MANITOU BF

BP 10249
44158 ANCENIS CEDEX - FRANCE
TEL: + 33 (0)2 40 09 10 11

YOUR DEALER

647387 EN (18/11/2011)

MLT 634 -120 LSU Srie G-E3

MLT 634 -120 LSU PS Srie G-E3

MLT 735 -120 LSU Srie 7-E3

OPERATORS MANUAL

THIS OPERATORS MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.
647387EN (18/11/2011)
1 - OPERATING AND SAFETY INSTRUCTIONS

2 - DESCRIPTION

3 - MAINTENANCE

4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE

5 - SPECIFIC AUSTRALIA
See also the operators manual supplement: 647065 AU

18/11/2011 1ST DATE OF ISSUE

647387EN (18/11/2011)

THE TEXTS AND ILLUSTRATIONS IN THIS DOCUMENT MUST NOT BE REPRODUCED EITHER WHOLLY OR IN PART.
647387EN (18/11/2011)
1 - OPERATING
AND SAFETY
INSTRUCTIONS

647387EN (18/11/2011)

1-1
1-2
647387EN (18/11/2011)
 TABLE OF CONTENTS

INSTRUCTIONS TO THE COMPANY MANAGER 1-4

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

INSTRUCTIONS FOR THE OPERATOR 1-6

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

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 - 24

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

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

INTRODUCTION 1 - 26
647387EN (18/11/2011)

PREPARING THE LIFT TRUCK 1 - 26

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

1-3
 INSTRUCTIONS TO THE COMPANY MANAGER

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

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

THE LIFT TRUCK

A - THE 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 (as model of lift truck).
- 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 2004/108/EC concerning electromagnetic compatibility (EMC), and with the corresponding harmonized
norm EN 12895. Their proper operation is no longer guaranteed if they are used within areas in which the electromagnetic fields exceed
the limit specified by that norm (10 V/m).
- Directive 2002/44/EC requires company managers to not expose their employees to excessive vibration doses. There is no recognized
code of measurement for comparing the machines of different manufacturers. The actual doses received can therefore be measured only
under actual operating conditions at the user's premises.
- The following are some tips for minimizing these vibration doses:

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potholes.

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

D - FRENCH ROAD TRAFFIC RULES

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

THE INSTRUCTIONS
- The 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.

647387EN (18/11/2011)

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.

GENERAL INSTRUCTIONS
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.
647387EN (18/11/2011)

1-6
E - LIFTING PEOPLE
- The use of working equipment and load lifting attachments to lift people is:
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the country in which the lift truck is used).
- The pictogram posted at the operator station reminds you that:
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- It is forbidden to lift people, with any kind of attachment, using a non PLATFORM-
fitted lift truck.
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- 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).

647387EN (18/11/2011)

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.

647387EN (18/11/2011)

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:
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- 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:
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- 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).
647387EN (18/11/2011)

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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 limiter and warning device system (see:
2 - DESCRIPTION: INSTRUMENTS AND CONTROLS). Do not use the lift truck if it does not conform to the regulations.
- Check the fuel level on the indicator.
- Turn the ignition key fully: the I.C. engine should then start. Release the ignition key and let the I.C. engine run at idle.
- Do not engage the starter motor for more than 15 seconds and carry out the preheating between unsuccessful attempts.
- Make sure all the signal lights on the control instrument panel are off.
- Check all control instruments when the I.C. engine is warm and at regular intervals during use, so as to quickly detect any faults and to be
able to correct them without any delay.
- If an instrument does not show the correct display, stop the I.C. engine and immediately carry out the necessary operations.

F - DRIVING THE LIFT TRUCK

SAFETY INSTRUCTIONS
Operators attention is drawn to the risks involved in using the lift truck, in particular:
- Risk of losing control.
- Risk of losing lateral and frontal stability of the lift truck.
The operator must remain in control of the lift truck.
In the event of the lift truck overturning, do not try to leave the cabin during the incident. YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN.
- Observe the 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.
- Never change the steering mode whilst driving.
- Do not manoeuvre the lift truck with the jib in the raised position unless under exceptional circumstances and then with extreme caution,
at very low speed and using gentle braking. Ensure that visibility is adequate.
- Take bends slowly.
- In all circumstances make sure you are in control of your speed.
- On damp, slippery or uneven terrain, drive slowly.
- Brake gently, never abruptly.
- Only use the lift 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.
647387EN (18/11/2011)

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).

647387EN (18/11/2011)

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

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

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

647387EN (18/11/2011)

1-12
DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT
- You must comply with current regulations in your country, covering the possibility of driving on the public highway with a front-mounted
attachment on your lift truck.
- If road legislation in your country authorizes circulation with a front-mounted attachment, you must at least:
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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 vertical force on the towing hook must not exceed the maximum authorised by the manufacturer (consult the manufacturers plate
on your lift truck).
- The authorised gross vehicle weight must not exceed the maximum weight authorised by the manufacturer (see: 2 - DESCRIPTION:
CHARACTERISTICS).

IF NECESSARY, CONSULT YOUR DEALER.

647387EN (18/11/2011)

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

B - MASS OF LOAD AND CENTRE OF GRAVITY B1

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

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

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

B2

C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE C

This device gives an indication of the longitudinal stability of the lift truck, and limits hydraulic
movements in order to ensure this stability, at least under the following operating conditions:
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- Move the jib very carefully when approaching the authorized load limit (see: 2 - DESCRIPTION:
INSTRUMENTS AND CONTROLS).
- Always watch this device during handling operations.
- In the event that "AGGRAVATING" hydraulic movements are cut-off, only perform de-aggravating
hydraulic movements in the following order (fig. C): if necessary, raise the jib (1), retract the jib
as far as possible (2) and lower the jib (3) to set down the load.
The instrument reading may be erroneous when the steering is at its maximum limit or the rear axle oscillated
to its limit. Before lifting a load, make sure that the lift truck is not in either of these situations.
647387EN (18/11/2011)

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

The transverse attitude is the transverse slope of the chassis with respect to the horizontal.
Raising the jib reduces the lift 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 D2
CONTROLS).

3 - LIFT TRUCK USED ON STABILIZERS

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

E - TAKING UP A LOAD ON THE GROUND E1

- 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).
- 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 E2

- 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.

E3 E4

1
2
2
1
3
647387EN (18/11/2011)

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

TAKING UP A HIGH LOAD ON TYRES

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

F3
2

F4
1

F5

3
647387EN (18/11/2011)

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

F7

F8

F9

F10
647387EN (18/11/2011)

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

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

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

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

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

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

G4

1
647387EN (18/11/2011)

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

G6

G7 G8
2
1

2
1

LAYING A HIGH LOAD ON STABILIZERS G9

- Raise and extend the jib (1) (2) until the load is above the elevation (fig. G9), while monitoring
the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR HANDLING A
LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE). 2
- 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). 1

- If possible, set the jib in transport position without moving the lift truck.

G10 G11

1
3

2
647387EN (18/11/2011)

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

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

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

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

HANDLING WITHOUT MOVING THE LIFT TRUCK

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

I - TRAVELLING WITH A SUSPENDED LOAD

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

647387EN (18/11/2011)

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 DISTANCE ABOVE THE

Operating the platform close to electricity cables is forbidden. Maintain the specified safe NOMINAL VOLTAGE GROUND OR THE FLOOR
distances. IN METRES
50 < U < 1000 2,30 M
1000 < U < 30000 2,50 M
30000 < U < 45000 2,60 M
45000 < U < 63000 2,80 M
63000 < U < 90000 3,00 M
90000 < U < 150000 3,40 M
150000 < U < 225000 4,00 M
225000 < U < 400000 5,30 M
400000 < U < 750000 7,90 M
647387EN (18/11/2011)

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

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

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

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

647387EN (18/11/2011)

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

HOW TO USE THE RADIO-CONTROL

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

Everyone working with this radio-control:

- Must be qualified in line with current regulations and therefore appropriately trained.
- Must follow this instruction manual as closely as possible.
- The system is used to control the lift truck remotely via radio waves. Commands are also transmitted if the lift truck is out of sight (behind
an obstacle or a building for example), this is why:
t

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dry place.
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and electric head units on hydraulic distributors must be disconnected at each section).
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FUD


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

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

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

PROTECTIVE DEVICES
- The lift truck will be immobilised within 450 milliseconds (approx. 0.5 second) at most:
t
*G
UIF
USBOTNJUUFS
FNFSHFODZ
TUPQ
CVUUPO

NJMMJTFDPOET

PS
UIF
POF
PO
UIF
MJGU
JT
QSFTTFE
t
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UIF
USBOTNJTTJPO
EJTUBODF
PG
UIF
SBEJP
XBWFT
JT
FYDFFEFE
t
*G
UIF
USBOTNJUUFS
JT
GBVMUZ
t
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BO
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SBEJP
TJHOBM
JT
SFDFJWFE
GSPN
FMTFXIFSF
t
*G
UIF
BDDVNVMBUPS
JT
SFNPWFE
GSPN
JUT
IPVTJOH
JO
UIF
USBOTNJUUFS
t
*G
UIF
BDDVNVMBUPS
SFBDIFT
UIF
FOE
PG
JUT
BVUPOPNZ
t
*G
UIF
USBOTNJUUFS
JT
TXJUDIFE
PGG
CZ
UVSOJOH
UIF
LFZ
CVUUPO
UP
TUPQ
- 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).
647387EN (18/11/2011)

1-23
 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

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

PLACING THE JIB SAFETY WEDGE

The lift truck is equipped with a jib safety wedge (see: 2 - DESCRIPTION: INSTRUMENTS
ANDCONTROLS) that must be installed on the rod of the lifting cylinder when working beneath
the jib.

FITTING THE WEDGE

- Raise the jib fully.
- Place the safety wedge 1 on the rod of the lifting cylinder and secure with the rod 2 and the
pin 3.
- Slowly lower the jib then stop the hydraulic movements before it comes into contact with the
wedge.

REMOVING THE WEDGE

- Raise the jib fully.
- Remove the pin and the rod.
- Return the safety wedge to the storage location provided on the lift truck.
1
Only use the wedge supplied with the lift truck.
3

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.
647387EN (18/11/2011)

1-24
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.

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.
647387EN (18/11/2011)

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.
647387EN (18/11/2011)

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.

647387EN (18/11/2011)

1-27
1-28
647387EN (18/11/2011)
2-1
2 - DESCRIPTION

647387EN (18/11/2011)
2-2
647387EN (18/11/2011)
TABLE OF CONTENTS

EC DECLARATION OF CONFORMITY 2-4

SAFETY PLATES AND STICKERS 2-6

IDENTIFICATION OF THE LIFT TRUCK 2-10

CHARACTERISTICS MLT 634 -120 LSU Srie G-E3 2-12

CHARACTERISTICS MLT 634 -120 LSU PS Srie G-E3 2-14

CHARACTERISTICS MLT 735 -120 LSU Srie 7-E3 2-16

FRONT AND REAR TIRES 2-18

DIMENSIONS AND LOAD CHART MLT 634 -120 LSU Srie G-E3 MLT 634 -120 LSU PS Srie G-E3 2-20

DIMENSIONS AND LOAD CHART MLT 735 -120 LSU Srie 7-E3 2-22

INSTRUMENTS AND CONTROLS 2-24

TOWING PIN AND HOOK 2-48

DESCRIPTION AND USE OF THE OPTIONS 2-52

647387EN (18/11/2011)

2-3
 EC DECLARATION OF CONFORMITY

1) DCLARATION CE DE CONFORMIT (originale)

EC DECLARATION OF CONFORMITY (original)

2) La socit, The company : MANITOU B.F.

3) Adresse, Address : 430, rue de lAubinire - B.P. 10249 - 44158 - ANCENIS CEDEX - FRANCE

4) Dossier technique, Technical file : MANITOU B.F. - 430, rue de lAubinire

B.P. 10249 - 44158 - ANCENIS CEDEX - FRANCE

5) Constructeur de la machine dcrite ci-aprs, Manufacturer of the machine described below :

MLT 634 -120 LSU Srie G-E3

MLT 634 -120 LSU PS Srie G-E3
MLT 735 -120 LSU Srie 7-E3

6) Dclare que cette machine, Declares that this machine :

7) Est conforme aux directives suivantes et leurs transpositions en droit national, Complies
with the following directives and their transpositions into national law :

2006/42/CE

8) Pour les machines annexe IV, For annex IV machines :

9) Numro dattestation, Certificate number :
10) Organisme notifi, Notified body :

15) Normes harmonises utilises, Harmonised standards used :

16) Normes ou dispositions techniques utilises, Standards or technical provisions used :

17) Fait , Done at : Ancenis 18) Date, Date : 18/11/2011

19) Nom du signataire, Name of signatory : ric LAMBERT

20) Fonction, Function : Prsident division RTH

21) Signature, Signature :

647387EN (18/11/2011)

2-4
bg : 1) (o), 2) , 3) , 4) , 5) - , 6) , , 7)
, 8) IV, 9) , 10) , 15)
, 16) , , 17) , 18) , 19) , 20) , 21) .

cs : 1) ES prohlen o shod (pvodn), 2) Nzev spolenosti, 3) Adresa, 4) Technick dokumentace, 5) Vrobce ne uvedenho stroje, 6) Prohlauje, e tento stroj,
7) Je v souladu s nsledujcmi smrnicemi a smrnicemi transponovanmi do vnitrosttnho prva, 8) Pro stroje v ploze IV, 9) slo certifiktu, 10) Notifikan orgn,
15) harmonizovan normy pouity, 16) Norem a technickch pravidel pouvanch, 17) Msto vydn, 18) Datum vydn, 19) Jmno podepsanho, 20) Funkce, 21) Podpis.

da : 1) EF Overensstemmelseserklring (original), 2) Firmaet, 3) Adresse, 4) tekniske dossier, 5) Konstruktr af nedenfor beskrevne maskine, 6) Erklrer, at denne maskine,
7) Overholder nedennvnte direktiver og disses gennemfrelse til national ret, 8) For maskiner under bilag IV, 9) Certifikat nummer, 10) Bemyndigede organ, 15) harmoniserede standarder,
der anvendes, 16) standarder eller tekniske regler, 17) Udfrdiget i, 18) Dato, 19) Underskrivers navn, 20) Funktion, 21) Underskrift.

de : 1) EG-Konformittserklrung (original), 2) Die Firma, 3) Adresse, 4) Technischen Unterlagen, 5) Hersteller der nachfolgend beschriebenen Maschine, 6) Erklrt, dass diese
Maschine, 7) den folgenden Richtlinien und deren Umsetzung in die nationale Gesetzgebung entspricht, 8) Fr die Maschinen laut Anhang IV, 9) Bescheinigungsnummer,
10) Benannte Stelle, 15) angewandten harmonisierten Normen, 16) angewandten sonstigen technischen Normen und Spezifikationen, 17) Ausgestellt in, 18) Datum,
19) Name des Unterzeichners, 20) Funktion, 21) Unterschrift.

el : 1) CE (), 2) , 3) , 4) , 5) ,
6) , 7) , 8) IV,
9) , 10) , 15) , 16) ,
16) , 17) , 18) , 19) , 20) , 21) .

es : 1) Declaracin DE de conformidad (original), 2) La sociedad, 3) Direccin, 4) expediente tcnico, 5) Constructor de la mquina descrita a continuacin, 6) Declara que esta mquina, 7) Est
conforme a las siguientes directivas y a sus transposiciones en derecho nacional, 8) Para las mquinas anexo IV, 9) Nmero de certificacin, 10) Organismo notificado, 15) normas armonizadas
utilizadas, 16) Otras normas o especificaciones tcnicas utilizadas, 17) Hecho en, 18) Fecha, 19) Nombre del signatario, 20) Funcin, 21) Firma.

et : 1) E vastavusdeklaratsioon (alguprane), 2) rihing, 3) Aadress, 4) Tehniline dokumentatsioon, 5) Seadme tootja, 6) Kinnitab, et see toode, 7) On vastavuses jrgmiste
direktiivide ja nende riigisisesesse igusesse levtmiseks vastuvetud igusaktidega, 8) IV lisas loetletud seadmete puhul, 9) Tunnistuse number, 10) Sertifitseerimisasutus,
15) kasutatud htlustatud standarditele, 16) Muud standardites vi spetsifikatsioonides kasutatakse, 17) Vljaandmise koht, 18) Vljaandmise aeg, 19) Allkirjastaja nimi,
20) Amet, 21) Allkiri.

fi : 1) EY-vaatimustenmukaisuusvakuutus (alkuperiset), 2) Yritys, 3) Osoite, 4) teknisen eritelmn, 5) Jljess kuvatun koneen valmistaja, 6) Vakuuttaa, ett tm kone,
7) Tytt seuraavien direktiivien sek niit vastaavien kansallisten snnsten vaatimukset, 8) Liitteen IV koneiden osalta, 9) Todistuksen numero, 10) Ilmoitettu laitos,
15) yhdenmukaistettuja standardeja kytetn, 16) muita standardeja tai, 17) Paikka, 18) Aika, 19) Allekirjoittajan nimi, 20) Toimi, 21) Allekirjoitus.

ga : 1) EC dearbh comhrireachta (bunaidh), 2) An comhlacht, 3) Seoladh, 4) comhad teicniil, 5) Dantir an innill a thuairisctear thos, 6) Dearbhaonn s go bhfuil an t-inneall,
7) Go gcloonn s le na treoracha seo a leanas agus a trasumh isteach i ndl nisinta, 8) Le haghaidh innill an aguisn IV, 9) Uimhir teastais, 10) Comhlacht a chuireadh i bhfios,
15) caighdein comhchuibhithe a sidtear, 16) caighdein eile n sonraochta teicnila a sidtear, 17) Danta ag, 18) Dta, 19) Ainm an tsnitheora, 20) Feidhm, 21) Sni.

hu : 1) CE megfelelsgi nyilatkozat (eredeti), 2) A vllalat, 3) Cm, 4) mszaki dokumentci, 5) Az albbi gp gyrtja, 6) Kijelenti, hogy a gp, 7) Megfelel az albbi
irnyelveknek valamint azok honostott elrsainak, 8) A IV. mellklet gpeihez, 9) Bizonylati szm, 10) rtestett szervezet, 15) felhasznlt harmonizlt szabvnyok,
16) egyb felhasznlt mszaki szabvnyok s elrsok hivatkozsai, 17) Kelt (hely), 18) Dtum, 19) Alr neve, 20) Funkci, 21) Alrs.

is : 1) Samrmisvottor ESB (upprunalega), 2) Fyrirtki, 3) Asetur, 4) Tknilegar skr, 5) Smiur tkisins sem lst er hr eftir, 6) Stafestir a tki, 7) Samrmist
eftirfarandi stlum og stafrslu eirra me hlisjn af jarrtti, 8) Fyrir tkin aukakafla IV, 9) Stafestingarnmer, 10) Tilkynnt til, 15) samhfa stala sem notair,
16) nnur stalar ea forskriftir nota, 17) Staur, 18) Dagsetning, 19) Nafn undirritas, 20) Staa, 21) Undirskrift.

