Operator Manual Manitou MTL 845 120 LSU - New - 2008

BP 249
44158 ANCENIS CEDEX - FRANCE

TEL : 33 (0)2 40 09 10 11
YOUR DEALER
547980 EN (01/04/2008)
MLT 845 120 LSU Srie 3-E3

MLT 940 L 120 LSU Srie 3-E3
OPERATORS MANUAL
THIS OPERATORS MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.
1 - OPERATING AND SAFETY INSTRUCTIONS
2 - DESCRIPTION
3 - MAINTENANCE
4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE
15/02/2008
1ST DATE OF ISSUE
01/04/2008
ADDING: 2-3 ; 2-7 ; 2-9 ; 2-16 ; 2-17 ; 2-24 2-26 ; 2-29 2-36 ; 2-40 ; 3-5 ; 3-9 ; 3-15 ; 3-35
THE TEXTS AND ILLUSTRATIONS IN THIS DOCUMENT MUST NOT BE REPRODUCED EITHER WHOLLY OR IN PART.
1 - OPERATING
AND SAFETY
INSTRUCTIONS
1-1
1-2
TABLE OF CONTENTS
INSTRUCTIONS TO THE COMPANY MANAGER
1-4
THE OPERATOR
THE LIFT TRUCK
A - THE LIFT TRUCKS SUITABILITY FOR THE JOB
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS
C - MODIFICATION OF THE LIFT TRUCK
THE INSTRUCTIONS
THE MAINTENANCE
1-4
1-4
1-4
1-4
1-5
1-5
1-5
INSTRUCTIONS FOR THE OPERATOR
1-6
PREAMBULE
GENERAL INSTRUCTIONS
A - OPERATORS MANUAL
B - AUTHORIZATION FOR USE IN FRANCE
(or see current legislation in other countries)
C - MAINTENANCE
D - MODIFICATION OF THE LIFT TRUCK
E - LIFTING PEOPLE
OPERATING INSTRUCTIONS UNLADEN AND LADEN
A - BEFORE STARTING THE LIFT TRUCK
B - DRIVERS OPERATING INSTRUCTIONS
C - ENVIRONMENT
D - VISIBILITY
E - STARTING THE LIFT TRUCK
F - DRIVING THE LIFT TRUCK
G - STOPPING THE LIFT TRUCK
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY
INSTRUCTIONS FOR HANDLING A LOAD
A - CHOICE OF ATTACHMENTS
B - MASS OF LOAD AND CENTRE OF GRAVITY
C - LONGITUDINAL STABILITY ALARM
D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK
E - TAKING UP A LOAD ON THE GROUND
F - TAKING UP AND LAYING A HIGH LOAD ON TYRES
G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS
H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD
I - TRAVELLING WITH A SUSPENDED LOAD
PLATFORM OPERATING INSTRUCTIONS
A - AUTHORISATION FOR USE
B - SUITABILITY OF THE PLATFORM FOR THE JOB
C - PRECAUTIONS WHEN USING THE PLATFORM
D - USING THE PLATFORM
E - ENVIRONMENT
F - MAINTENANCE
INSTRUCTIONS FOR USING THE RADIO-CONTROL
1-6
1-6
1-6
1-6
1-6
1-6
1-7
1-8
1-8
1-8
1-9
1-9
1 - 10
1 - 10
1 - 11
1 - 12
1 - 14
1 - 14
1 - 14
1 - 14
1 - 15
1 - 15
1 - 16
1 - 18
1 - 20
1 - 20
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 22
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK
1 - 24
MAINTENANCE
LUBRICANT AND FUEL LEVELS
HYDRAULIC
ELECTRICITY
WELDING
WASHING THE LIFT TRUCK
1
1
1
1
1
1
1
IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME
1 - 26
INTRODUCTION
PREPARING THE LIFT TRUCK
PROTECTING THE I.C. ENGINE
PROTECTING THE LIFT TRUCK
BRINGING THE LIFT TRUCK BACK INTO SERVICE
1
1
1
1
1
1-3
24
24
24
24
24
25
25
26
26
26
26
27
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 contra-indicated. Such foreseeable abnormal
uses, the main ones being listed below, are strictly forbidden.
- The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any wish to put the machinery to any improper use.
- The reflex reactions of a person in the event of a malfunction, incident, fault, etc. during operation of the lift truck.
- Behaviour resulting from application of the principle of least action when performing a task.
- For certain machines, the foreseeable behaviour of such persons as: apprentices, teenagers, handicapped persons, trainees tempted to drive a
lift truck, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.
The person in charge of the equipment must take these criteria into account when assessing whether or not a person will makea suitable driver.
THE LIFT TRUCK

A - THE TRUCKS SUITABILITY FOR THE JOB
- MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operators
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
perform certain tests (in accordance with current legislation).
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS
- In addition to series equipment mounted on your lift truck, many options are available, such as: road lighting, stop lights, flashing
light, reverse lights, reverse buzzer alarm, front light, rear light, light at the jib head, etc.
- The operator must take into account the operating conditions to define the lift trucks signalling and lighting equipment.
Contact your dealer.
- Take into account climatic and atmospheric conditions of the site of utilisation.
. Protection against frost (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
. Adaptation of lubricants (ask your dealer for information).
. I.C. engine filtration (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
For operation under average climatic conditions, i.e.: between - 15 C and + 35 C, correct levels of lubricants in all the circuits are checked in production.
For operation under more severe climatic conditions, before starting up, it is necessary to drain all the circuits, then ensure correct levels of lubricants
using lubricants properly suited to the relevant ambient temperatures. It is the same for the cooling liquid.
- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are
solutions, consult your dealer.
Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated premises. It is prohibited
to use the lift truck in areas where there is a risk of fire or which are potentially explosive (e.g. Refineries, fuel or gas depots, stores of inflammable
products). For use in these areas, specific equipment is available (ask your dealer for information).
- Our trucks comply with Directive 89/336/EC concerning electromagnetic compatibility (EMC), and with the corresponding harmonized
norm EN 12895. Their proper operation is no longer guaranteed if they are used within areas in which the electromagnetic fields
exceed the limit specified by that norm (10 V/m).
- Directive 2002/44/EC requires company managers to not expose their employees to excessive vibration doses. There is no
recognized code of measurement for comparing the machines of different manufacturers. The actual doses received can therefore
be measured only under actual operating conditions at the user's premises.
- The following are some tips for minimizing these vibration doses:
Select the most suitable lift truck and attachment for the intended use.
Adapt the seat adjustment to the operator's weight (according to lift truck model) and maintain it in good condition, as
well as the cab suspension. Inflate the tires in accordance with recommendations.
Ensure that the operators adapt their operating speed to suit the conditions on site.
As far as possible, arrange the site in such a way as to provide a flat running surface and remove obstacles and harmful
potholes.
1-4
C - MODIFICATION OF THE LIFT TRUCK

- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
THE INSTRUCTIONS
- The operators 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 operators manual and any plates or stickers which are no longer legible or are damaged, must be replaced immediately.
THE MAINTENANCE
- Maintenance or repairs other than those detailed in part: 3 - MAINTENANCE must be carried out by qualified personnel (consult
your dealer) and under the necessary safety conditions to maintain the health of the operator and any third party.
Your lift truck must be inspected periodically to ensure that it remains in compliance. The frequency of this inspection is defined by current legislation in
the country in which the lift truck is used.
1-5
INSTRUCTIONS FOR THE OPERATOR

PREAMBLE
WHENEVER YOU SEE THIS SYMBOL IT MEANS:
WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK.
The risk of accident while using, servicing or repairing your lift truck can be restricted if you follow the safety instructions and safety measures detailed
in these instruction.
- Only the operations and manuvres described in these operators manual must be performed. The manufacturer cannot predict
all possible risky situations. Consequently, the safety instructions given in the operators manual and on the lift truck itself are
not exhaustive.
- At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself
when you use it.
Failure to respect the safety and operating instructions, or the instructions for repairing or servicing your lift truck may lead to serious, even fatal
accident.
A - OPERATORS MANUAL
- Read the operators manual carefully.
- The operators manual must always be in good condition and in the place provided for it on the lift truck.
- You must report any plates and stickers which are no longer legible or which are damaged.
B - AUTHORISATION FOR USE IN FRANCE
(or see current legislation in other countries)
- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment with respect to the use of lift trucks and must be carried permanently by the operator.
- The operator is not competent to authorise the driving of the lift truck by another person.
C - MAINTENANCE
- The operator must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety
notice.
- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He must
keep the lift truck properly cleaned if this is among his responsibilities.
- The operator must carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- The operator must ensure tyres are adapted to the nature of the ground (see area of the contact surface of the tyres in the
chapter: 2 - DESCRIPTION: FRONT AND REAR TYRES). There are optional solutions, consult your dealer.
. SAND tyres.
. LAND tyres.
. Snow chains.
Do not use the lift truck if the tyres are incorrectly inflated, damaged or excessively worn, because this could put your own safety or that of others at
risk, or cause damage to the lift truck itself. The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer, excepting prior
authorisation.
D - MODIFICATION OF THE LIFT TRUCK
- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
1-6
E - LIFTING PEOPLE
- The use of working equipment and load lifting attachments to lift people is:
either forbidden
or authorized exceptionally and under certain conditions (see current regulations
in the country in which the lift truck is used).
- The pictogram posted at the operator station reminds you that:
Left-hand column
- It is forbidden to lift people, with any kind of attachment, using a non PLATFORMfitted lift truck.
Right-hand column
- With a PLATFORM-fitted lift truck, people can only be lifted using platforms
designed by MANITOU for the purpose.
- MANITOU sells equipment specifically designed for lifting people (OPTION PLATFORM
lift truck, contact your dealer).
1-7
OPERATING INSTRUCTIONS UNLADEN AND LADEN

A - BEFORE STARTING THE LIFT TRUCK
- Carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Make sure the lights, indicators and windscreen wipers are working properly.
- Make sure the rear view mirrors are in good condition, clean and properly adjusted.
- Make sure the horn works.
B - DRIVERS OPERATING INSTRUCTIONS
- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and
instruments before operating the lift truck.
- Wear clothes suited for driving the lift truck, avoid loose clothes.
- Make sure you have the appropriate protective equipment for the job to be done.
- Prolonged exposure to high noise levels may cause hearing problems. It is recommended to wear ear muffs to protect against
excessive noise.
- Always face the lift truck when getting into and leaving the driving seat and use the handle(s) provided for this purpose. Do not
jump out of the seat to get down.
- Always pay attention when using the lift truck. Do not listen to the radio or music using headphones or earphones.
- Never operate the lift truck when hands or feet are wet or soiled with greasy substances.
- For increased comfort, adjust the seat to your requirements and adopt the correct position in the drivers cab.
Under no circumstances must the seat be adjusted while the lift truck is moving.
- The operator must always be in his normal position in the drivers cab. It is prohibited to have arms or legs, or generally any part
of the body, protruding from the drivers cab of the lift truck.
- The safety belt must be worn and adjusted to the operators size.
- The control units must never in any event be used for any other than their intended purposes (e.g. climbing onto or down from the
lift truck, portmanteau, etc.).
- If the control components are fitted with a forced operation (lever lock) device, it is forbidden to leave the cab without first putting
these controls in neutral.
- It is prohibited to carry passengers either on the lift truck or in the cab.
1-8
C - ENVIRONMENT
- Comply with site safety regulations.
- If you have to use the lift truck in a dark area or at night, make sure it is equipped with working lights.
- During handling operations, make sure that no one is in the way of the lift truck and its load.
- Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load.
- When using the lift truck on a transverse slope, before lifting the jib, follow the instructions given in the paragraph: INSTRUCTIONS
FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK.
- Travelling on a longitudinal slope:
Drive and brake gently.
Moving without load: Forks or attachment facing downhill.
Moving with load: Forks or attachment facing uphill.

- Take into account the lift trucks dimensions and its load before trying to negotiate a narrow or low passageway.
- Never move onto a loading platform without having first checked:
That it is suitably positioned and made fast.
That the unit to which it is connected (wagon, lorry, etc.) will not shift.
That this platform is prescribed for the total weight of the lift truck to be loaded.
That this platform is prescribed for the size of the lift truck.
- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the lift
truck to be loaded and without having checked that they are in sound working order.
- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.
- Make sure the ground is stable and firm under the wheels and/or stabilizers before lifting or removing the load. If necessary, add
sufficient wedging under the stabilizers.
- Make sure that the scaffolding, loading platform, pilings or ground is capable of bearing the load.
- Never stack loads on uneven ground, they may tip over.
If the load or the attachment must remain above a structure for a long time, there is the risk that it will rest on the structure because of the jib
descending owing to the oil in the cylinders cooling down.
To eliminate this risk:
- Regularly check the distance between the load or the attachment and the structure and readjust this if necessary.
- If possible use the lift truck at an oil temperature as close as possible to ambient temperature.
- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and
the aerial line.
You must consult your local electrical agency. You could be electrocuted or seriously injured if you operate or park the lift truck too close to power
cables.
In the event of high winds, do not carry out handling work that jeopardizes the stability of the lift truck and its load, particularly if the load catches the
wind badly.
D - VISIBILITY
- The safety of people within the lift trucks working area, as well as that of the lift truck itself and the operator are depend on good
operator visibility of the lift trucks immediate vicinity in all situations and at all times.
- This lift truck has been designed to allow good operator visibility (direct or indirect by means of rear-view mirrors) of the immediate
vicinity of the lift truck while traveling with no load and with the jib in the transport position.
- Special precautions must be taken if the size of the load restricts visibility towards the front:
- moving in reverse,
- site layout,
- assisted by a person directing the maneuver (while standing outside the trucks area of travel), making sure to keep this
person clearly in view at all times.
- in any case, avoid reversing over long distances.
- Certain special accessories may require the truck to travel with the jib in the raised position. In such cases, visibility on the right
hand side is restricted, and special precautions must be taken:
- site layout,
- assisted by a person directing the maneuver (while standing outside the trucks area of travel).
- If visibility of your road is inadequate, ask someone to assist by directing the maneuver (while standing outside the trucks area
of travel), making sure to keep this person clearly in view at all times.
- Keep all components affecting visibility in a clean, properly adjusted state and in good working order (e.g. windscreens, windows,
windscreen wipers, windscreen washers, driving and work lights, rear-view mirrors).
1-9
E - STARTING THE LIFT TRUCK

SAFETY INSTRUCTIONS
The lift truck must only be started up or maneuvered when the operator is sitting in the drivers cab, with his seat belt adjusted and fastened.
- Never try to start the lift truck by pushing or towing it. Such operation may cause severe damage to the transmission. If necessary,
to tow the lift truck in an emergency, the transmission must be placed in the neutral position (see: 3 - MAINTENANCE: G OCCASIONAL MAINTENANCE).
- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connecting
it. Connect at first the positive terminals before the negative terminals.
Failure to respect polarity between batteries can cause serious damage to the electrical circuit. The electrolyte in the battery may produce an explosive
gas. Avoid flames and generation of sparks close to the batteries. Never disconnect a battery while it is charging.
INSTRUCTIONS
- Check the closing and locking of the hood(s).
- Check that the cab door is closed.
- Check that the forward/reverse selector is in neutral.
- Turn the ignition key to the position I to activate the electrical system and the preheat.
- Whenever you switch on the lift truck, perform the automatic check on the longitudinal stability alarm system (see: 2 - DESCRIPTION:
INSTRUMENTS AND CONTROLS). Do not use the lift truck if it does not conform to the regulations.
- Check the fuel level on the indicator.
- Turn the ignition key fully: the I.C. engine should then start. Release the ignition key and let the I.C. engine run at idle.
- Do not engage the starter motor for more than 15 seconds and carry out the preheating between unsuccessful attempts.
- Make sure all the signal lights on the control instrument panel are off.
- Check all control instruments when the I.C. engine is warm and at regular intervals during use, so as to quickly detect any faults
and to be able to correct them without any delay.
- If an instrument does not show the correct display, stop the I.C. engine and immediately carry out the necessary operations.
F - DRIVING THE LIFT TRUCK
SAFETY INSTRUCTIONS
Operators attention is drawn to the risks involved in using the lift truck, in particular:
- Risk of losing control.
- Risk of losing lateral and frontal stability of the lift truck.
The operator must remain in control of the lift truck.
In the event of the lift truck overturning, do not try to leave the cabin during the incident. YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN.
- Observe the companys traffic regulations or, by default, the public highway code.
- Do not carry out operations which exceed the capacities of your lift truck or attachments.
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 300 mm from the ground, the jib retracted
and the carriage sloping backwards.
- Only carry loads which are balanced and properly anchored to avoid any risk of a load falling off.
- Ensure that palettes, cases, etc, are in good order and suitable for the load to be lifted.
- Familiarise yourself with the lift truck on the terrain where it will be used.
- Ensure that the service brakes are working properly.
- The loaded lift truck must not travel at speeds in excess of 12 km/h.
- Drive smoothly at an appropriate speed for the operating conditions (land configuration, load on the lift truck).
- Do not use the hydraulic jib controls when the lift truck is moving.
- Do not manoeuvre the lift truck with the jib in the raised position unless under exceptional circumstances and then with extreme
caution, at very low speed and using gentle braking. Ensure that visibility is adequate.
- Take bends slowly.
- In all circumstances make sure you are in control of your speed.
- On damp, slippery or uneven terrain, drive slowly.
- Brake gently, never abruptly.
- Only use the lift trucks forward/reverse selector from a stationary position and never do so abruptly.
- Do not drive with your foot on the brake pedal.
- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, so turn it gently and
not jerkily.
- Never leave the I.C. engine on when the lift truck is unattended.
- Do not leave the cab when the lift truck has a raised load.
- Look where you are going and always make sure you have good visibility along the route.
1-10
Use the rear-view mirrors frequently.

