TRANSMISSION UNIVERSAL JOINT 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).

2 - Lubricators of the universal joint Transmission/Front axl (fig. B13/2 and 1
B13/3) (3 lubricators).
3 - Lubricators of the universal joint Front axle/Rear axle (fig. B13/3 and B13/4)
(3 lubricators).

B13/2 B13/3 B13/4

3
2
2
2 3

3 - 19
INTRODUCTION TO SAFETY

C - EVERY 250 HOURS SERVICE

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

C1 - ALTERNATOR/CRANKSHAFT BELT TENSION C1/1

CHECK - ADJUST

- Open the I.C. engine cover. 1

- Remove the fastening screws 1 (fig. C1/1).
- Lay down the protective guard 2 (fig. C1/1).
- Check the belt for signs of wear and cracks and change if necessary (see : 3 - 2
MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
1
- Check the belt tension between the pulleys of the crankshaft and of the alternator.
- Under a normal pressure exerted with the thumb (10 lb), the tension should be
approximately 3/8 in. 1
- Carry out adjustments if necessary.
- Loosen screws 3 (fig. C1/2) by two to three thread turns.
- Swivel the alternator assembly so as to obtain the belt tension required.
- Retighten screws 3 (fig. C1/2) (tightening torque 16 ft/lb).
C1/2
- Put the protective guard back 2 (fig. C1/1).
If the alternator beltIf has to be changed,
the alternator check
belt has to bethe tensioncheck
changed, again the
after the first
tension 20 after
again hoursthe
of
IMPORTANT
operation. first 20 hours of operation. 3

3 3

C2 - COMPRESSOR BELTS TENSION (OPTION AIR CONDITIONING) C2/1

CHECK - ADJUST

- Open the engine compartment.

- Unscrew the fastening screws 1 (fig. C2/1). 2
- Lay down the protective guard 2 (fig. C2/1). 1
- Check the belts for signs of wear and cracks, change them if necessary (see: 3 -
MAINTENANCE: FILTERS CARTRIDGES AND BELTS).

FAN/COMPRESSOR BELT
- Check the belt tension between the pulleys of the fan and compressor. 3
- Under a normal pressure exerted with the thumb (10 psi), the tension should be 3
approximately 3/8 in.
- Carry out adjustments if necessary.
- Loosen the screws 3 (fig. C2/1) and the lock-nut 4 (fig. C2/2) by two to three turns. C2/2
- Tighten the screw 5 (fig. C2/2) so as to obtain the required belt tension.
- Retighten lock nut 4 (fig. C2/2).
- Retighten screws 3 (fig. C2/1).
6
COMPRESSOR/ALTERNATOR BELT
1
- Check the belt tension between the pulleys of the compressor and alternator.
- Under a normal pressure exerted with the thumb (10 psi), the tension should be
approximately 3/8 in.
- Carry out adjustments if necessary. 6
- Loosen screws 6 (fig. C2/2) by two to three thread turns.
1
- Swivel the alternator assembly to obtain the belt tension required. 4
- Retighten screws 6 (fig. C2/2). 5
- Put the protective guard back 2 (fig. C2/1).

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

3 - 20
INTRODUCTION TO SAFETY

C3 - TRANSFER BOX OIL LEVEL C3/1

CHECK

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

- Remove access panel 1 (fig. C3/1).

- Remove level plug 1 (fig. C3/2). The oil should be flush with the edge of the filler port.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the same filler
port.
- Install and tighten the level plug 1 (fig. C3/2) (tightening torque 32 ft/lb).
1

C3/2

C4/1
C4 - PARKING BRAKE
5
CHECK - ADJUST
A
Park the lift truck on a slope less than 15 % with the rated load in the transport position.
- Check the tightening adjustment by locking the parking brake in position A (fig. C4/1).
- The adjustment is correct when the lift truck is held stationary on a slope.
- Carry out adjustments if necessary. B