it : 1) Dichiarazione CE di conformit (originale), 2) La societ, 3) Indirizzo, 4) fascicolo tecnico, 5) Costruttore della macchina descritta di seguito, 6) Dichiara che questa macchina, 7)
conforme alle direttive seguenti e alle relative trasposizioni nel diritto nazionale, 8) Per le macchine Allegato IV, 9) Numero di Attestazione, 10) Organismo notificato, 15) norme armonizzate
applicate, 16) altre norme e specifiche tecniche applicate, 17) Stabilita a, 18) Data, 19) Nome del firmatario, 20) Funzione, 21) Firma.

lt : 1) CE atitikties deklaracija (originalas), 2) Bendrov, 3) Adresas, 4) Technin byla, 5) emiau nurodytas renginio gamintojas, 6) Pareikia, kad is renginys, 7) Atitinka toliau nurodytas
direktyvas ir nacionalinius teiss aktus perkeltas j nuostatas, 8) IV priedas dl main, 9) Sertifikato Nr, 10) Paskelbtoji staiga, 15) suderintus standartus naudojamus, 16) Kiti standartai ir
technines specifikacijas, 17) Pasirayta, 18) Data, 19) Pasiraiusio asmens vardas ir pavard, 20) Pareigos, 21) Paraas.

lv : 1) EK atbilstbas deklarcija (oriinls), 2) Uzmums, 3) Adrese, 4) tehnisks lietas, 5) Tlk aprakstts iekrtas raotjs, 6) Apliecina, ka iekrta, 7) Ir atbilstoa tlk nordtajm
direktvm un to transpozcijai nacionlaj likumdoan, 8) Iekrtm IV pielikum, 9) Apliecbas numurs, 10) Reistrt organizcija, 15) lietotajiem saskaotajiem standartiem, 16) lietotajiem
tehniskajiem standartiem un specifikcijm, 17) Sastdts, 18) Datums, 19) Paraksttja vrds, 20) Amats, 21) Paraksts.

mt : 1) Dikjarazzjoni ta Konformit KE (oriinali), 2) Il-kumpanija, 3) Indirizz, 4) fajl tekniku, 5) Manifattrii tal-magna deskritta hawn isfel, 6) Tiddikjara li din il-magna,
7) Hija konformi hija konformi mad-Direttivi segwenti u l-liijiet li jimplimentawhom fil-lii nazzjonali, 8) Gall-magni fl-Anness IV, 9) Numru ta-ertifikat, 10) Entit nnotifikata,
15) l-istandards armonizzati uati, 16) standards teknii u speifikazzjonijiet ora uati, 17) Magmul f, 18) Data, 19) Isem il-firmatarju, 20) Kariga, 21) Firma.

nl : 1) EG-verklaring van overeenstemming (oorspronkelijke), 2) Het bedrijf, 3) Adres, 4) technisch dossier, 5) Constructeur van de hierna genoemde machine, 6) Verklaart dat
deze machine, 7) In overeenstemming is met de volgende richtlijnen en hun omzettingen in het nationale recht, 8) Voor machines van bijlage IV, 9) Goedkeuringsnummer,
10) Aangezegde instelling, 15) gehanteerde geharmoniseerde normen, 16) andere gehanteerde technische normen en specificaties, 17) Opgemaakt te, 18) Datum,
19) Naam van ondergetekende, 20) Functie, 21) Handtekening.

no : 1) CE-samsvarserklring (original), 2) Selskapet, 3) Adresse, 4) tekniske arkiv, 5) Fabrikant av flgende maskin, 6) Erklrer at denne maskinen, 7) Oppfyller kravene i flgende direktiver,
med nasjonale gjennomfringsbestemmelser, 8) For maskinene i tillegg IV, 9) Attestnummer, 10) Notifisert organ, 15) harmoniserte standarder som brukes, 16) Andre standarder og
spesifikasjoner brukt, 17) Utstedt i, 18) Dato, 19) Underskriverens navn, 20) Stilling, 21) Underskrift.

pl : 1) Deklaracja zgodnoci CE (oryginalne), 2) Spka, 3) Adres, 4) dokumentacji technicznej, 5) Wykonawca maszyny opisanej poniej, 6) Owiadcza, e ta maszyna,
7) Jest zgodna z nastpujcymi dyrektywami i odpowiadajcymi przepisami prawa krajowego, 8) Dla maszyn zacznik IV, 9) Numer certyfikatu, 10) Jednostka certyfikujca,
15) zastosowanych norm zharmonizowanych, 16) innych zastosowanych norm technicznych i specyfikacji, 17) Sporzdzono w, 18) Data, 19) Nazwisko podpisujcego,
20) Stanowisko, 21) Podpis.

pt : 1) Declarao de conformidade CE (original), 2) A empresa, 3) Morada, 4) processo tcnico, 5) Fabricante da mquina descrita abaixo, 6) Declara que esta mquina,
7) Est em conformidade s directivas seguintes e s suas transposies para o direito nacional, 8) Para as mquinas no anexo IV, 9) Nmero de certificado,
10) Entidade notificada, 15) normas harmonizadas utilizadas, 16) outras normas e especificaes tcnicas utilizadas, 17) Elaborado em, 18) Data, 19) Nome do signatrio,
20) Cargo, 21) Assinatura.

ro : 1) Declaraie de conformitate CE (original), 2) Societatea, 3) Adresa, 4) crtii tehnice, 5) Constructor al mainii descrise mai jos, 6) Declar c prezenta main,
7) Este conform cu directivele urmtoare i cu transpunerea lor n dreptul naional, 8) Pentru mainile din anexa IV, 9) Numr de atestare, 10) Organism notificat, 15) standardele armonizate
utilizate, 16) alte standarde si specificatii tehnice utilizate, 17) ntocmit la, 18) Data, 19) Numele persoanei care semneaz, 20) Funcia, 21) Semntura.

sk : 1) ES vyhlsenie o zhode (pvodn), 2) Nzov spolonosti, 3) Adresa, 4) technickej dokumentcie, 5) Vrobca niie opsanho stroja, 6) Vyhlasuje, e tento stroj,
7) Je v slade s nasledujcimi smernicami a smernicami transponovanmi do vntrottneho prva, 8) Pre stroje v prlohe IV, 9) slo certifiktu, 10) Notifikan orgn,
15) pouit harmonizovan normy, 16) pouit in technick normy a predpisy, 17) Miesto vydania, 18) Dtum vydania, 19) Meno podpisujceho, 20) Funkcia, 21) Podpis.

sl : 1) ES Izjava o ustreznosti (izvirna), 2) Druba. 3) Naslov. 4) tehnine dokumentacije, 5) Proizvajalac tukaj opisanega stroja, 6) Izjavlja, da je ta stroj, 7) Ustreza
naslednjim direktivam in njihovi transpoziciji v dravno pravo, 8) Za stroje priloga IV, 9) tevilka potrdila, 10) Obvestilo organu, 15) uporabljene harmonizirane standarde,
16) druge uporabljene tehnine standarde in zahteve, 17) V, 18) Datum, 19) Ime podpisnika, 20) Funkcija, 21) Podpis.
647387EN (18/11/2011)

sv : 1) CE-frskran om verensstmmelse (original), 2) Fretaget, 3) Adress, 4) tekniska dokumentationen, 5) Konstruktr av nedan beskrivna maskin, 6) Frskrar att denna maskin, 7)
verensstmmer med nedanstende direktiv och infrlivandet av dem i nationell rtt, 8) Fr maskinerna i bilaga IV, 9) Nummer fr godknnande, 10) Organism som underrttats, 15)
Harmoniserade standarder som anvnts, 16) andra tekniska standarder och specifikationer som anvnts, 17) Upprttat i, 18) Datum, 19) Namn p den som undertecknat, 20) Befattning, 21)
Namntecknin.

2-5
SAFETY PLATES AND STICKERS

You must replace illegible or damaged plates. Contact your dealer.

1 - EXTERNAL PLATES AND STICKERS

6 N256513
MAXI 4A

GAZ R134A

N$234797
7

N296998

4
8 STOP
N$234798
N$234805

CAPACITE DE LEVAGE
MAXI : 1500 daN
3 9
MAXIMUM LOAD LIFT :

N 24653
1500 daN
N207525

2 10
n289013

250707

1
N 24653

REF PART NUMBER DESCRIPTION

1 9 24653 Securing and slinging point
2 289013 Towing instruction
3 207525 Hydraulic trailer hook (option)
4 234798 Hydraulic oil
5 234797 Air conditioning (option)
6 256513 Electrical boom provision (option)
7 296998 Maniscopic safety instruction
8 234805 Hydraulic coupling instruction
10 250707 Cleanfix self-cleaning fan (option)
647387EN (18/11/2011)

2-6
2 - STICKERS AND PLATES UNDER THE ENGINE HOOD

FUEL / WATER
SEPARATOR

FUEL

259398

N$293887

1
35C
31F

REF PART NUMBER DESCRIPTION

1 293887 Anti-freeze
2 259398 Water/diesel separator

647387EN (18/11/2011)

2-7
3 - STICKERS AND PLATES IN THE CAB

CABINE CONFORME A :
CAB CONFORMS TO :

7 1 FOPS - ISO 3449

ROPS - ISO 3471
ANSI B 56.6
N$193032

N204079

BREVETS - PATENTS

2 FR 93 14367
EP 0 656 315
US PENDING
n$223324

6
MANITOU BF 44158 ANCENIS CEDEX FRANCE
MODELE MODELLO SERIE SERIE
MODEL MODELO SERIES SERIE

240078
Anne de fabrication Anno di fabbricazione Anne modle Anno modello
Year of manufacture Ao de fabricacin Model year Ao modelo

N de srie N di serie
Puissance ISO/TR14396
Serial Nr N de serie
Power ISO/TR14396
Potenza ISO/TR14396
Potencia ISO/TR14396

3
Masse vide Massa a vuoto kW
MANITOU BF - 44158 ANCENIS CEDEX FRANCE Unladen mass Masa en vacio

Type / Type / Tipo / Tipo / Typ kg Capacit nominale

Rated capacity
Capacit nominale
P.T.R.A. P.T.C.A.
Capacidad nominal
Authorized gross vehicle weight P.T.R.A.
N d'homologation / Homologation N / N di omologazione / N de homologacin / Homologatonsnummer

daN kg

N d'identification / Identification N / N d'identificazione / N de identificacin / Identifizierungsnummer Effort de traction Sforzo di trazione Effort vertical maxi. (sur crochet de remorquage)
Drag strain Esfuerzo de traccin Maximum vertical force (on trailer hook)
Sforzo verticale massimo (sul gancia di traino)
Masse totale admissible / Total permissible mass daN Esfuerzo vertical mximo (sobre gancho de remolque)
Massa totale ammissibile / Peso total admisible / Zulssige Gesamtmasse
Pression des pneumatiques (Bar) daN
kg Tyres pressure (Bar)
Masse maximale sur essieu AV / Maximum mass on front axle Pressione dei pneumatici (Bar)
Presin de los neumticos (Bar) N d'homologation
Massa complessiva su assale anteriore / Peso mximo sobre eje delantero / Maximale Achslast vorne
Homologation Nr
Avant Anteriore Arrire Posteriore N di omologazione
kg Front Adelante Rear Trasero N de homologacin
Masse maximale sur essieu AR / Maximum mass on rear axle
Massa complessiva su assale posteriore / Peso mximo sobre eje trasero / Maximale Achslast hinten

kg

MASSE REMORQUABLE ADMISSIBLE / PERMISSIBLE TOWABLE MASS

MASSA RIMORCHIABILE AMMISSIBILE / PESO REMOLCABLE ADMISIBLE / ZULSSIGE ANHNGEMASSE
5 N295449

- Masse remorquable non freine

- Towable mass with no braking
- Massa rimorchiabile non frenata kg
- Peso remolcable sin frenado
- Nichtgebremste Anhngemasse

- Masse remorquable avec freinage indpendant

- Towable mass with independent braking
- Massa rimorchiabile con freno indipendente kg
- Peso remolcable con frenado independiente

Cab Approval
- Anhngemasse mit unabhngiger Bremsung

N 301982
- Masse remorquable avec freinage inertie
- Towable mass with inertial braking
- Massa rimorchiabile con freno inerziale kg
OECD : 4/1139
- Peso remolcable con frenado de inertia
- Anhngemasse bei Auflaubremsung

- Masse remorquable avec freinage assist (Hydraul. ou pneumat.)

- Towable mass with assisted braking (Hydraulic or pneumatic)
kg
e13*2009/75*2009/75*0225*00
- Massa rimorchiabile con servofreno (idraulico o pneumatico)
- Peso remolcable con frenado asistido (hydrulico o neumtica)
- Anhngemasse bei Hilfskraftbremsung (hydraulisch oder pneumatisch)

4
Cab Approval
N283316

N 301983
OECD : 4/1150
e13*2009/75*2009/75*0225*00

REF PART NUMBER DESCRIPTION

1 193032 Cab compliance
2 223324 Patents
3 Consult your dealer Manufacturers plate
301982 Cab homologation (MLT 634 -120)
4
301983 Cab homologation (MLT 735 -120)
5 Consult your dealer Lift truck certification plate
6 240078 Acoustic power
7 204079 Hydraulic trailer hook (option)
8 268491 Break fluid instruction
9 33460 Gear lever control (except for MLT 634 -120 LSU PS Srie G-E3)
10 265284 Lifting ring on carriage (option MLT 735 -120)
11 184276 Steering slection
12 290183 Bucket instruction on telescope
13 297733 Operating mode management instruction
14 303195 Fuses
15 240805 Reach chart sheet
16 Consult your dealer Load chart
255968 Manipulator function sheet (except for MLT 634 -120 LSU PS Srie G-E3)
17
266412 Manipulator function sheet (for MLT 634 -120 LSU PS Srie G-E3)
18 272040 Transmission cut-off switch function sheet
19 241621 Safety instruction sheet
20 294831 Reset procedure sheet
21 289429 Carriage lifting ring sheet (option MLT 735 -120)
647387EN (18/11/2011)

2-8
 Kg

Kg Kg

N265284
Kg Kg Kg Kg Kg Kg

4 2

OK

N290183
Kg Kg Kg Kg
184276
3 1

9 10 11
12

X X
STANDARD
MODE kg

X X kg

HUILE MINERALE Uniquement

13
MINERAL OIL ONLY
MINERALL Nur
ACEITE MINERAL Solamente
8
OLIO MINERALE Soltanto
Kg

N297733 Kg

LHMS

F32 F31
DIAG
SPU
5A 5A
K0 K1
N268491

OPT.

K2 K3 K4

14
K5 K6

OPT.

K7 K8 K9

OPT.

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

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

N303195
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
DIAG
OPT. OPT.
OPT. OPT.
7.5A max 15A max 15A 15A 10A max 10A 15A max 7.5A 7.5A 7.5A 7.5A 15A 15A 15A 25A

15 16 17 17 18
MLT...
50 60 61,5
8

40 7
6,86

6
kg

1 2
00
35

30 5
3500kg

4 1
2
20 3
2500kg

3 4
2000kg

5
1600kg

6
1300kg

2
1150kg

10

1
N255968

0
N272040
N240805

N266412
N. . . . . .

-4 0.5m
5 4 3 2 1 0m
3.90 2.55 1.70 1.23
3.55 2.05 1.45

SUIVANT NORME EN 1459 annexe B.

19 20 21
MLT735 + TS AS 3T

ORH ORH
36km/h Maxi
(10m/s)
2''
1
+ 45
Maxi

3000KG
MAXI

3
0,3m Maxi 1,44km/h (0,4m/s)
Maxi
N 289429

1,52m Maxi
N241621

N294831

3m Mini
4

END
647387EN (18/11/2011)

2-9
 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.

A
LIFT TRUCK MANUFACTURERS PLATE (FIG. A)
1 - MODEL MANITOU BF 44158 ANCENIS CEDEX FRANCE

2 - SERIES
MODELE MODELLO SERIE SERIE
MODEL MODELO SERIES SERIE

1 2
3 - Year of manufacture Anne de fabrication
Year of manufacture
Anno di fabbricazione
Ao de fabricacin
Anne modle
Model year
Anno modello
Ao modelo

4 - Model year 3 4
N de srie N di serie
Puissance ISO/TR14396
Serial Nr N de serie

5 - Serial Nr
Power ISO/TR14396

5 Potenza ISO/TR14396
Potencia ISO/TR14396

6 - Power ISO 3046

Masse vide
Unladen mass
Massa a vuoto
Masa en vacio
kW
6
7 kg Capacit nominale
Rated capacity

7 - Unladen mass P.T.R.A.

Authorized gross vehicle weight
P.T.C.A.
P.T.R.A.
Capacit nominale
Capacidad nominal

8 - Authorized gross vehicle weight 8 daN kg

9
Effort de traction Sforzo di trazione Effort vertical maxi. (sur crochet de remorquage)
Drag strain Esfuerzo de traccin Maximum vertical force (on trailer hook)

9 - Rated capacity 10 daN

Sforzo verticale massimo (sul gancia di traino)
Esfuerzo vertical mximo (sobre gancho de remolque)

Pression des pneumatiques (Bar) daN

11
10 - Drag strain Tyres pressure (Bar)
Pressione dei pneumatici (Bar)
Presin de los neumticos (Bar) N d'homologation
Homologation Nr
Avant Anteriore Arrire Posteriore N di omologazione

11 - Maximun vertical force (on trailer hook) 12

Front Adelante Rear Trasero N de homologacin

13
12 - Tyres pressure (bar) N295449

13 - Homologation Nr

For any further technical information regarding your lift truck refer to chapter: 2 - DESCRIPTION: B
CHARACTERISTICS.

