Msi50h 547886asd

INTRODUCTION TO SAFETY AND TABLE OF CONTENTS
MANITOU NORTH AMERICA, INC.

6401 IMPERIAL DRIVE
WACO, TX 76712-6803
For Parts Orders contact your Manitou North America Dealer or call:
Manitou North America, Inc. Parts Dept. (800) 425-3727 or (254) 799-0232
Parts Dept. Fax (254) 867-6504 Website: www.manitou-na.com
MSI50H
Series 1-E2
OPERATOR'S MANUAL
THIS OPERATOR'S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ
AND UNDERSTOOD BY USERS.
547886AS
R11/10
MSI50H Series 1-E2

- INTRODUCTION TO SAFETY -
- ROUGH TERRAIN FORKLIFT TRUCK
GENERAL SAFETY STANDARDS - - - - - - - - - - - I
- SAFTETY MESSAGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII
- SAFETY DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
- TABLE OF CONTENTS
- OPERATING AND SAFETY INSTRUCTIONS - - - - - - - - - - - - - 1 - 3
- DESCRIPTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2 - 3
- MAINTENANCE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 - 3
R11-04
ROUGH TERRAIN FORKLIFT TRUCK

GENERAL SAFETY STANDARDS
I
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS
STUDY THE OPERATOR/SERVICE MANUALS

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

ASME B56.6 is the national consensus standard for rough terrain forklift trucks. It contains rules about fork-
lift 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 from the American Society of Mechanical Engineers (ASME), 345 East 47th St., United Engineering
Center, New York, NY 10017. The following references are examples from the standard, addressing forklift
operators:
A.) OPERATOR TRAINING QUALIFICATIONS

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

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

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

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

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

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

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

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

Before operating on a work site, learn the rules for movement of people, forklifts and all other traffic. Check
the size, weight, and condition of the loads you will be expected to handle. Verify that they are properly
secured and safe to transport. Learn where the loads are to be placed, planning your route for a safe
approach, watching for hazardous conditions. Will a signal man be required to help place the load? Remove
any debris which may cause tire damage or rupture. Plan your route around problem areas or have them cor-
rected. Inform the supervisor of any unsafe conditions observed at the site. Examples of hazards: power
lines, cables, low clearance structures, garage doors, telephone pole guide lines, fencing, loose lumber, build-
ing materials, drop-offs, trenches, rough/soft spots, oil spills, deep mud, steep inclines, railroad tracks, curbs,
etc.. NEVER approach power lines, gas lines or other utilities with the forklift! Always verify that local,
state/provincial and federal regulations have been met. Report any accidents involving personnel, building
structures, and equipment to the supervisor immediately. Always remain alert - conditions are constantly
changing at the work site!
TECHNICAL SUPPORT
All data provided in this manual is subject to production changes, addition of new models, and improved prod-
uct designs. If a question arises regarding your forklift, please consult your dealer or K-D Manitou, Inc. for the
latest information. When ordering service parts or requesting technical information, be prepared to quote the
applicable Model/Serial Numbers.
VIII
SAFETY MESSAGES
NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL

HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Also, observe
the safety messages places throughout this manual; providing special instructions, telling you when to take precautions
and to identify potential hazards. The safety messages are highlighted and outlined in a box similar to those shown in the
examples below.
SAFETY ALERT SYMBOL
NOTE or NOTICE
Provides information, special instructions or references about the lift truck.
IMPORTANT
Precautions which must be taken to avoid damage to the lift truck.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. May also alert unsafe practices.
WARNING
Indicates a potentially hazardous situation which, if not avoided, may result in death or
serious injury!
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
CALIFORNIA PROPOSITION 65 WARNING
Diesel Engine Exhaust and some of its constituents are known to the State of California
to cause cancer, birth defects or other reproductive harm.
WARNING: Battery posts, terminals and related accesories and related accessories
contain lead and lead compounds. Wash hands after handling.
IX
SAFETY DECALS
The purpose of this chapter is to introduce you to the safety messages, decals, and nameplates found on
your forklift truck. The decals are identified by name, part number, location, and a brief description. (The
forklift model logos, and other misc. decals not shown, can be found in your forklift parts manual.) The
decals illustrated may not be exactly the same as those installed on your forklift; installation of the decals
varies depending on the forklift model, series, decal updates, etc.. The size and location of some decals
limit the amount of information that can be placed upon it. For this reason, additional detailed information
not found on the decals is provided through-out this manual.
Every decal placed on the lift truck is important; they are constant reminders of safety and instructions that
should never be taken for granted. Even experienced operators can be seriously injured or killed by ignor-
ing, refusing to enforce, or forgetting to follow safe operating procedures! Do not assume you know all safe-
ty issues concerning the decals. Before operating the lift truck; learn the meaning(s) of the decals as
described in this manual. If any decal becomes illegible or missing, have it replaced immediately! Always
replace decals using the same decal part no., unless otherwise specified by the manufacturer. For replace-
ment decals not found in your parts manual, contact your nearest dealer. If you have any questions, contact
your supervisor or nearest dealer for advice before operating your forklift!
801011
Before Starting - 801011

(Boom equipped models). Location: on the brake fluid cover panel (to
the left and below the dash panel).
Safety Instructions - 420792

(Mast equipped models). Location: on or near the operator manual
storage case, and/or on the dash panel.
Instructions for the forklift operator; before operating the forklift.
Use of Seat Belt - 801012

(Boom equipped models). Location: to the right of the
operator, near the hydraulic control lever.
Instructs the operator to always wear the seat belt during

operations, and never jump from an over-turning forklift.
X
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 operator’s 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 mast’s outer rails,
at eye level (4 required).
Instructs personnel not to travel beneath or upon the lift truck forks.
Pinch Point, Large, 2.5 x 4.5 in. - 426643

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

crossbracing.
HAND THROTTLE DANGER - 804784

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

Disengage hand throttle before leaving the forklift.
XV
SAFETY DECALS
Acid in Battery - 801014

Location: in or near the battery
storage compartment.
Addresses battery hazards.
Jump Start Battery - 801015

Location: in or near the battery storage
compartment.
Jump start instructions.
Attachment Plate - 425995

Location: on the optional removeable forklift attachment.
Important manufacturer information about the attachment. Record this information for use
when contacting the maufacturer for parts and service.
Overhead Guard Data Plate - B6109

Location: attached to the overhead guard.
Overhead guard conformity.
496550 496538
Forklift Data Plate - 496550
(Boom equipped models)
Forklift Data Plate - 496538
(Mast equipped models)
Location: within the operator’s compartment.
Important forklift truck identification. Record

this information for use when contacting the
manufacturer for parts and service.
XVI
1 - OPERATING
AND SAFETY
INSTRUCTIONS
1-1
1-2
TABLE OF CONTENTS
INSTRUCTIONS TO THE COMPANY MANAGER 1-4

THE OPERATOR 1 - 4
THE LIFT TRUCK 1 - 4
A - THE LIFT TRUCK'S SUITABILITY FOR THE JOB 1 - 4
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS 1 - 4
C - MODIFICATION OF THE LIFT TRUCK 1 - 4
THE INSTRUCTIONS 1 - 5
THE MAINTENANCE 1 - 5
INSTRUCTIONS FOR THE OPERATOR 1-6

PREAMBULE 1-6
GENERAL INSTRUCTIONS 1-6
A - OPERATOR'S MANUAL 1-6
B - AUTHORIZATION FOR USE 1-6
C - MAINTENANCE 1-6
D - MODIFICATION OF THE LIFT TRUCK 1-6
E - LIFTING PEOPLE 1-7
OPERATING INSTRUCTIONS UNLADEN AND LADEN 1-8
A - BEFORE STARTING THE LIFT TRUCK 1-8
B - DRIVER’S OPERATING INSTRUCTIONS 1-8
C - ENVIRONMENT 1-9
D - VISIBILITY 1-9
E - STARTING THE LIFT TRUCK 1 - 10
F - DRIVING THE LIFT TRUCK 1 - 10
G - STOPPING THE LIFT TRUCK 1 - 11
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY 1 - 12
INSTRUCTIONS FOR HANDLING A LOAD 1 - 13
A - CHOICE OF ATTACHMENTS 1 - 13
B - MASS OF LOAD AND CENTER OF GRAVITY 1 - 13
C - TRANSVERSE (LEVEL) ATTITUDE OF THE LIFT TRUCK 1 - 14
D - TAKING UP A LOAD ON THE GROUND 1 - 14
E - TAKING UP AND LAYING A HIGH LOAD ON TIRES 1 - 15
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK 1 - 16

GENERAL INSTRUCTIONS 1 - 16
MAINTENANCE 1 - 16
LUBRICANT AND FUEL LEVELS 1 - 16
HYDRAULIC 1 - 16
ELECTRICITY 1 - 16
WELDING 1 - 17
WASHING THE LIFT TRUCK 1 - 17
IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME 1 - 18

INTRODUCTION 1 - 18
PREPARING THE LIFT TRUCK 1 - 18
PROTECTING THE I.C. ENGINE 1 - 18
PROTECTING THE LIFT TRUCK 1 - 18
BRINGING THE LIFT TRUCK BACK INTO SERVICE 1 - 19
1-3
INSTRUCTIONS TO THE COMPANY MANAGER
THE OPERATOR
- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment with respect to the use of lift trucks and must be carried permanently by the operator.
On the basis of experience, there are a number of possible situations in which operating the lift truck is unacceptable. Such foreseeable
abnormal uses, the main ones being listed below, are strictly WARNING
forbidden.
- The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any wish to put the machinery to any
On the basisuse.
improper of experience, there are a number of possible situations in which operating the lift truck is prohibited. Such fore-
seeable -abnormal uses, theofmain
The reflex reactions onesinbeing
a person listed
the event of below, are strictly
a malfunction, forbidden.
incident, fault, etc. during operation of the lift truck.
- The foreseeable
- Behaviour abnormal behavior
resulting from of neglect,
application but not intending
of the "principle to putwhen
of least action" the machinery
performing atotask.
any improper use.
- The reflex
- Forreactions of a person
certain machines, in the event
the foreseeable of a malfunction,
behaviour incident,
of such persons as : fault, etc. during
apprentices, operation
teenagers, of the liftpersons,
handicapped truck. trainees
- Behavior resulting from application of the "principle of least action" when performing a task.
tempted to drive a lift truck, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.
- ForThe
certain
personmachines, the
in charge of theforeseeable behavior
equipment must of such
take these persons
criteria as unauthorized:
into account apprentices,
when assessing whether teenagers,
or not a personhandicapped
will make aper-
sui-
sons and
table trainees tempted to drive a lift truck. Truck drivers tempted to operate a truck to win a bet, in competition or for their
driver.
own personal experience.
The person in charge of the equipment must take these criteria into account when assessing whether or not a person will
make a suitable driver.
THE LIFT TRUCK
A - THE LIFT TRUCK'S SUITABILITY FOR THE JOB

- MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator's
manual, with a STATIC test coefficient of 1.33 and a DYNAMIC test coefficient of 1, as specified in harmonized norm EN 1726-
1 for mast trucks.
- Before commissioning, the company manager must make sure that the lift truck is appropriate for the work to be done, and per-
form certain tests (in accordance with current legislation).
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS

- In addition to series equipment mounted on your lift truck, many options are available, such as : road lighting, stop lights, fla-
shing light, reverse lights, reverse buzzer alarm, front light, rear light, etc.
- The operator must take into account the operating conditions to define the lift truck's signalling and lighting equipment. Contact
your dealer.
- Take into account climatic and atmospheric conditions of the site of utilization.
. Protection against frost (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL).
. Adaptation of lubricants (ask your dealer for information).
. I.C. engine filtration (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
For operation underFor
average climatic
operation conditions,
under averagei.e. : between
climatic -15 °C and
conditions, i.e.+ between
35 °C, correct levels
-15 °C andof+ lubricants
35 °C (5°intoall95°F),
the circuits
correctarelevels
chec-
ked in production. of
Forlubricants
operation under more severe climatic conditions, before starting up, it is necessary to drain all
in all the circuits are provided in production. For operation under more severe climatic condi- the circuits, then
ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures. It is the
IMPORTANT tions, before starting up, it is necessary to drain all the circuits, then add the correct levels of lubricants pro- same for the cooling
liquid. perly suited to the relevant ambient temperatures. It is the same for the cooling fluid (Contact your dealer for
information, if necessary).
- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are
solutions, consult your dealer.
Your lift truck is designed
Your liftfor outdoor
truck use under
is designed for normal
outdooratmospheric conditions
use under normal and indoor
atmospheric use in suitably
conditions aerated
and indoor useand ventilated
in suitably premises.
aerated and
It is prohibited to use the lift truck
ventilated in areas
premises. It iswhere there is
prohibited toause
riskthe
of fire
lift or which
truck in are potentially
areas explosive
where there (e.g.ofRefineries,
is a risk fuelare
fire or which or gas depots,
potentially
WARNING explosive
stores of inflammable products…). For use in
(i.e. refineries, these
fuel areas,
or gas specific
depots, stores equipment is available
of inflammable (ask your
products…). Fordealer
use inforthese
information).
areas, specific equip-
ment is available (ask your dealer for information).
C - MODIFICATION OF THE LIFT TRUCK

- For your safety and that of others, you must not change the structure and settings of the various components used in your lift
truck (hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unap-
proved attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
1-4
THE INSTRUCTIONS
- The operator's manual must always be in good condition and kept in the place provided on the lift truck and in the language used
by the operator.
- The operator's manual and any plates or decals which are no longer legible or are damaged, must be replaced immediately.
THE MAINTENANCE
- Maintenance or repairs other than those detailed in part : 3 - MAINTENANCE must be carried out by qualified personnel (consult
your dealer) and under the necessary safety conditions to maintain the health of the operator and any third party.
Your lift truck must be inspected periodically to ensure that it remains in compliance. The frequency of this inspection is defined by cur-
rent legislation in the country
Your in which
lift truck must the lift truck isperiodically
be inspected used. to ensure that it remains in compliance. The frequency of this inspection
WARNING is defined by current legislation in the country in which the lift truck is used.
1-5
INSTRUCTIONS FOR THE OPERATOR
PREAMBULE
The risk of accidentThe

while
riskusing, servicing
of accident or operating,
while repairing your lift truck
servicing can be restricted
or repairing if youcan
your lift truck follow the safety
be reduced instructions
if you follow theand safety
safety ins-mea-
sures
DANGERdetailed in these instruction.
tructions and safety measures detailed in this manual. Failure to respect the safety and operating instructions, or the
instructions for repairing or servicing your lift truck can lead to serious injury or fatal accident.
- Only the operations and maneuvers described in these operator's manual must be performed. The manufacturer cannot predict
all possible risky situations. Consequently, the safety instructions given in the operator's manual and on the lift truck itself are
not all inclusive.
- At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself
when you use it.
GENERAL INSTRUCTIONS
A - OPERATOR'S MANUAL
- Read the operator's manual carefully.
- The operator's manual must always be in good condition and in the place provided for it on the lift truck.
- You must report any plates and decals which are no longer legible or which are damaged.
B - AUTHORIZATION FOR USE

