Manitou MSI 50D Rough Terrain Forklift Operator/Service Manual

SAFETY FIRST
CONTENTS
MANITOU NORTH AMERICA, INC.
6401 IMPERIAL DRIVE
Waco, TX 76712--6803
For Parts Orders contact your Manitou North America Dealer or call:
Manitou North America, Parts Dept. 800--425--3727 or (254) 799--0232
Parts Dept. Fax: (254) 867--6504
Website: www.manitou--na.com
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.
MSI 50D
OPERATOR/SERVICE
MANUAL
THIS OPERATOR’S MANUAL MUST BE KEPT IN THE LIFT TRUCK. IT MUST BE READ AND
UNDERSTOOD BY THE LIFT TRUCK OPERATOR.
CATALOG 47974AS
R11-10
SAFETY FIRST
CONTENTS
SAFETY FIRST
CONTENTS
- INTRODUCTION TO SAFETY -
- ROUGH TERRAIN FORKLIFT TRUCK
GENERAL SAFETY STANDARDS - - - I
- SAFTETY MESSAGES - - - - - - - - - - - - - - - - - - - - - - - - - - VII
- SAFETY DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII
- TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - - - XV
R03-04
SAFETY FIRST
CONTENTS
SAFETY FIRST
CONTENTS
ROUGH TERRAIN FORKLIFT TRUCK
GENERAL SAFETY STANDARDS
I
SAFETY FIRST
CONTENTS
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS
STUDY THE OPERATOR/SERVICE MANUALS
The information in this manual provides general instructions for the safe operation and maintenance of your
forklift truck. This information is vital and must be clearly understood by the operator and serviceman. Study
this manual and the Rough Terrain Forklift Safety Manual (part no. 422494) thoroughly and carefully before
operating or servicing your forklift. Contact your dealer or Manitou North America, Inc. if you have any questions concerning your forklift, its operation, service or parts. Keep both manuals in the literature box on the
forklift available for reference. If either manual becomes illegible or is missing, contact your dealer for replacements immediately. This manual cannot cover every situation that might result in an accident. It is the responsibility of the operator to always remain alert for potential hazards and be prepared to avoid them!
ADDITIONAL RECOMMENDED LITERATURE:
ANSI / ITSDF B56.6 is the national consensus standard for rough terrain forklift trucks. It contains rules about
forklift safety, maintenance, safe operation, training, and supervision. Forklift owners should learn this standard and make it available for their operators, service personnel, and supervisors. These standards can be
obtained, free of charge, from the Industrial Truck Standards Development Foundation (ITSDF) on their website at www.itsdf.org. The following references are examples from the standard, addressing forklift operators:
A.) OPERATOR TRAINING QUALIFICATIONS
1.) The user shall ensure that operators understand that safe operation is the 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 conditions, and rough terrain forklift trucks. The program should be presented completely to all new operators and
not be condensed for those claiming previous experience.
3.) Information on operator training is available from several sources, including rough terrain forklift truck manufacturers, users, government agencies, etc.
4.) An operator training program should consist of the following:
a.) careful selection of the operator, considering physical qualifications, job attitude, and aptitude;
b.) emphasis on safety of stock, equipment, operator, and other personnel;
c.) citing of rules and why they were formulated;
d.) basic fundamentals of rough terrain forklift truck and component design as related to safety, e.g.,
in.-lb (N-m) loading, mechanical limitations, center of gravity, stability, etc.;
e.) introduction to equipment, control locations, and functions. Explain how they work when used
properly and problems when used improperly.
f.) supervise practice on operating course remote from normal activity and designed to simulate
actual operations, e.g., lumber stacking, elevating shingles to the roof, etc.;
g.) oral, written, and operational performance tests and evaluations during and at completion of the
course;
h.) refresher courses, which may be condensed versions of the primary
course, and periodic “on job” operator evaluation;
i.) understanding of nameplate data and operator instructions and warning information appearing on
the rough terrain forklift truck.
B.) GENERAL SAFETY PRACTICES
1.) Rough terrain forklift trucks can cause injury if improperly used or maintained.
2.) Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to operate rough terrain forklift trucks. Unusual operating conditions may require additional safety precautions, training, and special operating instructions.
3.) Modifications and additions which affect capacity or safe operation shall not be preformed without the manufacturer’s prior written approval. Where such authorization is granted, capacity, operation, and maintenance
instruction plates, tags, or decals shall be changed accordingly.
4.) If the rough terrain forklift truck is equipped with front end attachment(s) or optional forks, the user shall see
that the truck is marked to identify the forks or attachment(s), show the approximate weight of the truck and
fork or attachment combination, and show the capacity of the truck with forks or attachment(s) at maximum
elevation with load laterally centered.
5.) The user shall see that all nameplates and caution and instruction markings are in place and legible.
6.) The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity.
II
SAFETY FIRST
CONTENTS
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
B.) GENERAL SAFETY PRACTICES (cont.)
7.) Where steering can be accomplished with either hand and the steering mechanism is of a type that prevents road reactions from causing the handwheel to spin (power steering or equivalent), steering knobs may
be used. When used, steering knobs shall be of a type that can be engaged by the operator’s hand from the
top and shall be within the periphery of the steering handwheel.
8.) Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable
when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the requirements.
9.) Users shall give consideration to special operating conditions. The amount of forward and rearward tilt to
be used is governed by the application. Although the use of maximum rearward tilt is allowable under certain
conditions, such as traveling with the load lowered, the stability of a rough terrain forklift truck as determined
by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation
of trucks with excessive off-center loads.
10.) Some of the conditions which may affect stability are ground and floor conditions, grade, speed, loading
(rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operated
without a load on the attachment), dynamic and static forces, improper tire inflation, and the judgement exercised by the operator.
C.) OPERATING SAFETY RULES AND PRACTICES
1.) Safe operation is the responsibility of the operator.
2.) This equipment can be dangerous if not used properly. The operator shall develop safe working habits and
also be aware of hazardous conditions in order to protect himself, other personnel, the rough terrain forklift
truck, and other material.
3.) The operator shall be familiar with the operation and function of all controls and instruments before undertaking to operate the rough terrain forklift truck.
4.) Before operating any rough terrain forklift truck, truck operators shall have read and be familiar with the
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 attachments.
10.) Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury
to personnel.
11.) Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck, whether
empty or loaded.
12.) Do not permit passengers to ride on rough terrain forklift trucks.
13.) Check clearance carefully before driving under electrical lines, bridges, etc.
14.) A rough terrain forklift truck is attended when the operator is less than 25 ft (7.6m) from the truck, which
remains in his view.
15.) A rough terrain forklift truck is unattended when the operator is 25ft (7.6m) or more from the truck, which
remains in his view, or whenever the operator leaves the truck and it is not in his view.
16.) Before leaving the operator’s position:
a.) bring rough terrain forklift truck to a complete stop;
b.) place directional controls in neutral;
c.) apply the parking brake;
d.) lower load-engaging means fully, unless supporting an occupied elevated platform;
e.) stop the engine;
f.) if the rough terrain forklift truck must be left on an incline, block the wheels;
g.) fully lower the load-engaging means.
17.) Maintain a safe distance from the edge of ramps, platforms, and other similar working surfaces.
18.) Do no move railroad cars or trailer with a rough terrain forklift truck.
III
SAFETY FIRST
CONTENTS
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
C.) OPERATING SAFETY RULES AND PRACTICES (cont.)
19.) Do not use a rough terrain forklift truck for opening or closing railroad car doors.
20.) In areas classified as hazardous, use only rough terrain forklift trucks approved for use in those areas.
21.) Report all accidents involving personnel, building structures, and equipment to the supervisor or as
directed.
22.) Do not add to, or modify, the rough terrain forklift truck.
23.) Do not block access to fire aisles, stairways, and fire equipment.
24.) For rough terrain forklift trucks equipped with a differential lock, the lock should not be engaged when driving on the road or at high speeds or when turning. If the lock is engaged when turning, there could be loss of
steering control.
25.) Observe all traffic regulations including authorized speed limits. Under normal traffic conditions, keep to
the right, maintain a safe distance, based on speed of travel, from the truck ahead; and keep the truck under
control at all times.
26.) Yield the right-of-way to pedestrians and emergency vehicles such as ambulances and fire trucks.
27.) Do not pass another truck traveling in the same direction at intersections, blind spots, or at other dangerous locations.
28.) Slow down and sound the audible warning device(s) at cross-aisles and other locations where vision is
obstructed.
29.) Cross railroad tracks at an angle wherever possible. Do not park closer than 6 ft (1.8m) to the nearest rail
of a railroad track.
30.) Keep a clear view of the path of travel and observe other traffic, personnel, and safe clearances.
31.) If the load being carried obstructs forward view, travel with the load trailing.
32.) Ascend or descend grades slowly and with caution.
a.) When ascending or descending grades in excess of 5%, loaded rough terrain forklift trucks
should be driven with the load upgrade.
b.) Unloaded rough terrain forklift trucks should be operated on all grades with the load-engaging
means downgrade.
c.) On all grades, the load and load-engaging means shall be tilted back, if applicable, and raised
only as far as necessary to clear the road surface.
d.) Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines; normally
travel straight up or down.
33.) Under all travel conditions, operate the rough terrain forklift truck at a speed that will permit it to be brought
to a stop in a safe manner.
34.) Travel with load-engaging means or load low and, where possible, tilted back. Do not elevate the load
except during stacking.
35.) Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift load and/or overturn
the rough terrain forklift truck.
36.) Do not indulge in stunt driving or horseplay.
37.) Slow down for wet and slippery surfaces.
38.) Before driving over a dockboard or bridge plate, be sure that it is properly secured. Drive carefully and
slowly across the dockboard or bridge plate, and never exceed its rated capacity.
39.) Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so.
Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off engine, and set brakes. It is advisable that all other personnel leave the
elevator before truck is allowed to enter or leave.
40.) Avoid running over loose objects on the roadway surface.
41.) When negotiating turns, reduce speed to a safe level, and turn steering handwheel in a smooth sweeping
motion. Except when maneuvering at a very low speed, turn the steering handwheel at a moderate, even rate.
42.) Use special care when traveling without load, as the risk of lateral overturning is greater.
43.) Improper use of stabilizer controls (if so equipped) could cause rough terrain forklift truck upset. Always
lower the carriage before operating stabilizer controls.
44.) For rough terrain forklift trucks equipped with lateral leveling:
a.) Always level the frame before raising the boom or mast, with or without a load.
b.) Lateral leveling should not be used to position an elevated load; instead, lower the load and
reposition the rough terrain forklift truck.
45.) Handle only stable or safely arranged loads.
a.) When handling off-center loads which cannot be centered, operate with extra caution.
b.) Handle only loads within the capacity of the rough terrain forklift truck.
c.) Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity
with extra caution. Stability and maneuverability may be adversely affected.
IV
SAFETY FIRST
CONTENTS
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
C.) OPERATING SAFETY RULES AND PRACTICES (cont.)
46.) When attachments are used, extra care shall be taken in securing, manipulating, positioning, and transporting the load. Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks
when not handling a load.
47.) Completely engage the load with the load-engaging means. Fork length should be at least two-thirds of
load length. Where tilt is provided, carefully tilt the load backward to stabilize the load. Caution should be used
in tilting backward with high or segmented loads.
48.) Use extreme care when tilting load forward or backward, particularly when high tiering. Do not tilt forward
with load-engaging means elevated except to pick up or deposit a load over a rack or stack. When stacking
or tiering, use only enough backward tilt to stabilize the load.
49.) The handling of suspended loads by means of a crane arm (boom) or other device can introduce dynamic forces affecting the stability of a rough terrain forklift truck. Grades and sudden starts, stops, and turns can
cause the load to swing and create a hazard if not externally stabilized. When handling suspended loads:
a.) do not exceed the truck manufacturer’s capacity of the rough terrain forklift truck as equipped
for handling suspended loads.
b.) only lift the load vertically and never drag it horizontally;
c.) transport the load with the bottom of the load and the mast as low as possible;
d.) with load elevated, maneuver the rough terrain forklift truck slowly and cautiously, and only to
the extent necessary to permit lowering to the transport position;
e.) use tag lines to restrain load swing whenever possible.
50.) At the beginning of each shift and before operating the rough terrain forklift truck, check its condition,
giving special attention to:
a.) tires and their inflation pressure
b.) warning devices
c.) lights
d.) lift and tilt systems, load-engaging means, chains, cables, and limit switches
e.) brakes
f.) steering mechanism
g.) fuel system(s)
51.) If the rough terrain forklift truck is found to be in need of repair or in any way unsafe, or if it contributes to
an unsafe condition, the matter shall be reported immediately to the user’s designated authority, and the truck
shall not be operated until it has been restored to safe operating condition.
52.) If during operation the rough terrain forklift truck becomes unsafe in any way, the matter shall be reported
immediately to the user’s designated authority, and the truck shall not be operated until it has been restored to
safe operating condition.
53.) Do not make repairs or adjustments unless specifically authorized to do so.
54.) When refueling, smoking in the area shall not be permitted, the engine shall be stopped, and the operator shall not be on the rough terrain forklift
truck.
55.) Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced
before restarting engine.
56.) Do not use open flames when checking electrolyte level in storage batteries, liquid level in fuel tanks, or
the condition of LPG fuel lines and connectors.
57.) Do not lift personnel with the forklift. If the forklift must be used to lift people, precautions for the protection of the personnel must be taken (see ITSDF B56.6, chapter 5.15 Elevating Personnel).
V
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
D.) SUSPENDED LOADS
A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame
is level. Transporting suspended loads must ALWAYS be done slowly and cautiously, with the boom and load
as low as possible. Use taglines to restrict loads from swinging, to avoid overturn.
The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic
forces affecting the stability of the machine that are not considered in the stability criteria of industry test
standards. Grades and sudden starts, stops and turns can cause the load to swing and create a hazard.
Guidelines for “Free Rigging / Suspended Loads”
1.
DO NOT exceed the rated capacity of the telescopic handler as equipped for handling suspended
loads. The weight of the rigging must be included as part of the load.
2.
During transport, DO NOT raise the load more than 12 inches (305 mm) above the ground, or raise
the boom more than 45 degrees.
3.
Only lift the load vertically – NEVER drag it horizontally.
4.
Use multiple pickup points on the load when possible. Use taglines to restrain the load from swinging
and rotating.
5.
Start, travel, turn and stop SLOWLY to prevent the load from swinging. DO NOT exceed walking
speed.
6.
Inspect rigging before use. Rigging must be in good condition and in the U.S. comply with OSHA
regulation §1910.184, “Slings,” or §1926.251, “Rigging equipment for material handling.”
7.
Rigging equipment attached to the forks must be secured such that it cannot move either sideways or
fore and aft. The load center must not exceed 24 inches (610 mm).
8.
DO NOT lift the load with anyone on the load, rigging or lift equipment, and NEVER lift the load over
personnel.
9.
Beware of the wind, which can cause suspended loads to swing, even with taglines.
10.
DO NOT attempt to use frame-leveling to compensate for load swing.
WARNING
U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in
Construction) include requirements for employers that use powered industrial trucks ("forklifts") configured
to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation
applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a
hook (with or without a winch), or a hook assembly attached to the forks. [Note: This regulation is in
addition to the OSHA regulation that requires specific forklift operator training: §1910.178(l).]
When a forklift / telescopic handler is configured and used for hoisting, the employer must ensure that:
1.
Forklift, lift equipment and rigging have been inspected (each shift, month and year) and are in
good, safe condition and properly installed.
2.
An operator's manual and applicable load charts are on the forklift.
3.
Work zone ground conditions can support the equipment and load. Any hazardous conditions in the
work area have been identified, and the operator notified.
4.
Equipment is being used within its rated capacity and in accordance with the manufacturer's
instructions.
VI
5.
Operator and crew members have been trained in the safe use and operation of the equipment,
including how to avoid electrocution.
6.
During use, no part of the equipment, load line or load will be within the minimum clearance
distance specified by OSHA [10 feet (3.0 m), and more for lines rated over 50 kV] of any energized
power line, and any taglines used are non-conductive.
7.
