Manitou MSI 20 D MSI 25 D MSI 30 D MSI 20 D MSI 25 D MSI 30 D BUGGIE Operator's Manual - DOWNLOAD

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BP 249 Z. I. 44 158 ANCENIS CEDEX FRANCE TEL : 02 40 09 10 11

YOUR DEALER

547041 EN (14 / 10 / 2002)

MSI 20 D MSI 25 D MSI 30 D MSI 20 D BUGGIE MSI 25 D BUGGIE MSI 30 D BUGGIE (FROM MACHINE Nr : 139126) OPERATOR'S MANUAL

THIS OPERATOR'S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY USERS.

1st DATE OF ISSUE DATE OF ISSUE

11 / 10 / 1996 OBSERVATION

11 / 10 / 1996

- 1st ISSUE

07 / 02 / 1997

- UP DATING (1-13 ; 2 - DESCRIPTION ; 3-4 ; 3-6 ; 3-7 ; 3-8 ; 3-11 ; 3-14 ; 3-23 ; 3-36 ; 3-37 ; 3-38) - ADDING "4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE"

02 / 11 / 1999

- UP DATING

14 / 10 / 2002

- UP DATING (For the machine up to Nr : 139125, see operator's manual : 547827 FR)

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

TABLE OF CONTENTS 1 - OPERATING

1-1

AND SAFETY INSTRUCTIONS

– ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS – DRIVER'S OPERATING INSTRUCTIONS • CAUTION • GENERAL INSTRUCTIONS • OPERATING INSTRUCTIONS • INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLING OPERATIONS • INSTRUCTIONS FOR HANDLING A LOAD – MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK – BEFORE STARTING UP A NEW LIFT TRUCK – IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME

2 - DESCRIPTION

2-4 MSI 20 D MSI 20 D BUGGIE MSI 25 D MSI 25 D BUGGIE MSI 30 D MSI 30 D BUGGIE

CHARACTERISTICS OF MASTS DIMENSIONS AND LOAD CHART INSTRUMENTS AND CONTROLS (OVERHEAD GUARD MODEL) INSTRUMENTS AND CONTROLS (CAB MODEL) TOWING PIN AND HOOK DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS

3 - MAINTENANCE – – – – – – – – – –

FILTERS CARTRIDGES AND BELTS LUBRICANTS AND FUEL SERVICING SCHEDULE A - DAILY OR EVERY 10 HOURS SERVICE B - EVERY 50 HOURS SERVICE C - EVERY 250 HOURS SERVICE D - EVERY 500 HOURS SERVICE E - EVERY 1000 HOURS SERVICE F - EVERY 2000 HOURS SERVICE G - OCCASIONAL MAINTENANCE

4 - ADAPTABLE

1 - 14 1 - 18 1 - 20 1 - 22

2-1

– IDENTIFICATION OF THE LIFT TRUCK – CHARACTERISTICS

– – – – – –

1-3 1-4 1-4 1-6 1-8 1 - 12

ATTACHMENTS IN OPTION ON THE RANGE

– INTRODUCTION – TECHNICAL SPECIFICATIONS OF ATTACHMENTS – ATTACHMENT SHIELDS

2 - 6 and 2 - 8 2 - 6 and 2 - 10 2 - 6 and 2 - 12 2 - 14 2 - 16 2 - 18 2 - 26 2 - 34 2 - 36

3-1 3-3 3-4 3-6 3-8 3 - 10 3 - 14 3 - 16 3 - 20 3 - 24 3 - 26

4-1 4-3 4-4 4 - 10

1 - OPERATING AND SAFETY INSTRUCTIONS

1-1

1-2

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.

BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS, YOU ARE LEGALLY COVERING YOURSELF

- Any user who procures parts from another quarter 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.

- Only 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. The dealer network list is available on MANITOU web site www.manitou.com 1-3

DRIVER'S OPERATING INSTRUCTIONS CAUTION WHENEVER YOU SEE THIS SYMBOL IT 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 should be able to avoid accidents occurring.

- Any operation or manœuvre not described in the operator's manual is theoretically prohibited, but anyone using a different method should first make sure that it does not endanger his own safety or that of others, or of the lift truck.

- 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 exhaustive.

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 be 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 contra-indicated.

Such foreseeable abnormal uses, the main ones being listed below, are strictly forbidden.

- The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any wish to put the machinery to any improper use.

- The reflex reactions of a person in the event of a malfunction, incident, fault, etc. during operation of the lift truck.

- Behaviour resulting from application of the "principle of least action" when performing a task.

- For certain machines, the foreseeable behaviour of such persons as : apprentices, teenagers, handicapped persons, trainees tempted to drive a lift truck, 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.

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1-5

GENERAL

INSTRUCTIONS

A - THE LIFT TRUCK'S SUITABILITY FOR THE JOB - The manufacturer has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator's manual, with a static test coefficient of 1.33 and a dynamic test coefficient of 1, as specified in harmonised norm EN 1726-1 for mast trucks.

B - 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.

C - AUTHORISATION TO OPERATE (LEGISLATION IN FORCE FOR FRANCE) (Or refer to the legislation for each particular country) - Only qualified personnel may use the lift truck. Its use is subject to authorisation to operate being given by the appropriate manager in the user establishment.

- The user must be bearing the driving licence during the period of service.

- The driver is not competent to authorise the driving of the lift truck by another person.

- In addition, the vehicle should be used in accordance with good practice for the profession.

D - 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 chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Ensure tyres are adapted to the nature of the ground (See area of the contact surface of the tyres in the chapter : CHARACTERISTICS in paragraph : 2 - DESCRIPTION). . SAND tyres. . LAND tyres. . Snow chains.

There are optional solutions, consult your dealer.

A worn or damaged tyre can result in the lift truck being temporarily out of service.

The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer, excepting prior authorisation.