(see current legislation)
- Only qualified, authorized personnel may use the lift truck. This authorization is given in writing by the appropriate person in the
company, in charge of using the lift truck, and must be permanently carried by the operator.
- The operator is not authorized to allow others to operate the lift truck.
C - MAINTENANCE
- The operator must immediately advise his superior if his lift truck is not in good working order or does not comply with the safe-
ty notice.
- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He
must keep the lift truck properly cleaned if this is among his responsibilities.
- The operator must carry out daily maintenance (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).
- The operator must ensure tires are adapted to the nature of the ground (see area of the contact surface of the tires in the chap-
ter : 2 - DESCRIPTION : CHARACTERISTICS). There are optional solutions, consult your dealer.
. SAND tires.
. LAND tires.
. Snow chains.
Do not use the lift Do
truck
notif operate
the tiresthe
arelift
incorrectly inflated,
truck if the damaged
tires are or excessively
incorrectly worn, because
inflated, damaged this could
or excessively put your
worn, Bad own
tires safety
can putor your
that
of others at risk, orsafety
DANGER causeordamage to the lift truck itself. The fitting of foam inflated tires is prohibited and is not guaranteed by the
that of others at risk, or cause damage to the lift truck. The installation of foam inflated tires is prohibited and manu-
facturer, exceptingisprior
not authorization.
guaranteed by the manufacturer (prior authorization is required).
D - MODIFICATION OF THE LIFT TRUCK

- For your safety and that of others, you must not change the structure and settings of the various components used in your lift
truck (hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unap-
proved attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
1-6
E - LIFTING PEOPLE
- The use of working equipment and load lifting attachments to lift people is strictly forbidden.
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 and backup alarm work.
B - DRIVER’S OPERATING INSTRUCTIONS

- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and ins-
truments before operating the lift truck.
- Wear clothes suited for driving the lift truck, avoid loose clothes.
- Make sure you have the appropriate protective equipment for the job to be done.
- Prolonged exposure to high noise levels may cause hearing problems. It is recommended to wear ear muffs to protect against
excessive noise.
- Always face the lift truck when getting into and leaving the driving seat and use the handle(s) provided for this purpose. Do not
jump out of the seat to get down.
- Always pay attention when using the lift truck. Do not listen to the radio or music using headphones or earphones.
- Never operate the lift truck when hands or feet are wet or soiled with greasy substances.
- For increased comfort, adjust the seat to your requirements and adopt the correct position in the driver’s cab.
CAUTION
Under Undermust
no circumstances no circumstances should the
the seat be adjusted seat
while thebe
liftadjusted while the lift truck is moving.
truck is moving.
- The operator must always be in his normal position in the driver’s cab. It is prohibited to have arms or legs, or generally any part
of the body, protruding from the driver’s cab of the lift truck.
- The safety belt must be worn and adjusted to the operator's size.
- The control 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 put-
ting 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 mast, follow the instructions given in the paragraph : INS-
TRUCTIONS FOR HANDLING A LOAD : C - TRANSVERSE ATTITUDE OF THE LIFT TRUCK.
- Travelling on a longitudinal slope :
• Drive and brake gently.
• Moving without load : Forks or attachment facing downhill.
• Moving with load : Forks or attachment facing uphill.

- Take into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passageway.
- Never move onto a loading platform without having first checked :
• That it is suitably positioned and made fast.
• That the unit to which it is connected (wagon, truck, etc.) will not shift.
• That this platform is prescribed for the total weight of the lift truck to be loaded.
• That this platform is prescribed for the size of the lift truck.
- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the lift
truck to be loaded and without having checked that they are in sound working order.
- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.
- Make sure the ground is stable and firm under the wheels before lifting the load.
- 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.
- The load or the attachment must not be left up high for a long time just above a structure because of the descent of the mast.
In such cases, it must be monitored constantly so that the height of the forks or the attachment can be adjusted, if necessary.
- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and
the aerial line.
You must consult your

You local
must electrical agency.
consult your local You could agency.
electrical be electrocuted or be
You could seriously injuredorif seriously
electrocuted you operate or park
injured theoperate
if you lift truck
or too
parkclose
the
DANGER
to power cables. lift truck too close to power lines.
In the event of high winds, do not carry out handling work that jeopardizes the stability of the lift truck and its load, particularly if the load
DANGER During high winds do not attempt moving loads that may catch the wind or cause the fork lift to be unstable.
catches the wind badly.
D - VISIBILITY
- Maintain permanently good visibility throughout the route. In reverse, either look directly behind you or use the panoramic rear-
view mirrors. In any case, avoid reversing over long distances.
- If the visibility in forward motion is not sufficient because of the bulkiness of the load, drive in reverse motion. This maneuver
must remain exceptional and for short distances.
- Ensure you have good visibility (clean windows, adequate lighting, correctly adjusted rear view mirrors, etc.).
- If visibility of your road is inadequate, ask someone to help, standing outside the area in which the truck will be moving, and
make sure you always have a good view of this person.
1-9
E - STARTING THE LIFT TRUCK

SAFETY NOTICE
The lift truck must only
The be
lift started up or be
truck must maneuvered
started orwhen the operator
maneuvered onlyis when
sittingthe
in the driver’siscab,
operator withinhis
sitting theseat belt adjusted
driver’s cab, hisand fas-
seat
WARNING
tened. belt fastened and properly adjusted.
- Never try to start the lift truck by pushing or towing it. Such operation may cause severe damage to the transmission. If neces-
sary, to tow the lift truck in an emergency, the transmission must be placed in the neutral position (see : 3 - MAINTENANCE : G
- OCCASIONAL MAINTENANCE).
- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connec-
ting it. Connect at first the positive terminals before the negative terminals.
Failurebetween
Failure to respect polarity to respect polaritycan
batteries between
cause batteries can cause
serious damage serious
to the damage
electrical to the
circuit. Theelectrical circuit.
electrolyte in theThe electrolyte
battery in the
may produce
WARNING
an battery
explosive gas. Avoid may and
flames produce an explosive
generation gas.close
of sparks Avoidtoflames and generation
the batteries. of sparks close
Never disconnect to the
a battery batteries.
while Never disconnect
it is charging.
a battery while it is charging.
INSTRUCTIONS
- Check the closing and locking of the hood(s).
- For lift trucks operating on gas carburization, open the gas bottle.
- Make sure that the forward/reverse lever is in neutral.
- Turn the ignition key to the position I to activate the electrical system.
- Make sure the signal lights on the instrument control panel and fuel level indicators are working properly (see : 2 - DESCRIP-
TION : INSTRUMENTS AND CONTROLS).
- Turn the ignition key to position II to preheat for 5 seconds and turn the ignition key fully : the I.C. engine should then start.
Release the ignition key and let the I.C. engine run at idle.
- Do not engage the starter motor for more than 15 seconds and carry out the preheating for 5 seconds between unsuccessful
attempts.
- Make sure all the signal lights on the control instrument panel are off.
- Check all control instruments when the I.C. engine is warm and at regular intervals during use, so as to quickly detect any pro-
blems and to be able to correct them without any delay.
- If an instrument does not show the correct display, stop the I.C. engine and immediately carry out the necessary operations.
F - DRIVING THE LIFT TRUCK

SAFETY NOTICE
Operators' attentionOperators'
is drawn toattention is involved
the risks drawn tointhe risksthe
using involved in using
lift truck, the lift truck,
in particular : in particular :
- Risk of losing control.
- Risk of losing control.
DANGER
- Risk of losing lateral- Risk of losing
and frontal lateral ofand
stability thefrontal stability
lift truck. The of the liftmust
operator truck.remain in control of the lift truck.
In the event of the The operator
lift truck must remain
overturning, do notin try
control of the
to leave theliftcabin
truck. In the
during theevent of theYOUR
incident. lift truck
BESToverturning,
PROTECTION do IS
notTOtrySTAY
to leave the
FASTE-
NED IN THE CABIN.cab during the incident. YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB.
- Observe the company’s traffic regulations or, by default, the public highway code.
- Do not carry out operations which exceed the capacities of your lift truck or attachments.
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 12 in. from the ground and the carriage
sloping backwards.
- Only carry loads which are balanced and properly anchored to avoid any risk of a load falling off.
- Ensure that palettes, cases, etc, are in good order and suitable for the load to be lifted.
- Familiarize yourself with the lift truck on the terrain where it will be used.
- Ensure that the service brakes are working properly.
- The loaded lift truck must not travel at speeds in excess of 7 mph.
- Drive smoothly at an appropriate speed for the operating conditions (land configuration, load on the lift truck).
- Do not use the hydraulic mast controls when the lift truck is moving.
- Do not maneuver the lift truck with the mast in the raised position unless under exceptional circumstances and then with extre-
me caution, at very low speed and using gentle braking. Ensure that visibility is adequate.
- Take turns slowly.
- In all circumstances make sure you are in control of your speed.
- On damp, slippery or uneven terrain, drive slowly.
- Brake gently, never abruptly.
- Only use the lift truck’s forward/reverse lever from a stationary position and never do so abruptly.
- Do not drive with your foot on the brake pedal.
- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, so turn it gently and
not abruptly.
- Never leave the I.C. engine on when the lift truck is unattended.
- Do not leave the cab when the lift truck has a raised load.
- Look where you are going and always make sure you have good visibility along the route.
1 - 10
- Use the rear-view mirrors frequently.

- Drive around obstacles.
- Never drive on the edge of a ditch or steep slope.
- It is dangerous to use two lift trucks simultaneously to handle heavy or voluminous loads. Since this operation requires particu-
lar precautions to be taken, it must be used exceptionally and only 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 at the transport position, i.e. at 12 in. from the ground and the carriage
sloping backwards.
- For lift trucks with gearboxes, use the recommended gear (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).
- Release the parking brake.
- Shift the forward/reverse lever to the selected direction of travel and accelerate gradually until the lift truck moves off.
G - STOPPING THE LIFT TRUCK

SAFETY NOTICE
- Never leave the ignition key in the lift truck during the operator's absence.
- When the lift truck is stationary, or if the operator has to leave his cab (even for a moment), place the forks or attachment on
the ground, apply the parking brake and put the forward/reverse lever in neutral.
- Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at least 6 feet from the track
of a railway.
- In the event of prolonged parking on a site, protect the lift truck from bad weather, particularly from frost (check the level of anti-
freeze), close and lock all the lift truck accesses (doors, windows, cowls…).
INSTRUCTIONS
- Park the lift truck on flat ground or on an incline lower than 15 %.
- Place the forward/reverse lever in neutral.
- Apply the parking brake.
- For lift trucks with gearboxes, place the gear lever in neutral.
- Lower the forks or attachment to rest on the ground.
- When using an attachment with a grab or jaws, or a bucket with hydraulic opening, close the attachment fully.
- Before stopping the lift truck after a long working period, allow the I.C. engine to idle for a few moments, to allow the coolant
liquid and oil to lower the temperature of the I.C. engine and transmission. Do not forget this precaution, in the event of frequent
stops or warm stalling of the I.C. engine, 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…).
- For lift trucks operating on gas carburization, shut the LPG bottle. For extended parking, let the engine stop by shutting the LPG
bottle before switching off the ignition, so as to eliminate all the fuel in the feed tube.
1 - 11
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY

SAFETY INSTRUCTIONS
- Operators driving on the public highway must comply with current highway code legislation.
- The lift truck must comply with current road legislation. If necessary, there are optional solutions. Contact your dealer.
INSTRUCTIONS
- Make sure the revolving light is in place, switch it on and verify its operation.
- Check the good working order and cleanness of lights, indicators and windscreen wiper.
- Switch off the working headlights if the lift truck is fitted with them.
- Put the attachment at 12 in. from the ground.
- For lift trucks with gearboxes :
On the road, set off in 3rd gear and go into 4th (as model of lift truck) when the conditions and state of the road allow. In hilly
areas, set off in 2nd gear and go into 3rd when the conditions and state of the road allow.
Never move in neutral
Do (gear reverser
not allow the or
liftgear
trucklever in neutral
to coast or transmission
in neutral cut-off
(using either button pressed) to
the forward/reverse preserve
lever, the lift
gear shift truck
lever or engine brake.
transmission
DANGER
Failure to respect this instruction
cut-off on a slopeonwill
button). Coasting lead to
a slope willexcessive speed which
lead to excessive speedmay make
which maythemake
lift truck uncontrollable
the lift (steering,
truck uncontrollable brakes)
(steering,
and may cause severe mechanical
brakes) and maydamage.
cause serious mechanical damage.
DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT

- You must comply with current regulations in your country, covering the possibility of driving on the public highway with a front-
mounted attachment on your lift truck.
- If road legislation in your country authorizes circulation with a front-mounted attachment, you must at least :
• Protect and 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 trailer’s electrical equipment to that of the lift truck.
- The trailer's braking system must comply with current legislation.
- If pulling a trailer with assisted braking, the lift truck must be equipped with a trailer braking mechanism. In this case, do not for-
get to connect the trailer braking equipment to the lift truck.
- The maximum vertical pull on the trailer hook must not exceed 3372 ft/lbs.
- The authorized maximum train weight must not exceed the maximum weight authorized by the manufacturer (consult the manu-
facturer’s plate on your lift truck).
- For lift trucks with gearboxes :
When driving with a trailer, set off in 2nd gear and go into 3rd when the conditions and state of the road allow. Do not exceed
4th gear to avoid overheating the internal combustion engine and the transmission.
IF NECESSARY, CONSULT YOUR DEALER.
1 - 12
INSTRUCTIONS FOR HANDLING A LOAD
A - CHOICE OF ATTACHMENTS
- Only attachments approved by MANITOU can be used on its lift trucks.
- Make sure the attachment is appropriate for the work to be done (see : 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE).
- Make sure the attachment is correctly installed and locked onto the lift truck carriage.
- Make sure that your lift truck attachments work properly.
- Comply with the load chart limits for the lift truck for the attachment used.
- Do not exceed the rated capacity of the attachment.
- Never lift a load in a sling without the attachment provided for the purpose. There are optional solutions ; contact your dealer.
B - MASS OF LOAD AND CENTER OF GRAVITY