In addition, for lift equipment with a rated capacity greater than 2000 lbs. (907 kg), the employer
must ensure that:
a.) An accessible fire extinguisher is on the forklift;
b.) Monthly and annual inspections are performed and documented, and records retained (three
months for monthly, one year for annual);
c.) Before November 10, 2014, operators must have had the additional training and qualification /
certification required by OSHA regulations §1926.1427 and §1926.1430.
Note: Refer to the full text of the OSHA crane regulation (29 CFR Part 1926, Subpart CC) for a detailed
description
VII
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
CONCLUSION:
1.) ATTEND OPERATOR TRAINING CLASSES
The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all
safety rules and regulations of the work site. They must have successfully completed a training coarse in
accordance with the Powered Industrial Truck Standard (29 CFR 1910.178) as described by the Occupational
Safety and Health Administration (OSHA). They must be qualified as to their visual, hearing, physical, and
mental ability to operate the equipment safely. NEVER use drugs or alcohol while operating a forklift! NEVER
operate or allow anyone to operate a forklift when mental alertness or coordination is impaired! An operator
on prescription or over-the-counter drugs must consult a medical professional regarding any side effects of the
medication that may impair their ability to safely operate the forklift.
2.) CREATE A MAINTENANCE PROGRAM
OSHA recommends a maintenance log, listing repairs requested and completed, for each forklift. Also, “lock
out tag procedures” should be utilized. If the forklift malfunctions; park it safely, remove the key, tag “Do Not
Use”, and report the problem to the proper authority or authorized service personnel immediately.
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
2.) CREATE A MAINTENANCE PROGRAM (cont.)
For the best forklift performance and operation, a maintenance program is required. Use the hour meter on
the instrument panel to keep maintenance properly scheduled (see SECTION TWO - “Servicing Schedule”).
For repairs on major components (engine, transmission, etc.), contact your nearest dealer for a Repair Manual.
Do not operate a forklift that is damaged or does not function properly. Only authorized personnel may make
repairs or adjustments to the lift truck. After repairs, the lift truck must be tested for safe operation before
returning to service.
3.) FORKLIFT KNOWLEDGE
Forklift trucks can cause serious injury if improperly used or maintained. Study all of the manuals provided for
your forklift model. Learn the locations and meanings of all safety decals. If any decals are illegible or missing, have them replaced immediately. Make sure all safety features provided by the original manufacturer are
in place and function properly. Do not operate a forklift with damaged, missing or unsafe components. Have
it repaired by authorized service personnel. Learn the functions of all controls, gauges, indicator lights, etc. on
the forklift. Know the speed/gear ranges, braking and steering capabilities, load ratings and clearances. When
referring to the location of forklift components, the terms “left”, “right”, “front”, and “rear” are related to the operator seated normally, facing forward in the operator’s seat. If you have any questions about the forklift, consult your supervisor. Failure to fully understand or obey safety warnings can result in serious injury or death!
4.) WORK SITE KNOWLEDGE
Before operating on a work site, learn the rules for movement of people, forklifts and all other traffic. Check
the size, weight, and condition of the loads you will be expected to handle. Verify that they are properly
secured and safe to transport. Learn where the loads are to be placed, planning your route for a safe
approach, watching for hazardous conditions. Will a signal man be required to help place the load? Remove
any debris which may cause tire damage or rupture. Plan your route around problem areas or have them corrected. Inform the supervisor of any unsafe conditions observed at the site. Examples of hazards: power
lines, cables, low clearance structures, garage doors, telephone pole guide lines, fencing, loose lumber, building materials, drop-offs, trenches, rough/soft spots, oil spills, deep mud, steep inclines, railroad tracks, curbs,
etc.. NEVER approach power lines, gas lines or other utilities with the forklift! Always verify that local,
state/provincial and federal regulations have been met. Report any accidents involving personnel, building
structures, and equipment to the supervisor immediately. Always remain alert - conditions are constantly
changing at the work site!
TECHNICAL SUPPORT
All data provided in this manual is subject to production changes, addition of new models, and improved product designs. If a question arises regarding your forklift, please consult your dealer or K-D Manitou, Inc. for the
latest information. When ordering service parts or requesting technical information, be prepared to quote the
applicable Model/Serial Numbers.
VIII
SAFETY MESSAGES
NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL
HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Also, observe
the safety messages places throughout this manual; providing special instructions, telling you when to take precautions
and to identify potential hazards. The safety messages are highlighted and outlined in a box similar to those shown in the
examples below.
SAFETY ALERT SYMBOL
NOTE or NOTICE
Provides information, special instructions or references about the lift truck.
IMPORTANT
Precautions which must be taken to avoid damage to the lift truck.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. May also alert unsafe practices.
WARNING
Indicates a potentially hazardous situation which, if not avoided, may result in death or
serious injury!
DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
CALIFORNIA PROPOSITION 65 WARNING
Diesel Engine Exhaust and some of its constituents are known to the State of California
to cause cancer, birth defects or other reproductive harm.
WARNING: Battery posts, terminals and related accesories and related accessories
contain lead and lead compounds. Wash hands after handling.
IX
SAFETY FIRST
CONTENTS
SAFETY DECALS
The purpose of this chapter is to introduce you to the safety messages, decals, and nameplates found on
your forklift truck. The decals are identified by name, part number, location, and a brief description. (The
forklift model logos, and other misc. decals not shown, can be found in your forklift parts manual.) The
decals illustrated may not be exactly the same as those installed on your forklift; installation of the decals
varies depending on the forklift model, series, decal updates, etc.. The size and location of some decals
limit the amount of information that can be placed upon it. For this reason, additional detailed information
not found on the decals is provided through-out this manual.
Every decal placed on the lift truck is important; they are constant reminders of safety and instructions that
should never be taken for granted. Even experienced operators can be seriously injured or killed by ignoring, refusing to enforce, or forgetting to follow safe operating procedures! Do not assume you know all safety issues concerning the decals. Before operating the lift truck; learn the meaning(s) of the decals as
described in this manual. If any decal becomes illegible or missing, have it replaced immediately! Always
replace decals using the same decal part no., unless otherwise specified by the manufacturer. For replacement decals not found in your parts manual, contact your nearest dealer. If you have any questions, contact
your supervisor or nearest dealer for advice before operating your forklift!
801011
Before Starting - 801011
(Boom equipped models). Location: on the brake fluid cover panel (to
the left and below the dash panel).
Safety Instructions - 420792
(Mast equipped models). Location: on or near the operator manual
storage case, and/or on the dash panel.
Instructions for the forklift operator; before operating the forklift.
Use of Seat Belt - 801012
(Boom equipped models). Location: to the right of the
operator, near the hydraulic control lever.
Instructs the operator to always wear the seat belt during
operations, and never jump from an over-turning forklift.
X
SAFETY FIRST
CONTENTS
SAFETY DECALS
Emergency and Parking Brake - 801010
Location: near the park brake lever.
Identifies the Emergency/Parking Brake Lever.
Alarm Must Sound - 496162
Location: on the dash, in direct view of the operator.
The backup alarm must sound when the forklift is placed in reverse gear.
No Riders - 420732
Location: on the cab entrance(s), and on or near wheel fenders and engine
cover.
Informs: riders are not allowed on the forklift.
Clear of Raised Boom - 801006
(Boom equipped models). Location: on both sides
of the boom nose.
Keep away from unsupported boom.
Clear of Power Lines - 801007
(Boom equipped models). Location: on both sides
of the boom nose.
Keep away from power lines.
XI
SAFETY FIRST
CONTENTS
SAFETY DECALS
Use of Frame Leveling - 801013
(Boom equipped models). Location: to the right of
the operator near the hydraulic control lever.
Frame leveling notice; load must be lowered.
Attachment and Boom Safety - 801009
(Boom equipped models). Location: on both sides of the
boom nose.
Important reminders of attachment and boom safety.
Hydraulic Coupling - 234805
Location: near the quick-disconnect adapters.
Stop the engine and release hydraulic pressure before changing
attachments.
Rotating Fan and Belt(s) - 801008
Location: on the radiator near the fan, and on any fan belt/pulley cover(s).
Keep hands and clothing away from rotating fan and belts.
XII
SAFETY FIRST
CONTENTS
SAFETY DECALS
Gear Shift Pattern - 33460
(4-speed transmission models). Location: near the gear shift lever.
Identifies the gear shift pattern of the forklift transmission.
Steering Mode - 184276
(4 wheel steer equipped models). Location: near the steering mode selection lever.
Identifies the steering mode selection.
221322
Mineral Oil (Brake Reservoir) - 221322 or 234800
Location: attached to the brake fluid reservoir.
Refer to the Operator/Service Manual for the correct brake fluid
(mineral oil) to be used in the brake system.
234800
XIII
SAFETY FIRST
CONTENTS
SAFETY DECALS
Hydraulic Oil - 234798 or 76573
Location: on the hydraulic tank or filler cap.
Identifies the hydraulic reservoir (tank) or filler cap.
Hydraulic Oil - 61024
Location: on the hydraulic tank.
Identifies the hydraulic reservoir (tank).
Anti-Freeze - 234799
Location: on the radiator, near the radiator filler cap.
Indicates required minimum to maximum anti-freeze protection (-220F to -400F).
Diesel Fuel - 161101
Location: on the fuel tank, near the filler cap.
Identifies the fuel tank, and use of diesel fuel.
No Step - 496735
Location: varies, depending on the forklift model.
Instructs personnel not to use the designated area as a step.
Do Not Tow - 494918
(Hydrostatic equipped models). Location: on the
dash, in view of the operator.
Towing the forklift will damage the transmission;
refer to the operator’s manual.
XIV
SAFETY FIRST
CONTENTS
SAFETY DECALS
Attachment Warning - 421016
(Boom equipped models). Location: on the boom coupler,
near where the retaining shaft is installed.
Reminder to operator; install attachment retaining shaft and
safety pin before operations.
Hook Here - 24653
Location: at points provided on the forklift, where straps or chains may be attached to
secure the forklift to a trailer during transport.
Fork Safety - 426641
(Mast equipped models). Location: on the front and back side of the mast’s outer rails,
at eye level (4 required).
Instructs personnel not to travel beneath or upon the lift truck forks.
Pinch Point, Large, 2.5 x 4.5 in. - 426643
Pinch Point, Small, 1.5 x 2.75 in. - 426642
(Mast equipped models). Location: on the front and rear sides
of the mast cross bracing.
Keep fingers away from the mast
crossbracing.
HAND THROTTLE DANGER - 804784
(Boom equipped models, option). Location: Near the hand throttle mechanism.
Reminder to operator; set parking brake before operating hand throttle.
Disengage hand throttle before leaving the forklift.
XV
SAFETY FIRST
CONTENTS
SAFETY DECALS
Acid in Battery - 801014
Location: in or near the battery
storage compartment.
Addresses battery hazards.
Jump Start Battery - 801015
Location: in or near the battery storage
compartment.
Jump start instructions.
Attachment Plate - 425995
Location: on the optional removeable forklift attachment.
Important manufacturer information about the attachment. Record this information for use
when contacting the maufacturer for parts and service.
Overhead Guard Data Plate - B6109
Location: attached to the overhead guard.
Overhead guard conformity.
496550
Forklift Data Plate - 496550
(Boom equipped models)
Forklift Data Plate - 496538
(Mast equipped models)
Location: within the operator’s compartment.
Important forklift truck identification. Record
this information for use when contacting the
manufacturer for parts and service.
XVI
496538
SAFETY FIRST
CONTENTS
TABLE OF CONTENTS
1 - OPERATING
AND SAFETY INSTRUCTIONS
– ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS
– DRIVER'S OPERATING INSTRUCTIONS
• WARNING
• GENERAL INSTRUCTIONS
• OPERATING INSTRUCTIONS
• HANDLING INSTRUCTIONS
• LOAD HANDLING
– MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK
– BEFORE STARTING UP A NEW LIFT TRUCK
2 - DESCRIPTION
–
–
–
–
–
1-1
1-3
1-4
1-4
1-5
1-7
1 - 11
1 - 13
1 - 16
1 - 18
2-1
IDENTIFICATION OF THE LIFT TRUCK
CHARACTERISTICS
DIMENSIONS AND LOAD CHART
INSTRUMENTS AND CONTROLS
DESCRIPTION AND OPERATION OF ELECTRIC AND HYDRAULIC OPTIONS
3 - MAINTENANCE
2-4
2-6
2 - 12
2 - 14
2 - 25
3-1
– FILTERS CARTRIDGES AND BELTS
– LUBRICANTS AND FUEL
– SERVICING SCHEDULE
3-3
3-4
3-6
XV
SAFETY FIRST
CONTENTS
SAFETY FIRST
CONTENTS
1 - OPERATING
AND SAFETY
INSTRUCTIONS
1-1
SAFETY FIRST
CONTENTS
1-2
SAFETY FIRST
CONTENTS
ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS
ALL MAINTENANCE ON OUR LIFT TRUCKS MUST BE CARRIED OUT USING ORIGINAL PARTS.
BY ALLOWING NON-ORIGINAL PARTS TO BE USED,
YOU RUN THE RISK
- Legally, of being liable in the event of an accident.
- Technically, of causing breakdowns to occur or of reducing your lift truck's service life.
Using counterfeit parts or components not approved by the manufacturer may put an end to
contract warranty terms and lead the maker to withdraw the lift truck's certificate of compliance.
IMPORTANT
BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS,
YOU ARE LEGALLY
COVERING
YOURSELF
- Any user who procures parts from another vendor does so at his own risk.
- Any user who modifies his lift truck or has it modified by a service company, must consider
that a new item of equipment has been brought onto the market and therefore takes liability
for it.
- Any user who copies original parts or has them copied is taking a risk from the legal viewpoint.
- The certificate of compliance only binds the maker for parts chosen or produced under the
maker's control.
- The practicalities of maintenance terms are set out by the maker. The maker is in no way
liable in the event of the user not complying with such terms.
YOU GET THE
BENEFIT OF THE
MANUFACTURER'S
KNOW-HOW
THE MANUFACTURER BRINGS TO THE USER,
- His know-how and skill.
- Guaranteed quality work.
- Original replacement parts.
- Help with preventive maintenance.
- Effective help with diagnosing faults.
- Enhancements gained from feedback.
- Training for operating staff.
- The manufacturer knows the details of the lift truck design and therefore has the best
technological capability to carry out maintenance.
ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY
BY MANITOU AND ITS DEALER NETWORK.
1-3
SAFETY FIRST
CONTENTS
DRIVER'S OPERATING INSTRUCTIONS
WARNING
WHENEVER YOU SEE THIS SYMBOL IN MEANS:
WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK.
- Most accidents connected with the use, maintenance and repair of the lift truck are due to non application of the basic
safety instructions. By being aware of the risks to which you are exposed and by taking the necessary preventive
measures, you can avoid accidents.
- Any operation or maneuver not described in the instructions is prohibited, however, any person who does use another
method must first ensure that he is not putting himself, another person or the lift truck in danger.
- The manufacturer is not able to anticipate all possible risk situations. Therefore the safety instructions and notices
given in the user manual and on the lift truck are not conclusive.
Any bending of the rules in safety notices or the user, maintenance or repair instructions for your lift truck may result in
serious, or even fatal accidents.
We would remind users of the risks in driving at excessive speed with regard to traffic conditions, particularly:
- Risk of loss of control on a poor-quality track.
- Increased stopping distance.
The user must remain in full control of his lift truck and should:
- Adapt his speed to each situation in order to maintain his own safety, that of others and of his
equipment.
- Always be aware of his stopping distance.
On the basis of experience, there are a number of possible situations in which operating the lift truck is prohibited.
Such foreseeable abnormal uses, the main ones being listed below, are strictly forbidden.
- The foreseeable abnormal behavior 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.
- Behavior resulting from application of the "principle of least action" when performing a task.
- For certain machines, the foreseeable behavior of such persons as: apprentices, teenagers, handicapped persons
and trainees tempted to drive a lift truck. Truck drivers 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 make a suitable driver.
1-4
SAFETY FIRST
CONTENTS
GENERAL
INSTRUCTIONS
A - DRIVER’S OPERATING INSTRUCTIONS
- Read the operator's manual carefully, making sure you understand it.
- The operator’s manual must always be kept in the lift truck, in the place provided and in the language understood by
the operator.
- Respect the safety notices and instructions given on the lift truck.