Drive round obstacles.
Never drive on the edge of a ditch or steep slope.
It is dangerous to use two lift trucks simultaneously to handle heavy or voluminous loads, since this operation requires particular
precautions to be taken. It must only be used exceptionally and after risk analysis.
- The ignition switch has an emergency stop mechanism in case of an operating anomaly occurring in the case of lift trucks not fitted
with a punch-operated cut-out.
INSTRUCTIONS
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 300 mm from the ground, the jib retracted
and the carriage sloping backwards.
- For lift trucks with gearboxes, use the recommended gear (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
- Select the steering mode appropriate for its use and/or working conditions (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS)
(as model of lift truck).
- Release the parking brake.
- Shift the forward/reverse selector to the selected direction of travel and accelerate gradually until the lift truck moves off.
G - STOPPING THE LIFT TRUCK
SAFETY INSTRUCTIONS
- Never leave the ignition key in the lift truck during the operators absence.
- When the lift truck is stationary, or if the operator has to leave his cab (even for a moment), place the forks or attachment on the
ground, apply the parking brake and place the forward/reverse selector in neutral.
- Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at less than one meter from
the track of a railway.
- In the event of prolonged parking on a site, protect the lift truck from bad weather, particularly from frost (check the level of
antifreeze), close and lock all the lift truck accesses (doors, windows, cowls).
INSTRUCTIONS
- Park the lift truck on flat ground or on an incline lower than 15 %.
- Set the forward/reverse selector to neutral.
- Apply the parking brake.
- For lift trucks with gearboxes, place the gear lever in neutral.
- Retract entirely the jib.
- Lower the forks or attachment to rest on the ground.
- When using an attachment with a grab or jaws, or a bucket with hydraulic opening, close the attachment fully.
- Before stopping the lift truck after a long working period, leave the I.C. engine idling for a few moments, to allow the coolant liquid
and oil to lower the temperature of the I.C. engine and transmission. Do not forget this precaution, in the event of frequent stops
or warm stalling of the I.C. engine, or else the temperature of certain parts will rise significantly due to the stopping of the cooling
system, with the risk of badly damaging such parts.
- Stop the I.C. engine with the ignition switch.
- Remove the ignition key.
- Lock all the accesses to the lift truck (doors, windows, cowls).
1-11
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY

SAFETY INSTRUCTIONS
- Operators driving on the public highway must comply with current highway code legislation.
- The lift truck must comply with current road legislation. If necessary, there are optional solutions. Contact your dealer.
INSTRUCTIONS
- Make sure the revolving light is in place, switch it on and verify its operation.
- Make sure the lights, indicators and windscreen wipers are working properly.
- Switch off the working headlights if the lift truck is fitted with them.
- Select the steering mode HIGHWAY TRAFFIC (as model of lift truck) (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
- Retract entirely the jib and put the attachment at 300 mm from the ground.
- Place the slope correctors in the central position, i.e. the transverse shaft of the axles parallel to the chassis (as model of lift truck).
- Lift up the stabilizers to the maximum and turn the blocks inwards (as model of lift truck).
- 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.
Never move in neutral (forward/reverse selector or gear lever in neutral or transmission cut-off button pressed) to preserve the lift truck engine brake.
Failure to respect this instruction on a slope will lead to excessive speed which may make the lift truck uncontrollable (steering, brakes) and cause
serious mechanical damage.
1-12
DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT

- You must comply with current regulations in your country, covering the possibility of driving on the public highway with a frontmounted attachment on your lift truck.
- If road legislation in your country authorizes circulation with a front-mounted attachment, you must at least:
Protect and report any sharp and/or dangerous edges on the attachment (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION
ON THE RANGE: ATTACHMENT SHIELDS).
The attachment must not be loaded.
Make sure that the attachment does not mask the lighting range of the forward lights.
Make sure that current legislation in your country does not require other obligations.
OPERATING THE LIFT TRUCK WITH A TRAILER
- For using a trailer, observe the regulations in force in your country (maximum travel speed, braking, maximum weight of trailer, etc.).
- Do not forget to connect the trailers electrical equipment to that of the lift truck.
- The trailers braking system must comply with current legislation.
- If pulling a trailer with assisted braking, the tractor lift truck must be equipped with a trailer braking mechanism. In this case, do
not forget to connect the trailer braking equipment to the lift truck.
- The maximum vertical pull on the trailer hook must not exceed 1500 daN.
- The authorised maximum train weight must not exceed the maximum weight authorised by the manufacturer (consult the
manufacturers 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
INSTRUCTIONS FOR HANDLING A LOAD

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

- Before taking up a load, you must know its mass and its centre of gravity.
- The load chart for your lift truck is valid for a load in which the longitudinal position of the
centre of gravity is 500 mm from the base of the forks (fig. B1). For a higher centre of
gravity, contact your dealer.
- For irregular loads, determine the transverse centre of gravity before any movement (fig.
B2) and set it in the longitudinal axis of the lift truck.
B1
500 mm
It is forbidden to move a load heavier than the effective capacity defined on the lift truck load chart.
For loads with a moving centre of gravity (e.g. liquids), take account of the variations in the centre of
gravity in order to determine the load to be handled and be vigilant and take extra care to limit these
variations as far as possible.
B2
C - LONGITUDINAL STABILITY ALARM

- This device gives an indication of the lift trucks longitudinal stability. Move the jib very
carefully when approaching the authorized load limit (see: 2 - DESCRIPTION: INSTRUMENTS
AND CONTROLS).
- Always watch this device during handling operations.
- When the device is in alert mode, it is forbidden to perform so-called AGGRAVATING
movements, these being:
A - Extending the jib.
B - Lowering the jib.
- Perform movements to relieve aggravation in the following order (fig. C): if necessary,
raise the jib (1), retract the jib as far as possible (2) and lower the jib (3) to 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
1
2
3
D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK

Depending on the model of lift truck
D1
The transverse attitude is the transverse slope of the chassis with respect to the
horizontal.
Raising the jib reduces the lift trucks lateral stability. The transverse attitude must be set
with the jib in down position as follows:
1 - LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TYRES

- Position the lift truck so that the bubble in the level is between the two lines (see: 2 DESCRIPTION: INSTRUMENTS AND CONTROLS).
2 - LIFT TRUCK WITH SLOPE CORRECTOR USED ON TYRES

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

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

- Approach the lift truck perpendicular to the load, with the jib retracted and the forks in a horizontal position (fig. E1).
- Adjust the fork spread and centering in connection with the load (fig. E2) (optional solutions
exist, consult your dealer).
E1
- Never lift a load with a single fork.
Beware of the risks of trapping or squashing limbs when manually adjusting the forks.
- Move the lift truck forward slowly (1) and bring the forks to stop in front of the load (fig.
E3), if necessary, slightly lift the jib (2) while taking up the load.
- Bring the load into the transport position.
- Tilt the load far enough backwards to ensure stability (loss of load on braking or going
downhill).
FOR A NON-PALLETIZED LOAD
- Tilt the carriage (1) forwards and move the lift truck slowly forwards (2), to insert the fork
under the load (fig. E4) (block the load if necessary).
- Continue to move the lift truck forwards (2) tilting the carriage (3) (fig. E4) backwards to
position the load on the forks and check the loads longitudinal and lateral stability.
E4
E3
1
2
2
3
1-15
E2
F - TAKING UP AND LAYING A HIGH LOAD ON TYRES
F1
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see:
INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK).
REMINDER: Make sure that the following operations can be performed with good visibility
(see: OPERATIONS INSTRUCTIONS UNLADEN AND LADEN: D - VISIBILITY).
2
1
TAKING UP A HIGH LOAD ON TYRES

- Ensure that the forks will easily pass under the load.
- Lift and extend the jib (1) (2) until the forks are level with the load, moving the lift truck (3)
forward if necessary (fig. F1), moving very slowly and carefully.
- Always think about keeping the distance necessary to fit the forks under the load, between
the pile and the lift truck (fig. F1) and use the shortest possible length of jib.
- Stop the forks in front of the load by alternately extending and retracting the jib (1) or, if
necessary, moving the lift truck forward (2) (fig. F2). Put the handbrake on and set the
forward/reverse selector to neutral.
- 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 longitudinal stability alarm (see: INSTRUCTIONS FOR HANDLING A LOAD: C
- LONGITUDINAL STABILITY ALARM). If it is overloaded, replace the load in the place from
which it was taken.
- If possible lower the load without shifting the lift truck. Lift the jib (1) to release the load,
retract (2) and lower the jib (3) to bring the load into the transport position (fig. F4).
- If this is not possible, back up the lift truck (1), manoeuvring very gently and carefully to
release the load. Retract (2) and lower the jib (3) to bring the load into the transport position
(fig. F5).
F2
1
F3
2
F4
1
2
F5
2
1-16
LAYING A HIGH LOAD ON TYRES

- Approach the load in the transport position in front of the pile (fig. F6).
- Put the handbrake on and set the forward/reverse selector to neutral.
- Lift and extend the jib (1) (2) until the load is above the pile, while keeping an eye on the
longitudinal stability alarm (see: INSTRUCTIONS FOR HANDLING A LOAD: C - LONGITUDINAL
STABILITY ALARM). If necessary, move the lift truck (3) forward (fig. F7), driving very slowly
and carefully.
- Place the load in a horizontal position and lay it down on the pile by lowering and retracting
the jib (1) (2) in order to position the load correctly (fig. F8).
- If possible, release the fork by alternately retracting and raising the jib (1) (fig. F9). Then set
the forks into transport position.
- If this is not possible, reverse the lift truck (1) very slowly and carefully to release the
forks (fig. F10). Then set them into transport position.
F6
F7
2
1
3
F8
1
2
F9
1
F10
1-17
G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS

Depending on the model of lift truck
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see: INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE
ATTITUDE OF THE LIFT TRUCK).
REMINDER: Make sure that the following operations can be performed with good visibility (see: OPERATIONS INSTRUCTIONS UNLADEN
AND LADEN: D - VISIBILITY).
USING THE STABILIZERS
The stabilizers are used to optimise the lift trucks lifting performances (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
POSITION THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION (UNLADEN AND LADEN)
- Set the forks in transport position in front of the elevation.
- Stay far enough away to have room for the jib to be raised.
- Put the handbrake on and put the gearshift lever into neutral.
- Set the two stabilizers on the ground and lift the two front wheels of the lift truck (fig. G1),
while maintaining its transverse stability.
G1
RAISE THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION (UNLADEN AND LADEN)
- Raise both stabilizers fully and at the same time.
SETTING THE STABILIZERS WITH THE JIB UP (UNLADEN AND LADEN)

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

- Keep the jib up and retract the telescopes completely (fig. G3).
- Move the stabilizers very slowly and gradually as soon as they are in contact with the
ground and when they leave the ground. During this operation, the transverse attitude
must be permanently maintained: the bubble in the level must be kept between the two
lines.
- Raise both stabilizers completely.
- Release the parking brake and reverse the lift truck (1) very slowly and carefully, to
release it and lower the forks (2) into transport position (fig. G4).
G4
1-18
TAKING UP A HIGH LOAD ON STABILIZERS

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

- Raise and extend the jib (1) (2) until the load is above the elevation (fig. G9), while
monitoring the longitudinal stability alarm (see: INSTRUCTIONS FOR HANDLING A LOAD: C
- LONGITUDINAL STABILITY ALARM).
- Position the load horizontally and release it by lowering and retracting the jib (1) (2) to
position the load correctly (fig. G10).
- Release the forks by alternating retracting and raising the jib (3) (fig. G11).
- If possible, set the jib in transport position without moving the lift truck.
G10
G9
G11
3
2
1-19
H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD

WARNING: Failure to follow the above instructions may lead the lift truck to loose stability and overturn.
MUST be used with a lift truck equipped with an operational hydraulic movement cut-out device.
CONDITIONS OF USE
- The length of the sling or the chain shall be as short as possible to limit swinging of the load.
- Lift the load vertically along its axis, never by pulling sideways or lengthways.
HANDLING WITHOUT MOVING THE LIFT TRUCK
- Whether on stabilisers or on tyres, the lateral attitude must not exceed 1 % and the longitudinal attitude must not exceed 5%, the
bubble of the level must be held at 0.
- Ensure that the wind speed is not higher than 10 m/s.
- Ensure that there is no one between the load and the lift truck.
I - TRAVELLING WITH A SUSPENDED LOAD

- Before moving, inspect the terrain in order to avoid excessive slopes and cross-falls, bumps and potholes, or soft ground.
- Ensure that the wind speed is not higher than 10 m/s.
- The lift truck must not travel at more than 0.4 m/s (1.5 km/h, i.e., one quarter walking speed).
- Drive and stop the lift truck gently and smoothly to minimise swinging of the load.
- Carry the load a few centimetres above the ground (max. 30 cm) the shortest possible jib length. Do not exceed the offset
indicated on the load chart. If the load begins to swing excessively, do not hesitate to stop and lower the jib to set down the
load.
- Before moving the lift truck, check the longitudinal stability alarm device (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS),
only the green LEDs and possibly the yellow LEDs should be lit.
- During transport, the lift truck operator must be assisted by a person on the ground (standing a minimum of 3 m from the load),
who will limit swinging of the load using a bar or a rope. Ensure that this person is always clearly in view.
- The lateral attitude must not exceed 5%, the bubble in the level must be kept between the two MAX. marks
- The longitudinal attitude must not exceed 15%, with the load facing uphill, and 10%, with the load facing downhill.
- The jib angle must not exceed 45.
- If the first red LED of the longitudinal stability alarm device (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS) comes on
while travelling, gently bring the lift truck to a stop and stabilise the load. Retract the telescope to reduce the offset of the load.
1-20
PLATFORM OPERATING INSTRUCTIONS

For PLATFORM-fitted lift trucks
Installation of the platform on the lift truck is only possible if the shields operating the platform of the lift truck and the platform are identical (see: 2
- DESCRIPTION: OPERATING THE PLATFORM).
A - AUTHORISATION FOR USE
- Operation of the platform requires further authorisation in addition to that of the lift truck.
B - SUITABILITY OF THE TRUCK FOR USE
- MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operators
manual, with a STATIC test coefficient of 1.25 and a DYNAMIC test coefficient of 1.1, as specified in harmonised standard
EN 280 for mobile elevating work platforms.
- Before commissioning, the company manager must make sure that the platform is appropriate for the work to be done, and
perform certain tests (in accordance with current legislation).
C - PRECAUTIONS WHEN USING THE PLATFORM
- Wear clothes suited for operating the platform, avoid loose clothes.
- Never operate the platform when hands or feet are wet or soiled with greasy substances.
- Always pay attention when using the platform. Do not listen to the radio or music using headphones or earphones.
- For increased comfort, adopt the correct position at the platforms operator station.
- The platforms guard rail exempts the operator from wearing a safety harness under normal operating conditions. As a result, you
are responsible deciding whether to wear a safety harness.
- The controls must not be used for any other than their intended purpose (e.g. getting in and out of the lift truck, coat hanger etc.).
- Safety helmets must be worn.
- The operator must always be in the normal operators position. It is prohibited to have arms or legs, or generally any part of the
body, protruding from the basket.
- Ensure that any materials loaded onto the platform (pipes, cables, containers, etc.) cannot fall out. Do not pile these materials
to the point where it is necessary to step over them.
D - USING THE PLATFORM
- However experienced they may be, operators must acquaint themselves with the emplacement and operation of all control
instruments prior to operating the platform.
- Check before operating that the platform has been correctly assembled and locked onto the lift truck.
- Check before operating the platform that the access gate has been properly locked.
- The platform should be operated in an area free of any obstructions or danger when it is lowered to the ground.
- The operator using the platform must be aided on the ground by a person with adequate training.
- You should stay within the limits set out in the platform load chart.
- The lateral stresses are limited pressure (see: 2 - DESCRIPTION: CHARACTERISTICS).
- It is strictly forbidden to hand a load from the platform or the lift truck jib without a specially designed attachment (see: INSTRUCTIONS
FOR HANDLING A LOAD: H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD).
- The platform cannot be used as a crane or a lift for permanently transporting people or materials, nor as jacks or supports.
- The lift truck must not be moved with one (or more) person(s) in the platform.
- It is forbidden to transport people on the platform using the hydraulic controls in the lift trucks drivers cab (except in case of rescue).
- The operator must not get in or out of the platform when it is not on ground level (jib retracted and in the down position).
- The platform must not be fitted with attachments that increase the units wind load.
- Do not use ladders or improvised structures in the platform to gain extra height.
- Do not climb onto the sides of the platform to gain extra height.
E - ENVIRONMENT
NOMINAL VOLTAGE
Operating the platform close to electricity cables is forbidden. Maintain the specified
safe distances.
Operation of the platform is strictly forbidden in the event of wind speeds of over 45 km/h.
50 < U < 1000

1000 < U < 30000
30000 < U < 45000
45000 < U < 63000
63000 < U < 90000
90000 < U < 150000
150000 < U < 225000
225000 < U < 400000
400000 < U < 750000
DISTANCE ABOVE THE

GROUND OR THE FLOOR
IN METRES
2,30 M
2,50 M
2,60 M
2,80 M
3,00 M
3,40 M
4,00 M
5,30 M
7,90 M
F - MAINTENANCE
Your platform must be periodically inspected to ensure its continued compliance. The inspection frequency is defined by the current legislation in the
country in which the platform is used.
1-21
INSTRUCTIONS FOR USING THE RADIO-CONTROL

For lift trucks with RC radio control
HOW TO USE THE RADIO-CONTROL
SAFETY INSTRUCTIONS
- This radio-control consists of electronic and mechanical safety elements. It cannot receive commands from another transmitter
because the internal encoding is unique to each radio-control.
If it is used improperly or incorrectly, there is a risk of danger to:
- The physical and mental health of the user or others.
- The lift truck and other neighbouring items.
Everyone working with this radio-control:
- Must be qualified in line with current regulations and therefore appropriately trained.
- Must follow this instruction manual as closely as possible.
- The system is used to control the lift truck remotely via radio waves. Commands are also transmitted if the lift truck is out of sight
(behind an obstacle or a building for example), this is why:
After stopping the truck and removing the key button (only possible when it is stationary), always place the transmitter in
a safe, dry place.
Before performing any installation, servicing or repair work, always switch off power sources (in particular, electric welding
devices and electric head units on hydraulic distributors must be disconnected at each section).
Never remove or alter the safety devices (such as the hand-guard frame, key, emergency stop button, etc.).
Never drive the lift truck if it is not continuously and perfectly within view of the operator!
- Before leaving the transmitter, the operator must make sure that it cannot be used by an unauthorized third person: either by
removing the key button from the transmitter or locking it in an inaccessible place.
- The user must ensure that the instruction manual is accessible at all times and that operators have read and understood it.
INSTRUCTIONS
- Take up position in a stable place with no risk of slipping.
- Before using the transmitter, make sure there is nobody within the working area.
- Only use the transmitter with its carrying device.
When you remove the transmitter, remove the accumulator and key button so that it cannot be used accidentally or deliberately by anyone else.
PROTECTIVE DEVICES
- The lift truck will be immobilised within 450 milliseconds (approx. 0.5 second) at most:
If the transmitter emergency stop button (50 milliseconds), or the one on the lift is pressed.
If the transmission distance of the radio waves is exceeded.
If the transmitter is faulty.
If an interfering radio signal is received from elsewhere.
If the accumulator is removed from its housing in the transmitter.
If the accumulator reaches the end of its autonomy.
If the transmitter is switched off by turning the key button to stop.
- These protective devices are provided for the safety of personnel and property and must never be altered, removed or bypassed
in any way whatsoever!
- The hand-guard frame prevents external action on a manipulator (if the transmitter falls, for example, or if the operator leans on
a guard-rail).
- An electronic safety device prevents radio transmission from being initiated if the manipulators are not mechanically and electrically
at rest and if the internal combustion engine speed selector is not set to idle.
In an emergency, press the transmitter emergency stop button immediately ; then follow the manuals instructions (see: 2 - DESCRIPTION: INSTRUMENTS
AND CONTROLS).
1-22
1-23
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

- Ensure the area is sufficiently ventilated before starting the lift truck.
- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie and protect your hair,
if necessary.
- Stop the I.C. engine and remove the ignition key, when an intervention is necessary.
- Read the operators manual carefully.
- Carry out all repairs immediately, even if the repairs concerned are minor.
- Repair all leaks immediately, even if the leak concerned is minor.
- Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.
- Be careful of the risk of burning and splashing (exhaust, radiator, I.C. engine, etc.).
MAINTENANCE
- Perform the periodic service (see: 3 - MAINTENANCE) to keep your lift truck in good working conditions. Failure to perform the periodic
service may cancel the contractual guarantee.
MAINTENANCE LOGBOOK
- The maintenance operations carried out in accordance with the recommendations given in part: 3 - MAINTENANCE and the other
inspection, servicing or repair operations or modifications performed on the lift truck or its attachments shall be recorded in a
maintenance logbook. The entry for each operation shall include details of the date of the works, the names of the individuals or
companies having performed them, the type of operation and its frequency, if applicable. The part numbers of any lift truck items
replaced shall also be indicated.
LUBRICANT AND FUEL LEVELS

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

Do not fill the fuel tank when the I.C. engine is running.
Only fill up the fuel tank in areas specified for this purpose.
Do not fill the fuel tank to the maximum level.
Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
HYDRAULIC
- Any work on the load handling hydraulic circuit is forbidden except for the operations described in part: 3 - MAINTENANCE.
- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.
BALANCING VALVE: It is dangerous to change the setting and remove the balancing valves or safety valves which may be fitted to your lift truck cylinders.
These operations must only be performed by approved personnel (consult your dealer).
The HYDRAULIC ACCUMULATORS that may be fitted on your lift truck are pressurized units. Removing these accumulators and their pipework is a
dangerous operation and must only be performed by approved personnel (consult your dealer).
ELECTRICITY
- Do not short-circuit the starter relay to start the IC engine. If the forward/reverse selector is not in neutral and the parking brake is
not engaged, the lift truck may suddenly start to move.
- Do not drop metallic items on the battery.
- Disconnect the battery before working on the electrical circuit.
1-24
WELDING
- Disconnect the battery before any welding operations on the lift truck.
- When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being
welded, so as to avoid high tension current passing through the alternator.
- Never carry out welding or work which gives off heat on an assembled tyre. The heat would increase the pressure which could
cause the tyre to explode.
- If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing
irreparable damage to electronic components.
WASHING THE LIFT TRUCK

-
Clean the lift truck or at least the area concerned before any intervention.
Remember to close and lock all accesses to the lift truck (doors, windows, cowls).
During washing, avoid the articulations and electrical components and connections.
If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged,
particularly electrical components and connections and the injection pump.
- Clean the lift truck of any fuel, oil or grease trace.
FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT YOUR DEALER.
1-25
IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME

INTRODUCTION
The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an
extended period.
For these operations, we recommend the use of a MANITOU protective product, reference 603726.
Instructions for using the product are given on the packaging.
Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership.
PREPARING THE LIFT TRUCK

-
Clean the lift truck thoroughly.

