MANITOU AMERICAS, INC.

One Gehl Way

P. O. Box 179
West Bend, WI 53095-0179 U.S.A
Website: www.us.manitou.com

For parts orders contact your Manitou dealer or call:

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

MLT625-75 H S1-E3
Operator Manual
Catalog No. 51900001
In. Rel. 03-2011

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

0 - ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

1 - OPERATING & SAFETY INSTRUCTION

2 - DESCRIPTION

3 - MAINTENANCE

4 - ATTACHMENTS

5 - ELECTRICAL & HYDRAULIC SCHEMATIC

RELEASE: 03/11

Initial Release

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

1-2

Contents

ROUGH TERRAIN FORKLIFT TRUCK

GENERAL SAFETY STANDARDS

1-2

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

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

ADDITIONAL RECOMMENDED LITERATURE:

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

A.) OPERATOR TRAINING QUALIFICATIONS

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

B.) GENERAL SAFETY PRACTICES

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

II

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

C.) OPERATING SAFETY RULES AND PRACTICES

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

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

D.) SUSPENDED LOADS
A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame
is level. Transporting suspended loads must ALWAYS be done slowly and cautiously, with the boom and load
as low as possible. Use taglines to restrict loads from swinging, to avoid overturn.
The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic
forces affecting the stability of the machine that are not considered in the stability criteria of industry test
standards. Grades and sudden starts, stops and turns can cause the load to swing and create a hazard.
Guidelines for Free Rigging / Suspended Loads
1.

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

2.

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

3.

Only lift the load vertically NEVER drag it horizontally.

4.

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

5.

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

6.

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

7.

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

8.

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

9.

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

10.

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

WARNING
U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in
Construction) include requirements for employers that use powered industrial trucks ("forklifts") configured
to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation
applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a
hook (with or without a winch), or a hook assembly attached to the forks. [Note: This regulation is in
addition to the OSHA regulation that requires specific forklift operator training: 1910.178(l).]
When a forklift / telescopic handler is configured and used for hoisting, the employer must ensure that:
1.

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

2.

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

3.

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

4.

Equipment is being used within its rated capacity and in accordance with the manufacturer's
instructions.
VI

5.

Operator and crew members have been trained in the safe use and operation of the equipment,
including how to avoid electrocution.

6.

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

7.

In addition, for lift equipment with a rated capacity greater than 2000 lbs. (907 kg), the employer
must ensure that:
a.) An accessible fire extinguisher is on the forklift;
b.) Monthly and annual inspections are performed and documented, and records retained (three
months for monthly, one year for annual);
c.) Before November 10, 2014, operators must have had the additional training and qualification /
certification required by OSHA regulations 1926.1427 and 1926.1430.

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

VII

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

2.) CREATE A MAINTENANCE PROGRAM

OSHA recommends a maintenance log, listing repairs requested and completed, for each forklift. Also, lock
out tag procedures should be utilized. If the forklift malfunctions; park it safely, remove the key, tag Do Not
Use, and report the problem to the proper authority or authorized service personnel immediately.

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

3.) FORKLIFT KNOWLEDGE

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

4.) WORK SITE KNOWLEDGE

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

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

VIII

SAFETY MESSAGES
NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL
HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Also, observe
the safety messages places throughout this manual; providing special instructions, telling you when to take precautions
and to identify potential hazards. The safety messages are highlighted and outlined in a box similar to those shown in the
examples below.

SAFETY ALERT SYMBOL

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

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

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

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

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

CALIFORNIA PROPOSITION 65 WARNING

Diesel Engine Exhaust and some of its constituents are known to the State of California
to cause cancer, birth defects or other reproductive harm.
WARNING: Battery posts, terminals and related accesories and related accessories
contain lead and lead compounds. Wash hands after handling.

IX

SAFETY DECALS
The purpose of this chapter is to introduce you to the safety messages, decals, and nameplates found on
your forklift truck. The decals are identified by name, part number, location, and a brief description. (The
forklift model logos, and other misc. decals not shown, can be found in your forklift parts manual.) The
decals illustrated may not be exactly the same as those installed on your forklift; installation of the decals
varies depending on the forklift model, series, decal updates, etc.. The size and location of some decals
limit the amount of information that can be placed upon it. For this reason, additional detailed information
not found on the decals is provided through-out this manual.
Every decal placed on the lift truck is important; they are constant reminders of safety and instructions that
should never be taken for granted. Even experienced operators can be seriously injured or killed by ignoring, refusing to enforce, or forgetting to follow safe operating procedures! Do not assume you know all safety issues concerning the decals. Before operating the lift truck; learn the meaning(s) of the decals as
described in this manual. If any decal becomes illegible or missing, have it replaced immediately! Always
replace decals using the same decal part no., unless otherwise specified by the manufacturer. For replacement decals not found in your parts manual, contact your nearest dealer. If you have any questions, contact
your supervisor or nearest dealer for advice before operating your forklift!

801011
Before Starting - 801011
(Boom equipped models). Location: on the brake fluid cover panel (to
the left and below the dash panel).

Safety Instructions - 420792

(Mast equipped models). Location: on or near the operator manual
storage case, and/or on the dash panel.
Instructions for the forklift operator; before operating the forklift.

Use of Seat Belt - 801012

(Boom equipped models). Location: to the right of the
operator, near the hydraulic control lever.
Instructs the operator to always wear the seat belt during
operations, and never jump from an over-turning forklift.

SAFETY DECALS

Emergency and Parking Brake - 801010

Location: near the park brake lever.
Identifies the Emergency/Parking Brake Lever.

Alarm Must Sound - 496162

Location: on the dash, in direct view of the operator.
The backup alarm must sound when the forklift is placed in reverse gear.

No Riders - 420732
Location: on the cab entrance(s), and on or near wheel fenders and engine
cover.
Informs: riders are not allowed on the forklift.

Clear of Raised Boom - 801006

(Boom equipped models). Location: on both sides
of the boom nose.
Keep away from unsupported boom.

Clear of Power Lines - 801007

(Boom equipped models). Location: on both sides
of the boom nose.
Keep away from power lines.

XI

SAFETY DECALS
Use of Frame Leveling - 801013
(Boom equipped models). Location: to the right of
the operator near the hydraulic control lever.
Frame leveling notice; load must be lowered.

Attachment and Boom Safety - 801009

(Boom equipped models). Location: on both sides of the
boom nose.
Important reminders of attachment and boom safety.

Hydraulic Coupling - 234805

Location: near the quick-disconnect adapters.
Stop the engine and release hydraulic pressure before changing
attachments.

Rotating Fan and Belt(s) - 801008

Location: on the radiator near the fan, and on any fan belt/pulley cover(s).
Keep hands and clothing away from rotating fan and belts.

XII

SAFETY DECALS

Gear Shift Pattern - 33460

(4-speed transmission models). Location: near the gear shift lever.
Identifies the gear shift pattern of the forklift transmission.

Steering Mode - 184276

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

221322

Mineral Oil (Brake Reservoir) - 221322 or 234800 has

been replaced by 164091.
Location: near the brake fluid reservoir where applicable.
Refer to the Operator/Service Manual for the correct brake fluid
(mineral oil) to be used in the brake system.

234800

XIII

SAFETY DECALS
Hydraulic Oil - 234798 or 76573
Location: on the hydraulic tank or filler cap.
Identifies the hydraulic reservoir (tank) or filler cap.

Hydraulic Oil - 61024

Location: on the hydraulic tank.
Identifies the hydraulic reservoir (tank).

Anti-Freeze - 234799
Location: on the radiator, near the radiator filler cap.
Indicates required minimum to maximum anti-freeze protection (-220F to -400F).

Diesel Fuel - 161101

Location: on the fuel tank, near the filler cap.
Identifies the fuel tank, and use of diesel fuel.

No Step - 496735
Location: varies, depending on the forklift model.
Instructs personnel not to use the designated area as a step.

Do Not Tow - 494918

(Hydrostatic equipped models). Location: on the
dash, in view of the operator.
Towing the forklift will damage the transmission;
refer to the operators manual.

XIV

SAFETY DECALS
Attachment Warning - 421016
(Boom equipped models). Location: on the boom coupler,
near where the retaining shaft is installed.
Reminder to operator; install attachment retaining shaft and
safety pin before operations.

Hook Here - 24653

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

Fork Safety - 426641

(Mast equipped models). Location: on the front and back side of the masts outer rails,
at eye level (4 required).
Instructs personnel not to travel beneath or upon the lift truck forks.

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

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

HAND THROTTLE DANGER - 804784

(Boom equipped models, option). Location: Near the hand throttle mechanism.
Reminder to operator; set parking brake before operating hand throttle.
Disengage hand throttle before leaving the forklift.

XV

SAFETY DECALS
Acid in Battery - 801014
Location: in or near the battery
storage compartment.
Addresses battery hazards.

Jump Start Battery - 801015

Location: in or near the battery storage
compartment.
Jump start instructions.

Attachment Plate - 425995

Location: on the optional removeable forklift attachment.
Important manufacturer information about the attachment. Record this information for use
when contacting the maufacturer for parts and service.

Overhead Guard Data Plate - B6109

Location: attached to the overhead guard.
Overhead guard conformity.

496550

Forklift Data Plate - 496550

283688

(Boom equipped models)

Forklift Data Plate - 283688

MANITOU BF 44158 ANCENIS CEDEX FRANCE

MODELE
MODEL

MODELLO
MODELO

SERIE
SERIES

SERIE
SERIE

Location: within the operators compartment.

N de srie
Serial Nr

Anne de fabrication
Year of manufacture
Anno di fabbricazione
Ao de fabricacion

Important forklift truck identification. Record

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

Numero di serie
Nmero de serie

Masse vide
Unladen mass
Puissance ISO/TR14396
Power ISO/TR14396
Potenza ISO/TR14396
Potencia ISO/TR14396

Massa a vuoto
Masa en vacio
kg

kW
Effort vertical max. (sur accrochage remorque)
Vertical max. effort (on trailer hook)
Carico max. verticale (sul gancio di traino)
Esfuerzo vertical max. (sobre el gancho de remolque)
daN
Pression des pneumatiques (Bar)
Tyre pressure (Bar)
Pressione per pneumatici (Bar)
Presion de los neumticos (Bar)
Avant
Anteriore
Arrire Posteriore
Front
Adelante
Rear
Trasero

Numro d'homologation
Homologation number
Numero d'omologazione
Contrasea homologacion

Capacit maxi nominale

Nominal maximum capacity
Capacit maxi nominale
Capacidad mximo nominal
kg
Effort de traction
Tractive effort
Forza di traino
Esfuerzo de traccion
daN

N283688

XVI

1-2

Content Page

1 - OPERATING
AND SAFETY
INSTRUCTIONS

1-1

1-2

TABLE OF CONTENTS
INSTRUCTIONS TO THE COMPANY MANAGER

1-4

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

1-4
1-4
1-4
1-4
1-4
1-5
1-5
1-5
1-5

INSTRUCTIONS FOR THE OPERATOR

1-6

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

1-6
1-6
1-6
1-6
1-6
1-6
1-7
1-8
1-8
1-8
1-9
1-9
1 - 10
1 - 10
1 - 11
1 - 12
1 - 14
1 - 14
1 - 14
1 - 14
1 - 15
1 - 15
1 - 16
1 - 18
1 - 20
1 - 20
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 22
1 - 23

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

1 - 24

GENERAL INSTRUCTIONS
MAINTENANCE
LUBRICANT AND FUEL LEVELS
HYDRAULIC
ELECTRICITY
WELDING
WASHING THE LIFT TRUCK

1
1
1
1
1
1
1

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

1 - 26

INTRODUCTION
PREPARING THE LIFT TRUCK
PROTECTING THE I.C. ENGINE
PROTECTING THE LIFT TRUCK
BRINGING THE LIFT TRUCK BACK INTO SERVICE

1
1
1
1
1
1-3

24
24
24
24
24
25
25

26
26
26
26
27

INSTRUCTIONS TO THE COMPANY MANAGER

THE 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, in accordance to ASME B56.6 - 2002
- Before commissioning, the company manager must make sure that the lift truck is appropriate for the work to be done, and
perform certain tests (in accordance with current legislation).
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS
- In addition to series equipment mounted on your lift truck, many options are available, such as: road lighting, stop lights, flashing
light, reverse lights, reverse buzzer alarm, front light, rear light, light at the jib head, etc (as model of lift truck).
- The operator must take into account the operating conditions to define the lift 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:
Select the most suitable lift truck and attachment for the intended use.
Adapt the seat adjustment to the operator's weight (according to lift truck model) and maintain it in good condition, as
well as the cab suspension. Inflate the tires in accordance with recommendations.
Ensure that the operators adapt their operating speed to suit the conditions on site.
As far as possible, arrange the site in such a way as to provide a flat running surface and remove obstacles and harmful
potholes.

1-4

C - MODIFICATION OF THE LIFT TRUCK

- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
D - FRENCH ROAD TRAFFIC RULES
(or see current legislation in other countries)
- Only one certificate of conformity is issued. It must be kept in a safe place.

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

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

1-5

INSTRUCTIONS FOR THE OPERATOR

PREAMBLE
WHENEVER YOU SEE THIS SYMBOL IT MEANS:

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

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.

1-6

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

1-7

OPERATING INSTRUCTIONS UNLADEN AND LADEN

A - BEFORE STARTING THE LIFT TRUCK
- Carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Make sure the lights, indicators and windscreen wipers are working properly.
- Make sure the rear view mirrors are in good condition, clean and properly adjusted.
- Make sure the horn works.
B - DRIVERS OPERATING INSTRUCTIONS
- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and
instruments before operating the lift truck.
- Wear clothes suited for driving the lift truck, avoid loose clothes.
- Make sure you have the appropriate protective equipment for the job to be done.
- Prolonged exposure to high noise levels may cause hearing problems. It is recommended to wear ear muffs to protect against
excessive noise.
- Always face the lift truck when getting into and leaving the driving seat and use the handle(s) provided for this purpose. Do not
jump out of the seat to get down.
- Always pay attention when using the lift truck. Do not listen to the radio or music using headphones or earphones.
- Never operate the lift truck when hands or feet are wet or soiled with greasy substances.
- For increased comfort, adjust the seat to your requirements and adopt the correct position in the drivers cab.
Under no circumstances must the seat be adjusted while the lift truck is moving.
- The operator must always be in his normal position in the drivers cab. It is prohibited to have arms or legs, or generally any part
of the body, protruding from the drivers cab of the lift truck.
- The safety belt must be worn and adjusted to the operators size.
- The control units must never in any event be used for any other than their intended purposes (e.g. climbing onto or down from the
lift truck, portmanteau, etc.).
- If the control components are fitted with a forced operation (lever lock) device, it is forbidden to leave the cab without first putting
these controls in neutral.
- It is prohibited to carry passengers either on the lift truck or in the cab.

1-8

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

Moving without load: Forks or attachment facing downhill.

Moving with load: Forks or attachment facing uphill.

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

1-9

E - STARTING THE LIFT TRUCK

SAFETY INSTRUCTIONS
The lift truck must only be started up or maneuvered when the operator is sitting in the drivers cab, with his seat belt adjusted and fastened.
- Never try to start the lift truck by pushing or towing it. Such operation may cause severe damage to the transmission. If necessary,
to tow the lift truck in an emergency, the transmission must be placed in the neutral position (see: 3 - MAINTENANCE: G OCCASIONAL MAINTENANCE).
- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connecting
it. Connect at first the positive terminals before the negative terminals.
Failure to respect polarity between batteries can cause serious damage to the electrical circuit. The electrolyte in the battery may produce an explosive
gas. Avoid flames and generation of sparks close to the batteries. Never disconnect a battery while it is charging.
INSTRUCTIONS
- Check the closing and locking of the hood(s).
- Check that the cab door is closed.
- Check that the forward/reverse selector is in neutral.
- Turn the ignition key to the position I to activate the electrical system and the preheat.
- Whenever you switch on the lift truck, perform the automatic check on the longitudinal stability 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.

1-10

Use the rear-view mirrors frequently.

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

1-11

H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY

(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.

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DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT

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

1-13

INSTRUCTIONS FOR HANDLING A LOAD

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

B - MASS OF LOAD AND CENTRE OF GRAVITY

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

B1

500 mm

It is forbidden to move a load heavier than the effective capacity defined on the lift truck load chart.
For loads with a moving centre of gravity (e.g. liquids), take account of the variations in the centre of
gravity in order to determine the load to be handled and be vigilant and take extra care to limit these
variations as far as possible.

B2

C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE

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

1-14

1
2
3

D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK

Depending on the model of lift truck

D1

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

1 - LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TYRES

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

2 - LIFT TRUCK WITH SLOPE CORRECTOR USED ON TYRES

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

D2

3 - LIFT TRUCK USED ON STABILIZERS

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

E - TAKING UP A LOAD ON THE GROUND

- Approach the lift truck perpendicular to the load, with the jib retracted and the forks in a horizontal position (fig. E1).
- Adjust the fork spread and centering in connection with the load (fig. E2) (optional solutions
exist, consult your dealer).
E1
- Never lift a load with a single fork.
Beware of the risks of trapping or squashing limbs when manually adjusting the forks.
- Move the lift truck forward slowly (1) and bring the forks to stop in front of the load (fig.
E3), if necessary, slightly lift the jib (2) while taking up the load.
- Bring the load into the transport position.
- Tilt the load far enough backwards to ensure stability (loss of load on braking or going
downhill).
FOR A NON-PALLETIZED LOAD
- Tilt the carriage (1) forwards and move the lift truck slowly forwards (2), to insert the fork
under the load (fig. E4) (block the load if necessary).
- Continue to move the lift truck forwards (2) tilting the carriage (3) (fig. E4) backwards to
position the load on the forks and check the loads longitudinal and lateral stability.

E4

E3

1
2

2
3

1-15

E2

F - TAKING UP AND LAYING A HIGH LOAD ON TIRES

F1

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

2
1

TAKING UP A HIGH LOAD ON TIRES

- Ensure that the forks will easily pass under the load.
- Lift and extend the jib (1) (2) until the forks are level with the load, moving the lift truck (3)
forward if necessary (fig. F1), moving very slowly and carefully.
- Always think about keeping the distance necessary to fit the forks under the load, between
the pile and the lift truck (fig. F1) and use the shortest possible length of jib.
- Stop the forks in front of the load by alternately extending and retracting the jib (1) or, if
necessary, moving the lift truck forward (2) (fig. F2). Put the handbrake on and set the
forward/reverse selector to neutral.
- Slightly lift the load (1) and incline the carriage (2) backwards to stabilize the load (fig. F3).
- Tilt the load sufficiently backwards to ensure its stability.
- Watch the longitudinal stability 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).
- If this is not possible, back up the lift truck (1), manoeuvring very gently and carefully to
release the load. Retract (2) and lower the jib (3) to bring the load into the transport position
(fig. F5).

F2
1

F3
2

F4
1
2

F5
2

1-16

LAYING A HIGH LOAD ON TYRES

- Approach the load in the transport position in front of the pile (fig. F6).
- Put the handbrake on and set the forward/reverse selector to neutral.
- Lift and extend the jib (1) (2) until the load is above the pile, while keeping an eye on the
longitudinal stability 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.

F6

F7

2
1
3

F8

1
2

F9
1

F10

1-17

G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS

Depending on the model of lift truck
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see: INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE
ATTITUDE OF THE LIFT TRUCK).
REMINDER: Make sure that the following operations can be performed with good visibility (see: OPERATIONS INSTRUCTIONS UNLADEN
AND LADEN: D - VISIBILITY).
USING THE STABILIZERS
The stabilizers are used to optimise the lift trucks lifting performances (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).

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

G1

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

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

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

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

G3

This operation must be exceptional and performed with great care.

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

G4

1-18

TAKING UP A HIGH LOAD ON STABILIZERS

- Make sure the forks will fit easily under the load.
- Check the position of the lift truck with respect to the load and make a test run, if
necessary, without taking the load.
- Raise and extend the jib (1) (2) until the forks are at the level of the load (fig. G5).
- Block the forks in front of the load by alternately using the controls to extend and lower
the jib (1) (fig. G6).
- Lift the load slightly (1) and tilt the carriage (2) backwards to stabilise the load (fig. G7).
- Monitor the longitudinal stability 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).

G5

2
1

G6
1

G8

G7
2

2
1

LAYING A HIGH LOAD ON STABILIZERS

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

G10

G9

G11

3
2

1-19

H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD

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

I - TRAVELLING WITH A SUSPENDED LOAD

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

1-20

PLATFORM OPERATING INSTRUCTIONS

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

1-21

50 < U < 1000

1000 < U < 30000
30000 < U < 45000
45000 < U < 63000
63000 < U < 90000
90000 < U < 150000
150000 < U < 225000
225000 < U < 400000
400000 < U < 750000

DISTANCE ABOVE THE

GROUND OR THE FLOOR
IN METRES
2,30 M
2,50 M
2,60 M
2,80 M
3,00 M
3,40 M
4,00 M
5,30 M
7,90 M

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)
Force

Type of wind

Speed
(knots)

Speed
(kph)

Speed
(m/s)

0
1

Calm
Light air

0-1
1-3

0-1
1-5

< 0,3
0,3 - 1,5

Light breeze

4-6

6 - 11

1,6 - 3,3

7 - 10

12 - 19

3,4 - 5,4

11 - 16

20 - 28

5,5 - 7,9

29 - 38

8 - 10,7

3
4

Gentle
breeze
Moderate
breeze

Fresh breeze

17 - 21

Strong
breeze

22 - 27

Near gale

28 - 33

Gale

34 - 40

Strong gale

41 - 47

10

Storm

48 - 55

11

Violent
storm

56 - 63

12

Hurricane

64 +

Effects on Land
Smoke rises vertically.
The wind bends the smoke.
The wind can be felt on the face,
shakes the leaves.
The wind continuously shakes the
leaves and twigs.
The wind raises dust and scraps of
paper, shakes the twigs.
Leafy shrubs sway.