- It is compulsory to replace all plates or stickers which are no longer legible or which have become worn or damaged.
B - AUTHORIZATION TO OPERATE
(Refer to the legislation for each particular country)
- Only qualified personnel may use the lift truck. Its use is subject to authorization to operate being given by the
appropriate manager in the user establishment.
- The user should always carry this authorization to operate with him while he is using the lift truck.
- The driver is not competent to authorize the driving of the lift truck by another person.
- In addition, the vehicle should be used in accordance with good practice for the profession.
C - MAINTENANCE
- The user must immediately advise his superior if his lift truck is not in good working order or does not comply with the
safety notice.
- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this
purpose. He must keep the lift truck properly cleaned if this is among his responsibilities.
- Carry out daily maintenance (See A - DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 - MAINTENANCE).
- Ensure tires are adapted to the nature of the ground.
. SAND tires.
. LAND tires.
. Snow chains.
There are optional solutions, consult your agent or dealer.
WARNING
IMPORTANT
A worn or damaged tire can result in the lift truck being temporarily out of service.
The fitting of foam inflated tires is prohibited and is not guaranteed by the manufacturer, without
prior authorization.
- For your own and other people's safety, it is forbidden to modify the structure and settings of the various components of
your lift truck yourself (Hydraulic pressure, relief valve calibration, engine running speed, addition of extra equipment
etc.). The same holds with regard to any suppression or modification of the safety systems, in which case the maker
would no longer be liable.
IMPORTANT
Regular inspection of your lift truck is mandatory if it is to be kept in conforming condition. The
frequency of such checks are defined by the current legislation of the country in which the lift truck
is being operated.
Maintenance or repairs other than those detailed in part: 3 - MAINTENANCE must be carried out
by qualified personnel (Consult your agent or dealer) and under the necessary safety conditions
to maintain the health of the operator and any third party.
1-5
SAFETY FIRST
CONTENTS
D - ENVIRONMENT
- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher.
There are optional solutions, consult your agent or dealer.
- Take into account climatic and atmospheric conditions of the site of utilization.
IMPORTANT
For operation under average climatic conditions, i.e. between -15 °C and + 35 °C (5° to 95°F), 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 add the correct
levels of lubricants properly suited to the relevant ambient temperatures. It is the same for the
engine cooling system (Contact your dealer for information, if necessary).
. Protection against frost (See LUBRICANTS AND FUEL in SECTION 3 - MAINTENANCE).
. Adaptation of lubricants (Ask your dealer for information).
. Engine filtration.
. Lighting (Working headlight).
Optional solutions exist, consult your dealer.
WARNING
Use of a lift truck is prohibited in protected areas (i.e. refinery, explosive atmosphere). For use in
these areas, specific equipment is available as an option. Consult your dealer.
IF NECESSARY, CONSULT YOUR DEALER.
1-6
SAFETY FIRST
CONTENTS
OPERATING
INSTRUCTIONS
A - DRIVER’S OPERATING INSTRUCTIONS
- Wear clothes suited for driving the lift truck, avoid loose clothing.
- Never operate the vehicle when hands or feet are wet or soiled with greasy substances.
- For increased comfort, adjust the driver’s seat to your requirements and adopt the correct position in the driver’s cab.
- 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 cab.
- Always remember to fasten your seat belt and adjust it to your requirements.
- The control units must never in any event be used for any other than their intended purposes (i.e., climbing onto or
down from the lift truck, etc.).
- If the control components are fitted with a forced operation (lever lock) device, never leave the cab without first placing
these controls in neutral.
- Never allow a passenger to travel on the lift truck or in the cab.
B - BEFORE STARTING THE LIFT TRUCK
- If the lift truck is new, refer to BEFORE STARTING UP A NEW LIFT TRUCK in SECTION 1 - OPERATING AND
SAFETY INSTRUCTIONS.
- Check the condition of the tires and the tire pressures (See CHARACTERISTICS in SECTION 2 - DESCRIPTION).
- Before starting the lift truck, check the different levels:
. Engine oil.
. Hydraulic reservoir oil.
. Cooling liquid.
. Braking oil.
- Also check for possible leakage of oil, fuel or liquid from the lift truck.
- Check the closing and locking of the hood.
- Whatever his experience as a truck driver, the operator is advised to familiarize himself with the position and operation
of all the controls and instruments before operating the lift truck.
C - STARTING THE LIFT TRUCK
SAFETY NOTICE
WARNING
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 start the lift truck by pushing or towing it.
IMPORTANT
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
H3 - OCCASIONAL MAINTENANCE in SECTION 3 - MAINTENANCE).
INSTRUCTIONS
- Open the LPG bottle (where applicable).
- Make sure that the forward/reverse lever is in neutral.
- Turn the ignition key to the position I to activate the electrical system.
- Check the level on the fuel level gauge.
- Turn the ignition key to position II to preheat for 15 seconds.
IMPORTANT
Do not engage the starter motor for more than 15 seconds and apply preheating for 10 seconds
between unsuccessful attempts.
1-7
SAFETY FIRST
CONTENTS
- Press the accelerator pedal and turn the ignition key fully: the engine should then start. Release the ignition key and let
the engine run at idle.
- Check all control instruments immediately after starting up, 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 proper working order, stop the engine and have the truck serviced.
D - DRIVING THE LIFT TRUCK
SAFETY NOTICE
- Always drive the lift truck with the forks or attachment at approximately 12 in. from the ground, i.e. In the transport
position.
- Familiarize yourself with the lift truck on the terrain where it will be used.
- Ensure that the service brakes and horn are working properly.
- Drive according to, and at an appropriate speed for, the conditions and state of the terrain.
- Slow down before executing a turn.
- In all circumstances make sure you are in control of your speed.
- On damp, slippery or uneven terrain, drive slowly.
- Brake gently, never abruptly.
- Only use the lift truck’s forward/reverse lever from a stationary position and never do so abruptly.
- Do not drive with your foot on the brake pedal or with the parking brake on.
- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, turn it gently
and not abruptly.
- Never leave the engine on when the lift truck is unattended.
- Look in the direction you are travelling and always keep clear visibility of the road. Use the left and right rear view
mirrors frequently and ensure that they are kept in good condition, are clean and correctly adjusted.
- When working at night, ensure that your lift truck is fitted with full beam lights. There are optional solutions, consult your
agent or dealer.
- Drive around obstacles.
- Never move onto a loading platform without having first checked :
. That it is suitably positioned and made fast.
. That the unit to which it is connected (truck, trailer etc.) will not shift.
. That this platform is approved for the total weight of the lift truck to be loaded.
. That this platform is approved for the width of the lift truck.
- Never move onto a foot bridge, floor or freight lift, without being certain that they are approved for the weight and size
of the lift truck to be loaded, and that they are in sound working order.
WARNING
Take extreme care with loading platforms, trenches, scaffolding, recently dug and/or backfilled
ground.
- The loaded lift truck must not travel at speeds in excess of 8 mph.
INSTRUCTIONS
- Raise the forks or attachment to the transport position approximately 12 in. from the ground.
- Shift the forward/reverse lever to the selected direction of travel.
- Release the parking brake and accelerate gradually until the lift truck moves off.
1-8
SAFETY FIRST
CONTENTS
E - STOPPING THE LIFT TRUCK
SAFETY NOTICE
- Before stopping (parking) the lift truck after a long working period, let the engine idling for a few moments, to allow the
coolant liquid and oil to lower the temperature of the engine and transmission.
IMPORTANT
Do not neglect this precaution: frequently stopping the engine will raise the temperature of some
components, with the risk of badly damaging them.
- Never leave the ignition key in the lift truck when the lift truck is unattended.
- When the lift truck is stationary, place the forks or attachment on the ground, apply the parking brake and place the
forward/reverse lever in neutral.
- If the driver has to leave the cab, even for a moment, it is essential to apply the parking brake and place the
forward/reverse lever in neutral.
- Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow. Park the forklift at least
6 ft. from the track of a railway.
- In the event of prolonged parking, protect the lift truck from bad weather, particularly from frost (Check the level of
antifreeze), close the rear windows, lock the cab doors and ensure that the hood is properly secured.
INSTRUCTIONS
- Park the lift truck on flat ground or on an incline with less than 15 % slope.
- Release the accelerator pedal and stop the lift truck.
- Place the forward/reverse lever in neutral.
- Apply the parking brake.
- Lower the forks or attachment to rest on the ground.
- Stop the engine with the ignition switch.
- Remove the pressure in the hydraulic circuits by using the hydraulic controls.
- Remove the ignition key.
- Check the closing and locking of doors, windows and hood.
WARNING
Before leaving your driver's cab, ensure that you have carried out all operations for parking the
lift truck, for your safety and the safety of others.
F - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY
SAFETY INSTRUCTIONS
- When driving a lift truck on roads open to public traffic, observe the provisions of the local Highway Code.
- Lift truck drivers, driving on the public highway, must abide by the general provisions relative to highway traffic.
- The lift truck must conform to the provisions of the Highway Code. If necessary, optional solutions exist, consult your
dealer.
CAUTION
Transport of loads on the public highway is forbidden and attachments mounted on the lift truck
must be fitted with equipment in accordance with regulations or removed.
1-9
SAFETY FIRST
CONTENTS
INSTRUCTIONS
- Ensure that the flashing light is in position and that it is working.
- Check the good working order and cleanness of lights, indicators and windscreen wiper.
- Check the adjustment of the rear view mirrors.
- Ensure that the fuel level is sufficient.
- Place the attachment at 12 in. from the ground.
G - OPERATING THE LIFT TRUCK WITH A TRAILER ON A PUBLIC HIGHWAY
- For using a trailer, consult the regulations required in your country (Maximum travel speed, braking, maximum weight
of trailer, etc.).
- Do not forget to connect the lift truck’s electrical equipment to that of the trailer.
- Do not use a non-braked trailer if the unit weight of a load exceeds that imposed by the highway code.
- Do not use a non-braked trailer without braking equipment for the trailer on the lift truck.
- Do not forget to connect the lift truck’s braking equipment to that of the trailer.
- The maximum vertical pull on the trailer hook must not exceed 3300 lbs.
- The authorized total towed weight (A.T.T.W.) must not exceed the maximum weight authorized by the manufacturer
(Consult the manufacturer’s plate on your lift truck).
H - OPERATING THE LIFT TRUCK WITH A FRONT-END ATTACHMENT ON A PUBLIC HIGHWAY
- For driving with an attachment, check the regulations currently applicable in your country.
- The attachment must not exceed the overall width of the lift truck.
- Do not mask the lighting range of the front headlamps.
- Set the attachment’s shields in place or remove the attachment.
IF NECESSARY, CONSULT YOUR DEALER.
1 - 10
SAFETY FIRST
CONTENTS
HANDLING
INSTRUCTIONS
A - GENERAL
- Ensure the correct functioning of your lift truck’s attachments.
- Do not attempt to carry out operations which exceed the capacities of your lift truck or attachments.
- It is prohibited to increase the counterweight value in any way.
- It is strictly prohibited to carry or to lift persons using the lift truck, unless the vehicle is specially equipped for this
purpose and has the corresponding certificate of conformance for lifting people.
- Avoid travelling for a long distance in reverse.
B - ATTACHMENTS
- Ensure that the attachment is correctly fitted and locked to its frame.
- Conform to the limits on the load chart for the lift truck and/or attachment.
- Ensure that palettes, cases, etc, are in good order and suitable for the load to be lifted.
- Position the forks perpendicular to the load to be lifted, taking account of the load’s center of gravity.
- Never lift a load with a single fork.
- Never lift a sling load with a single fork or with the carriage. Optional solutions exist, consult your dealer.
- Ensure that rapid hydraulic connections (quick-disconnect) on the attachment system are clean and protected.
IMPORTANT
Before each change of an attachment with hydraulic function, in order to avoid damaging the
rapid hydraulic connections:
- Place the attachment in the closed position, flat on the ground (For unstable attachments,
ensure they are secured using blocks or wedges).
- Switch off the engine.
- Remove pressure from the attachment hydraulic system using the hydraulic controls.
C - ENVIRONMENT
- Take care when raising the load that no object or person is in the way of movement and do not make any incorrect
maneuvers.
- In case of work near power lines, ensure that the safety distance is sufficient between the working area of the lift truck
and the power line.
DANGER
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. You are strongly advised to ensure that the
safety rules on the site conform to the local regulations regarding all types of work carried out close
to power cables.
- Do not allow personnel to come near the working area of the lift truck or pass beneath an elevated load.
- When using the lift truck on a slope, before raising the mast, ensure that the ground is horizontal (See F HORIZONTAL POSITION OF THE LIFT TRUCK in LOAD HANDLING).
- Travelling on a longitudinal slope:
• Drive and brake gently.
• Moving without load: Forks or attachment facing downhill.
• Moving with load: Forks or attachment facing uphill.
- Ensure that loading platform or pile is capable of bearing the weight.
- Ensure the stability and solidity of the ground before depositing a
load.
1 - 11
SAFETY FIRST
CONTENTS
D - HANDLING
- Always consider safety and only transport balanced and correctly secured loads to avoid any risk of tipping.
- Fully engage forks under the load and move it in the transport position (The forks 12 in. from the ground and the mast
tilting backwards).
- For obvious reasons regarding the lift truck’s stability and clear visibility of the surrounding environment, only move the
lift truck when the mast is in the transport position.
- Do not maneuver the lift truck with the mast 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 and get another
person to guide you along if necessary.
- Never shift the position of the load while the lift truck is in motion.
- The simultaneous use of two lift trucks to handle heavy or bulky loads is a dangerous maneuver, requiring specific
precautions. This should only be done in exceptional circumstances and in the presence of a handling manager.
- Never drive too fast or brake abruptly when carrying a load.
- During handling, drive at low speed.
- Check the load, particularly when turning corners and especially if it is very bulky.
- Secure unstable loads.
- Handle loads with caution, at slow speed, without sudden jerks when moving them at significant heights and mast
extention.
WARNING
In the event of high winds or storms, do not perform handling work that jeopardizes the stability of
the lift truck and its load, particularly if the load catches the wind badly.
- Do not change direction sharply or at high speed.
DANGER
In the event of the lift truck overturning, do not try to leave the cab during the incident.
YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CAB.
- Apply the parking brake when lifting or depositing a difficult load or when on an incline.
- Do not stop the lift truck with the load in an elevated position.
- Do not leave a laden lift truck with the parking brake applied on an incline which exceeds 15 %.
E - VISIBILITY
- Constantly keep clear visibility of the road, either direct view (looking backwards when reversing) or indirect view using
the panoramic rear view mirrors to check for people, animals, holes, obstacles, change of slope, etc.
- If the visibility in forward motion is not sufficient because of the bulkiness of the load, drive in reverse motion. This
maneuver must remain exceptional and for short distances.
- Ensure you have good visibility (Clean windows, adequate lighting, correctly adjusted rear view mirror, etc.).
- Signaling and lighting on the lift truck must take into account the conditions of use. In addition to standard equipment
mounted on your lift truck, a certain number of options are available, such as: road lighting, stop lights, flashing light,
reverse lights, front light, rear light, etc. Consult your agent or dealer.
IF NECESSARY, CONSULT YOUR DEALER.
1 - 12
SAFETY FIRST
CONTENTS
LOAD
HANDLING
A
A - WEIGHT OF LOAD AND CENTER OF GRAVITY
24
500in.
mm
CAUTION
Carrying a load greater than the rated capacity for the lift truck or for the
attachment is prohibited.
- Before taking up a load, you must know its weight and its center of gravity.
- The load chart relating to your lift truck is valid for a weight with its center of
gravity 24 in. from the heel of the forks (As model of lift truck) (Fig. A). For a
higher center of gravity, consult your agent or dealer.
- For irregular loads, determine the center of gravity in the transverse
direction before handling (Fig. B).
B
CAUTION
For loads with a moving center of gravity (i.e. liquids), take account of the
variations in the center of gravity in order to determine the load to be
handled (Consult your agent or dealer). Be vigilant and take extra care to
limit these variations as far as possible.
C
B - TAKING UP A LOAD ON THE GROUND
- Align the lift truck perpendicular to the load, with the forks in a horizontal
position (Fig. C).
- Adjust the fork spread and centering in relation to the load (Fig. D) (Optional
solutions exist, consult your dealer).