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

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

- Set the lift truck on axle stands so that the tyres are not in contact with the ground and release the handbrake.
- Protect cylinder rods which will not be retracted, from corrosion.
- Wrap the tyres.
NOTE: If the lift truck is to be stored outdoors, cover it with a waterproof tarpaulin.
1-26
BRINGING THE LIFT TRUCK BACK INTO SERVICE

-
Remove the waterproof adhesive tape from all the holes.

Refit the intake hose.
Refit and reconnect the battery.
Remove the protection from the cylinder rods.
Perform the daily service (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
Put the handbrake on and remove the axle stands.
Empty and replace the fuel and replace the fuel filter (see: 3 - MAINTENANCE: D - EVERY 500 HOURS SERVICE).
Refit and set the tension in the drive belts (see: 3 - MAINTENANCE: C - EVERY 250 HOURS SERVICE).
Turn the I.C. engine using the starter, to allow the oil pressure to rise.
Reconnect the engine cut-off solenoid.
Lubricate the lift truck completely (see: 3 - MAINTENANCE: SERVICING SCHEDULE).
Make sure the area is adequately ventilated before starting up the lift truck.
- Start up the lift truck, following the safety instructions and regulations (see: OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Run all the jibs hydraulic movements, concentrating on the ends of travel for each cylinder.
1-27
1-28
2 - DESCRIPTION
2-1
2-2
TABLE OF CONTENTS
IDENTIFICATION OF THE LIFT TRUCK
2-4
CHARACTERISTICS
2-6
FRONT AND REAR TIRES
2-6
2-8
2 - 10
DIMENSIONS AND LOAD CHARTS
2 - 12
2 - 12
2 - 14
INSTRUMENTS AND CONTROLS
2 - 16
TOWING PIN AND HOOK
2 - 34
DESCRIPTION AND USE OF THE OPTIONS
2 - 36
2-3
IDENTIFICATION OF THE LIFT TRUCK

As our policy is to promote a constant improvement of our products, our range of telescopic lift trucks may undergo certain
modifications, without obligation for us to advise our customers.
When you order parts, or when you require any technical information, always specify:
NOTE: For the owners convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time
of the delivery of the lift truck.
LIFT TRUCK MANUFACTURERS PLATE (FIG. A)

-
Model
Series
Serial Nr
Chassis Nr
Year of manufacture
MANITOU BF
44158 ANCENIS CEDEX
FRANCE
MODELE
SERIE
N dans la srie
Anne de fabrication
N de chssis
For any further technical information regarding your lift truck refer to chapter: 2 DESCRIPTION: CHARACTERISTICS.
Masse vide
P.T.R.A.
kg
daN
Effort de traction
Puissance ISO/TR14396
kW
daN
Pression des pneumatiques (Bar)

AV.
AR.
Effort vertical max.

(sur accrochage remorque)
daN
N240804
I.C. ENGINE (FIG. B)
- I.C. engine Nr
GEAR BOX (FIG. C)
- Type
- MANITOU reference
- Serial Nr
ANGLE GEAR BOX (FIG. D)
- Type
- MANITOU reference
- Serial Nr
2-4
FRONT AXLE (FIG. E)
- Type
- Serial Nr
- MANITOU reference
REAR AXLE (FIG. F)
- Type
- Serial Nr
- MANITOU reference
CAB (FIG. G)
- Type
- Serial Nr
JIB (FIG. H)
- MANITOU reference
- Date of manufacture
ATACHMENT MANUFACTURERS PLATE (FIG. I)
- Model
- Serial Nr
- Year of manufacture
MANITOU BF
44158 ANCENIS CEDEX
FRANCE
MODELE
N$ dans la srie
Anne fabrication
Masse vide
kg
C d G / Tablier
A vide / En charge : mm
Cap. Nominale
Pression de service
AVERTISSEMENT : RESPECTEZ
LA CAPACITE DE L'ENSEMBLE
"CHARIOT ET EQUIPEMENT"
N$241415
2-5
CHARACTERISTICS
I.C. ENGINE
Type
Fuel
Number of cylinders
Suction
Injection system
Ignition sequence
Capacity
Bore and stroke
Compression ratio
Nominal rating loaded
Rating slow unladen
Max. rating unladen
Power ISO/TR 14396
Power SAE J 1995
Maximum torque ISO/TR 14396
Air cleaner
Type of cooling
Fan
cm3
mm
rpm
rpm
rpm
cv- kW
cv- kW
Nm
m
TRANSMISSION
Gear box
Type
Forward/reverse selector
Torque converter
Number of forward speeds
Number of reverse speeds
Angle gear box
Front axle
Differential
Rear axle
Differential
Drive wheels
Switch for 2/4 drive wheels
Front tyres
Size
Pressure
Rear tyres
Size
Pressure
bar
bar
ELECTRIC CIRCUIT
Battery
Alternator
Type
Starter
Type
PERKINS 1104D-E44TA NJ38698

Diesel
4 in line
Supercharged
Direct
1.3.4.2
4400
105 x 127
16,2/1
2200
930
2360
124 - 91
124 - 91
490 to 1400 rpm
3
By water
Puller
TURNER POWERTRAIN SYSTEMS

Mechanical
Electro-hydraulic
SACHS
4
4
DANA
45 % limited slip differential
DANA
4RM Permanent
No
MICHELIN
460/70 R24 XMCL 159A8
4
MICHELIN
460/70 R24 XMCL 159A8
4
12 V - 135 Ah - 850 A EN
12 V - 85 A
DENSO A115
12 V - 4,2 kW
ISKRA AZF LHS
BRAKE CIRCUIT
Service brake
Type of brake
Type of control
Parking brake
Type of brake
Type of control
Hydraulic power brake

Multidisk brake immersed in oil
Foot-operated for the front and rear axles
Low pressure brake
Electro-hydraulic
SOUND AND VIBRATION

Level of sound pressure in the drivers cab LpA
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on drivers body
The average weighted acceleration transmitted to the drivers hand/arm system
(according to standard ISO 5349-2)
2-6
dB
80 (cab closed)
dB
107 (measured)
107 (ensured)
m/s2
m/s2
< 2,5
HYDRAULIC CIRCUIT
Hydraulic pump
Type
Capacity
Max. rating capacity unladen
Flow rate at 1600 rpm
Filtration
Return
Suction
Maximum service pressure
Telescoping circuit
Lifting circuit
Tilt circuit
Attachment circuit
Steering circuit
cm3
l/mn
l/mn
m
m
bar
bar
bar
bar
bar
bar
HYDRAULIC MOVEMENTS
Longitudinal stability alarm device
Lifting motions (jib retracted)
Unladen lifting
Laden lifting
Unladen lowering
Laden lowering
Telescoping motions (jib raised)
Unladen extending
Laden extending
Unladen retracting
Laden retracting
Tilting movements
Unladen digging
Forward tilting unladen
Variable volume piston pump

63
149
101
10
125
270
200/270
280/200
190/280
270
140
Electronic
s
s
s
s
SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen
1
2
3
4
Rear unladen
1
2
3
4
Standard attachment
Weight of equipment
Weight of forks (each one)
Rated capacity with standard attachment
Tipping load at maximum reach on tyres
Distance from the centre of gravity from the load to the lug of the forks
Standard lifting height
Lift truck weight without attachment
Lift truck weight with standard attachment
Unladen
At rated load
Weight per axle with standard attachment (transport position)
Front unladen
Rear unladen
Front rated load
Rear rated load
Weight per axle with standard attachment (jib extended)
Front rated load
Rear rated load
Contact pressure on the ground for the whole surface of each
stabilizer at maximum load when tilting
Drag strain on the coupling hook
Unladen (sliding)
At rated load (transmission setting)
Pull strain with open carrier (according to standard ISO 8313)
2-7
m/mn
m/mn
m/mn
m/mn
9,6 - 30,4
10,4 - 27,9
6,1 - 47,6
5,6 - 51,7
s - m/mn
s - m/mn
s - m/mn
s - m/mn
9,8 - 18,6
10,1 - 19,4
7,8 - 24,2
7,9 - 23,8
s - /s
s - /s
3,7 - 38,4
3,2 - 44,4
km/h
km/h
km/h
km/h
km/h
km/h
km/h
km/h
5,3
8,6
18,2
32,4
5,3
8,6
18,2
32,4
PFB 45 N MT-1260
286
78
4500
1610
500
7550
8460
kg
kg
kg
kg
mm
mm
kg
kg
kg
8738
13238
kg
kg
kg
kg
3930
4900
11590
1740
kg
kg
9010
1070
kg/cm2
daN
daN
daN
6605
10355
6650
CHARACTERISTICS
I.C. ENGINE
Type
Fuel
Number of cylinders
Suction
Injection system
Ignition sequence
Capacity
Bore and stroke
Compression ratio
Nominal rating loaded
Rating slow unladen
Max. rating unladen
Power ISO/TR 14396
Power SAE J 1995
Maximum torque ISO/TR 14396
Air cleaner
Type of cooling
Fan
cm3
mm
rpm
rpm
rpm
cv- kW
cv- kW
Nm
m
TRANSMISSION
Gear box
Type
Forward/reverse selector
Torque converter
Number of forward speeds
Number of reverse speeds
Angle gear box
Front axle
Differential
Rear axle
Differential
Drive wheels
Switch for 2/4 drive wheels
Front tyres
Size
Pressure
Rear tyres
Size
Pressure
bar
bar
ELECTRIC CIRCUIT
Battery
Alternator
Type
Starter
Type
PERKINS 1104D-E44TA NJ38698

Diesel
4 in line
Supercharged
Direct
1.3.4.2
4400
105 x 127
16,2/1
2200
930
2360
124 - 91
124 - 91
490 to 1400 rpm
3
By water
Puller

Mechanical
Electro-hydraulic
SACHS
4
4
DANA
DANA
4RM Permanent
No
MICHELIN
460/70 R24 XMCL 159A8
4
MICHELIN
460/70 R24 XMCL 159A8
4
12 V - 135 Ah - 850 A EN
12 V - 85 A
DENSO A115
12 V - 4,2 kW
ISKRA AZF LHS
BRAKE CIRCUIT
Service brake
Type of brake
Type of control
Parking brake
Type of brake
Type of control
Hydraulic power brake

Foot-operated for the front and rear axles
Low pressure brake
Electro-hydraulic
SOUND AND VIBRATION

Level of sound pressure in the drivers cab LpA
Level of sound power ensured in the LwA environment
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on drivers body
The average weighted acceleration transmitted to the drivers hand/arm system
(according to standard ISO 5349-2)
2-8
dB
79 (cab closed)
dB
104 (measured)
104 (ensured)
m/s2
m/s2
< 2,5
HYDRAULIC CIRCUIT
Hydraulic pump
Type
Capacity
Max. rating capacity unladen
Flow rate at 1600 rpm
Filtration
Return
Suction
Maximum service pressure
Telescoping circuit
Lifting circuit
Tilt circuit
Tilting correction circuit
Attachment circuit
Steering circuit
cm3
l/mn
l/mn
m
m
bar
bar
bar
bar
bar
bar
bar
HYDRAULIC MOVEMENTS
Lifting motions (jib retracted)
Unladen lifting
Laden lifting
Unladen lowering
Laden lowering
Telescoping motions (jib raised)
Unladen extending
Laden extending
Unladen retracting
Laden retracting
Tilting movements
Unladen digging
Forward tilting unladen
Variable volume piston pump

63
149
101
10
125
270
200/270
280/200
190/280
270
270
140
Electronic
s
s
s
s
SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen
1
2
3
4
Rear unladen
1
2
3
4
Standard attachment
Weight of equipment
Weight of forks (each one)
Rated capacity with standard attachment
Tipping load at maximum reach on tyres
Distance from the centre of gravity from the load to the lug of the forks
Standard lifting height
Lift truck weight without attachment
Lift truck weight with standard attachment
Unladen
At rated load
Weight per axle with standard attachment (transport position)
Front unladen
Rear unladen
Front rated load
Rear rated load
Weight per axle with standard attachment (jib extended)
Front rated load
Rear rated load
Contact pressure on the ground for the whole surface of each
stabilizer at maximum load when tilting
Drag strain on the coupling hook
Unladen (sliding)
At rated load (transmission setting)
Pull strain with open carrier (according to standard ISO 8313)
2-9
m/mn
m/mn
m/mn
m/mn
8,4 - 40,8
9 - 38,1
6 - 57,1
5,8 - 59,1
s - m/mn
s - m/mn
s - m/mn
s - m/mn
9,7 - 21,3
9,9 - 21,8
8,3 - 25,4
8,2 - 25,8
s - /s
s - /s
3,7 - 38,1
3,3 - 42,7
km/h
km/h
km/h
km/h
km/h
km/h
km/h
km/h
5,3
8,6
18,2
32,4
5,3
8,6
18,2
32,4
PFB 45 N MT-1260
286
78
4000
1342
500
8970
8955
kg
kg
kg
kg
mm
mm
kg
kg
kg
9233
13233
kg
kg
kg
kg
4255
5070
11885
1440
kg
kg
9295
1070
kg/cm2
daN
daN
daN
7420
10040
7000
FRONT AND REAR TIRES
MLT 845 -120 LSU Srie 3-E3

DUNLOP
GOODYEAR
MICHELIN
NOKIAN
440/80-24 T37 158B TUBELESS
4,1
15,5/25 12PR SGL DL 2A
4,5
15,5/80-24 SGI 16 PR TUBELESS
4,5
445/70R24 IT510 151G TUBELESS
4,1
460/70R24 XMCL 159A8
1200R24 X MINE D2
15,5R25 XHA TUBELESS
445/65R22,5 XZY 169K TUBELESS
4,5
480/65R24 146D SF TUBELESS
3,8

DUNLOP
GOODYEAR
PRESSURE
(bar)
PRESSURE
(bar)
440/80-24 T37 158B TUBELESS
4,5
400/80-24 T37 156B TUBELESS
4,75
15,5/25 12PR SGL DL 2A
4,5
4,5
4,1
460/70R24 XMCL 159A8
MICHELIN
1200R24 X MINE D2
6,5
NOKIAN
3,8
PRESSURE
(bar)
4,1
440/80-24 T37 158B TUBELESS
4,5
DUNLOP
400/80-24 T37 156B TUBELESS
4,75
15,5/25 12PR SGL DL 2A
4,5
4,5
GOODYEAR
LOAD PER TYRE (kg)

FRONT UNLADEN
FRONT LADEN
REAR UNLADEN
REAR LADEN
1950
5800
2450
900
FRONT UNLADEN
FRONT LADEN
REAR UNLADEN
REAR LADEN
2100
5950
2500
700
LOAD PER TYRE (kg)
LOAD (kg)
900
1950
2450
5800
700
2100
2500
5950
700
2100
2500
5950
700
900
1950
2100
2450
2500
5800
5950
700
900
1950
2100
2450
2500
5800
5950
2-10
GROUND CONTACT PRESSURE

(kg/cm2)
HARD SOIL
6,08
7,65
8,24
12,10
5,83
8,03
8,47
12,56
6,60
9,12
9,62
13,72
5,00
6,43
6,96
6,85
6,81
6,94
8,40
8,44
8,75
7,60
9,07
9,23
10,21
10,42
13,81
13,92
LOOSE SOIL
1,68
2,14
2,29
3,34
1,63
2,23
2,34
3,45
1,84
2,52
2,66
3,85
2,69
3,46
3,75
3,72
3,71
3,76
4,54
4,56
2,33
2,08
2,47
2,51
2,71
2,73
3,74
3,75
GROUND CONTACT AREA (cm2)

HARD SOIL
144
255
297
480
120
261
295
474
106
230
260
434
140
140
280
307
360
360
690
705
80
120
215
228
240
240
420
428
LOOSE SOIL
520
910
1070
1735
430
939
1070
1724
380
831
940
1544
260
260
520
565
660
665
1278
1304
300
436
790
836
903
915
1550
1588
PRESSURE
(bar)
GOODYEAR
4,1
460/70R24 XMCL 159A8
6
1200R24 X MINE D2
6,5
MICHELIN
NOKIAN
445/65R22,5 XZY 169K TUBELESS
4,5
3,8
LOAD (kg)
700
900
1950
2100
2450
2500
5800
5950
700
900
1950
2100
2450
2500
5800
5950
900
1950
2450
5800
700
2100
2500
5950
700
900
1950
2100
2450
2500
5800
5950
900
1950
2450
5800
700
900
1950
2100
2450
2500
5800
5950
2-11
GROUND CONTACT PRESSURE

(kg/cm2)
HARD SOIL
7,00
7,32
8,67
8,88
9,07
9,09
10,29
10,31
2,43
4,09
4,64
6,67
2,00
4,31
4,75
6,89
1,57
1,76
2,77
2,92
3,09
3,09
3,63
3,65
2,64
3,40
3,66
4,83
2,90
2,95
3,18
3,20
3,25
3,26
3,32
3,33
LOOSE SOIL
2,30
2,41
2,87
2,92
3,02
3,01
3,40
3,40
0,74
0,83
1,29
1,36
1,44
1,44
1,64
1,64
0,41
0,50
0,95
1,01
1,13
1,15
1,98
2,02
GROUND CONTACT AREA (cm2)

HARD SOIL
100
120
225
237
270
275
564
577
370
477
528
869
350
487
526
864
445
482
675
703
793
810
1600
1635
339
573
669
1200
238
298
613
655
754
768
1746
1790
LOOSE SOIL
305
364
680
718
810
830
1708
1749
951
1030
1446
1506
1699
1736
3540
3621
1648
1711
2033
2073
2167
2180
2931
2966

A
B
C
C1
D
D1
D2
E
F
F1
G
G1
G2
I
J
K
L
N
O
P2
P3
R
S
T
U1
U2
V
V1
V2
W
Y
Z
mm
1200
mm
2770
mm
1409
mm
1487
mm
5229
mm
5307
mm
4395
mm
6429
mm
1950
mm
1950
mm
455
mm
450
mm
455
mm
1050
mm
950
mm
1260
mm
50
mm 1865/1915
mm
125
43,5
40
mm
3930
mm
8146
mm
3703
mm
2580
mm
2760
mm
5173
mm
1470
mm
4153
mm
2420
12
130
2-12
MLT/MT 845
50$
59$
9
40$
8
7.55
7
2000KG
30$
1250KG
10$
1
0$
-3$
1500KG
0.5m
-1
4
3
2
1
4.57
3.29 2.33 1.55
4.12
2.75 2.02 1.45
0m
SUIVANT NORME EN 1459 annexe B.
2-13
N$245143
20$
2000KG
2500KG
3000KG
3500KG
4500KG

A
B
C
C1
D
D1
D2
E
F
F1
G
G1
G2
H
H1
I
J
K
L
N
O
P2
P3
R
S
T
U1
U2
V
V1
V2
W
W1
Y
Z
mm
1200
mm
2770
mm
1834
mm
1893
mm
5654
mm
5713
mm
4420
mm
6854
mm
1990
mm
1990
mm
455
mm
450
mm
455
10
10
mm
1050
mm
950
mm
1260
mm
50
mm 1865/1915
mm
125
43,5
40
mm
3950
mm
8569
mm
4037
mm
2580
mm
2760
mm
5507
mm
1470
mm
4150
mm
2420
mm
11
130
2-14
MLT/MT 940 L
50
10
8.97
40
60
70
9
8
3500KG
7
10
1000KG
3
2
1
1500KG
20
2000KG
2500KG
3000KG
4000KG
6
30
0
0
0.5m
-1
5
5.32
3
2
1
3.48 2.47 1.82
2.89 2.12
4.32
0m
SUIVANT NORME EN 1459 annexe B.
2-15
N245144
-3
INSTRUMENTS AND CONTROLS