I.C. ENGINE (FIG. B)

- I.C. engine Nr

GEAR BOX (FIG. C)

- Type
- MANITOU reference
- Serial Nr
C

ANGLE GEARBOX (FIG. D)

- Type
- MANITOU reference
- Serial Nr

D
647387EN (18/11/2011)

2-10
FRONT AXLE (FIG. E) E

- Type
- Serial Nr
- MANITOU reference

REAR AXLE (FIG. F)

- Type
- Serial Nr
- MANITOU reference

CAB (FIG. G) F

- Type
- Serial Nr

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

PLATE MANUFACTURER OF THE ATTACHMENT (FIG. I)

- Model G
- Serial Nr
- Year of manufacture

CHASSIS (FIG. J)
- Lift truck serial Nr

I J

MANITOU BF
44158 ANCENIS CEDEX
FRANCE

MODELE

N$ dans la srie

Anne fabrication

Masse vide
kg
647387EN (18/11/2011)

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

2-11
CHARACTERISTICS
MLT 634 -120 LSU Srie G-E3

I.C. ENGINE
Type MERCEDES OM904LA.E3A 3
Fuel Diesel
Number of cylinders 4 in line
Suction Supercharged
Injection system Direct
Ignition sequence 1-3-4-2
Capacity cm3 4250
Bore and stroke mm 102 x 130
Compression ratio 18
Nominal rating loaded rpm 2200
Rating slow unladen rpm 930
Max. rating unladen rpm 2360
Power ISO/TR 14396 cv- kW 122 - 90
Power SAE J 1995 cv- kW 122 - 90
Maximum torque ISO/TR 14396 Nm 470 to 1600 rpm
Air cleaner m 3
Type of cooling By water
Fan Blowing

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

ELECTRIC CIRCUIT
Battery 12 V - 2x 74 Ah - 2x 680 A EN
Alternator 14 V - 90 - 150 A
Type BOSCH 0 124 0AC 2DA
Starter 12 V - 3,3 kW
Type DELCRO MT29 type 500

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

SOUND AND VIBRATION

Level of sound pressure in the drivers cab LpA
dB 76
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
dB 107 (measured)
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on drivers body
m/s2 1,015
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the drivers hand/arm system
647387EN (18/11/2011)

m/s2 < 2,5

(according to standard ISO 5349-2)

2-12
HYDRAULIC CIRCUIT
Hydraulic pump
Type Variable volume pistons
Capacity cm3 63
Max. rating capacity unladen l/mn 173
Flow rate at 1600 rpm l/mn 101
Filtration
Return m 10
Suction m 125
Maximum service pressure bar 270
Telescoping circuit bar 200 / 270
Lifting circuit bar 270 / 270
Tilt circuit bar 190 / 270
Attachment circuit bar 270
Steering circuit bar 140

HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device Electronic
Lifting motions (boom retracted)
Unladen lifting s - m/mn 6,4 - 39,6
Laden lifting s - m/mn 7,6 - 33,3
Unladen lowering s - m/mn 4,6 - 55
Laden lowering s - m/mn 4,4 - 57,5
Telescoping motions (boom raised)
Unladen extending s - m/mn 6 - 19,1
Laden extending s - m/mn 6,6 - 21
Unladen retracting s - m/mn 5,5 - 22,9
Laden retracting s - m/mn 5,4 - 23,3
Tilting movements
Unladen digging s - /s 3,2 - 45,6
Forward tilting unladen s - /s 2,7 - 54,1

SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen 1 km/h 5,5
2 km/h 8,8
3 km/h 19,0
4 km/h 32,7
Rear unladen 1 km/h 5,5
2 km/h 8,8
3 km/h 19,0
4 km/h 32,7
Standard attachment PFB 35 MT 1260
Weight of attachment (without fork) kg 95
Weight of forks (each one) kg 72
Rated capacity with standard attachment kg 3400
Tipping load at maximum reach on tyres kg 1500
Distance from the centre of gravity from the load to the lug of the forks mm 500
Standard lifting height mm 6050
Lift truck weight without attachment kg 7100
Lift truck weight with standard attachment
Unladen kg 7339
At rated load kg 10739
Weight per axle with standard attachment (transport position)
Front unladen kg 3289
Rear unladen kg 4050
Front rated load kg 8999
Rear rated load kg 1740
Weight per axle with standard attachment (boom extended)
Front rated load kg 7919
Rear rated load kg 920
Drag strain on the coupling hook
Unladen (sliding) daN 4850
At rated load (transmission setting) daN 7800
Pull strain with open carrier (according to standard ISO 8313) daN 5200
647387EN (18/11/2011)

2-13
CHARACTERISTICS
MLT 634 -120 LSU PS Srie G-E3

I.C. ENGINE
Type MERCEDES OM904LA.E3A 3
Fuel Diesel
Number of cylinders 4 in line
Suction Supercharged
Injection system Direct
Ignition sequence 1-3-4-2
Capacity cm3 4250
Bore and stroke mm 102 x 130
Compression ratio 18
Nominal rating loaded rpm 2200
Rating slow unladen rpm 930
Max. rating unladen rpm 2360
Power ISO/TR 14396 cv- kW 122 - 90
Power SAE J 1995 cv- kW 122 - 90
Maximum torque ISO/TR 14396 Nm 470 to 1600 rpm
Air cleaner m 3
Type of cooling By water
Fan Blowing

TRANSMISSION
Gear box TURNER
Type Mechanical
Forward/reverse selector Electro-hydraulic
Torque converter SACHS
Number of forward speeds 6
Number of reverse speeds 3
Angle gear box TURNER
Front axle DANA
Differential Limited slip
Rear axle DANA
Differential Without locking
Drive wheels 4RM Permanent
Switch for 2/4 drive wheels No
Front tyres MICHELIN
Size 460-70 R24 159A8 XMCL
Pressure bar 3,4
Rear tyres MICHELIN
Size 460-70 R24 159A8 XMCL
Pressure bar 3,4

ELECTRIC CIRCUIT
Battery 12 V - 2x 74 Ah - 2x 680 A EN
Alternator 14 V - 90 - 150 A
Type BOSCH 0 124 0AC 2DA
Starter 12 V - 3,3 kW
Type DELCRO MT29 type 500

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

SOUND AND VIBRATION

Level of sound pressure in the drivers cab LpA
dB 76
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
dB 107 (measured)
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on drivers body
m/s2 1,015
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the drivers hand/arm system
647387EN (18/11/2011)

m/s2 < 2,5

(according to standard ISO 5349-2)

2-14
HYDRAULIC CIRCUIT
Hydraulic pump
Type Variable volume pistons
Capacity cm3 63
Max. rating capacity unladen l/mn 173
Flow rate at 1600 rpm l/mn 101
Filtration
Return m 10
Suction m 125
Maximum service pressure bar 270
Telescoping circuit bar 200 / 270
Lifting circuit bar 270 / 270
Tilt circuit bar 190 / 270
Attachment circuit bar 270
Steering circuit bar 140

HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device Electronic
Lifting motions (boom retracted)
Unladen lifting s - m/mn 6,4 - 39,6
Laden lifting s - m/mn 7,6 - 33,3
Unladen lowering s - m/mn 4,6 - 55
Laden lowering s - m/mn 4,4 - 57,5
Telescoping motions (boom raised)
Unladen extending s - m/mn 6 - 19,1
Laden extending s - m/mn 6,6 - 21
Unladen retracting s - m/mn 5,5 - 22,9
Laden retracting s - m/mn 5,4 - 23,3
Tilting movements
Unladen digging s - /s 3,2 - 45,6
Forward tilting unladen s - /s 2,7 - 54,1

SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen 1 km/h 5,7
2 km/h 9,2
3 km/h 12,2
4 km/h 19,4
5 km/h 23,6
6 km/h 37,4
Rear unladen 1 km/h 5,7
2 km/h 12,2
3 km/h 23,6
Standard attachment PFB 35 MT 1260
Weight of attachment (without fork) kg 95
Weight of forks (each one) kg 72
Rated capacity with standard attachment kg 3400
Tipping load at maximum reach on tyres kg 1500
Distance from the centre of gravity from the load to the lug of the forks mm 500
Standard lifting height mm 6050
Lift truck weight without attachment kg 7100
Lift truck weight with standard attachment
Unladen kg 7339
At rated load kg 10739
Weight per axle with standard attachment (transport position)
Front unladen kg 3289
Rear unladen kg 4050
Front rated load kg 8999
Rear rated load kg 1740
Weight per axle with standard attachment (boom extended)
Front rated load kg 7919
Rear rated load kg 920
Drag strain on the coupling hook
Unladen (sliding) daN 4850
At rated load (transmission setting) daN 7800
Pull strain with open carrier (according to standard ISO 8313) daN 5200
647387EN (18/11/2011)

2-15
CHARACTERISTICS
MLT 735 -120 LSU Srie 7-E3

I.C. ENGINE
Type MERCEDES OM904LA.E3A 3
Fuel Diesel
Number of cylinders 4 in line
Suction Supercharged
Injection system Direct
Ignition sequence 1-3-4-2
Capacity cm3 4250
Bore and stroke mm 102 x 130
Compression ratio 18
Nominal rating loaded rpm 2200
Rating slow unladen rpm 930
Max. rating unladen rpm 2360
Power ISO/TR 14396 cv- kW 122 - 90
Power SAE J 1995 cv- kW 122 - 90
Maximum torque ISO/TR 14396 Nm 470 to 1600 rpm
Air cleaner m 3
Type of cooling By water
Fan Blowing

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

ELECTRIC CIRCUIT
Battery 12 V - 2x 74 Ah - 2x 680 A EN
Alternator 14 V - 90 - 150 A
Type BOSCH 0 124 0AC 2DA
Starter 12 V - 3,3 kW
Type DELCRO MT29 type 500

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

SOUND AND VIBRATION

Level of sound pressure in the drivers cab LpA
dB 76
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
dB 107 (measured)
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on drivers body
m/s2 1,015
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the drivers hand/arm system
647387EN (18/11/2011)

m/s2 < 2,5

(according to standard ISO 5349-2)

2-16
HYDRAULIC CIRCUIT
Hydraulic pump
Type Variable volume pistons
Capacity cm3 63
Max. rating capacity unladen l/mn 173
Flow rate at 1600 rpm l/mn 101
Filtration
Return m 10
Suction m 125
Maximum service pressure bar 270
Telescoping circuit bar 200 / 270
Lifting circuit bar 270 / 270
Tilt circuit bar 190 / 270
Attachment circuit bar 270
Steering circuit bar 140

HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device Electronic
Lifting motions (boom retracted)
Unladen lifting s - m/mn 6,7 - 40,3
Laden lifting s - m/mn 7,3 - 37
Unladen lowering s - m/mn 4,8 - 56,3
Laden lowering s - m/mn 4,6 - 58,7
Telescoping motions (boom raised)
Unladen extending s - m/mn 7,1 - 22,2
Laden extending s - m/mn 7,3 - 22,8
Unladen retracting s - m/mn 5,7 - 28,4
Laden retracting s - m/mn 5,5 - 29,5
Tilting movements
Unladen digging s - /s 3 - 48,8
Forward tilting unladen s - /s 2,35 - 62,3

SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen 1 km/h 5,5
2 km/h 8,8
3 km/h 19
4 km/h 32,7
Rear unladen 1 km/h 5,5
2 km/h 8,8
3 km/h 19
4 km/h 32,7
Standard attachment PFB 35 MT 1260
Weight of attachment (without fork) kg 95
Weight of forks (each one) kg 72
Rated capacity with standard attachment kg 3500
Tipping load at maximum reach on tyres kg 1200
Distance from the centre of gravity from the load to the lug of the forks mm 500
Standard lifting height mm 6850
Lift truck weight without attachment kg 6915
Lift truck weight with standard attachment
Unladen kg 7154
At rated load kg 10654
Weight per axle with standard attachment (transport position)
Front unladen kg 3284
Rear unladen kg 3870
Front rated load kg 9014
Rear rated load kg 1640
Weight per axle with standard attachment (boom extended)
Front rated load kg 7610
Rear rated load kg 744
Drag strain on the coupling hook
Unladen (sliding) daN 5235
At rated load (transmission setting) daN 7280
Pull strain with open carrier (according to standard ISO 8313) daN 3700
647387EN (18/11/2011)

2-17
FRONT AND REAR TIRES

PRESSURE TYRE LOAD (kg)

MLT 634 -120 LSU Srie G-E3
(bar) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN
460/70R24 XMCL 159A8 TUBELESS 3,4
400/80-24 156A8 IND POWER CL TUBELESS *
MICHELIN
15,5R25 XHA TUBELESS 2,75
1200R20 X MINE D2 5,5
14,9X24 T35 STABILARGE 18PR 3,4
DUNLOP 400/70-20 T37 150B 14PR TUBELESS 3,25
405/70-24 MPT SPT9 168A2/152J TUBELESS 5 1650 4500 2050 850
15,5/80-24 SGI 12PR TUBELESS 4
GOODYEAR 460/70R24 IT520 152A8 TUBELESS 3,3
445/70R24 MPT IT510 151G TUBELESS 4,1
NOKIAN 460/65R24 SF TRI STEEL TUBELESS 3,8
ALLIANCE 17,5 LR 24 150 A8 A570 TUBELESS 3,2
TRELLEBORG 500-60/22,5 TWIN 404 12PR 2,5

PRESSURE TYRE LOAD (kg)

MLT 634 -120 LSU PS Srie G-E3
(bar) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN
460/70R24 XMCL 159A8 TUBELESS 3,4
400/80-24 156A8 IND POWER CL TUBELESS *
MICHELIN
15,5R25 XHA TUBELESS 2,75
1200R20 X MINE D2 5,5
14,9X24 T35 STABILARGE 18PR 3,4
DUNLOP 400/70-20 T37 150B 14PR TUBELESS 3,25
405/70-24 MPT SPT9 168A2/152J TUBELESS 5 1650 4500 2050 850
15,5/80-24 SGI 12PR TUBELESS 4
GOODYEAR 460/70R24 IT520 152A8 TUBELESS 3,3
445/70R24 MPT IT510 151G TUBELESS 4,1
NOKIAN 460/65R24 SF TRI STEEL TUBELESS 3,8
ALLIANCE 17,5 LR 24 150 A8 A570 TUBELESS 3,2
TRELLEBORG 500-60/22,5 TWIN 404 12PR 2,5

PRESSURE TYRE LOAD (kg)

MLT 735 -120 LSU Srie 7-E3
(bar) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN
460/70R24 XMCL 159A8 TUBELESS 3,4
400/80-24 156A8 IND POWER CL TUBELESS 3,8
MICHELIN
500/70R24 MCL 164A8 TUBELESS 2,6
15,5R25 XHA TUBELESS 2,75
14,9X24 T35 STABILARGE 18PR 3,6
DUNLOP
400/70-20 T37 150B 14PR TUBELESS 3,8 1650 4500 1950 800
15,5/80-24 SGI 12PR TUBELESS 4
GOODYEAR 460/70R24 IT520 152A8 TUBELESS 3,3
445/70R24 MPT IT510 151G TUBELESS 4,1
NOKIAN 460/65R24 SF TRI STEEL TUBELESS 3,8
ALLIANCE 17,5 LR 24 150 A8 A570 TUBELESS 3,2
647387EN (18/11/2011)

2-18
 PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE
PRESSURE
LOAD (kg) (kg/cm2) (cm2)
(bar)
HARD SOIL LOOSE SOIL HARD SOIL LOOSE SOIL
800 1,54 0,52 529 1568
850 1,56 0,54 546 1587
460/70R24 XMCL 159A8 TUBELESS 3,4
1650 1,99 0,87 827 1885
1950 2,12 0,97 917 1996
2050 2,16 1,00 947 2033
4500 2,88 1,52 1556 2944
850
1650
* 2050
4500
400/80-24 156A8 IND POWER CL TUBELESS 800
1650
3,8 1950
4500
MICHELIN 800 1,75 0,82 456 978
850 1,83 0,85 465 996
15,5R25 XHA TUBELESS 2,75
1650 2,12 0,99 778 1670
1950 2,20 1,02 887 1907
2050 2,22 1,03 922 1986
4500 2,37 1,12 1893 4009
850
1650
1200R20 X MINE D2 5,5 2050
4500
800
1650
500/70R24 MCL 164A8 TUBELESS 2,6 1950
4500
850 4,72 1,63 180 520
3,4
1650 5,69 1,99 290 830
2050 6,21 2,14 330 960
14,9X24 T35 STABILARGE 18PR
4500 9,34 3,10 482 1450
800 4,73 1,67 169 480
3,6
1650 5,41 1,90 305 868
1950 6,02 2,05 324 953
4500 9,49 3,12 467 1422
850 6,18 2,02 137 419
DUNLOP 3,25
1650 7,35 2,32 224 711
2050 7,70 2,46 266 830
400/70-20 T37 150B 14PR TUBELESS
4500 10,32 3,26 429 1360
800 6,50 2,09 123 383
3,8
1650 8,21 2,50 201 660
1950 8,35 2,65 233 735
4500 11,49 3,56 386 1247
850 7,73 3,40 110 250
405/70-24 MPT SPT9 168A2/152J TUBELESS 5
1650 7,11 3,12 233 530
2050 6,95 3,06 295 670
4500 8,18 3,60 550 1250
800 6,95 1,84 115 435
850 7,08 1,85 120 460
15,5/80-24 SGI 12PR TUBELESS 4
1650 7,86 2,14 210 770
1950 8,48 2,25 230 865
2050 8,63 2,29 238 895
4500 11,94 3,33 377 1353
800 8,42 2,22 95 360
850 8,50 2,24 100 380
GOODYEAR 460/70R24 IT520 152A8 TUBELESS 3,3
1650 8,25 2,26 200 730
1950 9,05 2,36 216 825
2050 9,15 2,39 224 858
4500 11,94 3,10 377 1453
800 7,16 2,35 110 334
850 7,24 2,38 115 349
445/70R24 MPT IT510 151G TUBELESS 4,1
1650 8,46 2,82 195 586
1950 8,67 2,87 225 680
2050 8,91 2,93 230 700
4500 9,88 3,28 452 1363
800
850
1650
NOKIAN 460/65R24 SF TRI STEEL TUBELESS 3,8 1950
2050
4500
800
850
1650
ALLIANCE 17,5 LR 24 150 A8 A570 TUBELESS 3,2 1950
2050
4500
850 2,70 1,40 315 607
1650 2,70 1,40 611 1179
647387EN (18/11/2011)

TRELLEBORG 500-60/22,5 TWIN 404 12PR 2,5 2050 2,70 1,40 760 1465
4500 2,70 1,40 1667 3214

2-19
DIMENSIONS AND LOAD CHART
MLT 634 -120 LSU Srie G-E3
MLT 634 -120 LSU PS Srie G-E3

A (mm) 1200
B (mm) 2560
C (mm) 1142
C1 (mm) 1245
D (mm) 4579
D1 (mm) 4682
D2 (mm) 4032
E (mm) 5779
F (mm) 1935
F1 (mm) 1935
G (mm) 450
G1 (mm) 435
G2 (mm) 435
I (mm) 877
J (mm) 980
K (mm) 1260
L (mm) 45
N (mm) 1715
O (mm) 125
P2 () 47,5
P3 () 53
R (mm) 3535
S (mm) 7390
T (mm) 3450
U1 (mm) 2295
U2 (mm) 2545
V (mm) 4650
V1 (mm) 1200
V2 (mm) 3769
W (mm) 2402
Y () 12
Z () 134

647387EN (18/11/2011)

2-20
 MLT634
50 60 63.5
7

40 6,056

30
4
3400kg
2500kg
2000kg

3
2800kg

20
1500kg

10
1

0
N244374

-3.5 0m
0.5m
4 3 2 1 0m
3,25 2,55 1,80 1,19
2,05 1,45
SUIVANT NORME EN 1459 annexe B.
647387EN (18/11/2011)

2-21
DIMENSIONS AND LOAD CHART
MLT 735 -120 LSU Srie 7-E3

A (mm) 1200
B (mm) 2810
C (mm) 1191
C1 (mm) 1287
D (mm) 4790
D1 (mm) 4886
D2 (mm) 4194
E (mm) 5990
F (mm) 1935
F1 (mm) 1935
G (mm) 450
G1 (mm) 435
G2 (mm) 435
I (mm) 789
J (mm) 980
K (mm) 1260
L (mm) 45
N (mm) 1715
O (mm) 125
P2 () 38
P3 () 53
R (mm) 3685
S (mm) 7715
T (mm) 3575
U1 (mm) 2295
U2 (mm) 2545
V (mm) 4885
V1 (mm) 1310
V2 (mm) 3919
W (mm) 2402
Y () 12
Z () 134

647387EN (18/11/2011)

2-22
 MLT735
50 60 62.5
8

40
7
6.85

g
6 00k
30
30 5
3500kg

20
2500kg

3
2000kg

1200kg
1600kg
1300kg

2
10

0
N286280

0m
-4 0.5m
5 4 3 2 1 0m
3.65 2.65 1.75 1.23
3.90 3.15 2.15 1.50

SUIVANT NORME EN 1459 annexe B.