ADJUSTMENT OF THE PARKING BRAKE CABLE ON THE FRONT AXLE

- Press and release the brake pedal, then release the parking brake, putting it in position
B (fig. C4/1).
- Remove the cover plate 1 (fig. C4/2).
- Unscrew nuts 2 (fig. C4/3).
- Adjust the cable by loosening nuts 2 (fig. C4/3), until a clearance of 0.06 in.between
cams 3 (fig. C4/3) and stops 4 (fig. C4/3) is obtained. C4/2

The adjustment of Make adjustments only to the stops noted. DO NOT MAKE ADJUSTMENTS
WARNING the stops performed by the manufacturer must not be modified under any
circumstances. TO THE DRIVE AXLE FACTORY SETTINGS! (CONTACT YOUR DEALER.)

ADJUSTMENT OF THE PARKING BRAKE

- Leave the parking brake in position B (fig. C4/1). 1
- Progressively tighten the end piece of the lever 5 (fig. C4/1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.

C4/3

3 3
4 2 2 4

3 - 21
INTRODUCTION TO SAFETY

C5 - CAB VENTILATION FILTER (OPTION AIR CONDITIONING) C5

CHANGE

- Lift up protective casing 1 (fig. C5).

- Lift out cabin ventilation filter 2 (fig. C5) and install a new replacement filter (see : 3 -
MAINTENANCE : FILTERS CARTRIDGES AND BELTS). 2
- Install the protective casing.
1

C6 - FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL C6

CHECK

Park the lift truck on level ground with the I.C. engine stopped.
2
- Remove level plug 1 (fig. C6). The oil should be flush with the edge of the hole.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the filler port 1
2 (fig. C6).
- Replace and tighten the level plug 1 (fig. C6) (tightening torque 32 ft/lb).
- Repeat this operation for the rear axle differential.

C7 - FRONT AND REAR WHEELS REDUCERS OIL LEVEL C7

CHECK

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

- Check the level on each front wheel reducer.

- Place level plug 1 (fig. C7) in the horizontal position. 1
- Remove the level plug ; the oil should be flush with the edge of the hole.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the same hole.
- Replace and tighten the level plug 1 (fig. C7) (tightening torque 32 ft/lb).
- Repeat the same operation on each rear wheel reducer.

3 - 22
INTRODUCTION TO SAFETY

3 - 23
INTRODUCTION TO SAFETY

D - EVERY 500 HOURS SERVICE

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

D1 - I.C. ENGINE OIL D1/1

DRAIN
D2 - I.C. ENGINE OIL FILTER
CHANGE

Park the lift truck on level ground, let the I.C. engine run at idle for a few minutes, then 1
stop the I.C. engine.

DRAINING THE OIL

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

IMPORTANT Dispose of the drain oil in an ecological manner.

Dispose of the drain oil in an ecological manner.
6

REPLACEMENT OF THE FILTER

- Remove I.C. engine oil filter 6 (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.
Tighten the oil filter by hand pressure only and lock the filter in place by a 2
IMPORTANT
Tighten the oil filterquarter
by hand pressure only and lock the filter in place by a quarter turn.
turn.

FILLING UP THE OIL

- Loosen, clean and return the drain hose 3 (fig. D1/3). D1/3
- Install and tighten drain plug 2 (fig. D1/2).
- Install access panel 1 (fig. D1/1).
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 7 (fig.
D1/5).
- Wait a few minutes to allow the oil to flow into the sump.
- Start the I.C. engine and let it run for a few minutes. 3
- Check for possible leaks at the drain plug and the oil filter.
- Stop the I.C. engine, wait a few minutes and check the level between the two notches on
dipstick 8 (fig. D1/6).
- Top up the level if necessary.

D1/4

D1/5 D1/6

5
7 8

3 - 24
INTRODUCTION TO SAFETY

D3 - DRY AIR FILTER CARTRIDGE D3

CHANGE

In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges, see : 1
2
3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS. Also, the checking and cleaning
schedule of the cartridge must be reduced (every 250 hours in a heavily laden dust atmos-
phere and with pre-filtration).