3
17
5
19
6
18
37
20
28
14
15
31
27
1
25
10
13
9
25
22
12
23
23
23
38
29
26
21
18
24
24
35
30
16
11
36
39
2-16
DESCRIPTION
1 - DRIVERS SEAT
2 - SAFETY BELT
3 - CONTROL AND SIGNAL LIGHTS PANEL
4 - LONGITUDINAL STABILITY ALARM
5 - SWITCHES
6 - LIGHTR SWITCH, HORN AND INDICATOR SWITCH
7 - IGNITION SWITCH
8 - BRAKING OIL TANK, FUSES AND RELAY ACCESS PANEL
9 - BRAKING OIL TANK
10 - FUSES AND RELAYS IN THE CAB
11 - FUSES AND RELAYS UNDER THE ENGINE HOOD
12 - WINDSCREEN WASHER TANK
13 - ROOF LIGHT
14 - ACCELERATOR PEDAL
15 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
16 - GEAR LEVER AND TRANSMISSION CUT-OFF
17 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
18 - STEERING SELECTION
19 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF
20 - FUNCTION FILES
21 - HEATER CONTROL
22 - AIR CONDITIONING CONTROLS (AIR CONDITIONING OPTION)
23 - RECYCLING INTAKES (AIR CONDITIONING OPTION)
24 - WINDSCREEN DEMISTER VENTS
25 - HEATING VENTS
26 - BUTTON FOR OPENING HYDRAULIC FLUID AND FUEL FILLER ACCESS PANEL
27 - DOOR LOCK
28 - LOCKING HANDLE FOR UPPER HALF-DOOR
29 - UNLOCKING BUTTON FOR UPPER HALF DOOR
30 - HANDLE FOR REAR WINDOW OPENING
31 - DOCUMENT HOLDER
32 - FRONT LIGHTS (NOT ILLUSTRATED)
33 - REAR LIGHTS (NOT ILLUSTRATED)
34 - FLASHING LIGHT (NOT ILLUSTRATED)
35 - LEVEL INDICATOR
36 - INSIDE REAR-VIEW MIRROR
37 - STEERING WHEEL ADJUSTMENT LEVER
38 - DIAGNOSTIC CONNECTOR
39 - TOOL BOX
NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are meant for an observer seated on drivers seat and looking in front of
him.
2-17
1 - DRIVERS SEAT
Designed for maximum comfort, this seat can be adjusted as follows.
4
LONGITUDINAL ADJUSTMENT
- Pull the locking lever 1 upwards.
- Slide the seat to the desired position.
- Release the lever and be sure it returns to the lock position.
SEAT CUSHION ADJUSTMENT

The front and the back of the seat cushion can be adjusted separately.
- To adjust the front, push the lever 2 downwards.
- Release it into one of the five possible positions.
- Same procedure to adjust the back by pulling the lever 2 upwards.
SEAT SUSPENSION ADJUSTMENT

- Turn the button 3 and adjust according to your weight.
ANGLE ADJUSTMENT OF THE BACK-REST
- Lean the back against the back-rest.
- Pull the lever 4 and place the back-rest into one of the possible positions.
1 - DELUXE PNEUMATIC DRIVERS SEAT (OPTION)

DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
WEIGHT ADJUSTMENT (FIG. A)
It is advised that you adjust the seat according to your weight when sitting.
- Switch on lift truck ignition.
- Pull or push lever 1 briefly. Adjustment is automatic.
NOTE: To avoid any health problems, it is recommended that the weight should be checked
and adjusted before starting up the lift truck.
SEAT HEIGHT ADJUSTMENT (FIG. B)

When weight adjustment has been carried out, you can then modify seat height.
- Keep the ignition on in the lift truck.
- Pull or push lever 1 and adjust the seat height.
To avoid causing any damage, do not activate the compressor for over 1 minute.
SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C)
The back-rest angle of the seat may be adjusted to suit the individual.
- Press the left-hand button while pushing on the seat or relaxing pressure on the seat to
find a comfortable position.
SEAT DEPTH ADJUSTMENT (FIG. D)

The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired
position.
EXTENDING THE HEAD-REST (FIG. E)
- The height of the back-rest can be adjusted by pulling it upwards (the notches will click)
up to the stop.
- The head-rest can be removed by applying sufficient pressure to pull it off the stop.
2-18
LUMBAR ADJUSTMENT (FIG. F)

This increases the comfort of the seat and the drivers freedom of movement.
- Press the raise and lower switches to adjust the curvature of the seat back to your
requirements.
ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)

- Support the back-rest, pull the lever and position the back-rest to find the desired
position.
If you do not support the back-rest when making adjustments, it swings completely forwards.
HORIZONTAL SHOCK ABSORBER (FIG. H)
In certain conditions (e.g. driving with a trailer) it is advised that a horizontal shock absorber
be used. The drivers seat is thus better able to absorb jerks in the direction of travel.
- Position 1: Horizontal shock absorber fitted.
- Position 2: Horizontal shock absorber removed.
DAMPING (FIG. I)
The damping of the seat can be adjusted to suit the nature of the terrain. The comfort of
the seat is thus adjustable to suit your requirements.
- Position 1: Soft damping.
- Position 2: Hard damping.
LONGITUDINAL ADJUSTMENT (FIG. J)
- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
MAINTENANCE (FIG. K)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.
A rocking head-rest increases the risk of an accident!

Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a
small hidden area before using any fabric or plastic cleaner.
2 - SAFETY BELT
-
Sit correctly on the seat.

Check that seat belt is not twisted.
Place the seat belt at hip level.
Attach the seat belt and check that it locks.
Adjust the seat belt to your body shape without squeezing your hip and without over-slack.
In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.
2-19
3 - CONTROL AND SIGNAL LIGHTS PANEL

A
A2
A1
A3
A4
A permanently lit or flashing warning lamp, with the engine running, is the sign of an operating fault. The lighting of some lamps may be accompanied
by an audible signal. Do not ignore this warning, consult your dealer without delay.
If one of the warning lamps comes on while the lift truck is in motion, stop the lift truck under the safest possible conditions.
In order to comprehend the diagnostic and find cause of the malfunction, refer to chapter: 3 - MAINTENANCE: SERVICING SCHEDULE.
When activating the electrical system of the lift truck, all the red and orange lamps and the panels buzzer must light to indicate
their good working order. If one of the red lamps or the buzzer does not function, carry out the necessary repairs.
A - I.C. ENGINE WATER TEMPERATURE
Temperature zone
A1 - Blue zone (0 - 50) Use the lift truck with moderation, wait for temperature to increase before normal operation.
A2 - Green zone (50 - 100) Use lift truck normally.
A3 - White/red zone (100 - 105) Use lift truck with moderation, monitor the temperature.
A4 - Red zone (105 - 120) Stop the lift truck, look for the cause of overheating.
NOTE: Red indicator light F comes on between zone A3 and A4.
B - RED I.C. ENGINE FAULT INDICATOR LIGHT
If the lamp comes on or flashes, when the lift truck is running, stop the I.C. engine immediately and consult your dealer.
C - ORANGE I.C. ENGINE FAULT INDICATOR LIGHT

If the lamp comes on or flashes while the lift truck is in operation, a diagnostic fault has been detected. The lift truck will operate
in reduced mode. Consult your dealer without delay.
D - ORANGE I.C. ENGINE PREHEATING INDICATOR LIGHT
Preheating is necessary. When the lift truck is switched on, the lamp comes on for 2 seconds and off as soon as preheating is
ended. Start the lift trucks I.C. engine.
E - RED I.C. ENGINE OIL PRESSURE INDICATOR LIGHT
If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and look for the cause (see oil
level in I.C. engine crankcase).
F - RED I.C. ENGINE WATER TEMPERATURE INDICATOR LIGHT
If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and investigate the cooling
circuit for the cause of the malfunction.
G - RED GEAR BOX OIL PRESSURE INDICATOR LIGHT
This lamp and buzzer come on when there is an abnormal drop in gear box pressure, in forward gear. Stop the lift truck and look
for the cause (e.g., Low oil level in the transmission, 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.
H - RED AIR FILTER CLOGGED INDICATOR LIGHT
The lamp and the buzzer come on when the air filter cartridge is clogged up. Stop the lift truck and carry out the necessary repairs
(see cleaning and replacement requirements in chapter: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
I - RED TRANSMISSION OIL TEMPERATURE INDICATOR LIGHT
The lamp and the buzzer come on when the gear box oil temperature is abnormally high. Stop the lift truck and look for the cause
of this overheating.
2-20
J - RED BATTERY CHARGE INDICATOR LIGHT

If the lamps G -G - H - I - J - N 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.
K - RED PARKING BRAKE INDICATOR LIGHT
This lamp comes on when the parking brake is applied.
L - GREEN DIRECTION INDICATOR LAMP
M - BLUE MAIN BEAM LAMP
N - RED BRAKINGNG 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.
O - HOUR METER
P - FUEL LEVEL
4 - LONGITUDINAL STABILITY ALARM

This device warns the operator that the lift truck is approaching the limit of longitudinal stability. However, lateral stability can
reduce the load chart in the upper part, and this reduction is not detected by the longitudinal stability alarm.
The operator must respect the lift trucks 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 the sound alarm function intermittently (stop the lift truck and consult your dealer, never attempt a
repair yourself).
A - VISUAL ALARM
A1 - 4 green leds: There is a large reserve of longitudinal stability.
A2 - 2 yellow leds: The lift truck is approaching the limit of longitudinal stability,
move carefully.
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. Move
very carefully.
A4 - 1 red led: The lift truck is at the authorized limit of longitudinal stability. The
alarm sounds simultaneously with a speed intermittent sound. Only
make de-aggravating hydraulic movements in the following order;
retract and raise the jib.
A4
A3
A2
A2
A1
A1
A1
A1
A
C
B1
B
B - SOUND ALARM
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
alarm must be switched on.
C - TEST SWITCH
Press the switch to verify at any time that the longitudinal stability alarm is working.
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
Disassembly or adjustment of the strain gauge is prohibited, this must only be done by specially trained
personnel, consult your dealer.
2-21
5 - SWITCHES
NOTE: The location of the switches may vary depending on the options.
A - HEATER BLOWER
This two speed switch allows warm or cold air to pass through the heating
ventilators.
B - 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.
H/M
K/L
C - OPTION ELECTROVALVE ON JIB HEAD + ATTACHMENT HYDRAULIC

LOCKING DEVICE
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS
D - FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER
This switch, when set to the intermediate position, the windscreen wiper to be operated and the down position and simultaneously
pressed, the windscreen-washer to be operated.
E - REAR WINDSCREEN WIPER + OPTIONAL ROOF WINDSCREEN WIPER
F - FLASHING LIGHT
G - OPTION WORKING HEAD LIGHT
H - OPTION CUTTING OFF SIMPLE and AGGRAVATING HYDRAULIC MOVEMENTS
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS
I - PARKING BRAKE
- Lower the button 1 and press the bottom of the switch to connect the parking brake. The signal lamp shows it is being used.
- Press the top of the switch to disconnect the parking brake.
J - TRANSMISSION CUT-OFF
The switch sets transmission cut-off to the service brake pedal
or the forward/reverse selector.
Position A: Indicator light on, transmission cut-off to service
brake pedal effected.
Position B: Indicator light off, transmission cut-off to forward/
reverse selector effected.
N272040
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.
Transmission cut-off to forward/reverse selector (position B).
When driving.
For inching and continuous stopping and starting (delicate handling). In order to optimise hydraulic movements, cut off transmission
to the forward/reverse selector.
Starting up on a slope.
K - OPTION WORKING TAIL LIGHT
L - OPTION SELF-CLEANING FAN
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS.
M - OPTION JIB SUSPENSION
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS.
2-22
6 - LIGHTR SWITCH, HORN AND INDICATOR SWITCH

The switch controls the visual and sound alarms.
A - All lights are off, the direction indicators do not flash.
B - The right hand direction indicators flash.
C - The left hand direction indicators flash.
D - The sidelights and the rear lights are on.
E - The dipped headlights and the rear lights are on.
F - The main beam headlights and the rear lights are on.
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 and pre-heating.
II - Not used.
III - The I.C. engine starts, return to position I as soon as the key is released.
8 - BRAKING OIL TANK, FUSES AND RELAY ACCESS PANEL

9 - BRAKING OIL TANK
See: 3 - MAINTENANCE: B - EVERY 50 HOURS SERVICE.
2-23
A
C
D
10 - FUSES AND RELAYS IN THE CAB
Always replace a faulty fuse with another of equivalent rating. Never use a fuse
that has been repaired.
3A
LSU
F2
F3
F4
F5
F6
F7
F8
F9
F10
OPT.
F11
F12
F13
15A max.
5A
10A
10A max.
7.5A
7.5A
7.5A
7.5A
15A
15A
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
5A
10A
10A
15A
7.5A
15A
15A
25A
7.5A
15A
10A max. 7.5A max.
F14
K5
STOP
OPT. OPT.
15A
10A
20A
A sticker on the protective lid gives you a rapid view of how to use the
components of the panel described below.
F25 F30
F1
OPT.
K4
K7
K6
K2
K3
K1
K0
OPT.
F1 - OPTION Pneumatic seat (10A).

F2 - Wheel alignment (5A).
F3 - Sound alarm (10A).
- Stop switch (10A).
F4 - OPTION Jib head light (10A).
F25 F30
- OPTIONAL Jib head electrovalve (10A).
- OPTION Electrovalve on jib head + attachment hydraulic locking device (10A).
F35
- OPTION Electrical jib provision (10A).
K17
K11
- OPTION Anti-theft device provision (10A).
- OPTION Anti-theft system (10A).
- OPTION Anti-start system (10A).
- OPTION Self-cleaning fan (10A).
- OPTION Jib suspension (10A).
F5 - Left indicators (7,5A).
F6 - Right sidelight (7,5A).
- Fuel gauge lighting (7,5A).
- Engine water temperature lighting module (7,5A).
F31
- Hour meter lighting (7,5A).
- OPTIONAL Number plate lighting (7,5A).
F7 - Left sidelights (7,5A).
F8 - Revolving light (7,5A).
F9 - OPTION Working tail light (15A).
F10 - OPTION Front working head light (15A).
F11 - Insulation of the compensation cylinders (7,5A).
- OPTION Air conditioning (7,5A).
F12 - Parking brake (7,5A).
- Tilt corrector safety (7,5A). MLT 940 L -120 LSU Srie 3-E3
- OPTION Jib suspension (7,5A).
F13 - Forward/reverse selector (15A).
- Transmission cut-off (15A).
- Reverse lights (15A).
- OPTION Reverse buzzer alarm (15A).
F14 - Longitudinal stability alarm (10A).
- OPTION Cutting off simple hydraulic movements (10A).
- Modules + OPTION Cutting off aggravating hydraulic movements (10A).
- Modules + OPTION Cutting off aggravating hydraulic movements + Forced operation (10A).
F15 - Signal lamp panel (5A).
- Fuel gauge (5A).
- Hour meter (5A).
F16 - Indicator power supply (10A).
F17 - Front windscreen wiper and windscreen washer (10A).
F18 - Main beam (15A).
- Main beam lamp (15A).
F19 - Right indicators (7,5A).
F20 - Low beam (15A).
F21 - Hazard warning lights power supply (15A).
- Roof light (15A).
- OPTIONAL (+)permanent (15A).
F22 - Light switch power supply, horn and indicators (25A).
F23 - Rear windscreen wiper (7,5A).
- OPTION Roof windscreen wiper (7,5A).
F24 - Heating (15A).
F25 - Starter (20A).
F30 - Electroproportional hydraulic control modules (3A).
- Modules + OPTION Forced operation (5A).
F31 - Diagnostic socket (1A).
F35 - Diagnostic socket (5A).
2-24
N244091
K0
K1
K2
K3
K4
K5
K6
K7
K9
K11
K12
K13
- Transmission cut-off relay.

- Transmission cut-off relay.
- Forward gear relay.
- Reverse gear relay.
- Safety system starting switch relay.
- Gear box oil pressure relay.
- Flashing unit.
- Buzzer.
- OPTION Relay cutting off simple hydraulic movements.
- Electroproportional hydraulic control power cut-off relay.
- OPTION Jib suspension relay.
- OPTION Jib head electrovalve relay.
- OPTION Jib head electrovalve relay + attachment hydraulic locking device.
K15 - OPTION Overload safety.
K17 - Aggravating hydraulic movements cut-off relay.
- OPTION Aggravating hydraulic movements cut-off relay + forced operation.
- OPTION Forced operation relay.
K18 - Hand brake indicator light relay.
K19 - Jib suspension cut-off relay.
K20 - Oil cooler relay.
K21 - Oil pressure indicator relay.
K12
K12
K13
K9
K9
11 - FUSES AND RELAYS UNDER THE ENGINE HOOD

Remove casing 1 and cover 2 for access to fuses and relays.
Always replace a faulty fuse with another of equivalent rating. Never use a fuse that has been repaired.
F32
F40
F41
F42
F43
F44
I.C engine electronic control unit (30A).

Lift truck electrical equipment (40A).
Lift truck electrical equipment (40A).
Preheating I.C. engine (80A).
Alternator (80A).
OPTION Diesel decongealant (15A).
K10 - Preheating I.C. engine relay.

K14 - OPTION Diesel decongealant.
F44 K14
F32
K10
F42
F43
2-25
F40
F41
12 - WINDSCREEN WASHER TANK

See: 3 - MAINTENANCE: B - EVERY 50 HOURS SERVICE.
13 - ROOF LIGHT
14 - ACCELERATOR PEDAL
15 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
The pedal acts on the front and rear wheels by a power assisted hydraulic brake system, and allows the lift truck to be slowed down
and stopped. Depending on the position of the transmission cut-off switch, it enables the transmission to be cut off during the free
travel (see: 2 - DESCRIPTION: 5 - SWITCHES).
16 - GEAR LEVER AND TRANSMISSION CUT-OFF

In order to change speeds, it is necessary to cut the transmission by pressing the button
1 on the lever.
1st gear: To the right, forwards.
2nd gear: To the right, backwards.
3rd gear: To the left, forwards.
4th gear: To the left, backwards.
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.
1
3
The choice of transmission gear ratio should be made carefully according to the nature of the work being
carried out. A poor choice may result in the extremely rapid rise of the transmission oil temperature
through excessive slipping of the converter, which could lead to serious damage to the transmission (it
is essential to stop and change the working conditions if the transmission oil temperature indicator light comes on). This poor choice may also result in
a reduction in the lift trucks performance in forward gear. When the forward force increases, the forward speed in the r gear (for example, in 3rd gear)
may be lower than the forward speed that could be obtained with the r-1 gear (in 2nd instead of 3rd).
In general, we would advise you to use the following gears according to the nature of the work being carried out.
On the road: Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it. In hilly areas, set off in 2nd
gear and go up to 3rd if the conditions and state of the road permit it.
With a trailer on the road: Set off in 2nd gear and switch 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.
2-26
17 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
FORWARD: Push the knob forward (position A).