647387EN (18/11/2011)

2-23
INSTRUMENTS AND CONTROLS
MLT 634 -120 LSU Srie G-E3 - MLT 735 -120 LSU Srie 7-E3

26 25 26
9 39
8 5
4 MLT 634 -120 LSU PS Srie G-E3
21
30 16 19
28
26 18
10 7
29 20
27
11 19
15 26 14 16
1 7 39

2 18 20
23

24
38
17 35
7
6 7
36
23
37

38

11

12
13

32

33
34
31

34
22
647387EN (18/11/2011)

48

2-24
DESCRIPTION
1 - DRIVER'S SEAT
2 - SAFETY BELT
3 - CONTROL AND SIGNAL LIGHTS PANEL
4 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
5 - EMERGENCY STOP BUTTON
6 - EMERGENCY EXIT
7 - SWITCHES
8 - LIGHT SWITCH, HORN AND INDICATOR SWITCH
9 - FRONT AND REAR WINDSCREEN WIPER SWITCH
10 - IGNITION SWITCH
11 - FUSES AND RELAYS IN THE CAB
12 MAIN FUSE
13 DIAGNOSTIC SOCKET (only for MLT 634 -120 LSU PS Srie G-E3)
14 - ACCELERATOR PEDAL
15 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
16 - GEAR LEVER AND TRANSMISSION CUT-OFF (except for MLT 634 -120 LSU PS Srie G-E3)
16 GEAR SELECTOR (only for MLT 634 -120 LSU PS Srie G-E3)
17 - PARKING BRAKE LEVER
18 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
19 - STEERING SELECTION
20 - HYDRAULIC CONTROLS
21 - FUNCTION FILES
22 - LEVEL INDICATOR
23 - HEATER CONTROL
23 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
24 - CAB FILTER VENTILATORS
25 - WINDSCREEN DEMISTER VENTS
26 - HEATING VENTS
27 - BRAKING OIL TANK AND WINDSCREEN WASHER ACCESS PANEL
28 - STEERING WHEEL REGULATING HANDLE
29 - DOOR LOCK
30 - LOCKING HANDLE FOR UPPER HALF-DOOR
31 - UNLOCKING BUTTON FOR UPPER HALF DOOR
32 - HANDLE FOR REAR WINDOW OPENING
33 - DOCUMENT HOLDER
34 - SUN VISOR
35 - OVERHEAD LIGHT
36 - HOOK
37 - CIGAR LIGHTER
38 - ARMREST AND STORAGE
39 - CAR RADIO (OPTION)
40 INSIDE REAR-VIEW MIRROR (OPTION) (NOT ILLUSTRATED)
41 TOOL BOX (NOT ILLUSTRATED)
42 - NUMBER PLATE (NOT ILLUSTRATED)
43 - NUMBER PLATE LIGHTING (NOT ILLUSTRATED)
44 - REAR REFLECTORS (NOT ILLUSTRATED)
45 - FRONT LIGHTS (NOT ILLUSTRATED)
46 - REAR LIGHTS (NOT ILLUSTRATED)
47 - FLASHING LIGHT (NOT ILLUSTRATED)
48 JIB SAFETY WEDGE

NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver's seat and looking in front of him.
647387EN (18/11/2011)

2-25
1 - DRIVERS SEAT A

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

WEIGHT ADJUSTMENT (FIG. A)

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

SEAT HEIGHT ADJUSTMENT (FIG. B)

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

SEAT DEPTH ADJUSTMENT (FIG. D)

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

EXTENDING THE HEAD-REST (FIG. E)

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

E
647387EN (18/11/2011)

2-26
LUMBAR ADJUSTMENT (FIG. F) F
This increases the comfort of the seat and the drivers freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.

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

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

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

LONGITUDINAL ADJUSTMENT (FIG. H)

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

MAINTENANCE (FIG. I) G
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.

647387EN (18/11/2011)

2-27
1 - BASIC PNEUMATIC DRIVERS SEAT (OPTION) A

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

WEIGHT ADJUSTMENT (FIG. A)

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

SEAT HEIGHT ADJUSTMENT (FIG. B)

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

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

SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C)

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

SEAT DEPTH ADJUSTMENT (FIG. D)

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

E
647387EN (18/11/2011)

2-28
LUMBAR ADJUSTMENT (FIG. F) F
This increases the comfort of the seat and the drivers freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.

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

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

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

HORIZONTAL SHOCK ABSORBER (FIG. H)

In certain conditions (e.g. driving with a trailer) it is advised that a horizontal shock absorber be
used. The 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. G

LONGITUDINAL ADJUSTMENT (FIG. I)

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

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

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

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

I J

2 - SAFETY BELT
- Sit correctly on the seat.
- Check that seat belt is not twisted.
- Place the seat belt at hip level.
- Attach the seat belt and check that it locks.
- Adjust the seat belt to your body shape without squeezing your hip and without over-slack.
647387EN (18/11/2011)

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.

2-29
3 - CONTROL AND SIGNAL LIGHTS PANEL

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

12
0 30
9 3

CONTROL INSTRUMENTS

A - I.C. ENGINE WATER TEMPERATURE

Temperature zone:
A1 - Blue zone (0 - 50) 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 comes on between zone A3 and A4.

B - HOUR METER AND REV COUNTER

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

D - CLOCK

SIGNAL LIGHTS
A permanently lit or flashing warning lamp, with the engine running, is the sign of an operating fault. The lighting of some lamps may be accompanied by an
audible signal. Do not ignore this warning, consult your dealer without delay.
If one of the warning lamps comes on while the lift truck is in motion, stop the lift truck under the safest possible conditions.
When activating the electrical system of the lift truck, all the red and orange lamps and the 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.

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.

ORANGE I.C. ENGINE WARNING INDICATOR LIGHT

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

STOP
RED I.C. ENGINE STOPPED 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.

RED STEERING SYSTEM OIL PRESSURE WARNING INDICATOR LIGHT

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

STOP

NOTE: The indicator lights go off after engine preheating.

647387EN (18/11/2011)

2-30
RED GEAR BOX OIL PRESSURE WARNING INDICATOR LIGHT
MLT 634 -120 LSU Srie G-E3
MLT 735 -120 LSU Srie 7-E3
The lamp and buzzer come on when there is an abnormal drop in gear box pressure, in forward gear. Stop the I.C engine and look
for the cause (gear box oil level, possible leak, radiator, etc.).
NOTE: The signal light operates in forward travel conditions only, the signal should not be taken into account when the I.C. engine
is running at idle or is stopped.

RED CLUTCH PRESSURE WARNING INDICATOR LIGHT

MLT 634 -120 LSU PS Srie G-E3
The lamp and buzzer come on when there is an abnormal drop in pressure in the gear box. Stop the I.C engine and look for the
cause (gear box oil level, possible leak, radiator, etc.).
NOTE: Since this light only operates while driving, do not take the information into consideration when the lift truck has stopped
or is idling.

RED TRANSMISSION OIL TEMPERATURE FAULT NDICATOR LIGHT

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

RED BRAKING OIL LEVEL WARNING INDICATOR LIGHT

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

RED PARKING BRAKE LAMP

This lamp comes on when the parking brake is applied.

BATTERY CHARGE WARNING INDICATOR LIGHT

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

RED I.C. ENGINE OIL PRESSURE WARNING INDICATOR LIGHT

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

RED I.C. ENGINE WATER TEMPERATURE WARNING INDICATOR LIGHT

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

RED AIR FILTER OR HYDRAULIC RETURN FILTER CLOGGED INDICATOR LIGHT

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

GREEN DIRECTION INDICATOR LAMP

GREEN SIDELIGHTS LAMP

GREEN LOW BEAM LAMP

BLUE MAIN BEAM LAMP

647387EN (18/11/2011)

2-31
4 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
A8
This device warns the operator of the lift trucks longitudinal stability limits. However, lateral stability A7
can reduce the load chart in the upper part, and this reduction is not detected by the device.
A6
According to the type of work required, the longitudinal stability limiter and warning device allows the
operator to operate the lift truck in complete safety. A5
A4
UPDATED: In order to gain maximum advantage from the longitudinal stability limiter and warning
A3
device of your lift truck, contact your dealer to receive the most recent available version of
the software. A2
A1
The operator must respect the lift truck's load chart, and the operating mode according to the attachment.

A - "HANDLING" MODE
Use on forks.
X X
STANDARD
- By default, the device is in "HANDLING" MODE when the MODE kg
lift truck is started-up, except if the "SUSPENDED LOAD"
MODE has been selected before shutting-down the

X X
engine.
A1 - A2 - A3: There is a significant reserve of kg

longitudinal stability.
A4 - A5: The lift truck is nearing the limit of
longitudinal stability. The alarm sounds
simultaneously with a very slow intermittent
sound. Move with care.
A6: The lift truck is near at the limit of longitudinal Kg
stability. The alarm sounds with a slow N297733 Kg

intermittent sound. Move with care.

A7: The lift truck is very near at the limit of
longitudinal stability. The alarm sounds with a fast intermittent sound. Move with extreme care.
A8: The lift truck is at the authorized limit of longitudinal stability. The alarm sounds with a very fast intermittent sound. All
"AGGRAVATING" hydraulic movements are cut-off. The hydraulic movement may automatically slow before cut-off. Only make
de-aggravating hydraulic movements in the following order: retract and raise the boom.
NOTE: When the boom is retracted, the function for cutting-off "AGGRAVATING" hydraulic movements is disconnected.

B - "BUCKET" MODE
Use with bucket.
X X
STANDARD
- Place the lift truck in the transport position. MODE kg

- Press the button for 2 seconds, "BUCKET" MODE

is confirmed by an audible beep and the lighting of the
lamp.
X X
kg

- Return to "HANDLING" MODE by pressing the button

, or loss of driver presence for a few seconds, or

shutting down the engine.
A1 - A2 - A3: There is a significant reserve of
Kg
longitudinal stability. N297733 Kg

A4 - A5: The lift truck is approaching the limit

of longitudinal stability, move with care.
A6: The lift truck is approaching the limit of longitudinal stability. An audible beep is sounded. Move with care.
A7: The lift truck is very close to the limit of longitudinal stability. Move with extreme care.
A8: The lift truck is at the authorized limit of longitudinal stability. Boom raising and lowering movements are cut-off, the other
movements remain available. Cut-off may be preceded by an automatic slowing of hydraulic movement.
NOTE: When the boom is retracted, the function for cutting-off "AGGRAVATING" hydraulic movements is disconnected.
647387EN (18/11/2011)

2-32
C - "SUSPENDED LOAD" MODE
Providing a higher margin of safety, use with boom crane.
X X
STANDARD
- Place the lift truck in the transport position. MODE kg

- Press the button for 2 seconds, "SUSPENDED

LOAD" MODE is validated by an audible beep and the
lighting of the lamp. Hydraulic tilting movements are
X X
kg

neutralised
- Return to "HANDLING" MODE by pressing the button

.
A1 - A2 - A3: There is a significant reserve of
Kg
longitudinal stability. N297733 Kg

A4 - A5: The lift truck is nearing the limit of

longitudinal stability. The alarm sounds
simultaneously with a very slow
intermittent sound. Move with care.
A6: The lift truck is near at the limit of longitudinal stability. The alarm sounds with a slow intermittent sound. Move with care.
A7: The lift truck is very near at the limit of longitudinal stability. The alarm sounds with a fast intermittent sound. Move with
extreme care.
A8: The lift truck is at the authorized limit of longitudinal stability. The alarm sounds with a very fast intermittent sound. All
"AGGRAVATING" hydraulic movements are cut-off. The hydraulic movement may automatically slow before cut-off. Only make
de-aggravating hydraulic movements in the following order: retract and raise the boom.
NOTE: When the boom is retracted, the function for switching off "AGGRAVATING" hydraulic movements is disconnected, and all hydraulic
movements are available.

D - DISABLING "AGGRAVATING" HYDRAULIC MOVEMENT CUT-OFF

In certain cases, in order to get out of a difficult situation, the operator can bypass this safety
system. Button D temporarily disables the cutting-off of "AGGRAVATING" hydraulic movements.
- Hold down button D, lamp D1 will light (60 second time delay), and simultaneously perform D
the necessary "AGGRAVATING" hydraulic movement with extreme care.
D1
Remain very vigilant during this operation. The only information available to the operator is the lift trucks
dynamic stability.

E - TESTING OF THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE

- Short press the button to verify at any time that the longitudinal stability alarm is working.
t
Correct operation: All the LEDs light for two seconds and an audible beep is sounded.
NOTE: This test does not check the proper adjustment of the longitudinal stability limiter that must be inspected daily or after every 10
hours of service (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).

F - FAULT INDICATOR LAMP

A permanently lit fault indicator lamp F, together with a combination of illuminated LEDs, indicates a F
A8
major fault liable to affect the safety of the lift truck. Refer to your agent or dealer.
A7
- The fault indicator lamp plus LEDs A1 and A7 lighting alternately with A4 and A8 indicates a
defective link in the operation of the longitudinal stability limiter and warning device.

- The fault indicator lamp plus continuously lit LEDs A7 and A8 indicate a faulty box. A4

A1

G - STRAIN GAUGE
Disassembly or calibration of the strain gauge is prohibited, this must only be done by specially trained G
personnel, consult your dealer.
647387EN (18/11/2011)

2-33
5 - EMERGENCY STOP BUTTON
- In the event of danger, it lets you stop the I.C. Engine and thereby cut out all hydraulic
movements.
- Pull the button to disable it before restarting the lift truck.

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

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

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

A - OPTION ELECTRICAL BOOM PROVISION

OR
OPTION ELECTROVALVE AT BOOM HEAD
2
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
1
B - OPTION BLUE FRONT AND REAR WORKING LIGHTS
E F G H
C - WHEEL ALIGNMENT LAMPS

D - WARNING LIGHTS

E - REAR FOG LIGHTS

F - SELF-CLEANING FAN OPTION H

See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
2
G - STEERING SELECTION
1
H - TRANSMISSION CUT-OFF
NOTE: In all cases transmission cut-off can be activated using the GEAR lever.
(except for MLT 634 -120 LSU PS Srie G-E3)

- Position 1: With the indicator light on, transmission cut-off is by means of the service MLT 634 -120 LSU PS Srie G-E3
brake pedal and the forward/neutral/reverse gear lever.
- Position 2: Indicator light off, transmission is cut-off from forward/neutral/reverse gear
selector.

USE OF TRANSMISSION CUT-OFF

Transmission cut-off to brake pedal (position 1). I J K L M
t

8IFO
MPBEJOH
Transmission cut-off to forward/neutral/reverse gear selector (position 2).
t

8IFO
ESJWJOH
t

'PS
JODIJOH
BOE
DPOUJOVPVT
TUPQQJOH
BOE
TUBSUJOH
EFMJDBUF
IBOEMJOH

647387EN (18/11/2011)

t

4UBSUJOH
PO
B
TMPQF

I - REVOLVING LIGHT

2-34
J - FRONT AND REAR WORKING LIGHTS

K - BOOM HEAD LIGHT OPTION

L - OPTION
N O P Q R
M - SIDE WINDSCREEN WIPER + ROOF WINDSCREEN WIPER

N/O - OPTION HYDRAULIC TOWING HOOK

OPTION SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.

P - OPTION ATTACHMENT HYDRAULIC LOCKING DEVICE

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

Q - OPTION BOOM SUSPENSION

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

R - NEUTRALIZATION OF HYDRAULIC MOVEMENTS T U

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

T - DISABLING 6TH GEAR

MLT 634 -120 LSU PS Srie G-E3
See: 2 - DESCRIPTION: 16 - GEAR SELECTOR.

U - GEAR INDICATOR
MLT 634 -120 LSU PS Srie G-E3 MLT 634 -120 LSU PS Srie G-E3
See: 2 - DESCRIPTION: 16 - GEAR SELECTOR.

V - ATTACHMENT EASY HYDRAULIC CONNECTION OPTION

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

W - OPTION
V

8 - LIGHT SWITCH, HORN AND INDICATOR SWITCH

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

Pressing the switch sounds the horn.

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

9 - FRONT AND REAR WINDSCREEN WIPER SWITCH

E
FRONT WINDSCREEN WIPER
A - Front windscreen wiper off.
B - Front windscreen wiper low speed setting.
C - Front windscreen wiper high speed setting. D A A F
D - Front windscreen wiper intermittent setting.
REAR WINDSCREEN WIPER
647387EN (18/11/2011)

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

2-35
10 - IGNITION SWITCH
The key switch has five positions:
P - Ignition off, parking position.
O - Ignition switched off and engine stopped.
I - Ignition and pre-heating.
II Not used.
III - The engine starts, returns to position I as soon as the key is released.

11 - FUSES AND RELAYS IN THE CAB

- Lift up the fuse and relay access panel 1. 1

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

Always replace a faulty fuse with another of equivalent rating. Never use a fuse that has been repaired.
F1 - Hydraulic control unit (7,5A).
- OPTION.
F2 - Working tail light (15A).
F3 - Rear windscreen wiper + roof windscreen wiper + side windscreen wiper (10A).
F4 - Engine and cab electronic control unit (15A).
F5 - Revolving light (7,5A).
F6 - Wheel alignment (5A). F32 F31
DIAG
- OPTION. SPU

F7 - Warning device and longitudinal stability limiter (7,5A). K0 K1

5A 5A

- Aggravating hydraulic movement cut-off deactivation (7,5A). OPT.