Change
Change the cartridge the cartridge
in a clean location,inwith
a clean
the location, with
I.C. engine the I.C. Never
stopped. enginerun
stopped.
the I.C.Never
engi-
IMPORTANT run the I.C. engine with the air filter removed or damaged.
ne 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 spilling the dust.
- Leave the safety cartridge in place.
- The following parts must be cleaned with a damp, clean lint-free cloth.
• The inside of the filter and cover.
• The inside of the filter inlet hose.
• The gasket surfaces in the filter and in the cover.
- Check pipes and connections between the air filter and the I.C. engine and the connection and state of the clogging indicator on
the filter.
- Before installation check the new cartridge (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.
- Reassemble the cover, guiding the valve downwards.

D4/1
D4 - FUEL FILTER CARTRIDGE
CHANGE

Make sure
Make sure the electrical the on
contact electrical
the lift contact
truck is on
cut,theotherwise
lift truckfuel
is off,
willotherwise fuelif will
be released the
IMPORTANT be released if the lift pump is on.
lift pump is on.
- Open the I.C. engine cover.
- Open battery cowl. 2
- Carefully clean the outside of the filter and its 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). 1
- Remove the filter cartridge by pressing the cartridge 3 (fig. D4/2) down against the pres-
sure of the spring and turn it to the left to extract it.
- Insert a new cartridge (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS), by D4/2
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.
- 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, hand-tighten it only and lock it with a quarter- 4 3
turn.
- Close drain plug 1 (fig. D4/1) and remove the container.
- Before starting the I.C. engine, leave the ignition on for three minutes 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.
- If necessary, bleed the fuel circuit (see : 3 - MAINTENANCE : G1 - FUEL SYSTEM).

3 - 25
INTRODUCTION TO SAFETY

D5 - TRANSMISSION OIL FILTER D5/1

CHANGE

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

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

D6 - HYDRAULIC RETURN OIL FILTER CARTRIDGE D6

CHANGE 1

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 intervention, to prevent risk of polluting the hydraulic circuit.
2
to prevent any risk of polluting the hydraulic circuit.
- Open the side cover.
- Unscrew the locking screws of the cover 1 (fig. D6).
- Remove the hydraulic return oil filter cartridge 2 (fig. D6), and fit new replacement car-
tridge (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
- Make sure that the cartridge is correctly positioned and install cover 1 (fig. D6).

D7 - BALANCING VALVE
CHECK

To be performed after the first 50 hours of operation and then every 500 hours.
Park the lift truck on horizontal ground, put the handbrake on and set the reverse gear to neutral.

ROLE OF BALANCING VALVES

- The balancing valves protect the user from any risk due to a fall in hydraulic pressure or an exploding hose during hydraulic ope-
rations.
Keep everyone wellKeep
awayeveryone
during these inspections.
well away during these inspections. In all cases, the balancing valve(s) concerned must be repaired
InDANGER
all cases, the balancing valve(s)
or replaced concerned
if hydraulic must be
movement repairedafter
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, lower the boom. While the boom is being lowered, 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.

3 - 26
INTRODUCTION TO SAFETY

TELESCOPING CIRCUIT :
- Start up the lift truck and raise the boom as far as it will go, extending the telescope(s) completely.
- With the I.C. engine running at mid- speed, retract the telescope(s). When retracting the boom, 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.

TILT CIRCUIT :
- Place the nominal load on the forks, anchor it correctly to prevent it from falling off during the test.
- Start up the lift truck and tilt the carriage 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 - PARKING BRAKE LEVER MECHANISM D8

GREASE

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

D9 - CAB VENTILATION FILTER

D9
CLEAN

- Lift up protective casing 1 (fig. D9).