- Before taking up a load, you must know its mass and its center of gravity.
B1
- The load chart for your lift truck is valid for a load in which the longitudinal position of the
center of gravity is 24 in. from the base of the forks (fig. B1). For a higher center of gra-
vity, contact your dealer.
- For irregular loads, determine the transverse center of gravity before any movement (fig.
B2) and set it in the longitudinal axis of the lift truck. 24
500 in.
mm
It is forbidden to move a load heavier than the effective capacity defined on the lift truck load
chart. CAUTION
Do not attempt to move a load heavier than the effective capacity defined on the lift truck load chart.
For loads with a moving center of gravity (e.g. liquids), take account of the variations in the cen-
CAUTION
ter of gravity in order to determine the load to be handled and be vigilant and take extra care
Fortoloads
limit with
theseavariations as far as
moving center possible.(i.e., liquids), take into account the variations
of gravity B2
of the center of gravity in order to determine the load to be handled (Consult your
agent or dealer). Be vigilant and take extra care to limit these variations as much as
possible.
1 - 13
C - TRANSVERSE (LEVEL) ATTITUDE OF THE LIFT TRUCK
The transverse attitude is the tilt of the chassis with respect to horizontal.
Raising the load reduces the lift truck's lateral stability. The transverse attitude must be set with the mast in down position as fol-
lows :
- Direct the lift truck so that the bubble in the level is between the two lines (see : 2 - DESCRIPTION : INSTRUMENTS AND
CONTROLS).
D - TAKING UP A LOAD ON THE GROUND

D1
- Approach the lift truck perpendicular to the load, with the the forks in a horizontal posi-
tion (fig. D1).
- Adjust the fork spread and centering in connection with the load (fig. D2) (optional solu-
tions exist, consult your dealer).
- Never lift a load with a single fork.
CAUTION
Beware of the risks of trapping or squashing limbs when manually adjusting the forks.
Beware of the risks of pinching or crushing limbs when manually adjusting the forks.
- Move the lift truck forward slowly (1) and bring the forks to rest in front of the load (fig.
D3), if necessary, slightly lift the mast (2) while taking up the load.
- Bring the load into the transport position.
- Tilt the load far enough backwards to ensure stability (avoid loss of load on braking or D2
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. D4) (block the load if necessary).
- Continue to move the lift truck forwards (2) tilting the carriage (3) (fig. D4) backwards to
position the load on the forks and check the load's longitudinal and lateral stability.
D3
1
2
D4
1 - 14
E - TAKING UP AND LAYING A HIGH LOAD ON TIRES E1

You must not raise the mast if you have not checked the transverse attitude of the lift truck
WARNING
(see : INSTRUCTIONS FOR HANDLING A LOAD : C - TRANSVERSE ATTITUDE OF THE LIFT 2
TRUCK).
Do not raise the mast until you have first checked the level attitude of the lift truck (see : INS-
TRUCTIONS FOR HANDLING A LOAD : C - TRANSVERSE ATTITUDE OF THE LIFT TRUCK).
REMINDER : Make sure that the following operations can be performed with good visibility 1
(see : OPERATIONS INSTRUCTIONS UNLADEN AND LADEN : D - VISIBILITY).
TAKING UP A HIGH LOAD ON TIRES

- Ensure that the forks will easily pass under the load.
- Keeping the mast vertical (1), advance the lift truck and raise the forks to level with the
load (2) (fig. E1).
- Maneuver carefully and gently to bring the forks to the rest in front of the load (fig. E2).
Set the handbrake and place the reversing lever to neutral. E2
- Slightly lift the load (1) and incline the carriage (2) backwards to stabilize the load (fig.
E3).
- Tilt the load sufficiently backwards to ensure its stability.
- Reverse the lift truck (1) very carefully and gently to free the load. Lower the mast (2) to
bring the load into transport position (fig. E4).
E3 E4
2
1
2
E5
LAYING A HIGH LOAD ON TIRES

- Direct the load in the transport position to the front of the pile (fig. E5).
- Raise the mast (1) until the load is higher than the pile and move the lift truck forward
(2) (fig. E6) very carefully and gently, until the load is over the pile. Put the handbrake on
and set the reversing lever to neutral.
- Place the load in a horizontal position by tilting the mast forwards (1) and lay it down on
the pile (2) while checking the correct positioning of the load (fig. E7).
- Reverse the lift truck (1) very slowly and carefully to release the forks (fig. E8). Then set
them into transport position.
E6 E7 E8
1
1 2
2 1
1 - 15
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK
GENERAL INSTRUCTIONS
- Ensure the area is sufficiently ventilated before starting the lift truck.
- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewelry and loose clothes. Tie and protect your hair, if
necessary.
- Stop the I.C. engine and remove the ignition key, when an intervention is necessary.
- Read the operator's manual carefully.
- Carry out all repairs immediately, even if the repairs concerned are minor.
- Repair all leaks immediately, even if the leak concerned is minor.
- Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.
- Beware of the risk of burning and splashing (exhaust, radiator, I.C. engine, etc.).
MAINTENANCE
- Perform the periodic service (see : 3 - MAINTENANCE) to keep your lift truck in good working conditions. Failure to perform the
periodic service may cancel the contractual guarantee.
LUBRICANT AND FUEL LEVELS
- Use the recommended lubricants (never use contaminated lubricants).

- Do not fill the fuel tank when the I.C. engine is running.
- Only fill up the fuel tank in areas specified for this purpose.
- Do not fill the fuel tank to the maximum level.
- Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
HYDRAULIC
- Any work on the load handling hydraulic circuit is forbidden except for the operations described in part : 3 - MAINTENANCE.
- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.
BALANCING VALVE BALANCING
: For inspection,
VALVEsee : 3inspection,
: For – MAINTENANCE
see : 3: –DMAINTENANCE
- EVERY 500 HOURS SERVICE.
: D - EVERY It is dangerous
500 HOURS SERVICE. toItchange the setting
is dangerous and
to chan-
WARNING
remove the balancing valves
ge the or safety
setting valves
or remove thewhich may be
balancing fittedortosafety
valves your valves
lift truck cylinders.
which may beThese
fitted operations must cylinders.
to your lift truck only be performed by
These ope-
approved personnelrations
(consult youronly
must dealer).
be performed by approved personnel (consult your dealer).
The HYDRAULIC ACCUMULATORS that may be fitted on your lift truck are pressurized units. Removing these accumulators and their pipe-
work is a dangerousThe
WARNING HYDRAULIC
operation ACCUMULATORS
and must which by
only be performed may be fittedpersonnel
approved on your lift(consult
truck, are under
your high pressure, it is dangerous to dis-
dealer).
mantle them. This operation must only be performed by approved personnel (consult your dealer).
ELECTRICITY
- Do not short-circuit the starter relay to start the IC engine. If the gear reverser is not in neutral and the parking brake is not enga-
ged, the lift truck may suddenly start to move.
- Do not drop metallic items on the battery.
- Disconnect the battery before working on the electrical circuit.
1 - 16
WELDING
- Disconnect the battery before any welding operations on the lift truck.
- When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being
welded, so as to avoid high tension current passing through the alternator.
- Never carry out welding or work which gives off heat on an assembled tire. The heat would increase the pressure which could
cause the tire to explode.
- If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing irre-
parable damage to electronic components.
WASHING THE LIFT TRUCK
- Clean the lift truck or at least the area concerned before any intervention.
- Remember to close and lock all accesses to the lift truck (doors, windows, cowls…).
- During washing, avoid the articulations and electrical components and connections.
- If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged, parti-
cularly electrical components and connections and the injection pump.
- Clean the lift truck of any fuel, oil or grease trace.
FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT YOUR DEALER.
1 - 17
IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME
INTRODUCTION
The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an
extended period.
For these operations, we recommend the use of protective products.
Instructions for using the products are given on the packaging.
Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dea-
IMPORTANT
lership.
It is recommended that your dealer perform the following procedures for lift truck storage and returning it to service.
PREPARING THE LIFT TRUCK
- Clean the lift truck thoroughly.

- Check and repair any leakage of fuel, oil, water or air.
- Replace or repair any worn or damaged parts.
- Wash the painted surfaces of the lift truck in clear, cold water and wipe dry.
- Touch up the paintwork if necessary.
- Shut down the lift truck (see : OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Make sure the mast cylinder rods are all in retracted position.
- Release the pressure in the hydraulic circuits.
PROTECTING THE I.C. ENGINE
- Fill the tank with fuel (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).
- Empty and replace the cooling liquid (see : 3 - MAINTENANCE : F - EVERY 2000 HOURS SERVICE).
- Leave the I.C. engine running at idle for a few minutes, then switch off.
- Replace the I.C. engine oil and oil filter (see : 3 - MAINTENANCE : D - EVERY 500 HOURS SERVICE).
- Add a protective product to the engine oil.
- Run the I.C. engine for a short time so that the oil and cooling liquid circulate inside.
- Disconnect the battery and store it in a safe place away from the cold, after charging it to a maximum.
- Remove the injectors and spray a protective product into each cylinder for two seconds with the piston in low neutral position.
- Turn the crankshaft once slowly and install the injectors (see I.C. engine REPAIR MANUAL).
- Remove the intake hose from the manifold or turbocharger and spray a protective product into the manifold or turbocharger.
- Cap the intake manifold or turbocharger hole with waterproof adhesive tape.
- Remove the exhaust pipe and spray a protective product into the exhaust manifold or turbocharger.
- Install the exhaust pipe and block the outlet with waterproof adhesive tape.
NOTE : The spray time is noted on the product packaging and must be increased by 50 % for turbo engines.
- Open the filler plug, spray a protective product around the rocker arm shaft and install the filler plug.
- Cap the fuel tank using waterproof adhesive tape.
- Remove the drive belts and store them in a safe place.
- Disconnect the engine cut-off solenoid on the injection pump and carefully insulate the connection.
PROTECTING THE LIFT TRUCK
- Set the lift truck on axle stands so that the tires are not in contact with the ground and release the handbrake.
- Protect cylinder rods which will not be retracted, from corrosion.
- Wrap the tires.
NOTE : If the lift truck is to be stored outdoors, cover it with a waterproof tarpaulin.
1 - 18
BRINGING THE LIFT TRUCK BACK INTO SERVICE
- Remove the waterproof adhesive tape from all the holes.

- Install the intake hose.
- Install and reconnect the battery.
- Remove the protection from the cylinder rods.
- Perform the daily service (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).
- Put the handbrake on and remove the axle stands.
- Empty and replace the fuel and replace the fuel filter (see : 3 - MAINTENANCE : D - EVERY 500 HOURS SERVICE).
- Install and set the tension in the drive belts (see : 3 - MAINTENANCE : C - EVERY 250 HOURS SERVICE).
- Turn the I.C. engine using the starter, to allow the oil pressure to rise.
- Reconnect the engine cut-off solenoid.
- Lubricate the lift truck completely (see : 3 - MAINTENANCE : SERVICING SCHEDULE).
WARNING Insure the area is adequately ventilated before starting the lift truck.
Make sure the area is adequately ventilated before starting up the lift truck.
- Start up the lift truck, following the safety instructions and regulations (see : OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Run all the mast's hydraulic movements, concentrating on the ends of travel for each cylinder.
1 - 19
1 - 20
2 - DESCRIPTION
2-1
2-2
TABLE OF CONTENTS
IDENTIFICATION OF THE LIFT TRUCK 2-4
CHARACTERISTICS 2-6
CHARACTERISTICS OF MASTS WITH ROLLERS 2 - 10
DIMENSIONS AND LOAD CHART 2 - 11
INSTRUMENTS AND CONTROLS 2 - 12
TOWING PIN AND HOOK 2 - 24
DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 2 - 26
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 modi-
fications without notice.
When you order parts, or when you require any technical information, always specify :
NOTE : For the owner's convenience, it is recommended that a note of these numbers is.
PLATE MANUFACTURER OF THE LIFT TRUCK (FIG. A) A
- Model
- Series
- Serial No
- Chassis No
- Year of manufacture
For any further technical information regarding your lift truck refer to chapter : 2 - DES-
CRIPTION : CHARACTERISTICS.
I.C. ENGINE (FIG. B) B
- I.C. engine No
HYDROSTATIC PUMP (FIG. C) C

- MANITOU reference
- Type of codification
- Serial No
- Manufacturer’s No
HYDROSTATIC MOTOR (FIG. D)

D
- MANITOU reference
- Type of codification
- Serial No
- Manufacturer’s No
2-4
FRONT AXLE - TRANSFER BOX (FIG. E) E
- Type
- Serial No
- MANITOU reference
CAB (FIG. F) F
- Type
- Serial No
MASTS WITH ROLLERS (FIG. G) G
- Mast identification No
PLATE MANUFACTURER OF THE ATTACHMENT (FIG. H) H
- Model
- Serial No
2-5
CHARACTERISTICS
I.C. ENGINE
- Type PERKINS 1104C-44 RE38214

- Number of cylinders 4 in line
- Number of strokes 4
- Suction Natural
- Injection system Direct
- Ignition sequence 1.3.4.2.
- Clearance of rocker valve (cold)
. Inlet 0,20 mm (0.008 in)
. Exhaust 0,45 mm (0.02 in)
- Capacity 4400 cm3 (268.5 in3)
- Bore 105 mm (4.13 in)
- Stroke 127 mm (5.0 in)
- Compression ratio 19,3 : 1
- Nominal rating loaded 2200 rpm
- Rating slow unladen 850 ± 10 rpm
- Max. rating unladen 2350 rpm
- Power ISO/TR 14396 84 cv/61,5 kw
- Maximum torque ISO/TR 14396 302 Nm at 1400 rpm (223 ft/lb)
- Air cleaner Dry 3 µ
COOLING CIRCUIT
- Type By water
- Fan Blowing
. Number of blades 7
. Diameter 508 mm (20 in)
- Thermostat
. Start opening 174 °F/183 °F
. Full opening 200 °F
HYDROSTATIC TRANSMISSION
HYDROSTATIC PUMP
- Type MANNESMANN REXROTH A4VG56DA1D7/32R with variable cubic capaci-
ty and with automatic power governor
- Gear reverser Electro-hydraulic
- Main pump
. Max./Mini displacement 0 to 56 cm3/r (0 to 3.4 in3)
. Max. flow rate 126 L/mn (33.3 gal/min)
. Working pressure 380 Bar (5510 psi)
- Boost pump
. Displacement cm3
. Max. flow rate L/mn
. Boost pressure Max. R.P.M. Bar (transmission in neutral)
HYDROSTATIC MOTOR
- Type MANNESMANN REXROTH A6VM107DA1/63W with variable cubic capacity
. Max./Mini displacement 32 to 107 cm3/r (1.95 to 6.5 in3/r)
FRONT AXLE - TRANSFER BOX
- Type DANA
- Hub reducers Epicyclic
- Differential lock Electro-hydraulic
2-6
BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
. Type Multidisc brake immersed in oil.
- Parking brake Mechanical hand lever applied on the front wheels.
. Type Multidisc brake immersed in oil.
ELECTRIC CIRCUIT
- Earth Negative
- Battery 12 V - 110 Ah - 750 A EN
- Alternator 12 V - 75 A
. Type Denso A115i
. Tension regulator Incorporated into the alternator
- Starter 12 V - 3,0 kW
. Type Denso E95RL
2-7
CHARACTERISTICS MSI 50 H Series 1-E2
FRONT TIRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