Sea condition
Sea like a mirror.
Ripples but without foam crests.
Small but evident wavelets.
Large wavelets Perhaps scattered
white horses.
Small waves. Fairly frequent white
horses.
Small waves form on inland waters.
Moderate waves, many white
horses.

Shakes thick branches, metal wires

Large waves begin to form, white
10,8 - 13,8 hum, it becomes difficult to keep an
foam crests, probably spray.
umbrella open.
Sea heaps up and white foam blown
Whole trees sway, it is difficult to
50 - 61 13,9 - 17,1
in streaks along the direction of the
walk against the wind.
wind.
Breaks the branches of trees, it is
Moderately high waves, crests begin
62 - 74 17,2 - 20,7 almost impossible to walk against
to break into spindrift.
the wind.
High waves. Dense foam along
Causes slight damage to buildings the direction of the wind. Crests of
75 - 88 20,8 - 24,4
(stacks, tiles, etc..).
waves begin to roll over. Spray may
affect visibility.
Rare inland, uproots trees, causes Very high waves with long overhanging
89 - 102 24,5 - 28,4
considerable damage to buildings.
crests. Visibility affected.
Exceptionally high waves that may
Very
rare,
causes
extensive
hide medium sized ships. Visibility
103 - 117 28,5 - 32,6
devastation.
affected.
The air is filled with foam and
spray. Sea completely white with
118 +
32,7 + Causes very serious catastrophes.
driving spray. Visibility very seriously
affected.
39 - 49

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

1-22

INSTRUCTIONS FOR USING THE RADIO-CONTROL

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

1-23

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

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

MAINTENANCE
- Perform the periodic service (see: 3 - MAINTENANCE) to keep your lift truck in good working conditions. Failure to perform the periodic
service may cancel the contractual guarantee.
MAINTENANCE LOGBOOK
- The maintenance operations carried out in accordance with the recommendations given in part: 3 - MAINTENANCE and the other
inspection, servicing or repair operations or modifications performed on the lift truck or its attachments shall be recorded in a
maintenance logbook. The entry for each operation shall include details of the date of the works, the names of the individuals or
companies having performed them, the type of operation and its frequency, if applicable. The part numbers of any lift truck items
replaced shall also be indicated.

LUBRICANT AND FUEL LEVELS

-

Use the recommended lubricants (never use contaminated lubricants).

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

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

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

1-24

WELDING
- Disconnect the battery before any welding operations on the lift truck.
- When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being
welded, so as to avoid high tension current passing through the alternator.
- Never carry out welding or work which gives off heat on an assembled tyre. The heat would increase the pressure which could
cause the tyre to explode.
- If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing
irreparable damage to electronic components.

WASHING THE LIFT TRUCK

-

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

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

1-25

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

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

PREPARING THE LIFT TRUCK

-

Clean the lift truck thoroughly.

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

PROTECTING THE I.C. ENGINE

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

PROTECTING THE LIFT TRUCK

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

1-26

BRINGING THE LIFT TRUCK BACK INTO SERVICE

-

Remove the waterproof adhesive tape from all the holes.

Refit the intake hose.
Refit and reconnect the battery.
Remove the protection from the cylinder rods.
Perform the daily service (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
Put the handbrake on and remove the axle stands.
Empty and replace the fuel and replace the fuel filter (see: 3 - MAINTENANCE: D - EVERY 500 HOURS SERVICE).
Refit and set the tension in the drive belts (see: 3 - MAINTENANCE: C - EVERY 250 HOURS SERVICE).
Turn the I.C. engine using the starter, to allow the oil pressure to rise.
Reconnect the engine cut-off solenoid.
Lubricate the lift truck completely (see: 3 - MAINTENANCE: SERVICING SCHEDULE).
Make sure the area is adequately ventilated before starting up the lift truck.

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

1-27

1-28

Content Page

2 - DESCRIPTION

2-1

2-2

TABLE OF CONTENTS
IDENTIFICATION OF THE LIFT TRUCK

2-6

CHARACTERISTICS

2-8

FRONT AND REAR TIRES

2-10

DIMENSIONS AND LOAD CHART

2-12

INSTRUMENTS AND CONTROLS

2-14

TOWING PIN AND HOOK

2-30

DESCRIPTION AND USE OF THE OPTIONS

2-32

2-3

IDENTIFICATION OF THE LIFT TRUCK

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

LIFT TRUCK MANUFACTURERS PLATE (FIG. A)

-

Model
Series
Serial Nr
Year of manufacture

MANITOU BF 44158 ANCENIS CEDEX FRANCE

MODELE
MODEL

MODELLO
MODELO

SERIE
SERIES

SERIE
SERIE

N de srie
Serial Nr

Anne de fabrication
Year of manufacture
Anno di fabbricazione
Ao de fabricacion

Numero di serie
Nmero de serie

Masse vide
Unladen mass

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

Puissance ISO 3046

Power ISO 3046
Potenza ISO 3046
Potencia ISO 3046

Massa a vuoto
Masa en vacio
kg

Numro d'homologation
Homologation number
Numero d'omologazione
Contrasea homologacion

kW
Effort vertical max. (sur accrochage remorque)
Vertical max. effort (on trailer hook)
Carico max. verticale (sul gancio di traino)
Esfuerzo vertical max. (sobre el gancho de remolque)
daN
Pression des pneumatiques (Bar)
Tyre pressure (Bar)
Pressione per pneumatici (Bar)
Presion de los neumticos (Bar)
Avant
Anteriore
Arrire Posteriore
Front
Adelante
Rear
Trasero

Capacit maxi nominale

Nominal maximum capacity
Capacit maxi nominale
Capacidad mximo nominal
kg
Effort de traction
Tractive effort
Forza di traino
Esfuerzo de traccion
daN

N283709

I.C. ENGINE (FIG. B)

- Model
- Serial Nr
- I.C. engine Nr

HYDROSTATIC PUMP (FIG. C)

-

MANITOU reference
Type of codification
Serial Nr
Manufacturers Nr
Year of manufacture

HYDROSTATIC MOTOR (FIG. D)

-

MANITOU reference
Type of codification
Serial Nr
Manufacturers Nr
Year of manufacture

2-6

FRONT AXLE (FIG. E)

- Type
- Serial Nr
- MANITOU reference

REAR AXLE (FIG. F)

- Type
- Serial Nr
- MANITOU reference

CAB (FIG. G)

- Type
- Serial Nr

JIB (FIG. H)

- MANITOU reference
- Date of manufacture

PLATE MANUFACTURER OF THE ATTACHMENT (FIG. I)

- Model
- Serial Nr
- Year of manufacture

MANITOU BF
44158 ANCENIS CEDEX
FRANCE

MODELE

N$ dans la srie

Anne fabrication

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

Cap. Nominale

Pression de service

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

N$207701

2-7

CHARACTERISTICS
I.C. ENGINE
Type
Fuel
Number of cylinders
Suction
Injection system
Ignition sequence
Capacity
Bore and stroke
Compression ratio
Nominal rating loaded
Rating slow unladen
Max. rating unladen
Power ISO 3046-1
Power SAE J 1995
Maximum torque ISO 3046-1
Air cleaner
Type of cooling
Fan

cm3 (cu/in)
mm (in)
rpm
rpm
rpm
cv- kW
cv- kW
N.m
m

TRANSMISSION
Hydrostatic pump
Type
Forward/reverse selector
Number of forward speeds
Number of reverse speeds
Main pump
MAX./MIN. displacement
MAX. flow rate
Working pressure
Boost pump
Capacity
MAX. flow rate
Boost pressure MAX. R.P.M.
Hydrostatic motor
Type
MAX./MIN. displacement
Gear box
Front axle
Differential
Rear axle
Differential
Drive wheels
Switch for 2/4 drive wheels
Front tyres
Size
Pressure
Rear tyres
Size
Pressure

KUBOTA V3307
Diesel
4 in line
Supercharged
Direct
1.3.4.2
3331 (203.3)
94 x 120 (3.7 x 4.7)
20
2600
895
2800
75 - 55,4
75 - 55,4
265 to 1400 rpm
3
By water
Puller

DANFOSS
Variable displacement piston
Electro-hydraulic
2 (1 low and 1 high)
2 (1 low and 1 high)
cm3/rev
l/mn (gl/mn)
bar (psi)
cm3/rev
l/mn (gl/mn)
bar (psi)
cm3/rev

bar (psi)
bar (psi)

0 - 45
117 (30.9)
400 (5802)
12
31 (8)
24 (348) (transmission in neutral)
DANFOSS
Variable displacement piston
23 - 80
DANA
DANA
45 % limited slip differential
DANA
Without locking
4RM Permanent
No
DUNLOP
12.0-18 12PR T86 Stabilarge TUBELESS
4,2 (61)
DUNLOP
12.0-18 12PR T86 Stabilarge TUBELESS
4,2 (61)

ELECTRIC CIRCUIT
Standard
Option

Battery
Alternator
Type
Starter
Type
SOUND AND VIBRATION
Level of sound pressure in the drivers cab LpA
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on drivers body
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the drivers hand/arm system
(according to standard ISO 5349-2)

2-8

12 V - 110 Ah - 750 A EN
-----12 V - 80 A
A5TA59 77B
12 V - 3 kW
M008T50671

dB

76 (cab closed)

dB

104 (measured)
104 (ensured)

m/s2
m/s2(ft/s2)

< 2,5 (< 8.2)

BRAKE CIRCUIT
Service brake
Type of brake
Type of control
Parking brake
Type of brake
Type of control

Non-servo hydraulic brake

Multidisk brake immersed in oil
By foot on front axle
Low pressure hydraulic brake
Multidisc brake immersed in oil
Switch-operated electro-hydraulic

HYDRAULIC CIRCUIT
Hydraulic pump
Type
Capacity
Max. rating capacity unladen
Flow rate at 1600 rpm
Filtration
Return
Suction
Maximum service pressure
Telescoping circuit
Lifting circuit
Tilt circuit
Attachment circuit
Steering circuit

cm3 (cu/in)
l/mn (gl/mn)
l/mn (gl/mn)
m
m
bar (psi)
bar (psi)
bar (psi)
bar (psi)
bar (psi)
bar (psi)

HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device
Lifting motions (jib retracted)
Unladen lifting
Laden lifting
Unladen lowering
Laden lowering
Telescoping motions (jib raised)
Unladen extending
Laden extending
Unladen retracting
Laden retracting
Tilting movements
Unladen digging
Forward tilting unladen

Double gear
1st chamber
2nd chamber
31 (1.9)
11 (.67)
86 (23)
31 (8)
49 (13)
18 (5)
10
125
235 (3408)
235 / 235 (3408)
235 / 235 (3408)
245 / 245 (3553)
235 (3408)
140 (2031)

10
125

Electronic

SPECIFICATIONS AND WEIGHTS

Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen
1 low
1 high
Rear unladen
1 low
1 high
Standard attachment
Weight of attachment (without forks)
Weight of forks (each one)
Rated capacity with standard attachment
Tipping load at maximum reach on tyres
Distance from the centre of gravity from the load to the lug of the forks
Standard lifting height
Lift truck weight without attachment
Lift truck weight with standard attachment
Unladen
At rated load
Weight per axle with standard attachment (transport position)
Front unladen
Rear unladen
Front rated load
Rear rated load
Weight per axle with standard attachment (jib extended)
Front rated load
Rear rated load
Authorised gross vehicle weight
Drag strain on the coupling hook
Unladen (sliding)
At rated load (transmission setting)
Pull strain with open carrier (according to standard ISO 8313)

2-9

s - m/mn
s - m/mn
s - m/mn
s - m/mn

7,3 - 32,1
7,45 - 31,4
4,95 - 47,3
5 - 46,8

s - m/mn
s - m/mn
s - m/mn
s - m/mn

5,2 - 24,8
5,3 - 25,3
3,7 - 35,5
3,75 - 35

s - /s
s - /s

3,2 - 40,1
3,2 - 40,1

km/h
km/h
km/h
km/h

9 (5.6)
25 (15.5)
9 (5.6)
25 (15.5)
PFB 25 N MT 1020
80 (176)
76 (168)
2500 (5512)

(mph)
(mph)
(mph)
(mph)

kg (lbs)
kg (lbs)
kg (lbs)
kg
Mm (in)
Mm (in)
kg (lbs)
kg (lbs)
kg (lbs)
kg
kg
kg
kg

(lbs)
(lbs)
(lbs)
(lbs)

500 (20)
5900 (232)
4690 (10340)
4922 (10851)
7422 (16363)
2362
2560
6622
800

(5207)
(5644)
(14599)
(1764)

kg (lbs)
kg (lbs)
daN (lbf)

5212 (11490)
510 (1124)
21000 (47210)

daN
daN
daN (lbf)

4205 (945)

FRONT AND REAR TIRES

PRESSURE
bar(psi)
DUNLOP
GOODYEAR
MICHELIN

12.0-18 12PR T86 Stabilarge

TUBELESS
12.5/80-18 SGI 14PR 134A6
TUBELESS
280/80R20 133A8 133B XMCL
TUBELESS

FRONT UNLADEN

TYRE LOAD kg(lbs)

FRONT LADEN
REAR UNLADEN

REAR LADEN

3300(7275)

400(882)

4,2(61)
4,9(71)

1200(2646)

1300(2866)

4,4(64)

PRESSURE
LOADkg(lb)
(bar(psi)

DUNLOP

12.0-18 12PR T86 Stabilarge

TUBELESS

4,2(61)

GOODYEAR

12.5/80-18 SGI 14PR 134A6

TUBELESS

4,9(71)

MICHELIN

280/80R20 133A8 133B XMCL

TUBELESS

4,4(64)

400
1200
1300
3300
400
1200
1300
3300
400
1200
1300
3300

2-10

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

kg/cm2 (lbs/in2)
cm2 (in2)
HARD SOIL
LOOSE SOIL
HARD SOIL
LOOSE SOIL
5,79(82)
1,88(27)
69(11)
214(33)
7,79(110)
2,50(36)
154(24)
480(74)
8,13(116)
2,60(37)
160(25)
500(78)
11,05(157)
3,80(54)
299(46)
869(135)

2-11

DIMENSIONS AND LOAD CHART

D1

N
P2

G2

G1

D2
C

D
E
J

F1

V1

V2

2-12

U2

U1

C1

P3

1200(47.2)
2300(90.6)
991(39)
928(36.5)
3894(153.3)
3831(150.8)
3393(133.6)
5094(200.6)
1500(59)
1500(59)
318(12.5)
378(14.9)
322(12.7)
603(23.7)
797(31.4)
1015(40)
45(1.8)
1398(55)
125(4.9)
45
65
3033(119.4)
6531(257.1)
3475(136.8)
2000(78.7)
2167(85.3)
4240(166.9)
765(30.1)
3190(125.6)
1814(71.4)
12
117

A mm(in)
B mm(in)
C mm(in)
C1 mm(in)
D mm(in)
D1 mm(in)
D2 mm(in)
E mm(in)
F mm(in)
F1 mm(in)
G mm(in)
G1 mm(in)
G2 mm(in)
mm(in)
I
mm(in)
J
K mm(in)
L mm(in)
N mm(in)
O mm(in)
()
P2
()
P3
R mm(in)
S mm(in)
T mm(in)
U1 mm(in)
U2 mm(in)
V mm(in)
V1 mm(in)
V2 mm(in)
W mm(in)
()
Y
()
Z

INSTRUMENTS AND CONTROLS

25
22

22

21
21
20

15

12

7
15

18 19
156

24
28

4
17

16

37

5
2
1

27
11

26
30

10

30

33

35
36
34
23

2-14

DESCRIPTION
1
2
3
4
5
6

DRIVERS SEAT
SAFETY BELT
IGNITION SWITCH
EMERGENCY STOP BUTTON
BATTERY CUT-OFF
MAN-MACHINE INTERFACE (MMI)
6A- CONTROL PANEL
6B - SCREEN DISPLAY
7 - SWITCHES
8 - ARMREST AND STORAGE
9 - FUSES AND RELAYS IN THE CAB
10 - FUSES AND RELAYS UNDER THE ENGINE HOOD
11 - CIGAR LIGHTER
12 - LIGHT SWITCH, HORN AND INDICATOR SWITCH
13 - FRONT AND REAR WINDSCREEN WIPER SWITCH
14 - FUNCTION FILES
15 - HYDRAULIC CONTROLS
16 - ACCELERATOR PEDAL
17 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
18 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
19 - STEERING SELECTION
20 - HEATER CONTROL
20 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
21 - HEATING VENTS
22 - WINDSCREEN DEMISTER VENTS
23 - LEVEL INDICATOR
24 - DOOR LOCK
25 - DOOR WINDOW OPENING HANDLE
26 - DOOR WINDOW RELEASE BUTTON
27 - HANDLE FOR REAR WINDOW OPENING
28 - STEERING WHEEL ADJUSTMENT LEVER
29 - DOCUMENT HOLDER NET
30 - REAR STORAGE SPACE
31 - FRONT LIGHTS (NOT ILLUSTRATED)
32 - REAR LIGHTS (NOT ILLUSTRATED)
33 - REVOLVING LIGHT
34 - ROOF LIGHT
35 - ROOF SCREENWIPER SWITCH
36 - SUN VISOR
37 - DIAGNOSTIC CONNECTOR
NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are meant for an observer seated on drivers seat and looking in front of
him.

2-15

1 - DRIVERS SEAT (STANDARD)

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

WEIGHT ADJUSTMENT (FIG. A)
Adjust the weight when the driver is sitting on the seat.
- Pull the weight adjustment lever 1 fully out.
- Move the weight adjustment lever 1 up to increase the weight or down to reduce it.
- There are ten possible positions between the min and max weights. Before each run,
return the lever to the central position. The max. or min. position is indicated by a freely
travelling lever.
- The driver's weight is correctly adjusted when the jib is in the centre of indicator 2.
- After completing weight adjustment, fully lower the lever 1.
NOTE: To avoid any health problems, it is recommended that the weight should be checked
and adjusted before starting up the lift truck.

2
1

LONGITUDINAL ADJUSTMENT (FIG. B)

- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
Only operate the lever by its recessed section and do not grasp from below, at the risk of crushing
the hand.
LUMBAR ADJUSTMENT (FIG. C)
This increases the comfort of the seat and the drivers freedom of movement.
- Turn the knob to 1 to adjust the height and depth of the lumbar support of the upper part
of the back-rest.
- Turn the knob to 2 to adjust the height and depth of the lumbar support of the lower part
of the back-rest.
C
ANGLE ADJUSTMENT OF THE BACK-REST (FIG. D)
- 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 will swing forwards.
MAINTENANCE
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- The cushions do not require to be removed from the seat frame for cleaning.
A rocking head-rest increases the risk of an accident!
First check the resistance of the fabric on a small concealed area before using any fabric
and plastic cleaner.

2-16

1 - PNEUMATIC DRIVER'S SEAT (OPTION)

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

WEIGHT AND SEAT HEIGHT ADJUSTMENT (FIG. A)
Adjust the weight when the driver is sitting on the seat.
- Switch on lift truck ignition.
- Move the weight adjustment lever 1 up to increase the weight or down to reduce it.
- The min and max weight can be set by engaging the upper or lower limit switch.
- The driver's weight is correctly adjusted when the jib is in the centre of indicator 2.
- The seat height can be adjusted within this zone.
NOTE: To avoid any health problems, it is recommended that the weight should be checked
and adjusted before starting up the lift truck.
To avoid causing any damage, do not activate the compressor for over 1 minute.

2
1

LONGITUDINAL ADJUSTMENT (FIG. B)

- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
Only operate the lever by its recessed section and do not grasp from below, at the risk of crushing
the hand.
LUMBAR ADJUSTMENT (FIG. C)
This increases the comfort of the seat and the drivers freedom of movement.
- Turn the knob to 1 to adjust the height and depth of the lumbar support of the upper part
of the back-rest.
- Turn the knob to 2 to adjust the height and depth of the lumbar support of the lower part
of the back-rest.

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

- 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 will swing forwards.
MAINTENANCE
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- The cushions do not require to be removed from the seat frame for cleaning.
A rocking head-rest increases the risk of an accident!
First check the resistance of the fabric on a small concealed area before using any fabric
and plastic cleaner.

2-17

2 - SAFETY BELT
-

Sit correctly on the seat.

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

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

4 - EMERGENCY STOP BUTTON

- In the event of danger, it lets you stop the I.C. Engine and thereby cut out all hydraulic
movements.
- Pull the button to disable it before restarting the lift truck.
Be ready for hydraulic movements suddenly stopping when you press this button.
Warning, when driving, the lift truck will be brought to a sudden stop. If possible, stop the lift truck before
using the emergency stop.

5 - BATTERY CUT-OFF
- For quickly disconnecting the battery when working on the electric circuit or when soldering,
for example.

6 - MAN-MACHINE INTERFACE (MMI)

6A - CONTROL PANEL
6B - SCREEN DISPLAY
V

6A - CONTROL PANEL

F %
C

am
pm

A permanently lit or flashing warning lamp, with the engine running, is the sign of an
operating fault. The lighting of some lamps may be accompanied by an audible signal.
Do not ignore this warning, consult your dealer without delay. If one of the warning
lamps comes on while the lift truck is in motion, stop the lift truck under the safest
possible conditions.
When activating the electrical system of the lift truck, all the red and orange
lamps and the panel's buzzer must light to indicate their good working
order. If one of the red lamps or the buzzer does not function, carry out the
necessary repairs.
2-18

mph
miles
rpm
km/h

milesmph
rpm km/h

RAZ

REV COUNTER
10 level leds display from 0 to 3,000 rpm.

