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MLT 845 120 LSU S4 - E3 Operator Manual

1. L e sm asas ES mesos a j L T eoouna runs nessa _ L m L ET a bel asas _ _ L E a e T I Tas ose ano fa L LT 80 02 M173FR 18 10 2010 gt Tm MLT 845 120 LSU S rie 4 Euro 3 Main Electrical Schematic Components Location on Diagram Correspondance 4 hydraulique ERERER mo memet s CITE m emere 0 Et I CI O ee Tvs ooo non uam oss E Tee CACA VET e Lm fowom Low wasaqa s EC w EC EC Description s L Ww omo wes L L wwmmeanon 17171711 memummweum O a us prense ou vave neo soona Tel wa femos e us ressurenecunonvave 71717171 we A us wmwonrswew L L w u mwmun 2 wo wasaman _ se _ uan A 18 10 2010 80 02 M173FR AT N Main E lectrical Schematic MLT 845 120 LSU S rie 4 Euro 3 LOCATION OF THE FUSIBLES AND RELAYS ON THE DIAGRAM Fusibles Relays Position sur sch ma Description 7 1 7 5 LSU OPTION AS Ai N 15 A REAR WORKING LIGHTS S 10A REAR WIPER WIPER TOP SIDE FA 15 A Maxi EV STO
2. 2 6 FRONT AXLE FIG E 6 0 00 000 esses ee es esee asse aa Serial Nr MANITOU reference REAR AXLE FIG F _ 6666666 Serial Nr MANITOU reference CAB FIG G Type iii eee ette ee esee ee s este ee arse te ases eren Serial Nr TIR m 1 5 a LI JIB FIG H MANITOU reference Date of manufacture ATACHMENT MANUFACTURER S PLATE FIG 1 Model Serial Nr Year of manufacture S MANITOU 2 1 CHARACTERISTICS Diesel 930 124 91 W Power SAE J 1995 cv 124 91 Maximum torque ISO TR 14396 490 361 at 1400 rpm Air cleaner um Type of cooling TRANSMISSION m Gear box TURNER POWERTRAIN SYSTEMS Type Mechanical Forward reverse selector Torque converter Number of forward speeds 4 Number of reverse speeds 4 2 4 7 TURNER POWERTRAIN SYSTEMS Front axle DANA Differential 45 96 limited slip differential Rear axle DANA Differential 45 96 limited slip differential Drive wheels 4RM Permanent No 4 O Pressure bar psi 4 58 ELECTRIC CIRCUIT RARE GIREU Parking brake Low pressure brake Type of brake Multidisk brake immersed in oil Type of control Electro hydraulic soupANDVBRATON Level of sound pressure in the driver s cab LpA 107 ensured according to directive 2000 14 EC
3. o o 0 For any further technical information regarding your lift truck refer to chapter 2 DESCRIPTION CHARACTERISTICS C ENGINE FIG B C engine Nr e e 6 9 9 0 9 9 0 GEAR BOX FIG MANITOU reference Serial Nr e 6 e 6 o o 0 9 e e e 6 o 0 0 ANGLE GEAR BOX FIG D MANITOU reference Serial Nr e 6 e 6 o o 0 9 0 9 e e e 6 0 o o 9 9 0
4. 14 14 i TAPA a AA AAA j 1 al 1 H bat canyi 130 Je b ISWG 8 GAL j QQ A A 231 CAN GND 22 i 1 niig _30A 1 X250L 14 JAIN lav 100m A PE 17 EIS 187 20 1 1 LJ 4 510 5V 200mA 5 0V Y ke SJT Lp 233 __ o BE BE vert noir O 150 151 152 157 224 156 S40 E PT J R2 a 97 729 LIAISON CABINE e N Masse avant cabine gauche M1 8 GYROPHARE Masse avant cabine droite M2 Masse Moteur Masset cabin PHARE TRAVAIL AVANT ARRIERE Masse arri re chassis M3 187 Masse support distributeur M5 4794 Y amp 10 25 mm 5 8 E plage ferm e de 8 Masse Cosse Ronde M8 1 j 2 4 J 5 J A Jj 0 1 2 J 18 10 2010 80 02 M173FR de gt EOS Gc K Mc SO A16 Main E lectrical Schematic 80 02 M173FR 18 10 2010 u Main E lectrical Schemati MLT 845 120 LSU S rie 4 Euro 3 2 4 _ ain E lectrical Schematic A17 AUTORADIO 68 3 K7 Al centrate IK6 zi NII El BUZZER T YA YA YA 87 86 CLIGNOTANTE z 344 128 LET 107 y Il 505 277
5. L us memes Jo PP m qesmmunes 0 L IT LIT zm qeememwum EE E m pel E ms wmwuwnumm I m wmwuwmenm EE CT er sl C mwonswewema O jer L me maaa 1 e L T Le umma sa 21820242 Lm waren L m mwmeseermensur e Lm wwswuwmeraum _ Lej e e mwmersummonnae a m rean nn oreenonuon Da LI m onossna more e Lm meuwwmera e ome pza mares e J L Lom fromens I el L ET L row mes une mono oma frenes weon Tas ms LT sun EE mewesum EE uj a TT l ES 80 02 M173FR 18 10 2010 MLT 845 120 LSU S rie 4 Euro 3 Main Electric Schematic Componants E on Diagram Correspondance D scription ENS hydraulique AI suma BE e wowemumamw awsunmm BE Lom fe e 1 E CS EU Lour CT SE CU EM T grum LI JIB O AAA a om room moro EP poor men moras e J LT NEN RN Low emm ow reso seo enero J Lm mee eme L el IS qm L T ms er E pem l IE
6. Do not tow a trailer or attachment which is not in perfect working order Using a trailer in poor condition may affect the lift truck s steering and braking and hence safety If a third party helps in coupling or uncoupling the trailer this person must be permanently visible to the driver and wait until the lift truck has stopped the handbrake is on and the 1 C engine is switched off before performing the operation NOTE There is an OPTIONAL rear view mirror which allows the lift truck to be approached more closely to the trailer ring A TOWING PIN STANDARD COUPLING AND UNCOUPLING THE TRAILER To couple the trailer position the lift truck as close as possible to the trailer ring Put the handbrake on and switch off the I C engine Remove the clip 1 lift the trailer pin 2 and place or remove the trailer ring Be careful not to get your fingers caught or crushed during this operation Do not forget to put clip 1 back in place When uncoupling make sure that the trailer is supported independently B REAR ELECTRIC SOCKET STANDARD Connect the male plug to the female socket 1 on the lift truck and make sure the lights of the trailer or the light bar are working properly A Ground C L H Rear Indicator D Stop Light E R H Rear Indicator F R H Tail Light G L H Tail Light ADJUSTABLE PROJECTING HOOK OPTION COUPLING AND UNCOUPLING THE TRAILER To couple the trailer position the lift truck
7. Release the forks by alternating retracting and raising the jib 3 fig G11 If possible set the jib in transport position without moving the lift truck H TAKING UP AND LAYING DOWN A SUSPENDED LOAD A WARNING Failure to follow the above instructions may lead the lift truck to loose stability and overturn A MUST be used with a lift truck equipped with an operational hydraulic movement cut out device CONDITIONS OF USE The length of the sling or the chain shall be as short as possible to limit swinging of the load Lift the load vertically along its axis never by pulling sideways or lengthways HANDLING WITHOUT MOVING THE LIFT TRUCK Whether on stabilisers or on tyres the lateral attitude must not exceed 1 and the longitudinal attitude must not exceed 5 the bubble of the level must be held at 0 Ensure that the wind speed is not higher than 10 m s Ensure that there is no one between the load and the lift truck I TRAVELLING WITH A SUSPENDED LOAD Before moving inspect the terrain in order to avoid excessive slopes and cross falls bumps and potholes or soft ground Ensure that the wind speed is not higher than 10 m s he lift truck must not travel at more than O 4 m s 1 5 km h i e one quarter walking speed Drive and stop the lift truck gently and smoothly to minimise swinging of the load Carry the load a few centimetres above the ground max 30
8. Unscrew locking screw 3 fig D4 Remove housing 4 fig D4 and discard cartridge 5 fig D4 as well as the seals of the cartridge Clean the inside of the pre filter head and the housing using a brush immersed in clean diesel oil Refit the assembly with a new pre filter and new seals see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Connect the harness Pressurise the circuit by means of the hand pump 6 fig DA If necessary bleed the fuel circuit see 3 MAINTENANCE G1 FUEL SYSTEM 3 21 D5 FUEL FILTER CHANGE Open engine hood and lift the battery cover Carefully clean the outside of the filter and its holder to prevent dust from getting into the system Place a container under the fuel filter 1 fig D5 1 Unscrew the filter and discard it Refit a new fuel filter see 3 MAINTENANCE FILTERS AND BELTS on its bracket A Tighten the fuel filter by hand pressure only and lock the filter in place by a quarter turn Bleed the fuel system work the hand pump 2 fig D5 2 100 times to remove air from the system Remove the container from under 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 GEAR OIL FILTER CHANGE Remove the cover plate 1 fig D6 1 Unscrew and discard gear box oil filter 2 fig D6 2 Carefully clean the filter hea
9. Check the condition of the tyres to detect cuts protuberances wear etc Check the torque load of the wheel nuts Non compliance with this instruction can cause damage and rupture to the wheel bolts and distortion to the wheels Wheel nuts tightening torque e Front tyres 630 N m 465 Ibf ft 15 e Rear tyres 630 N m 465 Ibf ft 15 Check and adjust the tyre pressures if necessary see 2 DESCRIPTION FRONT AND REAR TiRES Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation Respect the recommended tyre pressures given NOTE There is an OPTIONAL wheel toolkit 3 13 A8 JIB PADS CLEAN GREASE To be carried out every 10 hours during the first 5O hours service then once at 250 hours Extend the jib completely With a brush apply a coat of grease see 3 MAINTENANCE LUBRICANTS AND FUEL on the 4 sides of the telescope s fig A8 Telescope the jib several times in order to spread the coat of grease evenly Remove the surplus of grease If the lift truck is used in an abrasive environment dust sand coal use lubricating varnish MANITOU reference 483536 Please consult your dealer 3 14 3 15 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
10. 1 DELUXE PNEUMATIC DRIVER S SEAT OPTION DESIGNED FOR MAXIMUM COMFORT THIS SEAT CAN BE ADJUSTED AS FOLLOWS WEIGHT ADJUSTMENT FIG A It is advised that you adjust the seat according to your weight when sitting Switch on lift truck ignition Pull or push lever 1 briefly Adjustment is automatic NOTE To avoid any health problems it is recommended that the weight should be checked and adjusted before starting up the lift truck SEAT HEIGHT ADJUSTMENT FIG B When weight adjustment has been carried out you can then modify seat height Keep the ignition on in the lift truck Pull or push lever 1 and adjust the seat height A To avoid causing any damage do not activate the compressor for over 1 minute SEAT BACK REST ANGLE ADJUSTMENT FIG C The back rest angle of the seat may be adjusted to suit the individual Press the left hand button while pushing on the seat or relaxing pressure on the seat to find a comfortable position SEAT DEPTH ADJUSTMENT FIG D The depth of the seat may be adjusted to suit the individual Press the righthand 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
11. Switch on the lift truck and set the black key A next to the antenna B maximum 80 mm Wait a few seconds for red LED C to go out before starting the lift truck NOTE You can restart the lift truck within 20 seconds of stopping it after this time the anti start system reacts and LED C flashes red 8 MODCL ANTI START SYSTEM OPERATION Switch on lift truck ignition red led 1 will flash Apply key 2 to its base 3 and withdraw the moment the system emits a continuous beep and led 1 turns green Start the lift truck within the next 20 seconds otherwise the anti theft system will be reactivated and red led 1 will flash NOTE You can restart the lift truck within 20 seconds of stopping it after this time the anti start system reacts and red led 1 flashes 9 CLEANFIX SELF CLEANING FAN This system operated by switch 1 cleans the radiator core and the grille of the engine cover by reversing the air flow A When in use beware of the risk of projection into the eyes Position A The indicator light is on the fan operates in self cleaning mode for a few seconds once every 3 minutes Position B The indicator light is off the fan is in normal operating mode 2 36 10 ELECTRICAL JIB PROVISION Enables an electrical function to be used at the head of the jib foot OPERATION Hold button 2 down and button 3 forwards or backwards 11 EXTERIOR DRAIN BACK Enables connection of an attachment for which
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13. ANITOU MANI TOU AMERI CAS INC One Gehl Way P O Box 179 West Bend WI 53095 0179 U S A Website www us manitou com For parts orders contact your Manitou dealer or call Manitou Americas Parts Department 262 334 6653 Fax 254 867 6504 MLT 845 120 LSU 54 Operator Manual Catalog No 51900003 In Rel 03 2011 THI S OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS RELEASE 03 11 Initial Release CONTENTS ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDAHDS 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
14. Hydrauliic Pump PAAV PAAV O Front Accessory Outlet Prise 08 ss 23 9 6 11 35 32 16 23 Front Accessory Outlet option Pressure Outlet PRF Pressure Switch M32 S33 PRES PAAR Rear Accessory Outlet option Cooling Pump Cooling Pump option M M R P Nominal Speed Cooling Fan option RFV R3VD Leak Return Outlet option 123 M13 ton rte re rete rato van iwi _ voy isoon vane on e 70 02 M173FR 19 11 2010 SP D3 EE EA EL El ET EF FR M A C N O RF SC Main Hydraulic Schematic AS MLT 845 120 LSU S rie 4 E3 HYDRAULIC SCHEMATIC LEGEND vo compensation oyinger came Front Steering Cylinder Rear Steering Cylinder VC V VC Tilt Steering Cutoff Valve VL VT v Lifting Cylinder 133 135 de 110x70 c845 0 Telescope Cylinder de 85x60 c3150 ms Head Valve Isolation Compensation Cylinder 8Ge6 VIP VC Foot Valve isolation Compensation Cylinder de 50x30 c350 de 60x45 c183 VCHAR O Rear Hydraulic Cylinder Hook option VVT O Cylinder Lock Deck option NOTE 1 The set pressures of the main limitations in the input elements are given in the plan maximum engine 2 The set pressure restrictors are secondary to the plan 1000 Tr mn of engine 3 The setting of pressure relief mu
15. FRONT AND REAR TIRES PRESSURE LOAD PER TIRE kg bar psi FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN 155 2512 SGL DL2A TUBELESS 4569 169K TUBELESS 4569 280 65R24 SF 15248 1460 TUBELESS 3859 GROUND CONTACT PRESSURE GROUND CONTACT AREA cm2 ME HARD SOIL LOOSESOIL HARDSOIL LOOSE SOIL 608 168 144 50 DUNLOP 440 8024 137 STAB 158B TUBELESS 4 1 60 a 76 214 255 910 2450 1070 5800 1210 334 480 1735 _ 900 643 346 140 260 1950 696 375 20 520 IS EIS 2450 681 371 60 5800 GOODYEAR 1950 15 5 80 24 SGI 16PR TUBELESS 2450 5800 1950 445 70R24 IT510 1516 TUBELESS 0 DE 5800 460 70R24 XMCL 159A8 TUBELESS 1950 2450 5800 1950 1200R24 XKA 101 2450 5800 15 5R25 XHA TUBELESS MICHELIN 445 65R22 5 XZY 169K TUBELESS 500 70R24 XMCL 164A8 TUBELESS 1950 2033 5800 1746 2931 2 10 2 11 DIMENSIONS AND LOAD CHARTS mm in 1200 4724 mm in 2770 109 05 mm in 1409 55 47 C1 1487 58 54 ID mm in 5229 205 87 101 5307 208 94 D2 4410 173 62 E mm in 6429 253 11 F 1950 76 77 F4 1950 76 77 G mm i 455 17 91 61 mm in 450 17 72 G2 mm in X455 17 91 mm in 1050 41 34 J mm in 950 37 40 K mm in 1260 49 61
16. VIII SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL SHOWN BELOW IT IDENTIFIES POTENTIAL HAZARDS WHICH IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH 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 Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury May also alert unsafe practices Indicates a potentially hazardous situation which if not avoided may result in death or serious injury 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 SAFETY DECALS The purpose of this chapter is to introduce you to the safety messages decals and nameplates found on your forklift truck The de
17. depending on the type of attachment press button B and release button A The red indicator 1 flashes to indicate that it is in operation Set the required flowrate using potentiometer C To stop continuous hydraulic movement of the attachment move switch A forwards or backwards or press button B Indicator 1 goes out Set potentiometer C to O Never leave the driver s cab without resetting the potentiometer C to 0 Before starting the lift truck make sure the potentiometer is set to 0 NOTE If the operator leaves the driver s cab the continuous hydraulic movement will automatically stop and must be restarted 17 JIB SUSPENSION The jib is suspended to reduce shaking of the lift truck on rough ground e g moving straw in a field OPERATION Set the forks or attachment on the ground and relieve the front wheels a few centimetres only Press switch 1 set to position A the visual indicator comes on indicating that jib suspension is activated Press switch 1 set to position B the visual indicator goes out indicating that jib suspension is deactivated Jib suspension is active to a lifting height of 3m00 from the axis of articulation of the carriage with respect to the ground with the jib retracted When you move beyond this height or make another hydraulic movement tilting telescoping attachment jib suspension is momentarily deactivated and the visual indicator of switch 1 goes out When the e
18. lt lt Bearings and articulation rings 1 C lt lt lt 2 HYDRAULIC 3 19 E E E NNNM 343 C C pa Hydraulic oil level TT lt lt lt lt lt lt lt lt lt lt lt lt hydraulic return oil filter cartridge x 133 R R lt lt lt lt lt lt lt lt Hydraulic oil 38384 ce lt Suction strainer for hydraulic oiltank 334 J N lt lt lt lt lt lt Filter cap for hydraulic oil tank 834 lt lt lt lt lt Distributor control head filter 1384 I R lt lt lt lt lt Speeds of hydraulic movements C lt lt lt lt lt Hydraulic pump tubular filter 11112121 ee lt lt lt Condition of hoses and flexible pipes 1 1 C ee lt lt Condition of cylinders leakage shafts 7 1 1 1 C ee lt lt Hydraulic circuit pressures _ ee Hydraulic circuit outputs ce HHydrauicoilltank O IN ee 3 10 ADJUST C CHECK GREASE CLEAN A P BLEED R REPLACE V DRAIN SERVICE OR 6 MONTHS SERVICE c i LL Lis acc c ca HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 500 HOURS EVERY 1000 HOURS SERVICE OR 1 YEAR EVERY 2000 HOURS SERVICE OR 2 YEARS EVERY 4000 HOURS OC
19. 2 while taking up the load Bring the load into the transport position Tilt the load far enough backwards to ensure stability loss of load on braking or going downhill FOR A NON PALLETIZED LOAD Tilt the carriage 1 forwards and move the lift truck slowly forwards 2 to insert the fork under the load fig E4 block the load if necessary Continue to move the lift truck forwards 2 tilting the carriage 3 fig E4 backwards to position the load on the forks and check the load s longitudinal and lateral stability F TAKING UP AND LAYING A HIGH LOAD ON TYRES You must not raise the jib if you have not checked the transverse attitude of the lift truck see INSTRUCTIONS FOR HANDLING A LOAD D TRANSVERSE ATTITUDE OF THE LIFT TRUCK REMINDER Make sure that the following operations can be performed with good visibility see OPERATIONS INSTRUCTIONS UNLADEN AND LADEN D VISIBILITY TAKING UP A HIGH LOAD ON TYRES Ensure that the forks will easily pass under the load Lift and extend the jib 1 2 until the forks are level with the load moving the lift truck 3 forward if necessary fig F1 moving very slowly and carefully Always think about keeping the distance necessary to fit the forks under the load between the pile and the lift truck fig F1 and use the shortest possible length of jib Stop the forks in front of the load by alternately extending and retracting the jib 1 or if necessary mo
20. 6 E LIFTING PEOPLE he use of working equipment and load lifting attachments to lift people is e either forbidden e or authorized exceptionally and under certain conditions see current regulations in the country in which the lift truck is used he pictogram posted at the operator station reminds you that e Left hand column It is forbidden to lift people with any kind of attachment using a non PLATFORM fitted lift truck e Right hand column With a PLATFORM fitted lift truck people can only be lifted using platforms designed by MANITOU for the purpose MANITOU sells equipment specifically designed for lifting people OPTION PLATFORM lift truck contact your dealer 1 7 OPERATING INSTRUCTIONS UNLADEN AND LADEN A BEFORE STARTING THE LIFT TRUCK Carry out daily maintenance see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE Make sure the lights indicators and windscreen wipers are working properly Make sure the rear view mirrors are in good condition clean and properly adjusted Make sure the horn works B DRIVER S OPERATING INSTRUCTIONS Whatever his experience the operator is advised to familiarize himself with the position and operation of all the controls and instruments before operating the lift truck Wear clothes suited for driving the lift truck avoid loose clothes Make sure you have the appropriate protective equipment for the job to be done Prolonged exposure to high n
21. 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 ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 19 Do not use a rough terrain forklift truck for opening or closing railroad car doors 20 In areas classified as hazardous use only rough terrain forklift trucks approved for use in those areas 21 Report all accidents involving personnel building structures and equipment to the supervisor or as directed 22 Do not add to or modify the rough terrain forklift truck 23 Do not block access to fire aisles stairways and fire equipment 24 For rough terrain forklift trucks equipped with a differential lock the lock should not be engaged when driv
22. DANGER EXPLOSION HAZARD Can cause blindness or severe injury Protect eyes Keep away from sparks flames and cigarettes exercise caution when using tools that can cause Sparks Keep battery level and caps tight ACID POISON HAZARD Causes severe burns Contains sulfuric acid In event of contact flush with water and see a doctor Keep out of reach of children 801014 on c E r AN P STAF N RE ow BATTERY T E JUN E 1 Wear eye protection 2 1 P 18 were 7 gt m mija NEGATIVE GROL IDEC BA 4 Br A RU A I a Connect ends of one cable to positive terminals of both batteries 3 Connect one end of remaining cable to negative terminal of good battery 4 Connect other end of cable to engine block or reliable chassis ground of vehicle being started DO NOT CONNECT TO BATTERY 5 To prevent damage to electrical components of vehicle being started make certain that the engine is at idle speed prior to disconnecting jumper cables 801015 MODEL NUMBER SERIAL NUMBER YEAR OF MANUFACTURE attachment Record this information for use COUNTRY OF MANUFACTURE UNL ADEN WEIGHT LB HORIZONTAL CENTER OF GRAVITY IN OPERATING PRESSURE PSI A WARNING This attachment affects the capacity of the lift truck Check the operator service manual or load chart Tor net capacity with this attachment If the load chart is not avail
23. FUEL SYSTEM BLEED These operations are to be carried out only in the following cases e A component of the fuel system replaced e A drained tank e Running out of fuel Any contact with highly pressurized fuel risks presents a risk of percutaneous penetration or burns Spraying fuel under high pressure can cause a fire Failure to follow the inspection and maintenance instructions may result in serious injury Never work on the high pressure system Failure to follow this instruction may result in serious damage to the engine The high pressure furl system must be adjusted and repaired only by approved and suitably trained technicians Ensure that the level of fuel in the tank is sufficient and bleed in the following order Open the engine bonnet Check the condition of the fuel system Operate the hand pump 1 fig G1 5O times to remove air from the low pressure system So the engine is ready to be started up Turn the engine over slowly for 5 minutes immediately after bleeding the fuel feed circuit in order to ensure that the injection pump has been bled thoroughly NOTE If the I C engine functions correctly for a short time then stops or functions irregularly check for possible leaks in the low pressure circuit If in doubt contact your dealer 3 36 G2 WHEEL CHANGE A In the event of a wheel being changed on the public highway make sure of the following points For this opera