D
WARNING
Beware of the risks of trapping or injuring limbs when manually adjusting
the forks. Always maintain an equal distance between the forks and the
center of the carriage in order to keep the load completely stable.
- Move the lift truck forward slowly (1) and place the forks under the load (Fig.
E), slightly lift the mast (2) to take up the load.
- Apply the parking brake and place the forward/reverse lever in neutral.
- Slightly lift the load (1), and incline the mast (2) backwards in the transport
position (Fig. F).
E
1
2
CAUTION
Tilt the load sufficiently backwards to ensure its stability (loss of load on
braking) without upsetting the balance of the load.
F
2
1
1 - 13
SAFETY FIRST
CONTENTS
C - TAKING UP A HIGH LOAD ON TIRES
G
WARNING
Under no circumstances should you pick up a load if the lift truck is not in a
horizontal position. (See F - HORIZONTAL POSITION OF THE LIFT
TRUCK).
- Ensure that the forks will easily pass under the load.
- Align the lift truck perpendicular to the load, with the forks in a horizontal
position (Fig. G) maneuvering gently and carefully (See E - VISIBILITY in
HANDLING INSTRUCTIONS for visibility of the road).
- Place the forks under of the load (Fig. H). Apply the parking brake and place
the forward/reverse lever in neutral.
- Slightly lift the load (1) and incline the mast (2) backwards to stabilize the
load (Fig. I).
H
CAUTION
Tilt the load sufficiently backwards to ensure its stability (loss of load on
braking) without upsetting the balance of the load.
- Maneuvering very gently and carefully (See E - VISIBILITY in HANDLING
INSTRUCTIONS for visibility of the road), back the lift truck to clear the pile,
and lower the load into the transport position (Fig. J).
I
2
1
J
1
1 - 14
SAFETY FIRST
CONTENTS
D - LAYING A HIGH LOAD ON TIRES
K
WARNING
Under no circumstances should you place a load if the lift truck is not a
horizontal position. (See F - HORIZONTAL POSITION OF THE LIFT
TRUCK).
- Approach with the load in the transport position in front of the pile (Fig. K).
- Lift the mast (1) until the load is above the pile, and move the lift truck
forward (2) (Fig. L) maneuvering very gently and carefully (See SECTION E
- VISIBILITY in HANDLING INSTRUCTIONS for visibility of the road). Apply
the parking brake and place the forward/reverse lever in neutral.
- Place the load in a horizontal position by tilting the mast forwards (1) and lay
it down on the pile (2) while checking the correct positioning of the load (Fig.
M).
- Maneuver very gently and carefully.
- Free the forks by reversing the lift truck (3) (Fig. M) (See paragraph E VISIBILITY in HANDLING INSTRUCTIONS for visibility of the road). Then
bring the forks into the transport position.
L
1
2
M
1
2
3
N
E - TAKING UP A NON PALLETIZED LOAD
- Tilt the carriage (1) forwards and move the lift truck forward (2) while
simultaneously crowding the carriage backwards to slip the forks under the
load (Fig. N). If necessary, wedge the load.
F - HORIZONTAL POSITION OF THE LIFT TRUCK
Apart from the transverse slope of the ground, several parameters can upset
the horizontal position of the lift truck.
• The tire pressure.
• The stability of the ground.
• The balance of the load.
• Strong wind or stormy conditions.
WARNING
Before handling any work, check the points above and ensure that the lift
truck is completely horizontal (level).
1 - 15
1
2
3
SAFETY FIRST
CONTENTS
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK
MAINTENANCE
INSTRUCTIONS
A - GENERAL
- Read the operator's manual carefully and ensure you understand it.
- Stop the engine, when an intervention is necessary.
- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewelry and loose clothes. Tie and protect
your hair, if necessary.
- Ensure the area is sufficiently ventilated before starting the lift truck.
IMPORTANT
Make sure that the disposal of process materials and spare parts is carried out in a safe and
ecological manner.
- Perform all repairs immediately, even if the repairs are minor.
- Repair all leaks immediately, even if the leak is minor.
- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.
WARNING
The handling and removal of the balancing valves which may be fitted to the cylinders of your lift
truck can be dangerous. A balancing valve must be removed only after the cylinder is at rest and
the hydraulic circuit is depressurized.
This operation must be performed by authorized service personnel only!
- Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
- Take care not to burn yourself (Exhaust, radiator, engine, etc.).
- Disconnect the negative cable terminal (-) from the top of the battery before working on the electrical circuit or on the lift
truck (i.e., welding).
- Do not drop metallic objects on the battery.
- 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.
B - MAINTENANCE
- Maintenance and keeping the forklift in compliance are mandatory.
- Carry out daily maintenance (See A - DAILY OR EVERY 10 HOURS SERVICE in SECTION 3 - MAINTENANCE).
- Do not run the engine without air filter, or with oil, water or fuel leaks.
WARNING
Wait for the engine to cool before removing the radiator cap.
- Change the filter cartridges (See servicing schedules in FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE).
C - LEVELS
- Use the recommended lubricants (Never use contaminated lubricants).
- Do not fill the fuel tank when the engine is running.
- Only fill the fuel tank in areas specified for this purpose.
- Do not fill the fuel tank to the maximum level.
1 - 16
SAFETY FIRST
CONTENTS
D - WASHING
- Clean the lift truck or at least the area concerned before any intervention.
- Remember to close the doors and the windows of the cab.
- During washing, avoid the articulations, electrical components, and connections.
IMPORTANT
Protect components susceptible of being damaged; from penetration of water, steam or cleaning
agents; particularly electrical components, connections, and the injection pump.
- Clean the lift truck of any fuel, oil or grease trace.
FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT YOUR DEALER.
1 - 17
SAFETY FIRST
CONTENTS
BEFORE STARTING UP A NEW LIFT TRUCK
INTRODUCTION
- Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the
mechanic.
- However, before operating the lift truck, the user should carefully read and understand all the chapters of this manual
which has been provided to solve driving and maintenance problems. By following these instructions the user will be
able to take full advantage of the versatility of this lift truck.
- The operator must familiarize himself with the positions and functions of all the controls and instruments before
operating the lift truck.
IMPORTANT
Do not attempt to start a new lift truck before the following checks have been carried out:
LUBRICATION
- Check that all the correct grades of oils and greases that are required are available; see SERVICING SCHEDULE in
SECTION 3 - MAINTENANCE and top up if necessary.
IMPORTANT
For operation under average climatic conditions, i.e. between -15 °C and + 35 °C (5° to 95°F), 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 add the correct
levels of lubricants properly suited to the relevant ambient temperatures. It is the same for the
engine cooling system (Contact your dealer for information, if necessary).
DRY AIR FILTER
- Ensure that the air filter is undamaged and not blocked.
- Tighten the fastening devices if necessary.
IMPORTANT
Never run the engine with the air filter removed or damaged.
COOLING SYSTEM
- Do not start the lift truck without checking the radiator coolant level or if the fan belt is damaged or broken.
HYDRAULIC SYSTEM
- Check by a visual examination that there are no leaks or oil seeping from the hoses, connections and unions. If
necessary, tighten or repair the defective connections.
- Also check that the tank oil level is correct.
BRAKING SYSTEM
- Check by a visual examination that there are no leaks or oil seeping from the hoses, connections and unions. If
necessary, tighten or repair the defective connections.
- Also check the oil level in the tank.
DANGER
Ensure that the recommended oil is used, in order to avoid serious damage to the braking system.
TIRES
- Make sure that the wheel nuts are correctly tightened (See A - DAILY OR EVERY 10 HOURS SERVICE in
SECTION 3 - MAINTENANCE) and that the tire pressures are correct (See CHARACTERISTICS in SECTION 2 DESCRIPTION).
FUEL SYSTEM
- Check that all fuel lines are secured.
- If necessary drain the fuel filter and bleed the fuel system of air.
1 - 18
SAFETY FIRST
CONTENTS
ELECTRICAL CIRCUIT
- Check the level and the density of the electrolyte in the battery (See B - EVERY 50 HOURS SERVICE in SECTION 3 MAINTENANCE).
- Check the components of the electrical system, the connections and fastening devices.
IF NECESSARY, CONSULT YOUR DEALER.
1 - 19
SAFETY FIRST
CONTENTS
1 - 20
SAFETY FIRST
CONTENTS
2 - DESCRIPTION
2-1
SAFETY FIRST
CONTENTS
2-2
SAFETY FIRST
CONTENTS
2-3
SAFETY FIRST
CONTENTS
IDENTIFICATION OF THE LIFT TRUCK
As our policy is to promote a constant improvement of our products, our
range of masted lift trucks may undergo certain modifications, without prior
notice our customers.
A
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 be made in the spaces provided, at the time of the delivery
of the lift truck.
PLATE
MANUFACTURER OF THE LIFT TRUCK ( FIG. A )
B
- Truck Model
- Truck Serial No
- Mast Model
- Mast Serial No
- Attachment
- Attachment Serial No
ENGINE (FIG. B)
C
- Engine No
HYDROSTATIC
PUMP ( FIG. C )
- Pump No
- Codification type
- Manufacturer’s No
- Year of manufacture
D
HYDROSTATIC
MOTOR ( FIG. D )
- Pump No
- Codification type
- Manufacturer’s No
- Year of manufacture
2-4
SAFETY FIRST
CONTENTS
TRANSFER
BOX - FRONT ( FIG. E )
E
- Type
- MANITOU reference
F
CAB (FIG. F)
- Type
- Serial No
PLATE MANUFACTURER OF THE ATTACHMENT (FIG. G)
- Model
- Serial No
- Year of manufacture
2-5
G
SAFETY FIRST
CONTENTS
ENGINE
PERKINS 1004-42 AR 81155
4
4
Direct
1.3.4.2
- Type
- Number of cylinders
- Number of strokes
- Injection system
- Ignition sequence
- Rocker arm clearance (Hot)
. Inlet
. Exhaust
- Capacity
- Bore
- Stroke
- Volumetric ratio
- Nominal running speed
- Idle speed
- Full speed
- Power ISO 3046-1
- Power ISO/TR 14396
- Power SAE
- Maximum torque ISO 3046-1
- Maximum torque ISO/TR 14396
- Air cleaner
COOLING
0,20 mm (.008 in)
0,45 mm (.018 in)
4233 cm3 (258 cu in)
103 mm (4.06 in)
127 mm (5.00 in)
18.5 / 1
2300 rpm
825 rpm
2500 rpm
83 cv
85 cv
89 cv
220 ft/lb at 1400 rpm
221 ft/lb at 1400 rpm
dry 3 microns
CIRCUIT
By water
Puller
6
- Type
- Fan
. Number of blades
. Diameter
- Thermostat
. Start opening
. Full opening
ELECTRIC
61,5 kw
63 kw
65,5 kw
457 mm (18 in)
77° C to 85° C (171-185°F)
92° C to 98° C (198-208°F)
CIRCUIT
Negative
- Earth
- Battery
- Alternator
. Type
. Tension regulator
- Starter
. Type
HYDROSTATIC
12 V - 105 Ah - 680 A EN
12 V - 65 A
Magneti Marelli A127
Incorporated into the alternator
12 V
Magneti Marelli M127
TRANSMISSION
HYDROSTATIC PUMP
- Type
A4VG56DA With variable cubic capacity and
with automatic power governor.
Electromagnetic 12V.
Hydraulic by valve TH7
- Gear reverser
- Inching control
- Main pump
. Capacity MAXI
. Capacity MINI
. MAX. flow rate
. Working pressure
56 cm3 (3.41 cu in)
0 cm3
141,68 L/mn (37.43 gal/min)
380 Bar (5510 psi)
2-6
SAFETY FIRST
CONTENTS
- Boost pump
. Cubic capacity
. MAX. flow rate
. Boost pressure MAX. r.p.m.
11,1 cm3 (.677 cu in)
27,19 L/min.(7.2 gal/min)
25 Bar (362 psi) transmission in
neutral
HYDROSTATIC MOTOR
- Type
. Capacity MAXI
. Capacity MINI
TRANSFER
A6VM107DA variable displacement
107 cm3 (6.5 cu in)
26 cm3 (1.6 cu in)
BOX
- Type
- Number of forward speeds
- Number of reverse speeds
FRONT
HURTH Coupled with front axle.
1
1
AXLE
- Type
- Hub reducers
- Differential lock
HURTH
Epicyclic
Foot pedal. Mechanical
BRAKE
- Type
- Service brake
Multidisc brake immersed in oil.
Foot pedal. Hydraulic brake acting on front
wheels.
Mechanical hand lever applied on the front
wheels.
- Parking brake
2-7
SAFETY FIRST
CONTENTS
MSI 50
FRONT
TIRES
STANDARD
DIMENSIONS
PRESSURE
315/70 R22,5 G391
GOOD YEAR
7,75 Bar
112 psi
DIMENSIONS
PRESSURE
12-5 R20 22PR MPT80
CONTINENTAL
7 Bar
101 psi
445/65 R19,5 Tubeless XZY 165K
MICHELIN
7,5 Bar
109 psi
16/70-20 14PR E91-2
DUNLOP
5,5 Bar
80 psi
OPTION
2
IMPORTANT
When changing or replacing the tires and wheels; use
only the manufacturer’s approved components as
installed at the factory. Any substitutes or
modifications must first be approved by the
manufacturer.
10.00-20 CSE SC10
CONTINENTAL (Solid)
REAR
TIRES
STANDARD
DIMENSIONS
PRESSURE
225/75 R15 XZM 149 A5
MICHELIN
6 Bar
87 psi
OPTION
DIMENSIONS
PRESSURE
PPS 28-9x15 CSE SC10
CONTINENTAL (Solid)
2-8
SAFETY FIRST
CONTENTS
HYDRAULIC
CIRCUIT
- Type of pump
. Capacity
- Lifting, tilting, attachment circuit
. Flow rate at full speed
. Pressure
- Steering direction
. Flow rate at full speed
. Pressure
- Filtration
. Return
. Suction
- Hydraulic shock absorber
. Capacities
. Pressure
Gear pump
37 cm3 (2.26 cu in)
92,5 L/mn (24.4 gal/min)
200 Bar (2900 psi)
Load control system
145 Bar (2102 psi)
10 Microns
100 Microns
1,4 L (.4 gal)
120 Bar (1740 psi)
SPECIFICATIONS
- Level of sound pressure in the driver's cabin
(According to norm prEN 12053: 1995)
. Cab model
- Travel speed of the lift truck
. Forward unladen
. Reverse unladen
80,5 dBA
24 km/h (15 mph)
24 km/h (15 mph)
- Standard lift height
varies
- Rated capacity with standard mast
10,000 lbs
- Load center
24 in
- Weight of forks
varies
2-9
SAFETY FIRST
CONTENTS
- Lifting movement (With standard mast)
. Unladen lifting
. Rated load lifting
. Unladen lowering
. Rated load lowering
- Weight of lift truck with standard mast
. Unladen
. Rated load
- Weight per axle with standard mast (Transport position)
. Front unladen
rated load
. Rear unladen
rated load
- Drawbar pull
. Unladen
. Rated load
- Maximum ramp negotiable in forward motion
. Unladen
. Rated load
2 - 10
SAFETY FIRST
CONTENTS
2 - 11
SAFETY FIRST
CONTENTS
DIMENSIONS AND LOAD CHART
MSI 50
See Manufacturer’s I.D. Plate
for load capacities.