I.C. ENGINE WATER TEMPERATURE

Temperature zones:
1 led - (< 40 C) 104 F zone. Use the lift truck with moderation, wait for temperature to increase before normal operation.
2 leds - (40 C - 60 C) 104 F - 140 F zone.
3 leds - (60 C - 80 C) 140 F - 176 F zone.
4 leds - (80 C - 85 C) 176 F - 185 F zone.
5 leds - (85 C - 90 C) 185 F - 194 F zone.
6 leds - (90 C - 95 C) 194 F - 203 F -zone from 40 C to 95 C (140 F - 203 F) use the lift truck normally.
7 leds - (95 C - 105 C) 203 F - 221 F zone. Use the lift truck with moderation.
8 leds - (105 C - 110 C) 221 F - 230 F zone. Use the lift truck with moderation, ventilation control operating at full speed.
9 leds - Red zone (110 C - 115 C) 230 F - 239 F.
10 leds - Red zone (> 115 C) > 239 F Stop the lift truck, seek the cause of overheating.
and the buzzer come on (> 110 C) 230 F when the lift truck is running, stop the I.C. engine immediately and seek
NOTE: The red lamp
the cause of the failure in the cooling system.
FUEL LEVEL
When only one led remains displayed, the orange indicator lamp
and that your operating time is limited.

comes on, indicating that you using the reserve fuel supply

FORWARD/NEUTRAL/REVERSE LIGHT
See: 2 - DESCRIPTION: 19 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION.
RED PARKING BRAKE LAMP
This lamp comes on when the parking brake is applied (see: 2 - DESCRIPTION: 8 - SWITCHES).
RED BRAKING OIL LEVEL LAMP
If the lamp comes on, when the lift truck is running, stop the I.C. engine immediately and check the braking oil level. In the event
of an abnormal drop in the level, consult your dealer.
RED GENERAL FAULT WARNING INDICATOR LIGHT
If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and consult your dealer.

ORANGE TRANSMISSION OIL TEMPERATURE WARNING INDICATOR LIGHT

The lamp and the buzzer come on when the transmission oil temperature is abnormally high. Stop the lift truck and look for the
cause of this overheating.
ORANGE HYDRAULIC OIL FILTER CLOGGING LAMP WARNING 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 lift
truck and carry out the necessary repairs (see cleaning and replacement requirements in chapter: 3 - MAINTENANCE: FILTERS
CARTRIDGES AND BELTS).
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
(see oil level in I.C. engine crankcase).
ORANGE AIR FILTER CLOGGING INDICATOR LAMP
The lamp and buzzer come on when the air filter cartridge is clogged up. When this lamp comes on, the cartridge needs changing.
Stop the lift truck and carry out the necessary repairs (see cleaning and replacement intervals in chapter: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS: SERVICING SCHEDULE).

ORANGE I.C. ENGINE PREHEATING INDICATOR LIGHT

If preheating is required, the lamp comes on when the lift truck's ignition is switched on and should go out as soon as pre-heating
is ended. If this lamp comes on while the lift truck is in operation, immediately stop the I.C engine and find the cause.

2-19

RED BATTERY CHARGE 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.).
GREEN DIRECTION INDICATOR LAMP
BLUE MAIN BEAM LAMP

6B - SCREEN DISPLAY
V

V
mph
miles
rpm

F %
C

am
pm

km/h

F %
C

UPPER SCREEN DISPLAY

am
pm

milesmph
rpm km/h

mph
miles
rpm
km/h

milesmph
rpm km/h

LOWER SCREEN DISPLAY

SCROLL BUTTON

RAZ

RAZ

VALIDATION, RESET AND ERROR CODE BUTTON

UPPER SCREEN DISPLAY

Switch on the lift truck ignition, by default, the screen will show the time. Press the scroll button to switch from one screen to the
other in turn.

mph

%
rpm

am
pm

km/h

Clock (see adjustment).

Rev counter.

Attachment circuit
hydraulic flow rate
(see: 16 - HYDRAULIC
FLOW RATE).

Lift truck speed

(see your dealer
for adjustment).

Partial hour meter

(see resetting).

SETTING THE TIME

- Display clock screen.
- Press the button

for 2 seconds, choose the "24 hour" or "12 hour am/pm" clock with the button

- Rgler les heures avec le bouton

et valider

- Set the minutes with the button

and confirm

and confirm

.
.

RESETTING THE PARTIAL HOUR METER

- Display the partial hour meter screen.
- Press the button

for two seconds, resetting is confirmed by a beep.

LOWER SCREEN DISPLAY

Switch on the lift truck ignition, by default, the screen will show the hour meter
, i.e. the total number of hours the
lift truck has been used. As soon as the engine is running, the flashing pictogram records the hours of operation.
MAINTENANCE INTERVAL
will logically be displayed to provide a reminder to replace the
NOTE: When the new lift truck is started, the maintenance key
engine oil and the oil filter after the first 50 hours of operation (see: 3 - MAINTENANCE: SERVICING SCHEDULE).

The maintenance key

an audible beep.

appears on the hour meter screen

50 hours before the maintenance deadline and generates

- Press the button

to display the remaining time before maintenance
the hours are shown with a plus sign.

2-20

. In the event that the deadline is exceeded,

- Press once more on the button

to return to the hour meter screen. The maintenance key
will be displayed
for information.
- Contact your dealer to carry out the necessary maintenance operations and reset the maintenance interval.
NOTE: The frequency interval displayed by default is 500 hours, this interval can be modified. Please contract your dealer.
ERROR CODES

The appearance of the maintenance key

on the hour meter screen
together with the sounding of an audible beep,
indicate that an anomaly has been detected by one of the lift truck's Electronic Control Units (ECU).

- Press the button

to display the information

- If there are several error codes, press the button

on the upper screen and error code

to loop through the error codes.

- Press the button

once more to return to the hour meter screen, the maintenance key
remains displayed as long the
as the required repairs have not been carried out.
- Contact your dealer, stating the error code or codes.
NOTE: A faulty fuse can generate several error codes. When "error codes" and "maintenance interval" are displayed together,
the maintenance reminder time will appear at the end of the list.
ERROR CODE
520201
520214
520215
520217
520218
520224
520225
520226
520227
520273
520274
520275
520276
520277
520281
ERROR CODE
190
520400
520401
520402
520404
520405
520406
520407
520408
520409
520410
520411
520412
520413

HYDROSTATIC TRANSMISSION
Hydraulic transmission electronic control unit voltage fault.
Hydraulic transmission electronic control unit fault.
Hydrostatic motor regulator control fault.
Stop light control fault.
Hydraulic motor speed sensor.
Hydrostatic motor operating solenoid valve control fault.
Hydraulic transmission electronic control unit fault.
Hydraulic transmission electronic control unit fault.
Hydraulic transmission electronic control unit fault.
Forward/reverse selector error.
Inching sensor error.
Hydrostatic pump reverse operation control fault.
Hydrostatic pump forward operation control fault.
Hydraulic pump speed sensor fault.
Temperature outside operating range.
MAN-MACHINE INTERFACE
Engine speed data fault.
Network link fault.
Fuel gauge fault.
Engine temperature sensor fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Man-Machine Interface fault.
Hydrostatic transmission network link fault.
Electronic handling controller network connection fault.

ERROR CODE
2662
2663
520300
520307
520310
520315
520318
520336
520337
520338
520341
520350
520351
520352
520362
520363
520364
520365
520366
520370
520371
520376
520382
520383
520384
520386
520387
520388
520391
520392
520393
520394
520395
520396
520397
520398

2-21

TELESCOPE/ATTACHMENT
Telescope control setting fault.
Attachment control setting fault.
Seat sensor fault.
Proportional telescope control fault.
Proportional attachment control fault.
Telescope control ON/OFF fault.
Attachment control ON/OFF fault.
Electronic handling controller fault.
Electronic handling controller fault.
Electronic handling controller temperature fault.
Attachment selector fault.
Proportional ventilation adjustment fault.
Ventilation ON/OFF adjustment control fault.
Attachment forced operation control fault.
Electronic handling controller 10V output fault.
Attachment forced operation indicator fault.
Attachment hydraulic control button fault.
Attachment easy hydraulic connection button.
Solenoid valve on jib head fault.
Telescope retracted sensor fault (fault detected during test).
Electronic handling controller temperature fault.
Stability indicator fault.
Aggravating hydraulic movement cut-off disable fault
Computer earth output fault.
Telescope retracted senor fault.
Jib angle sensor fault.
Strain gauge fault.
Network communication fault.
Inclination cut-off valve fault.
Angle calibration fault (fault detected during test).
Gauge calibration fault (fault detected during test).
Safety valve fault.
Safety valve cut-off fault (fault detected during test).
Lowering regulating valve fault.
Regulating fault (fault detected during test).
Raising regulating valve fault.

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

N
A

A - WARNING LIGHTS

B - REAR FOG LIGHTS

C - REVOLVING LIGHT
D - FRONT AND REAR WORKING LIGHTS
OPTION JIB HEAD LIGHTS
E - OPTION REAR WINDOW DE-ICING
F - NEUTRALISATION OF HYDRAULIC MOVEMENTS
When driving on the road, it is highly recommended (mandatory in Germany) that you cut-off
all the hydraulic movements. The lamp shows when it is in use.
G - GEAR SELECTION
Gears can be selected while driving.
SLOW SPEED: Use for handling, switch in the up position, the indicator lamp
is off.
HIGH SPEED: Use on the road, switch in down position, the high speed indicator
lamp comes on.
H - WHEEL ALIGNMENT INDICATOR LAMPS
See: 2 - DESCRIPTION: 20 - STEERING SELECTION.
I - PARKING BRAKE
To connect the parking brake, press the bottom of the switch. The indicator lamp shows it is in use. To disconnect the parking
brake, press the top of the switch.
J - DISABLING THE "AGGRAVATING" HYDRAULIC MOVEMENT CUT-OFF
See: 2 - DESCRIPTION: 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE.
K - OPTION ATTACHMENT HYDRAULIC LOCKING DEVICE
OR
OPTION JIB HEAD SOLENOID VALVE
OR
OPTION JIB HEAD SOLENOID VALVE + ATTACHMENT HYDRAULIC LOCKING DEVICE
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
L - OPTIONAL ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
M - OPTION BLUE HEADLIGHTS
OR
OPTION ELECTRICAL JIB PROVISION
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
N - REVERSIBLE VENTILATION CONTROL
The system cleans the radiator core and the grille of the engine cover by reversing the
air flow.
Position A: The indicator light is on, the fans rotation is reversed for a few seconds
every 3 minutes.
Position B: The indicator light is off, the fan is in normal operating mode.

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

1

8 - ARMREST AND STORAGE

- Lift the armrest 1 to access the storage.

2-22

9- FUSES AND RELAYS IN THE CAB

A fuse function file and a relay function file give a quick indication of the use of the panel's
components described below.
- Lift the armrest.
- Remove the access panel 1 to access the fuses and relays.

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

2-23

F1

7.5A

F11

15A

F21

5A

F31

20A

F2

5A

F12

5A

F22

5A

F32

15A

F3

5A

F13

15A max

F23

15A

F33

5A

F4

10A

F14

7.5A

F24

15A

F34

7.5A

F5

10A

F15

10A

F25

7.5A

F35

10A

F6

10A

F16

7.5A

F26

7.5A

F36

3A

F7

15A

F17

15A

F27

10A

F37

10A

F8

5A

F18

15A

F28

10A

F38

15A

F9

15A

F19

30A

F29

10A

F39

7.5A

F10

5A

F20

20A

F30

25A

F40

20A
N290580

F1 - Control instrument module (7,5A).

F2 - Stop I.C. engine solenoid valve (5A).
- Alternator charge (5A).
- Longitudinal stability limiter and warning device (5A).
F3 - Diagnostic socket (5A).
- Anti-theft device provision (5A).
F4 - Transmission electronic control unit (10A).
- Telescoping and attachment movement control (10A).
- Negative parking brake solenoid valve (10A).
- Gear selection (10A).
F5 - Cigarette lighter (10A).
- OPTION Car radio (10A).
F6 - Driver present on seat (10A).
- Jib retracted and angle sensors (10A).
F7 - Hydraulic electronic control unit power supply (15A).
F8 - Inclination movement neutralization system supply (5A).
- "Aggravating" hydraulic movement cut-off deactivation (5A).
- OPTION Inclination movement neutralization system supply (5A).
F9 - Stop light relay supply (15A).
- Reversing light relay supply (15A).
- OPTION Reverse buzzer alarm relay supply (15A).
F10 - Wheel alignment (5A).
F11 - Flashing unit (15A).
F12 - Rear fog lights (5A).
F13 - OPTION Working lights on jib (15A).
F14 - Revolving light (7,5A).
F15 - OPTION Rear window defrosting (10A).
F16 - OPTION Jib head solenoid valve (7,5A).
- OPTION Jib head solenoid valve + attachment hydraulic locking
device (7,5A).
F17 - Rear windscreen wiper and washer + Roof windscreen wiper (15A).
F18 - Front windscreen wiper and windscreen washer (15A).
F19 - Power supply F27-F28-F29-F30 (30A).
F20 - Heating (20A).
F21 - Left sidelights (5A).
- Cigarette lighter light power supply (5A).
F22 - Right sidelight (5A).
- Control panel lighting (5A).
F23 - Low beam (15A).
F24 - Main beam (15A).
F25 - Right indicators (7,5A).
F26 - Left indicators (7,5A).
F27 - OPTION Jib base electrical provision (10A).
F28 - Ventilation control (10A).
F29 - OPTION Pneumatic seat (10A).
F30 - Front and rear working lights (25A).
- OPTION Blue headlights (25A).
F31 - Lights, horn and indicator switch (20A).
F32 - Warning lights (15A).
F33 - Diagnostic socket (+) permanent (5A).
- Anti-theft device provision (+) permanent (5A).
F34 - Alarm (7,5A).
- Roof light (7,5A).
F35 - OPTION Car radio (+) permanent (10A).
F36 - Hydraulic electronic control unit power supply (3A).
F37 - Rear windscreen wiper (+) permanent (10A).
F38 - Front windscreen wiper (+) permanent (15A).
F39 - OPTION Air conditioning compressor relay power supply (7,5A).
F40 - OPTION Air conditioning fan motor relay power supply (20A).

K1 - Not used.
K2 - Reversing light relay.
- OPTION Reverse sound alarm relay.
K3 - Stop light relay.
K4 - OPTION Jib-mounted working light relay
K5 - OPTION Air conditioning fan motor relay.
K6 - OPTION Air conditioning compressor relay.
K7 - Starting system safety relay.
K8 - Flashing unit.
K9 - OPTION Working light/blue headlight relay.
K10 - OPTION Air conditioning relay.

K3

K6
K10

OPT.

K8

STOP

OPT.
K2

K5
OPT.

K9

R
R

K7
K4

K1

OPT.

A.S.

N290571

OPT.

10 - FUSES AND RELAYS UNDER THE ENGINE HOOD

Open the engine bonnet, remove the cover 1 to access fuses and relays.
A sticker on the inside of the cover gives a quick indication of the use of the panel's
components described below.
Always replace a faulty fuse with another of equivalent rating. Never use a fuse that has been repaired.
F41
F42
F43
F44
F45
F46

Not used.
Ignition switch (60A).
Alternator (80A).
Power supply for fuses in the cab (50A).
Not used.
Preheating I.C. engine (40A).

F51
F52
F53
F54
F55
F56
F57
F58
F59
F60

Not used.
Not used.
Not used.
Not used.
Starter solenoid (20A).
Not used.
Not used.
Not used.
Not used.
Not used.

F46
F45

OPT.

F44

40A

F51

F56

20A

F52

F57

50A

F53

F58

CAB

F54
F43

80A

F42

60A

F59

F55

F60

20A

K20

F41

N 286287

K20 - Engine preheating relay.

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

12 - LIGHTING, HORN AND INDICATOR SWITCH

The switch controls the visual and sound alarms.
A - All lights are off, the direction indicators do not flash.
B - The right hand direction indicators flash.
C - The left hand direction indicators flash.
D - The sidelights and the rear lights are on.
E - The dipped headlights and the rear lights are on.
F - The main beam headlights and the rear lights are on.
G - Headlight signal.
Pressing the switch sounds the horn.
NOTE: The positions D - E - F - G can be carried out without the ignition being on.

2-24

B
G

A
C
A

13 - FRONT AND REAR WINDSCREEN WIPER SWITCH

F

FRONT WINDSCREEN WIPER

A - Front windscreen wiper stop.
B - Slow speed for front windscreen wiper.
C - Fast speed for front windscreen wiper.
D - Front windscreen wiper intermittent control.
E - Front windscreen washer, pulse-driven.
REAR WINDSCREEN WIPER
F - Rear windscreen wiper stop.
G - Rear windscreen wiper.
H - Rear windscreen washer, pulse-driven.

H
E

14 - FUNCTION FILES
These files contain, among other things, the description of the hydraulic controls and the load charts for the attachments used
on the lift truck.

15 - HYDRAULIC CONTROLS
A

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 NUL AND VOID.
Use the hydraulic controls carefully without jerking, to avoid accidents caused by shaking the
lift truck.

B
C

NOTE: When driving on the road, it is highly recommended (mandatory in Germany) that you
cut-off all the hydraulic movements (see: 2 - DESCRIPTION 8 - SWITCHES).
A - Lifting and tilting control lever.
B - Telescoping control button.
C - Attachment control button.

N26277

LIFTING THE LOAD

- The lever A backwards when lifting.
- The lever A forwards when lowering.
TILT OF CARRIAGE
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Button B forwards for extending.
- Button B backwards for retracting.
ATTACHMENT
- Button C forwards or backwards.
ADJUSTMENT OF ATTACHMENT HYDRAULIC FLOW RATE
- Switch on lift truck ignition.
%

- Select the attachment circuit hydraulic flow rate screen

with the scroll

button
. The screen displays, in turn, the hydraulic flow rate stored in the memory
of circuit B (without "-" sign) and of circuit A (with "-" sign).

- Press the button

for two seconds, the screen
will appear on the lower
screen display.
- Turn button C forward to select a hydraulic flow rate for circuit B of between 10 % and 100 %.
C

- Hold button C at the desired flow rate and confirm with the button

- The screen
appears on the lower screen display.
- Turn button C backwards to select a hydraulic flow rate for circuit A between -10 % and -100 %.
- Hold button C at the desired flow rate and confirm with the button

- The hour meter screen

appears on the lower display screen, confirming that adjustment is completed.

2-25

16 - ACCELERATOR PEDAL
17 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
The pedal acts on the front wheels by means of a hydraulic brake system enabling the slowing down and stopping of the lift truck.
During clearance travel it enables the transmission to be cut off progressively thus allowing a gradual approach (delicate handling)
with all the I.C. engine power.

18 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION

When operating this control, the lift truck should be travelling at slow speed and not
accelerating.
FORWARD: Push the knob forward (position A).
REVERSE: Pull the knob backward (position B). An OPTIONAL reversing light and audible
reversing alarm indicate that the lift truck is travelling in reverse.
or
are flashing, pass the forward/reverse selector
NEUTRAL: If indicators
back through neutral (position C).

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.
To stop the lift truck, he must observe the following sequence:
1 - set the forward/reverse selector to neutral,
2 - engage the parking brake,
3 - get out of the lift truck.

- If the operator leaves the driving cab with forward or reverse engaged, the screen
will appear and beep will sound
for two seconds. During this time, the operator can sit back down in the seat and continue advancing or reversing. When this time
or
will flash. The operator must
is exceeded, the forward/reverse selector will switch to neutral and the indicators
sit back down and pass the forward/reverse selector back through neutral.

19 - STEERING SELECTION
A - GREEN WHEEL ALIGNMENT LAMPS
These lamps come on to indicate the alignment of the wheels in relation to the lift truck.
Lamp A1 for the front wheels and lamp A2 for the rear wheels.

A1

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.
A2

B - STEERING SELECTION LEVER

B1 - Front drive wheels (highway traffic).
B2 - Front and rear drive wheels in opposite direction (short steering lock).
B3 - Front and rear drive wheels in the same direction (crab steering).
CONTROL FOR ALIGNMENT OF THE WHEELS.
- Shift the steering selection lever B into position B2 (short steering lock).
- Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up.
- Shift the steering selection lever B into position B1 (highway traffic).
- Turn the steering wheel and bring the front wheels into alignment until lamp A1 lights up.
Before driving on roads, it is necessary to check the alignment of the rear wheels and to drive in front
wheel steer. The control of the alignment of the rear wheels must be regularly done with the help of the
green lamps, while driving the lift truck. In case of anomalies, consult your dealer.

2-26

B3

B1

B2

20 - HEATER CONTROL
A - FAN CONTROL
This 3-speed control allows the air to be ventilated through the air vents.

B - TEMPERATURE CONTROL
Allows the temperature inside the cab to be adjusted.
B1 - The fan pumps in the air at ambient temperature.
B2 - The fan pumps in warm air.
The intermediate positions allow the temperature to be adjusted.

B1

B2
B

20 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)

The air conditioning only works if the lift truck has been started up. When using your air conditioning
unit you must work with the cab closed off.
In winter: So as to ensure correct operation and complete efficiency of the air conditioning unit,
start up the compressor once a week, if only for a short spell, so as to lubricate the internal seals.
In cold weather: Warm the I.C. engine before switching on the compressor, so as to allow the
coolant that has collected in a 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 a liquid state.

B1

B2
B

If your air conditioning does not seem to be working correctly, have it examined by your dealer (see: 3
- MAINTENANCE: F - EVERY 2000 HOURS OF SERVICE). Never try to repair any faults yourself.
A - FAN CONTROL
This 3-speed control allows the air to be ventilated through the air vents.
B - TEMPERATURE CONTROL
Allows the temperature inside the cab to be adjusted.
B1 - The fan pumps in cold air.
B2 - The fan pumps in warm air.
The intermediate positions allow the temperature to be adjusted.
C - AIR CONDITIONING CONTROL
This control with a pilot light allows the air conditioning unit to be switched on.
HEATING MODE
The controls must be adjusted in the following way:
C - Control with pilot light off.
B - At the required temperature.
A - At the desired speed: 1, 2 or 3.
CONDITIONED AIR MODE
The controls must be adjusted in the following way:
C - Control with pilot light on.
B - At the required temperature.
A - At the desired speed: 1, 2 or 3.
DEMISTING MODE
The controls must be adjusted in the following way:
C - Control with pilot light on.
B - At the required temperature.
A - At speed 3.
For optimum effectiveness, close the heating ventilators.