24. L 50 197 IN mm in 1865 1915 73 75 O mm in 125 4 92 P2 45 P3 40 R mm in 3930 154 72 S 8159 321 22 T mm in 3703 145 79 UL mm in 2580 101 57 02 mm in 2760 108 66 V 5173 203 66 V4 1470 57 87 V2 mm in 4165 163 98 MANITOU W mm in 2420 95 28 QUES MENS z 109 2 12 589 623 SS N y Ss gt Sy ANIL E 9ft ft in MLI 845 USA 13ft5in AA 4 Lr E p E 20 oO m em e Es t C o s J An American national standard ASME B56 6 2002 INSTRUMENTS AND CONTROLS DESCRIPTION 1 DRIVER S SEAT 2 SAFETY BELT 3 CONTROL AND SIGNAL LIGHTS PANEL 4 SWITCHES 5 LIGHTR SWITCH HORN AND INDICATOR SWITCH 6 IGNITION SWITCH 7 BRAKING OIL TANK FUSES AND RELAY ACCESS PANEL 8 BRAKING OIL TANK 9 FUSES AND RELAYS IN THE CAB 10 FUSES AND RELAYS UNDER THE ENGINE HOOD 11 WINDSCREEN WASHER TANK 12 ROOF LIGHT 13 ACCELERATOR PEDAL 14 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF 15 GEAR LEVER AND TRANSMISSION CUT OFF 16 FORWARD NEUTRAL REVERSE GEAR SELECTION 17 STEERING SELECTION 18 HYDRAULIC CONTROLS 19 FUNCTION FILES 20 HEATER CONTROL 21 AIR CONDITIONING CONTROLS AIR CONDITIONING OPTION 22 RECYCLING INTAKES AIR CONDITION
25. MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease B10 AIR CONDITIONING FILTER OPTION AIR CONDITIONING CLEAN Lift up protective casing 1 fig B10 Lift out cabin air conditioning filter 2 fig B10 Clean the filter with a compressed air jet Check its condition and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Refit the filter and protective casing B11 FRONT AND REAR WHEEL REDUCER PIVOTS GREASE Clean and lubricate the points 1 8 lubricators fig B11 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease B12 REAR AXLE OSCILLATION GREASE Clean and lubricate the points 1 2 lubricators fig B13 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease 3 20 3 21 C EVERY 250 HOURS SERVICE Carry out the operations described previously as well as the following operations C1 FAN BELT TENSION CHECK ADJUST Open the engine bonnet Checkthe belt for signs of wear and cracks and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Loosen screw 1 fig C1 1 on the tension pulley Loosen lock nut 2 fig C1 1 and C1 2 and screw 3 fig C1 1 and C1 2 Tighten the screw 2 fig C1 1 and C1 2 until the belt is as close as possible to the groove of the pulley 4 fig C1 1 Make a mark on the head of screw 3 fig C1 1 and C1 2 and tigh
26. On the basis of experience there are a number of possible situations in which operating the lift truck is contra indicated Such foreseeable abnormal uses the main ones being listed below are strictly forbidden The foreseeable abnormal behaviour resulting from ordinary neglect but does not result from any wish to put the machinery to any improper use The reflex reactions of a person in the event of a malfunction incident fault etc during operation of the lift truck Behaviour resulting from application of the principle of least action when performing a task For certain machines the foreseeable behaviour of such persons as apprentices teenagers handicapped persons trainees tempted to drive a lift truck operator tempted to operate a truck to win a bet in competition or for their own personal experience The person in charge of the equipment must take these criteria into account when assessing whether or not a person will makea suitable driver THE LIFT TRUCK A THE 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 in accordance to ASME B56 6 2002 Before commissioning the company manager must make sure that the lift truck is appropriate for the work to be done and perform certain tests in accordance with current legislation B ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS In
27. R lt lt lt lt lt lt lt Fuel tank SRS N lt lt lt lt lt lt Safety dry air filter cartridge 332 lt lt lt lt lt 1 engine silent blocks o o ort lt lt lt I C engine rates Lo Valves clearances Cooling liquid Radiator Water pump and the thermostat Alternator and the starter motor Turbo compressor Fuel circuit TRANSMISSION Gear box oil level Transmission universal joint Angle gear box oil level Gear box oil filter Gear box oil Gear box sump strainer Angle gear box oil __ V lt lt lt lt lt lt Silentblocks in the gear box Orr lt lt lt lt Gear box controls Orr lt lt lt ice Gear box pressures tt po C lt lt lt Converter pressure tt C lt lt TYRES Tyres pressure 343 C C lt lt lt lt lt lt lt lt lt lt lt lt lt lt Wheel nutstorque 313 C C lt lt lt lt lt lt lt lt lt lt lt lt lt lt Condition of wheels and tyres o po pets lt lt 7 Wheel alo R Jibpads 1 11 1 344 60 lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt Jib 1 1 1320 G G lt lt lt lt lt lt lt lt lt lt lt Jib pads wear yoo j C lt lt lt lt lt Condition of jib unit x j oee
28. RAILS 8 12VD 12VD 0 7 5 o o A 0qm mm 18 10 2010 80 02 M173FR p Mr Pr 99 A20 Main Electrical Sch matic 80 02 M173FR 18 10 2010 q OO F Main Electrical Sch matic 21 MLT 845 120 LSU S rie 4 Euro 3 4 4 53 i X230 X225 X226 EYE Y22 Y19L Yo1 PRISE DIAGNOSTIC 2 0 9 mS mU SWF 586 373 512 _ CONTACTACTEUR ANGULAIRE VERIN GAUCHE VERIN DROIT VERIN GAUCHE VERIN DROIT ES Cossenue plage ferm e born CAN J1939 L CAN J1939 H L CAN J1939 44 _ 14 465 _CAN J1939 461 noir 307 387 HH 222 2 386 AAA AHH GH HH HA 304 63 N m ___ PRESSOSTAT DE FREIN A MAIN OPTION TUV Eo 419 3 8 uH 3 3 EP5 7 d lt Y 5 yg Qd d eae 71 gt di ad JJ e co e o S S 5 S el re o SIT al A amp co N X X35 X34 X23 X92 _ X93 X28 X29 X02 X02 iA 4 TA An PA TAa T ess sl L9 n L ES L
29. Refit the strainer and the suction cover 4 fig E6 4 making sure the seal is in the correct position REPLACING THE DISTRIBUTOR CONTROL HEAD FILTER Remove the half clamp 5 fig 6 4 Undo the two couplings 6 fig E6 5 and replace the filter 7 fig E6 5 A Be careful to mount the new filter 7 fig E6 5 in the same direction as the arrow Refit the half clamp 5 fig E6 4 and the protective cover 3 fig E6 3 FILLING UP THE OIL Clean and refit drain plugs 1 fig E6 1 tightening torque 29 to 39 N m Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 8 fig E6 2 A Use a clean container and funnel and clean the underside of the oil drum before filling Observe the oil level on dipstick 9 fig E6 2 the oil level should be at the level of the red point Check for any possible leaks at the drain plugs Replace filler plug 2 fig E6 2 with a new filler plug see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS HYDRAULIC CIRCUIT DECONTAMINATION This should be carried out by your dealer after each oil change The hydraulic oil used in the circuit must be at least equal in quality to class 8 according to NAS 1638 Your dealer will be able to clean the hydraulic circuit using an external unit and check the quality of the oil in order to ensure the long life of hydraulic components and particularly of the main pump 3 32 E10 SEAT BELT CHECK Seat belt with two ancho
30. Shell Tellus T46 HYDRAULIC OIL TANK 131L 34 6 ga Citgo Transgard THF LoTemp BRAKE ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER Shell Donax TG Dexron lll BEER Citgo Transgard ATF Dexron Ill ORGANS TO BE LUBRICATED RECOMMENDATION e L Shell Rentinax Am WINDSCREEN WASHER TANK Windscreen washer fluid FRONT AXLE ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION FRONT AXLE DIFFERENTIAI 6 7L 1 8 ga u nel ate Shell Spirax DH 80w90 FRONT WHEELS REDUCERS 1 8L 0 5 gal Citgo Prem Gear MP 80w90 Shell Rentinax Am Citgo Lithoplex CM 2 FRONT WHEELS REDUCERS PIVOTS REAR AXLE ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION Shell Donax TD REAR AXLEDIFFERENTIAL 7 31 1 9 gal Citgo Transgard THF Shell Spirax DH 80w90 FRONT REAR REDUCING GEARDIFFERENTIAZ 1 8L 0 5 gal Citgo Prem Gear MP 80w90 REAR WHEELS REDUCERS PIVOTS Shell Rentinax Am REAR AXLE OSCILLATION Citgo Lithoplex CM 2 3 9 SERVICING SCHEDULE 1 MANDATORY 500 HOUR OR 6 MONTH SERVICE This service must be carried out after approximately the first 500 hours of operation or within the 6 months following the start up of the machine whichever occurs first A ADJUST C CHECK GREASE N CLEAN BLEED REPLACE V DRAIN 1 SERVICE c ac Lis gt Lis c ca HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 500 HOURS SERVICE OR 6
31. UU TR 1 ES me ummsuemm F1 77 el ms wwo ummemeuesmm E ums umswum E s as CIE m EP16 WEIGHT UNIT TDB EP Tf INDICATOR UNIT TDB 2 INFO T LESCOPIC RETRACTOR EP23 CDE START AV 18 10 2010 80 02 M173FR A13 A14 a DA Main E lectrical Schematic MLT 845 120 LSU S rie 4 Euro 3 80 02 M173FR 18 10 2010 q ee Main E lectrical Schematic A15 MLT 845 120 LSU S rie 4 Euro 3 1 4 X316 F35 2 X316 382 426 X115 16 ARRET D URGENCE CONTACTEUR A CLE X338 27 X338 304 328 1852 1 1 F33 21X329 504 168 ao X329L__ 5 X328 F56 2 X328 36G E XS17 1 P 14B X205 X110 2 X917 5 239 a S47 x239 o oo n 193 K10 X171 X167 R1 TA 90 10 1 LL cu Ue HOZ 5 1 BU L SWG9 GND prechl DT 5 21 d 52 E ao X E bat a 32 i Mm batt D 33 EP2 31 5 ef LG snan Ht m 101 SW RET bat O I i p batt prech j 12 12 25 Ch Am a ib rr 1 1 b bat stop 18 18 lt 28 ool fov i p batt
32. addition to series equipment mounted on your lift truck many options are available such as road lighting stop lights flashing light reverse lights reverse buzzer alarm front light rear light light at the jib head etc as model of lift truck he 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 utilisation Protection against frost see 3 MAINTENANCE LUBRICANTS AND FUEL Adaptation of lubricants ask your dealer for information 1 C engine filtration see MAINTENANCE FILTERS CARTRIDGES AND BELTS For operation under average climatic conditions i e between 15 C and 35 C correct levels of lubricants in all the circuits are checked in production For operation under more severe climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures It is the same for the cooling liquid A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher There are solutions consult your dealer Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated premises It is prohibited to use the lift truck in ar
33. and electric head units on hydraulic distributors must be disconnected at each section e Never remove or alter the safety devices such as the hand guard frame key emergency stop button etc A Never drive the lift truck if it is not continuously and perfectly within view of the operator Before leaving the transmitter the operator must make sure that it cannot be used by an unauthorized third person either by removing the key button from the transmitter or locking it in an inaccessible place he user must ensure that the instruction manual is accessible at all times and that operators have read and understood it INSTRUCTIONS Take up position in a stable place with no risk of slipping Before using the transmitter make sure there is nobody within the working area Only use the transmitter with its carrying device or installed correctly on the platform A When you remove the transmitter remove the accumulator and key button so that it cannot be used accidentally or deliberately by anyone else PROTECTIVE DEVICES The lift truck will be immobilised within 450 milliseconds approx 0 5 second at most If the transmitter emergency stop button 50 milliseconds or the one on the lift is pressed If the transmission distance of the radio waves is exceeded If the transmitter is faulty If an interfering radio signal is received from elsewhere If the accumulator is removed from its housing in the transmitter If the ac
34. and in a ecological way Be careful of the risk of burning and splashing exhaust radiator engine etc MAINTENANCE Perform the periodic service see 3 MAINTENANCE to keep your lift truck in good working conditions Failure to perform the periodic service may cancel the contractual guarantee MAINTENANCE LOGBOOK The maintenance operations carried out in accordance with the recommendations given in part MAINTENANCE and the other inspection servicing or repair operations or modifications performed on the lift truck or its attachments shall be recorded in a maintenance logbook The entry for each operation shall include details of the date of the works the names of the individuals or companies having performed them the type of operation and its frequency if applicable The part numbers of any lift truck items replaced shall also be indicated LUBRICANT AND FUEL LEVELS Use the recommended lubricants never use contaminated lubricants Do not fill the fuel tank when the I C engine is running Only fill up the fuel tank in areas specified for this purpose Do not fill the fuel tank to the maximum level Do not smoke or approach the lift truck with a flame when the fuel tank is open or is being filled HYDRAULIC Any work on the load handling hydraulic circuit is forbidden except for the operations described in part 3 MAINTENANCE Do not attempt to loosen unions hoses or any hydraulic component
35. 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 Ib 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 pre
36. as close as possible to the trailer ring Put the handbrake on and switch off the I C engine Set the coupling fitting 1 according to the height of the trailer ring A Do not forget to put rods and clip back in place Remove the clip 2 lift the trailer pin 3 and place or remove the trailer ring Be careful not to get your fingers caught or crushed during this operation Do not forget to put clip 2 back in place When uncoupling make sure that the trailer is supported independently 2 32 D ADJUSTABLE PROJECTING HOOK OPTION 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 ON THE FIXED PIN Remove pin 1 remove rod 2 and raise latch 3 Insert or remove the trailer ring lower latch 3 and refit rod 2 Be careful not to get your fingers caught or crushed during this operation Do not forget to put clip 1 back in place When uncoupling make sure that the trailer is supported independently ON THE COUPLING LADDER Set the coupling fitting 4 according to the height of the trailer ring A Do not forget to put rods and clip back in place Remove the clip 5 lift the trailer pin 6 and place or remove the trailer ring Be careful not to get your fingers caught or crushed during this operation Do not forget to put clip 5 back in place When uncoupling make sure that the trailer is supp
37. brake fluid cover panel to the left and below the dash panel 2 BEFORE STARTING OR OPERATING Safety Instructions 420792 Read and understand all safety and operaling Mast equipped models Location on or near the operator manual ar A storage case and or on the dash panel Clear the area of bystanders Locate and know operations of controls Instructions for the forklift operator before operating the forklift Fasten seat belt Keep all shields in place Operate only from operator s seat Carry load as law as possible avoid steep slopes and drive slowly on rough terrain to avoid machine overturn SAFETY INSTRUCTIONS 1 Read and understand operator s manual before you operate this truck If the operator s manual is missing a new manual may be obtained through your local dealer Refer lo operator s manual for Jump starting Instructions or directly from K D Manitou Inc Waco Tx WHEN PARKING OR SERVICING 2 Check truck for proper operation of all functions n c 3 Fasten seat belt C 1 Lower boom to the ground 2 Place controls in neutral 3 Apply parking brake 4 Stop engine FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 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 s
38. cm the shortest possible jib length Do not exceed the offset indicated on the load chart If the load begins to swing excessively do not hesitate to stop and lower the jib to set down the load Before moving the lift truck check the longitudinal stability limiter and warning device see 2 DESCRIPTION INSTRUMENTS AND CONTROLS only the green LEDs and possibly the yellow LEDs should be lit During transport the lift truck operator must be assisted by a person on the ground standing a minimum of 3 m from the load who will limit swinging of the load using a bar or a rope Ensure that this person is always clearly in view The lateral attitude must not exceed 5 the bubble in the level must be kept between the two MAX marks The longitudinal attitude must not exceed 15 with the load facing uphill and 10 with the load facing downhill The jib angle must not exceed 45 If the first red LED of the longitudinal stability limiter and warning device see 2 DESCRIPTION INSTRUMENTS AND CONTROLS comes on while travelling gently bring the lift truck to a stop and stabilise the load Retract the telescope to reduce the offset of the load 1 20 PLATFORM OPERATING INSTRUCTIONS For PLATFORM fitted lift trucks Installation of the platform on the lift truck is only possible if the shields operating the platform of the lift truck and the platform are identical see 2 DESCRIPTION OPERATING THE PLATFORM A AUTHORISATI
39. cs lt Bearings and articulation rings I Set lt lt lt ATTACHMENTS Forks wear Attachment carriage wass NE p Condition of attachments 0 ee lt lt LIFT TRUCK Tow the lift truck 340 poo XXX Sling the lift truck 340 1111 17 Transport the lift truck on a platform 394 XXX O O d d PAS Every 10 hours during the first 50 hours then once at 250 hours Consult your dealer AS 3 11 A DAILY OR EVERY 10 HOURS SERVICE 1 ENGINE OIL LEVEL CHECK Place the lift truck on level ground with the I C engine stopped and let the oil drain into the sump Open the engine bonnet Remove the dipstick 1 fig A1 Clean the dipstick and check the correct level between the two notches If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the filler port 2 fig A1 Check visually that there is no leakage or seepage of oil in the engine A2 COOLING LIQUID LEVEL CHECK Place the lift truck on level ground with the I C engine stopped and allow the I C engine to cool Open the engine bonnet Check the correct level in the middle of gauge 1 fig A2 If necessary add cooling liquid see MAINTENANCE LUBRICANTS AND FUEL Slowly turn the cap of the radiator 2 fig A2 up to the safety s
40. forklift and all safety rules and regulations of the work site They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard 29 CFR 1910 178 as described by the Occupational Safety and Health Administration OSHA They must be qualified as to their visual hearing physical and mental ability to operate the equipment safely NEVER use drugs or alcohol while operating a forklift NEVER operate or allow anyone to operate a forklift when mental alertness or coordination is impaired An operator on prescription or over the counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the forklift 2 CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenance log listing repairs requested and completed for each forklift Also lock out tag procedures should be utilized If the forklift malfunctions park it safely remove the key tag Do Not Use and report the problem to the proper authority or authorized service personnel immediately ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont 2 CREATE A MAINTENANCE PROGRAM cont For the best forklift performance and operation a maintenance program is required Use the hour meter on the instrument panel to keep maintenance properly scheduled see SECTION TWO Servicing Schedule For repairs on major components engine transmission etc contact
41. grease see MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease 1 Lubricators of the universal joint engine Angle gear box 2 lubricators fig B4 1 2 Lubricators of the universal joint Gear box Front axle 3 lubricators fig B4 2 3 Lubricators of the universal joint Gear box Rear axle 3 lubricators fig B4 3 3 17 B5 JIB GREASE To be carried out weekly if the lift truck has been operated for less than 5O hours during the week Clean and lubricate the following points with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease Lubricators of the jib axle 2 lubricators fig B5 1 Lubricators of the carriage axle 2 lubricators fig B5 2 Lubricator of the tilt cylinder foot axle 1 lubricator fig B5 3 Lubricator of the tilt cylinder head axle 1 lubricator fig B5 4 Lubricators of the carriage connecting rod axle 3 lubricators fig Bb 2 and B5 5 Lubricators of the lifting cylinder foot axle 2 lubricators fig B5 6 Lubricators of the lifting cylinder head axle 2 lubricators fig B5 7 Lubricators of the compensation cylinder foot axle 2 lubricators fig B5 8 Lubricators of the compensation cylinder head axle 2 lubricators fig B5 9 O1 N P O ON O B6 HYDRAULIC OIL LEVEL CHECK Place the lift truck on level ground with the engine stopped and the jib ret
42. gt attery 2 Tyre Pressure P O o FRAME AND BODYWORK PAINTING GENERAL OPERATION OPERATOR S MANUAL CUSTOMER INSTRUCTIONS P Raja a fa aia O 2 s gt 3 o 3 6 FILTERS CARTRIDGES AND BELTS ENGINE OIL FILTER Part number 476954 Change 500 H ALTERNATOR BELT Part number 244288 DRY AIR FILTER CARTRIDGE En Part number 563416 gt FAN BELT Clean 50 H Ss Part number 257524 Change 500 H SAFETY DRY AIR FILTER CARTRIDGE EN COMPRESSOR BELT Part number 563415 OPTION AIR CONDITIONING Change 1000 H Part number 244237 FUEL FILTER CYCLONIC PRE FILTER Part number 747351 N Part number 224713 Change 500 H Clean 10 FUEL PRE FILTER Part number 747462 Change 500 H AUTOMATIC VACUUM CLEANING PRE FILTER OPTION Part number 226611 CLEANFIX COMPRESSOR FILTER OPTION Part number 781443 Change 500 H AUTOMATIC VACUUM CLEANING PRE FILTER OPTION Part number 223510 This periodicity is given for information only see 3 MAINTENANCE SERVICING SCHEDULE for cleaning and changing TRANSMISSION GEAR BOX OIL FILTER Part number 561749 Change 500 H HYDRAULIC RETURN OIL FILTER CARTRIDGE Ly SUCTION STRAINER FOR HYDRAULIC OIL TANK Part number 221174 Qty 2 e Part number 257603 Change 500 H V Clean 1000 H FILTER CAP FOR HYDRAULIC OIL TANK DISTRIBUTOR CONTROL HEAD FILTER Part number 62415 Part
43. 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 2 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 On all grades the load and load engaging means shall be tilted back if applicable and raised only as far as necessary
44. modified by directive 2005 88 EC 107 ensured Average weighted acceleration on driver s body m s2 according to standard NF EN 13059 The average weighted acceleration transmitted to the driver s hand arm system according to standard ISO 5349 2 ft s2 ft s2 2 5 8 2 2 8 s Hydraulic pump S T O Max rating capacity unladen mn g min Flow rate at 1600 rpm mn g min Filtration 1 Maximum service pressure bar psi Longitudinal stability limiter and warning device Lifting motions jib retracted rr rr UU Lifting motions jib retracted 5 6 51 5 169 Tilting movements O SPECIFICATIONS AND WEIGHTS Speed of movement for lift truck in standard configuration on flat ground except particular conditions 3 6 5 3 3 mph 5 1 3 3 3 6 5 3 Weight of forks each one kg Ibs Lift truck weight with standard attachment S 1 Front unladen k Weight per axle with standard attachment transport position X Hontunladen ik IS 3916 8633 g lbs Weight per axle with standard attachment jib extended 00100 Contact pressure on the ground for the whole surface of each kg cm2 stabilizer at maximum load when tilting Drag strain the coupling hook SS 0 ooo Unladen sliding daN Ibf At rated load transmission setting daN Ibf Pull strain with open carrier according to standard ISO 8313 daN Ibf 2 9