- OPTIONAL Blue front and rear working lights (15A).
K2 K3 K4
F8 - Forward/neutral/reverse selector (15A).
- Transmission cut-off (15A).
- Reversing lights (15A).
K5 K6
- OPTION Reverse buzzer alarm (15A).
F9 - Control panel (5A). OPT.
F10 - Sound alarm (10A).
K7 K8 K9
- Stop switch (10A).
F11 - OPTION Working lights on jib head (15A). OPT.
F12 - Flashing unit (10A).
F13 - Ventilation/heating (30A). F1
OPT.
F2 F3 F4 F5 F6
OPT.
F7
OPT.
F8 F9 F10 F11 F12 F13 F14
OPT.
F15
ECU
OPT.
F14 - Cigarette lighter + Diesel reheater (25A).
STOP

LSU HYD.
10A max 15A 10A 15A max 7.5A 7.5A max 15A max 15A 5A 10A 15A max 10A 30A 25A max 20A
N303195

- OPTION.
F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29 F30
F15 - Hydraulic movement control unit (20A). DIAG
OPT. OPT.
OPT. OPT.
F16 - Diagnostic socket (5A). 7.5A max 15A max 15A 15A 10A max 10A 15A max 7.5A 7.5A 7.5A 7.5A 15A 15A 15A 25A

- OPTION.
F17 - OPTION Self-cleaning fan (5A).
- OPTION FINTRONIC anti-start system (10A).
- OPTION MODCOD / MODCL Anti-theft system (10A).
- OPTION Rear hydraulic predisposition (10A).
- OPTION Two rear hydraulic predispositions (15A).
F18 - Front working lights (15A).
F19 - Rear window de-icing (15A).
F20 - OPTION Pneumatic seat (10A).
- OPTION.
F21 - Front windscreen wiper and front windscreen washer (10A).
F22 - OPTION Jib suspension (10A).
- OPTION Electrical jib provision (5A).
- OPTIONAL Solenoid valve on jib head (7,5A).
F23 - Right sidelight (7,5A)
- Dashboard lighting (7.5A).
F24 - Left sidelights (7,5A)
- Number plate lighting (7.5A).
F25 - Right indicators (7,5A)
F26 - Left indicators (7,5A)
F27 - Low beam (15A).
- Low beam indicator light (15A).
647387EN (18/11/2011)

- Rear fog light (15A).

2-36
 F28 - Main beam (15A).
- Main beam headlamp (15A).
F29 - Warning lights (15A).
- Roof light (15A).
- Anti-theft device provision (15A). C K17
- Clock (15A). F32
F31
- Rev counter (15A).
F30 - Lights, horn and indicator switch (25A).
F31 - Starter relay (5A).
F32 - Diagnostic socket (5A).
- Hydraulic movement control unit (5A).

K0 - OPTION.
K1 - Transmission cut-off relay.
K2 - Transmission cut-off relay. (except for MLT 634 -120 LSU PS Srie G-E3)
K3 - Reverse gear relay.
K4 - Forward gear relay. (except for MLT 634 -120 LSU PS Srie G-E3)
K5 - Buzzer.
K6 - OPTION.
K7 - OPTION.
K8 - Safety system starting switch relay.
K9 - Flashing unit.
K17 - Indicator module relay. 2
K18 - Neutral safety relay. (except for MLT 634 -120 LSU PS Srie G-E3) 3

- Lift the lid 2 of the tool box for access to fuse. 4

F33 - Hydraulic control unit (1A).

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

- Remove the braking fluid and windscreen washer tank access panel 5 to access the fuses and
relays.
F40 - Key switch (40A).
F41 - Key switch (40A). F33
F42 - OPTION Air conditioning (30A)
F43 - Cab and starter relay electronic control unit (10A).
F44 - Engine electronic control unit (15A).
F45 - Engine electronic control unit (15A).

K19 - Engine starting relay.

K19
K11

F45
F44
F43
K10
F42

5
F41 F40

12 MAIN FUSE
Remove casing 1 and cover 2 to access
the fuse.

F46 - Main fuse (125A). F46

647387EN (18/11/2011)

2-37
13 - DIAGNOSTIC CONNECTOR

14 - ACCELERATOR PEDAL

15 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF

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

16 - GEAR LEVER AND TRANSMISSION CUT-OFF

MLT 634 -120 LSU Srie G-E3
MLT 735 -120 LSU Srie 7-E3
4 2
In order to change speeds, it is necessary to cut the transmission by pressing the button 1 on
1
the lever.
1st gear: to the right, backwards.
2nd gear: to the right, forwards.
3rd gear: to the left, backwards.
4th gear: to the left, forwards.
3 1
USING THE GEARS ON THE GEAR BOX
- On these lift trucks with a torque converter, it is not necessary to automatically start up in 1st
speed and progress up the gears.
The choice of transmission gear ratio should be made carefully according to the nature of the work being
carried out. A poor choice may result in the extremely rapid rise of the transmission oil temperature through excessive slipping of the converter, which could lead
to serious damage to the transmission (it is essential to stop and change the working conditions if the transmission oil temperature indicator light comes on). This
poor choice may also result in a reduction in the lift 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.
t
0/
5)&
30"%
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.
t
8*5)
"
53"*-&3
0/
5)&
30"%
Set off in 2nd gear and go up to 3rd if the conditions and state of the road permit it.
t
)"/%-*/(
3rd gear.
2nd gear in restricted spaces.
t
-0"%*/(
SFDMBJNJOH
XJUI
CVDLFU
NBOVSF
GPSL
FUD

2nd gear.
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.07*/(
1st gear.
647387EN (18/11/2011)

2-38
16 - GEAR SELECTOR
MLT 634 -120 LSU PS Srie G-E3 2

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

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

USING THE GEARS ON THE GEAR BOX

- On these lift trucks with a torque converter, it is not necessary to automatically start up in 1st
speed and progress up the gears.
The choice of transmission gear ratio should be made carefully according to the nature of the work being
carried out. A poor choice may result in the extremely rapid rise of the transmission oil temperature through
excessive slipping of the converter, which could lead to serious damage to the transmission (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 4
that could be obtained with the r-1 gear (in 2nd instead of 3rd).

3
In general, we would advise you to use the following gears according to the nature of the work
being carried out.

t
0/
5)&
30"%
Set off in 4th gear and go up to 5th and 6th if the conditions and state of the road permit
it.
In hilly areas, set off in 3rd gear and go up to 4th and 5th (the use of 6th gear is prohibited)
if the conditions and state of the road permit it.
t
8*5)
"
53"*-&3
0/
5)&
30"%
Set off in 2nd gear and go up through the gears to 5th if the conditions and state of the road permit it.
t
)"/%-*/(
3rd, 4th or 5th gear (the use of the 6th gear is prohibited).
2nd gear in restricted spaces.
t
-0"%*/(
SFDMBJNJOH
XJUI
CVDLFU
NBOVSF
GPSL
FUD

2nd gear.
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.07*/(
1st gear.

SWITCH FOR DISABLING 6TH GEAR

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

17 - PARKING BRAKE LEVER

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

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

B
647387EN (18/11/2011)

2-39
18 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION A

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

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

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

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

SAFETY FOR MOVING THE LIFT TRUCK

Authorisation to move the lift truck is controlled by an electronic unit. The operator must
observe the following sequence to move the truck forwards or backwards:
1 - sit down correctly in the 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.

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

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

B - STEERING SELECTION LEVER

B1 - Front drive wheels (highway traffic). C

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

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

CONTROL FOR ALIGNMENT OF THE WHEELS B2

- Connect the switch (signal light ON).
- Shift the steering selection lever B into position B2 (short steering lock).
- Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up.
- Shift the steering selection lever B into position B1 (highway traffic).
- Turn the steering wheel and bring the front wheels into alignment until lamp A1 lights up.
Before driving on roads, it is necessary to check the alignment of the rear wheels and to drive in front wheel
steer. The control of the alignment of the rear wheels must be regularly done with the help of the green lamps,
while driving the lift truck. In case of anomalies, consult your dealer.
647387EN (18/11/2011)

2-40
20 - HYDRAULIC CONTROLS
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.
When driving on the road, it is highly recommended (mandatory in Germany) that you cut-off all the hydraulic movements (see:
2 - DESCRIPTION 7 - SWITCHES).

A - Lifting and tilting control lever.

B - Telescoping control button.
C - Attachment control button.
D - Boom head electrovalve option control button.
LIFTING THE LOAD C
D
- The lever A backwards when lifting.
- The lever A forwards when lowering. B
TILT OF CARRIAGE
A
- 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 PROVISION FOR ELECTRICAL BOOM
OPTION BOOM HEAD ELECTROVALVE
- Button D (see: 2 - DESCRIPTION: DESCRIPTION AND USE OF ELECTRICAL AND HYDRAULIC OPTIONS).

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

22 - LEVEL INDICATOR
Enables the operator to check that the lift truck is in the horizontal position.

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

B - HEATING TEMPERATURE CONTROL B A

Allows the temperature inside the cab to be adjusted.
647387EN (18/11/2011)

B1 - With the valve closed, the fan delivers fresh air.

B2 - With the valve opened completely, the fan delivers warm air.
The intermediate positions allow the temperature to be adjusted.

2-41
23 - 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
A B C
the compressor once a week, if only for a short spell, so as to lubricate the internal seals.
In cold weather: Warm the I.C. engine before switching on the compressor, so as to allow the coolant
that has collected in the liquid state at the lowest point of the compressor circuit to turn into gas under the
effect of the heat given off by the I.C. engine, as the compressor is liable to be damaged by coolant in the liquid state.

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

DESCRIPTION OF THE AIR CONDITIONING CONTROLS

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

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

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

CONDITIONED AIR MODE

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

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

24 - CAB FILTER VENTILATORS

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

25 - WINDSCREEN DEMISTER VENTS

For optimum effectiveness, close the heating ventilators.

26 - HEATING VENTS
These heating vents enable the air to be directed to the interior of the cabin and onto the side windows.
647387EN (18/11/2011)

2-42
27 - BRAKING OIL AND WINDSCREEN WASHER TANK ACCESS PANEL
- Loosen screw 1 and lift up the braking oil and windscreen washer tank access panel
(see: 3 - MAINTENANCE: B - EVERY 50 HOURS OF SERVICE).

28 - STEERING WHEEL REGULATING HANDLE

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

- Pull handle 1 to adjust the steering wheel.

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

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

30 - LOCKING HANDLE FOR UPPER HALF-DOOR

31 - UNLOCKING BUTTON FOR UPPER HALF DOOR

32 - HANDLE FOR REAR WINDOW OPENING

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

NOTE: There is an OPTIONAL rear window stay.

647387EN (18/11/2011)

2-43
33 - DOCUMENT HOLDER
Ensure that the operators manual is in its place in the document holder.

34 - SUN VISOR

35 - OVERHEAD LIGHT

36 - HOOK
35

36

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

647387EN (18/11/2011)

2-44
38 - ARMREST AND STORAGE
- Lift the armrest 1 to access the storage.

39 - CAR RADIO (OPTION)

40 - INSIDE REAR-VIEW MIRROR (OPTION)

41 - TOOL BOX

42 - NUMBER PLATE

43 - NUMBER PLATE LIGHTING

42

43 43

44 - REAR REFLECTORS
647387EN (18/11/2011)

2-45
45 - FRONT HEADLIGHTS
A - Left front indicator.
B - Left front dipped headlight. F B
C - Left front main beam.
D - Left front sidelight.
E - Right front indicator. E H D A
F - Right front dipped headlight.
G - Right front main beam.
G C
H - Right front sidelight.

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

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

OPTIONAL AIR CONDITIONING

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

48 JIB SAFETY WEDGE

The lift truck is equipped with a jib safety wedge that must be installed on the rod of the lifting
cylinder when working beneath the jib. (see: 1 - OPERATING AND SAFETY INSTRUCTIONS).

Only use the wedge supplied with the lift truck.

647387EN (18/11/2011)

48

2-46
2-47
647387EN (18/11/2011)
 TOWING PIN AND HOOK

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

- To use a trailer, see current regulations in your country (maximum running speed, braking, maximum weight of trailer, etc.).
- Verify the 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: A rear-view mirror allows the lift truck to approach more closely to the trailer ring.

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

B - REAR ELECTRIC SOCKET

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

C - TRAILER BRAKE SYSTEM

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

1
647387EN (18/11/2011)

2-48
D - CHASSIS-MOUNTED FRONT TOWING HOOK
COUPLING AND UNCOUPLING THE TRAILER
- To couple the trailer, position the lift truck as close as possible to the trailer ring. 2
- Put the handbrake on and switch off the I.C. engine.
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put clip 1 back in place.
When uncoupling, make sure that the trailer is supported independently.
1

E - COUPLING LADDER (OPTIONAL)

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

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

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

F - HYDRAULIC TOWING HOOK (OPTION)

Never use the tow hook to raise the rear of the lift truck (when changing the rear wheel for example).
- Raise the hydraulic tow hook to release the hook lock 1 by pressing the upper part of switch 2.
- Pull the knob 3, retain this position and press the lower part of switch 2 to lower the tow hook.
- Release knob 3.
- Couple or uncouple the trailer.
1 1
When uncoupling, make sure that the trailer is supported independently.
- Raise the trailer hook by pressing the upper part of switch 2 and then lower the hook to verify
that the lock pin is in proper contact with hook 1 lock.

3
647387EN (18/11/2011)

2-49
G - AUTOMATIC TRAILER HOOK (OPTION)
COUPLING THE TRAILER
- Remove the automatic towing pin using lever 1. 1
- Move the lift truck backwards so that the trailer ring slots into the automatic hook.
NOTE: The pin closes automatically when the trailer ring touches the end of the fitting. The pin
can be lowered by hand using lever 1.

UNCOUPLING THE TRAILER

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

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

647387EN (18/11/2011)

2-50
2-51
647387EN (18/11/2011)
 DESCRIPTION AND USE OF THE OPTIONS

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

1 - BATTERY CUT-OFF

2 - 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.

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

OPERATION
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.

A
647387EN (18/11/2011)

2-52
3 - MODCOD ANTI-THEFT SYSTEM
OPERATION
- Switch on the lift truck: the red indicator 1 will flash.
- Enter your user code followed by V to validate: the green indicator 2 will come on. 2 1
- Start the lift truck within the next 60 seconds; otherwise the anti-theft system will be reactivated
and the red indicator 1 will flash.

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

4 - FINTRONIC ANTI-START SYSTEM

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

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

5 - MODCL ANTI-START SYSTEM

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

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

6 - ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION

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

CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT

- Make sure the potentiometer C is set to 0%.
- Switch button A to the front or the back (depending on the type of attachment), press button
B and release button A. The red indicator 1, flashes to indicate that it is in operation.
- Set the required flowrate using potentiometer C.
- To stop continuous hydraulic movement of the attachment, move switch A forwards or
backwards or press button B. Indicator 1 goes out.
- Set potentiometer C to 0%.
Never leave the 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.

B C
1
647387EN (18/11/2011)

2-53
7 - BOOM SUSPENSION
The boom is suspended to reduce shaking of the lift truck on rough ground (e.g. moving straw
in a field).

OPERATION A
- 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 boom suspension 1
is activated.
- Press switch 1 set to position B, the visual indicator goes out indicating that boom suspension B
is deactivated.
Boom suspension is active to a lifting height of 3m00 from the axis of articulation of the carriage with respect to
the ground with the boom retracted. When you move beyond this height or make another hydraulic movement
(tilting, telescoping, attachment), boom suspension is momentarily deactivated and the visual indicator of
switch 1 goes out.
- When the I.C. engine is off, boom suspension is automatically deactivated.

8 - ATTACHMENT EASY HYDRAULIC CONNECTION

For easily connecting and disconnecting the attachment.

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

9 - PROVISION FOR ELECTRICAL BOOM

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

ELECTRIC BOOM FUNCTION CONTROL

- Set switch 1 to position B (indicator light on). 1
- Hold button 2 down and button 3 forwards or backwards.

NOTE: Set switch 1 to position A (indicator light off ) controls the hydraulic attachment line (see: B
2 - DESCRIPTION: 20 - HYDRAULIC CONTROLS).

3
2
647387EN (18/11/2011)

2-54
10 - BOOM HEAD ELECTROVALVE
L1
Enables use of two hydraulic functions on the attachment circuit.
L2
To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing button 1 on L1
the electrovalve.

ATTACHMENT LINE L1 CONTROL L2

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

3 B
4

11 - HYDRAULIC ATTACHMENT LOCKING

Enables the attachment to be locked onto the carriage and a hydraulic attachment to be used
by the same hydraulic circuit. A

ATTACHMENT LOCKING CONTROL

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

HYDRAULIC ATTACHMENT CONTROL

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

3
647387EN (18/11/2011)

2-55
12 - BOOM HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING
A
The addition of these two options on the attachment line allows two hydraulic functions to be 4
used and locks the attachment onto the carriage.
B
To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing button 1 on
L1
the electrovalve.
ATTACHMENT LINE L1 CONTROL L2
L1
- Set switch 2 to position A (indicator light off ).
- Push button 3 forward or backward.
L2
ATTACHMENT LINE L2 CONTROL + HYDRAULIC ATTACHMENT LOCKING
1
LOCKING AN ATTACHMENT
- Set valve 4 to position A.
- Set switch 2 to position B (indicator light on).
- Hold button 5 down and push button 3 forward to lock the attachment and backward to
release it.
A
Once the attachment is locked, return valve 4 to position B to prevent accidental release of the attachment.
HYDRAULIC ATTACHMENT 2
- Set switch 2 to position B (indicator light on).
- Hold button 5 down and push button 3 forwards or backwards.
B

3
5

13 - MACH2 QUICK-RELEASE COUPLERS ON ACCESSORY CIRCUIT

1
Enables the use of a hydraulic attachment fitted with MACH2 quick-release couplers.

CONNECTING A HYDRAULIC ATTACHMENT

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

DISCONNECTING A HYDRAULIC ATTACHMENT 2

- Lower lever 1 and disconnect the MACH2 quick-release couplers from the attachment.
- Lift up lever 1.

14 - MACH2 QUICK-RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT + HYDRAULIC

ATTACHMENT LOCKING
Enables the locking of the attachment on the carriage to be controlled and a hydraulic
attachment with MACH2 quick-release couplers to be used.
647387EN (18/11/2011)

2-56
15 - EXTERIOR DRAIN BACK
Enables connection of a hydraulic attachment for which drain-back is required.

16 - LIFTING RING ON SINGLE CARRIAGE

MLT 735 -120 LSU Srie 7-E3 Kg

CONDITIONS OF USE Kg Kg

Follow the instructions given in the instruction manual (see: 1 - OPERATING

AND SAFETY INSTRUCTIONS: INSTRUCTIONS FOR HANDLING LOADS).
- The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS,
but the angle of inclination of the carriage must be same as when

N265284
the forks are used in the horizontal position. Kg Kg Kg Kg Kg Kg

- Check the maximum permitted angle, which is 45.