2-27

21 - HEATING VENTS
These swivelling heating vents, which can be shut off, allow you to direct and adjust the flow rate inside the cab.

22 - DEMIST VENTS
These vents allow the front windscreen and side windows to be demisted. For optimum efficiency, shut off the heating vents.

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

24

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

25 - DOOR WINDOW OPENING HANDLE

26 - DOOR WINDOW RELEASE BUTTON
27 - HANDLE FOR REAR WINDOW OPENING
EMERGENCY EXIT
Use the rear window as an emergency exit, if it is impossible to leave the cab by the door.

28 - STEERING WHEEL ADJUSTMENT LEVER

This handle enables the angle and height of the steering wheel to be adjusted.
- Pull the knob 1 backwards.
- Adjust the steering wheel to the desired position.
- Push the knob back to lock the steering wheel in position.

29 - DOCUMENT HOLDER NET

Make sure that the operators manual is in the right place, i.e. in the document holder net.
NOTE: An OPTION waterproof document-holder exists.

30 - REAR STORAGE SPACE

2-28

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

F
E

A
C

32 - REAR LIGHTS
A - Left rear indicator.
B - Left rear stoplight.
C - Left tail light.
D - Rear fog light
E - Reversing light.
F - Right tail light.
G - Right rear stoplight.
H - Right rear indicator.

A
B

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

34 - ROOF LIGHT
35 - ROOF SCREENWIPER SWITCH
36
35

36 - SUN VISOR
37 - DIAGNOSTIC CONNECTOR
38

2-29

TOWING PIN AND HOOK

Located at the rear of the lift truck, this device is used to attach a trailer. Its capacity is limited for each lift truck by the
authorised gross vehicle weight, tractive effort and maximum vertical force on the coupling point. This information is given on the
manufacturer's plate fixed to each lift truck (see: 2 - DESCRIPTION: IDENTIFICATION OF THE LIFT TRUCK).
- To use a trailer, see current regulations in your country (maximum running speed, braking, maximum weight of trailer, etc.).
- Verify the trailer's condition before using it (tyre condition and pressures, electrical connection, hydraulic hose, brake system).
Do not tow a trailer or attachment which is not in perfect working order. Using a trailer in poor condition may affect the lift truck's steering and braking,
and hence safety.
If a third party helps in coupling or uncoupling the trailer, this person must be permanently visible to the driver and wait until the lift truck has stopped,
the handbrake is on and the I.C. engine is switched off before performing the operation.
NOTE: There is an OPTIONAL rear-view mirror which allows the lift truck to be approached more closely to the trailer ring.

A - TOWING PIN
2

COUPLING AND UNCOUPLING THE TRAILER

- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- 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 the trailer or the light bar are working properly.
A - Left rear indicator.
B - Rear fog lights.
C - Earth.
D - Right rear indicator.
E - Right tail light.
F - Rear stop light.
G - Left rear light and number plate.

A
B

G
E

C
D

C - COUPLING FITTING (OPTION)

COUPLING AND UNCOUPLING THE TRAILER
- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- 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.

2-30

2-31

DESCRIPTION AND USE OF THE OPTIONS

1- PREHEATING ELEMENT
Enables the engine block to be kept warm during prolonged periods of stoppage and thus
improves engine starting.
SUPPLY CHARACTERISTICS OF PREHEATING SYSTEM:
Rated range of power: 220-240V ; 50-60Hz
Current consumption: 4,5A
Class 1 equipment
Equipment connectable only to Earth-Earth (TT) or Earth-Neutral (TN) circuits
Installation category 2
ENVIRONMENTAL CONDITIONS FOR USE:
Maximum ambient temperature for using preheating: +25C (77F)
Pollution level 2
CONDITIONS FOR CONNECTION AND USE OF PREHEATING:
- The preheating system should not be used for an external ambient temperature higher than + 25C (77F).
- It is essential that the power supply to the preheating system is:
Effected with a cable that conforms to the installation standards in force and contains a protective earth conductor.
Contains an appropriate isolation system.
Incorporate an appropriate safety system against short circuits (fuses or circuit breaker) and a differential circuit breaker
with 30 mA sensitivity.
- Only connect to and disconnect from the power supply while the unit is off and the I.C. engine is stopped.

2 - REVERSE BUZZER ALARM

3 - NUMBER PLATE LIGHTING

4 - ANGULAR SECTOR ON JIB

The angular sector displays the jib angle, and thus improves the reading of the load charts.

2-32

5 - ELECTRICAL PROVISION ON JIB

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

OPERATION
- Set switch 1 to position A to enable the electrical provision. The indicator light will come
on when it is enabled.
1

6 - ATTACHMENT EASY HYDRAULIC CONNECTION

For easily connecting and disconnecting the attachment.
OPERATION
- Switch on lift truck ignition.
- 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).

7 - EXTERIOR DRAIN BACK

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

8 - HYDRAULIC ATTACHMENT LOCKING

Enables the attachment to be locked onto the carriage and a hydraulic attachment
to be used by the same hydraulic circuit.
ATTACHMENT LOCKING CONTROL
- Set valve 1 to position A and place switch 2 in position B (indicator light on).
- Push button 3 forward to lock the attachment and backward to release it.
Once the attachment is locked, return switch 2 to position A to prevent accidental release of the
attachment.

N286989

ATTACHMENT OPERATION CONTROL

- Set the valve to position B.
- Push button 3 forward or backward.

3
A

2-33

9 - JIB HEAD SOLENOID VALVE

Enables use of two hydraulic functions on the attachment circuit.
To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing button 1
on the solenoid valve.
A1
B1

A2
B2

ATTACHMENT LINE A2/B2 CONTROL

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

B1
B2
A1
A2

N290439

ATTACHMENT LINE A1/B1 CONTROL

- Set switch 1 to position A (indicator light off).
- Push button 2 forward or backward.

3
A

2
B
1

10 - JIB HEAD SOLENOID VALVE + HYDRAULIC ATTACHMENT LOCKING

Enables the use of a hydraulic function and hydraulic locking of the attachment on the
attachment circuit.

ATTACHMENT LINE A1/B1 CONTROL

- Set switch 1 to position A (indicator light off).
- Push button 2 forward or backward.

A1
B1

A2
B2

ATTACHMENT A2/B2 LOCKING CONTROL

- Set switch 1 to position B (indicator light on) and hold down button 3.
- Push button 2 forward to lock the attachment and backward to release it.

B1
B2
A1
A2

3
A

2
B
1

2-34

N290439

To make connection of the rapid connectors easier, decompress the hydraulic circuit by pressing button 1
on the solenoid valve.

11 - ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION

This OPTION must only be used with an attachment requiring continuous hydraulic movement of type:
brush, supply bucket, mixer, spray It is strictly forbidden in handling operations and at all other events
(winch, crane jib, crane jib with winch, hook, etc.).
CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT
- Simultaneously hold button 1 in the forward or backward position (according to the type
of attachment) and switch 2 in position B (indicator light on). An audible beep will sound
when activated. Release button 1 and switch 2.
- To stop the movement, push again on the bottom of switch 1, or press pushbutton 2.
NOTE: If the operator leaves the driver's cab, the continuous hydraulic movement will
automatically stop and must be restarted.
1

12 - ATTACHMENT HYDRAULIC FLOW RATE SELECTOR

The selector has 4 positions, of which 3 can be configured according to the type
of attachment, the 4th position being fixed at 100 %.
ADJUSTING HYDRAULIC FLOW RATES
- Place the selector to position 1, and adjust the attachment flow rate (see: 2 - DESCRIPTION:
16 - HYDRAULIC CONTROLS).
- Repeat the procedure for positions 2 and 3.
READING HYDRAULIC FLOW RATES
V
F %
C

- Scroll the upper display screen

am
pm

mph
miles
rpm
km/h

until the attachment hydraulic flow rate

display screen

is displayed and set the flow rate selector to positions 1, 2 or 3 to read the recorded flow rate.

2-35

2-36

Content Page

3 - MAINTENANCE

3-1

3-2

TABLE OF CONTENTS
MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

3-4

START-UP CHECKLIST

3-5

FILTERS CARTRIDGES AND BELTS

3-6

LUBRICANTS AND FUEL

3-8

SERVICING SCHEDULE

3-10

A - DAILY OR EVERY 10 HOURS SERVICE

3-12

B - EVERY 50 HOURS SERVICE

3-16

C - EVERY 250 HOURS OF SERVICE

3-20

D - EVERY 500 HOURS SERVICE

3-22

E - EVERY 1000 HOURS OF SERVICE

3-26

F - EVERY 2000 HOURS OF SERVICE

3-30

G - OCCASIONAL MAINTENANCE

3-32

3-3

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.

IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,

YOU RISK

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

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

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

MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.

BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,

YOU BENEFIT
EXPERTISE

Through its network, MANITOU provides the user with

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

3-4

START-UP CHECKLIST
0 = OK
100

ENGINE

108

01 Air filter

1 = Missing

ATTACHMENTS

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
103

110

HYDRAULIC/HYDROSTATIC CIRCUIT

WHEEL

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

JIB/MANISCOPIC/MANIACCESS ASSEMBLY

01 Beam and telescope(s)

02 Skid
03 Hinges
04 Carriage
05 Forks
107

2 = Incorrect

MAST ASSEMBLY

01 Fixed and mobile uprights

02 Carriage
03 Chains
04 Rollers
05 Forks

3-5

FILTERS CARTRIDGES AND BELTS

I.C. ENGINE
I.C. ENGINE OIL FILTER
Part number: 279809
Change: 500 H

ALTERNATOR BELT
Part number: 292198

DRY AIR FILTER CARTRIDGE

Part number: 563416
Clean: 50 H*
Change: 500 H*

VENTILATION ADJUSTMENT BELT

Part number: 289330

SAFETY DRY AIR FILTER CARTRIDGE

Part number: 563415
Change: 1000 H*

WATER PUMP KIT

Part number: 894164
Change: 3000 H

FUEL FILTER
Part number: 746364
Change: 500 H

CYCLONIC PRE-FILTER
Part number: 224713
Clean: 10 H

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

HYDRAULIC
HYDRAULIC RETURN OIL FILTER CARTRIDGE
Part number: 686236
Change : 500 H

BRAKE ACCUMULATOR UNIT FILTER

Part number: 746308
Change : 1000 H

CAB
CAB VENTILATION FILTERS
Part number: 750306
Clean: 50 H
Change: 250 H

3-6

3-7

LUBRICANTS AND FUEL

USE THE RECOMMENDED LUBRICANTS AND FUEL:
- For topping up, oils may not be miscible.
- For oil changes, MANITOU oils are perfectly appropriate.
DIAGNOSTIC ANALYSIS OF OILS
If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle oils
may be requested depending on the rate of use.
(*) RECOMMENDED FUEL SPECIFICATION
Use a high-quality fuel to obtain optimal performance of the I.C. engine.
N590 diesel fuel type - Auto/C0/C1/C2/C3/C4
BS2869 Class A2
ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA
JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.
I.C. ENGINE
ORGANS TO BE LUBRICATED

I.C. ENGINE

CAPACITY

11,2L (3 gl)

RECOMMENDATION
Shell: Rotella 15w40
Citgo: C-600 15w40

Tulco 50/50 Premix Anti-freeze

COOLING CIRCUIT

FUEL TANK

12L (3.1 gl)

63L (16.4 gl)

Diesel fuel (*)

JIB
ORGANS TO BE LUBRICATED

RECOMMENDATION

JIB PADS

Shell: Rentinax Am
Citgo: Lithoplex CM-2

GREASING OF THE JIB

Shell: Rentinax Am
Citgo: Lithoplex CM-2

HYDRAULIC
ORGANS TO BE LUBRICATED
HYDRAULIC OIL TANK

CAPACITY

RECOMMENDATION

115L(30.4 gl)

Shell: Tellus T46

Citgo: Transgard THF Lo-Temp

BRAKE
ORGANS TO BE LUBRICATED

RECOMMENDATION
Shell: Donax TG Dexron III
Citgo: Transgard ATF Dexron III

ORGANS TO BE LUBRICATED

RECOMMENDATION

BRAKE CIRCUIT

CAB
WINDSCREEN WASHER TANK

Windscreen washer fluid

3-8

PACKAGING

PART NUMBER

FRONT AXLE
ORGANS TO BE LUBRICATED
FRONT AXLE DIFFERENTIAL

TRANSFER BOX
FRONT WHEELS REDUCERS

CAPACITY
4L (1 gl)

RECOMMENDATION
Shell: Donax TD
Citgo: Transgard (THF)

,75L (.8 qt) Shell: Spirax DH 80w90

,8L (.85 qt) Citgo: Premium Gear MP 80w90
Shell: Rentinax Am
Citgo: Lithoplex CM-2

FRONT WHEELS REDUCERS PIVOTS

REAR AXLE
ORGANS TO BE LUBRICATED

CAPACITY

REAR AXLE DIFFERENTIAL

3,8L (1 gl)

REAR WHEELS REDUCERS

0,9L (.95 qt)

RECOMMENDATION
Shell: Donax TD
Citgo: Transgard (THF)

Shell: Spirax DH 80w90

Citgo:Premium Gear MP 80w90
REAR WHEELS REDUCERS PIVOTS
REAR AXLE OSCILLATION

Shell: Rentinax Am
Citgo: Lithoplex CM-2

3-9

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

<<<
<<<
<<<
<<<
N
N
C/N

<<<
<<<
<<<
<<<
<<<
<<<
<<<
C/A
C/A
V

<<<
<<<
<<<
<<<
R
<<<
<<<
<<<
<<<
<<<
V
R
R
R**

3-26
3-26
C**

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
N
R
C**
C**
C**

3-30

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
V
C**
C**
C**
C**
C**
C**

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<

OCCASIONALLY

C
C
C
N

EVERY 4000 HOURS

OF SERVICE

C
C
C
N
R
N
C/N
C/A
C/A
V
V
R
R
R**

EVERY 3000 HOURS

OF SERVICE

3-12
3-12
3-12
3-12
3-16/22
3-16
3-16
3-20
3-20
3-20
3-22
3-22
3-23

EVERY 500 HOURS

OF SERVICE OR
EVERY 6 MONTHS
EVERY 1000 HOURS
OF SERVICE OR
EVERY YEAR
EVERY 2000 HOURS
OF SERVICE OR
EVERY TWO YEARS

(1)

EVERY 250 HOURS

OF SERVICE

I.C. ENGINE
I.C. engine oil level
Cooling liquid level
Fuel level
Cyclonic pre-filter
Dry air filter cartridge
Radiator cores
Condenser core (OPTION Air conditioning)
Alternator/fan/crankshaft belt tension
Compressor belt tension (OPTION Air conditioning)
Fuel water trap
I.C. engine oil (2)
I.C. engine oil filter (2)
Fuel filter
Alternator/fan/crankshaft belt
Fuel tank
Safety dry air filter cartridge
I.C. engine silent blocks
I.C. engine rates
Valves clearances
Cooling liquid
Injection pump
Injectors
Radiator
Water pump and the thermostat
Alternator and the starter motor
Turbocompressor
Water pump kit
Fuel circuit
TRANSMISSION
Hydrostatic transmission circuit pressures
Governing start of the hydrostatic transmission
Hydrostatic transmission cut-off operation
TYRES
Tyres pressure
Wheel nuts torque
Condition of wheels and tyres
Wheel
JIB
Jib pads
Jib
Jib pads wear
Condition of jib unit
Bearings and articulation rings
HYDRAULIC
Hydraulic oil level
Hydraulic return oil filter cartridge
Hydraulic oil
Brake accumulator unit filter
Speeds of hydraulic movements
Hydraulic pump tubular filter
Condition of hoses and flexible pipes
Condition of cylinders (leakage, shafts)
Hydraulic circuit pressures
Hydraulic circuit outputs
Hydraulic oil tank

PAGE

EVERY 50 HOURS OF
SERVICE

A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,

P = BLEED, R = REPLACE, V = DRAIN

DAILY OR EVERY 10
HOURS OF SERVICE

(2): The I.C engine oil and oil filter must be replaced after the first 50 hours of service, then every 500 hours of service.

R**
3-32

P
C**
C**
C**

3-13
3-13

C
C

C
C

<<<
<<<

<<<
<<<

<<<
<<<

<<<
<<<
C**

<<<
<<<
<<<

<<<
<<<
<<<
<<<
<<<
<<<

<<<
<<<
<<<

3-32

3-13
3-17

G*
G

3-18
3-23
3-27
3-27

C
R

3-10

<<<
G

<<<
<<<

<<<

<<<

<<<
C**

<<<
<<<
C**
C**

<<<
<<<

<<<
<<<
<<<
<<<

<<<
R

<<<
<<<
V
R
C**
N**
C**
C**

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
N**

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<

<<<

<<<
V**
P**
C**
A**

<<<
<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<
<<<

C**

3-18
3-18/20
3-28

C
R

3-14/38

<<<
C**

C
N

<<<
R

<<<
<<<

<<<
<<<
C
C**
C**

<<<
<<<
<<<
<<<
<<<
N/C

<<<
<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<
<<<
<<<

<<<

<<<

<<<

<<<
C**
C**
C**

<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<

<<<
<<<
<<<
<<<

3-31

OCCASIONALLY

<<<

EVERY 500 HOURS

OF SERVICE OR
EVERY 6 MONTHS
EVERY 1000 HOURS
OF SERVICE OR
EVERY YEAR
EVERY 2000 HOURS
OF SERVICE OR
EVERY TWO YEARS

EVERY 4000 HOURS

OF SERVICE

EVERY 3000 HOURS

OF SERVICE

3-18

EVERY 250 HOURS

OF SERVICE

(1)

EVERY 50 HOURS OF
SERVICE

BRAKE
Brake oil level
Brake oil
Brake system
Brake system pressure
Brake
STEERING
Steering
Steering swivel joints
CAB
Windscreen washer liquid level
Cab ventilation filters
Seat belt
Condition of the rear view mirrors
Structure
Air conditioning (OPTION)
ELECTRICITY
Longitudinal stability and limiter warning device
Condition of wiring harness and cables
Lights and signals
Warning indicators
Front headlights
Battery failure
FRONT AXLE
Front wheels reducers pivots
Transfer box oil level
Front axle differential oil level
Front wheels reducers oil level
Transfer box oil
Front axle differential oil
Front wheels reducers oil
Wear of front axle brake discs
Front wheels reducers universal joint
Front wheels reducers clearance
Set of transfer box rolling bearings
REAR AXLE
Rear wheels reducers pivots
Rear axle oscillation
Rear axle differential oil level
Rear wheels reducers oil level
Rear axle differential oil
Rear wheels reducers oil
Rear wheels reducers universal jointdifferential
Rear wheels reducers clearance
CHASSIS
Structure
Bearings and articulation rings
ATTACHMENTS
Forks wear
Attachment carriage
Condition of attachments
LIFT TRUCK
Tow the lift truck
Sling the lift truck
Transport the lift truck on a platform

PAGE

DAILY OR EVERY 10
HOURS OF SERVICE

A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,

P = BLEED, R = REPLACE, V = DRAIN

3-33
3-33

XXX

A
R

3-17
3-21
3-21
3-21
3-24
3-24
3-28

G
C
C
C
V
V
V

<<<
C
C
C

<<<
<<<
<<<
<<<
V
V

<<<
<<<
<<<
<<<
<<<
<<<
V

3-17
3-17
3-21
3-21
3-28
3-28

G
G
C
C
V
V

G
G

<<<
<<<
C
C

<<<
<<<
<<<
<<<

<<< <<< <<< G/C**

<<< G/C**
<<<
<<< <<< <<< <<<
<<< <<< <<< <<<
V
<<< <<< <<<
V
<<< <<< <<<
C**
C**

C**

C**

<<<
<<<
<<<
<<<
<<<
<<<
<<<

<<< G/C**
<<< <<<
<<< <<<
<<< <<<
<<< <<<
<<< <<<
<<< <<<
C**
C**
C**
C**

C**

<<<
C**

<<<

<<<
<<<

<<<
C**
C**

<<<
<<<
<<<

<<<
<<<
<<<

<<<
<<<
<<<

3-34
3-34
3-35

XXX
XXX
XXX

(*): Every 10 hours of service during the first 50 hours of service, then one last time at 250 hours of service.
(**): Consult your dealer.
3-11

A - DAILY OR EVERY 10 HOURS SERVICE

A1 - I.C. ENGINE OIL LEVEL

A1
CHECK

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

Open the I.C. engine bonnet.

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

A2 - COOLING LIQUID LEVEL

A2

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

- Open the I.C. engine bonnet.

- The liquid must be at mid-height on the expansion pan 1 (fig. A2).
- If necessary, add cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through
the filler port 2 (fig. A2).
- Check visually that there is no leakage in the radiator and pipes.

To avoid any risk of spraying or burning, wait until the I.C. engine has cooled down before removing
the cooling circuit filler plug. If the cooling liquid is very hot, add only hot cooling liquid (80 C) 176 F.
In an emergency, you can use water as a cooling liquid, then change the cooling circuit liquid as soon as
possible (see: 3 - MAINTENANCE: F1 - COOLING LIQUID).

A3 - FUEL LEVEL

A3

CHECK
2

Keep the fuel tank full, to reduce as much as possible any condensation due to the
atmospheric conditions.
- Open access panel 1 (fig. A3).
- Remove cap 2 (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 3 (fig. A3).
- Put the cap back 2 (fig. A3).
- Check visually that there is no leakage in the tank and pipes.
- Close the access panel.
Never smoke or approach with a flame during filling operations or when the tank is open. Never refill
while I.C. engine is running.