45. mounted attachment you must at least e Protect and report any sharp and or dangerous edges on the attachment see 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE ATTACHMENT SHIELDS e he attachment must not be loaded e Make sure that the attachment does not mask the lighting range of the forward lights e 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 tractor lift truck must be equipped with a trailer braking mechanism In this case do not forget to connect the trailer braking equipment to the lift truck The vertical force on the towing hook must not exceed the maximum authorised by the manufacturer consult the manufacturer s plate on your lift truck he authorised gross vehicle weight must not exceed the maximum weight authorised by the manufacturer see 2 DESCRIPTION CHARACTERISTICS IF NECESSARY CONSULT YOUR DEALER 1 13 INSTRUCTIONS FOR HANDLING A LOAD A CHOICE OF ATTACHMENTS Only attachments approved by MANITOU can be used on its lift trucks Make sure the attachment is appropriate for
46. number 254780 Change 1000 H gt Change 1000 H CAB VENTILATION FILTER OPTION AIR CONDITIONING Part number 552552 Clean 50 H Change 250 H 3 7 LUBRICANTS AND FUEL USE THE RECOMMENDED LUBRICANTS AND FUEL For topping up oils may not be miscible For oil changes MANITOU oils are perfectly appropriate DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been organized with the dealer a diagnostic analysis of engine transmission and axle oils may be requested depending on the rate of use RECOMMENDED FUEL SPECIFICATION Use a high quality fuel to obtain optimal performance of the C engine e N590 diesel fuel type Auto C0 C1 C2 C3 C4 e BS2869 Class A2 e ASTM D975 91 Class 2 2DA US DF1 US DF2 US DFA e JIS K2204 1992 Grades 1 2 3 and Special Grade 3 ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION pU Shell Rotella 15w40 I C ENGINE 11L 2 9 gal Citgo C 600 15w40 COOLING CIRCUIT TRANSMISSION ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION s L Shell Donax TG Dexron lll ar Citgo Transgard ATF Dexron Ill Shell Spirax DH 80w90 ANGLE GEAR BOX 2 2L 0 6 gal Citgo Prem Gear MP80W90 Shell Rentinax Am TRANSMISSION UNIVERSAL JOINT Citgo Lithoplex CM 2 ORGANS TO BE LUBRICATED Shell Rentinax Am Citgo Lithoplex CM 2 Shell Rentinax Am GREASING OF THE JIB Citgo Lithoplex CM 2 HYDRAULIC ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION
47. 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 jib s hydraulic movements concentrating on the ends of travel for each cylinder 1 27 1 28 CONTENTS 2 DESCRIPTION 2 2 TABLE OF CONTENTS IDENTIFICATION OF THE LIFT TRUCK 2 6 CHARACTERISTICS 2 8 FRONT AND REAR TIRES 2 10 DIMENSIONS AND LOAD CHART 2 12 INSTRUMENTS AND CONTROLS 24 TOWING PIN AND HOOK 23 2 3 IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement of our products our range of telescopic lift trucks may undergo certain modifications without obligation for us to advise our customers When you order parts or when you require any technical information always specify NOTE For the owner s convenience it is recommended that a note of these numbers is made in the spaces provided at the time of the delivery of the lift truck LIFT TRUCK MANUFACTURER S PLATE FIG A e Model MANITOU Model a ee ee a S H MANITOU BF 44158 ANCENIS CEDEX FRANCE CE Series nS Serial Nr Year of manufacture e e e 6 o 0 e e e 6 9 0
48. the comfort of the seat and the driver s freedom of movement Press the raise and lower switches to adjust the curvature of the seat back to your requirements ADJUSTMENT OF THE ANGLE OF THE BACK REST FIG G Support the back rest pull the lever and position the back rest to find the desired position A If you do not support the back rest when making adjustments it swings completely forwards HORIZONTAL SHOCK ABSORBER FIG H In certain conditions e g driving with a trailer it is advised that a horizontal shock absorber be used The driver s seat is thus better able to absorb jerks in the direction of travel Position 1 Horizontal shock absorber fitted Position 2 Horizontal shock absorber removed DAMPING FIG 1 The damping of the seat can be adjusted to suit the nature of the terrain The comfort of the seat is thus adjustable to suit your requirements Position 1 Soft damping Position 2 Hard damping LONGITUDINAL ADJUSTMENT FIG J Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position MAINTENANCE FIG K Dirt may adversely affect the correct functioning of the seat For this reason make sure your seat is always clean To clean or change the cushions simply remove them from the seat frame A A rocking head rest increases the risk of an accident Avoid wetting the cushion fabric when cleaning Check the resistance of
49. the work to be done see 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE If the lift truck is equipped with the Single side shift carriage OPTION TSDL use only the authorised attachments see 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE Make sure the attachment is correctly installed and locked onto the lift truck carriage Make sure that your lift truck attachments work properly Comply with the load chart limits for the lift truck for the attachment used Do not exceed the rated capacity of the attachment Never lift a load in a sling without the attachment provided for the purpose as the sling risks to slip see INSTRUCTIONS FOR HANDLING A LOAD H TAKING UP AND LAYING DOWN A SUSPENDED LOAD B MASS OF LOAD AND CENTRE OF GRAVITY Before taking up a load you must know its mass and its centre of gravity The load chart for your lift truck is valid for a load in which the longitudinal position of the centre of gravity is 500 mm from the base of the forks fig B1 For a higher centre of gravity contact your dealer For irregular loads determine the transverse centre of gravity before any movement fig B2 and set it in the longitudinal axis of the lift truck A It is forbidden to move a load heavier than the effective capacity defined on the lift truck load chart For loads with a moving centre of gravity e g liquids take account of the variations in the centre of gravity in order to determine the
50. 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 tu
51. v 9 DECOMPRESSION B7 Cde PWM Cde PWM VALVE DE VALVE REGULATION VALVE DE COUPURE Cde PWM Cde PWM VALVE FREIN A M LI DE SIEGE LIGNE ACCESS POTENTIOMETRE ACCESS sens 2 ACCESS sens 1 SECURITE DE PRESSION INCLINAISON VCI TELESC rentr e TELESC sortie MAIN NEGATIF 8 MARCHE FORCEE Ode MARCHE 3 DISTRIB VS 5 5 MANIPULATEUR JSM 85 CONTACTEUR 2 2 FORCEE AVEC VOYANT z a d INTERRUPTEUR RENTREE FLECHE S DE FREINAGE 18 10 2010 80 02 M173FR 443 PS o Oo lt Q a 0E qEo0 ER C GM C c C GO A22 Main E lectrical Schematic 80 02 M173FR 18 10 2010 1 2 Contents Main Hydraulic Sch matic AT MLT 845 120 LSU S rie 4 E3 19 11 2010 70 02 M173FR Main Hydraulic Sch matic MLT 845 120 LSU S rie 4 E3 HYDRAULIC SCHEMATIC LEGEND Nnm Location on m C Safety Pilot Valve E23 K27 K32 K37 Steering Distributor 3 positions Position 1 Tight Turning Position 2 Turning Front Wheels Distributor Input Element Attachment Element Telescoping Element Closing Element EVTF Boom Head Solenoid option Filtre Heads EMS FEMS FDAV s NEN mE 6 5 4 1 3 8 9 5 2 4 7 17 Tilt Element d inclinaison FDAR Rear Disc Brakes Return Filter Q14 015 Engine thermic Idle Speed 930 tr min 2200 tr min 2360 tr min Position 3 Turning Crab Front Disc Brake High Idle Manipulator Master Cylindre
52. with the circuit under pressure BALANCING VALVE It is dangerous to change the setting and remove the balancing valves or safety valves which may be fitted to your lift truck cylinders These operations must only be performed by approved personnel consult your dealer The HYDRAULIC ACCUMULATORS that may be fitted on your lift truck are pressurized units Removing these accumulators and their pipework is a dangerous operation and must only be performed by approved personnel consult your dealer ELECTRICITY Do not short circuit the starter relay to start the IC engine If the forward reverse selector is not in neutral and the parking brake is not engaged the lift truck may suddenly start to move Do not drop metallic items on the battery Disconnect the battery before working on the electrical circuit 1 24 WELDING Disconnect the battery before any welding operations on the lift truck When carrying out electric welding work on the lift truck connect the negative cable from the equipment directly to the part being welded so as to avoid high tension current passing through the alternator Never carry out welding or work which gives off heat on an assembled tyre The heat would increase the pressure which could cause the tyre to explode If the lift truck is equipped with an electronic control unit disconnect this before starting to weld to avoid the risk of causing irreparable damage to electronic components WASHI
53. 101 Location on the fuel tank near the filler cap Identifies the fuel tank and use of diesel fuel No Step 496735 NOTICE Location varies depending on the forklift model Instructs personnel not to use the designated area as a step NO STEP Do Not Tow 494918 Hydrostatic equipped models Location on the dash in view of the operator A WARNING Towinadhe Odd ips TONER THIS VEHICLE IS EQUIPPED WITH A A HYDROSTATIC TRANSMISSION DO refer to the operator s manual TO PUSH OR TOW TRANSMISSION DAMAGE WILL OCCUR SEE OPERATOR S MANUAL 494910 XIV SAFETY DECALS Attachment Warning 421016 Boom equipped models Location on the boom coupler WA R N N G near where the retaining shaft is installed THE ATTACHMENT RETAINING SHAFT MUST BE IN PLACE AND SECURED Reminder to operator install attachment retaining shaft and safety pin before operations TRUCK OPERATION 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 Locatio
54. 45 120 LSU S rie 4 Euro 3 Connectors composant Description dance hydraulique A EN DE 22 EIC A EA MODUE OF SECURITY LIMI T owroncurormwsmsson rune wn eto WER FRONT mwom xan TEN mmm wmm mweumosw _ NEN SEN s L s NEN ss G WI ame wa w s a e m w O N O O IB IN 00 9 PRINCIPAL PRINCIPAL 0 O N N O gt N m stoe swen _ CEE FRONT LIGHT ss FRONT MER _ ES gt NO W gt gt N SIR gt NO 00 PRINCIPAL PRINCIPAL PRINCIPAL EN EN m EN EN _ presume son TRANSMISSION OL PS T _ om ETT oum ESTATE ose oum Tunwentanaronrunm su Creen o frenv MTC o fremosa Coen oun premos E Croen a frone smer OT SE MTC ous EEE mem oua nemo E mem ous Dmm xus ET ome our wmwewewe ous ama 5 mem ous emwoemme ES mem meme ME gt O DISTRIB UJ C2 O N N D e gt W N gt O Q W W N Ol 00 gt gt Qo T O 2 9 D gt gt W W E O PRINCIPAL X134 RETRACTION ARROW SENSOR CABINE X149 WIPER SWITCH ROOF SIDE 80 02 M173FR 18 10 2010 UJ gt gt N P CO O gt
55. 5 GEAR LEVER AND TRANSMISSION CUT OFF In order to change speeds it is necessary to cut the transmission by pressing the button 1 on the lever 1st gear To the right forwards 2nd gear To the right backwards 3rd gear To the left forwards 4th gear To the left backwards Using the gears on the gearbox On these lift trucks with a torque converter it is not necessary to automatically start up in 1st speed and progress up the gears The choice of transmission gear ratio should be made carefully according to the nature of the work being carried out A poor choice may result in the extremely rapid rise of the transmission oil temperature through excessive slipping of the converter which could lead to serious damage to the transmission it is essential to stop and change the working conditions if the transmission oil temperature indicator light comes on This poor choice may also result in a reduction in the lift truck s performance in forward gear When the forward force increases the forward speed in the r gear for example in 3rd gear may be lower than the forward speed that could be obtained with the r 1 gear in 2nd instead of 3rd In general we would advise you to use the following gears according to the nature of the work being carried out e On the road Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it In hilly areas set off in 2nd gear and go up to 3rd if the conditions and s
56. 5 2 and unscrew filler cap 4 fig 2 in order to ensure that the oil is drained properly A Dispose of the drain oil in an ecological manner Refit and tighten drain plug 1 fig E5 1 tightening torque 20 to 29 N m Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 4 fig E5 2 and refit the filler cap Check the correct level between the MIN and MAX marks on dipstick 3 fig E5 2 Check for any possible leaks at the drain plug 3 31 E6 HYDRAULIC OIL DRAIN E7 SUCTION STRAINER FOR HYDRAULIC OIL TANK CLEAN ES FILTER CAP FOR HYDRAULIC OIL TANK CHANGE E9 DISTRIBUTOR CONTROL HEAD FILTER CHANGE Place the lift truck on level ground with the I C engine stopped and telescope jib retracted and lowered as far as possible Before any intervention thoroughly clean the area surrounding the drain plugs and the suction cover on the hydraulic tank DRAINING THE OIL Place a container under drain plug 1 fig E6 1 and unscrew the plug Open the access panel for hydraulic oil filling Remove filler cap 2 fig E6 2 in order to ensure that the oil is drained properly Dispose of the drain oil in an ecological manner CLEANING THE STRAINER Remove the shroud 3 fig E6 3 Remove the suction cover 4 fig E6 4 Remove and clean the strainer using a compressed air jet check its condition and replace if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS
57. 54 OPTION Reverse buzzer alarm 154 F14 N A A co F15 Signal lamp panel 5A Fuel gauge 5A Hour meter 5A Engine water temperature module 5A F16 Indicator power supply 104 F17 Front windscreen wiper and windscreen washer 10 F18 Main beam 154 Main beam lamp 154 F19 Right indicators 7 54 F20 Low beam 154 F21 Hazard warning lights power supply 154 Roof light 154A OPTIONAL permanent 154 F22 Light switch power supply horn and indicators 254 F23 Rear windscreen wiper 7 54 OPTION Roof windscreen wiper 7 54 F24 Heating 154 1 4 5 OPTION Air conditioning 15 cea 2 F25 Starter 20 F27 OPTION Electrovalve jib head 104 F30 F36 OPTION Electrovalve on jib head attachment hydraulic locking device 104 SPU SPU OPTION Electrical jib provision 104 F30 Hydraulic movement control unit power supply 10A F31 Electronic control unit 1A A ELI F32 Engine control unit power supply 304 F33 OPTION Jib head light 10A F34 Diagnostic socket 5A F35 Diagnostic socket 5A Hydraulic movement control unit 5A F36 Hydraulic movement control unit power supply 10 Engine fault indicator lamp 104 2 22 KO Transmission cut off relay K1 Not used K2 Forward gear r
58. 845 TS AS on Zw 36km h Maxi 10m s E eem iB 1 44km h 0 4m s Maxi 200mMaxi N 270140 2 40 2 41 3 MAINTENANCE 3 2 TABLE OF CONTENTS MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT START UP CHECKLIST FILTERS CARTRIDGES AND BELTS LUBRICANTS AND FUEL SERVICING SCHEDULE A DAILY OR EVERY 10 HOURS SERVICE B EVERY 50 HOURS SERVICE C EVERY 250 HOURS SERVICE D EVERY 500 HOURS SERVICE E EVERY 1000 HOURS SERVICE F EVERY 2000 HOURS OF SERVICE G OCCASIONAL MAINTENANCE 33 3 5 3 7 3 8 3 10 3 12 3 16 3 22 3 26 3 30 3 34 3 36 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 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 th
59. ACHMENT Set valve 4 to position A Set switch 2 to position B indicator light on Hold button 5 down and push button 3 forward to lock the attachment and backward to release it Once the attachment is locked return valve 4 to position B to prevent accidental release of the attachment HYDRAULIC ATTACHMENT Set valve 4 to position B Set switch 2 to position B indicator light on Hold button 5 down and push button 3 forwards or backwards 2 38 15 SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION Enables the use of a hydraulic rear hook or of a trailer with hydraulic tipping Single or double effect rear hydraulic control functions with hydraulic control of the additional attachment see chapter 2 DESCRIPTION 19 HYDRAULIC CONTROLS according to the position of tap 1 Position A Hydraulic control of the additional attachment at the front of the lift truck Position B Hydraulic control of the additional attachment at the rear of the lift truck 16 ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION This OPTION must only be used with an attachment requiring continuous hydraulic movement of type brush supply bucket mixer spray It is strictly forbidden in handling operations and at all other events winch crane jib crane jib with winch hook etc CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT Make sure the potentiometer C is set to O 96 Switch button A to the front or the back
60. ATING INSTRUCTIONS UNLADEN AND LADEN Make sure the jib cylinder rods are all in retracted position Release the pressure in the hydraulic circuits PROTECTING THE 1 C ENGINE Fill the tank with fuel see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE Empty and replace the cooling liquid see 3 MAINTENANCE F EVERY 2000 HOURS SERVICE Leave the I C engine running at idling speed for a few minutes then switch off Replace the engine oil and oil filter see 3 MAINTENANCE D EVERY 500 HOURS SERVICE Add the protective product to the engine oil Run the engine for a short time so that the oil and cooling liquid circulate inside Disconnect the battery and store it in a safe place away from the cold after charging it to a maximum Remove the injectors and spray the protective product into each cylinder for two seconds with the piston in low neutral position Turn the crankshaft once slowly refit the injectors see engine REPAIR MANUAL Remove the intake hose from the manifold or turbocharger and spray the protective product into the manifold or turbocharger Cap the intake manifold or turbocharger hole with waterproof adhesive tape Remove the exhaust pipe and spray the protective product into the exhaust manifold or turbocharger Refit the exhaust pipe and block the outlet with waterproof adhesive tape NOTE The spray time is noted on the product packaging and mus
61. CASIONALLY 1 BRAKE Brake oil level 921 C C lt lt lt lt lt lt lt lt lt lt lt lt lt Brake ol ce lt lt Brake system ___ pop ce lt lt Brake system pressure GX lt lt lt lt lt lt Brake __ A lt lt lt Manually unblocking the parking brake 339 XXX STEERING Steering JIQ A 4 j j C lt lt Steering swivel joints x j j S Cr Windscreen washer liquid level 921 C C lt lt lt lt lt lt lt lt lt lt lt lt lt Cabdor 32 G 6 lt lt lt lt lt lt lt lt lt lt lt lt Air conditioning filter OPTION air conditioning 322 22 R N R lt lt lt lt lt lt lt lt lt Seat belt 985 j C lt lt lt lt lt lt Condition of the rear view mirrors ___ pp jp j Le lt lt sl Structure JJ J j C lt lt lt lt lt lt Air conditioning OPTION 937 NC lt lt ELECTRICITY Longitudinal stability limiter and warning device 345 43 C C lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt XXX Condition of wiring harness and cables ___ pop ce lt lt Lights and signals o pp j C lt lt lt Warning indicators ic lt lt Front h
62. Category of insulation 2 Environmental conditions for use e Maximum ambient temperature for using preheating 25 C 77 F e Pollution level 2 Conditions for connection and use of preheating he preheating system should not be used for an external ambient temperature higher than 25 C 77 F It is essential that the power supply to the preheating system is e Effected with a cable that conforms to the installation standards in force and contains a protective earth conductor e Contains an appropriate sectioning system e Incorporates an appropriate safety system against short circuits fuses or circuit breaker and a differential circuit breaker with 30mA sensitivity Only connect to and disconnect from the power supply while the unit is off and the I C engine is stopped 2 35 6 MODCOD ANTI THEFT SYSTEM OPERATION Switch on the lift truck the red indicator 1 will flash Enter your user code followed by V to validate the green indicator 2 will come on Start the lift truck within the next 60 seconds otherwise the anti theft system will be reactivated and the red indicator will flash NOTE If you make a mistake when entering the code press key A to cancel and re enter the code in full If you wait more than 5 seconds between key presses or do not complete entering the code the anti theft system will be reactivated and the red indicator will flash 7 FINTRONIC ANTI START SYSTEM OPERATION
63. DS and unscrew the plugs Remove level plug 2 fig DS and filler plug 3 fig DS in order to ensure proper emptying Refit and tighten drain plugs 1 fig D8 tightening torque 34 to 49 N m 25 to 36 Ibf ft Fill up with oil see MAINTENANCE LUBRICANTS AND FUEL through filler port fig D8 The level is correct when the oil level is flush with the edge of port 2 fig DS Check for any possible leaks at the drain plugs Refit and tighten level cap 2 fig D8 tightening torque 34 to 49 N m and filler port 3 fig D8 tightening torque 34 to 49 N m Repeat this operation for the rear axle differential D9 CLEANFIX COMPRESSOR FILTER OPTION CHANGE Open the engine bonnet Remove clip 2 fig D9 Replace filter 3 fig D9 with a new one see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS and correctly refit clip 2 fig D9 3 29 E EVERY 1000 HOURS SERVICE Carry out the operations described previously as well as the following operations El FUEL TANK CLEAN A While carrying out these operations do not smoke or work near a flame Place the lift truck on level ground with the I C engine stopped Inspect the parts susceptible to leaks in the fuel circuit and in the tank In the event of a leak contact your dealer Never try to carry out a weld or any other operation by yourself this could provoke an explosion or a fire Place a container under drain plu
64. E 34 TRANSMISSION ESI IL 22 a 2 5 Jconracreur LEVIER CAPTEUR CAPTEUR ALIGNEMENT oa 2 ontacrson DEVTESSE ALIGNROUESAR 9 ALIGNROUESAV 8 DEROUES SA PEDALE DE FREIN 98 18E 95 94 95 Og G7 S Oo mom PO X68 7 rwv T OO Ej noir 17 97 G Dim 1o 1 jm JAUGE GAS OIL noir 418 418 306 A AA E o a 17 1 S 5 474 MEN m e s 5 IIIa NUN 178 AVERTISSEUR 151 MARCHE ARRIERE Lo PREDISPO OU VALVE Y 93 EN DE FLECHE INTER FORCAGE INTER NEUTRALISATION S INTER VERR MOUVEMENTS 5 MOUVEMENTS 7 HYDRAULIQUE Lem H EN SlEp7 AHHH GR EPS o oe a ul RRR K m LLLI rm EU TL X1iz 2 7 Y Y dc X a amp zi DPI E X 32 100 1 1 ey Off Was c Len 24 8 1 S16 Fae X20 X233 9 c Qo c e e LET LEJ E9E20F3 Es p LEBER l AM Ti LYS Spy a B15 X73 L FEUX ARRIERE FEUX ARRIERE M9 E29 FEUX AVANT FEUX AVANT j CAPTEUR GAUCHE DROITE OPTION GAUCHE DROITE VALVE REGULATION ANGULAIRE CONTACTEUR DE STOP 185 N p m m mn o Lal Lud L