REVERSE: Pull the knob backwards (position B).
NEUTRAL: The knob must be in the intermediate position to start the lift truck (position C).
C
B
When operating this control, the lift truck should be travelling at slow speed and not
accelerating.
NOTE: The reverse lights indicate that the lift truck is running in reverse motion. An
OPTIONAL audible reversing alarm can also be fitted.
SAFETY FOR MOVING THE LIFT TRUCK
Authorization to move the lift truck is controlled by an electronic unit. The operator must
observe the following sequence to move the truck forwards or backwards:
1 - sit down correctly in the drivers seat,
2 - release the parking brake,
3 - engage forward or reverse movement.
To stop the lift truck, he must observe the following sequence:
1 - set the forward/reverse selector to neutral.
2 - engage the parking brake,
3 - get out of the lift truck.
If these sequences are not observed (e.g.: leaving the drivers seat without setting the parking brake), a buzzer sounds. You must
then return the selector to the neutral position and repeat the sequence.
18 - STEERING SELECTION
Before selecting one of the three possible steering positions, bring the 4 wheels into
alignment, i.e., in the straight ahead position.
A - GREEN WHEEL ALIGNMENT LAMPS

These lamps come on to indicate the alignment of the wheels in relation to the lift truck.
Lamp A1 for the front wheels and lamp A2 for the rear wheels.
A1
A2
Before selecting one of the three possible steering positions, bring all 4 wheels into alignment with
regards to the lift truck axle. Never change the steering mode whilst driving.
B - STEERING SELECTION LEVER
B1 - Front drive wheels (highway traffic).
B2 - Front and rear drive wheels in opposite direction (short steering lock).
B2
B3 - Front and rear drive wheels in the same direction (crab steering).
B1
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.
B3
B
CONTROL FOR ALIGNMENT OF THE WHEELS

- Connect the switch (signal light ON).
- Shift the steering selection lever B into position B2 (short steering lock).
- Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up.
- Shift the steering selection lever B into position B1 (highway traffic).
- Turn the steering wheel and bring the front wheels into alignment until lamp A1 lights
up.
Before driving on roads, it is necessary to check the alignment of the rear wheels and to drive in front wheel steer. The control of the alignment of the
rear wheels must be regularly done with the help of the green lamps, while driving the lift truck. In case of anomalies, consult your dealer.
2-27
19 - HYDRAULIC CONTROLS AND TRANSMISSION CUT-OFF

Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve. In the event of suspected malfunction, contact
your dealer. ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID.
Use the hydraulic controls carefully without jerking, to avoid accidents caused by shaking the lift truck.
NOTE: If necessary use the steering to reset the hydraulic control steering accumulator.
A - Lifting and tilting control lever.
B - Telescoping control button.
C - Attachment control button.
D - Attachment control button.
N255968
LIFTING THE LOAD

- The lever A backwards when lifting.
- The lever A forwards when lowering.
TILT OF CARRIAGE
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Button B forwards for extending.
- Button B backwards for retracting.
ATTACHMENT
- The button C forwards or backwards.
OPTION JIB HEAD ELECTROVALVE
- Button D (see: 2 - DESCRIPTION: DESCRIPTION AND USE OF OPTIONS).
NOTE: When driving on the road, it is highly recommended that you cut-off all the hydraulic movements (see: 2 - DESCRIPTION:
5 - SWITCHES).
A - Lifting and tilting control lever.
B - Telescoping control button.
C - Attachment control button.
D - Attachment control button.
E - Tilting corrector control button.
N272035
LIFTING THE LOAD

- The lever A backwards when lifting.
- The lever A forwards when lowering.
TILT OF CARRIAGE
E
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Button B forwards for extending.
- Button B backwards for retracting.
ATTACHMENT
- The button C forwards or backwards.
OPTION JIB HEAD ELECTROVALVE
- Button D (see: 2 - DESCRIPTION: DESCRIPTION AND USE OF OPTIONS).
TILTING CORRECTOR
- Button E to the to the left to tilt the lift truck to the left.
- Button E to the right to tilt the lift truck to the right.
NOTE: Tilt can be corrected up to the carriage articulation axle height of 3m50 from the ground, with the jib retracted.
NOTE: When driving on the road, it is highly recommended that you cut-off all the hydraulic movements (see: 2 - DESCRIPTION:
5 - SWITCHES).
20 - FUNCTION FILES
These files contain the description of the hydraulic controls and the load charts for the attachments used on the lift truck.
2-28
21 - HEATER CONTROL
A - HEATING FAN CONTROL
This 2-speed control regulates warm or cold air through the heating ventilators.
In position 0, the fan is off.
In position 1, the fan is set to minimum speed.
In position 2, the fan is set to maximum speed.
A
0
1
2
B - HEATING TEMPERATURE CONTROL

Allows the temperature inside the cab to be adjusted.
In position 1, the valve is closed, the fan delivers fresh air.
In position 2, the valve is fully open, the fan delivers warm air.
The intermediate positions allow the temperature to be adjusted.
2
B
22 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)

The air conditioning only comes on when the forklift truck has been started up. When using your air
conditioning, you must work with the doors and windows closed.
In winter: So as to ensure correct operation and complete efficiency of the air conditioning unit, start
up the compressor once a week, if only for a short spell, so as to lubricate the internal seals.
In cold weather: Warm the I.C. engine before switching on the compressor, so as to allow the coolant
that has collected in the liquid state at the lowest point of the compressor circuit to turn into gas
under the effect of the heat given off by the I.C. engine, as the compressor is liable to be damaged by
coolant in the liquid state.
A
0
1
2
If your air conditioning does not seem to be working properly, have it examined by your dealer (see: 3
- MAINTENANCE: F - EVERY 2000 HOURS OF SERVICE). Never try to repair any possible problems by
yourself.
C - CONDITIONED AIR TEMPERATURE CONTROL
Allows the temperature inside the cab to be adjusted.
In position 0, the air-conditioning system is switched off.
In position 1, the air-conditioning system runs on minimum.
In position 2, the air-conditioning system runs on maximum.
The intermediate positions allow the temperature to be adjusted.
NOTE: Possible losses of water under the lift truck are due to condensate discharges caused
by the drying effect of the installation, especially with high outside temperatures
and high relative humidity.
For the air conditioning to perform properly, the air intakes must not be blocked by
frost, snow or leaves.
When the facility is running, at least one of the cab air grilles must be open so as
to avoid any risk of freezing to the evaporator.
2
B
CONDITIONED AIR MODE

The controls must be adjusted in the following way:
A - At the required position 1 or 2.
B - At the position 1 (heater valve closed).
C - At the required temperature.
2
1
DEMISTING MODE
The controls must be adjusted in the following way:
A - At the required position 1 or 2.
B - At the required temperature.
C - At the required temperature.
2-29
23 - RECYCLING INTAKES (AIR CONDITIONING OPTION)

24 - WINDSCREEN DEMISTER VENTS
For optimum effectiveness, close the heating ventilators.
25 - HEATING VENTS
These heating vents enable the air to be directed to the interior of the cabin and onto the side windows.
26 - BUTTON FOR OPENING HYDRAULIC FLUID AND FUEL FILLER ACCESS PANEL
- Push the button to open the access panel.
- Push the panel to close it.
27 - DOOR LOCK
Two keys are provided with the lift truck to enable the cabin to be locked.
28 - LOCKING HANDLE FOR UPPER HALF-DOOR

29 - UNLOCKING BUTTON FOR UPPER HALF DOOR
30 - HANDLE FOR REAR WINDOW OPENING
EMERGENCY EXIT
Use the rear window as an emergency exit, if it is impossible to leave the cab by the door.
31 - DOCUMENT HOLDER
Ensure that the operators manual is in its place in the document holder.
32 - FRONT LIGHTS
A - Left front indicator.
B - Left front dipped headlight.
C - Left front main beam.
D - Left front sidelight.
E - Right front indicator.
F - Right front dipped headlight.
G - Right front main beam.
H - Right front sidelight.
2-30
33 - REAR LIGHTS
A - Left rear indicator.
B - Left rear stoplight.
C - Left tail light.
D - Left rear reverse light.
E - Left rear fog light. (OPTION)
F - Right rear fog light. (OPTION)
G - Right rear reverse light.
H - Right tail light.
I - Right rear stoplight.
J - Right rear indicator.
34 - REVOLVING LIGHT
The revolving light is dismountable to make it possible, for example, to reduce the bulkiness
of the lift truck or to avoid being stolen.
- Loosen nut 1 and remove the revolving light.
- Protect mounting 2 with cap 3.
1
3
35 - LEVEL INDICATORS
A - SPIRIT LEVEL
Enables the operator to check that the lift truck is
in the horizontal position.

B - TILT INDICATOR
When the two marks are aligned, the chassis is
parallel with the front axle.
36 - INSIDE REAR-VIEW MIRROR
B
1
37 - STEERING WHEEL ADJUSTMENT LEVER

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.
38 - DIAGNOSTIC SOCKET
2-31
39 - TOOL BOX
2-32
2-33
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
authorised gross vehicle weight, tractive effort and maximum vertical force on the coupling point. This information is given on the
manufacturers plate fixed 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 trailers condition before using it (tyre condition and pressures, electrical connection, hydraulic hose, brake system).
Do not tow a trailer or attachment which is not in perfect working order. Using a trailer in poor condition may affect the lift trucks steering and braking,
and hence safety.
If a third party helps in coupling or uncoupling the trailer, this person must be permanently visible to the driver and wait until the lift truck has stopped,
the handbrake is on and the I.C. engine is switched off before performing the operation.
NOTE: There is an OPTIONAL rear-view mirror which allows the lift truck to be approached more closely to the trailer ring.
A - TOWING PINROCHE (STANDARD)

2
COUPLING AND UNCOUPLING THE TRAILER

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

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

- Set the coupling fitting 1 according to the height of the trailer ring.
Do not forget to put rods and clip back in place.
2-34
D - ADJUSTABLE PROJECTING HOOK (OPTION)

ON THE FIXED PIN
- Remove pin 1, remove rod 2 and raise latch 3.
- Insert or remove the trailer ring, lower latch 3 and refit rod 2.
ON THE COUPLING LADDER
- Set the coupling fitting 4 according to the height of the trailer ring.
Do not forget to put rods and clip back in place.
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 pulling the lever on distributor
2 backwards.
- Pull the knob 3, retain this position and push lever 2 forwards to lower the tow hook.
- Release knob 3.
- Couple or uncouple the trailer.
- Raise the trailer hook by pulling the lever on distributor 2 backwards and then lower the
hook to verify that the lock pin is in proper contact with hook 1 lock.
Never use the tow hook to raise the rear of the lift truck (when changing the rear wheel for example).
F - CONNECTING THE BRAKE SYSTEM (OPTION)

1
- Connect the brake hose to the provided brake unit 1 on the lift truck.
- Make sure the trailer brakes are working properly and test the effects of braking before
taking the trailer onto the public highway.
2-35
DESCRIPTION AND USE OF THE OPTIONS

1 - BATTERY CUT-OFF
2 - REVERSE BUZZER ALARM

3 - NUMBER PLATE
4 - NUMBER PLATE LIGHTING
3
5 - PREHEATING ELEMENT
Enables the engine to be kept warm during prolonged periods of stoppage and thus
improves engine starting.
Supply characteristics of preheating system:
Rated range of power: 220-240V; 50-60Hz
Current consumed: 4,5A
Equipment in class 1
Equipment connectable only on feeder circuit TT or TN
Category of insulation 2
Environmental conditions for use:

Maximum ambient temperature for using preheating: +25 C
Pollution level 2
Conditions for connection and use of preheating:
- The preheating system should not be used for an external ambient temperature higher than + 25 C.
- It is essential that the power supply to the preheating system is:
Effected with a cable that conforms to the installation standards in force and contains a protective earth conductor.
Contains an appropriate sectioning system.
Incorporates an appropriate safety system against short circuits (fuses or circuit breaker) and a differential circuit breaker
with 30mA sensitivity.
- Only connect to and disconnect from the power supply while the unit is off and the I.C. engine is stopped.
2-36
6 - MODCOD ANTI-THEFT SYSTEM

1
OPERATION
- Switch on the lift truck: the red indicator 1 will flash.
- Enter your user code followed by V to validate: the green indicator 2 will come on.
- Start the lift truck within the next 60 seconds; otherwise the anti-theft system will be
reactivated and the red indicator will flash.
NOTE:
- If you make a mistake when entering the code, press key A to cancel and re-enter the
code in full.
- If you wait more than 5 seconds between key presses or do not complete entering the
code, the anti-theft system will be reactivated and the red indicator will flash.
7 - FINTRONIC ANTI-START SYSTEM

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

This system, operated by switch 1, cleans the radiator core and the grille of the engine
cover by reversing the air flow.
B
When in use, beware of the risk of projection into the eyes.
Position A: The indicator light is on, the fan operates in self-cleaning mode for a few
seconds once every 3 minutes.
Position B: The indicator light is off, the fan is in normal operating mode.
2-37
9 - ELECTRICAL JIB PROVISION

Enables an electrical function to be used at the head of the jib.
OPERATION
- Hold button 1 down and move button 2 forwards or backwards.
NOTE: Switch 3 enables the function controlled by button 1 to be locked. Indicator 4 lights
up to show when it is in use.
1
2
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 - OPTIONAL ATTACHMENTS FOR USE WITH
THE RANGE: PICKING UP THE ATTACHMENTS).
2-38
12 - JIB HEAD ELECTROVALVE

Enables use of two hydraulic functions on the attachment circuit.
To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing button
1 on the electrovalve.
OPERATION
- With button 1 not engaged, button 2 controls a hydraulic function.
- Hold button 1 down, button 2 controls another hydraulic function.
NOTE: Switch 3 enables the hydraulic function controlled by button 1 to be locked. Indicator
4 lights up to show when it is in use.
1
3
13 - JIB HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING

The addition of these two options enables the combining of several hydraulic functions.
OPERATION
- Button 1 not engaged, button 2 controls a hydraulic function.
- Hold button 1 down, button 2 controls another hydraulic function.
NOTE: Switch 3 enables the hydraulic function controlled by button 1 to be locked. Indicator
4 lights up to show when it is in use.
1
3
2-39
14 - CUTTING OFF SIMPLE HYDRAULIC MOVEMENTS

The function which cuts hydraulic movements is used to automatically stop dangerous
movement of the jib when you are close to the limit of longitudinal stability. However, lateral
stability can reduce the load chart in its upper part and this reduction is not detected by
the longitudinal stability alarm.
A
B
B4
A1

All attachments with a suspended load (winch, crane jib, crane jib with winch, hook, etc.) MUST be used
with a lift truck equipped with a working hydraulic movement cut-out device.
OPERATION
Switch A allows you to cut off SIMPLE hydraulic movements or not. The cutting-off of
SIMPLE hydraulic movements is automatically enabled when the lift truck is started-up.
WITH CUT-PUT OF SIMPLE HYDRAULIC MOVEMENTS: VISUAL INDICATOR A1 OFF:
- Led B4 indicates that the lift truck has reached the authorized limit of longitudinal stability and all hydraulic movements are
neutralized.
- The sound alarm goes off at the same time.
- To restart hydraulic movement, proceed as follows:
- Press the bottom of switch A, visual indicator A1 comes on and indicates that the hydraulic movement cut-out is disabled.
- Only perform de-aggravating hydraulic movements in the following order: jib retracted and raised.
- Re-enable the hydraulic movement cut-out by pressing the top of switch A, visual indicator A1 will go out.
NOTE: When the jib is retracted, the function for switching off SIMPLE hydraulic movements is disconnected.
WITHOUT CUTTING-OUT SIMPLE HYDRAULIC MOVEMENTS: VISUAL INDICATOR A1 ON:
- To allow the use of loading or earth moving buckets, for example.
- In this case, the user is only informed by the longitudinal stability alarm system B (see: 2 - DESCRIPTION: 4 - LONGITUDINAL
STABILITY ALARM SYSTEM).
15 - CUTTING OFF AGGRAVATING HYDRAULIC MOVEMENTS

The function which cuts hydraulic movements is used to automatically stop dangerous
movement of the jib when you are close to the limit of longitudinal stability. However, lateral
stability can reduce the load chart in its upper part and this reduction is not detected by
the longitudinal stability alarm.
A
B
B4
A1

All attachments with a suspended load (winch, crane jib, crane jib with winch, hook, etc.) MUST be used
with a lift truck equipped with a working hydraulic movement cut-out device.
OPERATION
Switch A allows you to cut-off AGGRAVATING hydraulic movements or not. The cutting-off
of AGGRAVATING hydraulic movements is automatically enabled when the lift truck is
started-up.
WITH CUT-OUT OF AGGRAVATING HYDRAULIC MOVEMENTS: VISUAL INDICATOR A1 OFF:
- Led B4 indicates that the lift truck has reached the authorized limit of longitudinal stability and all aggravating hydraulic movements
are neutralized.
- The sound alarm goes off at the same time.
- To restart hydraulic movements, only perform de-aggravating hydraulic movements in the following order: jib retracted and
raised.
NOTE: When the jib is retracted, the function for switching off AGGRAVATING hydraulic movements is disconnected.
WITHOUT CUTTING-OUT AGGRAVATING HYDRAULIC MOVEMENTS: VISUAL INDICATOR A1 ON:
- To allow the use of loading or earth moving buckets, for example.
- In this case, the user is only informed by the longitudinal stability alarm system B (see: 2 - DESCRIPTION: 4 - LONGITUDINAL
STABILITY ALARM SYSTEM).
2-40
16 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION

Enables the use of a hydraulic rear hook or of a trailer with hydraulic tipping.
B
A
1
- Single or double effect rear hydraulic control functions with hydraulic control of the
additional attachment (see chapter: 2 - DESCRIPTION: 20 - HYDRAULIC CONTROLS)
according to the position of tap 1.
- Position A: Hydraulic control of the additional attachment at the front of the lift
truck.
- Position B: Hydraulic control of the additional attachment at the rear of the lift
truck.
17 - ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION

This OPTION must only be used with an attachment requiring continuous hydraulic movement of type:
brush, supply bucket, mixer, spray It is strictly forbidden in handling operations and at all other events
(winch, crane jib, crane jib with winch, hook, etc.).
CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT

- Make sure the potentiometer C is set to 0 %.
- Switch button A to the front or the back (depending on the type of attachment), press button
B and release button A. The red indicator 1, flashes to indicate that it is in operation.
- Set the required flowrate using potentiometer C.
- To stop continuous hydraulic movement of the attachment, move switch A forwards or
backwards or press button B. Indicator 1 goes out.
- Set potentiometer C to 0 %.
Never leave the drivers cab without resetting the potentiometer C to 0 %. Before starting the lift truck,
make sure the potentiometer is set to 0 %.
NOTE: If the operator leaves the drivers cab, the continuous hydraulic movement will
automatically stop and must be restarted.
1
B
18 - JIB SUSPENSION
The jib is suspended to reduce shaking of the lift truck on rough ground (e.g. moving straw
in a field).
OPERATION
- Set the forks or attachment on the ground and relieve the front wheels a few centimetres
only.
- Press switch 1 set to position A, the visual indicator comes on indicating that jib suspension
is activated.
- Press switch 1 set to position B, the visual indicator goes out indicating that jib suspension
is deactivated.
Jib suspension is active to a lifting height of 3m00 from the axis of articulation of the carriage with
respect to the ground with the jib retracted. When you move beyond this height or make another
hydraulic movement (tilting, telescoping, attachment), jib suspension is momentarily deactivated and
the visual indicator of switch 1 goes out.
- When the I.C. engine is off, jib suspension is automatically deactivated.
2-41
2-42
3 - MAINTENANCE
3-1
3-2
TABLE OF CONTENTS
ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT
3-4
FILTERS CARTRIDGES AND BELTS
3-5
LUBRICANTS AND FUEL
3-6
SERVICING SCHEDULE
3-8
A - DAILY OR EVERY 10 HOURS SERVICE
3 - 10
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 - 28
F - EVERY 2000 HOURS OF SERVICE
3 - 34
G - OCCASIONAL MAINTENANCE
3 - 36
3-3
MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.
IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,

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

- Technically - to generate operating failure or shorten the life of the lift truck.
THE USE OF COUNTERFEIT PARTS OR COMPONENTS NOT APPROVED BY THE MANUFACTURER,

MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.
BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,

YOU BENEFIT
EXPERTISE
Through its network, MANITOU provides the user with

- Know-how and competence.
- The guarantee of high-quality work.
- Original replacement components.
- Help with preventive maintenance.
- Efficient help with diagnosis.
- Improvements due to experience feedback.
- Operator training.
- Only the MANITOU network has detailed knowledge of the design of the lift truck and therefore the best
technical ability to provide maintenance.
ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
the dealer network list is available on manitou web site www.manitou.com
3-4
FILTERS CARTRIDGES AND BELTS

I.C. ENGINE
I.C. ENGINE OIL FILTER
Part number: 476954
Change: 500 H
ALTERNATOR BELT
Part number: 244288
DRY AIR FILTER CARTRIDGE

Part number: 563416
Clean: 50 H*
Change: 500 H*
FAN BELT
Part number: 257524
SAFETY DRY AIR FILTER CARTRIDGE

Part number: 563415
Change: 1000 H*
COMPRESSOR BELT
(OPTION AIR CONDITIONING)
Part number: 244237
FUEL FILTER
Part number: 747351
Change: 500 H
CYCLONIC PRE-FILTER
Part number: 224713
Clean: 10 H
FUEL PRE-FILTER
Part number: 747462
Change: 500 H
AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION)

Part number: 226611
AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION)

Part number: 223510
*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.
TRANSMISSION
GEAR BOX OIL FILTER
Part number: 561749
Change: 500 H
HYDRAULIC
HYDRAULIC RETURN OIL FILTER CARTRIDGE
Part number: 221174 (Qty: 2)
Change: 500 H
SUCTION STRAINER FOR HYDRAULIC OIL TANK

Part number: 257603
Clean: 1000 H
FILTER CAP FOR HYDRAULIC OIL TANK

Part number: 62415
Change: 1000 H
DISTRIBUTOR CONTROL HEAD FILTER

Part number: 254780
Change: 1000 H
CAB
CAB VENTILATION FILTER (OPTION AIR CONDITIONING)
Part number: 552552
Clean: 50 H
Change: 250 H
3-5
LUBRICANTS AND FUEL