3-12

A4 - CYCLONIC PRE-FILTER

A4
CLEAN
1

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

- Loosen nut 1 (fig. A4), remove cover 2 (fig. A4) 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.

A5 - TYRES PRESSURE AND WHEEL NUTS TORQUE

CHECK
- Check the condition of the tyres, to detect cuts, protuberances, wear, etc.
- Check the torque load of the wheel nuts. Non compliance with this instruction can cause damage and rupture to the wheel bolts
and distortion to the wheels.
Wheel nuts tightening torque
Front tyres: 630 N.m (465 lbf/ft) 15%
Rear tyres: 630 N.m (465 lbf/ft) 15%
- Check and adjust the tyre pressures if necessary (see: 2 - DESCRIPTION: FRONT AND REAR TYRES).
Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation. Respect the
recommended tyre pressures given.
NOTE: There is an OPTIONAL wheel toolkit.

A6 - JIB PADS

A6
CLEAN - GREASE

To be carried out every 10 hours during the first 50 hours service, then once at 250
hours.
- Extend the jib completely.
- With a brush, apply a coat of grease (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) on
the 4 sides of the telescope(s) (fig. A6).
- Telescope the jib several times in order to spread the coat of grease evenly.
- Remove the surplus of grease.
If the lift truck is used in an abrasive environment (dust, sand, coal) Use lubricating varnish (MANITOU
reference: 483536). In this respect, consult your dealer.

3-13

3-14

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 frequency 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 it 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(44 psi) directed from the top to the bottom and from the inside
towards the outside at a minimum distance of 30 mm (1.18 in.)from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.
Respect the safety distance of 30 mm (1.18 in) 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
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.
Using a soft cloth, clean the radiator cores in order to remove as much dirt as possible.
Clean the cores using a compressed air jet aimed in the same direction as the cooling
air flow (fig. B2).
- Clean with the fan running for best results.

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).
- Clean with the fan running for best results.

3-15

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
2
3
4
5
6
7
8

Lubricators of the jib axle (2 lubricators).

Lubricator of the carriage axle (1 lubricator).
Lubricator of the tilt cylinder head axle (1 lubricator).
Lubricator of the tilt cylinder foot axle (1 lubricator).
Lubricator of the lifting cylinder foot axle (1 lubricator).
Lubricator of the lifting cylinder head axle (1 lubricator).
Lubricator of the compensation cylinder foot axle (1 lubricator).
Lubricator of the compensation cylinder head axle (1
lubricator).
FRONT AND REAR WHEELS REDUCER PIVOTS
9 - Lubricators of the wheel reduction gear pivots (8
lubricators).
REAR AXLE OSCILLATION
10 - Rear axle oscillation lubricators (2 lubricators).
3

1
1

7
10

3-16

10

B5 - HYDRAULIC OIL LEVEL

B5/1
CHECK

If necessary, remove and reconnect the hydraulic attachment (see: 4 - OPTIONAL

ATTACHMENTS FOR USE WITH THE RANGE: PICKING UP THE ATTACHMENTS). Place the
lift truck on level ground with the engine stopped and the jib retracted and lowered to its
maximum extent.
-

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

The oil level is correct when it is at the level of the red point.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
Remove cap 2 (fig. B5/2).
Add oil through filler port 3 (fig. B5/2).
Use a clean funnel and clean the underside of the oil drum before filling.

B5/2

- Replace the cap.

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

B6 - BRAKE OIL LEVEL

B6/1
CHECK
2

Place the lift truck on level ground.

- Loosen the two knurled screws 1 (fig. B6/1) and remove the protective cover 2
(fig. B6/1).
- Check tank 3 (fig. B6/2). The correct level must stand at the MAX level in the tank.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
- Remove cap 4 (fig. B6/2).
- Add oil through filler port 5 (fig. B6/2).
- Replace the cap.
- Check visually that there is no leakage in the tank and pipes.

1
1

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

B6/2
4
5

B7 - WINDSCREEN WASHER LIQUID LEVEL

B7
CHECK
1

Open the I.C. engine bonnet.

Remove cap 1 (fig. B7).
Visually check the level in tank 2 (fig. B7).
If necessary add windscreen washer liquid (see: 3 - MAINTENANCE: LUBRICANTS
AND FUEL) through filler port 3 (fig. B7).
- Replace the cap.

3-17

B8 - CAB VENTILATION FILTER

B8
CLEAN

- Lift out cabin ventilation filter 1 (fig. B8).

- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS).
- Put the filter back into place.

3-18

C - EVERY 250 HOURS OF SERVICE

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

C1 - ALTERNATOR/FAN/CRANKSHAFT BELT TENSION

C1
CHECK - ADJUST

- Open the I.C. engine bonnet.

- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the crankshaft and of the alternator.
- Under a normal pressure exerted with the thumb (45 N), 10.1 lbf the belt should move
approximately 10 mm (.39 in).
- Carry out adjustments if necessary.
- Untighten screws 1 (fig. C1) by two to three thread turns.
- Swivel the alternator assembly so as to obtain the belt tension required.
- Retighten screws 1 (fig. C1) (tightening torque 22 N.m) 16.2 lbf/ft.

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

C2 - COMPRESSOR BELT TENSION (OPTION AIR CONDITIONING)

C2
CHECK - ADJUST

- Open the I.C. engine bonnet.

- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulley of the crankshaft and of the compressor.
- Under a normal pressure exerted with the thumb (45 N), the belt should move approximately
10 mm (.39 in).
- Carry out adjustments if necessary.
- Untighten screw 1 and nuts 2 (fig. C2) by two to three thread turns.
- Swivel the alternator assembly so as to obtain the belt tension required.
- Retighten screw 1 and nuts 2 (fig. C2) (tightening torque 22 N.m) 16.2 lbf/ft.

2
2

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

C3 - FUEL WATER TRAP

C3
DRAIN

The water trap serves to stop the water contained in the fuel, it is incorporated within the
fuel filter.
- Open the I.C. engine bonnet.
- Place a receptacle under drain port 1 (fig. C3).
- Unscrew ring 2 (fig. C3) by two or three thread turns to drain the water from the water
trap.
- Retighten ring 2 (fig. C3).

2
1

C4 - CAB VENTILATION FILTER

C4
CHANGE

- Lift out cab ventilation filter 1 (fig. C4) and replace it with a new one (see: 3 - MAINTENANCE:
FILTERS AND BELTS).

3-19

C5 - TRANSFER BOX OIL LEVEL

C5/1
CHECK

Place the lift truck on level ground with the I.C. engine stopped.
- Remove the access panel 1 (fig. C5/1).
- Remove level plug 2 (fig. C5/2). 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 2 (fig. C5/2) (tightening torque 34 to
49 N.m) 25 - 36 lbf/ft.
- Refit access panel 1 (fig. C5/1).

C5/2

C6 - FRONT AXLE DIFFERENTIAL OIL LEVEL

C6
CHECK

Place the lift truck on level ground with the I.C. engine stopped.
- Remove level plug 1 (fig. C6). The oil should be flush with the edge of the hole.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the same hole.
- Replace and tighten the level plug 1 (fig. C6)(tightening torque 34 to 49 N.m)25-36 lbf/ft
1

C7 - REAR AXLE DIFFERENTIAL OIL LEVEL

C7
CHECK

Place the lift truck on level ground with the I.C. engine stopped.
- Remove level plug 1 (fig. C7). The oil should be flush with the edge of the hole.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the same hole.
- Replace and tighten the level plug 1 (fig.C7)(tightening torque 34 to 49 N.m).25-36lbf/ft

C8 - FRONT AND REAR WHEELS REDUCERS OIL LEVEL

C8
CHECK

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

Check the level on each wheel reducer.

Place level plug 1 (fig. C8) in the horizontal position.
Remove the level plug ; the oil should be flush with the edge of the hole.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the same hole.
Refit and tighten the level plug (tightening torque 34 to 49 N.m)25-36 lbf/ft.

3-20

D - EVERY 500 HOURS SERVICE

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

D1 - I.C. ENGINE OIL

D1/1
DRAIN

D2 - I.C. ENGINE OIL FILTER

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

DRAINING THE OIL

- Open the engine cover.
- 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.
D1/2

Dispose of the drain oil in an ecological manner.

REPLACEMENT OF THE FILTER
- Unscrew and discard the I.C. engine oil filter 4 (fig. D1/2) as well as its seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly grease the new seal before refitting the new oil filter (see: 3 - MAINTENANCE:
FILTERS AND BELTS) on its bracket.

Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.
FILLING UP THE OIL
- Refit and tighten drain plug 2 (fig. D1/2).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 5
(fig. D1/3).
- Wait a few minutes to allow the oil to flow into the sump.
- Start the I.C. engine and let it run for a few minutes.
- Check for possible leaks from the drain plug and the oil filter.
- Stop the I.C. engine, wait a few minutes and check the correct level on the dipstick 6
(fig. D1/3) between the two level marks.
- Top up the level if necessary.
- Refit access panel 1 (fig. D1/1).

D1/3

D3 - DRY AIR FILTER CARTRIDGE

D3

CHANGE
1

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

Open the I.C. engine bonnet.

Loosen the bolts and remove cover 1 (fig. D3).
Gently remove the cartridge 2 (fig. D3), taking care to avoid spilling the dust.
Leave the safety cartridge in place.
The following parts must be cleaned with a damp, clean lint-free cloth.
The inside of the filter and cover.
The inside of the filter inlet hose.
The gasket surfaces in the filter and in the cover.
- Check pipes and connections between the air filter and the I.C. engine and the connection and state of the clogging indicator on
the filter.
- Before mounting check the condition of the new cartridge (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.
- Reassemble the cover, guiding the valve downwards.
3-21

D4 - FUEL FILTER

D4
CHANGE
3

- Open the I.C. engine bonnet.

- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
the system.
- Unscrew filter 1 (fig. D4) and discard it after having recovered part 2 (fig. D4).
- Refit the assembly with a new filter (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND
BELTS).
- Pressurise the circuit by means of the hand pump 3 (fig. D4).

D5 - HYDRAULIC RETURN OIL FILTER CARTRIDGE

D5/1
CHANGE

Stop the I.C. engine on level ground, with the jib raised and remove the pressure from the
circuits by acting on the hydraulic controls.
1

Before carrying out any work, thoroughly clean the areas concerned by these maintenance operations.
- Remove plug 1 (fig. D5/1);
- Place a container under hydraulic return oil filter.
- Unscrew cover 2 (fig. D5/2).
- Wait a few seconds for the oil to flow into the container.
- Slowly take out filter cartridge assembly 3 and 4 (fig. D5/3).
- Separate the head 3 from the filter cartridge 4 (fig. D5/4) with a twisting motion.
- Refit the head onto a new cartridge (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND
BELTS).
- Refit the assembly in place and retighten cover 2 (fig. D5/2).
- Put back cap 1 (fig. D5/1).

D5/2

D5/3

D5/4
3

3-22

D6 - TRANSFER BOX OIL

D6/1
DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the
transfer box oil still warm.
Dispose of the drain oil in an ecological manner.
- Remove access panel 1 (fig. D6/1).
- Place a container under drain plug 2 (fig. D6/2) and unscrew the plug.
- Remove level and filling plug 3 (fig. D6/2) in order to ensure that the oil is
drained properly.
- Refit and tighten drain plug 2 (fig. D6/2) (Tightening torque 34 to 49 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through
filler port 3 (fig. D6/2).
- The level is correct when the oil level is flush with the edge of the hole.
- Check for any possible leaks at the drain plug.
- Refit and tighten the level and filling plug 3 (fig. D6/2) (tightening torque 34 to 49 N.m).

D6/2

D7 - FRONT AXLE DIFFERENTIAL OIL

D7
DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the d oil still warm.
Dispose of the drain oil in an ecological manner.
- Place a container under drain plug 1 (fig. D7) and unscrew the plug.
- Remove level and filling plug 2 (fig. D7) in order to ensure that the oil is drained
properly.
- Refit and tighten drain plug 1 (fig. D7) (tightening torque 34 to 49 N.m) 25-36 lbf/ft.
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 2 (fig. D7).
- The level is correct when the oil level is flush with the edge of the hole.
- Check for any possible leaks at the drain plug.
- Refit and tighten the level and filling plug 2 (fig. D7) (tightening torque 34 to 49 N.m) 25-36 lbf/ft.

3-23

3-24

E - EVERY 1000 HOURS OF SERVICE

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

E1 - FUEL TANK

E1/1
CLEAN

While carrying out these operations, do not smoke or work near a flame.
Place the lift truck on level ground with the I.C. engine stopped.
1

- Inspect the parts susceptible to leaks in the fuel circuit and in the tank.
- In the event of a leak, contact your dealer.
Never try to carry out a weld or any other operation by yourself, this could provoke an explosion or a
fire.
-

Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
Open access panel 2 (fig. E1/2).
Remove filler plug 3 (fig. E1/2) in order to ensure that the oil is drained properly.
Rinse out with ten litres of clean diesel through filler port 4 (fig. E1/2).
Refit and tighten the drain plug (tightening torque 29 to 39 N.m) 21-29 lbf/ft.
Fill the fuel tank with clean diesel filtered through the filler port.
Refit the filler plug.
Close the access panel.
If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: G1 - FUEL SYSTEM).

E1/2
3
4

E2 - SAFETY DRY AIR FILTER CARTRIDGE

E2
CHANGE

- For the disassembly and reassembly of the dry air filter cartridge, see: 3 - MAINTENANCE:
D3 - AIR FILTER CARTRIDGE.
- Gently remove the dry air filter safety cartridge 1 (fig. E2), taking care to avoid spilling
the dust.
- Clean the gasket surface on the filter with a damp, clean lint-free cloth.
- Check the condition of the new safety cartridge before fitting (see: 3 - MAINTENANCE:
FILTERS AND BELTS).
- Insert the cartridge within the axis of the filter and push it home, pressing against the
outer edge and not the centre.
NOTE: The safety cartridge changing frequency is given for information only. It must be
changed for every two changes of the dry air filter cartridge.

3-25

E3 - HYDRAULIC OIL

E3/1
DRAIN

E4 - BRAKE ACCUMULATOR UNIT FILTER

CHANGE

Stop the I.C. engine on level ground, with the jib raised and remove the pressure from the
circuits by acting on the hydraulic controls.
1

Before carrying out any work, thoroughly clean the areas concerned by these maintenance operations.
DRAINING THE OIL
- Place a container under drain plugs 1 (fig. E3/1) and unscrew them.
- Remove filler plug 2 (fig. E3/2) in order to ensure that the oil is drained properly.
E3/2

Dispose of the drain oil in an ecological manner.

REPLACING THE BRAKE ACCUMULATOR UNIT FILTER
- Unscrew plug 3 (fig. E3/3), lift out the filter and fit a new one (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Refit and tighten plug 3 (fig. E3/3) (tightening torque 70 to 80 N.m) 52 - 59 lbf/ft.

FILLING UP THE OIL

- Refit and tighten drain plugs 1 (fig. E3/1) (tightening torque 29 to 39 N.m) 21-29 lbf/ft.
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 4 (fig.
E3/2).
Use a clean container and funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 5 (fig. E3/4), the oil level should be at the level of the red
point.
- Check for any possible leaks at the drain plugs.
- Refit filler plug 2 (fig. E3/2).

E3/3

E3/4

3-26

E5 - SEAT BELT
CHECK
SEAT BELT WITH TWO ANCHORING POINTS
- Check the following points:
Fixing of the anchoring points on the seat.
Cleanness of the strap and the locking mechanism.
Triggering of the locking mechanism.
Condition of the strap (cuts, curled edges).
REELED SEAT BELT WITH TWO ANCHORING POINTS
- Check the points listed above together with the following points:
The correct winding of the belt.
Condition of the reel guards.
Roller locking mechanism when the strap is given a sharp tug.
NOTE: After an accident, replace the seat belt.
In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.

E6 - REAR AXLE DIFFERENTIAL OIL

E6
DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the d oil still warm.
Dispose of the drain oil in an ecological manner.
2

- Place a container under drain plug 1 (fig. E6) and unscrew them.
- Remove level and filling plug 2 (fig. E6) to ensure that the oil is drained properly.
- Refit and tighten drain plug 1 (fig. E6) (tightening torque 34 to 49 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 2 (fig. E6).
- The level is correct when the oil level is flush with the edge of the hole.
- Check for any possible leaks at the drain plug.
- Refit and tighten level and filling plug 2 (fig. E6) (tightening torque 34 to 49 N.m)25-36lbf/ft.

E7 - FRONT AND REAR WHEELS REDUCERS OIL

E7
DRAIN

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

Dispose of the drain oil in an ecological manner.

- Drain and change the oil of each wheel reducer.
- Place drain plug 1 (fig. E7) in position A.
- Place a container under the drain plug and unscrew the plug.
- Let the oil drain fully.
- Place the drain port in position B, i.e. in a level port.
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through level port 1 (fig. E7).
- The level is correct when the oil level is flush with the edge of the hole.
- Refit and tighten the drain plug (tightening torque 34 to 49 N.m) 25-36-lbf/ft.

3-27

3-28

F - EVERY 2000 HOURS OF SERVICE

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

F1 - COOLING LIQUID

F1/1
DRAIN

These operations are to be carried out if necessary or every two years at the beginning of
winter. Place the lift truck on level ground with the I.C. engine stopped and cold.
DRAINING THE LIQUID
- Place a container under drain plug 1 (fig. F1/1) and unscrew the plug.
- Open the I.C. engine bonnet.
- Remove expansion pan filler plug 2 (fig. F1/2).
- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.
- Check the condition of the hoses as well as the fastening devices and change the hoses
if necessary.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
FILLING THE LIQUID
- Retighten drain plug 1 (fig. F1/1) (tightening torque 20 N.m) 15 lbf/ft.
- Slowly fill up the circuit with cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL) to mid-height on expansion pan 3 (fig. 1/2) through filler port 4 (fig. F1/2).
- Put back filler plug 2 (fig. F1/2).
- Run the I.C. engine at idle for a few minutes.
- Check for any possible leaks.
- Check the level and refill if necessary.
The I.C. engine does not contain any corrosion resistor and must be filled during the whole year with a
mixture containing 25 % of ethylene glycol-based antifreeze.

3-29

F1/2

2
4
3

F2 - AIR CONDITIONING (OPTION)

CLEANING - INSPECTION
CLEANING CONDENSER AND EVAPORATOR COILS (*)
CLEANING CONDENSATE TRAY AND RELIEF VALVE (*)
COLLECTING COOLANT TO REPLACE FILTER-DRIER (*)
REFILLING WITH COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES (*)
NOTE: When opening the evaporator unit, remember to replace the cover seal.
(*): (CONSULT YOUR DEALER).
CAUTION: DO NOT ATTEMPT TO REPAIR ANY PROBLEMS YOURSELF. ALWAYS REFER TO YOUR DEALER WHEN REFILLING CIRCUITS, AS THEY HOLD THE
CORRECT SPARE PARTS, AS WELL AS HAVING THE NECESSARY TECHNICAL KNOWLEDGE AND TOOLS.
- Do not open the circuit under any circumstances as this would cause the coolant to be lost.
- The cooling circuit contains a gas which can be dangerous under certain conditions. This gas, coolant R 134a, is colourless, odourless
and heavier than air.
If this gas is inhaled, take the victim into fresh air, give oxygen or artificial respiration if necessary and call a doctor.
If the gas is in contact with the skin, wash it immediately under running water and remove any contaminated garments.
If the gas is in contact with the eyes, rinse them in clear water for 15 minutes and call a doctor.
- The compressor has an oil level gauge (fig. F2). Never unscrew this gauge because it
would depressurizes the installation. The oil level is only checked when changing the oil
in the circuit.

3-30

F2

G - OCCASIONAL MAINTENANCE
G1 - FUEL SYSTEM

G1/1
BLEEDING

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

- A component of the fuel system replaced or drained.
- A drained tank.
- Running out of fuel.
Ensure that the level of fuel in the tank is sufficient and bleed in the following order:
BLEEDING THE FUEL FILTER
- Open the I.C. engine bonnet.
- Place a receptacle under drain port 1 (fig. G1/1).
- Unscrew ring 2 (fig. G1/1) by two or three thread turns to drain the water from the water
trap.
- Retighten ring 2 (fig. G1/1).

2
1

G1/2

BLEEDING THE INJECTION PUMP

- Untighten bleeder screw 3 (fig. G1/2) by two to three thread turns.
- Switch on the lift truck ignition until the diesel oil flows from the bleeder screw free of
any air.
- Tighten the bleed screw while the diesel fuel is flowing out.
The I.C. engine is ready to be started up.

NOTE: If the I.C. engine runs properly for a short time then stops or runs unevenly, 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, ensure the following:
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.
- Stop the 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).
- 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 OF SERVICE for tightening torque).

3-31

G2/2

G3 - FRONT HEADLAMPS

h2 = h1 - (l x 2 / 100)

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

h1

+%
-%

-2%

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

G3

h1
h2

Calculating the height of the dipped beam (h2)

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

G4 - BREAKDOWN OF BATTERY
CHANGE

G4/1

- Open the I.C. engine bonnet.

- Bring a floating battery of the same type as the one used for the lift truck and battery
cables.
- Connect the floating battery according to the correct polarity with the (-) on the engine
earth 1 (fig. G4/1) and the (+) on the (+) of starter 2 (fig. G4/2).
- Start the lift truck and remove the cables as son as the I.C engine is running.
- Raise the jib.
- Lift out protective casing 3 (fig. G4/3).
- Replace battery 4 (fig. G4/4).
Handling and servicing a battery can be dangerous, take the following precautions:
- Wear protective goggles.
- Keep the battery horizontal.
- Never smoke or work near a naked flame.
- Work in a well-ventilated area.
- In the event of electrolyte being spilled onto the skin or splashed in the eyes, rinse thoroughly
with cold water for 15 minutes and call a doctor.