- Do not change the angle of the carriage while using the lifting ring.
- The lifting hook, the chains and slings shall have a minimum capacity
of 3000 kg with a factor of safety against breakage of 4.
Kg Kg Kg Kg

MLT735 + TS A S 3T MLT735 + TS AS 3T
LOAD CHARTS AND FUNCTION SHEETS
The load charts are given for use without forks and without 40 45 50 60,5

attachments. 36km/h Maxi

7 (10m/s)
6,69

6
45
30 3000KG Maxi
MAXI
5 0kg

4
20
3000kg

3
3000KG
2000kg

MAXI
1600kg
900kg

1300kg

2
10
1000kg

0,3m Maxi 1,44km/h (0,4m/s)

1 Maxi

N 289429
1,52m Maxi
N 289299

0
0m

-3,7 3m Mini
5 4 3 2 1 0m
3,16 2,45 1,80
3,05 2,15 1,20 0,50

17 - ANGULAR SECTOR ON BOOM

The angular sector displays the boom angle, and thus improves the reading of the load charts.
647387EN (18/11/2011)

2-57
18 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
Enables the use of a hydraulic attachment at the rear of the lift truck (e.g. a trailer with hydraulic
tipping).
1

SINGLE EFFECT HYDRAULIC CONTROL L1

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

L1

DUAL EFFECT HYDRAULIC CONTROL L1

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

L1 L1

647387EN (18/11/2011)

2-58
19 - DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION + SINGLE OR DUAL
EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
Enables the use of a hydraulic attachment at the rear of the lift truck or another hydraulic
attachment at the rear of the lift truck. B 2

DUAL EFFECT L1 AND SINGLE EFFECT L2 REAR HYDRAULIC CONTROL

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

DUAL EFFECT L1 AND DUAL EFFECT L2 REAR HYDRAULIC CONTROL

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

647387EN (18/11/2011)

2-59
20 - HYDRAULIC TOWING HOOK + SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL
PREDISPOSITION
Enables the use of the trailer eye (see: 2 - DESCRIPTION: TRAILER PIN AND HOOK) or a hydraulic
attachment at the rear of the lift truck. B 2

HYDRAULIC TRAILER HOOK + SINGLE EFFECT REAR HYDRAULIC CONTROL L1

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

HYDRAULIC TRAILER HOOK + DUAL EFFECT REAR HYDRAULIC CONTROL L1

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

647387EN (18/11/2011)

2-60
3-1
3 - MAINTENANCE

647387EN (18/11/2011)
3-2
647387EN (18/11/2011)
TABLE OF CONTENTS

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT 3-4

START-UP CHECKLIST 3-5

FILTERS CARTRIDGES AND BELTS 3-6

LUBRICANTS AND FUEL 3-8

SERVICING SCHEDULE 3-10

A - DAILY OR EVERY 10 HOURS SERVICE 3-12

B - EVERY 50 HOURS SERVICE 3-18

C - EVERY 250 HOURS SERVICE 3-22

D - EVERY 500 HOURS SERVICE 3-24

E - EVERY 1000 HOURS SERVICE 3-30

F - EVERY 2000 HOURS SERVICE 3-36

G - OCCASIONAL MAINTENANCE 3-38

647387EN (18/11/2011)

3-3
 MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.

IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,

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

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

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

MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.

BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,

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

- The guarantee of high-quality work.

- Original replacement components.

- Help with preventive maintenance.

- Efficient help with diagnosis.

- Improvements due to experience feedback.

- Operator training.

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

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

647387EN (18/11/2011)

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

100 ENGINE 108 ATTACHMENTS

01 Air filter 01 Fitting on machine
02 Fuel tank 02 Hydraulic couplings
03 Fuel lines - Filter 109 CABIN/PROTECTOR/ELECTRIC CIRCUIT
04 Injection or carburetion system 01 Seat
05 Radiator and cooling system 02 Dashboard and radio
06 Belts 03 Sound and visual alarm/safety system
07 Hoses 04 Heating/Air conditioning
101 TRANSMISSION 05 Windscreen wiper/windscreen washer
01 Direction reversal system 06 Road horn
02 Gear shift 07 Reversing horn
03 Cut-off pedal 08 Road lights
04 Clutch 09 Additional lights
102 AXLES/TRANSFER GEAR BOX 10 Rotating beacon light
01 operation and seal 11 Battery
02 Stop settings 110 WHEEL
103 HYDRAULIC/HYDROSTATIC CIRCUIT 01 Rims
01 Tank 02 Tyre/Pressure
02 Pumps and couplings 111 SCREWS
03 Tightening of connections 112 FRAME AND BODYWORK
04 Lift cylinder(s) 113 PAINTING
05 Tilt cylinder(s) 114 GENERAL OPERATION
06 Attachment cylinder(s) 115 OPERATORS MANUAL
07 Telescope cylinder(s) 116 CUSTOMER INSTRUCTIONS
08 Compensation cylinder(s)
09 Steering cylinder(s)
10 Control Valve
11 Balancing valve
104 BRAKE SYSTEM
01 Service brake and parking brake operation
02 Brake fluid level
105 LUBRICATION AND GREASING
106 BOOM/MANISCOPIC/MANIACCESS ASSEMBLY
01 Beam and telescope(s)
02 Skid
03 Hinges
04 Carriage
05 Forks
107 MAST ASSEMBLY
01 Fixed and mobile uprights
02 Carriage
03 Chains
04 Rollers
05 Forks
647387EN (18/11/2011)

3-5
FILTERS CARTRIDGES AND BELTS

ENGINE

ENGINE OIL FILTER CARTRIDGE

ALTERNATOR BELT
Part number: 608773
Part number: 741906
Change: 500 H

DRY AIR FILTER CARTRIDGE

ALTERNATOR BELT
Part number: 907330
(OPTION AIR CONDITIONING)
Clean: 50 H*
Part number: 907332
Change: 500 H*

SAFETY DRY AIR FILTER CARTRIDGE CYCLONIC PRE-FILTER

Part number: 907331 Part number: 773433
Change: 1000 H* Clean: 10 H

FUEL FILTER CARTRIDGE AUTOMATIC VACUUM-CLEANING PRE-FILTER

Part number: 608774 (OPTION)
Change: 500 H Part number: 774301

FUEL FILTER STRAINER

TURBO 3 SELF-CLEANING PRE-FILTER (OPTION)
Part number: 710887
Part number: 906126
Clean: 500 H

FUEL PRE-FILTER
Part number: 608776
Change: 500 H

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

TRANSMISSION

GEAR BOX OIL FILTER

Part number: 561749
Change: 500 H

HYDRAULIC

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

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

CAB
CAB VENTILATION FILTER (WITH AIR CONDITIONING)
CAB VENTILATION FILTER (WITHOUT AIR CONDITIONING)
Part number: 282619
Part number: 282619
Clean: 50 H
Clean: 500 H
Change: 250 H
647387EN (18/11/2011)

3-6
3-7
647387EN (18/11/2011)
 LUBRICANTS AND FUEL
USE THE RECOMMENDED LUBRICANTS AND FUEL:
- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.
DIAGNOSTIC ANALYSIS OF OILS
If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, gear box and axle oils may be
requested depending on the rate of use.

(*) RECOMMENDED FUEL SPECIFICATION

Use a high-quality fuel to obtain optimal performance of the I.C. engine.
t
&/
EJFTFM
GVFM
UZQF
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GVFM
UZQF

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64
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(SBEF


I.C. ENGINE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5l 786744
MANITOU Oil
I.C. ENGINE 16 Liters 20 l 786745
GOLD
209 l 787729
4l 894967
Cooling liquid
COOLING CIRCUIT 22,5 Liters 20 l 894968
(protection - 35)
210 l 894969
FUEL TANK 120 Liters Diesel fuel (*)

TRANSMISSION
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
1l 62148
20 l 546332
MANITOU Oil
GEAR BOX 16,6 Liters 55 l 546217
Automatic transmission
209 l 546195
1000 l 720148
2l 499237
MANITOU Oil 5l 720184
ANGLE GEAR BOX 2,2 Liters SAE80W90 20 l 546330
Mechanical transmission 55 l 546221
209 l 546220
400 g 161589
1 kg 720683
MANITOU Grease
53"/4.*44*0/
6/*7&34"-
+0*/5 5 kg 554974
BLUE multi-purpose
20 kg 499233
50 kg 489670

BOOM
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g 545996
MANITOU Grease
BOOM PADS 1 kg 161590
BLACK multi-purpose
5 kg 499235
400 g 161589
1 kg 720683
MANITOU Grease
GREASING OF THE BOOM 5 kg 554974
BLUE multi-purpose
20 kg 499233
50 kg 489670
647387EN (18/11/2011)

3-8
HYDRAULIC
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5l 545500
MANITOU Oil 20 l 582297
HYDRAULIC OIL TANK 135 Liters
Hydraulic ISO VG 46 55 l 546108
209 l 546109

BRAKE
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
MANITOU Oil
BRAKE CIRCUIT 1l 490408
Mineral brake fluid

CAB
ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER
400 g 161589
1 kg 720683
MANITOU Grease
CAB DOOR 5 kg 554974
BLUE multi-purpose
20 kg 499233
50 kg 489670
1l 490402
WINDSCREEN WASHER TANK Windscreen washer fluid
5l 486424

FRONT AXLE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5l 545976
MANITOU Oil 20 l 582391
FRONT AXLE DIFFERENTIAL 8,1 Liters
Special immersed brakes 209 l 546222
1000 l 720149
2l 499237
MANITOU Oil 5l 720184
FRONT WHEELS REDUCERS 0,8 Liter SAE80W90 20 l 546330
Mechanical transmission 55 l 546221
209 l 546220
400 g 161589
1 kg 720683
MANITOU Grease
FRONT WHEELS REDUCERS PIVOTS 5 kg 554974
BLUE multi-purpose
20 kg 499233
50 kg 489670

REAR AXLE
ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER
5l 545976
MANITOU Oil 20 l 582391
REAR AXLE DIFFERENTIAL 8,1 Liters
Special immersed brakes 209 l 546222
1000 l 720149
2l 499237
MANITOU Oil 5l 720184
REAR WHEELS REDUCERS 0,8 Liter SAE80W90 20 l 546330
Mechanical transmission 55 l 546221
209 l 546220
400 g 161589
1 kg 720683
REAR WHEELS REDUCERS PIVOTS MANITOU Grease
5 kg 554974
REAR AXLE OSCILLATION BLUE multi-purpose
20 kg 499233
50 kg 489670
647387EN (18/11/2011)

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

SERVICE OR 2 YEARS
EVERY 1000 HOURS

EVERY 2000 HOURS

EVERY 4000 HOURS

DAILY OR EVERY 10

SERVICE OR 1 YEAR
EVERY 250 HOURS

EVERY 500 HOURS

EVERY 50 HOURS
HOURS SERVICE

OCCASIONALLY
SERVICE OR 6
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,

MONTHS
SERVICE

SERVICE

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

ENGINE
Engine oil level 3-12 C C <<< <<< <<< <<< <<< <<<
Cooling liquid level 3-12 C C <<< <<< <<< <<< <<< <<<
Fuel level 3-12 C C <<< <<< <<< <<< <<< <<<
Fuel pre-filter 3-13 C C <<< <<< <<< <<< <<< <<<
Cyclonic pre-filter 3-13 N N <<< <<< <<< <<< <<< <<<
Dry air filter cartridge 3-18/25 R C/N <<< R <<< <<< <<<
Radiator cores 3-18 N N <<< <<< <<< <<< <<<
Condenser core (OPTION Air conditioning) 3-18 C/N C/N <<< <<< <<< <<< <<<
Engine oil 3-24 V V <<< <<< <<<
Engine oil filter cartridge 3-24 R R <<< <<< <<<
Fuel pre-filter 3-25 R R <<< <<< <<<
Fuel filter strainer 3-25 N N <<< <<< <<<
Fuel filter cartridge 3-26 R R <<< <<< <<<
Alternator belt 3-26 C C <<< <<< <<<
Fuel tank 3-30 N <<< <<<
Safety dry air filter cartridge 3-30 R <<< <<<
Engine silent blocks C** <<< <<<
Engine speeds C** <<< <<<
Valve clearances C** C** <<< <<<
Cooling liquid 3-36 V <<<
Radiator C** <<<
Water pump and the thermostat C** <<<
Alternator and the starter motor C** <<<
Turbocharger C** <<<
Fuel system 3-38 P
TRANSMISSION
Gear box oil level 3-13 C C <<< <<< <<< <<< <<< <<<
Engine/Angle gear box universal joint 3-19 G G <<< <<< <<< <<< <<<
Angle gear box oil level 3-22 C C <<< <<< <<< <<<
Gear box oil filter 3-27 R R <<< <<< <<<
Gear box oil 3-31/32 V V <<< <<<
Gear box sump strainer 3-31/32 N N <<< <<<
Angle gear box oil 3-32 V V <<< <<<
Gear box silent blocks C** <<< <<<
Gear box controls C** <<< <<<
Gear box pressures C** <<<
Converter pressure C** <<<
TYRES
Tyre pressure 3-14 C C <<< <<< <<< <<< <<< <<<
Wheel nuts torque 3-14 C C <<< <<< <<< <<< <<< <<<
Condition of wheels and tyres C** <<< <<<
Wheel 3-38 R
JIB
+JC
QBET 3-16 G* <<< <<< <<< <<< <<< <<<
+JC 3-19 G G <<< <<< <<< <<< <<<
+JC
QBE
XFBS C** <<< <<<
Condition of jib unit C** <<<
Bearings and articulation rings C** <<<
HYDRAULICS
Hydraulic oil level 3-20 C C <<< <<< <<< <<< <<<
Hydraulic return oil filter cartridge 3-27 R R <<< <<< <<<
Hydraulic oil 3-33 V <<< <<<
Suction strainer for hydraulic oil tank 3-33 N <<< <<<
Filter cap for hydraulic oil tank 3-33 R <<< <<<
Distributor control head filter 3-33 R <<< <<<
Speeds of hydraulic movements C** <<< <<<
Condition of hoses and flexible pipes C** <<< <<<
647387EN (18/11/2011)

Condition of cylinders (leakage, shafts) C** <<< <<<

Hydraulic circuit pressures C** <<<
Hydraulic circuit outputs C** <<<
Hydraulic oil tank N** <<<

3-10
 SERVICE OR 2 YEARS
EVERY 1000 HOURS

EVERY 2000 HOURS

EVERY 4000 HOURS

DAILY OR EVERY 10

SERVICE OR 1 YEAR
EVERY 250 HOURS

EVERY 500 HOURS

EVERY 50 HOURS
HOURS SERVICE

OCCASIONALLY
SERVICE OR 6
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,

MONTHS
SERVICE

SERVICE

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

BRAKE
Brake oil level 3-20 C C <<< <<< <<< <<< <<<
Parking brake 3-22 C/A C/A <<< <<< <<< <<<
Parking brake lever mechanism 3-27 G G <<< <<< <<<
Parking brake mechanism on the transmission G** G** <<< <<< <<<
Brake oil V** <<< <<<
Brake system P** <<< <<<
Brake system pressure C** <<< <<<
Brake A** <<< <<<
STEERING
Steering C** <<<
Steering swivel joints C**
CAB
Windscreen washer liquid level 3-20 C C <<< <<< <<< <<< <<<
Cab door 3-19 G G <<< <<< <<< <<< <<<
Cab ventilation filter (OPTION Air conditioning) 3-21/22 R N R <<< <<< <<< <<<
Heating block non-return valve 3-22 N N <<< <<< <<< <<<
Cab ventilation filters 3-29 N N <<< <<< <<<
Seat belt 3-34 C <<< <<<
Condition of the rear view mirrors C** <<< <<<
Structure C** <<< <<<
Air conditioning (OPTION) 3-36 C/N <<<
ELECTRICITY
Longitudinal stability limiter and warning device 3-15/41 C C <<< <<< <<< <<< <<< <<< XXX
Condition of wiring harness and cables C** <<< <<<
Lights and signals C** <<< <<<
Warning indicators C** <<< <<<
Front headlights 3-39 A
FRONT AXLE
Front wheels reducers pivots 3-19 G G <<< <<< <<< <<< G/C**
Front axle differential oil level 3-23 C C <<< <<< <<< <<<
Front wheels reducers oil level 3-23 C C <<< <<< <<< <<<
Front axle differential oil 3-28 V V <<< <<< <<<
Front wheels reducers oil 3-34 V V <<< <<<
Wear of front axle brake discs C**
Front wheels reducers universal joint C**
Front wheels reducers clearance C**
REAR AXLE
Rear wheels reducers pivots 3-19 G G <<< <<< <<< <<< G/C**
Rear axle oscillation 3-19 G G <<< <<< <<< G/C** <<<
Rear axle differential oil level 3-23 C C <<< <<< <<< <<<
Rear wheels reducers oil level 3-23 C C <<< <<< <<< <<<
Rear axle differential oil 3-28 V V <<< <<< <<<
Rear wheels reducers oil 3-34 V V <<< <<<
Wearing of rear axle brake discs C**
Rear wheels reducers universal joint C**
Rear wheels reducers clearance C**
CHASSIS
Structure C** <<< <<<
Bearings and articulation rings C** <<<
ATTACHMENTS
Forks wear C** C** <<< <<< <<<
Attachment carriage C** <<< <<<
Condition of attachments C** <<< <<<
LIFT TRUCK
Tow the lift truck 3-39 XXX
Sling the lift truck 3-39 XXX
647387EN (18/11/2011)

Transport the lift truck on a platform 3-40 XXX

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

3-11
 A - DAILY OR EVERY 10 HOURS SERVICE

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

CHECK

Place the lift truck on level ground with the I.C. engine stopped, and let the oil drain into the 1
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.

A1/2

A2 - COOLING LIQUID LEVEL

CHECK A2
3
Place the lift truck on level ground with the I.C. engine stopped, and allow the I.C. engine to cool. 3

- Open the I.C. engine bonnet.

- Check the correct level in the middle of gauge 1 (fig. A2).
- If necessary, add cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
- Slowly turn the cap of the radiator 2 (fig. A2) up to the safety stop.
- 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 1
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

Keep the fuel tank full, to reduce as much as possible any condensation due to the atmospheric 1
conditions.
2
- Remove cap 1 (fig. A3).
- Fill the fuel tank with clean fuel (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL), filtered
through a strainer or a clean, lint free cloth, through filler port 2 (fig. A3).
- Put the cap back 1 (fig. A3).
- Check visually that there is no leakage in the tank and pipes.
Never smoke or approach with a flame during filling operations or when the tank is open. Never refill while
I.C. engine is running.
647387EN (18/11/2011)

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

3-12
A4 - FUEL PRE-FILTER A4
CHECK 3

-Open the engine bonnet.

- Check for the presence of water in the pre-filter housing 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).

A5 - CYCLONIC PRE-FILTER A5
CLEAN
1
The cleaning interval is given as a guide, however the pre-filter must be emptied as soon as 2
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 - GEAR BOX OIL LEVEL A6

CHECK
MLT 634 -120 LSU Srie G-E3 1
MLT 735 -120 LSU Srie 7-E3

Park the lift truck on level ground with the jib raised, the engine cold and stopped. Carry out the 2
control within 5 minutes of the engine being stopped.
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
- 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.