USE THE RECOMMENDED LUBRICANTS AND FUEL:
- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.
DIAGNOSTIC ANALYSIS OF OILS
If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle oils
may be requested depending on the rate of use.
(*) RECOMMENDED FUEL SPECIFICATION:
Use a high-quality fuel to obtain optimal performance of the I.C. engine.
N590 diesel fuel type - Auto/C0/C1/C2/C3/C4
BS2869 Class A2
ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA
JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.
I.C. ENGINE
ORGANS TO BE LUBRICATED
CAPACITY
I.C. ENGINE
11 Liters
RECOMMENDATION
MANITOU Oil
API CH4
Cooling liquid
(protection - 30)
COOLING CIRCUIT
18,5 Liters
Cooling liquid
(protection - 25)
FUEL TANK
135 Liters
TRANSMISSION
CAPACITY
GEAR BOX
15,1 Liters
ANGLE GEAR BOX
2,2 Liters
PART NUMBER
661706
582357
582358
582359
490205
473076
470077
470078
554002
554003
554004
PACKAGING
1l
20 l
55 l
209 l
1000 l
1l
20 l
55 l
209 l
1000 l
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
62148
546332
546217
546195
720148
62148
546332
546217
546195
720148
161589
720683
554974
499233
489670
PACKAGING
400 g
1 kg
5 kg
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
545996
161590
499235
161589
720683
554974
499233
489670
PACKAGING
5l
20 l
55 l
209 l
PART NUMBER
545500
582297
546108
546109
Diesel fuel (*)
RECOMMENDATION
MANITOU Oil
Automatic transmission
MANITOU Oil
SAE80W90
Mechanical transmission
MANITOU Grease
BLUE multi-purpose
TRANSMISSION UNIVERSAL JOINT
PACKAGING
5l
20 l
55 l
209 l
1000 l
2l
5l
20 l
2l
5l
20 l
JIB
RECOMMENDATION
JIB PADS
MANITOU Grease
BLACK multi-purpose
GREASING OF THE JIB
MANITOU Grease
BLUE multi-purpose
HYDRAULIC
CAPACITY
HYDRAULIC OIL TANK
131 Liters
RECOMMENDATION
MANITOU Oil
Hydraulic ISO VG 46
3-6
BRAKE
BRAKE CIRCUIT
RECOMMENDATION
MANITOU Oil
Mineral brake fluid
PACKAGING
PART NUMBER
1l
490408
RECOMMENDATION
PACKAGING
400 g
1 kg
5 kg
1l
5l
PART NUMBER
545996
161590
499235
490402
486424
PACKAGING
5l
20 l
209 l
1000 l
2l
5l
20 l
55 l
209 l
PART NUMBER
545976
582391
546222
720149
499237
720184
546330
546221
546220
400 g
1 kg
5 kg
545996
161590
499235
PACKAGING
5l
20 l
209 l
1000 l
2l
5l
20 l
55 l
209 l
PART NUMBER
545976
582391
546222
720149
499237
720184
546330
546221
546220
400 g
1 kg
5 kg
545996
161590
499235
PACKAGING
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
161589
720683
554974
499233
489670
CAB
CAB DOOR
MANITOU Grease
BLACK multi-purpose
WINDSCREEN WASHER TANK
Windscreen washer fluid
FRONT AXLE
CAPACITY
RECOMMENDATION
FRONT AXLE DIFFERENTIAL
6,7 Liters
MANITOU Oil
Special immersed brakes
FRONT WHEELS REDUCERS
1,8 Liter
MANITOU Oil
SAE80W90
FRONT WHEELS REDUCERS PIVOTS

Graisse MANITOU
Multi-usage NOIRE
FRONT AXLE OSCILLATION

REAR AXLE
CAPACITY
RECOMMENDATION
REAR AXLEDIFFERENTIAL
7,3 Liters
MANITOU Oil
Special immersed brakes
FRONT/REAR REDUCING GEARDIFFERENTIAL
1,8 Liter
MANITOU Oil
SAE80W90
REAR WHEELS REDUCERS PIVOTS

REAR AXLE OSCILLATION
MANITOU Grease
BLACK multi-purpose
CHASSIS
TILTING CORRECTOR
RECOMMENDATION
MANITOU Grease
BLUE multi-purpose
3-7
SERVICING SCHEDULE
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,P = BLEED,

R = REPLACE, V = DRAIN
I.C. ENGINE
I.C. engine oil level
Cooling liquid level
Fuel level
Fuel pre-filter
Cyclonic pre-filter
Dry air filter cartridge
Radiator cores
Condenser core (OPTION Air conditioning)
Fan belt tension
Alternator/crankshaft belt tension
Compressor belt tension (OPTION Air conditioning)
I.C. engine oil
I.C. engine oil filter
Fuel pre-filter
Fuel filter
Fuel tank
Safety dry air filter cartridge
I.C. engine silent blocks
I.C. engine rates
Valves clearances
Cooling liquid
Radiator
Water pump and the thermostat
Alternator and the starter motor
Turbo compressor
Fuel circuit
TRANSMISSION
Gear box oil level
Transmission universal joint
Angle gear box oil level
Gear box oil filter
Gear box oil
Gear box sump strainer
Angle gear box oil
Silentblocks in the gear box
Gear box controls
Gear box pressures
Converter pressure
TYRES
Tyres pressure
Wheel nuts torque
Condition of wheels and tyres
Wheel
JIB
Jib pads
Jib
Jib pads wear
Condition of jib unit
Bearings and articulation rings
HYDRAULIC
Hydraulic oil level
hydraulic return oil filter cartridge
Hydraulic oil
Suction strainer for hydraulic oil tank
Filter cap for hydraulic oil tank
Distributor control head filter
Speeds of hydraulic movements
Hydraulic pump tubular filter
Condition of hoses and flexible pipes
Condition of cylinders (leakage, shafts)
Hydraulic circuit pressures
Hydraulic circuit outputs
Hydraulic oil tank
AFTER THE
FIRST 50
HOURS
PAGE
3-10
3-10
3-10
3-11
3-11
3-14/25
3-14
3-14
3-20
3-22
3-21
3-24
3-24
3-25
3-25
3-28
3-28
DAILY OR
50
EVERY
HOURS
10
HOURS
C
C
C
C
N
<<<
<<<
<<<
<<<
<<<
N
N
C/N
A
A
A
V
R
R
R
1 YEAR
250
OR 500
HOURS
HOURS
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C/A
C/A
C/A
<<<
<<<
<<<
<<<
<<<
R
<<<
<<<
<<<
<<<
<<<
V
R
R
R
C**
1 YEAR
2 YEARS
OR
4000
OR 2000
1000
HOURS
HOURS
HOURS
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
N
R
C**
C**
C**
3-32
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
V
C**
C**
C**
C**
OCCASIONALLY
(*): Every 10 hours during the first 50 hours, then once at 250 hours.
(**): Consult your dealer.
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
3-36
3-11
3-15
3-21
3-26
3-29
3-29
3-29
<<<
G
<<<
<<<
C
<<<
<<<
<<<
R
<<<
<<<
<<<
<<<
V
N
V
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
<<<
G/C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C
C
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
<<<
<<<
<<<
<<<
<<<
<<<
R
V
V
3-11
3-14
3-34
3-12
3-16
G*
3-17
3-26
3-30
3-30
3-30
3-30
3-8
<<<
G
<<<
<<<
<<<
<<<
<<<
<<<
C**
<<<
<<<
<<<
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
R
<<<
<<<
V
N
R
R
C**
N**
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
N**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
BRAKE
Brake oil level
Brake oil
Brake system
Brake system pressure
Brake
Manually unblocking the parking brake
STEERING
Steering
Steering swivel joints
CAB
Windscreen washer liquid level
Cab door
Air conditioning filter (OPTION air conditioning)
Seat belt
Condition of the rear view mirrors
Structure
Air conditioning (OPTION)
ELECTRICITY
Condition of wiring harness and cables
Lights and signals
Warning indicators
Front headlights
FRONT AXLE
Front wheels reducers pivots
Front axle oscillation
Front axle differential oil level
Front wheels reducers oil level
Front axle differential oil
Front wheels reducers oil
Wear of front axle brake discs
Front wheels reducers universal joint
Front wheels reducers clearance
REAR AXLE
Rear wheels reducers pivots
Rear axle oscillation
Rear axle differential oil level
Rear wheels reducers oil level
Rear axle differential oil
Rear wheels reducers oil
Wearing of rear axle brake discs
Rear wheels reducers universal joint
Rear wheels reducers clearance
CHASSIS
Tilting corrector
Structure
Bearings and articulation rings
ATTACHMENTS
Forks wear
Attachment carriage
Condition of attachments
LIFT TRUCK
Tow the lift truck
Sling the lift truck
Transport the lift truck on a platform
AFTER THE
FIRST 50
HOURS
PAGE
3-17
DAILY OR
EVERY
50
HOURS
10
HOURS
C
1 YEAR
250
OR 500
HOURS
HOURS
<<<
<<<
1 YEAR
2 YEARS
OR
4000
OR 2000
1000
HOURS
HOURS
HOURS
<<<
V**
P**
C**
A**
<<<
<<<
<<<
<<<
<<<
OCCASIONALLY
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,P = BLEED,

R = REPLACE, V = DRAIN
<<<
<<<
<<<
<<<
<<<
3-34
XXX
3-17
3-18
3-18/22
3-31
C
G
N
<<<
<<<
R
<<<
<<<
<<<
C**
<<<
C**
<<<
<<<
<<<
C
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
N/C
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
3-33
3-34
3-18
3-18
3-22
3-22
3-27
3-31
G
G
<<<
<<<
C
C
<<<
<<<
<<<
<<<
V
<<<
<<<
<<<
<<<
<<<
V
<<< G/C**
G/C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
C**
G
G
<<<
<<<
C
C
<<<
<<<
<<<
<<<
V
<<<
<<<
<<<
<<<
<<<
V
<<< G/C**
G/C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
C**
<<<
<<<
<<<
C**
<<<
<<<
C**
<<<
<<<
<<<
C**
<<<
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
V
V
3-18
3-19
3-22
3-22
3-27
3-31
V
V
3-19
3-35
3-35
3-36
XXX
XXX
XXX
3-9
A - DAILY OR EVERY 10 HOURS SERVICE

A1 - I.C. ENGINE OIL LEVEL
A1
CHECK
2
Place the lift truck on level ground with the I.C. engine stopped, and let the oil drain into
the sump.
-
Open the I.C. engine bonnet.

Remove the dipstick 1 (fig. A1).
Clean the dipstick and check the correct level between the two notches.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port 2
(fig. A1).
- Check visually that there is no leakage or seepage of oil in the I.C. engine.
A2 - COOLING LIQUID LEVEL
A2
CHECK
Place the lift truck on level ground with the I.C. engine stopped, and allow the I.C. engine
to cool.

Check the correct level in the middle of gauge 1 (fig. A2).
If necessary, add cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
Slowly turn the cap of the radiator 2 (fig. A2) up to the safety stop.
Allow the pressure and the steam to escape.
Press down and turn the cap so as to release it.
Add cooling liquid via filler port 3 (fig. A2) up to the middle of gauge 1 (fig. A2).
Lubricate slightly the filler neck in order to facilitate the setting and the removal of the
radiator cap.
- Check visually that there is no leakage in the radiator and pipes.
To avoid any risk of spraying or burning, wait until the I.C. engine has cooled down before removing the cooling circuit filler plug. If the cooling liquid is
very hot, add only hot cooling liquid (80C). In an emergency, you can use water as a cooling liquid, then change the cooling circuit liquid as soon as
possible (see: 3 - MAINTENANCE: F1 - COOLING LIQUID).
A3 - FUEL LEVEL
A3
CHECK
2
Keep the fuel tank full, to reduce as much as possible any condensation due to the
atmospheric conditions.
- Open the access panel for hydraulic oil filling.
- Remove cap 1 (fig. A3).
- Fill the fuel tank with clean fuel (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL), filtered
through a strainer or a clean, lint free cloth, through filler port 2 (fig. A3).
- Put back the cap 1 (fig. A3) and close the fuel filler access panel.
- Check visually that there is no leakage in the tank and pipes.
Never smoke or approach with a flame during filling operations or when the tank is open. Never refill
while I.C. engine is running.
The fuel tank is degassed via the filler plug. When changing it, always use an original part, with degassing hole.
3-10
A4 - FUEL PRE-FILTER
A4
CHECK
3
- Open the I.C. engine bonnet.

- Check for the presence of water in the pre-filter bowl 1 (fig. A4) and empty it out if necessary.
- Place a receptacle under the drain plug 2 (fig. A4) and loosen it in two to three thread
turns.
- Allow the diesel fuel to flow out until it is free from impurities and water.
- Tighten the drain plug.
- Pressurise the circuit with the hand pump 3 (fig A4)
1
2
A5 - CYCLONIC PREFILTER
A5
CLEAN
1
2
The cleaning interval is given as a guide, however the pre-filter must be emptied as soon
as impurities reach the MAXI level on the tank.
- Loosen nut 1 (fig. A5), remove cover 2 (fig. A5) and empty the tank.
- Clean the pre-filter unit with a clean dry cloth and reassemble the unit.
When cleaning, take care not to let impurities into the dry air filter.
A6
A6 - GEAR BOX OIL LEVEL

CHECK
Park the lift truck on level ground with the jib raised, the I.C. engine cold and stopped. Carry
out the control within 5 minutes of the I.C. engine being stopped.
-
Remove the plastic cap 1 (fig. A6).

Remove the dipstick 2 (fig. A6).
Wipe the dipstick and check the correct level between the two MIN and MAX. marks.
If necessary, add oil (see: 3 - MAINTENANCE: E3 - GEAR BOX OIL).
Check visually that there is no leakage or seepage of oil in the transmission.
A7 - TYRES PRESSURE AND WHEEL NUTS TORQUE

CHECK
- Check the condition of the tyres, to detect cuts, protuberances, wear, etc.
- Check the torque load of the wheel nuts. Non compliance with this instruction can cause damage and rupture to the wheel bolts
and distortion to the wheels.
Wheel nuts tightening torque
Front tyres: 630 N.m 15%
Rear tyres: 630 N.m 15%
- Check and adjust the tyre pressures if necessary (see: 2 - DESCRIPTION: FRONT AND REAR TYRES).
Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation. Respect the
recommended tyre pressures given.
NOTE: There is an OPTIONAL wheel toolkit.
3-11
A8 - JIB PADS
A8
CLEAN - GREASE
To be carried out every 10 hours during the first 50 hours service, then once at 250
hours.
- Extend the jib completely.
- With a brush, apply a coat of grease (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) on
the 4 sides of the telescope(s) (fig. A8).
- Telescope the jib several times in order to spread the coat of grease evenly.
- Remove the surplus of grease.
If the lift truck is used in an abrasive environment (dust, sand, coal.) use lubricating varnish (MANITOU
reference: 483536). Please consult your dealer.
3-12
3-13
B - EVERY 50 HOURS SERVICE

Carry out the operations described previously as well as the following operations.
B1 - DRY AIR FILTER CARTRIDGE

CHECK - CLEAN
In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced.
If the clogging indicator light comes on, this operation must be carried out as quickly as possible (1 hour maximum). The cartridge must not be cleaned
more than seven times, after which the cartridge must be changed. Never use the lift truck without an air filter or with a damaged air filter.
- For the disassembly and reassembly of the cartridge, see: 3 - MAINTENANCE: D3 - DRY AIR FILTER CARTRIDGE.
- Clean the filter cartridge using a compressed air jet (max. pressure 3 bar) directed from the top to the bottom and from the inside
towards the outside at a minimum distance of 30 mm from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.
Respect the safety distance of 30 mm between the air jet and the cartridge to avoid tearing or making a hole in the cartridge. The cartridge must
not be blown anywhere near the air filter box. Never clean the cartridge by tapping it against a hard surface. Your eyes must be protected during this
intervention.
- Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU reference:
479292).
- Check visually the outer condition of the air filter and its mounts. Verify the condition of the hoses and their mounts also.
Never clean the dry air filter cartridge by washing it in liquid. Do not clean by any means the safety cartridge located inside the filter cartridge, change
it for a new one if it is clogged or damaged.
B2 - RADIATOR CORES
B2/1
CLEAN
In a polluting atmosphere, clean the radiator cores every day. Do not use a water jet or high-pressure
steam as this could damage the radiator fins.

If necessary, clean the suction grid on the engine hood.
Using a soft cloth, clean the radiator cores in order to remove as much dirt as possible.
Undo the screw 1 (fig. B2/1) of the fuel radiator and pivot for easier cleaning.
Clean the cores using a compressed air jet aimed in the same direction as the cooling air
flow (fig. B2/1).
- Clean with the fan running for best results.
NOTE: An OPTIONAL straw defector and self-cleaning fan can also be fitted.
B2/2
B3
B3 - CONDENSER CORE (OPTION AIR CONDITIONING)

CHECK - CLEAN
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure
steam as this could damage the condenser fins.
- Visually check whether the condenser (fig. B3) is clean and clean it if necessary.
- Clean the condenser using a compressed air jet aimed in the same direction as the air
flow.
NOTE: So as to enhance the cleaning, carry out this operation with the fans running.
3-14
B4 - TRANSMISSION UNIVERSAL JOINT
B4/1
GREASE
Clean and lubricate the following points with grease (see: 3 - MAINTENANCE: LUBRICANTS
AND FUEL) and remove the surplus of grease.
1 - Lubricators of the universal joint I.C. engine/Angle gear box (2 lubricators) (fig.
B4/1).
2 - Lubricators of the universal joint Gear box/Front axle (3 lubricators) (fig. B4/2).
3 - Lubricators of the universal joint Gear box/Rear axle (3 lubricators) (fig. B4/3).
B4/2
B4/3
3
3
3-15
B5 - JIB
B5/1
GREASE
To be carried out weekly, if the lift truck has been operated for less than 50 hours during
the week.
In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to 10
working hours or every day.
1
2
3
4
5
6
7
8
9
Lubricators of the jib axle (2 lubricators) (fig. B5/1).

Lubricators of the carriage axle (2 lubricators) (fig. B5/2).
Lubricator of the tilt cylinder foot axle (1 lubricator) (fig. B5/3).
Lubricator of the tilt cylinder head axle (1 lubricator) (fig. B5/4).
Lubricators of the carriage connecting rod axle (3 lubricators) (fig. B5/2 and
B5/5).
- Lubricators of the lifting cylinder foot axle (2 lubricators) (fig. B5/6).
- Lubricators of the lifting cylinder head axle (2 lubricators) (fig. B5/7).
- Lubricators of the compensation cylinder foot axle (2 lubricators) (fig. B5/8).
- Lubricators of the compensation cylinder head axle (2 lubricators) (fig. B5/9).
B5/2
5
B5/3
B5/4
B5/5
3
4
B5/6
B5/7
B5/8
6
7
B5/9
3-16
B6 - HYDRAULIC OIL LEVEL
B6
CHECK
Place the lift truck on level ground with the I.C. engine stopped, and the jib retracted and
lowered as far as possible.
-
Refer to gauge 1 (fig. B6).

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 access panel for hydraulic oil filling.
Remove cap 2 (fig. B6).
Add oil through filler port 3 (fig. B6).
2
1
Use a clean funnel and clean the underside of the oil drum before filling.
- Put the cap back and close the access panel for hydraulic oil filling.
Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank.
B7 - BRAKE OIL LEVEL
B7/1
CHECK
1
Place the lift truck on level ground.

2
- Loosen screw 1 (fig. B7/1) and remove the braking oil tank access panel 2 (fig. B7/1).
- The level is correct when it is at the MAXI level on the tank.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port 3
(fig. B7/2).
If the braking oil level is abnormally low, consult your dealer.
B7/2
B8 - WINDSCREEN WASHER LIQUID LEVEL
B8
CHECK
- Remove the filler cap 1 (fig. B8).

- Check visually the level.
- If necessary add windscreen washer liquid (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL) by filler port 2 (fig. B8).
3-17
1
2
B9 - CAB DOOR
B9
GREASE
Clean and lubricate the points 1 (4 lubricators) (fig. B9) with grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL) and remove the surplus of grease.
B10 - AIR CONDITIONING FILTER (OPTION AIR CONDITIONING)
B10
CLEAN
Lift up protective casing 1 (fig. B10).