G4/2

G4/3

G4/4
3

3-32

G5 - LIFT TRUCK
TOWING
If the lift truck is not on horizontal ground, chock its wheels it to prevent it rolling down the slope.
The lift truck must be towed at very slow speed (less than 5 km/h) 3.1 mph over the shortest possible distance (less than 100 m) 328 ft.
For towing a lift truck, the high pressure limiters must be unlocked to avoid damaging the hydrostatic transmission, and the parking
brake on the front axle must be released.
- Switch on lift truck ignition.
- Set the forward/reverse selector to neutral.
- Release the parking brake.
UNLOCKING THE HIGH PRESSURE LIMITERS
- Open the I.C. engine bonnet.
- Loosen nuts 1 (fig. G5/1) on the hydrostatic pump by no more than three turns.
RELEASING THE PARKING BRAKE ON THE FRONT AXLE
- Unscrew the screws 2 (fig. G5/2) on the front axle, remove the shims 3 (fig. G5/2) and
fully retighten the screws 2 (fig. G5/2).

G5/1

1
1

TOWING
- Switch on the warning lights.
- 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.
- After towing, retighten screws 1 (fig. G5/1) (tightening torque 70 N.m) 51.6 lbf/ft.
- Unscrew the screws 2 (fig. G5/2), refit the 3 shims
(fig. G5/2) and retighten the screws 2 (fig. G5/2)
(tightening torque 95 - 115 N.m) 70-85 lbf/ft.
G5/2

G6 - LIFT TRUCK

G6/1
SLINGING

- Take into account the position of the lift truck centre of gravity for lifting
(fig. G6/1).
A = 1,200 mm
B = 1,100 mm
- Place the hooks in the fastening points provided (fig. G6/2 and G6/3).

G6/2

3-33

G6/3

G7 - LIFT TRUCK ON A PLATFORM

G7/1
TRANSPORTING

Ensure that the safety instructions associated with the platform are complied with before loading the
lift truck and that the driver of the carrier vehicle is informed of the dimensions and the weight of the lift
truck (see: 2 - DESCRIPTION: CHARACTERISTICS).
Ensure that the platform is of sufficient size and load capacity for transporting the lift truck. Check also
the allowable ground contact pressure of the platform relative to 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.
LOADING THE LIFT TRUCK
- Block the wheels of the platform.
- Attach the loading ramps to the platform in such a way as to give the shallowest possible
ramp angle for the lift truck.
- Load the lift truck parallel to the platform.
- Stop the lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING INSTRUCTIONS
UNLADEN AND LADEN).

G7/2

STOWING THE LIFT TRUCK

- Fix the chocks to the platform at the front and at the rear of each tyre (fig. G7/1).
- Also fix the chocks to the platform on the inside of each tyre (fig. G7/2).
- Secure the lift truck to the platform at the anchoring points provided (fig. G7/3 and G7/4)
with sufficiently strong ropes.
- Tighten the ropes (fig. G7/5).

G7/3

G7/4

G7/5

3-34

3-35

3-36

Content Page

4 - OPTIONAL
ATTACHMENTS
FOR USE WITH
THE RANGE

4-1

4-2

TABLE OF CONTENTS
INTRODUCTION

4-5

PICKING UP THE ATTACHMENTS

4-6

TECHNICAL SPECIFICATIONS OF ATTACHMENTS

4-8

ATTACHMENT SHIELDS

4-10

4-3

INTRODUCTION
- Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS.
- A wide range of attachments is available, guaranteed by MANITOU and designed to fit your lift truck perfectly.
- 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 manufacturer shall not be liable for any modification or adaptation of an attachment made without its
knowledge.
Depending on their size, certain attachments may, when the jib is lowered and retracted, come into contact with the front tyres and cause damage
to them, if reverse tilt is activated in the forward tilt direction. TO PREVENT THIS RISK, EXTEND THE TELESCOPE TO A SUFFICIENT EXTENT FOR THE
PARTICULAR LIFT TRUCK AND ATTACHMENT SO THAT THIS CONTACT IS NOT POSSIBLE.
Maximum loads are defined by the capacity of a lift truck taking account of the attachments mass and centre of gravity. In the event of the attachment
having less capacity than the lift truck, never exceed this limit.

4-5

PICKING UP THE ATTACHMENTS

A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE

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

HAND RELEASING
- Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back
the locking pin and the clip in the bracket (fig. A).
LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.

4-6

B - HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE

TAKING UP AN ATTACHMENT
- Ensure that the attachment is in a position facilitating the locking to the carriage. If it is
not correctly oriented, take the necessary precautions in order to move it safely.
- Check that the locking pin and the clip are in position in the bracket (fig. A).
- Place the lift truck with the jib fully lowered in front of and parallel to the attachment, tilt
the carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the jib, incline the
carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.
MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT
- Take the locking pin and the clip on the bracket (fig. A) and lock the attachment (fig. D).
Do not forget to refit the clip.
- Stop the I.C. engine and keep the ignition on the lift truck.
- Release the pressure from the hydraulic circuit by pressing button 1 (fig. E) downwards
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 reverse order of paragraph HAND LOCKING AND CONNECTING THE ATTACHMENT
while making sure you put back the locking pin and the clip in the bracket (fig. A).
LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.

4-7

4-8

Contents

MAIN LECTRIC SHEMATIC

pages
CODES ON LECTRICAL SCHEMATIC....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
CBLES LABELS ON THE LECTRICAL HARNESS. . . . . . . . . . . . . . . . . . . . A4
ELECTRICAL SCHMATIC
MT 625 Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

80

MT 625 T COMFORT / MLT 625-75 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C

(18/11/2010)

80-02-M176FR

Main Electrical Schmatic

80

A2

80-02-M176FR

(18/11/2010)

A3

Main Electrical Schmatic

CODES ON ELECTRICAL SCHMATIC

1

10

11

12

13

14

15

16

17

18

19

3
M
is 1
ss M
ha is
C ss
se ha
as C
M sse
a
M

Ba
t

16

13
A2 / MP 22

8
CN1-P2 / X150

3
4

EP6

BF1 / M1
F3
F4

237

76

236

47

235

46

12
CN2-P2 / X151
72

234

17

233

16

420

11

421

420

71

CAN A L

CAN A H

Y40

X162

X116

X201

238

77

72

14

15
G

76

89

47

88

46

87

17

86

16

12

183

30

11

182

59

179

82

172

34

EP5

S25

42

CAN A L

77

90

Masse CAN A

91

41

CAN A H

11

8
9
A1 / MP 12

2
JSM

178

49

176

88

175

87

177

19

174

86

173

85

S16

10

232

89

S15

180

56

X160
58

10

440

EP68

Y28

B16

CN2-P1 / X149

80

B15

A12

CN1-P1 / X148
X67

Example labeling of the cbles and the components on the wiring diagram.

Lgende:
1 - Feed
2 - Electrical Component
3 - Description electrical component
4 - Electrical Connector
5 - Dscription electrical connector
6 - Splicing
7 - Connector ECU
8 - ECU
(18/11/2010)

9 - Dscription ECU
10 - Dscription connector ECU
11 - Dscription N wire
12 - Dscription N PIN electrical connector
13 - Masses
14 - CAN
15 - Shield CAN
16 - Grid location
80-02-M176FR

A4

Main Electrical Schmatic

CBLE LABELING ON THE LECTRICAL HARNESS

Electric harness installed in the carriage are made with connectors.
In order to identify the conectors and their wires to which are attached, inscriptions are on
each wire.
X32/88/X64

Support
N wire

Ending

X64

X32 / 88 / X64

X32 / 88 / X64

80

X32

80-02-M176FR

(18/11/2010)

Contents
C1

Main Electrical Schmatic

MT 625 T COMFORT / MLT 625-75 H

pages
POSITION OF THE CONNECTORS PER SCHMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C3
LECTRICAL SCHEMATIC PER FUNCTION :
1 - START / DIGICODE CLIENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7
2 - CAN H-L / OUTLET OBD (DIAGNOSTIC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C11
3 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C15
4 - HYDRAULIC MOVEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C19
5 - ILLUMINATION SIGNALS / VENTILATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C23

80

6 - OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C29

(09/02/2011)

80-02-M176FR

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

80

C2

80-02-M176FR

(09/02/2011)

C3

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

POSITION OF THE CONNECTORS PER SCHMATIC

Connecteurs

Sch. 1

X0

X1

X2

X3

X4

Sch. 2

Sch. 3

Sch. 4

X11

X12

X14

X17

X18
X19

X20

X21

X22

X25

X26

X27

X28

X29

X30
X31

X32

X35

X36

X37

X38

X39

X40

X41

X46

X47

X50

X56

X57

X58

X59
X62

X63

X64
X65

X66

X67

X91

(09/02/2011)

80

X13

Sch. 6

X6
X8

Sch. 5

80-02-M176FR

C4

Main Electrical Schmatic

Connecteurs

Sch. 1

MT 625 T COMFORT/ MLT 625-75 H

Sch. 2

Sch. 3

Sch. 4

Sch. 5

X92
X93

X94

X95

X99

X100
X103

X104

X105

X106

X107

X115

X118

X133

X134
X138

X114

X139

80

Sch. 6

X153

X154

X155

X166

X204

X205

X260

X261

X264

X265

X266

X267

X268

X269

X270

X274

X275

X276

X277

X286
X289

X290

X291

X292

X294
X295

X299

X300

X302
X303

X304

80-02-M176FR

(09/02/2011)

Connecteurs

Sch. 1

Sch. 2

Sch. 3

Sch. 4

X305

X308

X309
X310

C5

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Sch. 5

Sch. 6

X311

X312

X313

X314

X315

X316

X322

X321

X324
X326

X327

X330

X331

X358

X360

X362

X363

X365

X367

X368

X370

X372

X373
X374

X375

X377
X378
X381

X382
X383

X385

X386

(09/02/2011)

80

X376

80-02-M176FR

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

80

C6

80-02-M176FR

(09/02/2011)

C7

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

1 - START / DIGICODE CLIENT

Connectors
Rep.

Comp.
Name

X0

S1

Battery Cut off

S8

Chssis

X1

S2

4-way switch key

A11

Chssis

X2

S2

6-way switch key

A15

Moteur

X3

R1

Prheating

Q9

Harness type

Motor

X4

M1

Motor

X8

Y1/Y2

Chssis

X13

A1

Position on
schmatic

Dscription

Starter Sollnode

Correspondance
hydraulic

Q6

Engine stop elctrovalves

S11

Dashboard unit

I40

Chssis/Motor

X1

Interface Chssis/Engine

O29

Chssis

X56

A3

ECU hydraulic

M30

Chssis

X57

A3

ECU hydraulic

M39

Chssis

X115

PAD

Diagnostic oulet

039

Chssis

X118

A6

Digicode client

I5

Chssis

X138

S50

Emergency Stop

A7

Moteur

X289

G2

Alternator 12V/80A

O13

Moteur

X290

G2

Supply alternator

O14

Moteur

X295

A2

ECU transmission

M24

Moteur

X299

A2

ECU transmission

M27

Chssis/Moteur

X310

Interface Chssis/Engine

K13

Components
Dscription

Position on schmatic

A1

Dashboard unit

E24

A2

ECU transmission

M28

A3

ECU hydraulic

M36

A6

Digicode client

K8

G1

Battery 12V/110Ah

O8

G2

Alternator 12V/80A

Q13

M1

Start solenoid

P1

Hour Meter

Q6
G40

P2

Diesel Gauge Unit

G37

PAD

Diagnostic Outlet

039

R1

Preheating Rsistance

S1

Battery cut off

S2

Key switch

S50

Emergency stop

S9
S8
A11
A7

Y1

Engine stop electrovalve 1 (continued)

S11

Y2

Engine stop electrovalve 2 (appel)

S13

(09/02/2011)

Correspondance
hydraulique

80

Rep.

80-02-M176FR

C8

Main Electric Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Fuses and relays

Rep.

Position on schmatic

Dscription
BF1/M1

F41

Open

M13

F42

Key switch (60A)

M14

F43

Alternator (80A)

M14

F44

Cabin Fuse box (+BAT) (50A)

M15

F45

Dfigeur Diesel (option) (20A)

M15

F46

Prheating (40A)

M15

F55

Start Solnode (20AZ

M11

K20

Prheat Relays

M8

BF1/M2

BF2/M1
F1

Dashboard Alimentation (+apc) (7,5A)

C23

F2

Diesel pump + EV Engine Stop Maint. + excitation alternator (5A)

C23

F3

Digicode + Diagnostic oulet (5A)

C24

F7

ECU Hydraulic (15 A)

C25
BF2/M2

F33

Digicode + Diagnostic outlet (5A)

C36
BF2/M4

K7

Start Relay linked to digicode

E15

Splices
Rep.

Position on schmatic
O11

Ep.7

K29

80

Ep.1

80-02-M176FR

(09/02/2011)

MT 625 T COMFORT / MLT 625-75 H

x
x

19 / 9

54 / 5

15 / 6

45

267

299

37

38

39

40

41

42

54

55

F40

F34

F33

F32

C
270

171
5

36

269

PIN = 12 V

Towards K6-2 (page C33)

K7
276

35

B BF2/M1

279
280

34

BF2/M2
279

277

APC 15
APC 15

33

25 mm2

278

APC 54

32

272

APC 54

31

F31

44
70
278
277
279
280

273

30

323

58 / 10
APC 50a

29

280

X2

28

F20

58

19 / 8

10

27

F19

15
6

26

F18

54
5

25

F17

19
9

24

O P

IO

50a / 7

23

F15

275

19

273

50a

275

17

276

17

52

30

51

82

19

265

267

266

22

F16

30

X1
4

21

F13

OP

SIT

20

F14

SPU

EVM

DEM

19

PO

PIN

X138

18

r
eu
ot
M sis
se as
as Ch ine
- M se Cab e
00 as R bin
X3 - M e A Ca
21 ss AV
X3 Ma se
- as
04 M
X3 3 0
X3

S2

S50

17

278

16

F12

15

277

14

F11

13

F9

12

F10

11

F8

10

F7

F6

F5

F4

F3

F2

271

F1

C9

Main Electrical Schmatic

268

Electrical Schmatic Start / Digicode client

Towards K8-5 (page C27)

300

BF2/M4

A1
E1

RPM

HORAMETRE
MICRO CONTROLEUR

P1

B6

269

120 Ohm
1

13

171

BP2

22

21

X13

52

51

C8

A1

A8

B1

C2

12
A3

82

EP7

287

A2

286

C1

12

X310

A6

44

44

45

19

19

45

55

54

55

10

52

11

54

12

51

X118

25

14

173

26

BP1

CAN H

69

CAN L

271

266

265

268
8

67

170

10

70

11

12

12

285

X118

273

274

P2

287

CAN 1 HI

GND CAN

CAN 1 LOW

345

346

X57

CAN / CABLE 6

10

CAN / CABLE 7

X8

84

88

X3

M1

61

B+

X115

270

X290

3~

G2

PAD

61

60

59

70 mm2

60

59

19

EP1
10

CABLE 3

CABLE 2
1

S1
272

Y1

X0

R1

Y2

V C-Bat

(09/02/2011)

80-02-M176FR

80

W UP IN 1
12VD

12VD

286

CAN L

64

62

F60

F59

F58

F57

F56

F55

A3
01

02

X19

12
9

50 mm2

70 mm2

26

14

2 mm2

04

16

03

O
46

IG

X289

X4

13

41

87

173

G1

DRAIN

45

X56

B
85

F54

F51

K20

F53

BF1/M2

F52

44

43

X299 / C2
30 3

86 1

CAN GND

A2

X295 / C1
CAN H

BAT -

F46

F45

F44

F43

F42

F41

285

BF1/M1

CAN / CABLE 1

43

40

55

54

52
46

51

C10

MT 625 T COMFORT / MLT 625-75 H

80

Main Electrical Schmatic

80-02-M176FR

(09/02/2011)

C11

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

2 - CAN H-L / OUTLET OBD (DIAGNOSTIC)

Connectors
Harness Type

Rep.

Comp.
Name

Chssis

X13

A1

Dashboard unit

Position on
schmatic

Dscription

Correspondance
hydraulique

I31

Chssis/Moteur

X19

Interface Chssis/Engine

O21

Chssis

X56

A3

ECU hydraulic

M30

Chssis

X57

A3

ECU hydraulic

M39

Chssis

X58

A5

Longitudinal Security unit

C37

Chssis

X99

A11

Gauge Vishay

M22

Chssis

X115

PAD

Diagnostic outlet

036

Chssis

X276

A11

Gauge Vishay

M22

Moteur

X295

A2

ECU transmission

M16

Moteur

X299

A2

ECU transmission

M19

Chssis/Moteur

X310

Interface Chssis/Engine

K8

Components
Rep.

A1

Dashboard unit

E16

A2

ECU transmission

M20

A3

ECU hydraulic

M27

Longitudinal Security Unit

C38

Gauge Vishay

M22

P1

Hourmeter unit

G31

P2

Diesel Gauge Unit

G28

PAD

Diagnostic outlet

036

80

A5
A11

Correspondance
hydraulique

Position on schmatic

Dscription

Fuses and relays

Rep.

Position on schmatic

Dscription
BF1/M1

F44

Cabine Fuse Box (+BAT) (50A)

M8
BF2/M1

F1

Dashboard Alimentation (+apc) (7,5A)

C15

F2

Pump GO + Engine stop Electrovalve

C15

F3

Digicode + diagnostic outlet(5A)

C15

F4

ECU transmission + Seat contact + JSM (10A)

C16

F7

ECU hydraulic (10A)

C18

F19

Alimentation BUS-BAR C (F27/F28/F29/F30) (30A)

C23
BF2/M2

F33

Digicode + diagnostic outlet (5A)

C29

F36

Alimentation micro controler ECU hydraulic (+perm) (2A)

C30

(09/02/2011)

80-02-M176FR

C12

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Splices
Rep.

Position on schmatic
O30

Ep.13

E11

Ep.17

K31

80

Ep.12

80-02-M176FR

(09/02/2011)

Electric Schmatic CAN H-L / Outlet OBD (Diagnostic) MT

5

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

27

27

AP

C
AP 54
C
AP 5
C 4
AP 15
C
V 15
C
-B
at

27

40

41

r
eu
ot
M sis
se as
as Ch ine
- M se Cab e
00 as R bin
X3 - M e A Ca
21 ss AV
X3 Ma se
- as
04 M
X3 3 0
X3

C13

Main Electrical Schmatic

28

625 T COMFORT / MLT 625-75 H

42

25 mm2
323

CAN H

CAN L

89

141

GND

F40

F36

272

270

419

71

F34

F33

F32

F30

F31

X58

142

ALIM 12 V
2

140

55

419

54

D
F29

C
F27

F20

F19

F18

F17

F15

F16

F13

F14

BF2/M2

F28

280

278

F12

F11

F9

F10

F8

F7

F6

81

F5

F4

F3

F2

171

A
F1

BF2/M1

277

279

A5 / LLMI

80

76

E
81

A1
EP13

E1

38

RPM

HORAMETRE
MICRO CONTROLEUR

P1

B6
P2
BP1

BP2

120 Ohm

X310

55

69

170

X13

38
A8

55

54

A1

21

C3

EP17

38

54

171

22

67

25

26

CAN 1 HI

CAN 1 LOW
26

A3
X57

01

02

EP12
X99

BLUE

RED

WHITE

PAD

61

60

59

BLACK

61

60

59

CABLE 5
X19

X115

270
16

CABLE 6
59

347

142

348

348

CABLE 3

347

60

CABLE 7

67

69

CAN / CABLE M12

141

84

CABLE 7

WHITE

11

14

BLUE
88

CABLE 2
1

272

(09/02/2011)

80-02-M176FR

80

345

346

CAN H

R120

CAN L

ROUGE

A11

GND CAN

X276

21

REF OUT 10V

07

JAUGE CAN VISHAY

NOIR

64

62

87

71

12 VP IN

CAN GND

CAN L

X56

X299 / C2
DRAIN

CAN / CABLE 1

38

A2

X295 / C1
CAN H

F46

F45

F44

F43

F42

F41

BAT -

BF1/M1

BAT +

43

40

55

54

C14

MT 625 T COMFORT / MLT 625-75 H

80

Main Electrical Schmatic

80-02-M176FR

(09/02/2011)

C15

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

3 - TRANSMISSION
Connectors
Harness Type

Rep.

Comp.
Name

X62

B14

Position on
schmatic

Dscription
Hydraulic pump speed sensor

O7

X65

B21

Front wheel alignment sensor

G5

Chssis

X66

B12

Rear wheel alignment sensor

G3

Chssis

X67

A4

JSM (Joystick Switch and Move)

C7

Chssis

X92

Y13

Negative brake electrovalve

X114

S51

Off pedal sensor

Chssis

X139

B9

Angle inching pedal sensor

Engine

X260

Y6

Electrovalve proportional 2P engine hydrostatic

Q13

Engine

X261

Y7

Electrovalve BDP (Brake Pressure Defit)

Q15

Engine

X292

A2

ECU transmission

Chssis

X294

S13

Engine

X295

A2

Chssis

X302

S15

Negative parking brake switch

E16

Chssis

X309

H24

Rear wheel alignment indicatores

E3

Chssis/Engine

X310

Option

X373

B13

Hydrostatic motor speed sensor

G6

X378

H35

Rear wheel alignment indicator

E4

Correspondance
hydraulique

M16
M8
O10

I9

Low speed switch mode/High speed

A16

ECU transmission

I3

Interface Chssis/Engine

G10/K12

Composants
Dsignation

Position sur schma

A2

ECU transmission

I16

A4

JSM (Joystick Switch and Move)

A12
Q11

B9

Inching pedal angle sensor redundant

B12

Rear wheel alignment sensor

G3

B13

Hydrostatic motor speed sensor

G6

B14

Hydraulic pump speed sensor

Q6

B15

Roller 1 sur JSM (Tlescope)

A9

B16

Roller 2 sur JSM (Accessories)

A9

B21

Front wheel alignment sensor

E4

H13

High speed indicator (GV)

C16

H15

Parking brake Control Indicator

G16

H24

Rear wheel alignment indicator

E3

H35

Front wheel alignment indicator

E5

Slector FNR (Forward/Neutre/Reverse

A11

S13

S4

Slow speed/high speed mode switch

A16

S15

Negative parking brake switch

E16

S51

Off pedal sensor

M8

Y3

Forward proportional electrovalve

O3

Y4

Reverse proportional Electrovalve

Y6

Electrovalve proportional 2P hydrostatic engine

Y7
Y13
(09/02/2011)

Correspondance
hydraulique

80

Rep.