- Lift out cabin ventilation filter 2 (fig. D9).
- Clean the filter with a compressed air jet. 2
- Check its condition and change if necessary (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS).
- Install the filter and protective casing. 1

D10 - BATTERY ELECTROLYTE DENSITY

D10
CHECK 1.240

1.250
The electrolyte density varies depending on the temperature concerned, but a minimum of
1.260
1260 at 61°F must be maintained. In the shaded area (fig. D10), the battery is in a nor-
mal charge condition. Readings above this zone indicate that the battery needs to be 1.270
recharged. 1.280
The density should not vary more than 0.025 units between cells.
1.290

- Check the electrolyte density in each battery cell using a hydrometer. 1.300
- Do not carry out this check immediately after topping up with distilled water. Recharge the
battery for at least an hour before checking the battery electrolyte density. °C -18 -10 0 10 20 30 40
°F 0 14 32 50 68 86 104

Handling and servicing a battery can be dangerous, take the following precau-
Handling and servicing a battery can be dangerous, take the following precautions :
tions :
- 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 - 27
INTRODUCTION TO SAFETY

D11 - TRANSFER BOX OIL D11/1

DRAIN

Park the lift truck on level ground with the engine stopped and the transfer box oil still
warm.

IMPORTANT Dispose of the drain oil in an ecological manner.

Dispose the drain oil in an ecological manner.
- Remove access panel 1 (fig. D11/1).
- Place a container under drain plug 1 (fig. D11) and unscrew the plug.
- Remove level and filler cap 2 (fig. D11) in order to ensure that the oil is drained proper-
1
ly.
- Install and tighten drain plug 1 (fig. D11) (tightening torque 32 ft/lb).
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 2 (fig. D11).
- The level is correct when the oil is flush with the edge of the hole.
D11/2
- Check for any possible leaks at the drain plug.
- Install and tighten level and filler cap 2 (fig. D11) (tightening torque 32 ft/lb).

D12 - FRONT AND REAR AXLE DIFFERENTIAL OIL

D12
DRAIN

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

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

3 - 28
INTRODUCTION TO SAFETY

3 - 29
INTRODUCTION TO SAFETY

E - EVERY 1000 HOURS SERVICE

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

E1 - FUEL 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.
1
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.
- In the event of a leak, contact your dealer.
Never
Never try to carry out perform
a weld or anywelding on the fuelbysystem,
other operation yourself,this
thiscould
couldcause an explosion
provoke or
an explosion
WARNING a fire.
or a fire.
- Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
- Open the side cover.
- Remove cap 2 (fig. E1/2).
- Let the fuel flow and clean with 2 gal. of clean fuel by filler port 3 (fig. E1/2). E1/2
- Install and tighten drain plug 1 (fig. E1/1) (tightening torque 26 ft/lb).
- Fill the fuel tank with clean fuel (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) filte- 2
red through a strainer or a clean, lint-free cloth and install the filler plug 2 (fig. E1/2).
- If necessary, bleed the fuel circuit (see : 3 - MAINTENANCE : G1 - FUEL SYSTEM). 3

E2 - SAFETY DRY AIR FILTER CARTRIDGE E2

CHANGE

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

NOTE : The schedule for changing the safety cartridge is given for ref. only. The safety car-
tridge must be changed for every two changes of the air filter cartridge.

3 - 30
INTRODUCTION TO SAFETY

E3 - TRANSMISSION OIL E3/1

DRAIN
E4 - TRANSMISSION HOUSING STRAINER
CLEAN

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

DRAINING THE OIL

- Place a container under drain plug 1 (fig. E3/1) and under cover 2 (fig. E3/2) and uns-
crew the drain plug.
- Open the side
.
- Take drain hose 3 (fig. E3/3) and screw fully the union on draining port 4 (fig. E3/4).
- Remove cover plate 5 (fig. E3/5). E3/2
- Remove dipstick 6 (fig. E3/6) and unscrew filling plug 7 (fig. E3/6) in order to ensure that
the oil is drained properly.

IMPORTANT Dispose of the drain oil in an ecological manner.

Dispose the drain oil in an ecological manner.