2 - 12
SAFETY FIRST
CONTENTS
MSI 50
A
1200 mm (47.24 in)
B
2075 mm (81.69 in)
C
702 mm (27.63 in)
D
3322 mm (130.78 in)
E
4522 mm (178.03 in)
F
1391 mm (54.76 in)
F1
1135 mm (44.68 in)
G
185 mm (7.28 in)
G1
220 mm (8.66 in)
G2
225 mm (8.85 in)
G3
210 mm (8.26 in)
H
2775 mm (109.25 in)
H*
2575 mm (101.37 in)
H1
4672 mm (183.9 in)
H1*
4272 mm (168.18 in)
I
545 mm (21.45 in)
J
1300 mm (51.18 in)
K
1670 mm (65.74 in)
L
60 mm (2.36 in)
N
1775 mm (69.88 in)
O
150 mm (5.9 in)
P1
30 °
58 %
P2
27 °
51 %
P3
58 °
160 %
R
2700 mm (106.29 in)
S
2760 mm (108.66 in)
T
5002 mm (196.92 in)
U
2370 mm (93.30 in)
V
2900 mm (114.17 in)
V1
200 mm (7.87 in)
W
1735 mm (68.30 in)
Y
12 °
Z
10 °
H - H1
H* - H1*
= Standard mast
= Option mast
2 - 13
SAFETY FIRST
CONTENTS
INSTRUMENTS AND CONTROLS
26
26
24
14
24
25
12
5
14
15
22
22
2
4
13
20
3
1
21
1
6
19
20
7
17
8
7
19
10
9
11
10
9
30
16
18
23
27
28
32
1
2 - 14
SAFETY FIRST
CONTENTS
DESCRIPTION
1 - DRIVER’S SEAT
2 - TILTING HANDLE OF STEERING WHEEL
3 - INSTRUMENT PANEL
4 - SWITCH AND LAMP PANEL
5 - LIGHT SWITCH , HORN AND INDICATOR SWITCH
6 - IGNITION SWITCH
7 - KEY-OPERATED BATTERY DISCONNECT
8 - FUSE BOX
9 - ACCELERATOR PEDAL
10 - INCHING AND SERVICE BRAKE PEDAL
11 - DIFFERENTIAL LOCK PEDAL
12 - FORWARD/REVERSE LEVER
13 - PARKING BRAKE LEVER
14 - HYDRAULIC CONTROL DISTRIBUTOR LEVERS
15 - BRAKING OIL TANK SLUDGE DOOR
CAB LIFTING CONTROLS (16, 17 & 18)
16 - UNLOCKING HANDLE FOR CAB
17 - LIFTING CAB SWITCH
18 - SAFETY SHORE FOR LIFTING CAB
19 - CAB HEATER CONTROL
20 - HEATING VENTILATORS
21 - DOOR LOCKS
22 - CLOSING HANDLES FOR DOOR
23 - UNLOCKING HANDLES FOR OPEN DOOR
24 - ACCESS HANDLES
25 - HANDLES FOR L.H. SIDE WINDOW OPENING
26 - OUTSIDE REARVIEW MIRRORS
27 - WINDSCREEN WASHER TANK
28 - ROOF LIGHT
29 - TOWING PIN
30 - DOCUMENT HOLDER NET
31 - REAR LIGHTS AND INDICATORS
32 - SAFETY BELT
NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are meant for an observer seated normally in the driver's
seat, facing straight ahead.
2 - 15
SAFETY FIRST
CONTENTS
1 - DRIVER’S
SEAT
1st ASSEMBLY
FOR OPTIMAL COMFORT, THIS SEAT CAN BE ADJUSTED IN
DIFFERENT WAYS.
LONGITUDINAL ADJUSTMENT
- Pull the locking lever 1 upwards.
- Slide the seat to the required position.
- Release the lever and ensure it returns to the lock position.
2
1
SEAT SUSPENSION ADJUSTMENT
- Refer to the seat's graduation.
- Turn handle 2 depending on the driver's weight.
2nd ASSEMBLY
FOR OPTIMAL COMFORT, THIS SEAT CAN BE ADJUSTED IN
DIFFERENT WAYS.
LONGITUDINAL ADJUSTMENT
- Pull the locking lever 1 upwards.
- Slide the seat to the required position.
- Release the lever and ensure it returns to the lock position.
SEAT SUSPENSION ADJUSTMENT
- Pull and lift up the locking lever 2 so as to place it into one of these five
positions.
Position A : Light-weight driver (110 lb).
Position B : Intermediate.
Position C : Middle-weight driver.
Position D : Intermediate.
Position E : Heavy-weight driver (265 lb).
3
1
4
A
B
C
D
E
2
ANGLE ADJUSTMENT OF THE BACK-REST
- Pull the locking lever 3 backwards.
- Tilt the back-rest into one of the three possible positions.
- Release the locking lever and ensure it returns to the lock position.
ANGLE ADJUSTMENT OF THE WHOLE SEAT
- Lift up the locking lever 4.
- Tilt the seat forwards or backwards.
- Release the lever and ensure it returns to the lock position.
A
2 - TILTING
HANDLE OF STEERING WHEEL
1
- Turn the lever 1 towards A for loosening.
- Tilt the steering wheel into the required position.
- Turn the lever 1 towards B for locking.
2 - 16
B
SAFETY FIRST
CONTENTS
3 - INSTRUMENT
PANEL
A - Fuel level gauge.
B - Hourmeter.
C - Water temperature gauge.
D - Green indicator lamp.
E - Red engine oil pressure lamp.
F - Red alternator charge lamp.
G - Blue main beam lamp.
H - Red air filter clog lamp.
I - Red hydrostatic transmission oil filter clog lamp.
J - Fuses box.
A - FUEL LEVEL GAUGE
B - HOURMETER
It shows the number of hours the fork lift truck has run. The hours are shown on the dial up to a multiple of thousand.
The rotating knob indicates the good working order of the apparatus.
C - WATER TEMPERATURE GAUGE
When the truck works in normal conditions the needle of the indicator should indicate 80° to 90° C.
If the needle indicates an abnormally high temperature (100° C maximum), stop the engine immediately and investigate
the cooling system for problems.
D - GREEN INDICATOR LAMP
It is illuminated when the indicators are on and indicates that they are functioning properly.
E - RED ENGINE OIL PRESSURE LAMP
This lamp is illuminated when the ignition switch is in the ON position and should go out as soon as the fork lift truck
starts. If this lamp stays on when the engine is running, stop the fork lift truck immediately and look for the cause (see oil
level in engine crankcase).
F - RED ALTERNATOR CHARGE LAMP
This lamp is illuminated when the ignition switch is in the ON position and should go out as soon as the fork lift truck
starts. If this lamp stays on when the engine is running, stop the fork lift truck immediately and check the electrical circuit
as well as the alternator belt.
G - BLUE MAIN BEAM LAMP (OPTION)
The lamp is illuminated when lights are on main beam.
H - RED AIR FILTER CLOG LAMP
This lamp provides the operator with information about the condition of the filter cartridge. If this cartridge is clogged the
lamp comes on (See cleaning and replacement requirements in FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE).
I - RED HYDROSTATIC TRANSMISSION OIL FILTER CLOG LAMP
This lamp provides the operator with information about the condition of the filter cartridge. If this cartridge is clogged the
lamp comes on (See cleaning and replacement requirements in FILTERS CARTRIDGES AND BELTS in SECTION 3 MAINTENANCE).
NOTE: This lamp may come on in cold weather or when starting the forklift; it goes off when the hydraulic oil reaches
operating temperature.
2 - 17
SAFETY FIRST
CONTENTS
J - FUSE BOX
Remove the cover to replace a fuse. They are described here from left to
right:
1 : Indicators (7,5A).
2 : Horn. + Stop switch (7,5A).
3 : OPTION R.H. sidelight. + R.H. rear light (7,5A).
4 : OPTION L.H. sidelight + L.H. rear light (7,5A).
5 : OPTION Dipped headlights (7,5A).
6 : Forward / Reverse (7,5A).
7 : Heating.+ 2nd heating OPTION (7,5A).
8 : Front windscreen wiper and windscreen washer + Brake oil level
lamp (7,5A).
9 : OPTION Warning light (7,5A).
10 : OPTION (7,5A).
11 : OPTION (7,5A).
12 : OPTION Main beam (7,5A).
NOTE: Replace blown fuses with new ones of the same quality and capacity.
Never use a repaired fuse.
4 - SWITCH
AND LAMP PANEL
A - Front windscreen wiper switch and windscreen washer.
B - OPTION heater fan switch.
C - Rear windscreen washer switch.
E - OPTION warning light switch.
D - Brake oil level lamp.
F - OPTION working head light switch.
or
OPTION left working head light switch.
G - OPTION flashing alarm light switch.
H - OPTION working tail light switch.
or
OPTION left working tail light switch.
A - FRONT WINDSCREEN WIPER SWITCH AND WINDSCREEN
WASHER
This two position switch, when set in the "down" position and simultaneously
pressed, allows the windscreen-washer and the windscreen wiper to be operated.
When set in the "up" position, only the windscreen wiper operates.
B - HEATER FAN SWITCH
This two speed switch allows warm or cold air to pass through the heating
ventilators.
C - REAR WINDSCREEN WASHER SWITCH
D - BRAKE OIL LEVEL LAMP
This lamp comes on when the brake oil level is insufficient.
IMPORTANT
If the braking oil level is abnormally low, consult your
dealer.
2 - 18
E
F
D H
G A
B
C
SAFETY FIRST
CONTENTS
5 - LIGHT
SWITCH , HORN AND INDICATOR SWITCH
The switch controls the road lights and horn.
G
A
D
A - All lights are off, the rear direction indicators do not flash.
B - The right rear direction indicator flash.
C - The left rear direction indicator flash.
D - The sidelights (OPTION) and the rear lights are on.
E - The dipped headlights (OPTION) and the rear lights are on.
F - The main beam headlights (OPTION) and the rear lights are on.
G - Headlight signal (OPTION).
C
E
B
F
To operate the horn, press the switch.
NOTE: The positions D - E - F - G can be operated 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.
I - Ignition on.
II - Pre-Heating.
III - The engine starts, returns to position I as soon as the key is released
7 - KEY-OPERATED
BATTERY DISCONNECT
Enables the battery to be cut off from the electric circuit.
8 - FUSES
BOX
Remove the cover to replace a fuse:
1 - OPTION Working tail lights (10A).
OPTION Left working tail light (10A).
2 - OPTION Working head lights (10A).
OPTION Left working head light (10A).
3 - OPTION Flashing alarm light (7,5A).
4 - Cabin lifting (10A).
5 - OPTION (10A).
6 - Rear windscreen wiper (7,5A).
6
4
2
NOTE: Replace blown fuses with new ones of the same quality and capacity.
Never use a repaired fuse.
9 - ACCELERATOR
PEDAL
2 - 19
5
3
1
SAFETY FIRST
CONTENTS
10 - INCHING
AND SERVICE BRAKE PEDAL
This pedal acts in two stages:
In the first stage during the braking clearance stroke, it progressively
disengages the hydrostatic transmission for a slow approach, while allowing
full engine power.
In the second stage it acts on both front wheels through a hydraulic brake
system, allowing to slow and stop the fork lift truck.
11 - DIFFERENTIAL
LOCK PEDAL
The differential lock forces the front drive wheels to turn at the same speed
regardless of the terrain conditions.
- Press and hold the pedal in order to lock the differential as required.
- To disengage the differential lock simply release the pedal.
CAUTION
Because both front wheels turn at the same speed, the forklift will not
make turns. Steer the forklift in a straight line and at low speed before
engaging the differential lock.
12 - FORWARD/REVERSE
LEVER
The lift truck must be stationary when operating the forward/reverse lever.
FORWARD: Lift slightly and push the lever upwards (Position A).
REVERSE: Lift slightly and pull the lever downwards (Position B).
NEUTRAL: To start the truck, the lever must be in neutral (Position C).
NOTE: OPTIONAL backup lights exist, these lights are automatically turned
on when engaging reverse gear.
13 - PARKING
A
C
B
BRAKE LEVER
The parking brake acts on the front wheels.
To prevent accidental release, the lever is fitted with safety locking.
- To apply the parking brake, pull the lever backwards (Position A).
- To disengage the parking brake, release and push the lever forwards
(Position B).
2 - 20
A
B
SAFETY FIRST
CONTENTS
14 - HYDRAULIC
CONTROL DISTRIBUTOR LEVERS
LEVER A: Single acting section, controls raising and lowering the mast.
- Pull the lever backwards for raising the mast.
- Push the lever forwards for lowering the mast.
NOTE: The engine rpm automatically increases when lifting the load.
A
B
C
LEVER B: Double acting section, controls tilting the mast.
- Pull the lever backwards for reverse tilt of the mast.
- Push the lever forwards for forward tilt of the mast.
LEVER C: Double acting section, intended for control of additional optional
equipment.
A
WARNING
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 VOID THE WARRANTY.
16
A
B
15 - BRAKING OIL TANK SLUDGE DOOR
CAB
LIFTING CONTROLS
(16, 17 & 18)
B
CAUTION
Insure that the mast is tilted fully forward and the engine is stopped before
lifting the overhead guard.
17
CAUTION
Check for any objects left in the operator’s area which may interrupt the lifting
operation.
UNLOCKING THE CAB:
- Close the L.H. door.
- Open the R.H. door.
- Push lever 16 (Fig. A) to the left (position A) to unlock the cab.
- Turn the ignition to “on” (do not start the engine).
LIFTING THE CAB:
- With the R.H. door of the cab half open, press on the top of switch 17 (Fig.
B). Incline the cab fully forward.
- Place the locking lever 16 (Fig. A) in its initial position (position B).
- Close the R.H. door.
- Place the safety bar 18 (Fig. C) in the slot provided under the cab.
2 - 21
C
18
SAFETY FIRST
CONTENTS
LOWERING THE CAB:
- Lower the safety bar.
- Open the R.H. door half-way, press on the bottom of switch 17 (Fig. D) and
lower the cab, insure the cab locks into place.
- Close the R.H. door.
D
CAUTION
17
Check for clearance and obstacles while lowering the overhead guard.
19 - CAB
HEATER CONTROL
Allows the temperature inside the cab to be adjusted.
A - With the valve closed, the blower delivers fresh air.
B - With the valve opened, the blower delivers warm air.
A
The intermediate positions allow the temperature inside the cab to be adjusted.
B
20 - HEATING
VENTILATORS
These heating ventilators allow air ventilation to be directed inside the cab.
21 - DOOR
LOCKS
22 - CLOSING
HANDLES FOR DOOR
23 - UNLOCKING
24 - ACCESS
HANDLES
25 - HANDLES
26 - OUTSIDE
HANDLES FOR OPEN DOOR
FOR L . H . SIDE WINDOW OPENING
REARVIEW MIRRORS
2 - 22
SAFETY FIRST
CONTENTS
27 - WINDSCREEN
WASHER TANK
1
Check the level in the windscreen washer tank regularly, fill via the filler port 1.
28 - ROOF
LIGHT
The switch is located on the roof light.
29 - TOWING
PIN
Located at the back of the truck, this pin makes it possible to couple a trailer.
The capacity is limited for each lift truck by the Permissible Total Moveable
Weight (P. T. M. W.), the drawbar pull and the maximum vertical drawbar pull
on the towing pin. (See IDENTIFICATION OF THE LIFT TRUCK in SECTION
2 - DESCRIPTION).
NOTE: For towing, optional solutions exist, consult your dealer.
WARNING
Before towing trailers, ensure that the safety clip is fully engaged in the
towing pin.
30 - DOCUMENT
HOLDER NET
Make sure that the operator’s manual is properly stored, i.e., in the document
holder net.
31 - REAR
LIGHTS AND INDICATORS
A
A - Left rear indicator.
B - Left rear stoplight.
C - Left tail light.
D - Right tail light.
E - Right rear stoplight.
F - Right rear indicator.
2 - 23
B
C
D
E
F
SAFETY FIRST
CONTENTS
32 - SAFETY
BELT
- Sit correctly on the seat.
- Check that seat belt is not twisted.
- Place the seat belt at hip level and not across the stomach.
- Attach the seat belt and check that it locks.
- Adjust the seat belt to your body shape without squeezing your hip.
WARNING
In no event should the lift truck be used if the seat belt is defective (cuts,
tears, malfunctions, etc.). Repair or replace the seat belt immediately.
2 - 24
SAFETY FIRST
CONTENTS
DESCRIPTION AND OPERATION OF ELECTRIC AND HYDRAULIC
OPTIONS
1 - FLASHING
LIGHT
The flashing light is removeable, to reduce the height of the lift truck and to
avoid theft.
2
3
- Loose screw 1 and lower the flashing light.
- Protect the bracket 2 with the cap 3.
1
2 - FRONT
LIGHTS AND INDICATORS
A - Left front indicator.
B - Left front dipped headlight and main beam.
C - Left front sidelight.
D - Right front dipped headlight and main beam.
E - Right front sidelight.
F - Right front indicator.