O4
Q13

Electrovalve BDP (Brake Pressure Defit)

Q15

Negative brake Electrovalve

O17
80-02-M176FR

C16

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Fuses & relays

Rep.

Position on schmatic

Dscription
BF2/M1

F4
F10

ECU transmission + Seat contact + JSM (10A)

A3

Sensor + wheel alignment light (2A)

A4
BF2/M5

K2

Relay reverse light & buzzer (20A/35A)

G13

Splices
Rep.

Position on schmatic
K11

Ep.10

K10

Ep.13

E7

Ep.14

K18

80

Ep.9

80-02-M176FR

(09/02/2011)

C17

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Electric Schmatic Transmission

1

10

11

12

13

14

15

16

17

9
27

AP
C
AP 5
C 4
15

27

18

19

r
eu
ot
M sis
se as
as Ch ine
- M se Cab e
00 as R bin
X3 - M e A Ca
21 ss AV
X3 Ma se
- as
04 M
X3 3 0
X3

A
279

B15

277

BF2/M1

A4

B16

A
F4

F10
81

164

27

77
163

10

78

159

C
2

11

337

337

163

H13

12

68

10

76

31

X67

X309

80

335

76

323

X294

25 mm2

S13

S4

X378

S15
81

H35

80

H24

X302
1
5

X378

EP13

30

334

336

X373

6
8

K2

160

X310

C3

30

X65

31

335

334

167

BF2/M5

38

78

H15
9

10

159

164

162

162

38

X66

130

68

X309

C5

C6

79

CF

31

26

D OUT BOP

ANA OUT 2P

22

D IN MODE 2

D IN REV

ANA IN RPM MOT

A2

27

20

20

27

C4

X310

27

B7

16

20

17

21
21

11

B4

C3

EP9
72

73

75

74

80

340
3

X92

S51

Y3

129

130

341

342

339

EP14

X114

B6

EP10

Towards X374-1
(page C21)

30

17

17

D IN FORW

SENSOR -

B5

BAT +

ANA INCHING PED1

16

12

16

16

X292 / C6

SENSOR +

RPM SENSOR -

21

17

RPM PUMP -

RPM IN MOT HYDR

C5
6

340

RPM PUMP +

PWM OUT REV -

C4
2

342

PWM OUT FORW -

PWM OUT REV +

PWM OUT FORW +

BAT -

RPM MOT +

X295 / C1

RPM IN MOT HYDR

38

40

B21

ANA IN PED2

B12

B13

Y13

Y4

X139

73

20

75

72
3

X260

CF

26

22

23

B14

X261

24

X62

21

74

B9

Pedal Inching 5V
output 0.5 to 4.5V

2P

BDP

Y6

Y7

(09/02/2011)

80-02-M176FR

C18

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

4 - MOVEMENTS HYDRAULICOS

80

Connectors
Harness Type

Rep.

Name of
component

Chssis

X56

A3

ECU hydraulic

Chssis

X57

A3

ECU hydraulic

K31

Chssis

X67

A4

JSM (Joystick Switch and Move)

C17

Chssis

X100

B11

Redundant jib angle Potentiomtre

C27

Chssis

X134

S34

No jib retraction sensor

Chssis

X264

Y8

Telescope direction Electrovalve + ou -

Q32

Chssis

X265

Y9

Electrovalve accessory direction + ou -

Q35
Q36
Q37

Dscription

Position sur
schma
K31

I25

Chssis

X266

Y10

Pilot Electrovalve hydraulic proportional

(Tlescope)

Chssis

X267

Y11

Pilot Electrovalve hydraulic proportional

(Accessory)

Chssis

X269

Y12

Electrovalve hydraulic cutoff (TUV)

Chssis

X270

Y14

Descent cutoff Electrovalve (option cutoff

aggravating movements)

Q18

Chssis

X274

S5/S6

Seat Contactors

A13

Chssis

X275

Y15

Tilt cutoff Electrovalve (option coupure

aggravating movements)

O17

Moteur

X295

A2

ECU transmission

K15
I21

Q31

Chssis

X305

S31

Hydraulic movements cutoff shunt switch/

surcharge

Chssis

X308

S16

Warning switch

M7

Chssis/Moteur

X310

Interface Chssis/Engine

I12

Chssis

X311

S14

Hydraulic cutoff switch (TUV)

Chssis

X312

S18

Rear Fog Lamp Switch

Chssis

X313

S19

Beacon Switch

Q7

Chssis

X314

S20

Front working lights switch /front+rear

Q12

Chssis

X315

S21

Rear defrost switch

M11

Chssis

X363

S22

jib head electrovalve switch

I8

Chssis

X368

S46

Accessory Line Decompression control

C36
C34

M23
O5

Chssis

X370

Accessory line flow switch

Chssis

X374

Tilt nuetral switch

G5

Chssis

X375

S52

Accessory line decompression Button

G5

Y18

Jib head Electrovalve

S16

Prdisposition ventilation control

O25

Chssis

X377

Chssis

X381

Chssis

X383

S45

Flow switch accessory line

A35

Chssis

X385

Y19

Speed Electrovalve (TS) Fan Drive

Q24

Chssis

X386

Y20

Direction Electrovalve (SV) Fan Drive

Q26

80-02-M176FR

Correspondance
hydraulique

(09/02/2011)

C19

Main Electric Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Components
Dscription

Position on schmatic

A2

ECU transmission

K2

A3

ECU hydraulic

K30

A4

JSM (Joystick Switch and Move)

A21

B11

Redundant boom angel Potentiomtre

C35

B15

Roller 1 sur JSM (Tlescope)

A18

B16

Roller 2 sur JSM (Accessory)

D4

Diode

O22

A19

H14

Hydraulic movement cutoff indicator (TUV)

O23

H16

Warning indicator

M7

H18

Rear fog light control indicator

Q4

H19

Beacon indicator control

H20

Front/Rear Work lights control indicator

Q11

H21

Rear defrost control indicator

O12

H22

Boom head electrovalve indicator

I8

H31

Security shunt indicator surcharge

K22

H52

S7

Accessory line indicator

S4

Slector FNR (Forward/Neutre/Reverse)

S5

Seat Contact NO

I5
A20
C12

S6

Seat Contact NF

C13

S14

Hydraulic cutoff switch (TUV)

M24

S16

Warning Switch

M6

S18

Rear fog light switch

S19

Beacon Switch

S20

Work lights switch front/front+rear

Q11

S21

Rear defrost switch

M11

S22

Head Boom lectrovalve switch

I8

S31

Switch shunt cutoff movements hydraulic/surcharge

I22

S34

NO boom retraction sensor

K24

S45

Accessory Flow line Slector

A35

S46

Accessory line decompression control

C36

S52

Accessory line dcompression button

G5

Y8

Electrovalve tlescope direction + ou

Q32

Y9

Electrovalve accessory direction + ou

Q34

Y10

Hydraulic proportional Electrovalve pilotage (Tlescope)

Q36

Y11

Hydraulic proportional Electrovalve pilotage (Accessoire)

Q37

Y12

Hydraulic cutoff Electrovalve (TUV)

S22

Y14

Descent cutoff Electrovalve (option aggraviated movements cutoff)

S17

Y15

Tilt cutoff Electrovalve (option aggraviated movements cutoff)

M17

Y18

Boom head Electrovalve

S16

Y19

Speed Electrovalve (TS) Fan Drive

Q24

Y20

Electrovalve direction (SV) Fan Drive

Q26

(09/02/2011)

Correspondance
hydraulique

O
Q7

80

Rep.

80-02-M176FR

C20

Main Electric Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Fuses & relays

Rep.

Position on schmatic

Dscription
BF2/M1

F4

ECU transmission + seat contact + JSM (10A)

F6

Seat Contact + sensor supply boom angle retract (10A)

C6

F7

ECU hydraulic (10A)

C6

F8

Shunt movements cutoff / boom retract sensor / feed

scurity ECU (10A)

C7

Electrovalve boom head (7,5A)

C7

F16

C6

BF2/M5
K2
K4

Reverse light and buzzer (20A/35A)

M32

Movements cutoff relay (20A/35A)

K28

Splices
Rep.

Position on schmatic

Ep.5

E29

Ep.6

E13

Ep.8

C20

Ep.11

C18

Ep.12

G26
K33

Ep.24

Q18

Ep.25

C19

80

Ep.15

80-02-M176FR

(09/02/2011)

MT 625 T COMFORT / MLT 625-75 H

Electrical Schmatic Hydraulic Movement

5

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

A4

S22

S45

B11

373
11

125
85

326
4

X368

137

4
3

X368
1

326

85

86

X370

50

56

53

47

48

49

262

259

S46

0
375 374

X100

281

12

EP8

EP11

86

125

323

125

25 mm2

86

183

264

261

260

263

42

Angle de flche 12V

output 0.5 to 4.5V
370

282

10

257

S6

258

X67
357

S5

169

138

135

58

355

359

SEAT

83

41

Off

372

371

372

X274

F16

F8

F7

F6

F4

277

BF2/M1

373

83

279

X383

S4

137

B16

40

371

B15

370

AP
C
AP 5
C 4
15

27

r
eu
ot
M sis
se as
as Ch ine
- M se Cab e
00 as R bin
X3 - M e A Ca
21 ss AV
X3 Ma se
- as
04 M
X3 3 0
X3

2
27

C21

Main Electrical Schmatic

E
39

427

Ep.6

355

EP5

Towards EP17
(page C17)

58
48

195

X375
94

288

10

G
Towards X322-1
(page C33)

EP15

Towards X91-2
(page C33)

138

S52

53

166

S22

X363

600

264

262
24

16

OUT PWM 10

IN TOR 15

12

IN ANA V 4

357

86

13

IN ANA V 8

GND PW
12VC

12 VC

26

IN TOR 16

455

454
20

OUT LS 2

03

GND PW

310

123

OUT PWM 6

OUT PWM 1

02

OUT PWM 5

OUT PWM 7

14

OUT PWM 8

125
10

IN TOR 13

IN TOR 3

22

OUT PWM 3

GND PW

OUT PWM 2

IN TOR 10

IN ANA V 3

15

124

283

94

263

259

12 VB IN

IN TOR 14

427

172

56

360

12

GND ANA

S34

X295 / C1

01

OUT PWM 9

12

17

A3

05

29

08

09

X57

33

354

07

353

30

120

17

126

34

206

31

456

25

284

06

169

32

202

23

201

15

139

281

22

204

D IN NEUT

Towrds X91-1
(page C33)

BAT +

BAT -

288

392

H31

39

40

288

94

166

57

392

Towards EP14
(page C17)

94

X374

135
136

10

06

IN TOR 1

289

C7

08

OUT PWM 4

196
C3

25

OUT LS 1

X310

16

IN TOR 8

H22

05

OUT PWM 11

49

X56
2

IN ANA V 2

IN ANA V 1

IN TOR 6

IN TOR 5

X134

128

S31
X305

358
39

OUT LS 1

288 10

IN TOR 12

204

359

138

195

139

305

205

H52

Towards X322-9
(page C33)

284

A2

EP12

326

X308

0
2

Y15

8
3

0
0

X315

X275

5
7
2
6

197

EP24

208

X377

X270

X385

X386

10

X264

X265

X266

X267

122

124
2

Y8

Y9

T+

Y10

Y11

A+

211
210

X313

Y12

VS
H20

S19

370

369

362

X314

185

S20

Ep.25

202

209

X269

172

202

10

185

364

H18

121

X381

5
1

120

132

10

123

212
197

211

131

212

126

10

370

X312

363

S18

H14

128

H21

206

201

184

364

H16

S14
X311

363

362

S21
207

10

369

Towards X312-9
(page C27)

153

1
5

Y18
H19
9

(09/02/2011)

10

Y14

Y19

Y20

210
209

80-02-M176FR

80

183

S16

C22

MT 625 T COMFORT / MLT 625-75 H

80

Main Electrical Schmatic

80-02-M176FR

(09/02/2011)

C23

Main Electric Schmatic

MT 625 T COMFORT/ MLT 625-75 H

5 - LIGHTING SYSTEMS / VENTILATION

Connecteurs
Harness Type

Rep.

Name of
component

Cabine 1

X6

E15

Beacon outlet

S25/S26

S28

Wiper handle

M36

Wiper handle

O36

Dashboard unit

C39

Position on
schmatic

Chssis

X11

Chssis

X12

Chssis

X13

A1

Chssis

X14

S26 / S27

Light handle

C13

Moteur

X17

B3

Engine oil pressure switch

E33

Moteur

X18

B5

Thermocontact engine water

E34

Clogged air filter

G32

Clogged hydraulic filtre Colmatage

E31

X20

B35

Chssis

X21

B7

Chssis

X22

S11

Brake fluid level sensor

Chssis

X25

M6

Front Wiper Motor

Chssis

Interconnection chassis harness/front wiper pump

X26
X27

M5

Front wiper pump

M8

E30/G30
Q34
Q31
S31

Option

X28

Rear wiper pump

S33

Chssis

X31

Rear left light

Q10

Chssis

X32

Rear right light

Q13

Chssis

X35

Front light left

I11

Chssis

X36

Front right light

I15

Chssis

X37

E7

Minralogic lighting plate (TUV 25Km/h)

Q9

Chssis

X38

B1

Back up alarm

Q16

Chssis

X39

B2

Main Alarm Warning

I13

Chssis

X40

PER

Electric towing outlet

Q18

X41

S28

Wiping handle

O37

Chssis

X46

S30

Cigarrete lighter

Chssis

X47

S30

Cigarrete lighter

Cabine 2

X50

E16

Ceiling light

05
O6
O30

Cabine 1

X59

M7

Rear Wiper motor

Chssis

X63

B34

Fuel Gauge

Chssis

X64

B8

Master cylinder Pressure switch

X65

B21

Front wheel alignment Sensor

S21

Chssis

X66

B12

Rear Wheel alignment sensor

Q23

Chssis

X67

A4

JSM (Joystick Switch and Move)

G37

X103

E19

Boom Work lights

A10

X104

E19

Boom work lights

A8

Q29
E38/G38
M12/O12

Chssis

X105

Foot boom work lights Option

Chssis

X106

Foot boom prdisposition lectric option

C4

Cabine 2

X107

M4

Roof Wiper Motor

M31

Chssis

X133

B10

Negative brake info Pressure switch

Chssis/Cabine 1

X276

Interface Chssis/Cabine 1

A4/A7

E27/E28
Q25

Chssis/Cabine 2

X277

Interface Chssis/Cabine 2

K29

Moteur

X291

B4

Engine water temp. sensor

E35

Moteur

X292

A2

ECU transmission

I32

Moteur

X295

A2

ECU transmission

I34

Chssis

X308

S16

Warning switch

A20

Chssis

X309

H24

Rear wheel alignment indicator

(09/02/2011)

Correspondance
hydraulique

80

Dscription

O22/Q22
80-02-M176FR

C24

Main Electric Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Connectors
Harness Type

Rep.

Name of
component

Position on
schmatic

Dscription

Chssis/Moteur

X310

Chssis

X312

S18

Rear fog light switch

Chssis

X313

S19

Beacon Switch

O25

Chssis

X314

S20

Front Work light switch/front+rear

M27

X324

S42

Foot boom work lights switch

Cabine 1

Interface Chssis/Engine

E34/I3/I35/I31
M16

A6

X331

Rear work lights

Q29

X358

Boom work lights

A9

X378

H35

X382
X383

S53

Correspondance
hydraulique

Front wheel alignment indicator

O20

Prdisposition ventilation rgulation

G24

Ventilation rgulation switch

G24

Components

80

Rep.

Dscription

Position on schmatic

A1

Dashboard unit

A38

A2

ECU transmission

G33

A4

JSM (Joystick Switch and Move)

I40

B1

Back up alarm

S16

B2

Main buzzer warning

I13

B3

Engine oil Pressure switch

G33

B4

Engine water temperature Sensor

G36

B5

Engine water thermocontact

G34

B6

Dashboard failure buzzer

A35

B7

Clogg hydraulic filter

G31

B8

Master cylinder pressure switch

O12

B10

Negative brake info Pressure switch

G27

B12

Rear wheel alignment sensor

S22

B15

Roller 1 sur JSM (Tlescope)

G40

B16

Roller 2 sur JSM (Accessory)

G40

B21

Front wheel sensor

S20

B34

Fuel Gauge

E39

B35

Clogged air

G32

D1

Diode

C6

D2

Diode

M28

D5

Diode

A5

E2

Back up light

E3

Stop light right/left

E4

Rear fog light

E6

Illumination cigarette lighter

06

E7

Illumination plate minralogic (TUV 25Km/h)

S9

E8

Front/Rear left Night lights

I10/S11

E9

Front/Rear right night lights

I16/S14

E10

Front and Rear Left blinkers

I11/S10

E11

Front and Rear Right blinkers

I17/S13

E12

Codes right and left

I10/I16

E13

Lights Right/Left

I10/I16

E15

Beacon

80-02-M176FR

Correspondance
hydraulique

S14
S12/S14
S11

S27
(09/02/2011)

C25

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Components
Dscription

E16

Roof Ligh

E19

Boom work lights

Position on schmatic

O29
A8/A10

H1

Batery charge indicator

A24

H2

Active negative brake indicator

A25

H3

Engine oil pressure indicator

A25

H4

Engine water temp. indicator

A26

H5

Hydraulic filter clogging indicator

A27

H6

Container brake fluid level indicator

A28

H7

High beam

A28

H8

Turn signal indicator

A29

H9

Fault indicator ECU downgrade mode

A30

H10

Rserve fuel Indicator

A31

H16

Warning indicator

C21

H18

Rear fog light control indicator

O16

H19

Beacon Indicator control

O24

H20

Work light front/rear indicator control

O27

H24

Rear wheel alignment indicator

Q22

H25

General Fault indicator

A32

H26

Clogged air filter indicator

A32

H27

Prheating indicator

A33

H28

Forward indicator

A34

H29

Neutral indicator

A35

H30

Reverse indicator

A35

H35

Rear wheel alignment indicator

Q20

H42

Foot boom light control indicator

C6

H53

Regulation ventilation control indicator control

I25

M3

Beacon Motor

S27

M4

Roof Motor wiper

O31

M5

Front wiper pump motor

S31

M6

Front motor wiper

S35

M7

Rear wiper Motor

S29

M8

Rear wiper pump

S32

P1

Hourmeter unit

A39

P2

Diesel gauge unit

C36

PER

Electric tow outlet

S20

S4

Slector FNR (Forward/Neutre/Reverse)

I39

S11

Brake fluid level sensor

G29

S16

Warning switch

A20

S18

Rear fog light switch

M16

S19

Beacon switch

M24

S20

Front/front+rear work lights switch

M26

S25

Roof light switch control

O29

S26

Horn control

A16

S27

Illumination handle

C15

S28

Wiper handle

S38

S29

Roof wiper Handle

M32

S30

Cigarette lighter control Commande

07

S42

Foot boom light switch

A6

(09/02/2011)

Correspondance
hydraulique

80

Rep.

80-02-M176FR

C26

Schmas de principe lectrique

MT 625 T COMFORT/ MLT 625-75 H

Components
Rep.

S53

Correspondance
hydraulique

Position on schmatic

Dscription

Regulation ventilation control switch

G25

Fuses & relays

Rep.

Position on schmatic

Dscription
BF1/M1

F44

Cabine fuse box (+BAT) (50A)

I5
BF2/M1

F1

Feed dashboard (+apc) (7,5A)

M5

F4

ECU transmission + seat contact + JSM (10A)

M5

F5

Cigarette lighter + info autoradio (10A)

M5

F9

Feed K2 + K3 (reverse light + reverse buzzer + stop light) (5A)

M5

F10

Sensor + lamp wheel alignment (2A)

M5

F11

Central blinker (feed + APC) (15A)

M5

F12

Rear fog light switch

K5

F13

Boom work lights switch (15A maxi)

K5

F14

Beacon (7,5A)

K5

F17

Rear wiper control + Roof wiper + rear wiper

(15A)

K5

F18

Front wiper control + windshield washer (15A)

K5

F20

Heater (20A)

K5
BF2/M2

80

F21

Left Night lights feed + cigarette lighter light feed (3A)

G5

F22

Right night light feed + Hydrauilc pilot illumination button +

dashboard illumination (3A)

F23

Feed codes (15A)

G5

F24

Light feed (15A)

G5

F25

Right blinkers feed (7,5A)

G5

F26

Left blinkers feed (7,5A)

G5

F31

Illumination Handle (25A)

E5

F32

Warning + centrale blinking (alim+bat) (15A)

E5

F34

Horn + roof light + dashboard (7,5A)

E5

F37

Rear Motor wiper (+perm) (10A)

E5

F38

Front Motor wiper (+perm) (15A)

G5

E5
BF2/M3

K10

Air condition time relay

A17
BF2/M4

K8

Centrale blinker

C18

Splices
Rep.