CLEANING THE STRAINER 2

- Loosen, clean and return the drain hose 4 (fig. E3/4).
- Remove cover 2 (fig. E3/2) and set aside the O-ring joint and sealing washer.
- Allow the rest of the oil to drain away.
- Remove and clean the strainer using a compressed air jet.
- Clean the magnetic section on the plate.
- Install the assembly and tighten up plate 2 (fig. E3/2) (tightening torque 18 ft/lb).
E3/3
FILLING UP THE OIL
- Loosen, clean and return the drain hose 3 (fig. E3/3).
- Install and tighten drain plug 1 (fig. E3/1) (tightening torque 32 ft/lb).
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 7 (fig.
E3/6) and install the plug.
- Start the I.C. engine and let it run for a few minutes. 3
- Check any possible leaks from the drain plug or cover.
- Stop the I.C. engine, and within 5 minutes of the I.C. engine being stopped, check on the
dipstick 6 (fig. E3/6) the correct level between the MIN and MAX marks.
- Top up the level if necessary.
- install the cover plate 5 (fig. E3/5).

E3/4

E3/5 E3/6

7
5

3 - 31
INTRODUCTION TO SAFETY

E5 - HYDRAULIC OIL E5/1

DRAIN
E6 - SUCTION STRAINER FOR HYDRAULIC OIL TANK
CLEAN
E7 - FILTER CAP FOR HYDRAULIC OIL TANK
CHANGE

Park the lift truck on level ground with the I.C. engine stopped and telescope boom retrac-
ted 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. 1

DRAINING THE OIL

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

IMPORTANT Dispose of the drain oil in an ecological manner. 4

Dispose the drain oil in an ecological manner.

CLEANING THE STRAINER

- Remove the inspection panel 3 (fig. E5/3).
- Remove and clean the strainer using a compressed air, check its condition and replace if
necessary (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
- Install the strainer and tighten the inspection panel 3 (fig. E5/3) making sure the seal is
in the correct position.

FILLING UP THE OIL

E5/3
- Clean and install drain plug 1 (fig. E5/1) (tightening torque 26 ft/lb).
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 4 (fig.
E5/2). 3

Use a clean container and funnel, and clean the underside of the oil nozzle
IMPORTANT before
Use a clean container andfilling.
funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 5 (fig. E5/4) ; 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. E5/2) with a new filler plug (see : 3 - MAINTENANCE : FILTERS
CARTRIDGES AND BELTS).
- Close the side cover.

POLLUTION ABATEMENT OF THE HYDRAULIC CIRCUIT

- Let the I.C. engine run (accelerator pedal at halfway travel) for 5 minutes without using E5/4
anything on the lift truck, then for 5 more minutes while using all the hydraulic movements
(except the steering system).
- Accelerate the I.C. engine at full speed for 1 minute, then activate the steering system.
- This operation makes a pollution abatement of the circuit possible through the hydraulic
5
return oil filter.

3 - 32
INTRODUCTION TO SAFETY

E8 - SEAT BELT
CHECK

SEAT BELT WITH TWO ANCHORING POINTS

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

REELED SEAT BELT WITH TWO ANCHORING POINTS

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

NOTE : After an accident, replace the seat belt.

Under no circumstances
Under should you use the lift
no circumstances truckyou
should if the
useseat
the belt is faulty.
lift truck if the seat belt is
WARNING damaged! Repair or replace the seat belt immediately!

E9 - FRONT AND REAR WHEELS REDUCERS OIL

DRAIN E9

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

- Drain and change each front wheel reducer.

- Place drain plug 1 (fig. E9) in position A.
- Place a container under the drain plug and unscrew the plug.
A
- Let the oil drain fully.
- Place the drain port in position B, i.e. in a level port.
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by level port 1 (fig. E9).
- The level is correct when the oil level is flush with the edge of the hole.
- Install and tighten the drain plug 1 (fig. E9) (tightening torque 31 ft/lb).
- Repeat this operation on each rear wheel reducer.