65. EL 2 19 4 SWITCHES NOTE The location of the switches may vary depending on the options A HEATER BLOWER This two speed switch allows warm or cold air to pass through the heating ventilators WARNING LIGHTS This switch enables the L H and R H Indicators to be switched on simultaneously with the ignition off The signal light indicates that the switch is being used OPTION ELECTROVALVE ON JIB HEAD ATTACHMENT HYDRAULIC LOCKING DEVICE See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS D FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER This switch when set to the intermediate position the windscreen wiperto be operated and the down position and simultaneously pressed the windscreen washer to be operated E REAR WINDSCREEN WIPER OPTIONAL ROOF WINDSCREEN WIPER F FLASHING LIGHT G OPTION WORKING HEAD LIGHT H DISABLING AGGRAVATING HYDRAULIC MOVEMENT CUT OFF See 2 DESCRIPTION 4 LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE PARKING BRAKE Lower the button 1 and press the bottom of the switch to connect the parking brake The signal lamp shows it is being used Press the top of the switch to disconnect the parking brake J TRANSMISSION CUT OFF The switch sets transmission cut off to the service brake pedal or the forward reverse selector Position A Indicator light on transmission cut off to service brake pedal effected Position B Indicator light off trans
66. IGN STANDARDS ANSI ASME 56 6 MANUFACTURED IN MOS XVI 1 2 CONTENTS 1 OPERATING AND SAFETY INSTRUCTIONS 12 TABLE OF CONTENTS INSTRUCTIONS TO THE COMPANY MANAGER THE SITE THE OPERATOR THE LIFT TRUCK A THE LIFT TRUCK S SUITABILITY FOR THE JOB B ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS C MODIFICATION OF THE LIFT TRUCK D FRENCH ROAD TRAFFIC RULES or see current legislation in other countries THE INSTRUCTIONS THE MAINTENANCE INSTRUCTIONS FOR THE OPERATOR PREAMBULE GENERAL INSTRUCTIONS A OPERATOR S MANUAL B AUTHORIZATION FOR USE IN FRANCE or see current legislation in other countries C MAINTENANCE D MODIFICATION OF THE LIFT TRUCK E LIFTING PEOPLE OPERATING INSTRUCTIONS UNLADEN AND LADEN BEFORE STARTING THE LIFT TRUCK DRIVER S OPERATING INSTRUCTIONS ENVIRONMENT VISIBILITY STARTING THE LIFT TRUCK DRIVING THE LIFT TRUCK STOPPING THE LIFT TRUCK DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY or see current legislation in other countries INSTRUCTIONS FOR HANDLING A LOAD A CHOICE OF ATTACHMENTS B MASS OF LOAD AND CENTRE OF GRAVITY C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE D TRANSVERSE ATTITUDE OF THE LIFT TRUCK E TAKING UP A LOAD ON THE GROUND F G H cL TAKING UP AND LAYING A HIGH LOAD ON TYRES TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS TAKING UP AND LAYING DOWN A SUSPENDED LOAD TRAVELLI
67. ING OPTION 23 WINDSCREEN DEMISTER VENTS 24 HEATING VENTS 25 BUTTON FOR OPENING HYDRAULIC FLUID AND FUEL FILLER ACCESS PANEL 26 DOOR LOCK 27 LOCKING HANDLE FOR UPPER HALF DOOR 28 UNLOCKING BUTTON FOR UPPER HALF DOOR 29 HANDLE FOR REAR WINDOW OPENING 30 DOCUMENT HOLDER 31 FRONT LIGHTS NOT ILLUSTRATED 32 REAR LIGHTS NOT ILLUSTRATED 33 FLASHING LIGHT NOT ILLUSTRATED 34 LEVEL INDICATOR 35 INSIDE REAR VIEW MIRROR 36 STEERING WHEEL ADJUSTMENT LEVER 37 DIAGNOSTIC CONNECTOR 38 EMERGENCY STOP BUTTON NOTE All the terms such as RIGHT LEFT FRONT REAR are meant for an observer seated on driver s seat and looking in front of him 2 15 1 DRIVER S SEAT Designed for maximum comfort this seat can be adjusted as follows LONGITUDINAL ADJUSTMENT Pull the locking lever 1 upwards Slide the seat to the desired position Release the lever and be sure it returns to the lock position SEAT CUSHION ADJUSTMENT The front and the back of the seat cushion can be adjusted separately To adjust the front push the lever 2 downwards Release it into one of the five possible positions Same procedure to adjust the back by pulling the lever 2 upwards SEAT SUSPENSION ADJUSTMENT Turn the button 3 and adjust according to your weight ANGLE ADJUSTMENT OF THE BACK REST Lean the back against the back rest Pull the lever 4 and place the back rest into one of the possible positions
68. K 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 engine speed addition of extra equipment addition of counterweight unapproved attachments alarm systems etc yourself In this event the manufacturer cannot be held responsible D FRENCH ROAD TRAFFIC RULES or see current legislation in other countries Only one certificate of conformity is issued It must be kept in a safe place THE INSTRUCTIONS he 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 he operator s manual and any plates or stickers which are no longer legible or are damaged must be replaced immediately THE MAINTENANCE Maintenance or repairs other than those detailed in part 3 MAINTENANCE must be carried out by qualified personnel consult your dealer and under the necessary safety conditions to maintain the health of the operator and any third party Your lift truck must be inspected periodically to ensure that it remains in compliance The frequency of this inspection is defined by current legislation in the country in which the lift truck is used 1 5 INSTRUCTIONS FOR THE OPERATOR PREAMBLE WHENEVER YOU SEE THIS SYMBOL IT MEANS WARNING BE CAREFUL YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK The r
69. MAINTENANCE he operator must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety notice he 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 he operator must ensure tyres are adapted to the nature of the ground see area of the contact surface of the tyres in the chapter 2 DESCRIPTION FRONT AND REAR TYRES There are optional solutions consult your dealer SAND tyres LAND tyres Snow chains Do not use the lift truck if the tyres are incorrectly inflated damaged or excessively worn because this could put your own safety or that of others at risk or cause damage to the lift truck itself The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer excepting prior authorisation D MODIFICATION OF THE LIFT TRUCK For your safety and that of others you must not change the structure and settings of the various components used in your lift truck hydraulic pressure calibrating limiters engine speed addition of extra equipment addition of counterweight unapproved attachments alarm systems etc yourself In this event the manufacturer cannot be held responsible 1
70. MONTHS EVERY 1000 HOURS SERVICE OR 1 YEAR EVERY 2000 HOURS SERVICE OR 2 YEARS EVERY 4000 HOURS 1 6 engine oil level 77777 342 C C lt lt lt lt lt lt lt lt lt lt lt lt Cooling liquid level x 342 C C lt lt lt lt lt lt lt lt lt lt lt lt Fuel level 1 1 1 1 1 342 C C lt lt lt lt lt lt lt lt lt lt lt lt lt lt Fuel pre filter 1 843 C C lt lt lt lt lt lt lt lt lt lt lt lt lt Cyclonic prefilter lt lt lt lt lt lt lt lt lt lt lt Dry airfiltercartridge 15827 R N lt lt R lt lt lt lt Radiator cores 348 N lt lt lt lt lt lt lt lt lt Condenser core OPTION Air conditioning 348 C N X CA lt lt Fan belt tension 324 C A lt lt lt lt lt lt lt Alternator crankshaft belt tension 324 C A C A lt lt lt lt lt lt lt lt Compressor belt tension OPTION Air conditioning 325 C A C A lt lt lt lt lt lt lt lt engine oi 38 V 1 1 j V lt lt lt lt lt lt lt lt engine oil filter 328 R j R lt lt lt lt lt lt lt lt Fuel prefilter 139 R j R lt lt lt lt lt lt Fuel filter 330 R j R lt lt lt lt lt lt lt CLEANFIX compressor filter OPTION 331 7
71. NG THE LIFT TRUCK Clean the lift truck or at least the area concerned before any intervention Remember to close and lock all accesses to the lift truck doors windows cowls During washing avoid the articulations and electrical components and connections If necessary protect against penetration of water steam or cleaning agents components susceptible of being damaged particularly electrical components and connections and the injection pump Clean the lift truck of any fuel oil or grease trace FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE CONSULT YOUR DEALER 1 25 IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an extended period For these operations we recommend the use of a MANITOU protective product reference 603726 Instructions for using the product are given on the packaging A Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership PREPARING THE LIFT TRUCK Clean the lift truck thoroughly Check and repair any leakage of fuel oil water or air Replace or repair any worn or damaged parts Wash the painted surfaces of the lift truck in clear and cold water and wipe them Touch up the paintwork if necessary Shut down the lift truck see OPER
72. NG WITH A SUSPENDED LOAD PLATFORM OPERATING INSTRUCTIONS AUTHORISATION FOR USE SUITABILITY OF THE PLATFORM FOR THE JOB PRECAUTIONS WHEN USING THE PLATFORM USING THE PLATFORM ENVIRONMENT MAINTENANCE INSTRUCTIONS FOR USING THE RADIO CONTROL gt MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK GENERAL INSTRUCTIONS MAINTENANCE LUBRICANT AND FUEL LEVELS HYDRAULIC ELECTRICITY WELDING WASHING THE LIFT TRUCK IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION PREPARING THE LIFT TRUCK PROTECTING THE 1 C ENGINE PROTECTING THE LIFT TRUCK BRINGING THE LIFT TRUCK BACK INTO SERVICE 13 La D PHRPPpPPHHH QI QI OI OI P P b p p PR EBERSRRPRREBBRBRRPRR ESE55000m00 x00000 P PP P PE P gt P P E P P P O O O 1 18 1 20 1520 1 21 1 21 1 21 1 21 1 21 1 21 1 22 1 23 1 24 1 24 1 24 1 24 1 24 1 24 1 25 1 25 1 26 1 26 1 26 1 26 1 26 1 27 INSTRUCTIONS TO THE COMPANY MANAGER THE SITE Proper management of lift truck s area of travel will reduce the risk of accidents round not unnecessarily uneven or obstructed excessive slopes pedestrian traffic controlled etc THE OPERATOR Only qualified authorized personnel can use the lift truck This authorization is given in writing by the appropriate person in the establishment with respect to the use of lift trucks and must be carried permanently by the operator
73. O1 MLT 845 120 LSU S rie 4 Euro 3 Main Electric Schematic Connectors Location on Diagram Correspon Nom Harness Description dance composant B 4 hydraulique ome a e wara aF CT s2 _ as CT s o ETC 2 1 WATERTEMPSENSOR ur CS E worm eommoror asss wass 2 xe j pestowc s o Mour x armen e Xie armen e worum xer mena worm xaos em MOTEUR xir CE KE E A 45 POWER FUSE EQUIP FUSE worm m ewwooen sss sss NEN 2 s uuum EM NEN A 1 EM NEN HP Es UJ O i O1 O O Fa N E ar comen a fan Noron mw aamconomon omas over E om ms mon nam EN ewe a EEE IS 18 10 2010 80 02 M173FR B16 IN UJ G gt Main Electric Schematic MLT 845 120 LSU S rie 4 Euro 3 Connectors Location on Diagram Correspon Nom HE Harness Type Description dance composant hydraulique ame oe wenn ES DISTRIB 225 WHEEL ALIGNMENT SWITCH G38 ome oum Cmm oum Toosersanscmnon
74. ON FOR USE Operation of the platform requires further authorisation in addition to that of the lift truck B SUITABILITY OF THE TRUCK FOR USE MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator s manual with a STATIC test coefficient of 1 25 and a DYNAMIC test coefficient of 1 1 as specified in harmonised standard EN 280 for mobile elevating work platforms Before commissioning the company manager must make sure that the platform is appropriate for the work to be done and perform certain tests in accordance with current legislation C PRECAUTIONS WHEN USING THE PLATFORM Wear clothes suited for operating the platform avoid loose clothes Never operate the platform when hands or feet are wet or soiled with greasy substances Always pay attention when using the platform Do not listen to the radio or music using headphones or earphones For increased comfort adopt the correct position at the platform s operator station he platform s guard rail exempts the operator from wearing a safety harness under normal operating conditions As a result you are responsible deciding whether to wear a safety harness he controls must not be used for any other than their intended purpose e g getting in and out of the lift truck coat hanger etc Safety helmets must be worn he operator must always be in the normal operator s position It is prohibi
75. OUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont D SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level Transporting suspended loads must ALWAYS be done slowly and cautiously with the boom and load as low as possible Use taglines to restrict loads from swinging to avoid overturn The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards Grades and sudden starts stops and turns can cause the load to swing and create a hazard Guidelines for Free Rigging Suspended Loads 1 DO NOT exceed the rated capacity of the telescopic handler as equipped for handling suspended loads The weight of the rigging must be included as part of the load 2 During transport DO NOT raise the load more than 12 inches 305 mm above the ground or raise the boom more than 45 degrees 3 Only lift the load vertically NEVER drag it horizontally 4 Use multiple pickup points on the load when possible Use taglines to restrain the load from swinging and rotating 5 Start travel turn and stop SLOWLY to prevent the load from swinging DO NOT exceed walking speed 6 Inspect rigging before use Rigging must be in good condition and in the U S comply with OSHA regulation 1910 184 Slings
76. P ENGINE OU ECM MOTOR O1 7 5 BEACON F O 5A WHEEL ALIGNEMENT OPTION AS 7 5 LLMI INTER OVERRIDE SENSORS OPT BLUE LIGHTS 15A 7 8 15A REALY K2 K3 K4 TRANSMISSION CUTOFF JSM FNR 9 MODULE INDICATOR DASHBOARD F10 10A HORN STOP SWITCH F11 15A WORKING LIGHTS ARROW DI 10A BLINKERS 30A VENTILATION F14 10A CIGARRETE LIGHTER F15 20A SPU F16 5A DIAGNOSTIC OUTLET 15 CLEANFIX HYDRAULIC REAR ANTIVOL F18 15A FRONT WORKING LIGHTS F19 15 A REAR WINDOW DEFROST F20 10 A AIR SEAT OPTION AS F21 10 A FRONT WIPER LAVE GLACE AVANT SUSPENSION ARROW PR DISPO LEC ARROW EVTDF LF 10 A Maxi F23 7 5 NIGHT LIGHTS RIGHT LIGHT UNIT F24 7 5 NIGHT LIGHTS LEFT REAR LIGHT PLAC F25 7 5 TURN SIGNAL RIGHT F26 7 5 TURN SIGNAL LEFT 15 CODE ANTI FOG F28 15A HEADLIGHTS L 15A WARNING CEILING THEFT DETERRENT TIMER TACHOMETER F30 25 LIGHT WHEEL F31 25 STARTER E32 5A OUTLET DIAGNOSTIQUE SPU FAO 40 A KEY SWITCH FA1 40 A KEY SWITCH PR HEATING FA2 80A FA3 80 A ALTERNATOR F47 15 A DIESEL ANTIFREEZE 80 02 M173FR 18 10 2010 Main E lectrical Mchematic MLT 845 120 LSU S rie 4 Euro 3 LOCATION OF THE SPLICES ON THE SCH MATIC Epissures Position sur sch ma EIER umwmorwew m fe me vor SSCS NGN CV EN me j I en E
77. S CARTRIDGES AND BELTS Refit the protective casing C6 FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL CHECK Place the lift truck on level ground with the I C engine stopped Remove level plug 1 fig C6 The oil should be flush with the edge of the hole If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the filler port 2 fig C6 Replace and tighten the level plug 1 fig C6 tightening torque 34 to 49 N m 25 36 Ibf ft C7 FRONT AND REAR WHEELS REDUCERS OIL LEVEL CHECK Place the lift truck on level ground with the C engine stopped Check the level on each front wheel reducer Place level plug 1 fig C7 in the horizontal position Remove the level plug the oil should be flush with the edge of the hole If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL by the same hole Replace and tighten the level plug 1 fig C7 tightening torque 34 49Nm 25 to 36 Lb ft Repeat this operation on each rear wheel reducer 3 24 3 25 D EVERY 500 HOURS SERVICE Carry out the operations described previously as well as the following operations D1 I C ENGINE OIL DRAIN D2 I C ENGINE OIL FILTER CHANGE Place the lift truck on level ground let the engine run at idle for a few minutes then stop the I C engine DRAINING THE OIL Open the engine bonnet Remove access panel 1 fig D1 1 Place a container under drain plug 2 fig D1 2 an
78. TENSION OPTION AIR CONDITIONING CHECK ADJUST Open the engine bonnet Unscrew the fastening screws 1 fig C3 1 Lay down the protective guard 2 fig C3 1 Checkthe belt for signs of wear and cracks and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Check the belt tension between the pulleys of the crankshaft and of the compressor Under a normal pressure exerted with the thumb 45 N the belt should move approximately 10 mm Carry out adjustments if necessary Untighten screws 3 fig C3 2 with two to three thread turns Swivel the compressor assembly so as to obtain the belt tension required Retighten screws 3 fig C3 2 Put the protective guard back 2 fig C3 1 A If the compressor belt has to be changed check the tension again after the first 20 hours of operation C4 ANGLE GEAR BOX LEVEL CHECK Park the lift truck on level ground with the jib raised and the engine stopped Remove the plastic cap 1 fig C4 Remove level plug 2 fig C4 Wipe the dipstick and check the correct level between the MINI and MAX marks If necessary add oil by the filler port 3 fig C4 see 3 MAINTENANCE LUBRICANT AND FUEL 3 23 C5 AIR CONDITONING FILTER OPTION AIR CONDITIONING CHANGE Lift up protective casing 1 fig C5 Lift out the air conditioning filter 2 fig C5 and fit new replacement filter see 3 MAINTENANCE FILTER
79. THE SCHEMATIC A13 ELECTRIC SCHEMALNG 5 858 s RUE ARRA ME AURA AAA A15 18 10 2010 80 02 M173FR A2 Main Electrical Schematic MLT 845 120 LSU S rie 4 Euro 3 80 02 M173FR 18 10 2010 845 120 LSU S rie 4 Euro 3 Main Electrical Schematic LOCATION OF THE CONNECTORS ON THE SCHEMATIC PRINCIPAL PRINCIPAL PRINCIPAL PRINCIPAL PRINCIPAL PRINCIPAL m PRINCIPAL Connecteurs Location on Location on diagram Correspon componant Description E dance 4 hydraulique masseur or unes Tef one secouer fx usa see e JIB ELECTRICAL PREDISPOSITION Termostat TRANSMISSION ones ro wowo E r memecs E msnm monumen E Benno E s u E __ T __ __ TN NN NEN 1 SES 2 B a G G _ TT s s uma _ 9 frowns mem REVERSE ALARM AUGNEMENT REAR WHEELS 1 s NEN po LL NEN NEN A NEN s m T Tu mm rais PRINCIPAL PRINCIPAL ET ETS F EM EM veu eme mena Fse moer onse ron puso O mov wesc INTER DISABLING MOVEMENTS HYDR P PRINCIPAL INDICATOR REAR WHEEL ALIGNMENT PRINCIPAL BREAKER WHEEL ALIGNEMENT 18 10 2010 80 02 M173FR Main Electric Sch matic MLT 8
80. VERY 2000 HOURS OF SERVICE Carry out the operations described previously as well as the following operations F1 COOLING LIQUID DRAIN These operations are to be carried out if necessary or every two years at the beginning of winter Place the lift truck on level ground with the engine stopped and cold DRAINING THE LIQUID Open the engine bonnet Place a container under hose 1 fig F1 1 on the radiator and drain plug 2 fig F1 2 of the engine block Remove the hose and loosen the drain plug Remove filling plug 3 fig F1 3 of the radiator Let the cooling circuit drain entirely while ensuring that the ports do not get clogged Check the condition of the hoses as well as the fastening devices and change the hoses if necessary Rinse the circuit with clean water and use a cleaning agent if necessary FILLING THE LIQUID Refit and tighten the hose 1 fig F1 1 and drain plug 2 fig F1 2 tightening torque 40 N m Slowly fill up the circuit with cooling liquid see 3 MAINTENANCE LUBRICANTS AND FUEL to the middle of gauge 5 fig F1 3 through filler port 4 fig F1 3 Put back filling plug 3 fig F1 3 Run the I C engine at idle for a few minutes Check for any possible leaks Check the level and refill if necessary The 1 C engine does not contain any corrosion resistor and must be filled during the whole year with a mixture containing 25 of ethylene glycol based antifre
81. able contact the factory 425995 THIS OVERHEAD GUARD CONFORMS TO ANSI DESIGN RECOMMENDATION THIS QVERHEAD GUARD HAS PASSED AN IMPACT TEST OF FT LBS DO NOT REMOVE THIS OWERHEAD GUARD 496550 eMANITOU MANITOU NORTH AMERICA INC 6401 IMPERIAL DR WACO TX 76712 800 433 3304 www manitou na com MANITOU MANITOU BF 44158 ANCENIS CEDEX FRANCE C MODELE MODEL MODELLO MODELO SERIE SERIES Numero di serie N mero de serie Ann e de fabrication Year of manufacture Anno di fabbricazione A o de fabricacion Puissance ISO TR14396 TRUCK MODEL SERIAL NUMBER l UNLADEN we cHT Masse vide Massa a vuoto Unladen mass Masa en vacio Num ro d homologation Homologation number Numero d omologazione Contrase a homologacion Potencia ISO TR14396 Effort vertical max sur aca Vertical max effort Carico max vertical YEAR OF MFG rque 10 ue Capacit maxi nominale Nominal maximum capacity Capacit maxi nominale Capacidad m ximo nominal TIRE PRESSURE FRONT BI EE TIRE PRESSURE REAR rs ud Tyre pressure Bar Pressione per pneumatici Bar A Presion de los neum ticos Bar Effort de traction Tractive effort Avant Anteriore Arri re Posteriore Forza di traino Front Adelante Rear Trasero Esfuerzo de traccion u N 283688 o FOR CAPACITIES REFER TO THE APPROPRIATE LIFT CHART OR CONTACT THE FACTORY AS RELEASED FROM THE FACTORY THIS TRUCK CONFORMS TO DES
82. al position and lay it down on the pile by lowering and retracting the jib 1 2 in order to position the load correctly fig F8 If possible release the fork by alternately retracting and raising the jib 1 fig F9 Then set the forks into transport position If this is not possible reverse the lift truck 1 very slowly and carefully to release the forks fig F10 Then set them into transport position X lt X 1 17 G TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS Depending on the model of lift truck You must not raise the jib if you have not checked the transverse attitude of the lift truck see INSTRUCTIONS FOR HANDLING A LOAD D TRANSVERSE ATTITUDE OF THE LIFT TRUCK REMINDER Make sure that the following operations can be performed with good visibility see OPERATIONS INSTRUCTIONS UNLADEN AND LADEN D VISIBILITY USING THE STABILIZERS The stabilizers are used to optimise the lift truck s lifting performances see 2 DESCRIPTION INSTRUMENTS AND CONTROLS POSITION THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION UNLADEN AND LADEN Set the forks in transport position in front of the elevation Stay far enough away to have room for the jib to be raised Put the handbrake on and put the gearshift lever into neutral Set the two stabilizers on the ground and lift the two front wheels of the lift truck fig G1 while maintainin
83. are pre filtration cartridges see MAINTENANCE FILTERS CARTRIDGES AND BELTS Also the checking and cleaning periodicity of the cartridge must be reduced If the clogging indicator light comes on this operation must be carried out as quickly as possible 1 hour maximum The cartridge must not be cleaned more than seven times after which the cartridge must be changed Never use the lift truck without an air filter or with a damaged air filter For the disassembly and reassembly of the cartridge see 3 MAINTENANCE D3 DRY AIR FILTER CARTRIDGE Clean the filter cartridge using a compressed air jet max pressure 3 bar 43 psi directed from the top to the bottom and from the inside towards the outside at a minimum distance of 30 mm 1 18 in from the cartridge wall Cleaning is completed when there is no more dust on the cartridge Respect the safety distance of 30 mm 1 18 in between the air jet and the cartridge to avoid tearing or making a hole in the cartridge The cartridge must not be blown anywhere near the air filter box Never clean the cartridge by tapping it against a hard surface Your eyes must be protected during this intervention Clean the cartridge seal surfaces with a damp clean lint free cloth and grease with a silicone lubricant MANITOU reference 479292 Check visually the outer condition of the air filter and its mounts Verify the condition of the hoses and their mounts also Never clean the dry air fil