- 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, I.C. 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.

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 dealer) and under the necessary safety conditions to maintain the health of the operator and any third party.

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E - 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 dealer.

- Take into account climatic and atmospheric conditions of the site of utilisation. . Protection against frost (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE). . Adaptation of lubricants (Ask your dealer for information). . Engine filtration. . Lighting (Working headlight).

Optional solutions exist, consult your dealer.

For operation under average climatic conditions, i.e. : between -15 °C and + 35 °C, correct levels of lubricants in all the circuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessary to drain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures. It is the same for the cooling liquid.

Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated premises. It is prohibited to use the lift truck in areas where there is a risk of fire or which are potentially explosive (e.g. Refineries, fuel or gas depots, stores of inflammable products…). For use in these areas, specific equipment is available on option.

IF NECESSARY, CONSULT YOUR DEALER.

1-7

OPERATING

INSTRUCTIONS

A - DRIVER’S OPERATING INSTRUCTIONS - Wear clothes suited for driving the lift truck, avoid loose clothes.

- Make sure you have the appropriate protective equipment for the job to be done.

- Prolonged exposure to high sound levels may cause hearing problems. To protect your ears from uncomfortable sound levels, wear ear protectors.

- Always pay attention when using the lift truck. Do not listen to the radio or music using headphones or earphones.

- 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.

Under no circumstances must the seat be adjusted while the lift truck is moving.

- The operator must always be in his normal position in the driver’s cab. It is prohibited to have arms or legs, or generally any part of the body, protruding from the driver’s cab of the lift truck.

- 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 (e.g. climbing onto or down from the lift truck, portmanteau, etc.).

- If the control components are fitted with a forced operation (lever lock) device, it is forbidden to leave the cab without first putting these controls in neutral.

- Never allow a passenger to travel on the lift truck in the driver’s cab.

B - BEFORE STARTING THE LIFT TRUCK - If the lift truck is new, refer to chapter : BEFORE STARTING UP A NEW LIFT TRUCK in paragraph : 1 - OPERATING AND SAFETY INSTRUCTIONS. - Check the condition of the tyres and the tyre pressures (See chapter : CHARACTERISTICS in paragraph : 2 DESCRIPTION).

- Before starting the lift truck, check the different levels : . Engine oil. . Hydraulic reservoir oil. . Hydrostatic transmission oil. . Cooling liquid.

- Also check for possible leakage of oil, fuel or liquid from the lift truck.

- Check the closing and locking of the hood(s).

- Whatever his experience as a truck driver is, 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 The lift truck must only be started up or manoeuvred 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.

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 chapter : G - OCCASIONAL MAINTENANCE in paragraph : 3 MAINTENANCE).

- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connecting it. Always connect the positive terminals before the negative terminals.

Failure to respect polarity between batteries can cause serious damage to the electrical circuit. The electrolyte in the battery may produce an explosive gas. Avoid flames and generation of sparks close to the batteries.

Never disconnect a battery while it is charging.

1-8

INSTRUCTIONS - 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.

- Press the accelerator pedal and turn the ignition key fully : the I.C. engine should then start. Release the ignition key and let the I.C. engine run at idle.

Do not engage the starter motor for more than 15 seconds and carry out the preheating for 10 seconds between unsuccessful attempts.

- Check all control instruments immediately after starting up, when the I.C. engine is warm and at regular intervals during use, so as to quickly detect any faults and to be able to correct them without any delay.

- If an instrument does not show the correct display, stop the I.C. engine and immediately carry out the necessary operations.

D - DRIVING THE LIFT TRUCK SAFETY NOTICE - Always drive the lift truck with the forks or attachment to the transport position, i.e. at approximately 300 mm from the ground.

- Familiarise yourself with the lift truck on the terrain where it will be used.

- Ensure that the service brakes and the sound alarm 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, so turn it gently and not jerkily.

- Never leave the I.C. 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 dealer.

- Drive round obstacles.

- Never drive on the edge of a ditch or steep slope.

- Never move onto a loading platform without having first checked : . That it is suitably positioned and made fast. . That the unit to which it is connected (Wagon, lorry, etc.) will not shift. . That this platform is prescribed for the total weight of the lift truck to be loaded. . That this platform is prescribed for the width of the lift truck.

- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order.

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 12 km/h.

INSTRUCTIONS - Raise the forks or attachment to the transport position approximately 300 mm 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.

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E - STOPPING THE LIFT TRUCK SAFETY NOTICE - Before stopping the lift truck after a long working period, leave the I.C. engine idling for a few moments, to allow the coolant liquid and oil to lower the temperature of the I.C. engine and transmission.

Do not forget this precaution, in the event of frequent stops or warm stalling of the I.C. engine, or else the temperature of certain parts will rise significantly due to the stopping of the cooling system, with the risk of badly damaging such parts.

- 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 put the forward/reverse lever in neutral.

- If the driver has to leave his cab, even for a moment, it is essential to apply the parking brake and put the forward/reverse lever in neutral.

- Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at less than one meter from the track of a railway.

- In the event of prolonged parking on a site, protect the lift truck from bad weather, particularly from frost (Check the level of antifreeze), close and lock all the lift truck accesses (door, window, bonnet…).

INSTRUCTIONS - Park the lift truck on flat ground or on an incline lower than 15 %.

- 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 I.C. engine with the ignition switch.

- Remove the pressure in the hydraulic circuits by using the hydraulic controls.

- Remove the ignition key.

- Make sure all means of access to the lift truck are closed and locked (door, window, bonnet…).

Before leaving your driver's cabin, ensure that you have carried out all operations for stopping 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 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.

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 else dismounted.

1 - 10

INSTRUCTIONS - Ensure that the flashing light is in position and that it is working if the lift truck is fitted with them.

- Check the good working order and cleanness of lights, indicators and windscreen wiper.