3 - 33
INTRODUCTION TO SAFETY

F - EVERY 2000 HOURS SERVICE

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

F1 - COOLING LIQUID F1/1

DRAIN

These operations are to be carried out if necessary or every two years at the beginning of
winter. 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.
- Remove the fixing rod 1 (fig. F1/1).
- Push the shroud 2 forward (fig. F1/2).
- Place a container under drain plug 3 (fig. F1/2) of the radiator and drain plug 4 (fig. F1/3)
of the I.C. engine block and unscrew the plugs.
- Remove filler cap 5 (fig. F1/4) of the expansion pan 6 (fig. F1/4).
- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.
- Check the condition of the hoses and clamps, replace them if necessary.
F1/2
- Rinse the circuit with clean water and use a cleaning agent if necessary.

FILLING THE LIQUID

- Retighten drain plug 3 (fig. F1/2) (tightening torque 15 ft/lb) and 4 (fig. F1/3) (tightening 3
torque 30 ft/lb).
- Slowly fill up the cooling circuit (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) to half 2
way up the expansion pan 6 (fig. F1/4) through filler port 7 (fig. F1/4).
- install filler cap 4 (fig. F1/4).
- install the shroud 2 (fig. F1/2) with the fixing rod 1 (fig. F1/1).
- 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
duringbethefilled
whole year
with a
IMPORTANT
with a mixture containing
minimum 25 mixture
% of ethylene
of 25 %glycol-based antifreeze. antifreeze.
ethylene glycol-based
F1/3

F1/4

5
7

3 - 34
INTRODUCTION TO SAFETY

3 - 35
INTRODUCTION TO SAFETY

G - OCCASIONAL MAINTENANCE

G1 - FUEL SYSTEM G1/1

BLEED

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

• A component of the fuel system replaced. 1
• A drained tank.
• Running out of fuel.

Ensure that the level of fuel in the tank is sufficient and bleed in the following order :

- Open the I.C. engine cover.

- 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.

BLEEDING THE INJECTORS G1/2

- Remove the injectors cover 1 (fig. G1/1).
- Loosen high pressure connectors 2 (fig. G1/2) of all the injectors.
2
- Activate the starter until the diesel fuel flows out free of air at high pressure connectors
2
2 (fig. G1/2).
2
Do not motor
Do not engage the starter engageonthe starter motor
a continual on more
basis for a continual
than 30basis for more
seconds than
and let 30
it cool 2
IMPORTANT seconds
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).

- The I.C. engine is then ready to be started up.

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

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

G2 - WHEEL G2/1
CHANGE
In the event of a wheel being
In the changed
event on thebeing
of a wheel public highway,
changed onmake sure of
the public the following
highway, make points
sure of:
WARNING the following points

For this operation, we advise you to use an approved hydraulic jack and support (see your
dealer).

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

- Put the warning lights on.
- Immobilize the lift truck in both directions on the axle opposite to the wheel to be chan-
ged.
- 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
jack (fig. G2/1). G2/2
- 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 with rocking movements and roll it to the side.
- Slip the new wheel on the wheel hub.
- Install the nuts by hand, if necessary grease them.
- Remove the safety support and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see : 3 - MAINTENANCE : A - DAILY OR
EVERY 10 HOURS SERVICE for tightening torque).

3 - 36
INTRODUCTION TO SAFETY

G3 - LIFT TRUCK
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 jerky movements.

G4 - LIFT TRUCK G4/1

SLING

- Take into account the position of the lift truck gravity center for lif-
ting (fig. G4/1).
A = 52.4 in. B = 46.9 in.
- Place the hooks in the fastening points provided (fig. G4/2 and
G4/3).

A B

G4/2

G4/3

3 - 37
INTRODUCTION TO SAFETY

G5 - LIFT TRUCK ON A PLATFORM G5/1

TRANSPORT

Ensure
Ensure that the safety that the safety
instructions instructions
connected for the platform
to the platform are followed
are respected before
before the loa-
loading
ofWARNING
the lift truck andding
thatthe
the lift truck
driver andmeans
of the that the driver of is
of transport transport
informedisabout
informed about the
the dimensions
and the weight of thedimensions
lift truck and
(seeweight of the lift truck.
: 2 - DESCRIPTION : CHARACTERISTICS).