Lift out cabin air conditioning filter 2 (fig. B10).
Clean the filter with a compressed air jet.
Check its condition and change if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS).
- Refit the filter and protective casing.
B11 - FRONT AND REAR WHEEL REDUCER PIVOTS
B11
GREASE
B12 - FRONT AXLE OSCILLATION
B12
GREASE
3-18
B13 - REAR AXLE OSCILLATION
B13
GREASE
1
B14 - TILTING CORRECTOR
B14/1
GREASE

1
1 - Lubricator of the tilting corrector cylinder foot axle (1 lubricator) (fig. B14/1).
2 - Lubricator of the tilting corrector cylinder head axle (1 lubricator) (fig. B14/2).
B14/2
3-19
C - EVERY 250 HOURS SERVICE

C1 - FAN BELT TENSION
C1/1
CHECK ADJUST
3

- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Loosen screw 1 (fig. C1/1) on the tension pulley.
- Loosen lock nut 2 (fig. C1/1 and C1/2) and screw 3 (fig. C1/1 and C1/2).
- Tighten the screw 2 (fig. C1/1 and C1/2) until the belt is as close as possible to the
groove of the pulley 4 (fig. C1/1).
- Make a mark on the head of screw 3 (fig. C1/1 and C1/2) and tighten, turning it 5
times.
- Tighten the lock nut 2 (fig. C1/1 and C1/2).
- Retighten screw 1 (fig. C1/1) on the tension pulley.
When changing the fanbelt, tighten screw 3 (fig. C1/1 and C1/2) by one and a half turns, having allowed
the I.C. engine to idle for 30 minutes.
C1/2
3
C2 - ALTERNATOR/CRANKSHAFT BELT TENSION
C2/1
CHECK ADJUST
For this operation, we advise you to use the MANITOU tension meter (fig. C2/1) reference
167418.
-

Unscrew the fastening screws 1 (fig. C2/2).
Lay down the protective guard 2 (fig. C2/2).
Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
- Check the belt tension between the pulleys of the crankshaft and of the alternator.
NEW BELT:
- At a pressure of 15 N 0,4 on strap 3 (fig. C2/3), the displacement must be about 3,7 mm.
BELT AFTER 20 HOURS OF OPERATION:
- At a pressure of 13 N 0,4 on strap 3 (fig. C2/3), the displacement must be about 3,7 mm.
-
C2/2
2
1
1
Carry out adjustments if necessary.

Untighten screws 4 (fig. C2/3) by two to three thread turns.
Swivel the alternator assembly so as to obtain the belt tension required.
Retighten screws 4 (fig. C2/3) (tightening torque 22 N.m).
Put the protective guard back 2 (fig. C2/2).
C2/3
If the alternator belt has to be changed, check the tension again after the first 20 hours of operation.
4
4
4
3-20
C3 - COMPRESSOR BELT TENSION (OPTION AIR CONDITIONING)
C3/1
CHECK - ADJUST

Unscrew the fastening screws 1 (fig. C3/1).
Lay down the protective guard 2 (fig. C3/1).
Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
- Check the belt tension between the pulleys of the crankshaft and of the compressor.
- Under a normal pressure exerted with the thumb (45 N), the belt should move approximately
10 mm.
- Carry out adjustments if necessary.
- Untighten screws 3 (fig. C3/2) with two to three thread turns.
- Swivel the compressor assembly so as to obtain the belt tension required.
- Retighten screws 3 (fig. C3/2).
- Put the protective guard back 2 (fig. C3/1).
2
1
1
C3/2
If the compressor belt has to be changed, check the tension again after the first 20 hours of operation.
C4 - ANGLE GEAR BOX LEVEL
C4
CHECK
Park the lift truck on level ground with the jib raised and the I.C. engine stopped.
- Remove the plastic cap 1 (fig. C4).
- Remove level plug 2 (fig. C4).
- Wipe the dipstick and check the correct level between the MINI and MAX. marks.
- If necessary, add oil by the filler port 3 (fig. C4) (see: 3 - MAINTENANCE: LUBRICANT AND
FUEL).
3-21
C5 - AIR CONDITONING FILTER (OPTION AIR CONDITIONING)
C5
CHANGE
- Lift up protective casing 1 (fig. C5).

- Lift out the air conditioning filter 2 (fig. C5) and fit new replacement filter (see: 3 MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Refit the protective casing.
1
C6 - FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL
C6
CHECK
Place 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 2
(fig. C6).
- Replace and tighten the level plug 1 (fig. C6) (tightening torque 34 to 49 N.m).
C7 - FRONT AND REAR WHEELS REDUCERS OIL LEVEL
C7
CHECK
-
Check the level on each front wheel reducer.

Place level plug 1 (fig. C7) in the horizontal position.
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 34 to 49 N.m).
Repeat this operation on each rear wheel reducer.
3-22
3-23
D - EVERY 500 HOURS SERVICE

D1/1
D1 - I.C. ENGINE OIL

DRAIN
D2 - I.C. ENGINE OIL FILTER

CHANGE
Place the lift truck on level ground, let the I.C. engine run at idle for a few minutes, then
stop the I.C. engine.
DRAINING THE OIL
- Remove access panel 1 (fig. D1/1).
- Place a container under drain plug 2 (fig. D1/2) and unscrew the plug 3 (fig. D1/3).
- Take drain hose 4 (fig. D1/4).
- Place the end of the drain hose in the container and screw fully the union on draining port
5 (fig. D1/5).
- Remove filler cap 6 (fig. D1/6) in order to ensure that the oil is drained properly.
D1/2
Dispose of the drain oil in an ecological manner.

REPLACEMENT OF THE FILTER
- Remove I.C. engine oil filter 7 (fig. D1/3); discard the filter and the filter seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly grease the new oil filter seal and refit the oil filter (see: 3 - MAINTENANCE: FILTERS
CARTRIDGES AND BELTS) on the filter bracket.
Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.
FILLING UP THE OIL
- Loosen, clean and put back in place the drain hose 4 (fig. D1/4).
- Refit and tighten drain plug 3 (fig. D1/3).
- Refit access panel 1 (fig. D1/1).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 8 (fig.
D1/6).
- Wait a few minutes to allow the oil to flow into the sump.
- Start the I.C. engine and let it run for a few minutes.
- Check for possible leaks at the drain plug and the oil filter.
- Stop the I.C. engine, wait a few minutes and check the level between the two notches on
dipstick 9 (fig. D1/6).
- Top up the level if necessary.
D1/3
D1/4
D1/5
D1/6
6
8
3-24
D3 - DRY AIR FILTER CARTRIDGE
D3
CHANGE
1
In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges, see:
3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS. Also, the checking and cleaning
periodicity of the cartridge must be reduced (up to 250 hours in a heavily laden dust
atmosphere and with pre-filtration).
Change the cartridge in a clean location, with the I.C. engine stopped. Never operate the lift truck with
the air filter removed or damaged.

Loosen the bolts and remove cover 1 (fig. D3).
Gently remove the cartridge 2 (fig. D3), taking care to avoid spilling the dust.
Leave the safety cartridge in place.
The following parts must be cleaned with a damp, clean lint-free cloth.
The inside of the filter and cover.
The inside of the filter inlet hose.
The gasket surfaces in the filter and in the cover.
- Check pipes and connections between the air filter and the I.C. engine and the connection and state of the clogging indicator on
the filter.
- Before mounting check the state of the new cartridge (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.
- Reassemble the cover, guiding the valve downwards.
D4 - FUEL PRE-FILTER
D4
CHANGE

- Carefully clean the outside of the pre-filter and its holder, to prevent dust from getting into
the system.
- Place a container under the pre-filter and drain it using drain plug 1 (fig. D4).
- Unscrew locking screw 2 (fig. D4).
- Remove housing 3 (fig. D4) and discard cartridge 4 (fig. D4) as well as the seals of the cartridge.
- Clean the inside of the pre-filter head and the housing, using a brush immersed in clean
diesel oil.
- Refit the assembly with a new pre-filter and new seals (see: 3 - MAINTENANCE: FILTERS
CARTRIDGES AND BELTS).
- Pressurise the circuit with the hand pump 5 (fig D4).
3-25
3
2
D5 - FUEL FILTER
D5/1
CHANGE
- Open engine hood and lift the battery cover.

- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
the system.
- Place a container under the fuel filter 1 (fig. D5/1) and undo the filter.
- Fill up the new fuel filter (see: 3 - MAINTENANCE: FILTERS AND BELTS) with clean diesel.
- Refit the filter onto its holder.
Tighten the fuel filter by hand pressure only and lock the filter in place by a quarter turn.
- Pressurise the circuit by means of the hand pump 2 (fig. D5/2).
- Remove the container from under the filter.
- Start up the I.C. engine and make sure there is no leakage.
D5/2
2
D6 - GEAR BOX OIL FILTER
D6/1
CHANGE
Remove the cover plate 1 (fig. D6/1).

Unscrew and discard gear box oil filter 2 (fig. D6/2).
Carefully clean the filter head with a clean, lint-free cloth.
Slightly lubricate the new seal and fit the seal on the filter.
Fill up the new gear box oil filter (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND
BELTS) with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
- Refit the filter, making sure that the seal is correctly positioned and tightened.
Tighten the gear box oil filter by hand pressure only and lock the filter in place by a quarter turn.
- Put back the cover plate 1 (fig. D6/1).
D6/2
3-26
D7 - HYDRAULIC RETURN OIL FILTER CARTRIDHGE
D7/1
CHANGE
Stop the I.C. engine and remove the pressure from the circuits by acting on the hydraulic
controls.
Thoroughly clean the outside of the filter and its surroundings before any intervention in order to prevent
any risk of polluting the hydraulic circuit.
- Remove the shroud 1 (fig. D7/1).
- Unscrew the locking screws of the cover 2 (fig. D7/2).
- Remove the hydraulic return oil filter cartridge 3 (fig. D7/2), and fit new replacement
cartridge (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Make sure that the cartridge is correctly positioned and refit cover 2 (fig. D7/2).
- Perform the operation on both filters.
- Put back the shroud 1 (fig. D7/1).
D7/2
D8 - FRONT AND RTEAR AXLE DIFFERENTIAL OIL
D8
DRAIN
Place the lift truck on level ground with the I.C. engine stopped and the differential oil still
warm.
3
2
- Place a container under drain plugs 1 (fig. D8) and unscrew the plugs.
- Remove level plug 2 (fig. D8) and filler plug 3 (fig. D8) in order to ensure proper
1
emptying.
- Refit and tighten drain plugs 1 (fig. D8) (tightening torque 34 to 49 N.m).
1
1
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 3 (fig. D8).
- The level is correct when the oil level is flush with the edge of port 2 (fig. D8).
- Check for any possible leaks at the drain plugs.
- Refit and tighten level cap 2 (fig. D8) (tightening torque 34 to 49 N.m) and filler port 3 (fig. D8) (tightening torque 34 to 49 N.m).
- Repeat this operation for the rear axle differential.
3-27
E - EVERY 1000 HOURS SERVICE

E1/1
E1 - FUEL TANK
CLEAN
While carrying out these operations, do not smoke or work near a flame.
- Inspect the parts susceptible to leaks in the fuel circuit and in the tank.
- In the event of a leak, contact your dealer.
Never try to carry out a weld or any other operation by yourself, this could provoke an explosion or a
fire.
-
Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
Open the access panel for hydraulic oil filling.
Remove cap 2 (fig. E1/2).
Let the fuel flow and clean with ten liters of clean fuel by filler port 3 (fig. E1/2).
Refit and tighten drain plug 1 (fig. E1/1) (tightening torque 29 to 39 N.m).
Fill the fuel tank with clean diesel filtered through the filler port.
Refit the filling cap.
If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: G1 - FUEL SYSTEM).
E1/2
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 mounting check the state of the new safety cartridge (see: 3 - MAINTENANCE:
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the
middle.
NOTE: The periodicity for changing the safety cartridge is given for information only. The
safety cartridge must be changed for every two changes of the air filter cartridge.
3-28
E3 - GEAR BOX OIL
E3/1
DRAIN
E4 - GEAR BOX SUMP STRAINER

CLEAN
Place the lift truck on level ground with the I.C. engine stopped, the gear box oil still
warm.
DRAINING THE OIL

- Place a container under drain plug 1 (fig. E3/1) and under cover 2 (fig. E3/1) and unscrew
the drain plug.
- Remove cover plate 3 (fig. E3/2).
- Remove dipstick 4 (fig. E3/3) and unscrew filler cap 5 (fig. E3/3) in order to ensure that
the oil is drained properly.
E3/2
CLEANING THE STRAINER
- Remove cover 2 (fig. E3/1) and set aside the O-ring joint and sealing washer.
- Allow the rest of the oil to drain away.
- Remove and clean the strainer using a compressed air jet.
- Clean the magnetic section on the plate.
- Refit the assembly and tighten up plate 2 (fig. E3/1) (tightening torque 18 to 31 N.m).
FILLING UP THE OIL

- Refit and tighten drain plug 1 (fig. E3/1) (tightening torque 34 to 54 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 5 (fig. E3/3)
and refit the filler cap.
- Start the I.C. engine and let it run for a few minutes.
- Check any possible leaks from the drain plug or cover.
- Stop the I.C. engine, and within 5 minutes of the I.C. engine being stopped, check on the
dipstick 4 (fig. E3/3) the correct level between the two MIN and MAX. marks.
- Top up the level if necessary.
- Refit the shroud 3 (fig. E3/2).
E3/3
E5 - ANGLE GEARBOX OIL
E5/1
DRAIN
Place the lift truck on level ground with the I.C. engine stopped, the angle gear box oil still
warm.
1
- Place a container under drain plug 1 (fig. E5/1) and unscrew the plug.
- Remove the plastic cap 2 (fig. E5/2).
- Remove dipstick 3 (fig. E5/2) and unscrew filler cap 4 (fig. E5/2) in order to ensure that
the oil is drained properly.
- Refit and tighten drain plug 1 (fig. E5/1) (tightening torque 20 to 29 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 4 (fig. E5/2)
and refit the filler cap.
- Check the correct level between the MIN and MAX marks on dipstick 3 (fig. E5/2).
- Check for any possible leaks at the drain plug.
E5/2
3
4
3-29
E6 - HYDRAULIC OIL
E6/1
DRAIN
E7 - SUCTION STRAINER FOR HYDRAULIC OIL TANK

CLEAN
E8 - FILTER CAP FOR HYDRAULIC OIL TANK

CHANGE
E9 - DISTRIBUTOR CONTROL HEAD FILTER

1
CHANGE
Place the lift truck on level ground with the I.C. engine stopped and telescope jib retracted
and lowered as far as possible.
Before any intervention, thoroughly clean the area surrounding the drain plugs and the suction cover on
the hydraulic tank.
E6/2
DRAINING THE OIL
- Place a container under drain plug 1 (fig. E6/1) and unscrew the plug.
- Open the access panel for hydraulic oil filling.
- Remove filler cap 2 (fig. E6/2) in order to ensure that the oil is drained properly.

CLEANING THE STRAINER
- Remove the shroud 3 (fig. E6/3).
- Remove the suction cover 4 (fig. E6/4).
- Remove and clean the strainer using a compressed air jet, check its condition and replace
if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Refit the strainer and the suction cover 4 (fig. E6/4) making sure the seal is in the correct
position.
E6/3
REPLACING THE DISTRIBUTOR CONTROL HEAD FILTER

- Remove the half clamp 5 (fig. E6/4).
- Undo the two couplings 6 (fig.E6/5) and replace the filter 7 (fig. E6/5).
Be careful to mount the new filter 7 (fig. E6/5) in the same direction as the arrow.
- Refit the half clamp 5 (fig. E6/4) and the protective cover 3 (fig. E6/3).
FILLING UP THE OIL
- Clean and refit drain plugs 1 (fig. E6/1) (tightening torque 29 to 39 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 8 (fig.
E6/2).
Use a clean container and funnel and clean the underside of the oil drum before filling.
E6/4
- Observe the oil level on dipstick 9 (fig. E6/2), the oil level should be at the level of the
red point.
- Check for any possible leaks at the drain plugs.
- Replace filler plug 2 (fig. E6/2) with a new filler plug (see: 3 - MAINTENANCE: FILTERS
CARTRIDGES AND BELTS).
HYDRAULIC CIRCUIT DECONTAMINATION
This should be carried out by your dealer after each oil change.
The hydraulic oil used in the circuit must be at least equal in quality to class 8 (according
to NAS 1638). Your dealer will be able to clean the hydraulic circuit using an external unit
and check the quality of the oil in order to ensure the long life of hydraulic components and
particularly of the main pump.
E6/5
6
7
3-30
E10 - SEAT BELT

CHECK
Seat belt with two anchoring points
- Check the following points:
Fixing of the anchoring points on the seat.
Cleanness of the strap and the locking mechanism.
Triggering of the locking mechanism.
Condition of the strap (cuts, curled edges).
Reeled 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.
In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.
E11 - FRONT AND REAR WHEELS REDUCERS OIL
E11
DRAIN
Place the lift truck on level ground with the I.C. engine stopped and the reducers oil still
warm.
1
B

-
Drain and change each front wheel reducer.

Place drain plug 1 (fig. E11) in position A.
Place a container under the drain plug and unscrew the plug.
Let the oil drain fully.
Place the drain port in position B, i.e. in a level port.
Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by level port 1 (fig.
E11).
- The level is correct when the oil level is flush with the edge of the hole.
- Refit and tighten the drain plug 1 (fig. E11) (tightening torque 34 to 49 N.m).
- Repeat this operation on each rear wheel reducer.
3-31
F - EVERY 2000 HOURS OF SERVICE

F1 - COOLING LIQUID
F1/1
DRAIN
These operations are to be carried out if necessary or every two years at the beginning of
winter. Place the lift truck on level ground with the I.C. engine stopped and cold.
1
DRAINING THE LIQUID

- Place a container under hose 1 (fig. F1/1) on the radiator and drain plug 2 (fig. F1/2) of
the engine block. Remove the hose and loosen the drain plug.
- Remove filling plug 3 (fig. F1/3) of the radiator.
- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.
- Check the condition of the hoses as well as the fastening devices and change the hoses
if necessary.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
FILLING THE LIQUID
- Refit and tighten the hose 1 (fig. F1/1) and drain plug 2 (fig. F1/2) (tightening torque 40
N.m).
- Slowly fill up the circuit with cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL) to the middle of gauge 5 (fig. F1/3) through filler port 4 (fig. F1/3).
- Put back filling plug 3 (fig. F1/3).
- Run the I.C. engine at idle for a few minutes.
- Check for any possible leaks.
- Check the level and refill if necessary.
F1/2
The I.C. engine does not contain any corrosion resistor and must be filled during the whole year with a
mixture containing 25% of ethylene glycol-based antifreeze.
F1/3
3
4
3-32
F2 - AIR CONDITIONING (OPTION)

CLEANING INSPECTION
CLEANING CONDENSER AND EVAPORATOR COILS (*)
CLEANING CONDENSATE TRAY AND RELIEF VALVE (*)
COLLECTING COOLANT TO REPLACE FILTER-DRIER (*)
REFILLING WITH COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES (*)
NOTE: When opening the evaporator unit, remember to replace the cover seal.
(*): (CONSULT YOUR DEALER).
CAUTION: DO NOT ATTEMPT TO REPAIR ANY PROBLEMS YOURSELF. ALWAYS REFER TO YOUR DEALER WHEN REFILLING CIRCUITS, AS THEY HOLD THE
CORRECT SPARE PARTS, AS WELL AS HAVING THE NECESSARY TECHNICAL KNOWLEDGE AND TOOLS.
- Do not open the circuit under any circumstances as this would cause the coolant to be lost.
- The cooling circuit contains a gas which can be dangerous under certain conditions. This gas, coolant R 134a, is colourless,
odourless and heavier than air.
If this gas is inhaled, take the victim into fresh air, give oxygen or artificial respiration if necessary and call a doctor.
If the gas is in contact with the skin, wash it immediately under running water and remove any contaminated garments.
If the gas is in contact with the eyes, rinse them in clear water for 15 minutes and call a doctor.
- The compressor has an oil level gauge (fig. F2). Never unscrew this gauge because it
would depressurizes the installation. The oil level is only checked when changing the oil
in the circuit.
3-33
F2
G - OCCASIONAL MAINTENANCE
G1 - WHEEL
G1
CHANGE
In the event of a wheel being changed on the public highway, make sure of the following points:
For this operation, we advise you to use the hydraulic jack MANITOU reference 505507 and
the safety support MANITOU reference 554772.
2
1
- Stop the lift truck, if possible on even and hard ground.

- To pass on stop of lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING
INSTRUCTIONS UNLADEN AND LADEN).
- Put the warning lights on.
- Immobilise the lift truck in both directions on the axle opposite to the wheel to be changed.
- Unlock the nuts of the wheel to be changed.
- Place the jack under the flared axle tube, as near as possible to the wheel and adjust the
jack 1 (fig. G1).
- Lift the wheel until it comes off the ground and put in place the safety support 2 under the axle (fig. G1).
- Completely unscrew the wheel nuts and remove them.
- Free the wheel by reciprocating movements and roll it to the side.
- Slip the new wheel on the wheel hub.
- Refit the nuts by hand, if necessary grease them.
- Remove the safety support and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE for tightening
torque).
G2 - PARKING BRAKE
G2/1
UNBLOCKING
This procedure is to be performed in the event of parking brake
malfunction.
If the lift truck is not on a horizontal ground, to fix so that it does not
descend the slope.
Do not tow the lift truck at more than 25 km/h.
G2/2
- Put the forward/reverse selector and the gear shift in neutral.