DIMENSIONS PRESSURE TIRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
15 19.5
FRONT UNLADEN 1700 KG KG/CM2 KG/CM2 CM2 CM2
TUBELESS 90 PSI
FRONT LADEN 5750 KG KG/CM2 KG/CM2 CM2 CM2
SOLIDEAL
FRONT UNLADEN KG KG/CM2 KG/CM2 CM2 CM2

FRONT LADEN KG KG/CM2 KG/CM2 CM2 CM2




REAR TIRES
PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE

DIMENSIONS PRESSURE TIRE LOAD
HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND
REAR UNLADEN KG KG/CM2 KG/CM2 CM2 CM2
REAR LADEN KG KG/CM2 KG/CM2 CM2 CM2
225/75R15
REAR UNLADEN 2400 KG KG/CM2 KG/CM2 CM2 CM2
TUBELESS 101 PSI
REAR LADEN 850 KG KG/CM2 KG/CM2 CM2 CM2
MICHELIN
IMPORTANT
When changing or replacing the tires and

wheels; use only the manufacturer’s approved
components as installed at the factory. Any
substitutes or modifications must first be
approved by the manufacturer.
2-8
HYDRAULIC CIRCUIT
- Type of pump Gear pump with flow divider

. Capacity 43,77 cm3 (2.7 in3)
. Flow rate at full speed 103 L/mn (27.2 gal/min)
. Flow rate at 2300 rpm 101 L/mn (26.7 gal/min)
. Flow rate at 1600 rpm 70 L/mn (18.5 gal/min)
- Pressure
. Lifting, tilting, attachment circuit 230 Bar (3335 psi)
. Steering circuit 165 Bar (2392 psi)
- Filtration
. Return 10 µ
. Suction 100 µ
- Hydraulic shock absorber
. Capacities 1,5 L (0.4 gal)
. Pressure 150 Bar (2175 psi)
SPECIFICATIONS
- Level of sound pressure in the driver's cab LpA 84 dB
(accordng to standard prEN 12053 : 1995)
- Level of sound power in the LwA environment 104 dB

(according to directive 2000/14 CE guaranteed)
- Speed of movement of lift truck in standard configuration on horizontal

ground
(except particular conditions)
. Forward unladen 25,5 km/h (16 mph)
. Reverse unladen 25,5 km/h (16 mph)
- Standard lift height 3700 mm (146 in)
- Rated capacity with standard mast 5000 kg (11023
- Load center 24 in.
- Weight of forks (each) 128 kg (282.2 lb)
- Lifting motions with standard mast

. Unladen lifting 0,34 m/s (1.1 ft/s)
. Rated load lifting 0,25 m/s (0.8 ft/s)
. Unladen lowering 0,32 m/s (1.0 ft/s)
. Rated load lowering 0,41 m/s (1.3 ft/s)
- Lift truck weight with standard mast

. Unladen 8200 kg (18078 lb)
. Rated load 13200 kg (29101 lb)
- Axle weight with standard mast (transport position)

. Front unladen 3380 kg (7452 lb)
rated load 11510 kg (25375 lb)
. Rear unladen 4820 kg (10626 lb)
rated load 1690 kg (3726 lb)
- Tensible strain at coupling hook

. Unladen 2900 daN (6519 ft/lb)
. Rated load 3700 daN (8318 ft/lb)
- Maximum ramp negotiable in forward motion

. Unladen 33 % at 1 km/h (0.6 mph)
. Rated load 22 % at 1 km/h (0.6 mph)
2-9
CHARACTERISTICS OF MASTS WITH ROLLERS MSI 50 H Series 1-E2
10° 12°
MFH
OHL
FFH
2 - 10
DIMENSIONS AND LOAD CHART MSI 50 H Series 1-E2
A 1200 mm (47.2 in)

B 2075 mm (81.7 in)
C 701 mm (27.6 in)
D 3384 mm (133.2 in)
E 4584 mm (180.5 in)
F 1420 mm (55.9 in)
F1 1145 mm (45.1 in)
G 185 mm (7.3 in)
G* 140 mm (5.5 in)
G1 220 mm (8.7 in)
G1* 205 mm (8.1 in)
G2 225 mm (8.9 in)
G2* 247 mm (9.7 in)
G3 340 mm (13.4 in)
H 2775 mm (109.3 in)
H* 2575 mm (101.4 in)
H1 4672 mm (183.9 in)
H1* 4272 mm (168.2 in)
I 608 mm (23.9 in)
J 1300 mm (51.2 in)
K 1670 mm (65.7 in)
L 60 mm (2.4 in)
N 1799 mm (70.8 in)
O 150 mm (5.9 in)
P1 29 °
P2 27 °
P3 42 °
R 2715 mm (106.9 in)
S 2861 mm (112.6 in)
T 5241 mm (206.3 in)
U 2434 mm (95.8 in)
V 2950 mm (116.1 in)
V1 125 mm (4.9 in)
W 1732 mm (68.2 in)
Y 12 °
Z 10 °
H - H1 = Standard mast DUPLEX 3M70 with rollers
H* - H1* = Option mast DUPLEX 3M30 with rollers
G - G1 - G2 - G3 = Unladen
G* - G1* - G2* = Rated load
2 - 11
INSTRUMENTS AND CONTROLS
29 1
20
23
10 2
24
8
5
4 7
17
17
6 15
19
15
19
21
1
20
3
20
22
16
13
26
14
25
10
11 12
1 23
18
26
2
16
2 - 12
DESCRIPTION
1 - DRIVER'S SEAT
2 - SAFETY BELT
3 - STEERING WHEEL TILTING KNOB
4 - CONTROL AND SIGNAL LIGHTS PANEL
5 - SWITCHES AND SIGNAL LIGHTS PANEL
6 - HORN SWITCH
6 - LIGHT SWITCH, HORN AND INDICATOR SWITCH (OPTION)
7 - IGNITION SWITCH
8 - FUSES AND RELAY ACCESS PANEL
9 - FUSE AND RELAY
10 - CIGAR LIGHTER
11 - BRAKING OIL TANK
12 - WINDSCREEN WASHER TANK
13 - ACCELERATOR PEDAL
14 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF
15 - REVERSING SWITCH
16 - PARKING BRAKE LEVER
17 - HYDRAULIC CONTROLS
18 - ROOF LIGHT
19 - HEATER CONTROL
20 - HEATING VENTS
21 - CAB FILTER VENTILATORS
22 - DOOR LOCK
23 - DOOR RELEASE BUTTON
24 - BAY STOP
25 - BAY RELEASE BUTTON
26 - RAISING CAB
27 - FRONT LIGHTS (NOT ILLUSTRATED) (OPTION)
28 - REAR LIGHTS (NOT ILLUSTRATED)
29 - SPIRIT LEVEL
NOTE : All the terms such as : RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver's seat facing forward.
2 - 13
1 - DRIVER'S SEAT (STANDARD)
DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS. 3
LONGITUDINAL ADJUSTMENT
- Pull the locking lever 1 upwards. 4
- Slide the seat to the required position. A B C
- Release the lever and ensure it returns to the lock position. D E
1
SEAT SUSPENSION ADJUSTMENT
2
- Pull and lift up the locking lever 2 so as to place it into one of these five positions.
Position A : Light-weight driver (110 lb).
Position B : Intermediate.
Position C : Middle-weight driver.
Position D : Intermediate.
Position E : Heavy-weight driver (265 lb).
ANGLE ADJUSTMENT OF THE BACK-REST

- Pull the locking lever 3 backwards.
- Tilt the back-rest into one of the three possible positions.
- Release the locking lever and ensure it returns to the lock position.
ANGLE ADJUSTMENT OF THE WHOLE SEAT

- Lift up the locking lever 4.
- Tilt the seat forwards or backwards.
- Release the lever and ensure it returns to the lock position.
1 - DRIVER'S SEAT (OPTION)

A
DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
WEIGHT ADJUSTMENT (FIG. A)

It is advised that the weight be adjusted when the driver is not sitting in the cab.
- Refer to graduation 1 of the seat.
- Turn handle 2 according to the driver’s weight.
NOTE : To avoid any health problems, it is recommended that the weight should be chec- 2 1
ked and adjusted before starting up the lift truck.
SEAT HEIGHT ADJUSTMENT (FIG. B)

Raise the seat to the desired position, until you hear the ratchet click. If you raise the seat
above the last notch (stop), the seat drops down to the lowest position.
SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C) B

The back-rest angle of the seat may be adjusted to suit the individual.
- Press the left-hand button while pushing on the seat or relaxing pressure on the seat to
find a comfortable position.
2 - 14
SEAT DEPTH ADJUSTMENT (FIG. D) D

The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired position.
EXTENDING THE HEAD-REST (FIG. E)

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

This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.
ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)

- Support the back-rest, pull the lever and position the back-rest to find the desired posi-
tion. E
If you do notIfsupport
you do the
not back-rest
support the back-rest
when makingwhen making adjustments,
adjustments, it swingsforwards.
it swings completely comple-
NOTICE tely forwards.
LONGITUDINAL ADJUSTMENT (FIG. H)
- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
MAINTENANCE (FIG. I)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.
WARNING A rocking head-rest increases the risk of an accident!

A rocking head-rest increases the risk of an accident !
F
Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a
small hidden area before using any fabric or plastic cleaner.
G H I
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.
Do not
In no event should the operate
lift truck be the
usedliftif truck withbelt
the seat a defective seat(fixing,
is defective belt (fixing, locking,
locking, cuts, tears,
cuts, tears, etc.). etc.).
RepairRepair or replace
or replace thebelt
the seat seatimme-
belt
WARNING immediately.
diately.
2 - 15
3 - STEERING WHEEL TILTING KNOB
- Pull the knob 1 backwards.

- Tilt the steering wheel to the desired position.
- Push the knob back to lock the steering wheel in position.
4 - CONTROL AND SIGNAL LIGHTS PANEL G

F H
CONTROL INSTRUMENTS I
E B
A - HOURMETER B1
B - FUEL LEVEL D J
Red zone B1 indicates that you are using the reserve supply and that time of use is limi-
ted.
C 00000 00 h K
SIGNAL LIGHTS A
When activating the electrical system of the lift truck, all the red lamps and the panel's
buzzer must light to indicate their good working order. If one of the red lamps or the buz-
zer does not function, carry out the necessary repairs.
C - RED LAMP - HYDRAULIC RETURN FILTER CLOGGED

The lamp and buzzer come on when the hydraulic return oil filter cartridge is clogged. Park the lift truck and carry out the neces-
sary repairs (see cleaning and replacement requirements in chapter : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
NOTE : This lamp comes on in cold weather or when starting the fork lift truck, it goes off when the hydraulic oil reaches the tem-
perature of functionning.
D - RED BRAKING OIL LEVEL LAMP

If the lamp and the buzzer come on whele the lift truck is running, stop the I.C. engine immediately and check the braking oil level.
If the brake fluid drops abnormally, consult your dealer.
E - RED I.C. ENGINE WATER TEMPERATURE LAMP

If the lamp and the buzzer come on while the lift truck is running, stop the I.C. engine immediately and investigate the cooling sys-
tem for the malfunction.
F - RED PARKING BRAKE LAMP

This lamp comes on when the parking brake is applied.
G - RED ALTERNATOR CHARGE LAMP

If the lamps C - D - E - G - H - I - L and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately and
check the electrical circuit and alternator belt.
H - RED I.C. ENGINE OIL PRESSURE LAMP

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

The lamp and buzzer come on when the air filter cartridge is clogged. Park the lift truck and carry out the necessary repairs (see
cleaning and replacement requirements in chapter : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
J - BLUE MAIN BEAM LAMP (OPTION)
K - GREEN INDICATOR LAMP (OPTION)
2 - 16
5 - SWITCHES AND SIGNAL LIGHTS PANEL I K

The location of the switches may vary depending on the options.
A - FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER

This switch, when set on on the "intermediate" position, the windscreen wiper to be ope-
rated and the "down" position and simultaneously pressed, the windscreen-washer to be
G H J
operated.
B - REAR WINDSCREEN WIPER + ROOF WIPER OPTION
C - WARNING LIGHTS OPTION

This switch enables the L.H. and R.H. Indicators to be switched on simultaneously, with D E F
the ignition off. The signal light indicates that the switch is being used.
D - WORKING HEAD LIGHT OPTION
E - FLASHING LIGHT OPTION A B C
F - WORKING TAIL LIGHT OPTION
G - DIFFERENTIAL LOCK
The differential lock allows the main wheels to turn at the same speed whatever the ground condition. In order to engage it, fully
press the top of the switch.
- Maintain this position during the time required for locking. To interrupt its use, simply release the switch which returns to its ini-
tial position automatically.
WARNING
When While
the differential lockthe differential
is engaged, lock is
always engaged,
drive driveline
in straight in aand
straight
in firstline only and in first gear.
gear.
H - DIFFERENTIAL LOCK SIGNAL LIGHT

This signal light goes out when you push the differential lock switch.
I - NOT USED
J - NOT USED
K - NOT USED
6 - HORN SWITCH
6 - LIGHT SWITCH, HORN AND INDICATOR SWITCH (OPTION)
The switch controls the visual and sound alarms.

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

NOTE : The positions D - E - F - G can be carried out without the ignition being on.
7 - IGNITION SWITCH
The key switch has five positions :

P - Ignition off, parking position.
O - Ignition switched off and I.C. engine stopped.
I - Ignition on.
II - Heating.
III - The I.C. engine starts, return to position i as soon as the key is released.
2 - 17
8 - FUSES AND RELAY ACCESS PANEL
9 - FUSE AND RELAY
- Remove fuses and relay access panel 8 for access to fuses and relay. B1 K1 K7
B1 - Buzzer.
K1 - Safety system starting switch relay. K6
K2 - Preheating relay.
K3 - Raising cab relay.
K4
K4 - OPTION Flashing unit. K5 K8
K5 - Forward gear relay.
K6 - OPTION Reverse gear relay.
K7 - Transmission cut-off relay.
K8 - Attachment relay.
F1 - Control instruments panel (7,5A).