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 connec-
transporting the lift truck.
tion 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 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 : DRIVING INSTRUC-
TIONS UNLADEN AND LADEN).

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 on the inside of each tire (fig. G5/2).
- Stow the lift truck on the platform with straps/chains. At the front of the lift truck, on the
fastening points (fig. G5/3) and at the back, on the towing pin (fig. G5/4).
- Tighten the straps/chains (fig. G5/5).

G5/3

G5/4

G5/5

3 - 38
INTRODUCTION TO SAFETY

G6 - FRONT HEADLAMPS 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 of
the headlamp. h1
+%

ADJUSTING PROCEDURE -%

-2%
- Park the lift truck unloaded and in the transport position and per- h1
h2
pendicular to a white wall on flat, level ground (fig. G6).
- Check the tire pressures (see : 2 - DESCRIPTION : CHARACTERIS- l
TICS).
- Put the gear reverser lever in neutral and release the parking brake.

CALCULATING THE HEIGHT OF THE DIPPED BEAM (H2)

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

3 - 39
INTRODUCTION TO SAFETY

H - EVERY TWO YEARS (OPTION AIR CONDITIONING)

WARNING : NEVER DO
TRYNOT ATTEMPT
TO REPAIR ANYREPAIRS. ONLY
ANOMALIES A QUALIFIED
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
• If this gas is inhaled, takeopen the cooling
the victim circuit
into fresh under
air, give any circumstances,
oxygen this will
or artificial respiration cause the
if necessary andcoolant to be lost. The
call a doctor.
cooling circuit contains a gas which can be dangerous under certain conditions.
• If the gas is in contact with the skin, wash it immediately under running water and remove any contaminated garments.This gas, coolant R 134a,
is colorless,
• If the gas is in contact with theodorless and
eyes, rinse heavier
them than
in clear air. for 15 minutes and call a doctor.
water
WARNING
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.

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

H1 - CLEANING THE CONDENSER AND EVAPORATOR COILS (*)

H2 - CLEANING THE HOTWELL AND THE PRESSURE RELIEF VALVE (*)

H3 - COLLECTING THE COOLANT TO REPLACE THE FILTER-DRIER (*)

H4 - RELOADING COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES (*)
NOTE : When opening the evaporator unit, remember to replace the cover seal.

(*) : (CONSULT YOUR DEALER).

3 - 40
INTRODUCTION TO SAFETY

4 - PICKING UP
THE ATTACHMENTS

4-1
INTRODUCTION TO SAFETY

4-2
INTRODUCTION TO SAFETY

TABLE OF CONTENTS

INTRODUCTION 4-5

PICKING UP THE ATTACHMENTS 4-7

A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE 4-7

B - ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE (OPTION) 4-8

C - HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE 4-9

D - HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING DEVICE (OPTION) 4 - 10

4-3
INTRODUCTION TO SAFETY

4-4
INTRODUCTION TO SAFETY

INTRODUCTION

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

- A wide range of attachments studied and perfectly adapted to your lift truck is available and guaranteed by the manufacturer.

- 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.

All attachments with a suspended load (winch, crane boom, crane boom with winch, hook, etc.) MUST be used with a lift truck equipped
IMPORTANT
with a hydraulic movement cut-out device. In this case, the movement cut-out must be switched on and the transverse attitude perfectly
horizontal. approved by MANITOU are to be used on our lift trucks. The manufacturer's liability will be voided in case of modification(s)
Only attachments
without prior written permission.
Only attachments approved by MANITOU are to be used on our lift trucks (see : 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE :
Maximum loads are
TECHNICAL defined by the OF
SPECIFICATIONS capacity of a lift truck
ATTACHMENTS). taking
The into account
manufacturer's the attachment’s
liability will be deniedmass andofcenter
in case of gravity.
modification In attachment
or of the event ofadap-
the
attachment having out
tation carried lesswithout
capacityhisthan the liftit.truck, never exceed its limit.
knowing