- Put the warning lights on.
MANUALLY UNBLOCKING THE PARKING BRAKE
- First perform this operation on the left-hand side (fig.G2/1) of the front axle, then on the
right-hand side (fig.G2/1).
- Unscrew locknuts 1 (fig. G2/2) by approximately 8 mm.
- Alternately tighten the screws 2 (fig. G2/2) by a 1/4 turn at a time up to a maximum of 1
turn in order to free the brake discs.
- 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.
- Once this operation is completed, adjust the parking brake.
ADJUSTING THE PARKING BRAKE
- First perform this operation on the left-hand side (fig.G2/1) of the front axle, then on the
right-hand side (fig.G2/1).
- Completely unscrew screws 2 (fig. G2/2) by alternately unscrewing them a 1/4 turn at a time.
- Grease the threads with a silicone lubricant (MANITOU reference: 479292).
- Retighten the screws 2 (fig. G2/2) to obtain a dimension of 30 mm (fig. G2/2).
- Lock the locknuts 1 (fig. G2/2) while holding the screw 2 (fig. G2/2) in position.
3-34
2
1
2
1
G3 - FRONT HEADLAMPS
G3
ADJUST
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
+%
-%
-2%
h1
h2
ADJUSTING PROCEDURE
- Place the lift truck unloaded and in the transport position and
perpendicular to a white wall on flat, level ground (fig. G3).
- Check the tire pressures (see: 2 - DESCRIPTION: FRONT AND REAR
TIRES).
- Put the gearshift lever into neutral.
h2 = h1 - (l x 2 / 100)
Calculating the height of the dipped beam (h2)

h1 = Height of the dipped beam in relation to the ground.
h2 = Height of the adjusted beam.
l = Distance between the dipped beam and the white wall.
G4 - LIFT TRUCK
TOW
Do not tow the lift truck at more than 25 km/h.
-
Put the forward/reverse selector and the gear shift in neutral.

Release the hand 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.
G5 - LIFT TRUCK
G5/1
SLING
- Take into account the position of the lift truck centre of gravity for lifting
(fig. G5/1).
A = 1560 mm B = 1210 mm MLT 845 120 LSU Srie 3-E3
A = 1510 mm B = 1260 mm MLT 940 L 120 LSU Srie 3-E3
- Place the hooks in the fastening points provided (fig. G5/2 and G5/3).
G5/2
3-35
G5/3
G6 - LIFT TRUCK ON A PLATFORM
G6/1
TRANSPORT
Ensure that the safety instructions connected to the platform are respected before the loading of the lift
truck and that the driver of the means of transport is informed about the dimensions and the weight of
the lift truck (see: 2 - DESCRIPTION: CHARACTERISTICS).
Ensure that the platform has got dimensions and a load capacity sufficient for transporting the lift truck.
Check also the pressure on the contact surface allowable for the platform in connection with the lift
truck.
For lift trucks equipped with a turbo-charged I.C. engine, block off the exhaust outlet to avoid rotation of
the turbo shaft without lubrication when transporting the vehicle.
LOAD THE LIFT TRUCK
- Block the wheels of the platform.
- Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck.
- Load the lift truck parallel to the platform.
- Stop the lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING INSTRUCTIONS
UNLADEN AND LADEN).
G6/2
STOW THE LIFT TRUCK

- Fix the chocks to the platform at the front and at the back of each tyre (fig. G6/1).
- Fix also the chocks to the platform in the inside of each tyre (fig. G6/2).
- Secure the lift truck to the platform with sufficiently strong ropes. At the front of the lift
truck, attach the ropes to the fastening points 1 (fig. G6/3) and at the rear to the towing
pin 2 (fig. G6/4).
- Tighten the ropes (fig. G6/5).
G6/3
G6/3
G6/5
3-36
4 - OPTIONAL
ATTACHMENTS
FOR USE WITH
THE RANGE
4-1
4-2
TABLE OF CONTENTS
INTRODUCTION
4-4
PICKING UP THE ATTACHMENTS
4-6
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 (OPTION)
4 - 10
TECHNICAL SPECIFICATIONS OF ATTACHMENTS
4 - 12
ATTACHMENT SHIELDS
4 - 20
4-3
4-4
INTRODUCTION
- Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS.
- A wide range of attachments, specially designed and perfectly suitable for your lift truck is available and guaranteed by
MANITOU.
- The attachments are delivered with a load chart concerning your lift truck. The operators manual and the load chart should be
kept in the places provided in the lift truck. For standard attachments, their use is governed by the instructions contained on this
notice.
- Some particular uses require the adaptation of the attachment which is not provided in the price-listed options. Optional solutions
exist, consult your dealer.
All attachments with a suspended load (winch, crane jib, crane jib with winch, hook, etc.) MUST be used with a lift truck equipped with a hydraulic
movement cut-out device. In this case, the movement cut-out must be switched on and the transverse attitude perfectly horizontal.
Only attachments approved by MANITOU are to be used on our lift trucks (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE: TECHNICAL
SPECIFICATIONS OF ATTACHMENTS). The manufacturers liability will be denied in case of modification or of attachment adaptation carried out without
his knowing it.
Depending on their size, certain attachments may, when the jib is lowered and retracted, come into contact with the front tyres and cause damage
to them, if reverse tilt is activated in the forward tilt direction. TO REMOVE THIS RISK, EXTEND THE TELESCOPE TO A SUFFICIENT EXTENT FOR THE
PARTICULAR LIFT TRUCK AND ATTACHMENT SO THAT THIS CONTACT IS NOT POSSIBLE.
Maximum loads are defined by the capacity of a lift truck taking account of the attachments mass and centre of gravity. In the event of the attachment
having less capacity than the lift truck, never exceed this limit.
4-5
PICKING UP THE ATTACHMENTS

A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE
TAKING UP AN ATTACHMENT
- Ensure that the attachment is in a position facilitating the locking to the carriage. If it is
not correctly oriented, take the necessary precautions in order to move it safely.
- Check that the locking pin and the clip are in position in the bracket (fig. A).
- Place the lift truck with the jib fully lowered in front of and parallel to the attachment, tilt
the carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the jib, incline the
carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.
HAND LOCKING
- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D).
Do not forget to refit the clip.
HAND RELEASING
- Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back
the locking pin and the clip in the bracket (fig. A).
LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.
4-6
B - ATTACHMENT WITHOUT HYDRAULICS AND HYDRAULIC LOCKING DEVICE

(OPTION)
- Check that the rods on the locking cylinder are retracted (fig. A).
HYDRAULIC LOCKING
- Put the valve in position A (fig. D), that is to say, the hydraulic circuit of the attachment
locking open.
- Switch button 1 (fig. E) of the distributor lever forwards to completely lock the attachment
on the carriage.
- Close the valve in position B (fig. D), that is to say, the hydraulic circuit of the attachment
locking closed.
Always close the valve in position B (fig. D) after locking the attachment, in order to avoid accidental
unlocking and to use the attachment completely safely.
HYDRAULIC RELEASING
locking open.
- Switch button 1 (fig. E) of the distributor lever backwards to completely release the
attachment.
INACTIVATE THE HYDRAULIC RELEASE CONTROL
You can change an attachment without leaving the control post, by cutting the electricity
supply to the hydraulic control.
- Leave the valve in position A (fig. D).
- Use switch 2 (fig. F) to cut the electricity supply to the hydraulic control. The circuit is out
of action when indicator 3 (fig. F) is on.
Always cut the electrical power to the circuit using switch 2 (fig. F) after each change of attachment to
avoid involuntary release and use the attachment in complete safety.
D
B
A
1
2
4-7
C - HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE
- Check that the locking pin and the clip are in position in the bracket (fig. A).
MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT

- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D).
Do not forget to refit the clip.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Remove the pressure of the hydraulic circuit by operating switch 1 (fig. E) on the distributor
lever backwards and forwards 4 or 5 times.
- Connect the rapid connectors according to the logic of the attachments hydraulic
movements.
Make sure that the rapid connectors are clean and protect the holes which are not used, with the caps
provided.
HAND RELEASING AND DISCONNECTING THE ATTACHMENT
- Proceed in the opposite order to that described in MANUAL LOCKING AND CONNECTION
OF THE ATTACHMENT while making sure you put the locking pin back into the bracket (fig. A).
4-8
D - HYDRAULIC ATTACHMENT AND HYDRAULIC LOCKING (OPTION)
- Check that the rods on the locking cylinder are retracted (fig. A).
HYDRAULIC LOCKING AND CONNECTING THE ATTACHMENT

locking open.
- Switch button 1 (fig. E) of the distributor lever forwards to completely lock the attachment
on the carriage.
- Connect the rapid connectors according to the logic of the attachments hydraulic
movements.
provided.
- Close the valve in position B (fig. D), that is to say, the hydraulic circuit of the attachment
locking closed.
Always close the valve in position B (fig. D) after locking the attachment, in order to avoid accidental
unlocking and to use the attachment completely safely.
HYDRAULIC RELEASING AND DISCONNECTING THE ATTACHMENT

- Close the attachment.
locking open.
- Switch button 1 (fig. E) of the distributor lever backwards to completely release the
attachment.
- Disconnect the rapid connectors of the attachment.
provided.
4-9
TECHNICAL SPECIFICATIONS OF ATTACHMENTS

FLOATING FORK CARRIAGE
TFF 45 MT-1040
TFF 45 MT-1300
PART NUMBER
653344
653345
Rated capacity
4500 kg
4500 kg
Width
1040 mm
1300 mm
Weight
370 kg
400 kg
FLOATING FORK SIDE-SHIFT CARRIAGE

TFF 45 MT-1040 DL
TFF 45 MT-1300 DL
PART NUMBER
751545
751546
Rated capacity
4500 kg
4500 kg
Side-shift
2x100 mm
2x100 mm
Width
1040 mm
1300 mm
Weight
410 kg
450 kg
FLOATING FORK
PART NUMBER
211922
Section
125x50x1200 mm
Weight
71 kg
4-10
STANDARDISED TILTING FORK CARRIAGE

PFB 45 N MT-1260 S2
PFB 45 N MT-1670 S2
PFB 45 N MT-2000 S2
PART NUMBER
654407
653747
653748
Rated capacity
4500 kg
4500 kg
4500 kg
Width
1260 mm
1670 mm
2000 mm
Weight
200 kg
255 kg
300 kg
STANDARDISED SIDE-SHIFT CARRIAGE

TDLA 40 N MT-1670
TDLA 40 N MT-2000
PART NUMBER
751542
751369
Rated capacity
4300 kg
4300 kg
Side-shift
2x100 mm
2x100 mm
Width
1670 mm
2000 mm
Weight
265 kg
305 kg
STANDARDISED FORK
PART NUMBER
415652
Section
125x50x1200 mm
Weight
78 kg
LOAD BACK REST

PART NUMBER
727035
572788
572790
Width
1260 mm
1670 mm
2000 mm
Weight
46 kg
56 kg
63 kg
4-11
BUILDING BUCKET
CBC 700 L1950 S2
CBC 800 L2250 S3
CBC 900 L2450 S3
PART NUMBER
654472
654471
654470
Rated capacity
697 l
814 l
893 l
Width
1950 mm
2250 mm
2450 mm
Weight
330 kg
385 kg
410 kg
CBR 780 L1950 S2
CBR 900 L2250 S2
CBR 1000 L2450 S2
PART NUMBER
570613
653749
654716
Rated capacity
778 l
904 l
990 l
Width
1950 mm
2250 mm
2450 mm
Weight
340 kg
390 kg
410 kg
CBA 1500 L2450 S3
CBA 2000 L2450 S3
LOADING BUCKET
GRAIN BUCKET
PART NUMBER
570547
570551
Rated capacity
1502 l
1998 l
Width
2450 mm
2450 mm
Weight
514 kg
607 kg
CBA 2500 L2450 S3
CBA 3000 L2500 S3
GRAIN BUCKET
PART NUMBER
570553
570555
Rated capacity
2508 l
3003 l
Width
2450 mm
2500 mm
Weight
701 kg
774 kg
GRAIN BUCKET (REVERSING AND DISMOUNTABLE CUTTING EDGE)

CBA 1500 L2450 LDR S3
CBA 2000 L2450 LDR S3
CBA 2500 L2450 LDR S3
PART NUMBER
570548
570552
570554
Rated capacity
1502 l
1998 l
2508 l
Width
2450 mm
2450 mm
2450 mm
Weight
585 kg
678 kg
772 kg
4-12
BUCKET 4X1
CB4x1-700 L1950
CB4x1-850 L2300
CB4x1-900 L2450
PART NUMBER
751402
751401
751465
Rated capacity
700 l
850 l
900 l
Width
1950 mm
2300 mm
2450 mm
Weight
640 kg
735 kg
765 kg
MULTIPURPOSE BUCKET (REVERSING AND DISMOUNTABLE CUTTING EDGE)

CBM 2450 LDR S5
PART NUMBER
752195
Rated capacity
1,03 m3
Width
2450 mm
Grab
11
Weight
790 kg
4-13
GRAB BUCKET
CBG 1950 S4
CBG 2300 S4
CBG 2450 S4
PART NUMBER
751407
751414
751418
Rated capacity
1 m3
1,2 m3
1,26 m3
Width
1950 mm
2300 mm
2450 mm
Grab
555 kg
615 kg
635 kg
Weight
GRAB BUCKET (NON-HAZARDOUS INDUSTRIAL WASTE)

CBG 1950 DIB S4
CBG 2300 DIB S4
CBG 2450 DIB S4
PART NUMBER
653016
653018
653020
Rated capacity
1 m3
1,2 m3
1,26 m3
Width
1950 mm
2300 mm
2450 mm
Grab
678 kg
740 kg
767 kg
Weight
GRAB BUCKET (NON-HAZARDOUS INDUSTRIAL WASTE)

CBG 2450 DIB 1,4
PART NUMBER
654817
Rated capacity
1,4 m3
Width
2450 mm
Grab
Weight
1100 kg
GRAB BUCKET (GRAB CLOSED)

CBG 2300 GF S4
PART NUMBER
653008
Rated capacity
1,2 m3
Width
2300 mm
Grab
Weight
637 kg
GRAB BUCKET (CLOSED JAWS AND REVERSIBLE REMOVABLE BLADE)

CBG 1950 JFD-LDR S4
CBG 2300 JFD-LDR S4
CBG 2450 JFD-LDR S4
PART NUMBER
653003
653006
653009
Rated capacity
1 m3
1,2 m3
1,26 m3
Width
1950 mm
2300 mm
2450 mm
Grab
655 kg
715 kg
742 kg
Weight
4-14
CONCRETE BUCKET (ADAPTABLE ON FORKS)

BB 500 S4
BBH 500 S4
PART NUMBER
654409
751462
Rated capacity
500 l/1300 kg
500 l/1300 kg
Width
1100 mm
1100 mm
Weight
205 kg
220 kg
CONCRETE BUCKET (ADAPTABLE ON FORKS)

BBG 500 S4
BBHG 500 S4
PART NUMBER
654411
751464
Rated capacity
500 l/1300 kg
500 l/1300 kg
Width
1100 mm
1100 mm
Weight
220 kg
235 kg
SPOUT BUCKET (ADAPTABLE ON FORKS)

GL 300 S2
GL 400 S2
PART NUMBER
174371
174372
Rated capacity
300 l/725 kg
400 l/969 kg
150 kg
166 kg
Weight
HYDRAULIC KIT TO OPEN THE SPOUT

PART NUMBER
653750

GL 600 S2
GL 800 S2
PART NUMBER
174373
174374
Rated capacity
600 l/1440 kg
800 l/1920 kg
290 kg
325 kg
Weight

PART NUMBER
653750

GL 1000 S2
GL 1500 S2
PART NUMBER
174375
174376
Rated capacity
1000 l/2440 kg
1500 l/3591 kg
360 kg
409 kg
Weight

PART NUMBER
653750
4-15
MANURE FORK WITH GRAB

FFGR 30 MT 2100 S5
FFGR 30 MT 2400 S5
FFGR 30 MT 2100 DR
PART NUMBER
556843
570594
570728
Rated capacity
1700 Kg
1700 Kg
1700 Kg
Width
2100 mm
2400 mm
2100 mm
Finger
10
12
10 (round finger)
Grab
567 kg
606 kg
567 kg
Weight
4-16
CRANE JIB
P 600 MT S3
PART NUMBER
653228
Rated capacity
600 kg
Weight
170 kg
CRANE JIB
P 4000 MT S2
PART NUMBER
653226
Rated capacity
4000 kg/1200 kg
Weight
210 kg
CRANE JIB WITH WINCH

PT 600 MT S6
PART NUMBER
708538
Rated capacity
600 kg
Weight
288 kg
15/15 MULTI-DIRECTIONAL CRANE JIB

PO 600 L2500 S2
PO 1000 L1500 S2
PO 2000 L1000 S2
PART NUMBER
751547
751548
751549
Rated capacity
600 kg
1000 kg
2000 kg
Weight
320 kg
275 kg
255 kg
4-17
ATTACHMENT SHIELDS
FORK PROTECTOR
PART NUMBER
227801
FORK BLOCK FOR FLOATING FORK CARRIAGE

PART NUMBER
254221
BUCKET PROTECTOR
NOTE: Always ensure that the width of the protector you choose is less than or equal to the width of the bucket.
PART NUMBER
Width
PART NUMBER
Width
PART NUMBER
Width
PART NUMBER
Width
206734
206732
206730
1375 mm
1500 mm
1650 mm
235854
206728
206726
1850 mm
1950 mm
2000 mm
223771
223773
206724
2050 mm
2100 mm
2150 mm
206099
206722
223775
2250 mm
2450 mm
2500 mm
MANURE FORK PROTECTOR

PART NUMBER
230689
4-18

Operator Manual Manitou MTL 845 120 LSU - New - 2008

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BP 249

44158 ANCENIS CEDEX - FRANCE

MLT 845 120 LSU Srie 3-E3

1 - OPERATING AND SAFETY INSTRUCTIONS

4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE

1ST DATE OF ISSUE

INSTRUCTIONS FOR THE OPERATOR

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

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

INSTRUCTIONS TO THE COMPANY MANAGER

THE LIFT TRUCK

C - MODIFICATION OF THE LIFT TRUCK

INSTRUCTIONS FOR THE OPERATOR

OPERATING INSTRUCTIONS UNLADEN AND LADEN

Moving without load: Forks or attachment facing downhill.

Moving with load: Forks or attachment facing uphill.

E - STARTING THE LIFT TRUCK

Use the rear-view mirrors frequently.

H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY

DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT

INSTRUCTIONS FOR HANDLING A LOAD

B - MASS OF LOAD AND CENTRE OF GRAVITY

C - LONGITUDINAL STABILITY ALARM

D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK

1 - LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TYRES

2 - LIFT TRUCK WITH SLOPE CORRECTOR USED ON TYRES

3 - LIFT TRUCK USED ON STABILIZERS

E - TAKING UP A LOAD ON THE GROUND

F - TAKING UP AND LAYING A HIGH LOAD ON TYRES

TAKING UP A HIGH LOAD ON TYRES

LAYING A HIGH LOAD ON TYRES

G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS

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

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

This operation must be exceptional and performed with great care.

TAKING UP A HIGH LOAD ON STABILIZERS

LAYING A HIGH LOAD ON STABILIZERS

H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD

I - TRAVELLING WITH A SUSPENDED LOAD

PLATFORM OPERATING INSTRUCTIONS

50 < U < 1000

DISTANCE ABOVE THE

INSTRUCTIONS FOR USING THE RADIO-CONTROL

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

LUBRICANT AND FUEL LEVELS

Use the recommended lubricants (never use contaminated lubricants).

WASHING THE LIFT TRUCK

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

PREPARING THE LIFT TRUCK

Clean the lift truck thoroughly.

PROTECTING THE I.C. ENGINE

PROTECTING THE LIFT TRUCK

BRINGING THE LIFT TRUCK BACK INTO SERVICE

Remove the waterproof adhesive tape from all the holes.

FRONT AND REAR TIRES

DIMENSIONS AND LOAD CHARTS

INSTRUMENTS AND CONTROLS

TOWING PIN AND HOOK