F2 - Sound alarm (10A). F20 F30
- Stop switch (10A).
F3 - Heating (20A).
- OPTION Air conditioning (20A).
F4 - Front windscreen wiper and windscreen washer (15A). F5 F10
F5 - Stop I.C. engine electrovalve (10A).
- OPTION Emergency Stop (10A).
- Cold start system (10A).
- Fuel pump (10A).
F6 - Gear reverser (15A).
- Transmission cut-off (15A).
F1 F6 F11 F21
- OPTION Reverse lights (15A).
- OPTION Reverse buzzer alarm (15A).
F7 - Rear windscreen wiper (10A).
- OPTION Roof windscreen wiper (10A).
F8 - Differential lock (7,5A).
- OPTION Air conditioning (7,5A). F33 F31
1
F9 - OPTION.
F10 - OPTION Flashing light (7,5A). F34
F11 - OPTION Working tail light (10A).
F32
F12 - OPTION Front working head light (10A). K3
F13 - Starter (20A).
F14 - OPTION. K2
F15 - OPTION.
F16 - OPTION.
F17 - OPTION.
F18 - OPTION.
F19 - OPTION.
F20 - OPTION.
F21 - Roof light (15A).
- OPTION Hazard warning lights power supply (15A).
F22 - Raising cab (7,5A).
F23 - Cigar lighter (10A).
F24 - OPTION Light switch power supply, horn and indicators (25A).
F25 - OPTION Left sidelights (3A).
F26 - OPTION Right sidelight (3A).
- OPTION Sidelight indicator light (3A).
- OPTION Control panel lighting (3A).
2 - 18
F27 - OPTION Low beam (15A).

- OPTION Low beam indicator light (15A).
F28 - OPTION Main beam (15A).
- OPTION Main beam lamp (15A).
F29 - OPTION Right indicators (15A).
F30 - OPTION Left indicators (15A).
- Open the side cover for access to fuses F31 to F34 and relay K2, K3.
F31 - Preheating I.C. engine (80A).
F32 - Raising cab (50A).
F33 - Alternator (80A).
F34 - Lift truck electrical equipment (80A).
NOTE : Replace a used fuse with a new fuse of the same quality and capacity. Never reuse a repaired fuse.
10 - CIGAR LIGHTER
11 - BRAKING OIL TANK
See : 3 - MAINTENANCE : B - EVERY 50 HOURS SERVICE.
12 - WINDSCREEN WASHER TANK
See : 3 - MAINTENANCE : B - EVERY 50 HOURS SERVICE.
13 - ACCELERATOR PEDAL
14 - 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 the lift truck.
During clearance travel it enables the transmission to be cut off progressively, allowing a gradual approach (delicate handling) with
all the I.C. engine power.
15 - REVERSING SWITCH
FORWARD : Push the knob forward (position A).

REVERSE : Pull the knob backwards (position B).
NEUTRAL : The knob must be in the intermediate position to start the lift truck (position C).
A
The lift truck’s motion must only be reversed at slow speed, with no acceleration. C
NOTE : In OPTION, The reverse lights and the reverse buzzer (backup) alarm indicate that B
the lift truck is running in reverse motion.
SAFETY FOR MOVING THE LIFT TRUCK

Authorization to move the lift truck is controlled by an electronic unit. The operator must
observe the following sequence to move the truck forwards or backwards :
1 - sit down correctly in the driver’s seat,
2 - release the parking brake,
3 - engage forward or reverse movement.
To park the lift truck, he must observe the following sequence :
1 - set the gear reverser in neutral,
2 - engage the parking brake,
3 - get out of the lift truck.
If these sequences are not observed (e.g. : leaving the driver’s seat without setting the parking brake), a buzzer sounds. You must
then return the gear reverser to the neutral position and repeat the sequence.
2 - 19
16 - PARKING BRAKE LEVER

A
To prevent accidental loosening or release, the lever is fitted with safety locking.
- To apply the parking brake, pull the lever backwards (position A).
- To loosen the parking brake, release and push the lever forwards (position B).
17 - HYDRAULIC CONTROLS
Do not attempt to Do notthe
alter attempt to alter
hydraulic the hydraulic
system system
pressure by pressure
interfering withbythe
interfering
pressurewith the
regula-
WARNING
ting pressure
valve. In the event regulatingmalfunction,
of suspected valve. In the event your
contact of suspected
dealer. ANYmalfunction,
ALTERATION contact
MAY
RENDER THE WARRANTY your dealer.
NULL ANY
ANDALTERATION
VOID. MAY VOID THE WARRANTY.
Use the hydraulicwithout

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

- Move lever A backward to raise the forks.
- Move lever A forward to lower the forks. A
NOTE : The engine r.p.m. automatically increases when lifting the load. B
TILT OF THE MAST
- Move lever A to the right for forward tilting.
- Move lever A to the left for back tilting.
ATTACHMENT
- The lever B forwards or backwards.
18 - ROOF LIGHT
19 - HEATER CONTROL
A - HEATING FAN CONTROL

This 3-speed control regulates warm or cold air through the heating ventilators.
B - HEATING TEMPERATURE CONTROL

B2 B1
Allows the temperature inside the cab to be adjusted.
B1 - With the valve closed, the fan delivers fresh air.
B2 - With the valve opened completely, the fan delivers warm air.
B A
The intermediate positions allow the temperature to be adjusted.
20 - HEATING VENTS
21 - CAB FILTER VENTILATORS
See : 3 - MAINTENANCE : D - EVERY 500 HOURS SERVICE.
22 - DOOR LOCK
Two keys are provided with the lift truck to enable the cabin to be locked.
23 - DOOR RELEASE BUTTON
2 - 20
24 - BAY STOP
- Remove the stop to open the bay fully.
24
25 - BAY RELEASE BUTTON
26 - RAISING CAB A
Ensure that the mast is set to maximumCAUTION

forward tilt and the engine is off before raising the
cab.
Make sure that the mast is tilted fully forward and the engine is stopped before lifting
the overhead guard.
UNLOCKING THE CAB :

- Close the left-hand side bay.
- Partially open the cab door. 1
- Pull out and lock the pull handle 1 (fig. A) on the right-hand side to release the cab rai-
sing mechanism.
RAISING THE CAB :
CAUTION B
Check that there is nothing laying on the driver’s seat, which could disrupt the operation.
Check for any objects left in the operator’s area which may interrupt the lifting operation.
- Keep the cab door partially open and press the switch upwards 2 (fig. B) to raise the cab
about an inch. 2
- Release the handle 1 (fig. A).
- Raise the cab completely.
- Close the cab door.
- Fit the safety stay 3 (fig. C) vertically in its clip under the cab.
LOWERING THE CAB :
CAUTION
Check that there is nothing laying on the driver’s seat, which could disrupt the operation. C
Check for clearance and obstacles while lowering the overhead guard.
- Fold back the safety stay 3 (fig. C).

- Partially open the cab door, press the switch downwards 2 (fig. B) to lower the cab to its
initial position and ensure it is locked in place. 3
2 - 21
27 - FRONT LIGHTS (OPTION)
A - Left front indicator.

B - Left front dipped headlight. F B
C - Left front main beam.
D - Left front sidelight.
E - Right front indicator. H D
F - Right front dipped headlight.
G - Right front main beam.
H - Right front sidelight.
E G C A
28 - REAR LIGHTS
A - Left rear indicator (option).

B - Left rear stoplight.
Left tail light (option).
C - Right rear stoplight
Right tail light (option). A B C D
D - Right rear indicator (option).
29 - SPIRIT LEVEL
Enables the operator to check that the lift truck is in the horizontal position.
29
2 - 22
2 - 23
TOWING PIN AND HOOK
Located at the rear of the lift truck, this device is used to attach a trailer. Its capacity is limited for each lift truck by the authori-
zed gross vehicle weight, tractive effort and maximum vertical force on the coupling point. This information is given on the manu-
facturer's plate attached to each lift truck (see : 2 - DESCRIPTION : IDENTIFICATION OF THE LIFT TRUCK).
- To use a trailer, see current regulations in your country (maximum running speed, braking, maximum weight of trailer, etc.).
- Verify the trailer's condition before using it (tire condition and pressures, electrical connection, hydraulic hose, braking system…).
Do not tow a trailerDoor not tow a trailer
accessory whichoris accessory which
not in perfect is not order.
working in proper working
Using order.
a trailer Using
in poor a trailermay
condition in poor
effectcondition may effect
the lift truck's the
steering
WARNING lift truck's steering and braking, and safety.
and braking, and hence safety.
If a third party helpsIf in coupling

a third partyorhelps
uncoupling the trailer,
in coupling this person
or uncoupling must be
the trailer, permanently
they visible to the
must be continually driver
visible anddriver
to the wait until
until the lift truck
truck
WARNING
has stopped, the handbrake
is parked isandon the
andI.C.
theengine
I.C. engine is switched
is turned off. off before performing the operation.
A - TOWING PIN
COUPLING AND UNCOUPLING THE TRAILER

- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- Put the handbrake on and switch off the I.C. engine.
- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.
Be careful not to get
Riskyour fingers caught
of crushed fingersororcrushed
hands! during this operation.
Keep hands and fingers clear while cou- 2
DoWARNING
not forget to putpling
clip the
1 back in place.
trailer! The safety clip 1 must be installed after coupling. Before
When uncoupling, make sure that
uncoupling, make thesure
trailer
theistrailer
supported independently.
is blocked in place and independently
supported.
1
2 - 24
2 - 25
DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS
1 - REVOLVING LIGHT
The revolving light is dismountable to make it possible, for example, to reduce the bulki-
ness of the lift truck or to avoid being stolen.
- Loosen nut 1 and remove the revolving light. 2

- Protect mounting 2 with cap 3. 3
2 - REVERSE LIGHTS
3 - REVERSE BUZZER ALARM
4 - EMERGENCY STOP BUTTON
- In the event of danger, it lets you stop the I.C. Engine and thereby cut out all hydraulic
movements.
- Turn the button to disable it before restarting the lift truck.
Be ready for hydraulic movements suddenly stopping when you press this
BeWARNING
ready for hydraulic movements suddenly stopping when you press this button.
button.
2 - 26
5 - ADAPTATION 4TH DISTRIBUTOR ELEMENT
ADDITIONAL ATTACHMENT
- The lever A forwards or backwards.
6 - ADAPTING THE COMPENSATION VALVE ON THE TILTING CIRCUIT
2 - 27
2 - 28
3 - MAINTENANCE
3-1
3-2
TABLE OF CONTENTS
MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT 3-5
FILTERS CARTRIDGES AND BELTS 3-6
LUBRICANTS AND FUEL 3-8
SERVICING SCHEDULE 3 - 10
A - DAILY OR EVERY 10 HOURS SERVICE 3 - 12
B - EVERY 50 HOURS SERVICE 3 - 14
C - EVERY 250 HOURS SERVICE 3 - 18
D - EVERY 500 HOURS SERVICE 3 - 20
E - EVERY 1000 HOURS SERVICE 3 - 26
F - EVERY 2000 HOURS SERVICE 3 - 30
G - OCCASIONAL MAINTENANCE 3 - 32
3-3
3-4
MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT
OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.
IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,

YOU RISK - Legally - to be held responsible in the event of an accident.
- Technically - to generate operating failure or shorten the life of the lift truck.
THE USE OF COUNTERFEIT PARTS OR COMPONENTS NOT APPROVED BY THE MANUFACTURER,

MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.
BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,
YOU BENEFIT THROUGH ITS NETWORK, MANITOU PROVIDES THE USER WITH
EXPERTISE
- Know-how and competence.
- The guarantee of high-quality work.
- Original replacement components.
- Help with preventive maintenance.
- Efficient help with diagnosis.
- Improvements due to experience feedback.
- Operator training.
- Only the MANITOU network has detailed knowledge of the design of the lift truck and therefore the
best technical ability to provide maintenance.
ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
The dealer network list is available on MANITOU web site www.manitou.com
3-5
FILTERS CARTRIDGES AND BELTS
I.C. ENGINE
I.C. ENGINE OIL FILTER

ALTERNATOR BELT
Part number : 476954
Change : 500 H
DRY AIR FILTER CARTRIDGE

CYCLONIC PRE-FILTER (OPTION)
Clean : 50 H*
Clean : 10 H
Change : 500 H*
SAFETY DRY AIR FILTER CARTRIDGE

AUTOMATIC VACUUM-CLEANING PRE-FILTER (OPTION)
Change : 1000 H*
FUEL FILTER CARTRIDGE

Part number : 605013 DUST BOWL CYCLONIC PRE-CLEANER (OPTION)
Change : 500 H ITEM 1 - 803071, ITEM 2 - B2236-15
TURBO II PRE-CLEANER (OPTION)

496998 (NOT SHOWN)
* : This schedule is given for information only (see : 3 - MAINTENANCE : SERVICING SCHEDULE) for cleaning and changing.
HYDRAULICS
HYDRAULIC RETURN OIL FILTER CARTRIDGE SUCTION STRAINER FOR HYDRAULIC OIL TANK
Part number : 602096 Part number : 77402
Change : 500 H Clean : 1000 H
FILTER CAP FOR HYDRAULIC OIL TANK

Part number : 62415
Change : 1000 H
CAB
CAB VENTILATION FILTER

Clean : 500 H
3-6
3-7
LUBRICANTS AND FUEL
IMPORTANT USE ONLY THE RECOMMENDED LUBRICANTS AND FUEL : - For topping up, lubricants may not be mixed.
DIAGNOSTIC ANALYSIS OF OILS

If a service or maintenance contract has been organized with the dealer, a diagnostic analysis of engine, transmission and axle
oils may be requested depending on the rate of use.
(*) FUEL CHARACTERISTICS

Use a high-quality fuel to obtain optimal performance of the I.C. engine.
CHARACTERISTICS OF RECOMMENDED FUEL :

• Types of diesel EN590 - Auto/CO/C1/C2/C3/C4
• BS2869 Class A2
• ASTM D975 - 91 Class 2D
• JIS K2204 (1992) Grades 1, 2, 3 and Special Grade 3.
I.C. ENGINE
COMPONENT CAPACITY RECOMMENDATION
8,5 Liters Shell: Rotella 15w40

I.C. ENGINE
(2.25 gal) Citgo: C-600 15w40
Tulco: Anti-Freeze Pre-mix

50/50 (-22°F)
12 Liters
COOLING CIRCUIT
(3.2 gal)
FUEL TANK 85 Liters (22.5 gal) Diesel fuel (*)
MAST
COMPONENT RECOMMENDATION
Engine oil
MAST LIFTING CHAINS
Shell: Rentinax Am
GREASING OF THE MAST
Citgo: Lithoplex CM-2
HYDRAULICS
132 Liters Shell: Tellus T46

HYDRAULIC OIL TANK
(34.9 gal) Citgo: Transgard THF Lo-Temp
BRAKE
Shell: Donax TG Dexron III
BRAKE CIRCUIT
Citgo: Transgard ATF Dexron III
CAB
Shell: Rentinax Am
CAB DOOR
WINDSCREEN WASHER TANK Windscreen washer fluid
3-8
FRONT AXLE
Shell: Donax TD
1,10 Liter
TRANSFER BOX Citgo: Transgard Tractor
(0.3 gal)
Hydraulic Fluid
Shell: Donax TD
7,20 Liters
FRONT AXLE DIFFERENTIAL Citgo: Transgard Tractor
(1.9 gal)
Hydraulic Fluid
Shell: Spirax DH80x90