Depending on their size, certain attachments may, when the WARNING

boom is lowered and retracted, come into contact with the front tires and
cause damage to them, if reverse tilt is activated in the forward tilt direction. TO REMOVE THIS RISK, EXTEND THE TELESCOPE TO A SUF-
FICIENT
Depending onEXTENT FORcertain
their size, THE PARTICULAR
attachmentsLIFT TRUCK
(when AND ATTACHMENT
the boom SO THAT
is lowered and/or THIS CONTACT
retracted, or the tilt IS
is NOT POSSIBLE.
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
INTRODUCTION TO SAFETY

4-6
INTRODUCTION TO SAFETY

PICKING UP THE ATTACHMENTS

A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE A

TAKING UP AN ATTACHMENT
- Ensure that the attachment is in alignment with the carriage. If it is not correctly orien-
ted, take the necessary precautions to move it 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 in front of and parallel to the attachment, tilt the
carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the boom, incline
the carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to enable 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
- 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 while making sure
you place the attachment flat on the ground and in closed position.

4-7
INTRODUCTION TO SAFETY

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

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

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

Always Always
close the valve close the
in position valveD)inafter
B (fig. position B (fig. D)
the locking afterattachment,
of the locking theinattachment, to
order to avoid
WARNING avoid
accidental unlocking andaccidental unlocking! safety.
use the attachment

HYDRAULIC RELEASING
- Put the valve in position A (fig. D), the hydraulic circuit of the attachment locking open.
- Press button 2 (fig. E) on the distributor lever to completely unlock the attachment.

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

D
A

4-8
INTRODUCTION TO SAFETY

C - HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE A

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

HAND LOCKING AND CONNECTING THE ATTACHMENT

- 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
- Stop the I.C. engine and keep the ignition on in the lift truck.
- Remove the pressure of the hydraulic circuit by pressing buttons 1 and 2 (fig. E) on the
distributor lever 4 or 5 times.
- Connect the rapid connectors according to the logic of the attachment’s hydraulic move-
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 ATTACHMENT

- Proceed in the reverse order of paragraph HAND LOCKING AND CONNECTING THE
ATTACHMENT while making sure you install the locking pin and the clip in the bracket (fig.
A).

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

4-9
INTRODUCTION TO SAFETY

D - HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING DEVICE (OPTION) A

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

HYDRAULIC LOCKING AND CONNECTING THE ATTACHMENT

- Put the valve in position A (fig. D), the hydraulic circuit of the attachment locking open.
- Press button 1 (fig. E) on the distributor lever to completely lock the attachment to the B
carriage.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Remove the pressure of the hydraulic circuit by pressing buttons 1 and 2 (fig. E) on the
distributor lever 4 or 5 times.
- Connect the rapid connectors according to the logic of the attachment’s hydraulic move-
ments.

Make sure that the rapid (quick-release) connectors are clean and protec-
Make sure that the rapid connectors are clean and protect the holes which are not used, with
IMPORTANT
the caps provided. ted with the caps provided when not in use.
- Close the valve in position B (fig. D), the hydraulic circuit of the attachment locking clo-
sed.

Always
Always close the valve close the
in position valveD)inafter
B (fig. position B (fig. D)
the locking afterattachment,
of the locking theinattachment, to
order to avoid
WARNING avoid
accidental unlocking andaccidental unlocking! safety.
use the attachment
C

HYDRAULIC RELEASING AND DISCONNECTING THE ATTACHMENT

- Close the attachment.
- Put the valve in position A (fig. D), the hydraulic circuit of the attachment locking open.
- Press button 2 (fig. E) on the distributor lever to completely unlock the attachment.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Remove the pressure of the attachment hydraulic circuit by pressing buttons 1 and 2 (fig.
E) on the distributor lever 4 or 5 times.
- Disconnect the rapid connectors of the attachment.

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

4 - 10