84. area or at night make sure it is equipped with working lights During handling operations make sure that no one is in the way of the lift truck and its load Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load When using the lift truck on a transverse slope before lifting the jib follow the instructions given in the paragraph INSTRUCTIONS FOR HANDLING A LOAD D TRANSVERSE ATTITUDE OF THE LIFT TRUCK Travelling on a longitudinal slope e Drive and brake gently e 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 e hat it is suitably positioned and made fast e hat the unit to which it is connected wagon lorry etc will not shift e hat this platform is prescribed for the total weight of the lift truck to be loaded e hat this platform is prescribed for the size of the lift truck Never move onto a foot bridge floor or freight lift without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Be careful in the area of loading bays trenches scaffolding soft land and manholes Make sure the ground is stable and firm under the wheels and or stabilizers before lifting or removing the load I
85. arning devices C lights d lift and tilt systems load engaging means chains cables and limit switches e f steering mechanism 9 fuel system s 51 If the rough terrain forklift truck is found to be in need of repair or in any way unsafe or if it contributes to an unsafe condition the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 52 If during operation the rough terrain forklift truck becomes unsafe in any way the matter shall be reported immediately to the user s designated authority and the truck shall not be operated until it has been restored to safe operating condition 53 Do not make repairs or adjustments unless specifically authorized to do so 54 When refueling smoking in the area shall not be permitted the engine shall be stopped and the opera tor shall not be on the rough terrain forklift truck 55 Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced before restarting engine 56 Do not use open flames when checking electrolyte level in storage batteries liquid level in fuel tanks or the condition of LPG fuel lines and connectors 57 Do not lift personnel with the forklift If the forklift must be used to lift people precautions for the protec tion of the personnel must be taken see ITSDF B56 6 chapter 5 15 Elevating Personnel R
86. cals 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
87. ct or indirect by means of rear view mirrors of the immediate vicinity of the lift truck while traveling with no load and with the jib in the transport position Special precautions must be taken if the size of the load restricts visibility towards the front moving in reverse site layout assisted by a person directing the maneuver while standing outside the truck s area of travel making sure to keep this person clearly in view at all times in any case avoid reversing over long distances Certain special accessories may require the truck to travel with the jib in the raised position In such cases visibility on the right hand side is restricted and special precautions must be taken site layout assisted by a person directing the maneuver while standing outside the truck s area of travel If visibility of your road is inadequate ask someone to assist by directing the maneuver while standing outside the truck s area of travel making sure to keep this person clearly in view at all times Keep all components affecting visibility in a clean properly adjusted state and in good working order e g windscreens windows windscreen wipers windscreen washers driving and work lights rear view mirrors 1 9 E STARTING THE LIFT TRUCK SAFETY INSTRUCTIONS A The lift truck must only be started up or maneuvered when the operator is sitting in the driver s cab with his seat belt adjusted and fastened Never try to star
88. cumulator reaches the end of its autonomy If the transmitter is switched off by turning the key button to stop hese protective devices are provided for the safety of personnel and property and must never be altered removed or bypassed in any way whatsoever he hand guard frame prevents external action on a manipulator if the transmitter falls for example or if the operator leans on a guard rail An electronic safety device prevents radio transmission from being initiated if the manipulators are not mechanically and electrically at rest and if the internal combustion engine speed selector is not set to idle In an emergency press the transmitter emergency stop button immediately then follow the manual s instructions see 2 DESCRIPTION INSTRUMENTS AND CONTROLS 1 23 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK GENERAL INSTRUCTIONS Ensure the area is sufficiently ventilated before starting the lift truck Wear clothes suitable for the maintenance of the lift truck avoid wearing jewellery and loose clothes Tie and protect your hair if necessary Stop the I C engine and remove the ignition key when an intervention is necessary Read the 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
89. d unscrew the plug 3 fig D1 3 Take drain hose 4 fig D1 4 Place the end of the drain hose in the container and screw fully the union on draining port 5 fg DT1 5 Remove filler cap 6 fig D1 6 in order to ensure that the oil is drained properly A Dispose of the drain oil in an ecological manner REPLACEMENT OF THE FILTER Remove engine oil filter 7 fig D1 3 discard the filter and the filter seal Clean the filter bracket with a clean lint free cloth Lightly grease the new oil filter seal and refit the oil filter see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS on the filter bracket A Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn FILLING UP THE OIL Loosen clean and put back in place the drain hose 4 fig D1 4 Refit and tighten drain plug 3 fig D1 3 Refit access panel 1 fig D1 1 Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL through filler port 8 fig D1 6 Wait a few minutes to allow the oil to flow into the sump Start the engine and let it run for a few minutes Check for possible leaks at the drain plug and the oil filter Stop the engine wait a few minutes and check the level between the two notches on dipstick 9 fig D1 6 Top up the level if necessary D3 DRY AIR FILTER CARTRIDGE CHANGE In case of use in a heavily dust laden atmosphere there are pre filtration cartr
90. d with a clean lint free cloth Slightly lubricate the new seal and fit the seal on the filter Fill up the new gear box oil filter see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS with oil see 3 MAINTENANCE LUBRICANTS AND FUEL Refit the filter making sure that the seal is correctly positioned and tightened A Tighten the gear box oil filter by hand pressure only and lock the filter in place by a quarter turn Put back the cover plate 1 fig D6 1 3 28 D7 HYDRAULIC RETURN OIL FILTER CARTRIDGE CHANGE Stop the engine and remove the pressure from the circuits by acting on the hydraulic controls Thoroughly clean the outside of the filter and its surroundings before any intervention in order to prevent any risk of polluting the hydraulic circuit Remove the shroud 1 fig 07 1 Unscrew the locking screws of the cover 2 fig D7 2 Remove the hydraulic return oil filter cartridge 3 fig D 2 and fit new replacement cartridge see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Make sure that the cartridge is correctly positioned and refit cover 2 fig D7 2 Perform the operation on both filters Put back the shroud 1 fig D7 1 D8 FRONT AND REAR AXLE DIFFERENTIAL OIL DRAIN Place the lift truck on level ground with the I C engine stopped and the differential oil still warm A Dispose of the drain oil in an ecological manner Place a container under drain plugs 1 fig
91. dangerous to use two lift trucks simultaneously to handle heavy or voluminous loads since this operation requires particular precautions to be taken It must only be used exceptionally and after risk analysis The ignition switch has an emergency stop mechanism in case of an operating anomaly occurring in the case of lift trucks not fitted with a punch operated cut out INSTRUCTIONS Always drive the lift truck with the forks or attachment to the transport position i e at 300 mm from the ground the jib retracted and the carriage sloping backwards For lift trucks with gearboxes use the recommended gear see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Select the steering mode appropriate for its use and or working conditions see 2 DESCRIPTION INSTRUMENTS AND CONTROLS as model of lift truck Release the parking brake Shift the forward reverse selector to the selected direction of travel and accelerate gradually until the lift truck moves off G STOPPING THE LIFT TRUCK SAFETY INSTRUCTIONS Never leave the ignition key in the lift truck during the 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 place the forward reverse selector in neutral Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at less than one meter from the
92. drain back is required 12 HYDRAULIC ATTACHMENT LOCKING Enables the attachment to be locked onto the carriage and a hydraulic attachment to be used by the same hydraulic circuit ATTACHMENT LOCKING CONTROL Set valve 1 to position A Push button 3 forward to lock the attachment and backward to release it Once the attachment is locked return valve 1 to position B to prevent accidental release of the attachment HYDRAULIC ATTACHMENT CONTROL Set valve 1 to position B Push button 3 forward or backward 2 31 13 JIB HEAD ELECTROVALVE Enables use of two hydraulic functions on the attachment circuit To make connection of the rapid connectors easier decompress the hydraulic circuit by pressing button 1 on the electrovalve ATTACHMENT LINE L1 CONTROL Push button 3 forward or backward ATTACHMENT LINE L2 CONTROL Hold button 2 down and button 3 forwards or backwards 14 JIB HEAD ELECTROVALVE HYDRAULIC ATTACHMENT LOCKING The addition of these two options on the attachment line allows two hydraulic functions to be used and locks the attachment onto the carriage To make connection of the rapid connectors easier decompress the hydraulic circuit by pressing button 1 on the electrovalve ATTACHMENT LINE L1 CONTROL Set valve 4 to position B Set switch 2 to position A indicator light off Push button 3 forward or backward ATTACHMENT LINE L2 CONTROL HYDRAULIC ATTACHMENT LOCKING LOCKING AN ATT
93. e 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 Ibs 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 81926 1427 and 81926 1430 Note Refer to the full text of the OSHA crane regulation 29 CFR Part 1926 Subpart CC for a detailed description VII ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont CONCLUSION 1 ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the
94. e lift truck and therefore the best technical ability to provide maintenance 34 START UP CHECKLIST ao 01 Fuel ines Fer 04 Injection or carburetion system 06 Radiator and cooling system or oses 102 Transmission 01 Direction reversal system IICA 02 AXLES TRANSFER GEARBOX 01 operation and seal 303 HYDRAULIC HYDROSTATIC circum D MN 02 Pumps and couine os 05 Tit oyindens Attachment oyinder s 07 Telescope cyinderts 08 Compensation cylinder s 09 Steering oyinderts 00 1 10 Control vale 104 BRAKESYSTEM _ Service brake and parking brake operation 7 2 Brake fluid level 105 LUBRICATION AND GREASING 106 J1B MANISCOPIC MANIACCESS ASSEMBLY 01 Beam and telescope _ Forks E masrassem 01 Fixed and mobile uprights olcam Omm om 3 5 0 0K 1 Missing 2 Incorrect P e 00 ATTACHMENTS Fitting on machine O 1 2 Hydraulic couplings CABIN PROTECTOR ELECTRIC CIRCUIT Seat Dashboard and radio 0 OT 02 03 04 Heating Air conditioning 05 Sound and visual alarm safety system Windscreen wiper windscreen washer Road horn O Reversing horn oad lights dditional lights otating beacon light P O 0
95. eadlights 340 1 A FRONT AXLE Front wheels reducers pivots 922 G G lt lt lt lt lt lt lt lt lt lt G C Front axle differential oil level 8206 C 1 C lt lt lt lt lt lt lt lt lt lt lt lt Front wheels reducers oil level 9206 C lt lt lt lt lt lt lt lt lt lt Front axle differential oil 931 V V lt lt lt lt lt lt lt lt lt Front wheels reducers oil 335 V V lt lt lt lt lt lt Wear of front axle brake discs ll op j j Front wheels reducers universal joint ll op j j 111 Front wheels reducers clearance x j j j Cr REAR AXLE Rear wheels reducers pivots 922 G G lt lt lt lt lt lt lt lt lt lt lt lt G C Rear axle oscillation 922 G G lt lt lt lt lt lt lt lt lt G C Rear axle differential oil level 326 C 1 C lt lt lt lt lt lt lt lt lt lt lt lt Rear wheels reducers oil level 9206 C C lt lt lt lt lt lt lt lt lt lt Rear axle differential oil 931 V V lt lt lt lt lt lt lt lt Rear wheels reducers oil 985 V V lt lt lt eee Wearing of rear axle brake discs L dq Ll dq d d L 1 Rear wheels reducers universal joint p cepe EE Rear wheels reducers clearance p M p p 15 1 Structure 11111112
96. ear box pressure in forward gear Stop the lift truck and look for the cause e g Low oil level in the transmission internal leak in the transmission etc NOTE The signal light operates in forward travel conditions only the signal should not be taken into account when the I C engine is running at idle or is stopped H RED AIR FILTER CLOGGED INDICATOR LIGHT The lamp and the buzzer come on when the air filter cartridge is clogged up Stop the lift truck and carry out the necessary repairs see cleaning and replacement requirements in chapter 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS RED TRANSMISSION OIL TEMPERATURE INDICATOR LIGHT The lamp and the buzzer come on when the gear box oil temperature is abnormally high Stop the lift truck and look for the cause of this overheating 2 18 J RED BATTERY CHARGE INDICATOR LIGHT If the lamps G G H I J N and the buzzer come on when the lift truck is running stop the I C engine immediately and check the electrical circuit as well as the alternator belt K RED PARKING BRAKE INDICATOR LIGHT This lamp comes on when the parking brake is applied L GREEN DIRECTION INDICATOR LAMP M BLUE MAIN BEAM LAMP N RED BRAKINGNG OIL LEVEL LAMP If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately and check the braking oil level In the event of an abnormal dropping of the level consult your dealer O HOUR METER FUEL LEV
97. eas where there is a risk of fire or which are potentially explosive e g Refineries fuel or gas depots stores of inflammable products For use in these areas specific equipment is available ask your dealer for information Our trucks comply with Directive 2004 108 EC concerning electromagnetic compatibility EMC and with the corresponding harmonized norm EN 12895 Their proper operation is no longer guaranteed if they are used within areas in which the electromagnetic fields exceed the limit specified by that norm 10 V m Directive 2002 44 EC requires company managers to not expose their employees to excessive vibration doses There is no recognized code of measurement for comparing the machines of different manufacturers The actual doses received can therefore be measured only under actual operating conditions at the user s premises he following are some tips for minimizing these vibration doses e Select the most suitable lift truck and attachment for the intended use e Adapt the seat adjustment to the operator s weight according to lift truck model and maintain it in good condition as well as the cab suspension Inflate the tires in accordance with recommendations e Ensure that the operators adapt their operating speed to suit the conditions on site e As far as possible arrange the site in such a way as to provide a flat running surface and remove obstacles and harmful potholes 14 C MODIFICATION OF THE LIFT TRUC
98. eat belt during operations and never jump from an over turning forklift n ay 5 er j e it nen 11 set LJ SAFETY DECALS THIS VEHICLE IS EQUIPPED WITH A BACK UP Alarm Must Sound 496162 ALARM WHEN BACKING THE Location on the dash in direct view of the operator ALARM The backup alarm must sound when the forklift is placed in reverse gear MUST SOUND THE OPERATOR IS RESPONSIBLE FOR THE SAFE USE OF THIS VEHICLE No Riders 420732 Location on the cab entrance s and on or near wheel fenders and engine cover CAUTION Informs riders are not allowed on the forklift NO RIDERS Clear of Raised Boom 801006 DANGER Boom equipped models Location on both sides Stay cl f raised b of the boom nose ay clear of raised boom unless properly supported Operator may be crushed Keep away from unsupported boom between falling boom and main frame Failure to comply may result in serious injury or death Clear of Power Lines 801007 Boom equipped models Location on both sides of the boom nose o DANGER Keep machine at least 25 feet from overhead power lines Keep away from power lines Failure to comply may result in serious injury or death by electrocution 801007 XI SAFETY DECALS Use of Frame Leveling 801013 Boom equipped models Location to the right of DANGER the operator near the hydraulic control lever READ OPERATOR S MANUAL
99. el machine at ground level before Frame leveling notice load must be lowered Attachment and Boom Safety 801009 Boom equipped models Location on both sides of the boom nose ATTACHMENT AND BOOM SAFETY Improper operating techniques can cause the machine to tip over Refer to machine load charts and operator s manual for proper operating techniques Important reminders of attachment and boom safety Refer to operator s manual for proper attachments mounting and dismounting instructions Never use this machine as manlift Attachment must be properly locked to the carrier before raising boom Use only approved attachments on this machine Do not work under raised boom or attachments unless supported FAILURE TO FOLLOW ANY OF THE ABOVE INSTRUCTIONS CAN CAUSE SERIOUS INJURY TO THE OPERATOR OR OTHER PERSONS 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 Keep hands and clothing away from rotating fan and belts AND CLOTHING AWAY FROM ROTATING FAN AND BELTS TO PREVENT SERIOUS INJURY 801008 XII SAFETY DECALS Gear Shift Pattern 61039 4 speed transmission models Location near the gear shift lever Identifies the gear shift pattern of the forklift t
100. elay K3 Reverse gear relay K4 Safety system starting switch relay K5 Gear box oil pressure relay K6 Flashing unit KT Buzzer K8 Hydraulic movement cut off relay K18 Hand brake indicator lamp relay K19 Jib suspension cut off relay K20 Jib suspension relay K21 Brake system pressure fault K22 Oil cooler relay K23 OPTION Jib head electrovalve relay OPTION Jib head electrovalve relay attachment hydraulic locking device OPTION Electrical jib provision 10 FUSES AND RELAYS UNDER THE ENGINE HOOD Remove casing 1 and cover 2 for access to fuses and relays A Always replace a faulty fuse with another of equivalent rating Never use a fuse that has been repaired F32 I C engine electronic control unit 304 F40 Lift truck electrical equipment 40 F41 Lift truck electrical equipment 40 F42 Preheating engine 80A F43 Alternator 80A K10 Preheating C engine relay 2 23 11 WINDSCREEN WASHER TANK See 3 MAINTENANCE B EVERY 50 HOURS SERVICE 12 ROOF LIGHT 13 ACCELERATOR PEDAL 14 SERVICE BRAKE PEDAL AND TRANSMISSION CUT OFF The pedal acts on the front and rear wheels by a power assisted hydraulic brake system and allows the lift truck to be slowed down and stopped Depending on the position of the transmission cut off switch it enables the transmission to be cut off during the free travel see 2 DESCRIPTION 5 SWITCHES 1
101. entilators 24 HEATING VENTS These heating vents enable the air to be directed to the interior of the cabin and onto the side windows 25 BUTTON FOR OPENING HYDRAULIC FLUID AND FUEL FILLER ACCESS PANEL Push the button to open the access panel Push the panel to close it 26 DOOR LOCK Two keys are provided with the lift truck to enable the cabin to be locked 27 LOCKING HANDLE FOR UPPER HALF DOOR 28 UNLOCKING BUTTON FOR UPPER HALF DOOR 29 HANDLE FOR REAR WINDOW OPENING EMERGENCY EXIT Use the rear window as an emergency exit if it is impossible to leave the cab by the door 30 DOCUMENT HOLDER Ensure that the operator s manual is in its place in the document holder 31 FRONT LIGHTS Left front indicator Left front dipped headlight Left front main beam Left front sidelight Right front indicator Right front dipped headlight Right front main beam Right front sidelight 0 Tr g O u 3 2 28 32 REAR LIGHTS A Left rear indicator B Left rear stoplight C Left tail light D Left rear reverse light E Left rear fog light OPTION F Right rear fog light OPTION G Right rear reverse light H Right tail light Right rear stoplight J Right rear indicator 33 REVOLVING LIGHT The revolving light is dismountable to make it possible for example to reduce the bulkiness of the lift truck or to avoid being stolen Loosen nu
102. eze 3 34 F2 AIR CONDITIONING OPTION CLEANING INSPECTION CLEANING CONDENSER AND EVAPORATOR COILS CLEANING CONDENSATE TRAY AND RELIEF VALVE COLLECTING COOLANT TO REPLACE FILTER DRIER REFILLING WITH COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES NOTE When opening the evaporator unit remember to replace the cover seal CONSULT YOUR DEALER CAUTION DO NOT ATTEMPT TO REPAIR ANY PROBLEMS YOURSELF ALWAYS REFER TO YOUR DEALER WHEN REFILLING CIRCUITS AS THEY HOLD THE CORRECT SPARE PARTS AS WELL AS HAVING THE NECESSARY TECHNICAL KNOWLEDGE AND TOOLS Do not open the circuit under any circumstances as this would cause the coolant to be lost The cooling circuit contains a gas which can be dangerous under certain conditions This gas coolant R 134a is colourless odourless and heavier than air Y f this gas is inhaled take the victim into fresh air give oxygen or artificial respiration if necessary and call a doctor f the gas is in contact with the skin wash it immediately under running water and remove any contaminated garments If the gas is in contact with the eyes rinse them in clear water for 15 minutes and call a doctor he compressor has an oil level gauge fig F2 Never unscrew this gauge because it would depressurizes the installation The oil level is only checked when changing the oil in the circuit 3 35 G OCCASIONAL MAINTENANCE G1
103. f necessary add sufficient wedging under the stabilizers Make sure that the scaffolding loading platform pilings or ground is capable of bearing the load Never stack loads on uneven ground they may tip over If the load or the attachment must remain above a structure for a long time there is the risk that it will rest on the structure because of the jib descending owing to the oil in the cylinders cooling down To eliminate this risk Regularly check the distance between the load or the attachment and the structure and readjust this if necessary If possible use the lift truck at an oil temperature as close as possible to ambient temperature n the case of work near aerial lines ensure that the safety distance is sufficient between the working area of the lift truck and the aerial line You must consult your local electrical agency You could be electrocuted or seriously injured if you operate or park the lift truck too close to power cables In the event of high winds do not carry out handling work that jeopardizes the stability of the lift truck and its load particularly if the load catches the wind badly D VISIBILITY he safety of people within the lift truck s working area as well as that of the lift truck itself and the operator are depend on good operator visibility of the lift truck s immediate vicinity in all situations and at all times This lift truck has been designed to allow good operator visibility dire