A6 - GEAR BOX OIL LEVEL A6

CHECK
MLT 634 -120 LSU PS Srie G-E3

Park the lift truck on level ground with the jib raised, the engine cold and stopped. Carry out the 1 2
control within 5 minutes of the engine being stopped.
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
- 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.
647387EN (18/11/2011)

3-13
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
t
'SPOU
UZSFT

/N


t
3FBS
UZSFT

/N


- Check and adjust the tyre pressures if necessary (see: 2 - DESCRIPTION: FRONT AND REAR TYRES).
Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation. Respect the recommended tyre
pressures given.
NOTE: There is an OPTIONAL wheel toolkit and anti-puncture kit.

A8 - BOOM PADS A8
CLEAN - GREASE

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

- Extend the boom completely.

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

647387EN (18/11/2011)

3-14
A9 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
CHECK

- These tests are essential for checking the correct operation and adjustment of the different components of the device.
- Place the lift truck on flat, level ground with the wheels straight.

Use the test button only when requested to do so, performing short presses (less than 1 second) and long presses (5 seconds) as instructed. If in doubt

during the test procedure, exit cleanly by short pressing the BUCKET MODE or SUSPENDED LOAD MODE button .

Long press on the test button.

TEST OK
Short press - One audible beep and progresses to stage 2.
the test TEST NOT OK
STAGE 1 - Two audible beeps and lighting of the fault
button.
1
- Place the lift truck without any warning light .
- An audible beep. attachment, with the boom fully - Exit test mode.
- First green led flashing. retracted and raised. - Go to stage 4.
- Test button lit.

TEST OK
Short press - One audible beep and progresses to stage 3.
the test TEST NOT OK
STAGE 2
button. - Two audible beeps and lighting of the fault
2 1 - Lower the boom with the engine
running at full revs and the hydraulic warning light .
- First green led continuously lit. control at the maximum setting. - Exit test mode.
- Second green led flashing. Lowering slows until movement is - Go to stage 4.
- Test button lit. cut-off.

TEST OK
- Conformity of aggravating movement
- Lower the boom until the movement cut-off.
3 Short press - Exit test mode. All the LEDs will light
is cut-off.
the test for 2 seconds and an audible beep will
STAGE 2 - Request the following, in order:a
button. be sounded.
3 1 reverse tilt, a forward tilt (dumping) and
a telescope extension. None of these 3 TEST NOT OK
- First and second green leds
movements should be possible. - Fault warning light comes on .
continuously lit.
- Third green led flashing. - Exit test mode.
- Test button lit. - Go to stage 4.

- The fault indicator and a beep indicate a fault.

- Press the button briefly to view the error code.

- If there are several error codes, press the button briefly several times to loop through the error
codes.
NOTE: A defective fuse can generate several error codes. If this is the case, check the fuses
(see: 2 - DESCRIPTION: 11 - FUSES AND RELAYS IN THE CAB)
STAGE
4 A7
A6
- The fault warning light remains
permanently on until the error
A4
is repaired.
- If error code A3 is displayed, the problem may be resolved by resetting the longitudinal stability
limiter and warning device (see: 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE).
- Contact your dealer, stating the error code or error codes (see following table).
NOTE: For the stage 3 test, specify the non-conforming aggravating hydraulic movements, if necessary.
647387EN (18/11/2011)

3-15
The error codes are indicated by leds A3 to A7 on the warning device and longitudinal stability limiter.

A7
A6
A5

A4

A3

ERROR CODES
LEDS
DESIGNATIONS
A7 A6 A5 A4 A3
Regulating fault (fault detected during the test).
Lowering regulating valve fault.
Safety valve cut-off fault (fault detected during the test).
Safety valve fault.
Gauge calibration fault (fault detected during the test).
the problem may be resolved by resetting the longitudinal stability limiter and warning device
(see: 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE).
Angle calibration fault (fault detected during the test).
Inclination cut-off valve fault.
Strain gauge fault.
Boom angle sensor fault.
Telescope or attachment control fault.
Telescope retracted senor fault.
Computer earth output fault.
Aggravating hydraulic movement cut-off disable fault.
Stability indicator fault.
Electronic handling controller fault.
Hydraulic control lever control setting fault.
Transmission cut-off output fault.
Electronic handling controller supply fault.
Telescope retracted sensor fault (fault detected during the test).
Forward tilt cut-off valve fault. (according to model)
Boom head electrovalve fault. (OPTION)
Attachment easy hydraulic connection fault button. (OPTION)
Electrovalve attachment hydraulic control and electrical boom provision fault button. (OPTION)
Attachment forced operation indicator fault. (OPTION)
Electric handling controller 10V output fault.
Forced operation button fault. (OPTION)
647387EN (18/11/2011)

3-16
3-17
647387EN (18/11/2011)
 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.
- Open the I.C. engine bonnet.
- If necessary, clean the suction grid on the engine hood (fig. B2/1).
- Using a soft cloth, clean the radiator cores in order to remove as much dirt as possible.
- Clean the radiator cores using a compressed air jet aimed in the same direction as the cooling
air flow (fig. B2/2).
- Clean with the fan running for best results.

NOTE: There is an OPTIONAL self-cleaning fan.

B2/2

B3 - CONDENSER CORE (OPTION AIR CONDITIONING) B3

CHECK - CLEAN
1
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure steam as
this could damage the condenser fins.
- Remove the protective grid 1 (fig. B3) and clean it if necessary.
- Visually check whether the condenser 2 (fig. B3) is clean and clean it if necessary.
- Clean the condenser using a compressed air jet aimed in the same direction as the air flow (fig.
B3).
2
647387EN (18/11/2011)

- Clean with the fans running for best results.

3-18
B4 - GENERAL GREASING
GREASE

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

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

JIB
1 - Lubricators of the jib axle (2 lubricators).
2 - Lubricators of the carriage axle (2 lubricators).
3 - Lubricator of the tilt cylinder foot axle (1 lubricator).
4 - Lubricator of the tilt cylinder head axle (1 lubricator).
5 - Lubricators of the carriage connecting rod axle (3 lubricators).
6 - Lubricator of the lifting cylinder foot axle (1 lubricator).
7 - Lubricator of the lifting cylinder head axle (1 lubricator).
8 - Lubricator of the compensation cylinder foot axle (1 lubricator).
9 - Lubricator of the compensation cylinder head axle (1 lubricator).
TRANSMISSION UNIVERSAL JOINT
10 - Lubricators of the Engine/Angle gear box universal joint (2 lubricators).
NOTE: Check the cleanliness of the universal joint behind the splash guards. If necessary, removeand
clean the outside of the universal joint. 5
5
CAB
11 Cab door lubricators (4 lubricators).
FRONT AND REAR WHEELS REDUCER PIVOTS
5
12 - Lubricators of the wheel reduction gear pivots (8 lubricators).
REAR AXLE OSCILLATION
13 - Rear axle oscillation lubricators (2 lubricators).

11 3
2

4
11

6
8
13
13

1
1

12

10
647387EN (18/11/2011)

10

3-19
B5 - HYDRAULIC OIL LEVEL B5/1
CHECK

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

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

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

Use a clean funnel and clean the underside of the oil drum before filling.
- Put the cap back.
- Check visually that there is no leakage in the tank and pipes. B5/2

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

B6 - BRAKE OIL LEVEL B6/1

CHECK
2
Place the lift truck on level ground.

- Loosen screw 1 (fig. B6/1) and remove the access panel for braking oil tank and windscreen
washer tank 2 (fig. B6/1).
- The level is correct when it is at the MAX. level in tank 3 (fig. B6/2)
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port.
1
- Pivot the tank 3 (fig. B6/2) to access the filler cap 4 (fig. B6/2).
- Check visually that there is no leakage in the tank and pipes.

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

B6/2

B7 - WINDSCREEN WASHER LIQUID LEVEL B7/2

CHECK

- Loosen screw 1 (fig. B6/1) and remove the access panel for braking oil tank and windscreen
washer tank 2 (fig. B6/1). 3
- Visually check the level.
- If necessary add windscreen washer liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by
filler port 3 (fig. B7/2).
647387EN (18/11/2011)

3-20
B8 - CAB VENTILATION FILTER (OPTION AIR CONDITIONING) B8/1
CLEAN

- Unscrew the thumbscrew 1 (fig. B8/1) and remove protective guard back 2 (fig. B8/1).
- Lift out cabin ventilation filter 3 (fig. B8/2).
- Clean the filter using a compressed air jet.
- Check its condition and change if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND 2
BELTS).
- Refit the filter and protective casing.
1

B8/2

647387EN (18/11/2011)

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

C1 - ANGLE GEAR BOX OIL LEVEL C1

CHECK

Park the lift truck on level ground with the jib raised and the engine stopped. 1
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
- Remove dipstick 1 (fig. C1).
- Wipe the dipstick and check the correct level between the MIN and MAX marks.
- If necessary, add oil (see: 3 - MAINTENANCE: E5 - ANGLE GEAR BOX OIL).

C2 - PARKING BRAKE C2
CHECK - ADJUST
A 1
Place the lift truck on level ground with the rated load in the transport position.

- Check braking by locking the parking brake in position A (fig. C2).

- Pull on the lift truck rear towing pin with a minimum force of 3500 daN. The wheels of the lift B
truck must not rotate.
- Carry out adjustments if necessary.
- Progressively tighten the end piece of the lever 1 (fig. C2) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.

C3 - CAB VENTILATION FILTER (OPTION AIR CONDITIONING) C3/1

CHANGE

- Unscrew thumbscrew 1 (fig. C3/1) and remove protective guard 2 (fig. C3/1).
- Lift out cabin ventilation filter 3 (fig. C3/2) and replace it with a new one (see: 3 - MAINTENANCE:
FILTERS AND BELTS).
- Refit the protective casing. 2

C3/2 1

C4 - HEATING BLOCK NON-RETURN VALVE C4

CLEAN

- Since non-return valve 1 (fig. C4) is located under the cab, it is possible for it to become
obstructed with spattered mud for example. Clean if necessary.

1
647387EN (18/11/2011)

3-22
C5 - FRONT AND REAR DIFFERENTIAL OIL LEVEL C5
CHECK

Place the lift truck on level ground with the I.C. engine stopped.
2
- Remove level plug 1 (fig. C5). 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. C5).
- Replace and tighten the level plug 1 (fig. C5) (tightening torque 34 to 49 N.m). 1
- Repeat this operation for the rear axle differential.

C6 - FRONT AND REAR WHEELS REDUCERS OIL LEVEL C6

CHECK

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

- Check the level on each front wheel reducer.

- Place level plug 1 (fig. C6) in the horizontal position. 1
- Remove the level plug, the oil should be flush with the edge of the hole.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the same hole.
- Replace and tighten the level plug 1 (fig. C6) (tightening torque 34 to 49 N.m).
- Repeat this operation on each rear wheel reducer.

647387EN (18/11/2011)

3-23
 D - EVERY 500 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

D1 - ENGINE OIL D1/1

DRAIN
D2 ENGINE OIL FILTER CARTRIDGE
CHANGE

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

DRAINING THE OIL 1

-Open the engine bonnet.
- Remove access panel 1 (fig. D1/1).
- Place a container under the drain plug and unscrew the drain plug 2 (fig. D1/2).
- Remove filler cap 3 (fig. D1/3) in order to ensure that the oil is drained properly.

Dispose of the drain oil in an ecological manner. D1/2

REPLACING THE CARTRIDGE

- Carefully clean the outside of the filter and its holder, to prevent dust from getting into the
system.
- Unscrew the engine oil filter cover 4 (fig. D1/4) and allow the oil to settle inside the body ofthe
filter. 2
- Remove the cover and push sideways on the cartridge 5 (fig. D1/4) to release it.
- Replace and lightly oil the new cover seal 6 (fig. D1/4) and fit the new cartridge
(see:3-MAINTENANCE: FILTERS CARTRIDGES AND BELTS) by pushing it into the cover.
- Refit the assembly into the body of the filter and screw on the cover 4 (fig. D1/4) (tightening
torque 25 N.m).

FILLING UP THE OIL

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

D1/4
4

D1/5

8
647387EN (18/11/2011)

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 engine stopped. Never operate the lift truck with the air filter
removed or damaged. 2
-Open the engine bonnet.
- Loosen the bolts and remove cover 1 (fig. D3).
- Carefully remove 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.
t
5IF
JOTJEF
PG
UIF
GJMUFS
BOE
DPWFS
t
5IF
HBTLFU
TVSGBDFT
JO
UIF
GJMUFS
BOE
JO
UIF
DPWFS
- Check pipes and connections between the air filter and the 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).
- Insert the cartridge within the axis of the filter and screw in the cartridge, tightening only by hand.
- Refit the cover, with the valve directed downwards and check that it is properly secured.

D4 - FUEL PRE-FILTER D4
2
CHANGE 6
1
-Open the engine bonnet.
- Carefully clean the outside of the pre-filter and its holder, to prevent dust from getting into the
system.
- Close the diesel inlet by turning the thumbwheel 1 (fig. D4) clockwise, and unscrew the bleed 5
screw 2 (fig. D4).
- Place a container under the pre-filter and drain it using drain plug 3 (fig. D4).
- Unscrew the housing 4 and the pre-filter 5 (fig. D4) and discard the pre-filter and its seals.
- Clean the inside of the pre-filter head and the housing, using a brush immersed in clean diesel 4
oil.
- Refit the assembly with a new pre-filter and new, ready-lubricated seals (see: 3 - MAINTENANCE: 3
FILTERS CARTRIDGES AND BELTS).

Tighten the fuel pre-filter and the housing by hand only.

- Re-tighten drain plug 3 (fig. D4).
- Open the diesel inlet by turning the thumbwheel 1 (fig. D4) anti-clockwise.
- Pressurise the circuit with the hand pump 6 (fig. D4), and close the bleed screw 2 (fig. D4) as soon as the diesel begins to flow.

D5/1
D5 - FUEL FILTER CARTRIDGE STRAINER
CLEAN

-Open the engine bonnet.

- Carefully clean the outside of the filter and its holder, to prevent dust from getting into the 1
system.
- Protect the outside of the filter with absorbent paper.
- Unscrew the cover 1 (fig. D5/1), and wait a few moments before removing it.
- Take out the strainer 2 (fig. D5/2), clean the inside of the cover and the strainer with a brush
immersed with clean diesel.
- Replace the strainer if it is excessively dirty or damaged.
- Refit the strainer 2 (fig. D5/2) and re-tighten the cover 1 (fig. D5/1) (tightening torque: 25 N.m).

D5/2

2
647387EN (18/11/2011)

3-25
D6 - FUEL FILTER CARTRIDGE D6/1
CHANGE

-Open the engine bonnet.

- Remove the access panel 1 (fig. D6/1) and place a container under the opening.
- Open the drain valve 2 (fig. D6/2),with the arrow pointing downwards, to drain the fuel filter.
- Carefully clean the outside of the filter and its holder, to prevent dust from getting into the
system.
- Protect the outside of the filter with absorbent paper. 1
- Unscrew the over 3 (fig. D6/3) approximately 1 cm, wait a few moments for the fuel level
todrop in the body of the filter.
- Fully unscrew the cover and remove the assembly together with the cartridge.
- Push sideways on the cartridge 4 (fig. D6/3) to release it.
- Replace and lightly oil the new cover seal 5 (fig. D6/3) and fit the new cartridge
(see:3-MAINTENANCE: FILTERS CARTRIDGES AND BELTS) by pushing it into the cover.
D6/2
- Refit the assembly into the body of the filter and screw on the cover 3 (fig. D6/3) (tightening
torque 25 N.m).
- Remove the absorbent paper and remove all traces of fuel.
- Close the drain valve 2 (fig. D6/2), with the arrow pointing upwards.
- Refit access panel 1 (fig. D6/1).

D6/3

4 5

D7 ALTERNATOR BELT
CHECK D7/1

- Open the engine bonnet.

- Remove the protective guard 1 (fig. D7/1).
1
REMOVING THE BELT
- Place a socket wrench in the square of the automatic belt tensioner 2 (fig. D7/2) to slacken the
belt and remove it.
- Release the force and remove the socket wrench.

CHECKING BELT TENSION

- Check the condition of the belt and replacer it if one of the following is noted.
t
4JEF
XFBS
t
5SBOTWFSTF
DSBDLT
PWFS
TFWFSBM
SJCT
t
%FUBDIFE
SJCT
PS
NJTTJOH
NBUFSJBM
D7/2
t
5PSO
PS
GSBZFE
TUSVDUVSBM
UISFBET
t
%FQPTJU
PO
UIF
CPUUPN
PG
UIF
CFMU
- Check the condition of the alternator bracket, belt tensioner and return pulley.
2
NOTE: Take advantage of the belt being removed to check the operation of pulleys and bearings
(noise, rubbing, play, etc.).

REFITTING THE BELT

- Refit a new alternator belt if required (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
647387EN (18/11/2011)

Ensure that it is properly seated in the grooves of each pulley and tighten the belt using the
automatic belt tensioner 2 (fig. D7/2).

- Refit protective casing 1 (fig. D7/1).

3-26
D8 - GEAR BOX OIL FILTER D8/1
CHANGE
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
- Remove the cover plate 1 (fig. D8/1).
- Unscrew and discard gear box oil filter 2 (fig. D8/2).
- 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). 1
- 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. D8/1). D8/2

D9 - HYDRAULIC RETURN OIL FILTER CARTRIDGE D9

CHANGE

Stop the 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.
- Place a container under hydraulic drain filter 1 (fig. D9).
- Unscrew the body of the filter. 1
- Remove the hydraulic return oil filter cartridge and fit new replacement cartridge
(see:3-MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Make sure that the cartridge is correctly positioned and refit the body of the filter.

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

D10 - PARKING BRAKE LEVER MECHANISM D10

GREASE

- Clean and grease the pivot pins 1 (fig. D10) with grease (see: 3 - MAINTENANCE: LUBRICANTS
AND FUEL).
1 1

1
1
647387EN (18/11/2011)

3-27
D11 - CAB VENTILATION FILTER D11/1
CLEAN

- Unscrew thumbscrew 1 (fig. D11/1) remove protective guard back 2 (fig. D11/1).
- Lift out cabin ventilation filter 3 (fig. D11/2).
- Clean the filter using a compressed air jet.
- Check its condition and change if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND 2
BELTS).
- Refit the filter and protective casing.
1

D11/2

D12 - FRONT AND REAR AXLE DIFFERENTIAL OIL D12

DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the differential oil still warm.
3
Dispose of the drain oil in an ecological manner.
2
- Place a container under drain plugs 1 (fig. D12) and unscrew the plugs.
- Remove level plug 2 (fig. D12) and filler plug 3 (fig. D12) in order to ensure proper emptying.
- Refit and tighten drain plugs 1 (fig. D12) (tightening torque 34 to 49 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 3 (fig. D12). 1 1 1
- The level is correct when the oil level is flush with the edge of port 2 (fig. D12).
- Check for any possible leaks at the drain plugs.
- Refit and tighten level cap 2 (fig. D12) (tightening torque 34 to 49 N.m) and filler port 3 (fig. D12)
(tightening torque 34 to 49 N.m).
- Repeat this operation for the rear axle differential.