- Switch off the working headlights if the lift truck is fitted with them.

- Check the adjustment of the rear view mirrors.

- Ensure that the fuel level is sufficient.

- Put the attachment at 300 mm from the ground.

While on the road do not use the transmission cut-off to maintain I.C. engine braking on the lift truck.

G - OPERATING THE LIFT TRUCK WITH A TRAILER ON A PUBLIC HIGHWAY - For using a trailer, consult the regulations in force 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.

- The trailer's braking system must comply with current legislation.

- Do not use a trailer with assisted braking without trailer braking equipment on the lift truck.

- Do not forget to connect the lift truck's braking system to that of the trailer, when it is present.

- The maximum vertical pull on the trailer hook must not exceed 1500 daN. - The authorised total towed weight (A.T.T.W.) must not exceed the maximum weight authorised 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.

- The length of the entire unit must not exceed the overall length by 6 metres.

- Do not mask the lighting range of the front headlamps.

- Set the attachments shields in place (See chapter : ATTACHMENT SHIELDS in paragraph : 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE) or disassemble the attachment.

IF NECESSARY, CONSULT YOUR DEALER.

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INSTRUCTIONS

FOR MOVING THE LIFT TRUCK DURING HANDLING OPERATIONS

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 prohibited to lift people except with working equipment and accessories provided for the purpose.

- The use of working equipment and load lifting accessories to lift people is : • either prohibited • or authorised exceptionally under certain conditions (see current regulations in the country where the lift truck is in use).

- MANITOU supplies equipment specifically designed 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 centre 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 on the attachment system are clean and protected.

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 wedges).

- Switch off the I.C. engine.

- Remove pressure from the attachment hydraulic system using the 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 manoeuvres.

- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and the aerial line.

You must consult your local electrical agency.

You could be electrocuted or seriously injured if you operate or park the lift truck too close to power cables. You are strongly advised to ensure that the safety rules on the site conform to the local regulations in force regarding all types of work carried out close to power cables.

- Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load.

- When using the lift truck on a slope, before lifting the mast, make sure that the ground is laterally horizontal (See paragraph : F - LATERAL HORIZONTALITY OF THE LIFT TRUCK in the chapter : INSTRUCTIONS FOR HANDLING A LOAD).

- 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 scaffolding, loading platform or pile are capable of bearing the weight.

- Ensure the stability and solidity of the ground before depositing a load.

- Never stack loads on uneven ground, they may tip over.

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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 300 mm from the ground and the mast sloping 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 manoeuvre 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 manoeuvre, requiring specific precautions to be taken. 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 operations, drive at an appropriate speed for the operation.

- 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 jib extention.

In the event of high winds or storms, do not carry out handling work that jeopardizes the stability of the lift truck and its load, particularly if the load catches the wind badly.

- Do not change direction sharply and at high speed.

In the event of the lift truck overturning, do not try to leave the cabin during the incident.

YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN. - 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 - Make sure you always have good visibility of the road. When reversing, either look directly behind you or indirectly, using panoramic rear-view mirrors to verify the eventual presence of people, animals, holes, obstacles, changing slope…

- If the visibility in forward motion is not sufficient because of the bulkiness of the load, drive in reverse motion. This manoeuvre must remain exceptional and for short distances.

- Ensure you have good visibility (Clean windows, adequate lighting, correctly adjusted rear view mirrors, etc.).

- If visibility of your road is inadequate, ask someone to help, standing outside the area in which the truck will be moving, and make sure you always have a good view of this person.

- Signalling and lighting on the lift truck must take account of the conditions of use. In addition to series equipment mounted on your lift truck, many options are available, such as : road lighting, stop lights, flashing light, reverse lights, reverse buzzer alarm, front light, rear light, etc. Consult your dealer.

IF NECESSARY, CONSULT YOUR DEALER.

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INSTRUCTIONS

FOR HANDLING A LOAD

A - WEIGHT OF LOAD AND CENTRE OF GRAVITY

A

Carrying a load greater than the rated capacity for the lift truck or for the attachment is prohibited.

500 mm

- Before taking up a load, you must know its weight and its centre of gravity.

- The load chart relating to your lift truck is valid for a weight with its centre of gravity 500 or 600 mm from the heel of the forks (As model of lift truck) (Fig. A). For a higher centre of gravity, consult your dealer.

- For irregular loads, determine the centre of gravity in the transverse direction before handling (Fig. B).

B

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

B - TAKING UP A LOAD ON THE GROUND - Approach the lift truck perpendicular to the load, with the forks in a horizontal position (Fig. C).

- Adjust the fork spread and centering in connection with the load (Fig. D) (Optional solutions exist, consult your dealer).

C

Beware of the risks of trapping or squashing limbs when manually adjusting the forks. Always maintain an equal distance between the forks and the centre of the carriage in order to keep the load completely stable.

- Move the lift truck forward slowly (1) and bring the forks to stop in front of the load (Fig. E), if necessary, slightly lift the mast (2) while taking up the load.

- Apply the parking brake and place the forward/reverse lever in neutral.

- Slightly lift the load (1), incline the mast (2) backwards in the transport position (Fig. F).

D

Tilt the load sufficiently backwards to ensure its stability (loss of load on braking) without upsetting the balance of the load in so doing.

E 1

2

F 2 1

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C - TAKING UP A HIGH LOAD ON TYRES

G

Do not lift the mast under any circumstances if the lift truck is not laterally horizontal (See paragraph : F - LATERAL HORIZONTALITY OF THE LIFT TRUCK in the chapter : INSTRUCTIONS FOR HANDLING A LOAD).

- Ensure that the forks will easily pass under the load.

- Approach the lift truck perpendicular to the load and with the forks in a horizontal position (Fig. G) manoeuvring gently and carefully (See paragraph : E - VISIBILITY in the chapter : INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLING OPERATIONS for visibility of the road).