104. formed 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 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 housekeepi
105. ft truck on the terrain where it will be used Ensure that the service brakes are working properly The loaded lift truck must not travel at speeds in excess of 12 km h Drive smoothly at an appropriate speed for the operating conditions land configuration load on the lift truck Do not use the hydraulic jib controls when the lift truck is moving Never change the steering mode whilst driving Do not manoeuvre the lift truck with the jib in the raised position unless under exceptional circumstances and then with extreme caution at very low speed and using gentle braking Ensure that visibility is adequate Take bends slowly In all circumstances make sure you are in control of your speed On damp slippery or uneven terrain drive slowly Brake gently never abruptly Only use the lift truck s forward reverse selector from a stationary position and never do so abruptly Do not drive with your foot on the brake pedal Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel so turn it gently and not jerkily Never leave the engine on when the lift truck is unattended Do not leave the cab when the lift truck has a raised load Look where you are going and always make sure you have good visibility along the route 1 10 Use the rear view mirrors frequently Drive round obstacles Never drive on the edge of a ditch or steep slope It is
106. g 1 fig E1 1 and unscrew the plug Open the access panel for hydraulic oil filling Remove cap 2 fig E1 2 Let the fuel flow and clean with ten liters of clean fuel by filler port 3 fig E1 2 Refit and tighten drain plug 1 fig E1 1 tightening torque 29 to 39 N m Fill the fuel tank with clean diesel filtered through the filler port Refit the filling cap If necessary bleed the fuel circuit see 3 MAINTENANCE G1 FUEL SYSTEM E2 SAFETY DRY AIR FILTER CARTRIDGE CHANGE For the disassembly and reassembly of the cartridge see 3 MAINTENANCE D3 DRY AIR FILTER CARTRIDGE Gently remove the dry air filter safety cartridge 1 fig E2 taking care to avoid spilling the dust Clean the gasket surface on the filter with a damp clean lint free cloth Before mounting check the state of the new safety cartridge see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Introduce the cartridge into the filter axis and push it in pressing the edges and not the middle NOTE The periodicity for changing the safety cartridge is given for information only The safety cartridge must be changed for every two changes of the air filter cartridge 3 30 E3 GEAR BOX OIL DRAIN E4 GEAR BOX SUMP STRAINER CLEAN Place the lift truck on level ground with the engine stopped the gear box oil still warm DRAINING THE OIL Place a container under drain plug 1 fig E3 1 and under cover 2 f
107. g its transverse stability RAISE THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION UNLADEN AND LADEN Raise both stabilizers fully and at the same time SETTING THE STABILIZERS WITH THE JIB UP UNLADEN AND LADEN A This operation must be exceptional and performed with great care Raise the jib and retract the telescopes completely Set the lift truck in position in front of the elevation fig G2 moving very slowly and carefully Put the handbrake on and put the gearshift lever into neutral Move the stabilizers very slowly and gradually as soon as they are close to the ground or in contact with it Lower the two stabilizers and lift the two front wheels of the lift truck fig G3 During this operation transverse attitude must be permanently maintained the bubble in the level must be kept between the two lines SETTING THE STABILIZERS WITH THE JIB UP UNLADEN AND LADEN A This operation must be exceptional and performed with great care Keep the jib up and retract the telescopes completely fig G3 Move the stabilizers very slowly and gradually as soon as they are in contact with the ground and when they leave the ground During this operation the transverse attitude must be permanently maintained the bubble in the level must be kept between the two lines Raise both stabilizers completely Release the parking brake and reverse the lift truck 1 very slowly and carefully to relea
108. h 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
109. hematic LOCATION OF THE COMPONANTS DIAGRAM Components Location on Diagram Correspondance D scription 4 hydraulique EUM SPU UNIT F28 Cu wanun re SAFETY UNIT LONGITUD LLMI o Le wem A A E Bl ar junu E DO o EE sl Lo ju 71741 uo emserowmeme tes I L mmammwe mr wmwmum O pe ram ma e L Lm sam te Lm oa E I non re ec no sor fe e Lm ememoenmensm OS 2 Low roncco sr corra mr rf m ero men en sensor uo reee sesos L mi meesssmwse ES ES ES mr CN L L COo us eemeeeeowe __ et ES ua perese pereon pressure sun ms T Lm qwwsenwsm Fre Te mwmewwsm el Lm qwwunwwsm O a mwumwamm el Tel Lm CE Feb EE Ter CEEI el m monos A A e m wwurmmseuw A Les 18 10 2010 80 02 M173FR Main Electric Schematic MLT 845 120 LSU S rie 4 Euro 3 Components Location on Diagram Correspondance Description 4 hydraulique pe uo monro sl mr mowussosmuw L fee ur mormones mL us A jewel me rom osos sem PES 2 1 LIT ur remeros L L T us qenewewuen
110. hway code legislation he lift truck must comply with current road legislation If necessary there are optional solutions Contact your dealer INSTRUCTIONS Make sure the revolving light is in place switch it on and verify its operation Make sure the lights indicators and windscreen wipers are working properly Switch off the working headlights if the lift truck is fitted with them Select the steering mode HIGHWAY TRAFFIC as model of lift truck see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Retract entirely the jib and put the attachment at 300 mm from the ground Place the slope correctors in the central position i e the transverse shaft of the axles parallel to the chassis as model of lift truck Lift up the stabilizers to the maximum and turn the blocks inwards as model of lift truck Never move in neutral forward reverse selector or gear lever in neutral or transmission cut off button pressed to preserve the lift truck engine brake Failure to respect this instruction on a slope will lead to excessive speed which may make the lift truck uncontrollable steering brakes and cause serious mechanical damage 1 12 DRIVING THE LIFT TRUCK WITH A FRONT MOUNTED ATTACHMENT You must comply with current regulations in your country covering the possibility of driving on the public highway with a front mounted attachment on your lift truck If road legislation in your country authorizes circulation with a front
111. idges see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Also the checking and cleaning periodicity of the cartridge must be reduced up to 250 hours in a heavily laden dust atmosphere and with pre filtration Change the cartridge in a clean location with the 1 C engine stopped Never operate the lift truck with the air filter removed or damaged Open the engine bonnet Loosen the bolts and remove cover 1 fig D3 Gently remove the cartridge 2 fig D3 taking care to avoid spilling the dust Leave the safety cartridge in place he following parts must be cleaned with a damp clean lint free cloth e he inside of the filter and cover e he inside of the filter inlet hose e The gasket surfaces in the filter and in the cover Check pipes and connections between the air filter and the engine and the connection and state of the clogging indicator on the filter Before mounting check the state of the new cartridge see MAINTENANCE FILTERS CARTRIDGES AND BELTS Introduce the cartridge into the filter axis and push it in pressing the edges and not the middle Reassemble the cover guiding the valve downwards D4 FUEL PRE FILTER CHANGE Open the engine bonnet Carefully clean the outside of the filter and its holder to prevent dust from getting into the system Place a container under the pre filter and drain it using drain plug 1 fig D4 Disconnect the harness 2 fig D4
112. ig E3 1 and unscrew the drain plug Remove cover plate 3 fig E3 2 Remove dipstick 4 fig E3 3 and unscrew filler cap 5 fig E3 3 in order to ensure that the oil is drained properly A Dispose of the drain oil in an ecological manner CLEANING THE STRAINER Remove cover 2 fig E3 1 and set aside the O ring joint and sealing washer Allow the rest of the oil to drain away Remove and clean the strainer using a compressed air jet Clean the magnetic section on the plate Refit the assembly and tighten up plate 2 fig E3 1 tightening torque 18 to 31 N m FILLING UP THE OIL Refit and tighten drain plug 1 fig E3 1 tightening torque 34 to 54 N m 25 to 40 Ibf ft Fill up with oil see MAINTENANCE LUBRICANTS AND FUEL by filler port 5 fig E3 3 and refit the filler cap Start the 1 C engine and let it run for a few minutes Check any possible leaks from the drain plug or cover Stop the I C engine and within 5 minutes of the I C engine being stopped check on the dipstick 4 fig E3 3 the correct level between the two MIN and MAX marks Top up the level if necessary Refit the shroud 3 fig E3 2 E5 ANGLE GEARBOX OIL DRAIN Place the lift truck on level ground with the engine stopped the angle gear box oil still warm Place a container under drain plug 1 fig 5 1 and unscrew the plug Remove the plastic cap 2 fig E5 2 Remove dipstick 3 fig E
113. isk of accident while using servicing or repairing your lift truck can be restricted if you follow the safety instructions and safety measures detailed in these instruction Only the operations and manceuvres 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 exhaustive At any time as an operator you must envisage within reason the possible risk to yourself to others or to the lift truck itself when you use it Failure to respect the safety and operating instructions or the instructions for repairing or servicing your lift truck may lead to serious even fatal accident GENERAL INSTRUCTIONS A OPERATOR S MANUAL Read the operator s manual carefully he 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 stickers which are no longer legible or which are damaged B AUTHORISATION FOR USE IN FRANCE or see current legislation in other countries Only qualified authorized personnel can use the lift truck This authorization is given in writing by the appropriate person in the establishment with respect to the use of lift trucks and must be carried permanently by the operator he operator is not competent to authorise the driving of the lift truck by another person C
114. ize 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 Manitou NA Inc for the latest information When ordering service parts or requesting technical information be prepared to quote the applicable Model Serial Numbers
115. jib incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to facilitate locking MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT Take the locking pin and the clip on the bracket fig A and lock the attachment fig D Do not forget to refit the clip Stop the engine and keep the ignition on the lift truck Remove the pressure of the hydraulic circuit by operating switch 1 fig E on the distributor lever backwards and forwards 4 or 5 times Connect the rapid connectors according to the logic of the attachment s hydraulic movements Make sure that the rapid connectors are clean and protect the holes which are not used with the caps provided HAND RELEASING AND DISCONNECTING THE ATTACHMENT Proceed in the opposite order to that described in MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT while making sure you put the locking pin back into the bracket fig A LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position 4 6 4 7 Contents Main Electrical Schematic A MLT 845 120 LSU S rie 4 Euro 3 Pages LOCATION OF THE CONNECTORS ON THE SCHEMATIC A3 LOCATION OF THE COMPONENTS ON THE SCHEMATIC AT LOCATION OF THE FUSES AND RELAYS ON THE SCHEMATIC A12 LOCATION OF THE SPLICES ON
116. k that the locking pin and the clip are in position in the bracket fig A Place the lift truck with the jib fully lowered in front of and parallel to the attachment tilt the carriage forwards fig B Bring the carriage under the locking tube of the attachment slightly lift the jib incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to facilitate locking HAND LOCKING Take the locking pin and the clip on the bracket fig A and lock the attachment fig D Do not forget to refit the clip HAND RELEASING Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back the locking pin and the clip in the bracket fig A LAYING AN ATTACHMENT Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure you place the attachment flat on the ground and in closed position 4 5 B HYDRAULIC ATTACHMENT AND HAND LOCKING DEVICE TAKING UP AN ATTACHMENT Ensure that the attachment is in a position facilitating the locking to the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Check that the locking pin and the clip are in position in the bracket fig A Place the lift truck with the jib fully lowered in front of and parallel to the attachment tilt the carriage forwards fig B Bring the carriage under the locking tube of the attachment slightly lift the
117. l Not used III The 1 C engine starts return to position as soon as the key is released 7 BRAKING OIL TANK FUSES AND RELAY ACCESS PANEL 8 BRAKING OIL TANK See 3 MAINTENANCE B EVERY 50 HOURS SERVICE 2 21 9 FUSES AND RELAYS IN THE CAB A sticker on the protective lid gives a quick indication of the use of the panel s components described below Always replace a faulty fuse with another of equivalent rating Never use a fuse that has been repaired OPTION Pneumatic seat 10A F2 Wheel alignment 54A Electrical control unit 5A Diagnostic connector 5A F3 Sound alarm 104 Stop switch 104 F4 OPTION Self cleaning fan 10 F5 Left indicators 7 54 F6 Right sidelight 7 54 Fuel gauge lighting 7 5A F4 F10 Engine water temperature lighting module 7 54 BW Hour meter lighting 7 5A E em OPTIONAL Number plate lighting 7 54 9 og F7 Left sidelights 7 5A 154 154 F8 Revolving light 7 5A F9 OPTION Working tail light 15A F10 OPTION Front working head light 154 F11 Insulation of the compensation cylinders 104 Brake pressure indicator 104 OPTION Jib suspension 10 F12 Parking brake electrovalve 7 54 F13 Forward reverse selector 154 Transmission cut off 154 Reverse lights 1
118. lignment of the rear wheels and to drive in front wheel steer The control of the alignment of the rear wheels must be regularly done with the help of the green lamps while driving the lift truck In case of anomalies consult your dealer 2 25 18 HYDRAULIC CONTROLS Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve In the event of suspected malfunction contact your dealer ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID A Use the hydraulic controls carefully without jerking to avoid accidents caused by shaking the lift truck NOTE If necessary use the steering to reset the hydraulic control steering accumulator A Lifting and tilting control lever B Telescoping control button C Attachment control button D Attachment control button LIFTING THE LOAD The lever A backwards when lifting The lever A forwards when lowering TILT OF CARRIAGE The lever A to the left for reverse tilt The lever A to the right for forward tilt TELESCOPING Button B forwards for extending Button B backwards for retracting ATTACHMENT The button C forwards or backwards OPTION JIB HEAD ELECTROVALVE Button D see 2 DESCRIPTION DESCRIPTION AND USE OF OPTIONS 8 o i 2 NOTE When driving on the road it is highly recommended that you cut off all the hydraulic movements see 2 DESCRIPTION 5 SWITCHES 19 FUNCTION FILES The
119. load to be handled and be vigilant and take extra care to limit these variations as far as possible C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE This device gives an indication of the longitudinal stability of the lift truck and limits hydraulic movements in order to ensure this stability at least under the following operating conditions e when the lift truck is at a standstill e when the lift truck is on firm stable and consolidated ground e when the lift truck is performing handling and placing operations Movetthe jib very carefully when approaching the authorized load limit see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Always watch this device during handling operations In the event that AGGRAVATING hydraulic movements are cutoff only perform de aggravating hydraulic movements in the following order fig C if necessary raise the jib 1 retract the jib as far as possible 2 and lower the jib 3 to set down the load The instrument reading may be erroneous when the steering is at its maximum limit or the rear axle oscillated to its limit Before lifting a load make sure that the lift truck is not in either of these situations 1 14 X X D TRANSVERSE ATTITUDE OF THE LIFT TRUCK Depending on the model of lift truck The transverse attitude is the transverse slope of the chassis with respect to the horizontal Raising the jib reduces the lift truck s lateral stability The transverse attit
120. m h2 e h1 Height of the dipped beam in relation to the ground e h2 Height of the adjusted beam e Distance between the dipped beam and the white wall G5 LIFT TRUCK TOW A Do not tow the lift truck at more than 25 km h 15 5 mph Put the forward reverse selector and the gear shift in neutral Release the hand brake Put the warning lights on If the I C engine is not running there will be no steering or braking assistance Operate the steering and pedal slowly avoiding sudden jerky movements G6 LIFT TRUCK SLING Take into account the position of the lift truck centre of gravity for lifting fig G6 1 A 1560 mm B 1210 mm Place the hooks in the fastening points provided fig G6 2 and G6 3 3 38 G7 LIFT TRUCK ON A PLATFORM TRANSPORT Ensure that the safety instructions connected to the platform are respected before the loading of the lift truck and that the driver of the means of transport is informed about the dimensions and the weight of the lift truck see 2 DESCRIPTION CHARACTERISTICS Ensure that the platform has got dimensions and a load capacity sufficient for transporting the lift truck Check also the pressure on the contact surface allowable for the platform in connection with the lift truck For lift trucks equipped with a turbo charged 1 C engine block off the exhaust outlet to avoid rotation of the turbo shaft without lubrication when transporting the
121. mission cut off to forward reverse selector effected NOTE In all cases transmission cut off can be effected using the gear lever USE OF TRANSMISSION CUT OFF Transmission cut off to brake pedal position A e When loading Transmission cut off to forward reverse selector position B e When driving e Forinching and continuous stopping and starting delicate handling In orderto optimise hydraulic movements cut off transmission to the forward reverse selector e Starting up on a slope K OPTION WORKING TAIL LIGHT L OPTION SELF CLEANING FAN See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS M OPTION JIB SUSPENSION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS 2 20 5 LIGHTR SWITCH HORN AND INDICATOR SWITCH The switch controls the visual and sound alarms A All lights are off the direction indicators do not flash B The right hand direction indicators flash C The left hand direction indicators flash D The sidelights and the rear lights are on E The dipped headlights and the rear lights are on F The main beam headlights and the rear lights are on G Headlight signal Pressing the switch sounds the horn NOTE The positions D E F G can be carried out without the ignition being on 6 IGNITION SWITCH The key switch has five positions P Ignition off parking position O Ignition switched off and engine stopped Ignition and pre heating I
122. ms won T e ms cwwswansm e T LT ms worovam oram mon Lm CE e roses comer Seal Lm mum tr Bl m a Lm mas ES ES Lm unus E E fen m _ p none waren nn senson 1 E I U e fen Te os smwwewmoma I 18 10 2010 80 02 M173FR A10 uu 2 Main ceca Scnematio MLT 845 120 LSU S rie 4 Euro 3 Components Location on Diagram Correspondance Description 4 hydraulique pe dem LU Lm ous 19 EE J EE rro remos a L s morem morimos mee mwesumoomu ui anne nous none U ma ss L ur mmemweweswsns e L us cwmumiwneaem A L L ms pm mo anne rennen FF Lm eme DI m FE IEA sw memmsna E IE sm sm sw TE L Del ooo S L sm CE Jel se mwwsswonesm e L I sm emuwwweesms CTI E IS qemwwomersm E IS sr enormes EE L 9 mess Ls wmsweonewmsueswonw
123. n on the front and rear sides of the mast cross bracing Keep fingers away from the mast FINGERS crossbracing CLEAR OF 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 DANGER A DISENGAGE HAND THROTTLE BEFORE LEAVING TRUCK OPERATE HAND THROTTLE ONLY WITH PARKING BRAKE SET FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH 804784 XV WITH THE SAFETY SNAP PIN BEFORE 421016 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 when contacting the maufacturer for parts and service Overhead Guard Data Plate B6109 Location attached to the overhead guard Overhead guard conformity Forklift Data Plate 496550 Boom equipped models Forklift Data Plate 283688 Location within the operator s compartment Important forklift truck identification Record this information for use when contacting the manufacturer for parts and service 4
124. nds and carry out the preheating between unsuccessful attempts Make sure all the signal lights on the control instrument panel are off Check all control instruments when the engine is warm and at regular intervals during use so as to quickly detect any faults and to be able to correct them without any delay If an instrument does not show the correct display stop the engine and immediately carry out the necessary operations F DRIVING THE LIFT TRUCK SAFETY INSTRUCTIONS Operators attention is drawn to the risks involved in using the lift truck in particular Risk of losing control Risk of losing lateral and frontal stability of the lift truck The operator must remain in control of the lift truck In the event of the lift truck overturning do not try to leave the cabin during the incident YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN Observe the 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 300 mm from the ground the jib retracted and the carriage sloping backwards Only carry loads which are balanced and properly anchored to avoid any risk of a load falling off Ensure that palettes cases etc are in good order and suitable for the load to be lifted Familiarise yourself with the li