F
3 - A D A P TAT I O N 4 A N D 5 S I N G L E - A C T I N G
DOUBLE - ACTING DISTRIBUTOR ELEMENT
TH
TH
OR
LEVER A : Intended for controlling a single or double acting additional
equipment.
LEVER B : Intended for controlling a single or double acting additional
equipment.
2 - 25
D
B
E
C
A
SAFETY FIRST
CONTENTS
2 - 26
SAFETY FIRST
CONTENTS
3 - MAINTENANCE
3-1
SAFETY FIRST
CONTENTS
3-2
SAFETY FIRST
CONTENTS
FILTERS CARTRIDGES AND BELTS
1
2
3
8
9
4
5
10
11
DESIGNATION
PART NUMBER
6
CLEAN
7
CHANGE
1 - Engine oil filter
133 755
2 - Dry air filter cartridge
563 416
3 - Safety dry air filter cartridge
563 415
800 H
4 - Hydrostatic transmission oil filter cartridge
46 028
800 H
5 - Hydraulic return oil filter cartridge
221 174
400 H
6 - Oil tank breather
457 509
400 H
7 - Fuel filter cartridge
49 660
400 H
8 - Fan belt
601 464
9 - Heating suction filter
197 926
800 H
10 - Suction strainer for hydraulic oil tank
77 402
800 H
11 - Automatic vacuum-cleaning pre-filter (OPTION)
160 946
3-3
400 H
50 H
400 H
SAFETY FIRST
CONTENTS
LUBRICANTS AND FUEL
COMPONENT
ENGINE
CAPACITY
7,6 L.
(2 gal)
RECOMMENDATION
Shell: Rotella 15w40
Texaco: URSA Super +15w40
TRANSFER BOX
0,7 L.
(0.75 qt)
Shell: Donax TD
Texaco: TDH 1893
FRONT AXLE DIFFERENTIAL
7 L.
(0.75 qt)
Shell: Donax TD
Texaco: TDH 1893
FRONT WHEEL REDUCER
0,7 L.
(0.75 qt)
Shell: Spirax DH80w90
Texaco: TDH EP 80w90
HYDRAULIC OIL TANK
155 L.
(41 gal)
Shell: Tellus T46
Texaco: Rando HDZ46
BRAKING CIRCUIT
Shell: Donax TG Dexron
Texaco: Havoline Dexron III
MAST LIFTING CHAINS
engine oil
MAST GREASING
Shell: Rentinax Am
Texaco: Havoline WBCG
GREASING MAST GUIDE ROLLER
Shell: Rentinax Am
Texaco: Havoline WBCG
GENERAL GREASING
Shell: Rentinax Am
Texaco: Havoline WBCG
COOLING CIRCUIT
FUEL TANK
15 L.
(4 gal)
90 L.
(23.75 gal)
Texguard Anti-Freeze Pre-mix 45/55 (-22°F)
Grade No.1-D diesel
DIAGNOSTIC ANALYSIS OF OIL
In the event of a maintenance or service contract with the dealer you may be requested to provide a sample of a
selected component's oil, for diagnostic analysis.
3-4
SAFETY FIRST
CONTENTS
3-5
SAFETY FIRST
CONTENTS
SERVICING SCHEDULE
AFTER
D1
D2
D4
D5
D6
E3
E4
E5
E6
THE FIRST
WORKING HOURS SERVICE
- Drain and change the engine oil.
- Change the engine oil filter.
- Change the fuel filter cartridge.
- Change the hydraulic return oil filter cartridge.
- Change the oil tank breather.
- Change the hydrostatic transmission oil filter cartridge.
- Drain and change the transfer box oil.
- Drain and change the front axle differential oil.
- Drain and change the front wheel reducers oil.
A - EVERY
A1
A2
A3
A4
50
DAY OR EVERY
10
WORKING HOURS SERVICE
- Check the engine oil level.
- Check the cooling liquid level.
- Check the fuel level.
- Check the tire pressure and the wheel nut torque.
B - EVERY 50
3 - 20
3 - 20
3 - 21
3 - 22
3 - 22
3 - 24
3 - 25
3 - 26
3 - 26
3 - 10
3 - 10
3 - 11
3 - 11
WORKING HOURS SERVICE
B1 - Clean the dry air filter cartridge.
(In heavily dust laden atmosphere, more frequent servicing required)
B2 - Check the hydraulic oil level.
B3 - Check the braking oil level.
B4 - Check the level of the windscreen washer liquid.
B5 - Check the battery electrolyte level (if applicable).
B6 - Clean the radiator core.
B7 - Check and adjust the tension and alignment of the mast lifting chains.
B8 - Lubricate the mast guide rollers.
B9 - Mast greasing.
B10 - General greasing.
C - EVERY 200
3 - 12
3 - 13
3 - 13
3 - 14
3 - 14
3 - 14
3 - 15
3 - 15
3 - 16
3 - 16
WORKING HOURS SERVICE
C1
C2
C3
C4
C5
C6
- Check and adjust the parking brake.
- Check and adjust the tension of the belt Alternator / Fan / Crankshaft.
- Check the level of the transfer box oil.
- Check the level of the front axle differential oil.
- Check the level of the front wheel reducer oil.
- Clean and lubricate the mast uprights.
(Before starting up the new lift truck and again after 200 hours service)
C7 - Drain the fuel filter.
3-6
3 - 18
3 - 18
3 - 18
3 - 19
3 - 19
3 - 19
3 - 19
SAFETY FIRST
CONTENTS
D - EVERY 400
WORKING HOURS SERVICE
To be performed once a year if the lift truck has not reached the 400 hours service in the year.
D1 - Drain and change the engine oil.
D2 - Change the engine oil filter.
D3 - Change the dry air filter cartridge.
D4 - Change the fuel filter cartridge.
D5 - Change the hydraulic return oil filter cartridge.
D6 - Change the oil tank breather.
D7 - Check the density of the battery electrolyte (where applicable).
D8 - Clean the fuel lift pump.
D9 - Check, clean and lubricate the mast lifting chains.
D10- Grease the parking brake lever mechanism.
D11- Check the wear on the forks (*).
* Consult your dealer
E - EVERY 800
3 - 20
3 - 20
3 - 21
3 - 21
3 - 22
3 - 22
3 - 22
3 - 23
3 - 23
3 - 23
WORKING HOURS SERVICE
To be performed once a year if the lift truck has not reached the 800 hours service in the year.
E1 - Drain and change the hydraulic oil.
E2 - Clean the suction strainer of the hydraulic oil tank.
E3 - Change the hydrostatic transmission oil filter cartridge.
E4 - Drain and change the transfer box oil.
E5 - Drain and change the front axle differential oil.
E6 - Drain and change the front wheel reducers oil.
E7 - Drain and change the cooling liquid.
E8 - Drain and clean the fuel tank.
E9 - Change the safety dry air filter cartridge.
E10 - Clean the heating suction filter.
E11 - Check the brake circuit pressure (*).
E12- Bleed the brake circuit (*).
E13- Check the brake adjustment (*).
E14 - Change the braking oil (*).
E15 - Check the engine mounts (*).
E16 - Check the engine speeds (*).
E17 - Check the attachment carriage (*).
E18 - Check the condition of the wheels and tires (*).
E19 - Check the speeds of the hydraulic movements (*).
E20 - Check the condition of the attachments (*).
E21 - Clean the hydraulic pump tubular filter (*).
F - EVERY 2400
F1
F2
F3
F4
F5
F6
3 - 24
3 - 24
3 - 24
3 - 25
3 - 26
3 - 26
3 - 27
3 - 28
3 - 28
3 - 29
* Consult your dealer
WORKING HOURS SERVICE
- Check the hydraulic circuit pressures and discharge rates (*).
- Check the hydrostatic transmission circuit pressures (*).
- Check and adjust the governing start r.p.m. of the hydrostatic transmission (*).
- Check the chain rollers wear (*).
- Check the mast guide rollers (*).
- Check the mast lifting chains (*).
3-7
SAFETY FIRST
CONTENTS
F7 - Check the steering system (*).
F8 - Clean the hydraulic oil tank (*).
F9 - Check the oscillation of the rear axle (*).
F10 - Check and adjust the valves clearances (*).
F11 - Check the injectors (*).
F12 - Check and scale the radiator (*).
F13 - Check the water pump and the thermostat (*).
F14 - Check the condition of the mast assembly (*).
* Consult your dealer
G - EVERY 4800
G1
G2
G3
G4
G5
WORKING HOURS SERVICE
- Check the wear of the brake disks (*).
- Check the steering axle (*).
- Check the clearance of the front wheel reducers (*).
- Check the bearings clearance of the transfer box (*).
- Check the alternator and the starter motor (*).
* Consult your dealer
H - OCCASIONAL
H1
H2
H3
H4
H5
H6
H7
MAINTENANCE
- Bleed the fuel system.
- Change a wheel.
- Tow the lift truck.
- Transport the lift truck on a trailer.
- Lift the cab in case of electric failure.
- Emergency Jump-start
- Lift the cab in the event of hydraulic failure in the lifting system.
3-8
3 - 30
3 - 32
3 - 33
3 - 34
3 - 35
3 - 36
3 - 37
SAFETY FIRST
CONTENTS
3-9
SAFETY FIRST
CONTENTS
A - EVERY DAY OR EVERY 10 WORKING HOURS SERVICE
A1 - CHECK
A1/1
THE ENGINE OIL LEVEL
Park the truck on level ground with the engine stopped, allow the engine oil to
settle.
1
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the dipstick 1 (Fig. A1/1).
- Clean the dipstick and check the oil level, it should be between the two
MAXI and MINI notches.
- If necessary, add oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through the filler port 2 (Fig. A1/2).
A1/2
2
A2 - CHECK
THE COOLING LIQUID LEVEL
A2/1
WARNING
ALWAYS ALLOW THE RADIATOR TO COOL
BEFORE OPENING THE RADIATOR CAP!
2
Park the lift truck on level ground with the engine stopped, wait for the engine
to cool down.
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- The liquid must be at the MAXIMUM level on the expansion pan 1 (Fig.
A2/1).
- If necessary, add cooling liquid through the filler port 2 (Fig. A2/1).
When the expansion pan is empty, check the level in the radiator before filling
the expansion pan.
- Rotate the radiator cap 3 (Fig. A2/2) to the safety stop.
- Allow any pressure to escape.
- Press down and turn the cap to release it.
- Add cooling liquid through the filler port 4 (Fig. A2/2).
- Slightly lubricate the cap to ease installation and removal.
3 - 10
1
A2/2
3
4
SAFETY FIRST
CONTENTS
A3 - CHECK
A3
THE FUEL LEVEL
Keep the fuel tank near full, to reduce condensation due to high humidity.
1
- Remove cap 1 (Fig. A3).
- Fill the fuel tank with clean fuel, filtered through a strainer or a clean, lint free
cloth, through filler port 2 (Fig. A3).
- Put the cap back 1 (Fig. A3).
2
WARNING
Never smoke or approach with a flame during filling operations or when the
tank is open. Never refill while engine is running.
A4 - CHECK
THE TIRE PRESSURES AND WHEEL NUT
TORQUES
A4
- Check the condition of the tires, for cuts, wear, etc.
- Check the torque load of the wheel nuts (See fig. A4). Non compliance with
this instruction can cause damage and rupture to the wheel bolts and
distortion to the wheels.
- Check and adjust the tire pressures if necessary (See CHARACTERISTICS
SECTION 2 - DESCRIPTION).
WARNING
Check that the air hose is correctly connected to the tire valve before
inflating, and keep all persons at a distance during inflation. Follow the
recommended tire pressures given.
3 - 11
WHEEL NUTS TORQUE
FRONT WHEEL
295 ft/lbs
REAR WHEEL
250 ft/lbs
SAFETY FIRST
CONTENTS
B - EVERY 50 WORKING HOURS SERVICE
B1 - CLEAN
THE DRY AIR FILTER CARTRIDGE
In a heavily dust laden atmosphere, increase inspections, see FILTERS
CARTRIDGES AND BELTS in SECTION 3 - MAINTENANCE.
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Loosen the clamps and remove cover 1 (Fig. B1).
- Remove filter cartridge 2 (Fig. B1).
- Leave the safety cartridge in place.
- Clean the filter cartridge using a low pressure air jet (Maxi pressure 40 psi)
directed from the inside to the outside surface of the cartridge, at least 1.5
in. from the cartridge wall.
- Cleaning is completed when there is no dust on the cartridge.
IMPORTANT
Respect the safety distance of 1.5 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.
- Clean the inside of the casing with a clean, damp, lint-free cloth. Also clean
the cartridge seal surfaces on the filter and cover.
- Check the condition of the filter cartridge, replace the cartridge if necessary.
- Install the cartridge, insure it is in the correct position.
- Replace the cover, guiding the valve downwards.
IMPORTANT
Do not clean the dry air filter cartridge by washing it in liquid. Do not clean
the safety cartridge located inside the filter cartridge, change it for a new
one if it is dirty or damaged.
3 - 12
B1
1
2
SAFETY FIRST
CONTENTS
B2 - CHECK
THE HYDRAULIC OIL LEVEL
B2
Park the lift truck on level ground with the engine stopped and the mast
lowered as far as possible.
1
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Refer to gauge 1 (Fig. B2).
- The level is correct when it is between the upper and lower marks.
- If necessary, add oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through filler port 2 (Fig. B2).
2
IMPORTANT
Always use a clean funnel and nozzle when filling.
Always maintain the oil level as stated, cooling depends on the oil flowing
through the tank.
B3/1
B3 - CHECK
THE BRAKING OIL LEVEL
Park the lift truck on level ground.
- Remove the access panel 1 (Fig. B3/1).
- The level is correct when it is at the maximum level on the tank.2 (Fig.
B3/2).
- If necessary, add oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through the filler port.
- Re-install the access panel 1 (Fig. B3/1).
WARNING
1
B3/2
If the braking oil level is abnormally low, consult your dealer.
3 - 13
2
SAFETY FIRST
CONTENTS
B4
B4 - C HECK
THE LEVEL OF WINDSCREEN WASHER
1
2
LIQUID
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Open the filling cap 1 (Fig. B4).
- Visually check the level.
- If necessary add windscreen washer liquid through the filler port 2 (Fig. B4).
B5 - CHECK
THE BATTERY ELECTROLYTE LEVEL
B5
Check the electrolyte level in each cell of the battery. If the truck is working in
a high temperature environment, check the level more frequently.
1
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove caps 1 (Fig. B5) from each cell of the battery.
- The level is correct when it is 1/2 in. above the top of the plates in the
battery.
- If necessary, top up the cells with clean distilled water.
- Clean and dry caps 1 (Fig. B5) and refit in place.
- Check the terminal connections, lightly lubricate with petroleum jelly to
prevent corrosion.
WARNING
Handling and servicing a battery can be dangerous, take the following
precautions:
- Wear protective goggles.
- Keep the battery horizontal.
- Never smoke or work near an open flame.
- Work in a well-ventilated area.
- In the event of electrolyte being spilled onto the skin or splashed in the
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.
B6 - CLEAN
THE RADIATOR CORE
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
To avoid clogging the radiator, keep it clean with a compressed air jet
directed from the front to the back. This is the best way to efficiently remove
debris. (High pressure steam or water will damage the cooling fins.)
IMPORTANT
When handling straw, grains or cereals, clean the radiator core every day.
3 - 14
1
1
1
1
1
SAFETY FIRST
CONTENTS
B7 - C H E C K
AND ADJUST THE TENSION AND
B7
ALIGNMENT OF THE MAST LIFTING CHAINS
Park the lift truck on level ground with the mast in a vertical position and the
forks lifted approximately 8 in.
- Check the alignment of the mast lifting chains between the carriage’s chain
fasteners and the chain rollers.
- Manually verify the chain tension, if necessary adjust the carriage while
ensuring it remains perpendicular to the mast.
- Adjust the tension by tightening or loosening the lock nut 1 (Fig. B7, on the
backside of the carriage) while checking the alignment of the lifting chains.
1
IMPORTANT
In case of technical problems, consult your dealer.
B8 - LUBRICATE
THE MAST GUIDE ROLLERS
B8/1
Current masts are supplied with mast rollers which are self contained, having
permanently sealed roller bearings. They require no general servicing.