0,80 Liter
FRONT WHEELS REDUCERS Citgo: Premium Gear MP
(0.2 gal)
80w90
REAR AXLE
SWIVEL PINS
Shell: Rentinax Am
STEERING CONNECTING ROD
REAR AXLE OSCILLATION
3-9
SERVICING SCHEDULE
A = AJUST N = CLEAN After Day 1 year 1 year

C = CHECK P = BLEED the first or 50 250 or or 2000 4000
D = DESCALE R = CHANGE 50 10 hours hours 500 1000 hours hours
G = GREASE V = DRAIN/CHANGE hours hours hours hours
I.C. ENGINE
I.C. engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Cooling liquid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Cyclonic prefilter (OPTION) . . . . . . . . . . . . . . . . . . . . . . . N
Dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . N R
Radiator core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Alternator/fan/crankshaft belt tension . . . . . . . . . . . . . . . C/A C/A
I.C. engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V V
I.C. engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R R
Fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R R
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Safety dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . . R
I.C. engine silent blocks . . . . . . . . . . . . . . . . . . . . . . . . . C*
I.C. engine rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Valves clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C* C*
Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/D*
Water pump and the thermostat . . . . . . . . . . . . . . . . . . . C*
Alternator and the starter motor . . . . . . . . . . . . . . . . . . . C*
Bleed the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION
Hydrostatic transmission circuit pressures . . . . . . . . . . . . C*
Governing start of the hydrostatic transmission . . . . . . . . C*
Working order of the hydraulic valves . . . . . . . . . . . . . . . . C*
TIRES
Tires pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Wheel nuts torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Condition of wheels and tires . . . . . . . . . . . . . . . . . . . . . C*
Change a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAST
Tension and alignment of the mast lifting chains . . . . . . . C/A
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
Mast lifting chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G G/C*
Condition of mast unit . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Mast guide rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Mast bearing rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
HYDRAULICS
Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Hydraulic return oil filter cartridge . . . . . . . . . . . . . . . . . . R R
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
Suction strainer for hydraulic oil tank . . . . . . . . . . . . . . . . N
Filter cap for hydraulic oil tank . . . . . . . . . . . . . . . . . . . . R
Speeds of hydraulic movements . . . . . . . . . . . . . . . . . . . C*
Hydraulic pump pipe filter . . . . . . . . . . . . . . . . . . . . . . . . N*
Condition of hoses and flexibles pipes . . . . . . . . . . . . . . C*
Condition of cylinders (leakage, shafts) . . . . . . . . . . . . . . C*
Hydraulic circuit pressures . . . . . . . . . . . . . . . . . . . . . . . C*
Hydraulic circuit outputs . . . . . . . . . . . . . . . . . . . . . . . . . C*
Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N*
STEERING
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
3 - 10
A = AJUST N = CLEAN After Day 1 year 1 year

C = CHECK P = BLEED the first or 50 250 or or 2000 4000
D = DESCALE R = CHANGE 50 10 hours hours 500 1000 hours hours
G = GREASE V = DRAIN/CHANGE hours hours hours hours
BRAKE
Brake oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
Parking brake lever mechanism . . . . . . . . . . . . . . . . . . . . G
Brake oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V*
Brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P*
Brake circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A*
CAB
Windscreen washer liquid level . . . . . . . . . . . . . . . . . . . . C
Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
Cab ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Condition of the rear view mirrors . . . . . . . . . . . . . . . . . . C*
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Lift the cab in case of failure . . . . . . . . . . . . . . . . . . . . .
ELECTRICITY
Battery electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . C
Battery electrolyte density . . . . . . . . . . . . . . . . . . . . . . . . C
Condition of wiring harness and cables . . . . . . . . . . . . . . C*
Lights and signals (OPTION) . . . . . . . . . . . . . . . . . . . . . . C*
Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Adjust the front headlamps (OPTION) . . . . . . . . . . . . . . . .
FRONT AXLE
Front axle differential oil level . . . . . . . . . . . . . . . . . . . . . C
Transfer box oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Front wheels reducers oil level . . . . . . . . . . . . . . . . . . . . C
Front axle differential oil . . . . . . . . . . . . . . . . . . . . . . . . . V V
Transfer box oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V V
Front wheels reducers oil . . . . . . . . . . . . . . . . . . . . . . . . V V
Wearing of front axle brake discs . . . . . . . . . . . . . . . . . . C*
Front wheels reducers clearance . . . . . . . . . . . . . . . . . . . C*
Bearings clearance of the transfer box . . . . . . . . . . . . . . C*
REAR AXLE
Swivel pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G G/C*
Steering connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . G G/C*
Rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . G G/C*
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
CHASSIS
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Bearings and articulation rings . . . . . . . . . . . . . . . . . . . . C*
ATTACHMENTS
Forks wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Attachment carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . C*
Condition of attachments . . . . . . . . . . . . . . . . . . . . . . . . C*
LIFT TRUCK
Tow the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sling the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport the lift truck on a platform . . . . . . . . . . . . . . . .
(*) : Consult your dealer.
3 - 11
A - DAILY OR EVERY 10 HOURS SERVICE
A1 - I.C. ENGINE OIL LEVEL A1

CHECK
Park the lift truck on level ground with the I.C. engine stopped, allow the oil to settle. 2
- Lift up the cab (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).

- 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.
1
A2 - COOLING LIQUID LEVEL

CHECK A2
Park the lift truck on level ground with the I.C. engine stopped, and allow the I.C. engine
to cool.
1
- Slowly turn the cap of the radiator 1 (fig. A2) counterclockwise up to the safety stop. 2
- Allow the pressure and vapour to escape.
- Press down and turn the cap so as to release the cap.
- If necessary, add cooling liquid (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) in
order to top up the level to 1/2 in. below the filler port 2 (fig. A2).
- Lightly lubricate the filler neck and install the radiator cap.
- Check visually that there is no leakage in the radiator and pipes.
To avoid risk of boiling water or steam, wait until the I.C. engine has cooled
before removing the filler plug. If the cooling liquid is hot, add only hot
WARNING cooling liquid. In an emergency, you can use water as a cooling liquid, then
change the cooling circuit liquid as soon as possible (see : 3 - MAINTE-
NANCE : F1 - COOLING LIQUID).
A3 - FUEL LEVEL
CHECK A3
Keep the fuel tank full, to reduce condensation.

1
- Open the side cover.
2
- Remove cap 1 (fig. A3).
- Fill the fuel tank with clean fuel (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL), filte-
red through a strainer or a clean, lint free cloth, through filler port 2 (fig. A3).
- Put the cap back 1 (fig. A3).
- Check visually that there is no leakage in the tank and pipes.
Never smoke
Never smoke or approach or approach
with a flame with aoperations
during filling flame during
or filling
when operations
the tank is or when
open. the
Never
WARNING tankis isrunning.
refill while I.C. engine open. Never refill while the I.C. engine is running.
The fuel tank is vented via the filler plug. When changing it, always use an
WARNING original part, with vented hole.
3 - 12
A4 - CYCLONIC PREFILTER (OPTION) A4

CLEAN
2
1
The cleaning interval is given as a guide, however the prefilter 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 prefilter unit with a clean dry cloth and reassemble the unit.
IMPORTANT
When cleaning, takeWhen
care cleaning,
not to lettake care not
impurities intotothe
let dry
impurities
air filter.into the dry air filter.
A5 - TIRES PRESSURE AND WHEEL NUTS TORQUE

CHECK
- Check the condition of the tires, 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 tires : 465 ft/lb
• Rear tires : 243 ft/lb
- Check and adjust the tire pressures if necessary (see : 2 - DESCRIPTION : CHARACTERISTICS).
Check that the air hose
Check is that
correctly
the airconnected to the tire
hose is correctly valve before
connected to theinflating andbefore
tire valve keep inflating
all persons
andatkeep
a distance during
all persons at inflation.
a distanceRespect
during
WARNING
the recommended tire pressures
inflation. given.
Respect the recommended tire pressures given.
3 - 13
B - EVERY 50 HOURS SERVICE

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

CHECK - CLEAN
In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced.
If the clogging indicator
If thelight comes
clogging on, thislight
indicator operation
comes must be carried
on, this outmust
operation as quickly as possible
be carried (1 houras
out as quickly maximum). Thehour
possible (1 cartridge must
maximum).
IMPORTANT
not be cleaned moreThe
than seven times,
cartridge after
must not bewhich themore
cleaned cartridge
than must
sevenbetimes,
changed.
after which the cartridge must be changed.
- For the disassembly and reassembly of the cartridge, see : 3 - MAINTENANCE

: D3 - DRY AIR FILTER CARTRIDGE.
- Clean the filter cartridge using a compressed air jet (max. 40 psi) directed from the top to the bottom and from the inside towards
the outside at a minimum distance of 1 in. from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.
Respect the safetyAvoid
distance of 30
tearing or mm between
making a holethe
in air
thejet and the The
cartridge. cartridge to avoid
cartridge musttearing
not be or making
blown a holenear
anywhere in thethe
cartridge.
air filter The
box.cartrid-
Never
IMPORTANT
ge must not be blown anywhere
clean near the
the cartridge air filteritbox.
by tapping Never
against cleansurface.
a hard the cartridge by tapping
Your eyes it against
must be a hard
protected surface.
during this intervention.
- Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant.
- Check visually the outer condition of the air filter and its mounts. Verify the condition of the hoses and their mounts also.
Do not clean the dryDoairnot
filter cartridge
clean the drybyairwashing it in liquid.
filter cartridge Do not clean
by washing by anyDomeans
it in liquid. the safety
not clean cartridge
the safety located
cartridge inside
located the filter
inside car-
the filter
IMPORTANT
tridge, change it forcartridge,
a new onechange
if it is itdirty
for aornew
damaged.
one if it is dirty or damaged.
B2 - RADIATOR CORE B2
CLEAN
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-
In a heavy dust atmosphere, clean the radiator core every day. Do not use
IMPORTANT
pressure steam as this could
a water jetdamage the radiator
or high-pressure fins.as this could damage the radiator fins.
steam
- Open the counterweight cowling.
- In order to prevent the radiator becoming clogged, clean the radiator with a compressed
air jet directed from outside to inside. This is the only way to clean the core of debris (fig.
B2).
3 - 14
B4 - TENSION AND ALIGNMENT OF THE MAST LIFTING CHAINS B4

CHECK - ADJUST
Park the lift truck on level ground with the mast in a vertical position and the forks lifted
at approximately 8 in.
- Check the alignment of the mast lifting chains between the carriage’s chain fasteners and 1
the chain rollers.
- Manually verify the chain tension, if necessary adjust as following while ensuring that the
carriage is perpendicular to the mast.
- Loosen the lock nut 1 (fig. B4) of the chain tension adjuster.
- Adjust the tension by tightening or loosening the nut 2 (fig. B4) while checking the align- 2
ment of the lifting chains.
- Then block the lock nut 1 (fig. B4) and the nut 2 (fig. B4).
These checks are important for the good working operation of the mast. In case of technical
faults, consult your dealer.
IMPORTANT B5/1
In case of technical problems, consult your dealer.
B5 - MAST
GREASE 1
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 oxidizing atmosphere, reduce this inter-
IMPORTANT
val to 10 working hours or every day.
In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to
10 working hours or every day.
B5/2
Clean and lubricate the following points with grease (see : 3 - MAINTENANCE : LUBRI-
CANTS AND FUEL) and remove the surplus of grease.
1 - Lubricators of the articulation axles at the foot of the mast (2 lubricators) (fig.
B5/1).
2 - Lubricators of the tilt cylinders foot axles (2 lubricators) (fig. B5/2).
3 - Lubricators of the tilt cylinders head axles (2 lubricators) (fig. B5/3). 2
4 - Lubricators of upper guide rollers on mast (2 lubricators) (fig. B5/4).
5 - Lubricators of lower guide rollers on mast (2 lubricators) (fig. B5/5).
NOTE : With wide tires OPTION, lift the forks by approximately 6.5 ft. to grease the lower
guide rollers of the mast through the port 6 (fig. B5/6).
In case of technical faults, consultIMPORTANT

your dealer. B5/3
In case of technical problems, consult your dealer.
B5/4 B5/5 B5/6
3 - 15
B6 - HYDRAULIC OIL LEVEL B6

CHECK 2
Park the lift truck on level ground with the I.C. engine stopped, the mast tilted backwards 3
and lowered as far as possible.
- Refer to gauge 1 (fig. B6).

- The oil level is correct when it is at the level of the red point.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL).
- Remove cap 2 (fig. B6). 1
- Add oil by filler port 3 (fig. B6).
IMPORTANT Use a clean funnel and clean the oil nozzle before filling.
Use a clean funnel and clean the underside of the oil drum before filling.
- Put the cap back.
Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank.
B7 - BRAKE OIL LEVEL B7

CHECK
Park the lift truck on level ground.

1
- The level is correct when it is at the MAXI level on the tank.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the filler port
1 (fig. B7).
WARNING If the braking oil level is abnormally low, consult your dealer.
If the braking oil level is abnormally low, consult your dealer.
B8 - WINDSCREEN WASHER LIQUID LEVEL B8

CHECK
Park the lift truck on level ground.
- Lift up the cab (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS). 1

- Check visually the level.
- If necessary add windscreen washer liquid (see : 3 - MAINTENANCE : LUBRICANTS AND
FUEL) by filler port 1 (fig. B8).
B9 - CAB DOOR B9
GREASE
Clean and lubricate the points 1 (2 lubricators) (fig. B9) with grease (see : 3 - MAINTE-
1
NANCE : LUBRICANTS AND FUEL) and remove the surplus.
3 - 16
B11 - BATTERY ELECTROLYTE LEVEL B11/1

CHECK
Check the electrolyte level in each cell of the battery.

If the lift truck is working in a high temperature environment, check the level more fre-
quently than every 50 hours service.

- Remove the fixing plate 1 (fig. B11/1) and pull the battery out 3/4 in. 1
- Disconnect the battery, starting with the negative terminal, and remove it.
- Remove caps 2 (fig. B11/2) from each cell of the battery.
- The level is correct when it is 1/2 in. above the top of the plates in the battery.
- If necessary, top up the cells with clean distilled water that has been stored in a glass
container.
- Clean and dry caps 2 (fig. B11/2) and install. B11/2
- Check the terminal connections and lightly smear them with petroleum jelly to prevent the
formation of corrosion.
2 2
- Replace the battery and reconnect it, starting with the positive terminal.
- Reassemble the fastening plate 1 (fig. B11/1).
Handling and servicing
Handlingaandbattery can be
servicing dangerous,
a battery take
can be the following
dangerous, takeprecautions : precau-
the following
- Wear protective
tions : goggles.
- Keep the battery horizontal.
- Wear protective goggles.
- Never smoke or work nearbattery
- Keep the a naked flame.
horizontal.
WARNING
- Work in a well-ventilated area.or work near an open flame.
- Never smoke
- In the event of- electrolyte being spilled onto
Work in a well-ventilated area.the skin or splashed in the eyes, rinse tho-
roughly with cold water for 15 minutes and call aspilled
- In the event of electrolyte being doctor.onto the skin or splashed in the
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.
B12/1
B12 - REAR AXLE 1
GREASE 1
Clean and lubricate the following points with grease (see : 3 - MAINTENANCE : LUBRI-
CANTS AND FUEL) and remove the surplus of grease.
1 - Lubricators of the swivel pins (6 lubricators) (fig. B12/1).