125. ng 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 roug
126. ngine is off jib suspension is automatically deactivated 2 39 18 ATTACHMENT EASY HYDRAULIC CONNECTION For easily connecting and disconnecting the attachment OPERATION Press the push button 1 to release the attachment circuit hydraulic pressure Connect or disconnect the rapid connectors of the hydraulic attachment Connect or disconnect the rapid connectors of the hydraulic attachment see 4 OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE PICKING UP THE ATTACHMENTS 19 ANGULAR SECTOR ON JIB The angular sector displays the jib angle and thus improves the reading of the load charts 20 LIFTING RING ON SINGLE CARRIAGE CONDITIONS OF USE Follow the instructions given in your lift truck s instruction manual see 1 OPERATING AND SAFETY INSTRUCTIONS ON HANDLING LOADS in addition to those given below The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS but the angle of inclination of the carriage must be same as when the forks are used in the horizontal position Check the maximum permitted angle which is 45 Do not change the angle of the carriage while using the lifting ring The lifting hook the chains and slings shall have a minimum capacity of 3000 kg with a factor of safety against breakage of 4 h ER 782990 LOAD CHARTS AND FUNCTION SHEETS A The load charts are given for use without forks and without attachments Co 845 TS AS O Co
127. 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 w
128. oise 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 A Under no circumstances must the seat be adjusted while the lift truck is moving The operator must always be in his normal position in the 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 he control units must never in any event be used for any other than their intended purposes e g climbing onto or down from the lift truck portmanteau etc If the control components are fitted with a forced operation lever lock device it is forbidden to leave the cab without first putting these controls in neutral It is prohibited to carry passengers either on the lift truck or in the cab 18 C ENVIRONMENT Comply with site safety regulations If you have to use the lift truck in a dark
129. ons exist consult your dealer All attachments with a suspended load winch crane jib crane jib with winch hook etc MUST be used with a lift truck equipped with a hydraulic movement cut out device In this case the movement cut out must be switched on and the transverse attitude perfectly horizontal Only attachments approved by MANITOU are to be used on our lift trucks see 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE TECHNICAL SPECIFICATIONS OF ATTACHMENTS The manufacturer s liability will be denied in case of modification or of attachment adaptation carried out without his knowing it Depending on their size certain attachments may when the jib is lowered and retracted come into contact with the front tyres and cause damage to them if reverse tilt is activated in the forward tilt direction TO REMOVE THIS RISK EXTEND THE TELESCOPE TO A SUFFICIENT EXTENT FOR THE PARTICULAR LIFT TRUCK AND ATTACHMENT SO THAT THIS CONTACT IS NOT POSSIBLE Maximum loads are defined by the capacity of a lift truck taking account of the attachment s mass and centre of gravity In the event of the attachment having less capacity than the lift truck never exceed this limit 4 3 A ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE TAKING UP AN ATTACHMENT Ensure that the attachment is in a position facilitating the locking to the carriage If it is not correctly oriented take the necessary precautions in order to move it safely Chec
130. or 81926 251 Rigging equipment for material handling 7 Rigging equipment attached to the forks must be secured such that it cannot move either sideways 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 persomnel 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 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 81910 1 78 1 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 zon
131. or reversing If the alarm becomes discontinuous the operator must sit back in the seat put the forward reverse selector back in neutral and select forward or reverse if he wishes to continue moving 17 STEERING SELECTION A GREEN WHEEL ALIGNMENT LAMPS These lamps come on to indicate the alignment of the wheels in relation to the lift truck Lamp AT for the front wheels and lamp A2 for the rear wheels Before selecting one of the three possible steering positions bring all 4 wheels into alignment with regards to the lift truck axle Never change the steering mode whilst driving B STEERING SELECTION LEVER B1 Front drive wheels highway traffic 2 Front and rear drive wheels in opposite direction short steering lock pd B3 Front and rear drive wheels in the same direction crab steering C SWITCH FOR ALIGNMENT OF THE WHEELS This switch enables the use or not of the device for alignment of the wheels The indicator light indicates its use CONTROL FOR ALIGNMENT OF THE WHEELS Connect the switch signal light ON Shift the steering selection lever B into position B2 short steering lock Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up Shift the steering selection lever B into position B1 highway traffic Turn the steering wheel and bring the front wheels into alignment until lamp A1 lights up Before driving on roads it is necessary to check the a
132. orted independently E HYDRAULIC TRAILER HOOK OPTION NOTE The rear view mirror OPTION is mandatory with the hydraulic trailer tow hook A Never use the tow hook to raise the rear of the lift truck when changing the rear wheel for example Valve 1 in position B Raise the hydraulic tow hook to release the hook lock 4 by moving switch 3 forwards Pull knob 5 hold in this position and move switch 3 backwards to lower the tow hook Release knob 5 Couple or uncouple the trailer A When uncoupling make sure that the trailer is supported independently Raise the hydraulic tow hook by moving switch 3 forwards Lower the hook slightly to verify that the lock pin is in proper contact with the hook lock 4 F CONNECTING THE BRAKE SYSTEM OPTION Connect the brake hose to the provided brake unit 1 on the lift truck Make sure the trailer brakes are working properly and test the effects of braking before taking the trailer onto the public highway 2 33 DESCRIPTION AND USE OF THE OPTIONS 1 BATTERY CUT OFF 2 REVERSE BUZZER ALARM 3 NUMBER PLATE 4 NUMBER PLATE LIGHTING 5 PREHEATING ELEMENT Enables the engine to be kept warm during prolonged periods of stoppage and thus improves engine starting Supply characteristics of preheating system e Rated range of power 220 240V 50 60Hz e Current consumed 4 5A e Equipment in class 1 e Equipment connectable only on feeder circuit TT or TN e
133. potential hazards and be prepared to avoid them ADDITIONAL RECOMMENDED LITERATURE ANSI ITSDF B56 6 is the national consensus standard for rough terrain forklift trucks It contains rules about forklift safety maintenance safe operation training and supervision Forklift owners should learn this stan dard and make it available for their operators service personnel and supervisors These standards can be obtained free of charge from the Industrial Truck Standards Development Foundation ITSDF on their web site at www itsdf org The following references are examples from the standard addressing forklift operators A OPERATOR TRAINING QUALIFICATIONS 1 The user shall ensure that operators understand that safe operation is the operator s responsibility The user shall ensure that operators are knowledgeable of and observe all safety rules and practices 2 Create an effective operator training program centered around user company s policies operating condi tions and rough terrain forklift trucks The program should be presented completely to all new operators and not be condensed for those claiming previous experience 3 Information on operator training is available from several sources including rough terrain forklift truck man ufacturers users government agencies etc 4 An operator training program should consist of the following a careful selection of the operator considering physical qualifications job attitude and
134. racted and lowered as far as possible Refer to gauge 1 fig The oil level is correct when it is at the level of the red point If necessary add oil see 3 MAINTENANCE LUBRICANTS AND FUEL Open the access panel for hydraulic oil filling Remove cap 2 fig Add oil through filler port 3 fig B6 A Use a clean funnel and clean the underside of the oil drum before filling Put the cap back and close the access panel for hydraulic oil filling Check visually that there is no leakage in the tank and pipes Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank B7 BRAKE OIL LEVEL CHECK Place the lift truck on level ground Loosen screw 1 fig B7 1 and remove the braking oil tank access panel 2 fig B7 1 The level is correct when it is at the MAXI level on the tank If necessary add oil see MAINTENANCE LUBRICANTS AND FUEL by the filler port fig B7 2 Check visually that there is no leakage in the tank and pipes A If the braking oil level is abnormally low consult your dealer B8 WINDSCREEN WASHER LIQUID LEVEL CHECK Remove the filler cap 1 fig B Check visually the level If necessary add windscreen washer liquid see 3 MAINTENANCE LUBRICANTS AND FUEL by filler port 2 fig B8 3 19 B9 CAB DOOR GREASE Clean and lubricate the points 1 4 lubricators fig B9 with grease see 3
135. ransmission 9 Tral Steering Mode 184276 4 wheel steer equipped models Location near the steering mode selection lever Identifies the steering mode selection e 221322 ATTENTION CUIDADO ACHTUNG ATTENZIONE Mineral Oil Brake Reservoir 221322 or 234800 has LIQUIDE DE FREIN been replaced by 164091 BREMSFLUESSIGKEIT Location near the brake fluid reservoir where applicable LIQUIDO DE FRENO LIQUIDO FRENI Refer to the Operator Service Manual for the correct brake fluid ON 3 mineral to be used in the brake system Utiliser IMPERATIVEMENT de l huile min rale IMPERATIVE to use mineral oil Verwenden Sie UNBEDINGT Mineral l Usar IMPERATIVAMENTE de aceite mineral Utilizzare IMPERATIVAMENTE oli olio minerale IMPERATIVE to use MINERAL OIL Recommendation ATF DEXRON Il SHELL _ 164091 234800 n 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 N 234798 Hydraulic Oil 61024 HUILE HYDRAULIQUE Location on the hydraulic tank HYDRAULIC OIL Identifies the hydraulic reservoir tank HYDRAULIK OL ACEITE HIDRAULICO OLIO IDRAULICO N 234799 Anti Freeze 234799 Location on the radiator near the radiator filler cap Indicates required minimum to maximum anti freeze protection 229F to 40 F Diesel Fuel 161
136. ring points Check the following points e Fixing of the anchoring points on the seat e Cleanness of the strap and the locking mechanism e Triggering of the locking mechanism e Condition of the strap cuts curled edges Reeled seat belt with two anchoring points Check the points listed above together with the following points e he correct winding of the belt e Condition of the reel guards e Roller locking mechanism when the strap is given a sharp tug NOTE After an accident replace the seat belt A In no event should the lift truck be used if the seat belt is defective fixing locking cuts tears etc Repair or replace the seat belt immediately E11 FRONT AND REAR WHEELS REDUCERS OIL DRAIN Place the lift truck on level ground with the engine stopped and the reducers oil still warm A Dispose of the drain oil in an ecological manner Drain and change each front wheel reducer Place drain plug 1 fig E11 in position A Place a container under the drain plug and unscrew the plug Let the oil drain fully Place the drain port in position B i e in a level port Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL by level port 1 fig ETT The level is correct when the oil level is flush with the edge of the hole Refit and tighten the drain plug 1 fig E11 tightening torque 34 to 49 N m 25 to 36 Ibf ft Repeat this operation on each rear wheel reducer 3 33 F E
137. rn the steering handwheel at a moderate even rate 42 Use special care when traveling without load as the risk of lateral overturning is greater 43 Improper use of stabilizer controls if so equipped could cause rough terrain forklift truck upset Always lower the carriage before operating stabilizer controls 44 For rough terrain forklift trucks equipped with lateral leveling a Always level the frame before raising the boom or mast with or without a load b Lateral leveling should not be used to position an elevated load instead lower the load and reposition the rough terrain forklift truck 45 Handle only stable or safely arranged loads a When handling off center loads which cannot be centered operate with extra caution b Handle only loads within the capacity of the rough terrain forklift truck c Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity with extra caution Stability and maneuverability may be adversely affected IV ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS cont C OPERATING SAFETY RULES AND PRACTICES cont 46 When attachments are used extra care shall be taken in securing manipulating positioning and 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
138. s abad ee nee uid driving spray Visibility very seriously affected F MAINTENANCE Your platform must be periodically inspected to ensure its continued compliance The inspection frequency is defined by the current legislation in the country in which the platform is used 1 22 INSTRUCTIONS FOR USING THE RADIO CONTROL For lift trucks with RC radio control HOW TO USE THE RADIO CONTROL SAFETY INSTRUCTIONS his radio control consists of electronic and mechanical safety elements It cannot receive commands from another transmitter because the internal encoding is unique to each radio control If it is used improperly or incorrectly there is a risk of danger to The physical and mental health of the user or others The lift truck and other neighbouring items Everyone working with this radio control Must be qualified in line with current regulations and therefore appropriately trained Must follow this instruction manual as closely as possible he system is used to control the lift truck remotely via radio waves Commands are also transmitted if the lift truck is out of sight behind an obstacle or a building for example this is why e After stopping the truck and removing the key button only possible when it is stationary always place the transmitter in a safe dry place e Before performing any installation servicing or repair work always switch off power sources in particular electric welding devices
139. scattered 1 10 12 19 U breeze leaves and twigs white horses Moderate The wind raises dust and scraps of Small waves Fairly frequent white 11 16 5 5 7 9 breeze paper shakes the twigs horses Small waves form on inland waters Fresh breeze 17 21 8 10 7 Leafy shrubs sway Moderate waves many white horses Shakes thick branches metal wires SHORE 22 21 10 8 13 8 hum it becomes difficult to keep an Ma WANG breeze foam crests probably spray umbrella open Sea heaps and white foam blown 1 Near gale 50 61 13 9 17 1 ee in streaks along the direction of the walk against the wind wind Breaks the branches of trees it is Gale 62 74 17 2 20 7 almost impossible to walk against Monetary NEN Waves to break into spindrift the wind High waves Dense foam along Strong gale 41 47 75 88 20 8 24 4 Causes slight damage to buildings the direction of the wind Crests of stacks tiles etc waves begin to roll over Spray may affect visibility Rare inland uproots trees causes Very high waves with long overhanging 48 55 89 102 245 28 4 onsiderable damage to buildings crests Visibility affected _ Exceptionally high waves that aq wen 103 117 very Tale Sales Mene medun sized Shins Visibility storm devastation affected The air is filled with foam and 12 Hurricane 64 118 32 7 Causes very serious catastrophe
140. se files contain the description of the hydraulic controls and the load charts for the attachments used on the lift truck 2 26 20 HEATER CONTROL A HEATING FAN CONTROL This 2 speed control regulates warm or cold air through the heating ventilators In position O the fan is off In position 1 the fan is set to minimum speed In position 2 the fan is set to maximum speed B HEATING TEMPERATURE CONTROL Allows the temperature inside the cab to be adjusted In position 1 the valve is closed the fan delivers fresh air In position 2 the valve is fully open the fan delivers warm air The intermediate positions allow the temperature to be adjusted 21 AIR CONDITIONING CONTROLS OPTION AIR CONDITIONING The air conditioning only comes on when the forklift truck has been started up When using your air conditioning you must work with the doors and windows closed In winter So as to ensure correct operation and complete efficiency of the air conditioning unit start up the compressor once a week if only for a short spell so as to lubricate the internal seals In cold weather Warm the 1 C engine before switching on the compressor so as to allow the coolant that has collected in the liquid state at the lowest point of the compressor circuit to turn into gas under the effect of the heat given off by the 1 C engine as the compressor is liable to be damaged by coolant in the liquid state If your air conditioning does not seem
141. se it and lower the forks 2 into transport position fig G4 1 18 TAKING UP A HIGH LOAD ON STABILIZERS Make sure the forks will fit easily under the load Check the position of the lift truck with respect to the load and make a test run if necessary without taking the load Raise and extend the jib 1 2 until the forks are at the level of the load fig G5 Block the forks in front of the load by alternately using the controls to extend and lower the jib 1 fig G6 Lift the load slightly 1 and tilt the carriage 2 backwards to stabilise the load fig G7 Monitor the longitudinal stability limiter and warning device see INSTRUCTIONS FOR HANDLING A LOAD C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE If it is overloaded set the load down in the place from where it was taken If possible lower the load without moving the lift truck Raise the jib 1 to release the load retract 2 and lower the jib 3 to set the load into transport position fig G8 LAYING A HIGH LOAD ON STABILIZERS Raise and extend the jib 1 2 until the load is above the elevation fig G9 while monitoring the longitudinal stability limiter and warning device see INSTRUCTIONS FOR HANDLING A LOAD C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE Position the load horizontally and release it by lowering and retracting the jib 1 2 to position the load correctly fig G10
142. st be made at the oil temperature of 5O C 19 11 2010 70 02 M173FR Main Hydraulique Schematic 2 MLT 845 120 LSU S rie 4 E3 70 02 M173FR 19 11 2010 A5 MLT 845 120 LSU S rie 4 Euro 3 Main Hydraulique Schematic 1 2 3 4 5 6 7 8 9 10 11 12 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 AAA A 7 MLT845 120K SU VCHAR O PAAV O PAAV VVT O A B L A E M E EU PAAR O 21 13 gt VAI O G AA VC LL E E VC G Y G 77 ar Accessoire L Descente 1 D versement A 2 Levage o al Gicleur 0 8 mm K S Ar a eee Ajout Gicleur I S 19 11 2010 70 02 M173FR P AG Main Hydraulique Schematic MLT 845 120 LSU S rie 4 Euro 3 70 02 M173FR 19 11 2010
143. t 1 and remove the revolving light Protect mounting 2 with cap 3 34 LEVEL INDICATORS A SPIRIT LEVEL Enables the operator to check that the lift truck is in the horizontal position 35 INSIDE REAR VIEW MIRROR 36 STEERING WHEEL ADJUSTMENT LEVER This handle enables the angle and height of the steering wheel to be adjusted Turn handle 1 towards A to loosen and adjust steering wheel Turn handle 1 towards B to lock steering wheel in the position required 37 DIAGNOSTIC SOCKET 2 29 38 EMERGENCY STOP BUTTON In the event of danger it lets you stop the Engine and thereby cut out all hydraulic movements Pull the button to disable it before restarting the lift truck A Be ready for hydraulic movements suddenly stopping when you press this button 2 30 2 31 TOWING PIN AND HOOK Located at the rear of the lift truck this device is used to attach a trailer Its capacity is limited for each lift truck by the authorised gross vehicle weight tractive effort and maximum vertical force on the coupling point This information is given on the manufacturer s plate fixed to each lift truck see 2 DESCRIPTION IDENTIFICATION OF THE LIFT TRUCK To use a trailer see current regulations in your country maximum running speed braking maximum weight of trailer etc Verify the trailer s condition before using it tyre condition and pressures electrical connection hydraulic hose brake system
144. t be increased by 50 96 for turbo engines Open the filler plug spray the protective product around the rocker arm shaft and refit the filler plug Cap the fuel tank using waterproof adhesive tape Remove the drive belts and store them in a safe place Disconnect the engine cut off solenoid on the injection pump and carefully insulate the connection PROTECTING THE LIFT TRUCK Set the lift truck on axle stands so that the tyres are not in contact with the ground and release the handbrake Protect cylinder rods which will not be retracted from corrosion Wrap the tyres NOTE If the lift truck is to be stored outdoors cover it with a waterproof tarpaulin 1 26 BRINGING THE LIFT TRUCK BACK INTO SERVICE Remove the waterproof adhesive tape from all the holes Refit the intake hose Refit and reconnect the battery Remove the protection from the cylinder rods Perform the daily service see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE Put the handbrake on and remove the axle stands Empty and replace the fuel and replace the fuel filter see MAINTENANCE D EVERY 500 HOURS SERVICE Refit and set the tension in the drive belts see 3 MAINTENANCE C EVERY 250 HOURS SERVICE Turn the 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 A Make
145. t people on the platform using the hydraulic controls in the lift truck s driver s cab except in case of rescue he operator must not get in or out of the platform when it is not on ground level jib retracted and in the down position he platform must not be fitted with attachments that increase the unit s wind load Do not use ladders or improvised structures in the platform to gain extra height Do not climb onto the sides of the platform to gain extra height ENVIRONMENT DISTANCE ABOVE THE A NOMINAL VOLTAGE GROUND OR THE FLOOR Operating the platform close to electricity cables is forbidden Maintain the specified IN METRES safe distances 50 lt U lt 1000 2 30 M 1000 lt U lt 30000 2 50 M 30000 lt U lt 45000 2 60 M 45000 lt U lt 63000 63000 lt U lt 90000 90000 lt U lt 150000 150000 lt U lt 225000 225000 lt U lt 400000 1 21 A Operation of the platform is strictly forbidden in the event of wind speeds of over 45 km h The following scale is given for an empiric evaluation of the wind speed BEAUFORT scale wind speed at a height of 10 m from flat ground Speed Speed Speed 0 Cam 0 1 0 1 03 Smoke rises vertically Light air 0 3 1 5 The wind bends the smoke Ripples but without foam crests Light breeze 6 11 1 6 3 3 WNG CAN DE TEE ON Ne tack Small but evident wavelets shakes the leaves Gentle he wind continuously shakes the Large wavelets Perhaps