IMPORTANT
In case of technical problems, consult your dealer.
3 - 15
1
SAFETY FIRST
CONTENTS
B9 - MAST
B9/1
GREASING
Clean and lubricate the following points with grease (See LUBRICANTS AND
FUEL in SECTION 3 - MAINTENANCE), remove any surplus grease.
1 - Lubricators on the mast mounting pins 1 (Fig. B9/1) (2 lubricators).
1
2 - Lubricators on the tilt cylinder base 2 (Fig. B9/2) and rod ends 3 (Fig.
B9/3) (4 lubricators).
B9/2
B9/3
2
3
B10 - GENERAL
B10/1
GREASING
Clean and lubricate the following points with grease (See LUBRICANTS AND
FUEL in SECTION 3 - MAINTENANCE), remove any surplus grease.
1
1 - Lubricators of the cabin doors 1 (Fig. B10/1) (4 lubricators).
2 - Lubricators of the steering cylinder pins 2 (Fig. B10/2)
(2 lubricators).
3 - Lubricators of steering rod pins 3 (fig. B10/2) (2 lubricator).
4 - Lubricators of the swivel pins 4 (Fig. B10/2) (6
lubricators).
B10/3
B10/2
5 - Lubricators of the rear axle
4
4
pivot 5 (Fig. B10/3) (2
lubricators).
5
3
2
4
3 - 16
SAFETY FIRST
CONTENTS
3 - 17
SAFETY FIRST
CONTENTS
C - EVERY 200 WORKING HOURS SERVICE
C1 - CHECK
C1
AND ADJUST THE PARKING BRAKE
Park the lift truck on level ground.
1
A
- Release the parking brake, position B (Fig. C1).
- Remove the rubber handle 1 (Fig. C1).
- Check the tightening adjustment by locking the parking brake in position A
(Fig. C1).
- The adjustment is correct when the lift truck is held stationary with the
nominal load, on a slope with a gradient of 15%.
- Repeat the operation until the correct braking adjustment is obtained.
C2 - C H E C K
B
AND ADJUST THE TENSION OF THE
ALTERNATOR
/
FAN
/
CRANKSHAFT BELT
C2
Park the lift truck on level ground with the engine stopped.
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Check the belt for wear and cracks and change it if necessary.
- Check the tension of the belt between the fan and alternator pulleys.
- Under a normal pressure exerted with the thumb, the tension should allow
approximately 3/8 in.of play.
- Carry out adjustments if necessary.
- Loosen screws 1 (Fig. C2) by two to three thread turns.
- Swivel the alternator assembly to adjust the belt tension as required.
- Retighten screws 1 (Fig. C2).
1
1
IMPORTANT
If the alternator belt has to be changed, check the tension again after the
first 20 hours of operation.
C3 - CHECK
THE LEVEL OF THE TRANSFER BOX OIL
C3
Park the lift truck on level ground with the engine stopped.
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the level plug 1 (Fig. C3). The oil should be flush with the edge of
the filler port.
- If necessary, add oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through the same hole.
- Replace and tighten the level plug 1 (Fig. C3) (Tightening torque 23 ft/lbs).
3 - 18
1
SAFETY FIRST
CONTENTS
C4 - C H E C K
C4
THE LEVEL OF THE FRONT AXLE
DIFFERENTIAL OIL
Park the lift truck on level ground with the engine stopped.
- Remove level plug 1 (Fig. C4). The oil should be flush with the edge of the
hole.
- If necessary, add oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through filler port 2 (Fig. C4).
- Replace and tighten the level plug 1 (Fig. C4) (Tightening torque 31
ft/lbs).
C5 - C H E C K
THE LEVEL OF THE FRONT WHEEL
REDUCER OIL
2
1
C5
Park the lift truck on level ground with the engine stopped.
- Check the level on both front wheel reducers.
- Place level plug 1 (Fig. C5) in the horizontal position.
- Remove the level plug; the oil should be flush with the edge of the hole.
- If necessary, add oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through the same hole.
- Replace and tighten the level plug 1 (Fig. C5) (Tightening torque 31 ft/lbs).
C6 - CLEAN
AND LUBRICATE THE MAST UPRIGHTS
1
C6
OPERATION TO BE DONE BEFORE OPERATING A NEW LIFT TRUCK
AND EVERY 200 HOURS SERVICE.
- Clean the length of the mast uprights (See fig. C6).
- Carefully check the different rollers for wear and replace them if necessary.
- Lubricate very lightly with grease (See LUBRICANTS AND FUEL in
SECTION 3 - MAINTENANCE) the entire length of the mast uprights. In
very dusty conditions, use a dry graphite lubricant (contact your local dealer)
IMPORTANT
In case of technical problems, consult your dealer.
C7 - DRAIN
C7
THE FUEL FILTER
- Open the engine compartment.
- Check for water in the filter tank 1 (Fig. C7), drain if necessary.
- Place a receptacle under the tank and loosen the drain plug 2 (Fig. C7) by
two of three turns.
- Let the diesel fuel flow until it is free from impurities and water.
- Tighten the drain plug.
1
If necessary, bleed the fuel circuit (See H1 - BLEED THE FUEL SYSTEM in
SECTION 3 - MAINTENANCE).
3 - 19
2
SAFETY FIRST
CONTENTS
D - EVERY 400 WORKING HOURS SERVICE
D1 - DRAIN AND CHANGE THE ENGINE
D2 - CHANGE THE ENGINE OIL FILTER
OIL
D1/1
Park the truck on level ground, let the engine run at idle to warm the oil, then
stop the engine.
1
DRAINING THE OIL
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Locate the service entrance 1 (Fig. D1/1) on the bottom of the lift truck.
- Place a container under drain plug 2 (Fig. D1/2) and unscrew the plug.
- Remove filler cap 3 (Fig. D1/3) to help the oil drain properly.
D1/2
IMPORTANT
Dispose of the drain oil in an ecological manner.
REPLACEMENT OF THE FILTER
- Remove engine oil filter 4 (Fig. D1/2); discard the filter and the filter seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly lubricate the new seal.
- Install the new oil filter on the filter bracket.
2
4
IMPORTANT
Tighten the oil filter by hand pressure only and lock the filter in place with a
quarter turn.
D1/3
FILLING THE OIL
- Install and tighten drain plug 2 (Fig. D1/2) (Tightening torque 26 ft/lbs).
- Fill with oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through filler port 5 (Fig. D1/3).
- Wait a few minutes to allow the oil to settle in 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 oil level. It should be
between the two notches on dipstick 6 (Fig. D1/4).
- Add oil if necessary.
3
5
D1/4
6
3 - 20
SAFETY FIRST
CONTENTS
D3 - CHANGE
D3
THE DRY AIR FILTER CARTRIDGE
The engine air intake is purified by a dry air filter. It is very important that the
lift truck never be operated with the cartridge removed or damaged.
1
2
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Loosen the clamps and remove cover 1 (Fig. D3).
- Lift out and discard filter cartridge 2 (Fig. D3).
- Leave the safety cartridge in place.
- Clean the inside of the casing with a clean lint free cloth. Also clean the
cartridge seal surfaces on the filter and cover.
- Install a new cartridge, insure it is in the correct position.
- Install the cover, guiding the valve downwards.
For info on operating the lift truck in a heavily dust laden atmosphere, see
FILTERS CARTRIDGES AND BELTS in SECTION 3 - MAINTENANCE.
D4 - CHANGE
THE FUEL FILTER CARTRIDGE
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Carefully clean the exterior of the filter and bracket to prevent the dust from
entering the system.
- Loosen the locking screw 1 (Fig. D4).
- Remove the tank 2 (Fig. D4) and discard the cartridge 3 (Fig. D4) and
cartridge seals.
- Clean the inside of the filter head and tank, using a brush and clean diesel
oil.
- Install the assembly with a new cartridge and new seals.
If necessary, bleed the fuel circuit (See H1 - BLEED THE FUEL SYSTEM in
SECTION 3 - MAINTENANCE).
3 - 21
D4
1
3
2
SAFETY FIRST
CONTENTS
D5 - CHANGE
D5
THE HYDRAULIC RETURN OIL FILTER
CARTRIDGE
1
IMPORTANT
To prevent debris from entering the hydraulic circuit, thoroughly clean the
outside of the filter and its surroundings before servicing.
2
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the screws on the cover 1 (Fig. D5).
- Remove the hydraulic return oil filter cartridge 2 (Fig. D5), and install a new
one.
- Make sure that the cartridge is correctly positioned, and install cover 1 (Fig.
D5).
D6 - CHANGE
THE OIL TANK BREATHER
D6
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the oil tank air breather 1 (fig. D6) and install a new one, tighten by
hand pressure only.
D7 - C H E C K
THE
DENSITY
OF
THE
1
B AT T E R Y
ELECTROLYTE
The electrolyte density varies depending on the temperature, but a minimum
of 1260 at 61° F must be maintained.
In the shaded area (Fig. D7), the battery is in a normal charge condition.
Readings above this zone indicate that the battery needs to be recharged.
The density should not vary more than 0.025 units between cells.
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Check the electrolyte density in each battery cell using a hydrometer.
D7
1.240
1.250
1.260
1.270
1.280
Do not perform this check immediately after adding distilled water. Recharge
the battery for at least an hour before checking the battery electrolyte density.
1.290
1.300
°C -18 -10 0 10 20 30 40
°F 0 14 32 50 68 86 104
WARNING
Handling and servicing a battery can be dangerous, take the following
precautions:
- Wear protective goggles.
- Keep the battery horizontal.
- Never smoke or work near an open flame.
- Work in a well-ventilated area.
- In the event of electrolyte being spilled onto the skin or splashed in the
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.
3 - 22
SAFETY FIRST
CONTENTS
D8 - CLEAN
D8
THE FUEL LIFT PUMP
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the retaining screw 1 (Fig. D8).
- Remove the strainer 2 (Fig. D8).
- Carefully clean the interior of the fuel lift pump, strainer and cover using a
brush and clean diesel fuel.
- Re-assemble and insure that the seal between the cover and the pump are
correct.
- Re-prime the fuel lift pump.
D9 - C H E C K ,
1
2
C L E A N A N D L U B R I C AT E T H E M A S T
LIFTING CHAINS
D9
- Wipe the mast lifting chains 1 (Fig. D9) with a clean, lint-free cloth. Examine
them closely for signs of wear.
- Clean the chains with a stiff nylon brush and clean diesel fuel.
- Rinse the chains with a soft brush and clean diesel fuel. Dry them with a
compressed air jet.
- Moderately lubricate the chains with a brush and lubricating oil (See
LUBRICANTS AND FUEL in SECTION 3 - MAINTENANCE).
- Remove the excess oil with a clean cloth along the full length of the chains.
D10 - G R E A S E
THE
PA R K I N G
BRAKE
1
LEVER
MECHANISM
D10
- Move the protective boot 1 (Fig. D10).
- Clean and grease the pivot points 2 (Fig. D10) with grease (See
LUBRICANTS AND FUEL in SECTION 3 - MAINTENANCE).
- Re-adjust the protective boot 1 (Fig. D10).
IMPORTANT
1
2
2
In case of technical problems, consult your dealer.
3 - 23
2
SAFETY FIRST
CONTENTS
E - EVERY 800 WORKING HOURS SERVICE
E1 - DRAIN AND CHANGE THE HYDRAULIC OIL
E2 - CLEAN THE SUCTION STRAINER OF THE
E1/1
HYDRAULIC OIL TANK
E3 - CHANGE
THE HYDROSTATIC TRANSMISSION OIL
FILTER CARTRIDGE
1
Park the lift truck on level ground with the engine stopped and the mast
lowered as far as possible.
DRAINING THE OIL
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
E1/2
IMPORTANT
Thoroughly clean the drain plug surroundings before servicing.
2
- Place a container under the drain plug 1 (Fig. E1/1) and remove it.
- Remove the cap 2 (Fig. E1/2) to help the oil drain properly.
IMPORTANT
9
Dispose of the oil in an ecological manner.
STRAINER CLEANING
- Disconnect the clogging indicator 3 (Fig. E1/3).
- Disconnect the hose 4 (Fig. E1/3) at the level of the hydrostatic transmission
oil filter 5 (Fig. E1/3).
- Remove the four screws 6 (Fig. E1/3) and the filter 5 (Fig. E1/3).
- Remove the suction strainer at the bottom of the tank, clean it with the help
of a compressed air jet, check its condition and change it, if necessary.
- Reassemble the strainer, the filter and reconnect the hose and clogging
indicator.
E1/3
4
5
6
6
HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE CHANGE
- Unscrew the cap 7 (Fig. E1/4).
- Remove the hydrostatic transmission oil filter cartridge 8 (Fig. E1/4) and
replace it with a new one.
- Ensure that the cartridge is correctly positioned, and install the cap.
IMPORTANT
6
3
E1/4
Do not operate the lift truck without the cartridge. It protects against the
deterioration of the hydraulic transmission circuit, the hydrostatic pump, and
the wheel reducers.
FILLING WITH OIL
- Clean and install the drain plug 1 (Fig. E1/1) (Tightening torque 26 ft/lbs).
- Fill with oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through filler port 9 (Fig. E1/2).
- (Continued on the next page.)
3 - 24
7
8
SAFETY FIRST
CONTENTS
IMPORTANT
Always use a clean container and funnel when filling.
- Examine the oil level on the cap-gauge 2 (Fig. E1/2), the oil level should be
between the lower and the upper marks.
- Check for any leaks at the drain plug.
- Install the cap-gauge 2 (Fig. E1/2).
IMPORTANT
If air bubbles have formed during draining, it may be necessary to bleed the
system at the pump inlets. If so, consult your dealer.
POLLUTION ABATEMENT OF THE HYDRAULIC CIRCUIT
- Let the engine run (Accelerator pedal at half throttle) for 5 minutes without
operating the lift truck, then for 5 more minutes while using all of the
hydraulic movements (Except the steering system and the service brakes).
- Accelerate the engine at full speed for 1 minute, then activate the steering
system and the service brakes.
This operation makes a pollution abatement of the circuit possible through the
hydraulic return oil filter.
E4 - DRAIN
AND CHANGE THE TRANSFER BOX OIL
E4
Park the lift truck on level ground with the engine stopped, the transfer box oil
still warm.
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Place a container under drain plug 1 (Fig. E4) and remove the plug.
- Remove level and filler cap 2 (Fig. E4) in order to ensure that the oil is
drained properly.
IMPORTANT
Dispose of the oil in an ecological manner.
- Refit and tighten drain plug 1 (Fig. E4) (Tightening torque 26 ft/lbs).
- Fill up with oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through filler port 2 (Fig. E4).
- The level is correct when the oil is flush with the edge of the hole.
- Check for any possible leaks at the drain plug.
- Refit and tighten level and filler cap 2 (Fig. E4) (Tightening torque 26
ft/lbs).
3 - 25
2
1
SAFETY FIRST
CONTENTS
E5 - D R A I N
AND
CHANGE
THE
FRONT
E5/1
AXLE
DIFFERENTIAL OIL
Park the truck on level ground with the engine stopped and the differential oil
still warm.
- Place a container under the drain plugs 1 (Fig. E5/1) and unscrew them.
- Remove the filler plug 2 (Fig. E5/1) and the level plug 3 (Fig. E5/1) to ensure
good draining.
1
1
1
IMPORTANT
Dispose of the oil in an ecological manner.
E5/2
- Refit and tighten drain plugs 1 (Fig. E5/1) (Tightening torque 31 ft/lbs).
- Fill up with oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) by filler port 2 (Fig. E5/2).
- The level is correct when the oil level is flush with the edge of port 3 (Fig.
E5/2).
- Check for any possible leaks at the drain plugs.
- Refit and tighten the filler plug 2 (Fig. E5/2) and the level plug 3 (Fig. E5/2).
(Tightening torque 31 ft/lbs).
E6 - DRAIN
2
3
AND CHANGE THE FRONT WHEEL
REDUCER OIL
E6
Park the lift truck on level ground with the engine stopped and the reducers’
oil still warm.
- Drain and change each front wheel reducer.
- Place drain plug 1 (Fig. E6) in position A.
- Place a container under the drain plug and unscrew the plug.
- Let the oil drain fully.
IMPORTANT
1
A
Dispose of the oil in an ecological manner.