- Bring the forks to stop in front 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).

Tilt the load sufficiently backwards to ensure its stability (loss of load on braking) without upsetting the balance of the load in so doing.

H

- Manoeuvring very gently and carefully (See paragraph : E - VISIBILITY in the chapter : INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLING OPERATIONS for visibility of the road), back up the lift truck (1) to release the load, and bring the load into the transport position (Fig. J).

I 2

1

J

1

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D - LAYING A HIGH LOAD ON TYRES

K

Do not lift the mast under any circumstances if the lift truck is not laterally horizontal (See paragraph : F - LATERAL HORIZONTALITY OF THE LIFT TRUCK in the chapter : INSTRUCTIONS FOR HANDLING A LOAD).

- Approach 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) manoeuvring very gently and carefully (See paragraph : E - VISIBILITY in the chapter : INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLING OPERATIONS 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).

- To drive very gently and carefully.

- Free the forks by reversing the lift truck (3) (Fig. M) (See paragraph : E - VISIBILITY in the chapter : INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLING OPERATIONS 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 PALLETISED 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.

1

2

3

F - LATERAL HORIZONTALITY OF THE LIFT TRUCK - The lift truck's lateral horizontality must be ascertained with the mast in low position.

- Apart from the transverse slope of the ground, several parameters can upset the stability of the lift truck.

• The tyre pressure.

• The strength of the ground.

• The balance of the load.

• Strong wind or stormy conditions.

Before any handling operation, check the above points and make sure the lift truck is laterally horizontal.

1 - 16

1 - 17

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK MAINTENANCE

INSTRUCTIONS

A - GENERAL - Read the operator's manual carefully and ensure you understand it.

- Stop the I.C. engine and remove the ignition key, when an intervention is necessary.

- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie and protect your hair, if necessary.

- Ensure the area is sufficiently ventilated before starting the lift truck.

Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.

- Carry out all repairs immediately, even if the repairs concerned are minor.

- Repair all leaks immediately, even if the leak concerned is minor.

- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.

The handling and removal of the balancing valves or safety valves which may be fitted to the cylinders of your lift truck can be dangerous. A balancing valve must only be removed when the cylinder concerned is without load and the hydraulic circuit is depressurised. THIS OPERATION MUST BE PERFORMED BY AUTHORISED PERSONNEL. - 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, I.C. engine, etc.).

- Disconnect the negative cable terminal (-) from the top of the battery before working on the electrical circuit or on the lift truck (e.g. : Welding).

- Do not drop metallic items 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.

- Never carry out welding or work which gives off heat on an assembled tyre. The heat would increase the pressure which could cause the tyre to explode.

If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing irreparable damage to electronic components.

Do not short-circuit the starter terminals to start the lift truck. If the reverse gear is not in neutral, the lift truck will start to move immediately.

B - MAINTENANCE - The maintenance and the keeping in compliance of the lift truck are compulsory.

- Carry out daily maintenance (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Do not run the I.C. engine without air filter, or with oil, water or fuel leaks.

To avoid any risk of spraying or burning, wait until the engine has cooled down before removing the cooling circuit filler plug.

- Change the filter cartridges (See servicing schedules in chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

C - LEVELS - Use the recommended lubricants (Never use contaminated lubricants).

- Do not fill the fuel tank when the I.C. engine is running.

- Only fill up the fuel tank in areas specified for this purpose.

- Do not fill the fuel tank to the maximum level.

1 - 18

D - WASHING - Clean the lift truck or at least the area concerned before any intervention.

- Remember to close and lock all accesses to the lift truck (door, window, bonnet…).

- During washing, avoid the articulations and electrical components and connections.

If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged, particularly electrical components and connections and the injection pump.

- Clean the lift truck of any fuel, oil or grease trace.

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

1 - 19

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 commencing to operate the lift truck, the user should carefully read and understand the various 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.

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 chapter : SERVICING SCHEDULE in paragraph : 3 - MAINTENANCE and top up if necessary.

For operation under average climatic conditions, i.e. : between -15 °C and + 35 °C, correct levels of lubricants in all the circuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessary to drain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures. It is the same for the cooling liquid (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.

Never run the I.C. 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 oozing in 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 oozing in the hoses, connections and unions. If necessary, tighten or repair the defective connections.

- Also check the oil level in the tank.

Ensure that the recommended oil is used, in order to avoid serious damage to the braking system.

TYRES - Make sure that the wheel nuts are correctly tightened (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE) and that the tyre pressures are correct (See chapter : CHARACTERISTICS in paragraph : 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 - 20

ELECTRICAL CIRCUIT - Check the level and the density of the electrolyte in the battery (See chapter : B - EVERY 50 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Check the components of the electrical system, the connections and fastening devices.

IF NECESSARY, CONSULT YOUR DEALER.

1 - 21

IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an extended period.

For these operations, we recommend the use of a MANITOU protective product, reference 603726.

Instructions for using the product are given on the packaging.

Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership.

PREPARING

THE LIFT TRUCK

- Clean the lift truck thoroughly.

- Check and repair any leakage of fuel, oil, water or air.

- Replace or repair any worn or damaged parts.

- Wash the painted surfaces of the lift truck in clear and cold water and wipe them with a soft cloth.

- Touch up the paintwork if necessary.

- Shut down the lift truck (See chapter : OPERATING INSTRUCTIONS in paragraph : 1 - OPERATING AND SAFETY INSTRUCTIONS).

Make sure the mast cylinder rods are all in retracted position.

PROTECTING

THE INTERNAL COMBUSTION ENGINE

- Fill the tank with fuel (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Empty and replace the cooling liquid (See chapter : F - EVERY 2000 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Leave the internal combustion engine running at idling speed for a few minutes, then switch off.

- Replace the engine oil and oil filter (See chapter : D - EVERY 500 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Add the protective product to the engine oil.