2 - Lubricators of the steering cylinder head axles (4 lubricators) (fig. B12/1).
3 - Lubricators of the rear axle oscillation pin (2 lubricators) (fig. B12/2). 2 2
B12/2
3 - 17
C - EVERY 250 HOURS SERVICE

C1 - ALTERNATOR/FAN/CRANKSHAFT BELT TENSION C1

CHECK - ADJUST

- Check the belt for signs of wear and cracks and change if necessary (see : 3 - MAINTE-
NANCE : FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the crankshaft and of the alternator.
- Under a normal pressure exerted with the thumb (10 lb), the tension should be approxi-
mately 3/8 in.
1
- Carry out adjustments if necessary.
- Loosen screws 1 (fig. C1) by two to three thread turns.
1
- Swivel the alternator assembly so as to obtain the belt tension required.
- Retighten screws 1 (fig. C1) (tightening torque 16 ft/lbs).
If the alternator belt has to be changed, check the tension again after the
IMPORTANT first 20 hours of operation.
C2 - PARKING BRAKE
CHECK - ADJUST C2/1
A
Park the lift truck on a slope less than 15 % with the rated load in the transport position. 4
- Check the tightening adjustment by locking the parking brake in position A (fig. C2/1).
- The adjustment is correct when the lift truck is held stationary on a slope.
- Carry out adjustments if necessary.
ADJUSTMENT OF THE PARKING BRAKE CABLE ON THE FRONT AXLE B

- Press and release the brake pedal, then release the parking brake, putting it in position
B (fig. C2/1).
- Unscrew nuts 1 (fig. C2/2).
- Adjust the cable by loosening nuts 1 (fig. C2/2), until a clearance of 0.06 in. between
cams 2 (fig. C2/2) and stops 3 (fig. C2/2) is obtained.
The adjustment of the stops performed by the manufacturer must not be
WARNING modified under any circumstances.
ADJUSTMENT OF THE PARKING BRAKE

- Leave the parking brake in position B (fig. C2/1). C2/2
- Progressively tighten the end piece of the lever 4
(fig. C2/1) and recheck braking.
2
- Repeat the operation until the correct braking 2
adjustment is obtained. 3
3
1 1
C3 - FRONT AXLE DIFFERENTIAL OIL LEVEL C3

CHECK
Park the lift truck on level ground with the I.C. engine stopped.
2
- Remove level plug 1 (fig. C3). The oil should be flush with the edge of the hole.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the filler port 1
2 (fig. C3).
- Replace and tighten the level plug 1 (fig. C3) (tightening torque 30 ft/lbs).
3 - 18
C4 - TRANSFER BOX OIL LEVEL C4

CHECK

- Remove level plug 1 (fig. C4). The oil should be flush with the edge of the hole.
1
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the same hole.
C5 - FRONT WHEELS REDUCERS OIL LEVEL C5

CHECK
- Check the level on each front wheel reducer.

- Place level plug 1 (fig. C5) in the horizontal position. 1
- Remove the level plug ; the oil should be flush with the edge of the hole.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the same hole.
3 - 19
D - EVERY 500 HOURS SERVICE

D1 - I.C. ENGINE OIL D1/1

DRAIN
D2 - I.C. ENGINE OIL FILTER
CHANGE
Park the lift truck on level ground, let the I.C. engine run at idle for a few minutes, then
stop the I.C. engine.
DRAINING THE OIL 1

- Remove the inspection panel 1 (fig. D1/1).
- Place a container under drain plug 2 (fig. D1/2) and unscrew the plug.
- Remove filler cap 3 (fig. D1/3) in order to ensure that the oil is drained properly.
IMPORTANT Dispose
Dispose of the drain of ecological
oil in an the drain oil in an ecological manner.
manner. D1/2
REPLACEMENT OF THE FILTER

- Remove I.C. engine oil filter 4 (fig. D1/2) ; discard the filter and the filter seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly grease the new oil filter seal and install the oil filter (see : 3 - MAINTENANCE : FIL-
TERS CARTRIDGES AND BELTS) on the filter bracket.
2
Tighten the oil filter by hand pressure only and lock the filter in place by a 4
IMPORTANT
Tighten the oil filterquarter
by hand pressure only and lock the filter in place by a quarter turn.
turn.
FILLING UP THE OIL

- Install and tighten drain plug 2 (fig. D1/2) (tightening torque 26 ft/lb).
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by filler port 5 (fig.
D1/3). D1/3
- Wait a few minutes to allow the oil to flow into the sump. 3
- Start the I.C. engine and let it run for a few minutes.
5
- Check for possible leaks at the drain plug and the oil filter.
- Stop the I.C. engine, wait a few minutes and check the level between the two notches on
dipstick 6 (fig. D1/3).
- Top up the level if necessary.
- Install the inspection panel 1 (fig. D1/1).
3 - 20
D3 - DRY AIR FILTER CARTRIDGE D3

CHANGE
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 per-
iodicity of the cartridge must be reduced (up to 250 hours in a heavily laden dust atmos-
phere and with pre-filtration).
Change the cartridge Change the cartridge
in a clean location,inwith
a clean
the location, with
I.C. engine the I.C. Never
stopped. enginerun
stopped.
the I.C.Never
engi-
IMPORTANT
ne with the air filterrun the I.C.orengine
removed with the air filter removed or damaged.
damaged. 2
1
- 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 installing, check the state of the new cartridge (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.
- Reassemble the cover, guiding the valve downwards.
D4 - FUEL FILTER CARTRIDGE D4/1

CHANGE
Make Make contact

sure the electrical sure theon
ignition
the liftswitch
truck on the lift
is cut, truck is fuel
otherwise off, will
otherwise fuel will
be released be
if the
WARNING released if the lift pump is on.
lift pump is on.
2
- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
the system.
- Place a container under the filter and drain it via drain plug 1 (fig. D4/1). 1
- Loosen the body of filter 2 (fig. D4/1).
- Remove the filter cartridge by pressing the cartridge 3 (fig. D4/2) down against the pres-
sure of the spring and turn it to the left to extract it.
- Insert a new cartridge (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS), by
pressing the cartridge 3 (fig. D4/2) down against the pressure of the spring and turn it D4/2
to the right to lock it into the body of the filter.
- Place the new seal 4 (fig. D4/2) onto the body of the filter and lubricate the contact sur-
face using clean engine oil. 3
- Install the body of the filter onto its holder, hand-tighten it only and lock it with a quarter-
turn.
4
- Close drain plug 1 (fig. D4/1) and remove the container.
- Before starting the I.C. engine, leave the ignition on for three minutes on the lift truck, to
give the lift pump time to release air from the filter.
- Start up the I.C. engine and make sure there is no leakage.
- If necessary, bleed the fuel circuit (see : 3 - MAINTENANCE : G1 - FUEL SYSTEM).
3 - 21
D5 - MAST LIFTING CHAINS D5

CLEAN - CHECK - GREASE
- Wipe the mast lifting chains 1 (fig. D5) with a clean, lint-free cloth, then examine them
closely so as to detect any signs of wear.
- Vigorously brush the chains to get rid of any foreign matter, with a hard nylon brush and
clean diesel fuel.
- Rinse the chains by means of a paint brush impregnated with clean diesel fuel and dry 1
them with a compressed air jet.
- Moderately lubricate the chains (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL).
IMPORTANT In case of technical problems, consult your dealer.

In case of technical faults, consult your dealer.
D6 - HYDRAULIC RETURN OIL FILTER CARTRIDGE D6/1

CHANGE
1
Stop the I.C. engine and remove the pressure from the circuits by acting on the hydraulic 2
controls.
Thoroughly
Thoroughly clean the clean
outside of the outside
the filter and its of the filter and
surroundings its surroundings
before before
any intervention any
in order
IMPORTANT
to prevent any risk intervention, to prevent
of polluting the hydraulicrisk of polluting the hydraulic circuit.
circuit.

- Remove cap 1 (fig. D6/1) and unscrew the cover 2 (fig. D6/1) two or three turns
- Wait a few moments while the oil flows into the tank.
- Remove the cover and take out the filter cartridge assembly 3 (fig. D6/2).
- Place the assembly in a clean container and empty the bowl.
- Remove the bowl 4 and the top 5 of the filter cartridge 6 (fig. D6/3) by a movement of D6/2
rotation.
- Install the bowl and the top onto a new cartridge (see : 3 - MAINTENANCE : FILTER ELE-
MENTS AND BELTS).
- Fit the assembly in place and tighten the cover 2 (fig D6/1).
3
- Put the cap back 1 (fig. D6/1).
D6/3
3 - 22
D7 - PARKING BRAKE LEVER MECHANISM D7

GREASE
1
- Release the protective boot 1 (fig. D7).
- Clean and grease articulation axles 2 (fig. D7) with grease (see : 3 - MAINTENANCE :
LUBRICANTS AND FUEL).
- Install the protective boot 1 (fig. D7). 2
D8 - CAB VENTILATION FILTER D8/1

CLEAN
1
- Lift up protective casing 1 (fig. D8/1).
- Lift out cabin ventilation filter 2 (fig. D8/2).
- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see : 3 - MAINTENANCE : FILTERS CAR-
TRIDGES AND BELTS).
- Install the filter and protective casing.
D8/2
D9 - BATTERY ELECTROLYTE DENSITY

D9
CHECK 1.240
1.250
The electrolyte density varies depending on the temperature concerned, but a minimum of
1.260
1260 at 61°F must be maintained. In the shaded area (fig. D9), the battery is in a normal
charge condition. Readings above this zone indicate that the battery needs to be rechar- 1.270
ged. 1.280
The density should not vary more than 0.025 units between cells.
1.290
- Check the electrolyte density in each battery cell using a hydrometer. 1.300
- Do not carry out this check immediately after topping up with distilled water. Recharge the
battery for at least an hour before checking the battery electrolyte density. °C -18 -10 0 10 20 30 40
°F 0 14 32 50 68 86 104
Handling and servicing
Handlingaandbattery can be
servicing dangerous,
a battery take
can be the following
dangerous, takeprecautions : precau-
the following
- Wear protective
tions : goggles.
- Keep the battery horizontal.
- Wear protective goggles.
- Never smoke or work nearbattery
- Keep the a naked flame.
horizontal.
WARNING
- Work in a well-ventilated area.or work near an open flame.
- Never smoke
- In the event of- electrolyte being spilled onto
Work in a well-ventilated area.the skin or splashed in the eyes,
rinse thoroughly with cold water for 15 minutes and callonto
- In the event of electrolyte being spilled a doctor.
the skin or splashed in the
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.
3 - 23
D10 - FRONT AXLE DIFFERENTIAL OIL D10/1

DRAIN
Park the lift truck on level ground with the I.C. engine stopped and the differential oil still
warm.
1
IMPORTANT Dispose
Dispose the drain oil of the drainmanner.
in an ecological oil in an ecological manner.
1 1
- Place a container under drain plugs 1 (fig. D10/1) and unscrew the plugs.
- Remove level plug 2 (fig. D10/2) and filler plug 3 (fig. D10/2) in order to ensure that the
oil is drained properly.
- Install and tighten drain plugs 1 (fig. D10/1) (tightening torque 30 ft/lb).
D10/2).
D10/2
- The level is correct when the oil level is flush with the edge of port 2 (fig. D10/2).
- Check for any possible leaks at the drain plugs.
- Install and tighten level plug 2 (fig. D10/2) (tightening torque 30 ft/lb) and filler plug 3
(fig. D10/2) (tightening torque 30 ft/lb).
3
3 - 24
3 - 25
E - EVERY 1000 HOURS SERVICE

E1 - FUEL TANK E1/1

CLEAN
WARNING While carrying out these operations, do not smoke or work near a flame.
While carrying out these operations, do not smoke or work near a flame.

1
- 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
Never or anywelding
perform other operation
on the fuelbysystem,
yourself,this
thiscould
couldcause
provoke an explosion
an explosion or
orWARNING
a fire. a fire.
- Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
- Remove cap 2 (fig. E1/2). E1/2
- Let the fuel flow and clean with 2 gal. of clean fuel by filler port 3 (fig. E1/2).
- Install and tighten drain plug 1 (fig. E1/1) (tightening torque 26 ft/lbs).
- Fill the fuel tank with clean fuel (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) filte- 2
red through a strainer or a clean, lint-free cloth and install the filler plug 2 (fig. E1/2).
- If necessary, bleed the fuel circuit (see : 3 - MAINTENANCE : G1 - FUEL SYSTEM). 3
E2
E2 - SAFETY DRY AIR FILTER CARTRIDGE
CHANGE
- For the disassembly and reassembly of the cartridge, see : 3 - MAINTENANCE : D3 - DRY 1
AIR FILTER CARTRIDGE.
- Gently remove the dry air filter safety cartridge 1 (fig. E2), taking care to avoid spilling the
dust.
- Clean the gasket surface on the filter with a damp, clean lint-free cloth.
- Before installing, check the state of the new safety 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.
NOTE : The schedule for changing the safety cartridge is given for information only. The
safety cartridge must be changed for every two changes of the air filter cartridge.
3 - 26
E3 - HYDRAULIC OIL E3/1

DRAIN
E4 - SUCTION STRAINER FOR HYDRAULIC OIL TANK
CLEAN
E5 - FILTER CAP FOR HYDRAULIC OIL TANK
CHANGE
Park the lift truck on level ground with the I.C. engine stopped, the mast tilted backwards 1
and lowered as far as possible.
Thoroughly
Before any intervention, clean clean
thoroughly the area
thesurrounding the drain
area surrounding the plug
drainand
plugthe suction
and cover
the suction
IMPORTANT on the
cover on the hydraulic hydraulic tank.
tank.
DRAINING THE OIL E3/2

- Place a container under drain plug 1 (fig. E3/1) and unscrew the plug. 2
- Remove filler cap 2 (fig. E3/2) in order to ensure that the oil is drained properly.
4
IMPORTANT Dispose
Dispose the drain oil of the drainmanner.
in an ecological oil in an ecological manner.
CLEANING THE STRAINER

- Remove the inspection panel 3 (fig. E3/3).
- Unscrew the suction strainer at the bottom of the tank, clean it with the help of a com-
pressed air jet, check its condition and change it, if necessary (see : 3 - MAINTENANCE :
5
FILTERS CARTRIDGES AND BELTS).
- Install the strainer and the inspection panel 3 (fig. E3/3).
FILLING UP THE OIL

E3/3
- Clean and install drain plug 1 (fig. E3/1) (tightening torque 26 ft/lb).
E3/2).
Use a clean container and funnel, and clean the underside of the oil nozzle
IMPORTANT before
Use a clean container andfilling.
funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 5 (fig. E3/2) ; the oil level should be at the level of the
red point.
- Check for any possible leaks at the drain plug.
- Replace a new filler plug 2 (fig. E3/2) (see : 3 - MAINTENANCE : FILTERS CARTRIDGES 3
AND BELTS).
POLLUTION ABATEMENT OF THE HYDRAULIC CIRCUIT

- Let the I.C. engine run (accelerator pedal at halfway travel) for 5 minutes without using anything on the lift truck, then for 5 more
minutes while using all the hydraulic movements (except the steering system).
- Accelerate the engine at full speed for 1 minute, then activate the steering system.
- This operation makes a pollution abatement of the circuit possible through the hydraulic return oil filter.
E6 - 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.