- Place the drain port in position B (Fig. E6).
- Fill with oil (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through level port 1 (Fig. E6).
- The level is correct when the oil level is flush with the edge of the hole.
- Refit and tighten the drain plug 1 (Fig. E6) (Tightening torque 31 ft/lbs).
3 - 26
B
SAFETY FIRST
CONTENTS
E7 - DRAIN
E7/1
AND CHANGE THE COOLING LIQUID
These operations are to be carried out as necessary or once a year at the
coming of winter.
Park the truck on level ground with the engine stopped and cold.
LIQUID DRAINING
- Raise the cab (See INSTRUMENTS AND CONTROLS in 2 DESCRIPTION).
- Open the tap 1 (fig. A7/1) of the radiator.
- Remove the drain plug 2 (Fig. E7/2) on the engine block.
- Unscrew the filler plug 3 (Fig. E7/3) on the expansion pan and empty.
- Remove the filler plug 4 (Fig. E7/4) on the radiator.
- Allow the cooling circuit to drain completely.
- Check the condition of the hoses and clamps, change them if necessary.
- Rinse the circuit with clean water and use a cleaning product if necessary.
1
E7/2
LIQUID FILLING
- Close the tap 1 (fig. A7/1).
- Tighten the drain plug 2 (Fig. E7/2) (Tightening torque 7 ft/lbs).
- Slowly fill the cooling circuit (See LUBRICANTS AND FUEL in SECTION 3 MAINTENANCE) through the filler port 5 (Fig. E7/4).
- Fill the expansion pan to the maximum level.
- Allow the engine to run at idle for a few minutes.
- Check for leaks.
- Check the level and top up if necessary.
- Refit the filler plug 4 (Fig. E7/4).
- Install the filler plug 3 (Fig. E7/3)
2
E7/3
3
IMPORTANT
The engine does not contain a corrosion resistor and must be filled with a
minimum mixture containing 25% ethylene glycol-based antifreeze.
E7/4
4
5
3 - 27
SAFETY FIRST
CONTENTS
E8 - DRAIN
AND CLEAN THE FUEL TANK
E8/1
WARNING
While performing these operations, do not smoke or work near an open flame.
Park the lift truck on level ground with the engine stopped.
1
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Inspect the parts susceptible to leaks in the fuel circuit and tank.
- In the event of a leak, contact your dealer.
WARNING
E8/2
Never perform welding or any other major repair unless certified; such
action could provoke an explosion or a fire.
- Place a container under drain plug 1 (Fig. E8/1) and unscrew the plug.
- Remove cap 2 (Fig. E8/2).
- Let the fuel drain, then flush the tank with 2 gal. of clean fuel through filler
port 3 (Fig. E8/2).
- Install the drain plug 1 (Fig. E8/1) (Tightening torque 25 ft/lbs).
- Fill the fuel tank with clean fuel (See LUBRICANTS AND FUEL in SECTION
3 - MAINTENANCE) filtered through a strainer or a clean, lint-free cloth.
- Install the filler plug 2 (Fig. E8/2).
- Re-prime the system by activating fuel feed pump 4 (Fig. E8/3).
- If necessary, bleed the system (See H1 - BLEED THE FUEL SYSTEM in
SECTION 3 - MAINTENANCE).
2
3
E8/3
4
E9 - CHANGE
THE SAFETY DRY AIR FILTER
CARTRIDGE
E9/1
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the dry air filter cartridge (See D3 - CHANGE THE DRY AIR
FILTER CARTRIDGE in SECTION 3 - MAINTENANCE).
- Remove and replace the air filter safety cartridge 1 (Fig. E9/1).
- Reassemble the entire unit (See D3 - CHANGE THE DRY AIR FILTER
CARTRIDGE in SECTION 3 - MAINTENANCE).
3 - 28
1
SAFETY FIRST
CONTENTS
E10 - CLEAN
E10/1
THE HEATING SUCTION FILTER
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
- Remove the knurled nuts 1 (Fig. E10/1) and washers.
- Remove the heating suction filter 2 (Fig. E10/2).
- Clean the filter with a compressed air jet.
- Check its condition and replace it if necessary.
- Reassemble the unit.
1
1
E10/2
2
3 - 29
SAFETY FIRST
CONTENTS
H - OCCASIONAL MAINTENANCE
H1 - BLEED
H1/1
THE FUEL SYSTEM
1
These operations may be required in the following cases:
- A component of the fuel system has been replaced or drained.
- A drained tank.
- Running the tank out of fuel.
Ensure that the level of fuel in the tank is sufficient, turn the ignition key to
notch I to establish electrical contact and bleed in the following order:
- Raise the cab (See INSTRUMENTS AND CONTROLS in SECTION 2 DESCRIPTION).
H1/2
BLEEDING THE FUEL FILTER
- Loosen bleed screw 1 (Fig. H1/1).
- Activate feed pump 2 (Fig. H1/2) until the diesel fuel flows out free from air
bubbles at the bleed screw.
NOTE: If the lever on the feed pump is in the maximum raised position, turn
the crankshaft by one turn.
- Tighten the bleed screw while diesel fuel is flowing out.
2
BLEEDING THE HEATER PLUG
- Loosen connection 3 (Fig. H1/3) on the heater plug.
- Activate feed pump 2 (Fig. H1/2) until diesel fuel is flowing out free from air
bubbles at the connection.
- Tighten the connection while the diesel fuel is flowing out.
H1/3
3
IMPORTANT
Immobilize the heater plug with a spanner wrench before loosening
connection 3 (fig. H1/3)
BLEEDING THE INJECTION PUMP
- Loosen connection 4 (Fig. H1/4) of the low pressure fuel return circuit on the
regulator housing.
- Activate feed pump 2 (Fig. H1/2) until diesel fuel is flowing out free from air
bubbles at the connection.
- Tighten the connection while the diesel fuel is flowing out.
H1/4
4
3 - 30
SAFETY FIRST
CONTENTS
BLEEDING THE INJECTORS
- Slightly loosen any two high pressure connectors 5 (Fig. H1/5).
- Activate the starter until diesel fuel flows out free of air bubbles at the
connections.
- Tighten the connections while the diesel fuel is flowing out (Tightening
torque 16 ft/lbs).
The engine is then ready to be started.
IMPORTANT
Run the engine at slow idle for 5 minutes immediatly after bleeding the fuel
feed circuit, in order to ensure that the injection pump has been bled
thoroughly.
NOTE: If the 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 - 31
H1/5
5
5
5
5
SAFETY FIRST
CONTENTS
H2 - CHANGE
H2/1
A WHEEL
WARNING
In the event of a wheel being changed on the public highway, make sure of
the following points:
- Stop the lift truck on hard level ground.
- Park the lift truck (See OPERATING INSTRUCTIONS,SECTION ESTOPPING THE LIFT TRUCK in SECTION 1 - OPERATING AND SAFETY
INSTRUCTIONS).
- Turn the warning lights on.
H2/2
- Park the lift truck on level, solid ground.
- Turn the warning lights on.
- Chock the lift truck tire in both directions on the axle opposite to the wheel to
be changed.
- Loosen the nuts of the wheel to be changed.
NOTE: For this operation use an approved hydraulic jack.
REAR WHEEL
- Place the jack under the hind carriage, as near as possible to the wheel to
be changed and adjust the jack (Fig. H2/1).
- Raise the wheel until it lifts off the ground, place security wedges under the
carriage (Fig. H2/2).
H2/3
- Remove the wheel nuts.
- Free the wheel and roll it aside.
- Place the new wheel on the wheel hub.
- Start the nuts by hand, if necessary grease them.
- Remove the safety wedges and lower the lift truck using the jack.
- Tighten the wheel nuts with a torque wrench (See A - DAILY OR EVERY 10
HOURS SERVICE in SECTION 3 - MAINTENANCE for tightening torque).
FRONT WHEEL
- Place the jack under the flared tube, as near as possible to the wheel to be
changed, and adjust the jack (Fig. H2/3).
- Raise the wheel until it lifts off the ground and place security wedges under
the chassis (Fig. H2/4).
H2/4
- Remove the wheel nuts.
- Free the wheel and roll it aside.
- Place the new wheel on the wheel hub.
- Start the nuts by hand, if necessary grease them.
- Remove the safety wedges and lower the lift truck using the jack.
- Tighten the wheel nuts with a torque wrench (See A - DAILY OR EVERY 10
HOURS SERVICE in SECTION 3 - MAINTENANCE for tightening torque).
3 - 32
SAFETY FIRST
CONTENTS
H3 - TOW
H3/1
THE LIFT TRUCK
1
IMPORTANT
NEVER try to push or pull the lift truck to start it! Such a maneuver would
cause serious damage to the hydrostatic transmission.
UNLOCKING THE HIGH PRESSURE VALVES.
ACCESS TO HIGH PRESSURE VALVES.
- The upper HP valve 1 (Fig.3/1) is accessible after raising the cab.(See
INSTRUMENTS AND CONTROLS in SECTION 2 - DESCRIPTION).
- The lower HP valve 2 (Fig.3/1) is accessible from under the frame.
UNLOCKING OF HIGH PRESSURE VALVES.
- Check the X dimension (Fig.H3/2) on the two HP valves.
- Unlock the jam nut 3 (Fig.H3/2)
- Tighten the screw 4 (Fig.H3/2) until flush with the jam nut 3 (Fig.H3/2)
- After towing proceed in reverse order and reposition the HP valves to the X
position.
TOWING THE LIFT TRUCK
IMPORTANT
Tow the forklift at a slow speed, 3 mph max., and for no further than 330 ft.
- Turn on the warning lights (OPTION).
- Place the forward/ reverser lever in neutral.
- Release the park brake.
- Because the steering and braking booster are disabled, move slowly and
grip the steering wheel firmly. Avoid sudden or abrupt movements.
3 - 33
2
H3/2
4
3
X
SAFETY FIRST
CONTENTS
H4 - TRANSPORTING
THE LIFT TRUCK ON A TRAILER
H4/1
CAUTION
Ensure that the safety instructions concerning the platform are followed
before loading the lift truck, and that the truck driver has been informed
about the dimensions and weight of the lift truck (See CHARACTERISTICS
in SECTION 2 - DESCRIPTION).
Ensure that the platform has the dimensions and load capacity sufficient for
transporting the lift truck. Check also the loads allowable on the contact
surface of the platform before loading the lift truck.
LOAD THE LIFT TRUCK
- Block the wheels of the trailer.
- When wheel ramps must used, use only approved loading ramps which load
the forklift at a slight angle.
- Load the lift truck parallel to the trailer.
- Park the lift truck (See DRIVING INSTRUCTIONS in SECTION 1 OPERATING AND SAFETY INSTRUCTIONS).
STOW THE LIFT TRUCK
- Attach the chocks to the trailer at the front and at the back of each tire (Fig.
H4/1). Also use chocks on the inside of each tire (Fig. H4/2).
- Attach the lift truck to the trailer with approved chain, cable or belts. Attach
to the front by passing above the mast mountings 1 (Fig. H4/3), on the rear at
the towing pin 2 (Fig. H4/4).
- Tighten the connections (Fig. H4/5).
H4/2
H4/3
1
H4/4
H4/5
2
3 - 34
SAFETY FIRST
CONTENTS
H5 - L I F T I N G
H5/2
THE CABIN IN THE EVENT OF AN
ELECTRICAL FAILURE
WARNING
1
Handling and servicing a battery can be dangerous, take the following
precautions:
- Wear protective goggles.
- Keep the battery horizontal.
- Never smoke or work near an open flame.
- Work in a well-ventilated area.
- In the event of electrolyte being spilled onto the skin or splashed in the
eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.
- Provide a battery of the same type as that on the lift truck, and battery
cables.
- Close the left door and open the right door of the cab.
- Unlock the cab, place lever 1 (Fig. H5/2) in position A.
- Remove the key from the battery disconnecting device.
- Disassemble the panel 2 (Fig. H5/3) for access to the connections on the
battery disconnecting device.
- Connect the negative cable to the battery and make a good earth on the lift
truck (i.e., locking screw of the front axle of the frame) (Fig. H5/4).
- Connect the positive cable to the battery and the terminal 3 (Fig. H5/5) of
the battery disconnecting device.
- Turn on the ignition in the lift truck.
- Half-open the right door of the cab and press the upper part of the switch 4
(Fig. H5/6) to tilt the cab as far as possible without interfering with the mast.
- Disconnect the positive cable from the terminal 3 (Fig. H5/5) of the battery
disconnecting device.
- Disconnect the ground on the lift truck.
- Access the lift truck battery and connect the spare battery, insure
connection to the proper polarity (Fig. H5/7).
- Then continue lifting the cab (See INSTRUMENTS AND CONTROLS in
SECTION 2 - DESCRIPTION).
A
B
H5/3
2
H5/4
For jump-starting the forklift see the following page.
H5/5
H5/6
H5/7
3
4
3 - 35
SAFETY FIRST
CONTENTS
H6 - EMERGENCY
JUMP - STARTING
Read and follow the instructions carefully. If you have any questions, ask for assistance from an experienced mechanic
or contact your nearest dealer. To access the battery, see paragraph H5 on the previous page.
Before attempting a jump-start, determine the condition of the forklift’s battery: if it is damaged, has corroded
connections or weak electrolyte, it will have to be serviced or replaced before proceeding (see D7 in SECTION 3 MAINTENANCE for electrolyte servicing).
Jump-starting the forkllift requires a good, fully charged 12 volt battery or a vehicle with a 12 volt, negative ground
electrical system. Park the jumper vehicle next to the disabled forklift, do not allow the vehicles to touch.
WARNING
Improper jump starting procedures can result in battery explosion.
Follow jump start instructions carefully.
Do not allow the jumper cable clamps to contact each other or any metal
surfaces (except as instructed) while attaching or removing the cables.
Use only a 12 volt, negative ground system to jump-start your forklift.
Set the parking brake and turn off all electrical components on both vehicles.
Turn the jumper vehicle engine off.
Connect the jumper cables in the following sequence:
STEP 1: Clamp the positive (+) jumper cable to the good battery’s positive (+) terminal.
STEP 2: Clamp the other end of the positive (+) cable to the dead battery’s positive (+) terminal.
STEP 3: Clamp the negative (-) jumper cable to the good battery’s negative (-) terminal.
STEP 4: Clamp the other end of the negative (-) cable to a solid metel point on the frame or engine (ground), at least 18
inches away from the battery. Keep the clamps away from the engine fan and belts.
DEAD BATTERY
GOOD BATTERY
(Jumper Vehicle)
STEP 1
STEP 2
JUMPER
CABLES
TO
GROUND
STEP 3
TO
GROUND
STEP 4
ENGINE BLOCK OR FRAME
Start the engine on the jumper vehicle and allow it to run at high idle for about 5 minutes.
Start the forklift. Make sure that the engines in both vehicles are at low idle before disconnecting the jumper cables.
Remove the cables in reverse order of installation:
Remove the negative (-) cable from the forklift frame or engine (ground).
Remove the negative (-) cable from the jumper vehicle.
Remove the positive (+) cable from the forklift.
Remove the positive (+) cable from the jumper vehicle.
If the forklift fails to start after several attempts, seek assistance from a qualified mechanic or contact your nearest
dealer.
3 - 36
SAFETY FIRST
CONTENTS
H7 - LIFT
H7/1
THE CABIN IN THE EVENT OF A HYDRAULIC
FAILURE IN THE LIFTING SYSTEM .
- Unlock the cab with lever 1 (Fig. H7/1) in position A.
- Tilt the mast all the way back and raise the mast until approx. 20 in. above
the cab.
- Close the cab doors.
- Pass an approved sling around the upper crossbrace of the mast (Fig.
H7/2). Fasten the sling ends to the back of the cab roof 2 (Fig. H7/3).
- Start the engine.
- Carefully lift the mast to stretch the sling.
- Slowly tilt and lift the mast forwards until you can insert the safety rod 3 (Fig.
H7/4) into its stop 4 (Fig. H7/4).
- Lower the mast to release and remove the sling.
- Reset the lever 1 (Fig. H7/1) into position B.
1
A
B
H7/2
H7/4
H7/3
4
2
3
2
3 - 37
SAFETY FIRST
CONTENTS
3 - 38