- Run the internal combustion engine for a short time so that the oil and cooling liquid circulate inside.

- Disconnect the battery and store it in a safe place away from the cold, after charging it to a maximum.

- Cap the engine breather pipe hole.

- Remove the injectors and spray the protective product into each cylinder for two seconds with the piston in low neutral position.

- Turn the crankshaft once slowly and refit the injectors (see internal combustion engine REPAIR MANUAL).

- Remove the intake hose from the manifold or turbocharger and spray the protective product into the manifold or turbocharger.

- Cap the intake manifold or turbocharger hole with waterproof adhesive tape.

- Remove the exhaust pipe and spray the protective product into the exhaust manifold or turbocharger.

- Refit the exhaust pipe and block the outlet with waterproof adhesive tape.

NOTE : The spray time is noted on the product packaging and must be increased by 50% for turbo engines.

- Open the filler plug, spray the protective product around the rocker arm shaft and refit the filler plug.

- Cap the fuel tank using waterproof adhesive tape.

- Remove the drive belts and store them in a safe place.

- Disconnect the engine cut-off solenoid on the injection pump and carefully insulate the connection.

PROTECTING

THE LIFT TRUCK

- Set the lift truck on axle stands so that the tyres are not in contact with the ground and release the handbrake.

- Protect the steering cylinder rods against corrosion.

- Wrap the tyres.

NOTE : If the lift truck is to be stored outdoors, cover it with a waterproof tarpaulin.

1 - 22

BRINGING

THE LIFT TRUCK BACK INTO SERVICE

- Remove the waterproof adhesive tape from all the holes.

- Refit the intake hose.

- Refit and reconnect the battery.

- Remove the protection from the steering cylinder rods.

- Perform the daily service (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE).

- Put the handbrake on and remove the axle stands.

- Empty and replace the fuel and replace the fuel filter (See chapter : D - EVERY 500 HOURS SERVICE in paragraph : 3 MAINTENANCE).

- Refit and set the tension in the drive belts (See chapter : C - EVERY 250 HOURS SERVICE in paragraph : 3 MAINTENANCE).

- Turn the internal combustion engine using the starter, to allow the oil pressure to rise.

- Reconnect the engine cut-off solenoid.

- Lubricate the lift truck completely (See chapter : SERVICING SCHEDULE in paragraph : 3 - MAINTENANCE).

Make sure the area is adequately ventilated before starting up the lift truck.

- Start up the lift truck, following the safety instructions and regulations (See chapter : OPERATING INSTRUCTIONS in paragraph : 1 - OPERATING AND SAFETY INSTRUCTIONS).

- Run all the mast's hydraulic movements, concentrating on the ends of travel for each cylinder.

1 - 23

1 - 24

2 - DESCRIPTION

2-1

2-2

2-3

IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement of our products, our range of telescopic lift trucks may undergo certain modifications, without obligation for us to advise our customers.

When you order parts, or when you require any technical information, always specify : NOTE : For the owner's convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time of the delivery of the lift truck.

A MANITOU BF 44158 ANCENIS CEDEX FRANCE MODELE

SERIE

N° dans la série

Année de fabrication

N° de chassis

Masse à vide

P.T.R.A. kg

daN

Puissance ISO/TR14396

Effort de traction

kW

PLATE

MANUFACTURER OF THE LIFT TRUCK

(FIG. A)

daN

Pression des pneumatiques (Bar) AV. AR.

Effort vertical max. (sur accrochage remorque)

daN N°240130

- Model - Series - Serial Nr - Chassis Nr - Year of manufacture

B

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

I.C.

ENGINE

(FIG. B)

- Engine Nr C

HYDROSTATIC

PUMP

(FIG. C)

- Pump Nr - Codification type - Manufacturer’s Nr - Year of manufacture

FRONT

WHEEL HYDROSTATIC MOTORS

(FIG. D)

D

- MANITOU part number - Codification type - Motor Nr - Manufacturer’s Nr - Year of manufacture

2-4

FRONT

WHEEL REDUCERS

(FIG. E)

E

- Type - Serial Nr - Date

OVERHEAD

GUARD

(FIG. F)

- Type - Serial Nr F

CAB (OPTION) (FIG. G) - Type - Serial Nr

MAST (FIG. H) G

- Mast identification Nr

PLATE

MANUFACTURER OF THE ATTACHMENT

(FIG. I)

- Model - Serial Nr - Year of manufacture

I

H

MANITOU BF 44158 ANCENIS CEDEX FRANCE

MODELE

N° dans la série

Année fabrication

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

Cap. Nominale

Pression de service

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

N° 207701

2-5

CHARACTERISTICS ENGINE - Type - Number of cylinders - Number of strokes - Suction - Injection system - Ignition sequence - Clearance of rocker valve (Cold) . Inlet . Exhaust - Capacity - Bore - Stroke - Compression ratio - Nominal rating loaded - Rating slow unladen - Max. rating unladen - Power ISO/TR 14396 - Maximum torque ISO/TR 14396 - Air cleaner

COOLING

PERKINS 903-27 A LOW EMISSION CP 81120 3 in line 4 Natural Direct 1.2.3.

0,20 mm 0,45 mm 2700 cm3 95 mm 127 mm 17.25 / 1 2100 rpm 925 rpm ±25 2400 rpm 52 cv / 38,5 kw 192 Nm at 1200 rpm Dry 3 µ

CIRCUIT

- Type - Fan

By water Blowing

. Number of blades . Diameter - Thermostat . Start opening . Full opening

HYDROSTATIC

6 406,4 mm 80°C to 84 °C 92°C to 98 °C

TRANSMISSION

HYDROSTATIC PUMP - Type

MANNESMANN REXROTH A4VG90DA1D7/32R with variable cubic capacity and with automatic power governor.