647387EN (18/11/2011)

3-28
3-29
647387EN (18/11/2011)
 E - EVERY 1000 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

E1 - FUEL TANK E1/1

CLEAN

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

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

Never try to carry out a weld or any other operation by yourself, this could provoke an explosion or a fire.
- Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
- Remove filling plug 2 (fig. E1/2) in order to ensure that the oil is drained properly.
- Rinse out with ten litres of clean diesel through filler port 3 (fig. E1/2).
- Refit and tighten the drain plug (tightening torque 29 to 39 Nm).
E1/2
- 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).
2

E2 - SAFETY DRY AIR FILTER CARTRIDGE E2

CHANGE

- For the disassembly and reassembly of the dry air filter cartridge, see: 3 - MAINTENANCE: D3 -
AIR FILTER CARTRIDGE.
- Unscrew the dry air filter safety cartridge 1 (fig. E2), taking care to avoid spilling the dust.
- Clean the gasket surface of the filter with a damp, clean lint-free cloth.
- Before mounting, check the state of the new safety cartridge (see: 3 - MAINTENANCE: FILTERS
AND BELTS).
- Insert the cartridge within the axis of the filter and screw in the cartridge, tightening only 1
byhand.

NOTE: The periodicity for changing the safety cartridge is given for information only.
Itmustbechanged for every two changes of the dry air filter cartridge.
647387EN (18/11/2011)

3-30
E3 - GEAR BOX OIL E3/1
DRAIN
E4 -GEAR BOX SUMP STRAINER
CLEAN
MLT 634 -120 LSU Srie G-E3
MLT 735 -120 LSU Srie 7-E3
1
Place the lift truck on level ground with the engine stopped, the gear box oil still warm.
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).

DRAINING THE OIL

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

Dispose of the drain oil in an ecological manner. 2

CLEANING THE STRAINER

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

FILLING UP THE OIL E3/3

- 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. E3/4) and
refit the filler cap.
- Start the engine and let it run for a few minutes.
- Check any possible leaks from the drain plug or the plate.
- Stop the engine, and within 5 minutes of it being stopped, check on the dipstick 4 (fig. E3/4) the
correct level between the two MIN and MAX marks.
- Top up the level if necessary.
- Replace the cover plate 3 (fig. E3/3).
3

E3/4

4
647387EN (18/11/2011)

3-31
E3 - GEAR BOX OIL E3/1
DRAIN
E4 -GEAR BOX SUMP STRAINER
CLEAN
MLT 634 -120 LSU PS Srie G-E3

Place the lift truck on level ground with the engine stopped, the gear box oil still warm.
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS). 1

DRAINING THE OIL

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

Dispose of the drain oil in an ecological manner.

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

FILLING UP THE OIL

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

5 E5/1

1
E5 - ANGLE GEARBOX OIL
DRAIN

Place the lift truck on level ground with the engine stopped, the angle gear box oil still warm.
Raise the jib and place the jib safety wedge on the rod of the lifting cylinder (see: 1 - OPERATING AND SAFETY
INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
- Place a container under drain plug 1 (fig. E5/1) and unscrew the plug. E5/2
- Remove dipstick 2 (fig. E5/2) and unscrew filler cap 3 (fig. E5/2) in order to ensure that the oil
is drained properly.

Dispose of the drain oil in an ecological manner. 2

- Refit and tighten drain plug 1 (fig. E5/1) (tightening torque 20 to 29 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 3 (fig. E5/2) and
refit the filler cap.
647387EN (18/11/2011)

- Check the correct level between the MINI and MAXI marks on dipstick 2 (fig. E5/2).
3
- Check for any possible leaks at the drain plug.

3-32
E6 - HYDRAULIC OIL E6/1
DRAIN
E7 - SUCTION OIL STRAINER FOR HYDRAULIC OIL TANK
CLEAN
E8 - FILTER CAP FOR HYDRAULIC OIL TANK
CHANGE
E9 - DISTRIBUTOR CONTROL HEAD FILTER
CHANGE
1
Place the lift truck on level ground with the I.C. engine stopped and telescope boom retracted
and lowered as far as possible. 1

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

CLEANING THE STRAINER

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

REPLACING THE DISTRIBUTOR CONTROL HEAD FILTER E6/3

- Remove the half clamp 4 (fig. E6/4).
- Undo the two couplings 5 (fig.E6/4) and replace the filter 6 (fig. E6/4).
3
Be careful to mount the filter 6 (fig. D6/4) in the same direction as the arrow.
- Refit the half clamp 4 (fig. E6/4).

FILLING UP THE OIL

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

Use a clean container and funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 8 (fig. E6/5), the oil level should be at the level of the red point. E6/4
- 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
4
AND BELTS).
5 5
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 6
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

8
647387EN (18/11/2011)

3-33
E10 - SEAT BELT
CHECK

SEAT BELT WITH TWO ANCHORING POINTS

- Check the following points:
t
'JYJOH
PG
UIF
BODIPSJOH
QPJOUT
PO
UIF
TFBU
t
$MFBOOFTT
PG
UIF
TUSBQ
BOE
UIF
MPDLJOH
NFDIBOJTN
t
5SJHHFSJOH
PG
UIF
MPDLJOH
NFDIBOJTN
t
$POEJUJPO
PG
UIF
TUSBQ
DVUT
DVSMFE
FEHFT


REELED BELT WITH TWO ANCHORING POINTS

- Check the points listed above together with the following points:
t
5IF
DPSSFDU
XJOEJOH
PG
UIF
CFMU
t
$POEJUJPO
PG
UIF
SFFM
HVBSET
t
3PMMFS
MPDLJOH
NFDIBOJTN
XIFO
UIF
TUSBQ
JT
HJWFO
B
TIBSQ
UVH

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

DRAIN E11

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

Dispose of the drain oil in an ecological manner.

1
- Drain and change each front wheel reducer. B
- 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. A
- 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.

647387EN (18/11/2011)

3-34
3-35
647387EN (18/11/2011)
 F - EVERY 2000 HOURS SERVICE
Carry out the operations described previously as well as the following operations.

F1 - COOLING LIQUID F1/1

DRAIN

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

DRAINING THE LIQUID

-Open the engine bonnet. 1
- Remove access panel 1 (fig. F1/1).
- Place a container under the radiator hose 2 (fig. F1/2) and remove it.
- 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
ifnecessary.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
F1/2
FILLING THE LIQUID
- Refit and tighten the hose 1 (fig. F1/2).
- Slowly fill up the circuit with cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) 2
to the middle of gauge 4 (fig. F1/3) through filler port 5 (fig. F1/3).
- Put back filling plug 3 (fig. F1/3).
- Run the engine at idle for a few minutes.
- Check for any possible leaks.
- Check the level and refill if necessary.
The 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
5

4
F2 - AIR CONDITIONING (OPTION)
CHECK - CLEAN

CLEANING CONDENSER AND EVAPORATOR COILS (*)

CLEANING CONDENSATE TRAY AND RELIEF VALVE (*) F2
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.


t
*G
UIJT
HBT
JT
JOIBMFE
UBLF
UIF
WJDUJN
JOUP
GSFTI
BJS
HJWF
PYZHFO
PS
BSUJGJDJBM
SFTQJSBUJPO
JG
OFDFTTBSZ
BOE
DBMM
B

EPDUPS
647387EN (18/11/2011)

t
*G
UIF
HBT
JT
JO
DPOUBDU
XJUI
UIF
TLJO
XBTI
JU
JNNFEJBUFMZ
VOEFS
SVOOJOH
XBUFS
BOE
SFNPWF
BOZ
DPOUBNJOBUFE
HBSNFOUT
t
*G
UIF
HBT
JT
JO
DPOUBDU
XJUI
UIF
FZFT
SJOTF
UIFN
JO
DMFBS
XBUFS
GPS

NJOVUFT
BOE
DBMM
B
EPDUPS
- The compressor has an oil level gauge (fig. F2). Never unscrew this gauge because it would depressurizes the installation. The oil level
isonly checked when changing the oil in the circuit.

3-36
3-37
647387EN (18/11/2011)
 G - OCCASIONAL MAINTENANCE

G1 - FUEL SYSTEM G1
BLEED
1

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

t
"
DPNQPOFOU
PG
UIF
GVFM
TZTUFN
SFQMBDFE
t
"
ESBJOFE
UBOL
t
3VOOJOH
PVU
PG
GVFM
Any contact with highly pressurized fuel risks presents a risk of percutaneous penetration or burns. Spraying
fuel under high pressure can cause a fire.
Failure to follow the inspection and maintenance instructions may result in serious injury.

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

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

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

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

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

G2 - WHEEL G2/1
CHANGE

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

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

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

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

647387EN (18/11/2011)

3-38
G3 - FRONT HEADLAMPS G3
ADJUST
h2 = h1 - (l x 2 / 100)

RECOMMENDED SETTING
(as per standard ECE-76/756 76/761 ECE20) h1
4FU
UP


PG
UIF
EJQQFE
CFBN
JO
SFMBUJPO
UP
UIF
IPSJ[POUBM
MJOF
PG
UIF

+%
headlamp.
-%

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

CALCULATING THE HEIGHT OF THE DIPPED BEAM (H2)

t
I

)FJHIU
PG
UIF
EJQQFE
CFBN
JO
SFMBUJPO
UP
UIF
HSPVOE
t
I

)FJHIU
PG
UIF
BEKVTUFE
CFBN
t
M


%JTUBODF
CFUXFFO
UIF
EJQQFE
CFBN
BOE
UIF
XIJUF
XBMM

G4 - LIFT TRUCK
TOW

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

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

G5 - LIFT TRUCK G5/1

SLING

- Take into account the position of the lift truck centre of gravity for lifting (fig.
G5/1).

A = 1410 mm B = 1150 mm MLT 634 -120

A = 1520 mm B = 1290 mm MLT 735 -120

- Place the hooks in the fastening points provided (fig. G5/2 and G5/3).

A B

G5/2

G5/3
647387EN (18/11/2011)

3-39
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. G6/2
- Stop the lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING INSTRUCTIONS
UNLADEN AND LADEN).

STOW THE LIFT TRUCK

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

G6/3

G6/4

G6/5
647387EN (18/11/2011)

3-40
G7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
RESET

According to the use of the lift truck, the device may require to be periodically reset.
This operation can be easily performed by means of the following procedure.
- Provide a fork carrier or a bucket and a load corresponding to at least half the lift trucks rated capacity.
- Preferably perform the reset when the lift truck is still cold (before it is used) or ensure that the temperature of the rear axle is not more
than 50C.
- Place the lift truck on flat, level ground with the wheels straight.
Scrupulously follow the boom positioning instructions. Should you fail to follow these instructions, two audible beeps will be sounded and the fault
indicator lamp will come on. If in doubt, consult your dealer.

STAGE 1
START Simultaneously press and hold down the BUCKET MODE and TEST buttons.
- Without attachments. - Two audible beeps will be sounded and all the leds will flash twice to confirm the start of the procedure.
- Boom fully retracted and
raised.

Short press the test

1 button.
STAGE 2
- Without attachments.
- Carriage tilted fully backward.
- An audible beep. - Boom fully retracted and in the down position a few centimetres off the ground.
- First green led flashing.
- Flashing test button.

/
- With the fork carrier or the bucket and a load (keep boom retracted to allow all other Short press the test
hydraulic movements). button.
- Boom fully retracted and in the down position a few centimetres off the ground.
2
- Two audible beeps
STAGE 3 1 / will be sounded
and all the leds
- First green led continuously will flash twice to
Keep the load as close to the ground as possible throughout this operation.
lit. confirm the end
- Second green led flashing. of the procedure.
- Hold down the disable the aggravating hydraulic movement cut-off button
- - Flashing test button.
(indicator lamp lit), and telescope the boom until the rear wheels are off the ground.
NOTA: This stage consists in unloading the rear axle. It can be done using a jack
but without bearing on the rear axle.

STAGE 4
/
FINISH
- After completing the resetting procedure, the lift truck is in an overloaded condition. Retract the telescope to restore the
situation.
- All leds lit.
- A continuous audible beep.

When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see: 3 - MAINTENANCE: A - DAILY OF EVERY 10 HOURS
647387EN (18/11/2011)

SERVICE).

3-41
3-42
647387EN (18/11/2011)
4 - OPTIONAL
ATTACHMENTS
FOR USE WITH
THE RANGE

647387EN (18/11/2011)

4-1
4-2
647387EN (18/11/2011)
TABLE OF CONTENTS

INTRODUCTION 4-5

PICKING UP THE ATTACHMENTS 4-6

TECHNICAL SPECIFICATIONS OF ATTACHMENTS 4-8

ATTACHMENT SHIELDS 4-16

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4-3
4-4
647387EN (18/11/2011)
 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.
Suspended loads MUST be handled with a lift truck designed for that purpose (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: LOAD HANDLING INSTRUCTIONS:
H - TAKING-UP AND SETTING-DOWN A SUSPENDED LOAD).

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

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

647387EN (18/11/2011)

4-5
 PICKING UP THE ATTACHMENTS

A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE A

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

HAND LOCKING
- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D). Do not
forget to refit the clip.
B
HAND RELEASING
- Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back the
locking pin and the clip in the bracket (fig. A).

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

D
647387EN (18/11/2011)

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

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

MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT

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

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

1
647387EN (18/11/2011)

4-7
TECHNICAL SPECIFICATIONS OF ATTACHMENTS

FLOATING FORK CARRIAGE

TFF 35 MT-1040 TFF 35 MT-1300
PART NUMBER 654093 654094
Rated capacity 3500 kg 3500 kg
Width 1040 mm 1300 mm
Weight 300 kg 340 kg

FLOATING FORK SIDE-SHIFT CARRIAGE

TFF 35 MT-1040 DL TFF 35 MT-1300 DL
PART NUMBER 751543 751544
Rated capacity 3500 kg 3500 kg
Side-shift 2x100 mm 2x100 mm
Width 1040 mm 1300 mm
Weight 345 kg 375 kg

FLOATING FORK
PART NUMBER 415801
Section 125x45x1200 mm
Weight 68 kg

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4-8
STANDARDISED TILTING FORK CARRIAGE
PFB 35 N MT-1260 S2 PFB 35 N MT-1470 S2 PFB 35 N MT-1580 S2
PART NUMBER 653744 653745 653746
Rated capacity 3500 kg 3500 kg 3500 kg
Width 1260 mm 1470 mm 1580 mm
Weight 103 kg 126 kg 131 kg

STANDARDISED SIDE-SHIFT CARRIAGE

TDL 3T5 L1260 FEM3 TDL 5T L1470 FEM3 TDL 5T L1580 FEM3
PART NUMBER 751375 751376 751377
Rated capacity 3000 kg 5000 kg 5000 kg
Side-shift 2x100 mm 2x100 mm 2x100 mm
Width 1260 mm 1470 mm 1580 mm
Weight 79 kg 192 kg 200 kg

STANDARDISED FORK
PART NUMBER 415618
Section 125x45x1200 mm
Weight 72 kg

LOAD BACK REST

PART NUMBER 556008 555325 556010
Width 1260 mm 1470 mm 1580 mm
Weight 36 kg 39 kg 41 kg
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4-9
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

LOADING BUCKET
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

GRAIN BUCKET
CBA 1500 L2450 S3 CBA 1800 L2250 S3
PART NUMBER 570547 570550
Rated capacity 1502 l 1820 l
Width 2450 mm 2250 mm
Weight 514 kg 571 kg

GRAIN BUCKET
CBA 2000 L2450 S3 CBA 2500 L2450 S3
PART NUMBER 570551 570553
Rated capacity 1998 l 2508 l
Width 2450 mm 2450 mm
Weight 607 kg 701 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
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4-10
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

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4-11
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 7 8 8
Weight 555 kg 615 kg 635 kg

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 7 8 8
Weight 678 kg 740 kg 767 kg

GRAB BUCKET (GRAB CLOSED)

CBG 2300 GF S4
PART NUMBER 653008
Rated capacity 1,2 m3
Width 2300 mm
Grab 8
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 7 8 8
Weight 655 kg 715 kg 742 kg
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4-12
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 WITH SPOUT(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
Weight 150 kg 166 kg

HYDRAULIC KIT TO OPEN THE SPOUT

PART NUMBER 653750

SPOUT BUCKET (ADAPTABLE ON FORKS)

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

HYDRAULIC KIT TO OPEN THE SPOUT

PART NUMBER 653750

SPOUT BUCKET (ADAPTABLE ON FORKS)

GL 1000 S2 GL 1500 S2
PART NUMBER 174375 174376
Rated capacity 1000 l/2440 kg 1500 l/3591 kg
Weight 360 kg 409 kg
647387EN (18/11/2011)

HYDRAULIC KIT TO OPEN THE SPOUT

PART NUMBER 653750

4-13
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 7 8 7
Weight 567 kg 606 kg 567 kg

647387EN (18/11/2011)

4-14
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

CRANE JIB
PC 50
PART NUMBER 708544
Rated capacity 5000 kg
Weight 120 kg
647387EN (18/11/2011)

4-15
ATTACHMENT SHIELDS

FORK PROTECTOR

PART NUMBER 227801

FORK BLOCK FOR FLOATING FORK CARRIAGE

PART NUMBER 261210

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 206734 206732 206730
Width 1375 mm 1500 mm 1650 mm

PART NUMBER 235854 206728 206726

Width 1850 mm 1950 mm 2000 mm

PART NUMBER 223771 223773 206724

Width 2050 mm 2100 mm 2150 mm

PART NUMBER 206099 206722 223775

Width 2250 mm 2450 mm 2500 mm

MANURE FORK PROTECTOR

PART NUMBER 230689

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4-16
5 - SPECIFIC AUSTRALIA
See also the operators manual supplement: 647065 AU

647387EN (18/11/2011)

5-1
5-2
647387EN (18/11/2011)
LOAD CHART
MLT 735 -120 LSU Srie 7-E3

MLT735
50 60 61.5
8

40
7 E
6,86 36km/h Maxi
D (10m/s) Ground conditions:
6 C solid surface
kg B
00
30

0.3m Maxi
5 A
30

3500kg
4
3500kg

MAXI

20
3
2500kg
2000kg

12km/h Maxi (3,33m/s)

1600kg
1300kg
11000kg

2
10
kg
1 kg
15% maxi 10% maxi

N283876
N283823

0
0m
C B A 0.6m
-4 E D
5 4 3 2 1 0m kg kg
3,55

2,55
2,05
1,70
1,45
1,33

5% maxi 5% maxi
Standard used AS 1418-19 Standard used AS 1418-19

647387EN (18/11/2011)

5-3
5-4
647387EN (18/11/2011)