Under no circumstances
Under should you use theshould
no circumstances lift truck
youifuse
the the
seatliftbelt is iffaulty
truck (fixing,
the seat beltlocking, it has Repair
is damaged! cuts orortears, etc).
replace theRepair or replace
seat belt imme-
WARNING
the seat belt immediately.
diately!
3 - 27
E7 - TRANSFER BOX OIL E7/1

DRAIN
Park the lift truck on level ground with the I.C. engine stopped and the transfer box oil still
warm.
1
IMPORTANT Dispose of the drain oil in an ecological manner.
Dispose the drain oil in an ecological manner.
- Remove the inspection panel 1 (fig. E7/1).
- Place a container under drain plug 1 (fig. E7/2) and unscrew the plug.
- Remove level plug 3 (fig. E7/2) in order to ensure that the oil is drained properly.
- Install and tighten drain plug 2 (fig. E7/2) (tightening torque 30 ft/lb).
E7/2).
E7/2
- The level is correct when the oil level is flush with the edge of port.
- Check for any possible leaks at the drain plugs.
- Install and tighten level plug 3 (fig. E7/2) (tightening torque 30 ft/lb).
- Install the inspection panel 1 (fig. E7/1).
E8 - FRONT WHEELS REDUCERS OIL E8

DRAIN
Park the lift truck on level ground with the I.C. engine stopped and the reducers oil still
warm.
B 1
IMPORTANT Dispose of the drain oil in an ecological manner.
Dispose the drain oil in an ecological manner.
- Drain and change each front wheel reducer.
- Place drain plug 1 (fig. E8) in position A.
- Place a container under the drain plug and unscrew the plug.
A
- Let the oil drain fully.
- Place the drain port in position B, i.e. in a level position.
- Fill up with oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by level port 1 (fig. E8).
- The level is correct when the oil level is flush with the edge of the hole.
- Install and tighten the drain plug 1 (fig. E8) (tightening torque 30 ft/lb).
3 - 28
3 - 29
F - EVERY 2000 HOURS SERVICE

F1 - COOLING LIQUID F1/1

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

- Lift up the cab (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS). 1
- Place a container under hose 1 (fig. F1/1) on the radiator and drain plug 2 (fig. F1/2) of
the engine block. Remove the hose and loosen the drain plug.
- Remove filler cap 3 (fig. F1/3) of the radiator.
- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.
- Check the condition of the hoses as well as the fastening devices and change the hoses
if necessary.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
F1/2
FILLING THE LIQUID
- Install and tighten the hose 1 (fig. F1/1) and drain plug 2 (fig. F1/2) (tightening torque
30 ft/lb).
- Slowly fill up the cooling circuit (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) to 1/2
in. under filler port 4 (fig. F1/3).
- Install filler cap 3 (fig. F1/3). 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
Tonot contain
pervent any corrosion
corrosion resistor
the I.C. engineand must system
cooling be filled must
duringbethefilled
whole year
with a
IMPORTANT
with a mixture containing
minimum 25 mixture
% of ethylene
of 25 %glycol-based antifreeze. antifreeze.
ethylene glycol-based
F1/3
3 - 30
3 - 31
G - OCCASIONAL MAINTENANCE
G1 - FUEL SYSTEM
BLEED
These operations are to be carried out only in the following cases :

• A component of the fuel system replaced.
• A drained tank.
• Running out of fuel.
Ensure that the level of fuel in the tank is sufficient and bleed in the following order :

- Put the ignition on for three minutes on the lift truck, to give the lift pump time to pump air from the filter.
- Switch off the ignition with the ignition key.
BLEEDING THE INJECTORS G1/1

- Remove the injectors cover 1 (fig. G1/1).
- Loosen high pressure connectors 2 (fig. G1/2) of all the injectors.
- Activate the starter until the diesel fuel flows out free of air at high pressure connectors
2 (fig. G1/2).
Do not engage the starter
Do not motor onthe
engage a continual basis for
starter motor on more than 30basis
a continual seconds and let
for more it cool
than 30 1
IMPORTANT
between unsuccessful attempts.
seconds and let it cool between unsuccessful attempts.
- Tighten the connection while the diesel fuel is flowing out (tightening torque 22 ft/lb).
G1/2
2 2 2 2
- The I.C. engine is then ready to be started up.

- Let the I.C. engine idle slowly for 5 minutes immediately after bleeding the fuel feed circuit, in order to ensure that the injection
pump has been bled thoroughly.
NOTE : If the I.C. engine functions correctly for a short time then stops or functions irregularly, check for possible leaks in the low
pressure circuit. If in doubt, contact your dealer.
3 - 32
G2 - WHEEL
CHANGE
In the event of a wheel being changed on the public highway, make sure of
WARNING
In the event of a wheelthe following
being changedpoints:
on the public highway, make sure of the following points
- Park the lift truck, if possible on even and hard ground.
- Put the warning lights on.
- Immobilize the lift truck in both directions on the axle opposite to the wheel to be changed.
- Unlock the nuts of the wheel to be changed.
REAR WHEEL
For this operation, we advise you to use an approved hydraulic jack (see your dealer). G2/1
- Fit the jack under the rear axle, as near as possible to the wheel to be changed and
adjust the jack (fig. G2/1).
- Lift the wheel until it lifts off the ground and fit security wedges under the rear 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.
- Install the nuts by hand, if necessary grease them.
- Remove the security wedges and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see : 3 - MAINTENANCE : A - DAILY OR
EVERY 10 HOURS SERVICE for tightening torque).
G2/2
FRONT WHEEL G2/3

For this operation, we advise you to use an approved hydraulic jack (see your dealer).
- Place the jack under the flared axle tube, as near as possible to the wheel and adjust the
jack (fig. G2/3).
- Lift the wheel until it lifts off the ground and fit security wedges under the rear axle (fig.
G2/4).
- 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.
- Install the nuts by hand, if necessary grease them.
- Remove the security wedges and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see : 3 - MAINTENANCE : A - DAILY OR
EVERY 10 HOURS SERVICE for tightening torque).
G2/4
3 - 33
G3 - LIFT THE CAB IN CASE OF FAILURE G3/1
PROCEDURE IN CASE OF FAILURE ON THE LIFTING SYSTEM
UNLOCKING THE CAB :

- Close the left-hand side bay.
- Partially open the cab door.
- Pull out and lock the pull handle 1 (fig. G3/1) on the right-hand side to release the cab
raising mechanism. 1
RAISING THE CAB :
Check that there is nothing laying on the driver’s seat or in the cab which
CAUTION
Check that there iscould
nothing laying
disrupt theonoperation
the driver’s seat, which
of raising could disrupt the operation.
the cab.
G3/2
- If necessary, raise the mast until it is approximately 20 in. above the cab.
3
- Unscrew the two screws 2 (fig. G3/2) on the roof and replace them with two eyes 3 (fig.
G3/2).
2
- Pass a sling around the mobile upright’s upper belt (fig. G3/3) and fasten the ends of the
sling onto the eyes welded 3 (fig. G3/3) on the back of the roof.
- Switch on the engine.
- Gently raise the mast to tension the sling and raise the cab an inch (fig G3/4).
- Release the handle 1 (fig. G3/1).
- Tilt the mast forwards and raise it slowly until you can insert the safety stay 4 (fig. G3/5)
vertically in its clip under the cab.
- Lower the mast to release and remove the sling.
G3/3
3
3
G3/4
G3/5
3 - 34
G4 - FRONT HEADLAMPS (OPTION) G4

ADJUST
h2 = h1 - (l x 2 / 100)
RECOMMENDED SETTING
(as per standard ECE-76/756 76/761 ECE20)
h1
Set to - 2 % of the dipped beam in relation to the horizontal line of
the headlamp. +%
-%
ADJUSTING PROCEDURE
-2%
h1
- Park the lift truck unloaded and in the transport position and per- h2
pendicular to a white wall on flat, level ground (fig. G4).

- Check the tire pressures (see : 2 - DESCRIPTION : CHARACTERIS- l
TICS).
- Put the gear reverser lever in neutral and release the parking brake.
CALCULATING THE HEIGHT OF THE DIPPED BEAM (H2)

• h1 = Height of the dipped beam in relation to the ground.
• h2 = Height of the adjusted beam.
•l = Distance between the dipped beam and the white wall.
G5 - LIFT TRUCK
TOWING
G5/1
The lift truck mustThe lift truck
be towed at must be towed
very slow speedat(less
very than
slow 5speed
kph) (less thanshortest
over the 3mph) over the
possible
IMPORTANT
distance (less thanshortest
100 m).possible distance (less than 328 ft.).
- To tow a lift truck, the high pressure limiters 1 (fig. G5/1 and G5/2) must be unlocked to
avoid damaging the hydrostatic transmission.
1
- Remove the covers 2 (fig. G5/1 and G5/2).
- Loosen screw HC 3 (fig. G5/3) by three thread turns.
- Release the handbrake.
- Switch on the warning lights (option).
- After towing, proceed in the reverse order to lock the high pressure limiters.
G5/2
3 2
G5/3
3 - 35
G6 - LIFT TRUCK G6/1

SLING
- Take into account the position of the lift truck gravity center for lif-
ting (fig. G6/1).
A = 1075 mm B = 1000 mm MSI 40 H Series 1-E2
A = 1225 mm B = 850 mm MSI 50 H Series 1-E2
- Place the hooks in the fastening points provided (fig. G6/2 and
G6/3).
A B
G6/2
G6/3
3 - 36
G7 - LIFT TRUCK ON A PLATFORM G7/1

TRANSPORT
Ensure that the safety instructions connected CAUTION to the platform are respected before the loading
of the lift truck and that the driver of the means of transport is informed about the dimensions
Ensure
and thethatweight
the safety of theinstructions
lift truck (seeconcerning the platform
: 2 - DESCRIPTION are followed before loading
: CHARACTERISTICS).
the lift truck, and that the truck driver has been informed about the dimensions and the
Ensure
weight of thethatliftthe platform
truck (Seehas 2 -got dimensions and:aCHARACTERISTICS).
DESCRIPTION load capacity sufficient for transporting the
lift truck.
Ensure Check
that the also the
platform pressure
has on the contact
dimensions and a loadsurface allowable
capacity for the for
sufficient platform in connec-
transporting
tiontruck.
the lift with the
Check lift truck.
also the pressure on the contact surface allowable for the platform in
connection with the lift truck.
Fortrucks
For lift lift trucks
equipped equipped
with awith a turbo-charged
turbo-charged I.C. engine,
I.C. engine, blockblock
off theoffexhaust
the exhaust
outletoutlet to rota-
to avoid avoid
rotation of the turbo shaft without lubrication when
tion of the turbo shaft without lubrication when transporting the vehicle. transporting the vehicle.
LOAD THE LIFT TRUCK

- Block the wheels of the platform. G7/2
- Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck.
- Load the lift truck parallel to the platform.
- Park the lift truck (see : 1 - OPERATING AND SAFETY INSTRUCTIONS : DRIVING INSTRUC-
TIONS UNLADEN AND LADEN).
STOW THE LIFT TRUCK

- Fix the chocks to the platform at the front and at the back of each tire (fig. G7/1).
- Fix also the chocks to the platform in the inside of each tire (fig. G7/2).
- Stow the lift truck onto the semi-trailer with sufficiently resistant straps/chains. To the
front by passing above the articulation fittings 1 (fig. G7/3) of the mast and to the back
onto the towing pin 2 (fig. G7/4).
- Tighten the straps/chains (fig. G7/5).
G7/3
G7/4
G7/5
3 - 37
3 - 38

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INTRODUCTION TO SAFETY AND TABLE OF CONTENTS

MANITOU NORTH AMERICA, INC.

MSI50H Series 1-E2

- ROUGH TERRAIN FORKLIFT TRUCK

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

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

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

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

ROUGH TERRAIN FORKLIFT TRUCK

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

STUDY THE OPERATOR/SERVICE MANUALS

ADDITIONAL RECOMMENDED LITERATURE:

A.) OPERATOR TRAINING QUALIFICATIONS

B.) GENERAL SAFETY PRACTICES

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

B.) GENERAL SAFETY PRACTICES (cont.)

C.) OPERATING SAFETY RULES AND PRACTICES

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

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

D.) SUSPENDED LOADS

Guidelines for “Free Rigging / Suspended Loads”

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

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

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

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

1.) ATTEND OPERATOR TRAINING CLASSES

2.) CREATE A MAINTENANCE PROGRAM

2.) CREATE A MAINTENANCE PROGRAM (cont.)

3.) FORKLIFT KNOWLEDGE

4.) WORK SITE KNOWLEDGE

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

SAFETY ALERT SYMBOL

CALIFORNIA PROPOSITION 65 WARNING

Before Starting - 801011

Safety Instructions - 420792

Instructions for the forklift operator; before operating the forklift.

Use of Seat Belt - 801012

Instructs the operator to always wear the seat belt during

Emergency and Parking Brake - 801010

Identifies the Emergency/Parking Brake Lever.

Alarm Must Sound - 496162

Informs: riders are not allowed on the forklift.

Clear of Raised Boom - 801006

Keep away from unsupported boom.

Clear of Power Lines - 801007

Keep away from power lines.

Use of Frame Leveling - 801013

Frame leveling notice; load must be lowered.

Attachment and Boom Safety - 801009

Important reminders of attachment and boom safety.

Hydraulic Coupling - 234805

Stop the engine and release hydraulic pressure before changing

Rotating Fan and Belt(s) - 801008

Gear Shift Pattern - 33460

Identifies the gear shift pattern of the forklift transmission.

Steering Mode - 184276

Identifies the steering mode selection.