Electromagnetic 12V 1 1

- Gear reverser . Number of forward gears . Number of reverse gears - Main pump . Max. / Mini displacement . Max. flow rate . Working pressure - Boost pump . Displacement . Max. flow rate . Boost pressure Max. R.P.M.

0 to 90 cm3/r 215 L/min 500 Bar 18,7 cm3 42 L/min 30 Bar (Transmission in neutral)

FRONT WHEEL HYDROSTATIC MOTOR - Type . Max. displacement

FRONT

MANNESMANN REXROTH A2FE28/61W with fixed capacity.

28 cm3/r

WHEEL REDUCERS BREVINI CWD 2050/M (Up to machine Nr 144562) CWD 2050/1M (From machine Nr 144563)

- Type

2-6

BRAKE - Type

Multidisc brake immersed in oil.

4 5 Foot pedal. Hydraulic brake acting on front wheels through pressure break.

Switch. Electro-hydraulic brake acting on front wheels through pressure break.

. Number of steel disks . Number of friction disks - Service brakes - Parking brake

ELECTRIC

CIRCUIT

- Earth - Battery - Alternator . Type . Tension regulator - Starter . Type

Negative 12 V - 105 Ah - 680 A EN 12 V - 55 A Magneti Marelli A127 Incorporated into the alternator 12 V - 2,4KW Magneti Marelli 2M113

2-7

CHARACTERISTICS MSI 20 D FRONT

MSI 20 D BUGGIE

TYRES DIMENSIONS

PRESSURE

275/70 R22,5 RHS GOODYEAR

9 Bar

Unladen Laden

950 kg 2600 kg

6,6 kg/cm2 8,5 kg/cm2

5 kg/cm2 6,7 kg/cm2

145 cm2 305 cm2

190 cm2 390 cm2

10,5R20 MPT80 14PR 134G CONTINENTAL

4,4 Bar

Unladen Laden

950 kg 2600 kg

kg/cm2 4,2 kg/cm2

kg/cm2 kg/cm2

cm2 620 cm2

cm2 cm2

10,5-20 MPT AS FARMER 8PR 123G 4,1 Bar CONTINENTAL

Unladen Laden

950 kg 2600 kg

kg/cm2 4,3 kg/cm2

kg/cm2 kg/cm2

cm2 610 cm2

cm2 cm2

STANDARD OPTION OPTION

TYRE LOAD

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

OPTION

8,25-20 CSE SC15 CONTINENTAL

Solid

Unladen Laden

950 kg 2600 kg

3,5 kg/cm2 6,8 kg/cm2

kg/cm2 kg/cm2

269 cm2 382 cm2

cm2 cm2

OPTION

15,5/55R18 SPPG7 14PR DUNLOP

3,3 Bar

Unladen Laden

950 kg 2600 kg

2,7 kg/cm2 3,1 kg/cm2

1,5 kg/cm2 1,7 kg/cm2

360 cm2 845 cm2

650 cm2 1521 cm2

OPTION

12,0-18 12PR T86 DUNLOP

3,5 Bar

Unladen Laden

950 kg 2600 kg

7,1 kg/cm2 9,3 kg/cm2

2,3 kg/cm2 3,1 kg/cm2

134 cm2 279 cm2

409 cm2 824 cm2

OPTION

275/80 R20 XM27 MICHELIN

4,1 Bar

Unladen Laden

950 kg 2600 kg

3,8 kg/cm2 3,7 kg/cm2

kg/cm2 kg/cm2

250 cm2 700 cm2

cm2 cm2

OPTION

285/70 R19,5 XZY 140/137L MICHELIN

6 Bar

Unladen Laden

950 kg 2600 kg

6,9 kg/cm2 5,8 kg/cm2

kg/cm2 kg/cm2

138 cm2 450 cm2

cm2 cm2

DIMENSIONS

PRESSURE

STANDARD

700x12 14PR IC40 CONTINENTAL

4,5 Bar

Unladen Laden

1000 kg 350 kg

kg/cm2 kg/cm2

kg/cm2 kg/cm2

cm2 cm2

cm2 cm2

OPTION

27.10.12 14PR IC12 CONTINENTAL

4,5 Bar

Unladen Laden

1000 kg 350 kg

kg/cm2 kg/cm2

kg/cm2 kg/cm2

cm2 cm2

cm2 cm2

OPTION

7,00-12 CSE SC10 CONTINENTAL

Solid

Unladen Laden

1000 kg 350 kg

5,8 kg/cm2 3,3 kg/cm2

kg/cm2 kg/cm2

173 cm2 107 cm2

cm2 cm2

OPTION

195R14C SPLT3 DUNLOP

5 Bar

Unladen Laden

1000 kg 350 kg

5,9 kg/cm2 5,3 kg/cm2

4,8 kg/cm2 4 kg/cm2

170 cm2 66 cm2

210 cm2 88 cm2

OPTION

700R12 136 A5 XZM MICHELIN

3,5 Bar

Unladen Laden

1000 kg 350 kg

3,2 kg/cm2 3,2 kg/cm2

kg/cm2 kg/cm2

310 cm2 110 cm2

cm2 cm2

REAR

TYRES

HYDRAULIC

TYRE LOAD

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

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

Gear pump with flow divider 32,6 cm3 73 L/min 140 Bar 73 L/min 125 Bar 20 µ 100 µ

2-8

SPECIFICATIONS - Level of sound pressure in the driver's cab LpA (According to standard prEN 12053 : 1995)

dB

- Level of sound power in the LwA environment (According to directive 2000 / 14 CE guaranteed)

dB

- Travel speed of the lift truck . Forward unladen rated load . Reverse unladen rated load

19,5 km/h 19 km/h 19,5 km/h 19 km/h

- Standard lift height

3300 mm

- Rated capacity with standard mast

2000 kg 500 mm

- Load center

43 kg

- Weight of forks (Each) - Lifting motions (With standard mast) . Unladen lifting . Rated load lifting . Unladen lowering . Rated load lowering