146. t the lift truck by pushing or towing it Such operation may cause severe damage to the transmission If necessary to tow the lift truck in an emergency the transmission must be placed in the neutral position see 3 MAINTENANCE G OCCASIONAL MAINTENANCE If using an emergency battery for start up use a battery with the same characteristics and respect battery polarity when connecting it Connect at first the positive terminals before the negative terminals Failure to respect polarity between batteries can cause serious damage to the electrical circuit The electrolyte in the battery may produce an explosive gas Avoid flames and generation of sparks close to the batteries Never disconnect a battery while it is charging INSTRUCTIONS Check the closing and locking of the hood s Check that the cab door is closed Check that the forward reverse selector is in neutral Turn the ignition key to the position to activate the electrical system and the preheat Whenever you switch on the lift truck perform the automatic check on the longitudinal stability limiter and warning device system see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Do not use the lift truck if it does not conform to the regulations Check the fuel level on the indicator Turn the ignition key fully the engine should then start Release the ignition key and let the engine run at idle Do not engage the starter motor for more than 15 seco
147. t truck normally AS White red zone 212 F 221 F 100 105 C Use lift truck with moderation monitor the temperature A4 Red zone 221 F 248 F 221 248 C Stop the lift truck look for the cause of overheating NOTE Red indicator light F comes on between zone and A4 B RED ENGINE FAULT INDICATOR LIGHT If the lamp comes on or flashes when the lift truck is running stop the engine immediately and consult your dealer C ORANGE ENGINE FAULT INDICATOR LIGHT If the lamp comes on or flashes while the lift truck is in operation a diagnostic fault has been detected The lift truck will operate in reduced mode Consult your dealer without delay D ORANGE I C ENGINE PREHEATING INDICATOR LIGHT Preheating is necessary When the lift truck is switched on the lamp comes on for 2 seconds and off as soon as preheating is ended Start the lift truck s 1 C engine E RED 1 C ENGINE OIL PRESSURE INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the engine immediately and look for the cause see oil level in I C engine crankcase F RED 1 C ENGINE WATER TEMPERATURE INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the engine immediately and investigate the cooling circuit for the cause of the malfunction G RED GEAR BOX OIL PRESSURE INDICATOR LIGHT This lamp and buzzer come on when there is an abnormal drop in g
148. tate of the road permit it e With a trailer on the road Set off in 2nd gear and switch to 3rd if the conditions and state of the road permit it e Handling 3rd gear 2nd gear in restricted spaces e Earth moving 1st gear e Loading reclaiming with bucket manure fork etc 2nd gear 2 24 16 FORWARD NEUTRAL REVERSE GEAR SELECTION FORWARD Push the knob forward position A REVERSE Pull the knob backwards position B NEUTRAL The knob must be in the intermediate position to start the lift truck position C When operating this control the lift truck should be travelling at slow speed and not accelerating NOTE The reverse lights indicate that the lift truck is running in reverse motion An OPTIONAL audible reversing alarm can also be fitted SAFETY FOR MOVING THE LIFT TRUCK Authorization to move the lift truck is controlled by an electronic unit The operator must observe the following sequence to move the truck forwards or backwards 1 sit down correctly in the driver s seat 2 release the parking brake 3 engage forward or reverse movement To stop the lift truck he must observe the following sequence 1 set the forward reverse selector to neutral 2 engage the parking brake 3 get out of the lift truck NOTE If the operator leaves the driving cab with forward or reverse engaged a continuous alarm will sound While this alarm sounds the operator can simply sit back in the seat and continue advancing
149. ted to have arms or legs or generally any part of the body protruding from the basket Ensure that any materials loaded onto the platform pipes cables containers etc cannot fall out Do not pile these materials to the point where it is necessary to step over them D USING THE PLATFORM However experienced they may be operators must acquaint themselves with the emplacement and operation of all control instruments prior to operating the platform Check before operating that the platform has been correctly assembled and locked onto the lift truck Check before operating the platform that the access gate has been properly locked he platform should be operated in an area free of any obstructions or danger when it is lowered to the ground he operator using the platform must be aided on the ground by a person with adequate training You should stay within the limits set out in the platform load chart The lateral stresses are limited pressure see 2 DESCRIPTION CHARACTERISTICS t is strictly forbidden to hand a load from the platform or the lift truck jib without a specially designed attachment see INSTRUCTIONS FOR HANDLING A LOAD H TAKING UP AND LAYING DOWN A SUSPENDED LOAD he platform cannot be used as a crane or a lift for permanently transporting people or materials nor as jacks or supports The lift truck must not be moved with one or more person s in the platform t is forbidden to transpor
150. ten turning it 5 times Tighten the lock nut 2 fig C1 1 and C1 2 Retighten screw 1 fig C1 1 on the tension pulley When changing the fanbelt tighten screw 3 fig C1 1 and C1 2 by one and a half turns having allowed the 1 C engine to idle for 30 minutes C2 ALTERNATOR CRANKSHAFT BELT TENSION CHECK ADJUST For this operation we advise you to use the MANITOU tension meter fig C2 1 reference 167418 Open the engine bonnet Unscrew the fastening screws 1 fig C2 2 Lay down the protective guard 2 fig C2 2 Checkthe belt for signs of wear and cracks and change if necessary see 3 MAINTENANCE FILTERS CARTRIDGES AND BELTS Check the belt tension between the pulleys of the crankshaft and of the alternator NEW BELT At a pressure of 15 N 0 4 on strap 3 fig C2 3 the displacement must be about 3 7 mm BELT AFTER 20 HOURS OF OPERATION At a pressure of 13 N 0 4 on strap 3 fig C2 3 the displacement must be about 3 7 mm Carry out adjustments if necessary Untighten screws 4 fig C2 3 by two to three thread turns Swivel the alternator assembly so as to obtain the belt tension required Retighten screws 4 fig C2 3 tightening torque 22 N m Put the protective guard back 2 fig C2 2 A If the alternator belt has to be changed check the tension again after the first 20 hours of operation 3 22 Ea h k Hu C3 COMPRESSOR BELT
151. ter cartridge by washing it in liquid Do not clean by any means the safety cartridge located inside the filter cartridge change it for a new one if it is clogged or damaged B2 RADIATOR CORES CLEAN In a polluting atmosphere clean the radiator cores every day Do not use a water jet or high pressure steam as this could damage the radiator fins Open the engine bonnet If necessary clean the suction grid on the engine hood Using a soft cloth clean the radiator cores in order to remove as much dirt as possible Undo the screw 1 fig B2 1 of the fuel radiator and pivot for easier cleaning Clean the cores using a compressed air jet aimed in the same direction as the cooling air flow fig B2 1 Clean with the fan running for best results NOTE An OPTIONAL straw defector and self cleaning fan can also be fitted M D E B3 CONDENSER CORE OPTION AIR CONDITIONING CHECK CLEAN In a polluting atmosphere clean the radiator core every day Do not use a water jet or high pressure steam as this could damage the condenser fins Visually check whether the condenser fig B3 is clean and clean it if necessary Clean the condenser using a compressed air jet aimed in the same direction as the air flow NOTE So as to enhance the cleaning carry out this operation with the fans running 3 16 B4 TRANSMISSION UNIVERSAL JOINT GREASE Clean and lubricate the following points with
152. the front axle then on the right hand side fig G3 1 Unscrew locknuts 1 fig G3 2 by approximately 8 mm Alternately tighten the screws 2 fig G3 2 by a 1 4 turn at a time up to a maximum of 1 turn in order to free the brake discs If the I C engine is not running there will be no steering or braking assistance Operate the steering and pedal slowly avoiding sudden jerky movements Once this operation is completed adjust the parking brake ADJUSTING THE PARKING BRAKE First perform this operation on the left hand side fig G3 1 of the front axle then on the right hand side fig G3 1 Completely unscrew screws 2 fig G3 2 by alternately unscrewing them a 1 4 turn at a time Grease the threads with a silicone lubricant MANITOU reference 479292 Retighten the screws 2 fig G3 2 to obtain a dimension of 30 mm fig G3 2 Lock the locknuts 1 fig G3 2 while holding the screw 2 fig G3 2 in position 3 37 G4 FRONT HEADLAMPS ADJUST RECOMMENDED SETTING as per standard ECE 76 756 76 761 ECE20 Set to 2 of the dipped beam in relation to the horizontal line of the headlamp ADJUSTING PROCEDURE Place the lift truck unloaded and in the transport position and perpendicular to a white wall on flat level ground fig G4 Check the tire pressures see 2 DESCRIPTION FRONT AND REAR TIRES Put the gearshift lever into neutral Calculating the height of the dipped bea
153. the fabric on a small hidden area before using any fabric or plastic cleaner SS y 2 9 m x 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 Agjust the seat belt to your body shape without squeezing your hip and without over slack A In no event should the lift truck be used if the seat belt is defective fixing locking cuts tears etc Repair or replace the seat belt immediately 2 17 3 CONTROL AND SIGNAL LIGHTS PANEL IE A permanently lit or flashing warning lamp with the engine running is the sign of an operating fault The lighting of some lamps may be accompanied by an audible signal Do not ignore this warning consult your dealer without delay If one of the warning lamps comes on while the lift truck is in motion stop the lift truck under the safest possible conditions When activating the electrical system of the lift truck all the red and orange lamps and the panel s buzzer must light to indicate their good working order If one of the red lamps or the buzzer does not function carry out the necessary repairs A 1 C ENGINE WATER TEMPERATURE Temperature zone 1 Blue zone 0 122 F O 50 C Use the lift truck with moderation wait for temperature to increase before normal operation A2 Green zone 122 F 212 F 50 100 C Use lif
154. tion we advise you to use the hydraulic jack MANITOU reference 505507 and the safety support MANITOU reference 554772 Stop the lift truck if possible on even and hard ground To pass on stop of lift truck see 1 OPERATING AND SAFETY INSTRUCTIONS DRIVING INSTRUCTIONS UNLADEN AND LADEN Put the warning lights on Immobilise the lift truck in both directions on the axle opposite to the wheel to be changed Unlock the nuts of the wheel to be changed Place the jack under the flared axle tube as near as possible to the wheel and adjust the jack 1 fig G2 Lift the wheel until it comes off the ground and put in place the safety support 2 under the axle fig G2 Completely unscrew the wheel nuts and remove them Free the wheel by reciprocating movements and roll it to the side Slip the new wheel on the wheel hub Refit the nuts by hand if necessary grease them Remove the safety support and lower the lift truck with the jack Tighten the wheel nuts with a torque wrench see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE for tightening torque G3 PARKING BRAKE UNBLOCKING This procedure is to be performed in the event of parking brake malfunction If the lift truck is not on a horizontal ground to fix so that it does not descend the slope MANUALLY UNBLOCKING THE PARKING BRAKE First perform this operation on the left hand side fig G3 1 of
155. to be working properly have it examined by your dealer see 3 MAINTENANCE F EVERY 2000 HOURS OF SERVICE Never try to repair any possible problems by yourself C CONDITIONED AIR TEMPERATURE CONTROL Allows the temperature inside the cab to be adjusted In position O the air conditioning system is switched off In position 1 the air conditioning system runs on minimum In position 2 the air conditioning system runs on maximum The intermediate positions allow the temperature to be adjusted NOTE Possible losses of water under the lift truck are due to condensate discharges caused by the drying effect of the installation especially with high outside temperatures and high relative humidity For the air conditioning to perform properly the air intakes must not be blocked by frost snow or leaves When the facility is running at least one of the cab air grilles must be open so as to avoid any risk of freezing to the evaporator CONDITIONED AIR MODE The controls must be adjusted in the following way A At the required position 1 or 2 B At the position 1 heater valve closed C At the required temperature DEMISTING MODE The controls must be adjusted in the following way A At the required position 1 or 2 B At the required temperature C At the required temperature 2 21 22 RECYCLING INTAKES AIR CONDITIONING OPTION 23 WINDSCREEN DEMISTER VENTS For optimum effectiveness close the heating v
156. top Allow the pressure and the steam to escape Press down and turn the cap so as to release it Add cooling liquid via filler port 3 fig A2 up to the middle of gauge 1 fig A2 Lubricate slightly the filler neck in order to facilitate the setting and the removal of the radiator cap Check visually that there is no leakage in the radiator and pipes To avoid any risk of spraying or burning wait until the 1 C engine has cooled down before removing the cooling circuit filler plug If the cooling liquid is very hot add only hot cooling liquid 80 C In an emergency you can use water as a cooling liquid then change the cooling circuit liquid as soon as possible see 3 MAINTENANCE F1 COOLING LIQUID A3 FUEL LEVEL CHECK Keep the fuel tank full to reduce as much as possible any condensation due to the atmospheric conditions Open the access panel for hydraulic oil filling Remove cap 1 fig A3 Fill the fuel tank with clean fuel see 3 MAINTENANCE LUBRICANTS AND FUEL filtered through a strainer or a clean lint free cloth through filler port 2 fig A3 Put back the cap 1 fig A3 and close the fuel filler access panel Check visually that there is no leakage in the tank and pipes Never smoke or approach with a flame during filling operations or when the tank is open Never refill while engine is running A The fuel tank is degassed via the filler plug When changing it al
157. track of a railway In the event of prolonged parking on a site protect the lift truck from bad weather particularly from frost check the level of antifreeze close and lock all the lift truck accesses doors windows cowls INSTRUCTIONS Park the lift truck on flat ground or on an incline lower than 15 96 Set the forward reverse selector to neutral Apply the parking brake For lift trucks with gearboxes place the gear lever in neutral Retract entirely the jib Lower the forks or attachment to rest on the ground When using an attachment with a grab or jaws or a bucket with hydraulic opening close the attachment fully Before stopping the lift truck after a long working period leave the engine idling for a few moments to allow the coolant liquid and oil to lower the temperature of the engine and transmission Do not forget this precaution in the event of frequent stops or warm stalling of the I C engine or else the temperature of certain parts will rise significantly due to the stopping of the cooling system with the risk of badly damaging such parts Stop the I C engine with the ignition switch Remove the ignition key Lock all the accesses to the lift truck doors windows cowls 1 11 H DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY or see current legislation in other countries SAFETY INSTRUCTIONS Operators driving on the public highway must comply with current hig
158. ude must be set with the jib in down position as follows 1 LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TYRES Position the lift truck so that the bubble in the level is between the two lines see 2 DESCRIPTION INSTRUMENTS AND CONTROLS 2 LIFT TRUCK WITH SLOPE CORRECTOR USED ON TYRES Correct the slope using the hydraulic control and verify the horizontality via the level The bubble in the level must be between the two lines see 2 DESCRIPTION INSTRUMENTS AND CONTROLS 3 LIFT TRUCK USED ON STABILIZERS Set the two stabilizers on the ground and raise the two front wheels of the lift truck fig D1 Correct the slope using the stabilizers fig D2 and make sure the truck is horizontal by checking the level The bubble of the level must be between the two lines see 2 DESCRIPTION INSTRUMENTS AND CONTROLS In this position the two front wheels must be off the ground E TAKING UP A LOAD ON THE GROUND Approach the lift truck perpendicular to the load with the jib retracted and the forks in a horizontal position fig E1 Adjust the fork spread and centering in connection with the load fig E2 optional solutions exist consult your dealer Never lift a load with a single fork A Beware of the risks of trapping or squashing limbs when manually adjusting the forks Move the lift truck forward slowly 1 and bring the forks to stop in front of the load fig ES if necessary slightly lift the jib
159. unuam Cmm oum poorno mem 2 EEE TS ee mem oum pexmawaw se Loo oum omamo o ome meme o oum E ose oue ETA E ose oue ssmecwoemeswssovuw Lom oue soos osme oue ETT ome xe Lom oue wan ome xem ema ome xm wasa omm xum wem DISTRB x250 SENSORB DISTRIBACCESSORY SENSOR B DISTRIB ACCESSORY e REVERSE HARNESS SECURITY UNIT TIRE ALIGNEMENT STANDARD X315 DIAGNOSTIC OUTLET 00000000000 DIAGNOSTIC OUTLET STANDARD X316 DIAGNOSTIC OUTLET CALCULATOR SPU DIAGNOSTIC OUTLET CALCULATOR SPU au A sew xus mem Je MEA fe uum ETE E gt N N O gt UJ A N N He H N PA O N O N STANDARD X324 5 PR DISPO POWER WORK LIGHTS STANDARD X321 MAIN BRAKE VALVE NEGATIVE 00000000 MAIN BRAKE VALVE NEGATIVE on Da a CIN E MOTOR STANDARD x329 OPTIONWORKINGLIGHTS JIB OPTION WORKING LIGHTS JIB al aM smono rntonrorowenansenr s METIO oum Tworoneomeenon CIC smono ome enmumawwonr e smono or enmmmawwoee 108 Cw us 80 02 M173FR 18 10 2010 00 UJ A7 MLT 845 120 LSU S rie 4 Euro 3 Main Electrical Sc
160. vehicle LOAD THE LIFT TRUCK Block the wheels of the platform Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck Load the lift truck parallel to the platform Stopthe lifttruck see 1 OPERATING AND SAFETY INSTRUCTIONS DRIVING INSTRUCTIONS UNLADEN AND LADEN STOW THE LIFT TRUCK Fix the chocks to the platform at the front and at the back of each tyre fig 67 1 Fix also the chocks to the platform in the inside of each tyre fig G 7 2 Secure the lift truck to the platform with sufficiently strong ropes At the front of the lift truck attach the ropes to the fastening points fig G 3 and at the rear to the towing pin 2 fig G7 4 Tighten the ropes fig G 7 5 3 39 LL OO A 3 40 4 ATTACHMENTS 4 2 INTRODUCTION Your lift truck must be used with interchangeable equipment These items are called ATTACHMENTS A wide range of attachments specially designed and perfectly suitable for your lift truck is available and guaranteed by MANITOU he attachments are delivered with a load chart concerning your lift truck The operator s manual and the load chart should be kept in the places provided in the lift truck For standard attachments their use is governed by the instructions contained on this notice Some particular uses require the adaptation of the attachment which is not provided in the price listed options Optional soluti
161. ving the lift truck forward 2 fig F2 Put the handbrake on and set the forward reverse selector to neutral Slightly lift the load 1 and incline the carriage 2 backwards to stabilize the load fig F3 Tilt the load sufficiently backwards to ensure its stability Watch the longitudinal stability limiter and warning device see INSTRUCTIONS FOR HANDLING A LOAD C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE If it is overloaded replace the load in the place from which it was taken If possible lower the load without shifting the lift truck Lift the jib 1 to release the load retract 2 and lower the jib 3 to bring the load into the transport position fig F4 If this is not possible back up the lift truck 1 manoeuvring very gently and carefully to release the load Retract 2 and lower the jib 3 to bring the load into the transport position fig F5 1 16 LAYING A HIGH LOAD ON TYRES Approach the load in the transport position in front of the pile fig F6 Put the handbrake on and set the forward reverse selector to neutral Lift and extend the jib 1 2 until the load is above the pile while keeping an eye on the longitudinal stability limiter and warning device see INSTRUCTIONS FOR HANDLING A LOAD C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE If necessary move the lift truck 3 forward fig F7 driving very slowly and carefully Place the load in a horizont
162. ways use an original part with degassing hole 3 12 A4 FUEL PRE FILTER Open the engine bonnet Check for the presence of water in the pre filter bowl 1 fig A4 and empty it out if necessary HIHHHHI Place a receptacle under the drain plug 2 fig A4 and loosen it in two to three thread II turns Allow the diesel fuel to flow out until it is free from impurities and water Tighten the drain plug Pressurise the circuit with the hand pump 3 fig A4 A5 CYCLONIC PREFILTER CLEAN The cleaning interval is given as a guide however the pre filter must be emptied as soon as impurities reach the MAXI level on the tank Loosen nut 1 fig A5 remove cover 2 fig A5 and empty the tank Clean the pre filter unit with a clean dry cloth and reassemble the unit A When cleaning take care not to let impurities into the dry air filter A6 GEAR BOX OIL LEVEL CHECK Park the lift truck on level ground with the jib raised the engine cold and stopped Carry out the control within 5 minutes of the engine being stopped Remove the plastic cap 1 fig AG Remove the dipstick 2 fig AG Wipe the dipstick and check the correct level between the two MIN and MAX marks If necessary add oil see 3 MAINTENANCE ES3 GEAR BOX OIL Check visually that there is no leakage or seepage of oil in the transmission A7 TYRES PRESSURE AND WHEEL NUTS TORQUE CHECK
163. 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 s

MLT 845 120 LSU S4 - E3 Operator Manual

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