80-02-M176FR

Position on schmatic

Ep.18

E39

Ep.39

M32

(09/02/2011)

Electric Schmatic Lighting System / VentilationMT

10

11

12

13

14

15

16

17

18

19

20

21

C27

Main Electric Schmatic

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

214

49

54d

S26

Towards
300
K7-2
(Page C9)

H42

E19

E19

30

31

BF2/M4

BP1

CL

26

K8
177

11

18

15

12

178
1

14
14

X18

X382

S53

327

135

97

B34

X291

344

EP20

108
143

104
118

308

X35

X36

B2

114

108

101

97

111

118

102

98

100
1

B7

S11

B3

B5

242

327

E13 E12

G
B15

332
338

3
2

BAT -

40

B16

X310

H53

2
10

135

C3

BAT +

X292 / C6

X310

95

96

BF2/M1
B F20
280

10

D IN FORW

E8 E10

B4

X20-2

X22.2

B3

37
E13 E12

B35

A2

X63

B10

X383

107
344

D IN REV

31

C5

30

C6

31
7

30

PWM -/D OUT -

E9 E11

31
11

68

A4
F

12

249

250

F17

S4

37

X295 / C1

F18

13

14

X17

X63

X67

F44

247
246

X277

217

S18

H18
221
Towards X294-10
(page C17)

E3

E3

E2

331

329
C

Towards X276
(page C33)

X59
1

X27

X25

0
6

+perm

S28

vit 1
vit2

M5
-

M7

vit

raz

320

403

X28

E15
167

X6

M3

B12

330

256

332

569
569

251

336

96

192

193

188

252

X6

B21
191

255

X66

254

242

X26
406

320

+perm

100
295

X41

X331

242

E7

174

247
2

X309

B1

X12

320
5

X65

E9

244

X38

319

M4

167

X378

164

E16

244

X40

162

raz

209

X276

336

E11

vit

254

PER

192

STOP

E10

210

M8

raz

M6

256

E4

10

403

E8

H24

334

STOP

X309

H35

334

194

193

182

105

110

189

199
5

190

113

116

168

168

191
4

+perm

162

253

113

X32

X50

S25

H19

223

105

112

194

X31

252

253

199

X37

X378
6

3 110

222

163
2

1
2

116

337

37

110
105

10

187

335

182

E6

223

115

104

295

190

187

S30

109

X47

198

209

188

228

208

115

X64-2

H20

X313
10

570

220

569

244
329
251

244

K3

210

B8

S29

248

235

K2

117

569
331
249

S19

250

198

319

235

BF2/M5

219

36

180

179

30

BF2/M5

180

68

171

248

F1

246

X314

406

F4

0
X312

248

X64-1

X11

EP39

570

181

234

S20

X107

149

179

F5

247

407

D2

164
335

F9

322

224

F10

149

155

219

F11

322

149

407

221
318

253

F14
F13
F12

234

X20-1

243

X39.2

(09/02/2011)

X21

N
P

99

BF1/M1

A7

451

365

368

366

103

54

X46

170

3
Towards X57-14
(page C17)

101

X39.1

279

A6

114

55

Towards X268-3
(page C17)

117

277

A5

X22.1

165

133

X133-2

X133-1

F21

278

14

166

6 (C)

112

F22

21

22

25

X13

111

F23

14

176

8 (R)

10

134

X14

BP2

120 Ohm

A1

B6

4 (+)

119

146
150

323

P1

P2

109

X310
A8

H16

366

F24

152

MICRO CONTROLEUR

107

25 mm2

HORAMETRE

144

F25

154

H30

156

H29

X310

F26

145

H28

215

F28

147

H27

173

F31

H26

148

F32

150

H25

H10

319
149

F34

151

H9

255

F37

H8

42

158

157

145

144

214
151
216
148

450

147

312

450

BF2/M2
D F38

158

218

(R2)

155

D1

154

217

312

H7

X103

H6

10

213

301

5 (-)
X104

S27

H5

3
87

316

54s

56b

215

143

X106

X103

56a

173

H4

41

177

312

294

146

X104

10

314

57/58

317

85

171

RT

H3

213

H2

157

86
86

216

X105

H1

X308

207

318

S16

K10

X358

208

E1

RPM

BF2/M3

BLUE

502
2

314

X324

156

S42

X105

BROWN

156

AP

X105

BLACK
YELLOW
GREEN

28

27

27

C
AP 54
C
AP 5
C 4
AP 15
C
V 15
C
-B
at

27

A1
1

D5

40

r
eu
ot
M sis
se as
as Ch ine
- M se Cab e
00 as R bin
X3 - M e A Ca
21 ss AV
X3 Ma se
- as
04 M
X3 3 0
X3

Towards K4
(page C33)

80-02-M176FR

80

625 T COMFORT / MLT 625-75 H

C28

MT 625 T COMFORT / MLT 625-75 H

80

Main Electric Schmatic

80-02-M176FR

(09/02/2011)

Schmas de principe lectrique

MT 625 T COMFORT/ MLT 625-75 H

C29

6 - OPTIONS
Connectors
Rep.

Chssis

X29

Name of
component

Dscription

Position on
schmatic

Heater Ventilator / air condition

E38

Chssis

X91

Boom head electrovalve Option

Q20

Chssis

X93

A7

Autoradio feed

E13

Chssis

X94

A7

Speaker autoradio

E16

Chssis

X95

Option Air condition

M35

Chssis

X105

Foot boom work lights Option

K25

Chssis

X106

Foot boom prdisposition lectric

M24

X153

A10

Bloc condenser

O35

X154

A10

Bloc condenser

O36

Chssis

X155

A9

Air condition harness option

X166

Y17

Head boom Electrovalve

Chssis

X204

HPD

Right speaker

Chssis

X205

HPG

Left speaker

E16

Chssis

X268

Accessory shunt

M18

Option

X274

Seat Contactor

C26

Chssis/Cabine 1

X276

Interface Chssis/Cabine 1

M9/Q8

Chssis/Cabine 2

X277

Interface Chssis/Cabine 2

M14/Q15

Chssis

X285

M9

Chssis

X286

S44/M11

G35
Q19
C14/C16

Ventilator

E38

S24

Ventilation control

E37
I19
Q4

Chssis

X305

S31

Cutoff movements hydraulic switch shunt/

surcharge

Chssis

X308

S16

Warning switch
Interface Chssis/Engine

Chssis/Moteur

X310

Chssis

X311

S14

hydraulic cutoff switch (TUV)

I16

Chssis

X312

S18

Rear fog lamp switch

M4

G5/M29

Chssis

X313

S19

Beacon Switch

I4

Chssis

X314

S20

Work light switch front/front + rear

I7

Rear window defrost switch

Chssis

X315

S21

Cabine 2

X316

R6

Chssis

X322

S12

Forward forced switch

X326

S23

Air condition control switch

C35

X327

B18

Air condition evaporator thermostat

E34

Cabine 1

X330

E18

Work lights front, right and left

O10

Cabine 1

X331

E17

Work lights rear, right and left

X360

S22

X362

S32

Electric boom prdisposition switch

O25

X363

S22

Line accessory lock switch

O20

Interconnection harness chassis/blue headlights harness

poultry

G7

Rear window defrost

Line accessory lock switch

I14
M15/O15
I22

M8/O8
018/O27/Q19

Chssis

X365

Option

X367

S43

Blue lights poultry switch

E10

Option

X372

S33

Accessory lock switch

M20

(09/02/2011)

Correspondance
hydraulique

80

Harness Type

80-02-M176FR

C30

Main Electrical S

MT 625 T COMFORT/ MLT 625-75 H

Components

80

Rep.

Dscription

Position on schmatic

A3

ECU hydraulic

G20

A7

Autoradio

G15

A9

Cooling Block

C38

A10

Condenser Block

Q36

B17

Evaporator probe

G33

B18

Evaporateur cooling Thermostat

E33

B20

Binary Pressureswitch (HP/BP) climate

Q36

D1

Diode

I10

D2

Diode

I10

D3

Diode

K34

D4

Diode

E17

Rear right and left working lights

O8/O9

E18

Front right and left working lights

O18/O12

E20

Poultry blue lights

O13

H12

Forced forward indicator

K22

H14

Hydraulics movements cutoff indicator (TUV)

K17

H16

Warning indicator

S5

H18

Control indicator

O4

H19

Bacon control indicator

K4

H20

Working lights front/rear control indicator

K7

H21

Rear window defrost control indicator

K12

H22

Accessory lock indicator

H31

Security surcharge shunt indicator

K20

K15

O20

H32

Electric boom prdisposition indicator

O25

H36

Poultry blue light indicator

G10

HPD

Right speaker

C18

HPG

Left speaker

C18

M9

Heater moto fan

G37

M10

Air condition condenser Moto fan

Q35

M11

Air seat Motor

E26

R6

Rear window defrost

O15

S12

Forced forward switch option

I23

S14

Hydraulic cutoff switch

I17

S16

Warning switch

Q4

S18

Rear fog lamp switch

M4

S19

Beacon Switch

I4

S20

Front/front+ Rear working lights switch

I7

S21

Rear window defroster

I12

S22

Accessory Line Lock Switch

O20

S23

Air condition control switch

C32

S24

Heater switch control

E36

S31

Hydraulic movements /surcharge cutoff shunt switch

I20

S32

Electric boom prdisposition switch

M25

S33

Accessory lock switch

M20

S36

Poultry blue lights switch

E10

S44

Air seat control

C26

80-02-M176FR

Correspondance
hydraulic

(09/02/2011)

C31

Main Electrical Schmatic

MT 625 T COMFORT/ MLT 625-75 H

Components
Rep.

Dsignation

Correspondance
hydraulique

Position sur schma

Y16

Air conditioning compressor clutch

Q30

Y17

Boom head Electrovalve

S19

Fusibles et relais
Rep.

Dsignation

Position sur schma

BF1/M1

F44

Cabin fuse box (+BAT) (50A)

I5
BF2/M1

F5

Cigartte lighter + autoradio (+apc) (10A)

C5

F6

Boom head Electrovalve + forced forward accessory (10A)

C5

F8

Tilt neutral feed + movements Shunt cutoff +

Accelerator pedal sensor

C5

F15

Rear window defrost (10A)

C5

F19

Alimentation BUS-BAR C (F27/F28/F29/F30) (30A maxi)

A5

F20

Heater (20A)

A5

F22

Right night light + Hydraulic steering illumination button + illumination

board (3A)

G4

F27

Accessory line dcompression (7,5A)

G4

F29

Air seat (10A)

E5

F30

Front working light + night lights/poultry blue lights (25A)

E5

F35

Autoradio (+perm) (10A)

E5

F39

Alimentation K6 (air condition Compressor) (7,5A)

E5

F40

Alimentation K5 (air condition motoventilator ) (20A)

C5

BF2/M2

K10

Delay relay air condition

80

BF2/M3
I32
BF2/M4
K7

Start cutoff Relay / digicode (20A/40A)

K26

K8

Flasher

I39
BF2/M5

K4

Movement cutoff Relay (20A/35A)

K38

K5

Air condition motoventilator relay (20A/35A)

I32

K6

Air condition compressor Relay (20A/35A)

I30

Splices
Rep.
Ep.39

(09/02/2011)

Position on schmatic
Q14

80-02-M176FR

Main Electric Schmatic

MT 625 T COMFORT/ MLT 625-75 H

80

C32

80-02-M176FR

(09/02/2011)

MT 625 T COMFORT / MLT 625-75 H

Electric Schmatic Options

6

10

11

12

13

14

15

16

18

19

20

21

22

23

24

25

26

27

28

BF2/M1
B F20

29

30

31

32

33

34

35

36

37

38

39

292

F15
F8

290

X274

432

S44

Blue

233

555

553
2

555

553

551

H36

Red

Green
5

M9

389

430
3

430

K10

BF2/M3

D1
87a

4
550

450

5
551

85
552

154
30

87
2

K9

86

X29

X155

F44

385

A7

BF1/M1

E
1

430

553

226

54
555

A1

431

B17
55

X310
A8

430

432

Black

B18

10 556

386

388

240

1 3 5 7
HP-AUTO

X327

1 3 5 7
ALIM-AUTO

X286

387

240

554

552

X365

M11

241

5
55

X94

239

C F22

236

553

313

X93

238

X367

558

Off

+ BAT

553

237

+ APC

S36

226

S24

X205-2
241

X205-1

BROWN

F27

292

389
1

293

Black

237

F29

431
2

302

F30

A9

X326

BROWN

F35

419

Black

303

F39
55

238

239

D F40

54

X204-1

S23
HPG

X204-2

BF2/M2

233

F5

279

35

F6

277

42

25 mm2

389

277

41

323

231

559

278

40

419

558

280

F19

15 86

Towards X56-22
(page C21)

RT

85

294
301

301

87
106

1 230

227

H19
10 210

232

212

10

289 10

H14

10 212

10 211

228

2 299

86

28

15

303

302

BF2/M5

K6

135

283 1

136

5 291

86

H31

288

30
87

87a

85

K7

312
288 10

87
2

358
9
311

K5 BF2/M5

D3
87a

85
5

2
298

H12

5 (-)

4 (+)
CL
K8

8 (R)

6 (C)

4
297

BF2/M5

K4

106

210

209

H21

H20
9

BF2/M4

30

S12
X322

5
7

D4

211

324

231

X305

299

225

S31

X311

X315

1 229

222

S14

155

325

S21

D2

224

550 6

288

X314

153

S20

0
X313

156

S19

3 (R2)

BF2/M4

28

156

Supply +12V

17

HPD

AP

27

27

C
AP 54
C
AP 5
C 4
AP 15
C
V 15
C
-B
at

27

r
eu
ot
M sis
se as
as Ch ine
- M se Cab e
00 as R bin
X3 - M e A Ca
21 ss AV
X3 Ma se
- as
04 M
X3 3 0
X3

28

C33

Main Electrical Schmatic

X106

327 1
5 143

X310

X330

BROWN

BROWN

320

E18

S22

E20

E20
BLUE

E18

R6

X363

X316-2

10

320

X276

X277

X166

305

X308

388
2

X154

10

Towards X312-9
(page C27)

X30

Y16
X91

310

312
308

408

BROWN

EP39

322

S16

X360
501

Towards K5-2
(page C33)

X153

H32
9

306

500

5
312

BLUE

305 1
Towards X382-2
(page C71)

H22
X331

313

X95

X362

BLUE

229

E17

E17

S32

135
143

X330

10

208

327
135
35

209

H18
220

X268

Towards X57-33
(page C21)

389

308

H33

X316-1
X331

324

229

0
X312

390

S18

A4

325

135 10

230

EC

+
-

M10

B20

A10

5
208

1
10
7
H16

(09/02/2011)

321

320

207

X361

306

306

289

552

322

Y17

80-02-M176FR

80

306

313

230

X277

X372

312

S33

313

X276

225

229

C34

MT 625 T COMFORT / MLT 625-75 H

80

Main Electrical Schmatic

80-02-M176FR

(09/02/2011)

Contents
Main Hydraulic Schematic

B1

MLT 625-75 H
pages

70

Lgend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3
Schmatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5

(22/10/2010)

70-02-M176FR

Main Hydraulic Schmatic

70

B2

70-02-M176FR

(22/10/2010)

B3

Main Hydraulic Schmatic

MLT 625-75 H

HYDRAULIC SCHEMATIC LEGEND (MLT 625-75 H)

BA

Dscription
BLOCK FEED + ACCUMULATOR (

Position on
schmatic
K15

BCMA

AGGRAVATING MOVEMENT CUT OFF BLOCK

Q27

BMHP

PROPORTIONAL HYDRAULIC MANIPULATEUR BLOCK

Q24

SUCTION STRAINER

S11

CA
CAR
D
D3

ANTI-RETURN FLAP

S12

DISTRIBUTOR

M37

3 POSITION STEERING DISTRIBUTOR

A13

- POSITION 1 : TURNING SHORT

A14

- POSITION 2 : FRONT WHEEL STEERING

A14

- POSITION 3 : CRAB STEERING

EVTF (O)

A14

HEAD BOOM LECTROVALVE

G41

FDAR

REAR FRONT DISC

C18

FDAV

FRONT BRAKE DISC

FR

RETURN FILTRE

THERMIC ENGINE KUBOTA V3307 DI-T (TURBO)

Q14
O2
895 25 Tr/min

- SYSTEM RATED LOAD

2600 Tr/min

- HIGH IDLE

MH
MHRV
P

MASTER CYLINDER
HYDROSTATIC MOTOR

A7
K8

HYDRAULIC PUMP

O4

PAAV

FRONT ACCESSORY OUTLET

FRONT ACCESSORY OUTLET

PDD

DYNAMIC STEERING PUMP

PH

HYDROSTATIC PUMP

PP

PRESSION OUTLET

PRF (O)
R

2800 Tr/min
A8

HYDRAULIC MOTOR REGULATION VENTILATION

PAAV (O)

RETURN RELEASE OUTLET

G37
E35 E40

O11
E8/K15/O25
M40
S15

R1

SECONDARY HYDRAULIC TANK

Q19

RF

COOLER

K12

RLF

BRAKE FLUID TANK

COMPENSATION CYLINDER

VE

BALANCING VALVE

VDAR

REAR STEERING CYLINDER

VDAV

OPTION

A8

ISOLATION VALVE

VC

OPTIO

I15

PRINCIPAL HYDRAULIC TANK

VAI(O)

OPTION

C4

- IDLING

MC

Caractristiques (Options)

70

Rep.

OPTION
E30

DE 115x60 C310

E32 /G30/I28/
I37
C16

FRONT STEERING CYLINDER

C6

VI

TILT CYLINDER

G27

DE 125x65 C 396

VL

LIFT CYLINDER

I26

DE 120x70 C 1100

VT

TLESCOPING CYLINDER

I35

DECK LOCK CYLINDER

E38

VVT (O)
Y3

FORWARD LECTROVALVE PROPORTIONAL

O7

Y4

REVERSE LECTROVALVE PROPORTIONAL

O6

Y6

LECTROVALVE PROPORTIONAL 2P HYDROSTATIC MOTOR

SAUER (PCOR)

C8

Y7

LECTROVALVE BPD (BRAKE PRESSURE DEFEAT)

C9

Y8

LECTROVALVE TLESCOPING SENS + OU -

K19

Y9

LECTROVALVE ACCESSORY SENS + OU -

K19

(22/10/2010)

DE 70x45 C 2200
DE 60x45 C 183 - OPTION

70-02-M176FR

B4

Main Hydraulic Schmatic

MLT 625-75 H

HYDRAULIC SCHEMATIC LGEND (MLT 625-75 H)

70

Rep.

Dscription

Position on
schmatic

Y10

LECTROVALVE STEERING HYDRAULIC PROPORTIONAL

(TLESCOPING)

K18

Y11

LECTROVALVE STEERING HYDRAULIC PROPORTIONAL

(ACCESSORY)

K18

Y12

LECTROVALVE HYDRAULIC CUTOFF (TUV)

K17

Y13

LECTROVALVE NEGATIVE BRAKE

M19

Y14

LECTROVALVE PROPORTIONAL CUTOFF DESCENT

Q28

Y15

LECTROVALVE TILT CUTOFF

S28

Y17

LECTROVALVE BOOM HEAD

G39

Y18

LECTROVALVE PROPORTIONAL RAISE CUTOFF

Q28

r = 1.16 x RPM

O3

tlescope retract-4b

K20

tlescope release-4a

K20

locking accessory-3b

K20

locking accessory-3a

K20

lift-1b

Q30

descent-1a

Q31

breakout-2a

S32

discharge-2b

S30

10

dynamic priority flow valve

O27

11

lift

O30

12

tilt

O32

13

accessory

O34

14

tlescoping

O36

15

(90l/min) descent

K30

16

(90l/min) lift

K16

17

(90l/min) breakout

K32

18

(90l/min) discharge

K32

19

(90l/min) unlocking accesory

K34

20

(90l/min) locking accessory

K34

21

(90l/min) tlescope release

K35

22

(90l/min) retracted tlescope

K36

23

security valve *

O28

Caractristiques (Options)

OPTION

* (cuts all the aggravating movements when the machine have reached its limits of stability)

70-02-M176FR

(22/10/2010)

B5

Main Hydraulic Schmatic

MLT 625-75 H
4

10

11

12

13

14

RLF
B2

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

AR
3 2 1

MC
L2

D3

42

AV

B1

MH

15

A BT
1

3 2

VDAV

P1

80 cm/tr

Y7

FDAR

P2

FDAV
min

max

VDAR

L1
B

PONT ARRIERE

PONT AVANT

Y6

M4

M5

PP
E

VC
L

VVT(O)

VE

PAAV(O)

V1

V1

V2

C4

PAAV(O)

200bar

V2

C1

C2

200bar

VI

PAAV

VE

V2

B1 B2

270 bar

V1

160cm/tr

C1

C3
Y17

EVTF(O)

C2

VAI(O)

A1 A2

P2

P1

140 bar

T LS

PDD
V1

VE

VL

Y8

Y10

Pp

MHRV

T+

A+

AC

RVE

Pin

Y13

DR

16

21
K

22

20

18

5
Psahr

PRF(O)

SAHR

EF

IN

19

A-

0.32 Litre
15 bar

+5

17

15

Y9

Y11

160b 0

V2

VE

T-

Y12

RF

8 cm/tr

V2

V1

PPC

BA
K

210 bar

VT

210 bar

LS

1b 1A 1B

2b 2A 2B

245 bar

245 bar

3b 3A 3B

4b 4A 4B
180 bar

245 bar

T
235 bar
8 bar

P
Y4

PH

Y3

1
O

31 cm/tr

M3
11 cm/tr

F00B

F00A

12 cm/tr

L2

MA

PP

400 bar

10

45 cm/tr

23

1a

2a

11

12

3a

13

4a

14

M5

M4

B
400 bar

S L1

MB

FR
VA

BMHP

4 bar

P
4
T

CAR

2 bar

R1

4.5 bar

3 bar
10m

(22/10/2010)

L-

1
2

T+

T-

P
L+
Y18

Y14

L-

Q
6

T+
Y15

T-

8
9

CA
90l/min
125m

L+
T

BCMA

70-02-M176FR

70

B6

70

Main Hydraulic Schmatic

70-02-M176FR

(22/10/2010)