0,59 m/s 0,53 m/s 0,46 m/s 0,49 m/s

- Lift truck weight with standard mast . Unladen . Rated load

3830 kg 5830 kg

- Axle weight with standard mast (Transport position) . Front unladen rated load . Rear unladen rated load

1870 kg 5140 kg 1960 kg 690 kg

- Tensible strain at coupling hook . Unladen . Rated load

1300 daN 2500 daN

- Maximum ramp negotiable in forward motion . Unladen . Rated load

32 % at 1 km/h 36 % at 1 km/h daN

- Break out force with bucket (According to standard ISO 8313)

2-9

CHARACTERISTICS MSI 25 D FRONT

MSI 25 D BUGGIE

TYRES DIMENSIONS

PRESSURE

275/70 R22,5 RHS GOODYEAR

9 Bar

Unladen Laden

950 kg 3000 kg

6,6 kg/cm2 9 kg/cm2

5 kg/cm2 7,1 kg/cm2

145 cm2 335 cm2

190 cm2 425 cm2

OPTION

10,5R20 MPT80 14PR 134G CONTINENTAL

5,3 Bar

Unladen Laden

950 kg 3000 kg

kg/cm2 5,1 kg/cm2

kg/cm2 kg/cm2

cm2 585 cm2

cm2 cm2

OPTION

8,25-20 CSE SC15 CONTINENTAL

Solid

Unladen Laden

950 kg 3000 kg

3,5 kg/cm2 7,5 kg/cm2

kg/cm2 kg/cm2

269 cm2 400 cm2

cm2 cm2

OPTION

15,5/55R18 SPPG7 14PR DUNLOP

4 Bar

Unladen Laden

950 kg 3000 kg

3,1 kg/cm2 3,6 kg/cm2

1,7 kg/cm2 2 kg/cm2

310 cm2 835 cm2

558 cm2 1503 cm2

OPTION

12,0-18 12PR T86 DUNLOP

3,5 Bar

Unladen Laden

950 kg 3000 kg

7,1 kg/cm2 9,8 kg/cm2

2,3 kg/cm2 3,3 kg/cm2

134 cm2 308 cm2

409 cm2 900 cm2

OPTION

275/80 R20 XM27 MICHELIN

4,1 Bar

Unladen Laden

950 kg 3000 kg

3,8 kg/cm2 3,7 kg/cm2

kg/cm2 kg/cm2

250 cm2 810 cm2

cm2 cm2

OPTION

285/70 R19,5 XZY 140/137L MICHELIN

7 Bar

Unladen Laden

950 kg 3000 kg

7 kg/cm2 6,2 kg/cm2

kg/cm2 kg/cm2

135 cm2 485 cm2

cm2 cm2

DIMENSIONS

PRESSURE

STANDARD

700x12 14PR IC40 CONTINENTAL

5,3 Bar

Unladen Laden

1150 kg 350 kg

kg/cm2 kg/cm2

kg/cm2 kg/cm2

cm2 cm2

cm2 cm2

OPTION

27.10.12 14PR IC12 CONTINENTAL

4,5 Bar

Unladen Laden

1150 kg 350 kg

kg/cm2 kg/cm2

kg/cm2 kg/cm2

cm2 cm2

cm2 cm2

OPTION

7,00-12 CSE SC10 CONTINENTAL

Solid

Unladen Laden

1150 kg 350 kg

6,2 kg/cm2 3,3 kg/cm2

kg/cm2 kg/cm2

186 cm2 107 cm2

cm2 cm2

OPTION

700R12 136 A5 XZM MICHELIN

4 Bar

Unladen Laden

1150 kg 350 kg

4,4 kg/cm2 3,2 kg/cm2

kg/cm2 kg/cm2

259 cm2 110 cm2

cm2 cm2

STANDARD

REAR

TYRE LOAD

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

TYRES

HYDRAULIC

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

TYRE LOAD

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

Gear pump with flow divider 32,6 cm3 73 L/min 160 Bar 73 L/min 125 Bar 20 µ 100 µ

2 - 10

SPECIFICATIONS - Level of sound pressure in the driver's cab LpA (According to standard prEN 12053 : 1995)

dB

- Level of sound power in the LwA environment (According to directive 2000 / 14 CE guaranteed)

dB

- Travel speed of the lift truck . Forward unladen rated load . Reverse unladen rated load

19,5 km/h 19 km/h 19,5 km/h 19 km/h

- Standard lift height

3300 mm

- Rated capacity with standard mast

2500 kg 500 mm

- Load center

43 kg

- Weight of forks (Each) - Lifting motions (With standard mast) . Unladen lifting . Rated load lifting . Unladen lowering . Rated load lowering

0,59 m/s 0,53 m/s 0,46 m/s 0,49 m/s

- Lift truck weight with standard mast . Unladen . Rated load

4135 kg 6635 kg

- Axle weight with standard mast (Transport position) . Front unladen rated load . Rear unladen rated load

1840 kg 5995 kg 2295 kg 640 kg

- Tensible strain at coupling hook . Unladen . Rated load

1300 daN 2500 daN

- Maximum ramp negotiable in forward motion . Unladen . Rated load

28 % at 1 km/h 35 % at 1 km/h daN

- Break out force with bucket (According to standard ISO 8313)

2 - 11

CHARACTERISTICS MSI 30 D FRONT

MSI 30 D BUGGIE

TYRES DIMENSIONS

PRESSURE

275/70 R22,5 RHS GOODYEAR

9 Bar

Unladen Laden

900 kg 3400 kg

6,4 kg/cm2 9,3 kg/cm2

4,9 kg/cm2 7,4 kg/cm2

140 cm2 365 cm2

185 cm2 460 cm2

OPTION

10,5R20 MPT80 14PR 134G CONTINENTAL

5,6 Bar

Unladen Laden

900 kg 3400 kg

kg/cm2 5,4 kg/cm2

kg/cm2 kg/cm2

cm2 630 cm2

cm2 cm2

OPTION

8,25-20 CSE SC15 CONTINENTAL

Solid

Unladen Laden

900 kg 3400 kg

3,4 kg/cm2 8,2 kg/cm2

kg/cm2 kg/cm2

265 cm2 415 cm2

cm2 cm2

OPTION

15,5/55R18 SPPG7 14PR DUNLOP

4,5 Bar

Unladen Laden

900 kg 3400 kg

3,3 kg/cm2 4 kg/cm2

1,8 kg/cm2 2,2 kg/cm2

280 cm2 860 cm2

504 cm2 1548 cm2

OPTION

12,0-18 12PR T86 DUNLOP

4,2 Bar

Unladen Laden

900 kg 3400 kg

7,4 kg/cm2 11,1 kg/cm2

2,4 kg/cm2 3,8 kg/cm2

121 cm2 306 cm2

368 cm2 895 cm2

OPTION

285/70 R19,5 XZY 140/137L MICHELIN

8 Bar

Unladen Laden

900 kg 3400 kg

6,9 kg/cm2 6,8 kg/cm2

kg/cm2 kg/cm2

130 cm2 501 cm2

cm2 cm2

DIMENSIONS

PRESSURE

STANDARD

700x12 14PR IC40 CONTINENTAL

6,7 Bar

Unladen Laden

1400 kg 450 kg

kg/cm2 kg/cm2

kg/cm2 kg/cm2

cm2 cm2

cm2 cm2

OPTION

27.10.12 14PR IC12 CONTINENTAL

4,5 Bar

Unladen Laden

1400 kg 450 kg

kg/cm2 kg/cm2

kg/cm2 kg/cm2

cm2 cm2

cm2 cm2

OPTION

7,00-12 CSE SC10 CONTINENTAL

Solid

Unladen Laden

1400 kg 450 kg

6,9 kg/cm2 3,8 kg/cm2

kg/cm2 kg/cm2

204 cm2 119 cm2

cm2 cm2

OPTION

700R12 136 A5 XZM MICHELIN

4,75 Bar Unladen Laden

1400 kg 450 kg

4,7 kg/cm2 3,5 kg/cm2

kg/cm2 kg/cm2

296 cm2 129 cm2

cm2 cm2

STANDARD

REAR

TYRE LOAD

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

TYRES

HYDRAULIC

TYRE LOAD

PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACE HARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

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

Gear pump with flow divider 32,6 cm3 73 L/min 185 Bar 73 L/min 125 Bar 20 µ 100 µ

2 - 12

SPECIFICATIONS - Level of sound pressure in the driver's cab LpA (According to standard prEN 12053 : 1995)

dB

- Level of sound power in the LwA environment (According to directive 2000 / 14 CE guaranteed)

dB

- Travel speed of the lift truck . Forward unladen rated load . Reverse unladen rated load

19,5 km/h 19 km/h 19,5 km/h 19 km/h

- Standard lift height

3300 mm

- Rated capacity with standard mast

3000 kg 500 mm

- Load center

55 kg

- Weight of forks (Each) - Lifting motions (With standard mast) . Unladen lifting . Rated load lifting . Unladen lowering . Rated load lowering

0,49 m/s 0,44 m/s 0,46 m/s 0,49 m/s

- Lift truck weight with standard mast . Unladen . Rated load

4515 kg 7515 kg

- Axle weight with standard mast (Transport position) . Front unladen rated load . Rear unladen rated load

1795 kg 6710 kg 2720 kg 805 kg

- Tensible strain at coupling hook . Unladen . Rated load

1300 daN 2500 daN

- Maximum ramp negotiable in forward motion . Unladen . Rated load

27 % at 1 km/h 34 % at 1 km/h daN

- Break out force with bucket (According to standard ISO 8313)

2 - 13

CHARACTERISTICS OF MASTS MSI 20 D MSI 25 D

MSI 20 D BUGGIE MSI 25 D BUGGIE

DOUBLE MAST WITH ALL-ROUND VISION MAST

HL

Z

Y

LL

H

H1

H2

2m70

2730

10°

12°

150

2005

3530

236

3m00

3030

10°

12°

150

2155

3830

236

3m30

3330

10°

12°

150

2305

4130

236

3m50

3530

10°

12°

150

2405

4330

236

3m70

3730

10°

12°

150

2565

4530

176

4m00

4030

10°

12°

150

2755

4830

136

4m50

4530

10°

12°

150

3005

5330

136

5m00

5030

6°

6°

150

3255

5830

136

5m50

5530

6°

6°

150

3505

6330

136

6m00

6030

6°

6°

150

3795

6830

136

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT MAST

HL

Z

Y

LL

H

H1

H2

3m00

3040

10°

12°

1400

2155

3800

142

3m30

3340

10°

12°

1550

2305

4100

142

3m50

3540

10°

12°

1650

2405

4300

142

3m70

3740

10°

12°

1810

2565

4500

142

4m00

4040

10°

12°

2000

2755

4800

142

4m50

4540

10°

12°

2250

3005

5300

142

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT MAST

HL

Z

Y

LL

H

H1

H2

3m70

3740

10°

12°

1226

1955

4470

44

4m00

4040

10°

12°

1326

2055

4770

44

4m30

4340

10°

12°

1426

2155

5070

44

4m70

4740

10°

12°

1576

2305

5470

44

5m00

5040

6°

6°

1676

2405

5770

44

5m50

5540

6°

6°

1836

2565

6270

44

6m00

6040

6°

6°

2026

2755

6770

44

6m50

6540

6°

6°

2276

3005

7270

44

7m00

7040

6°

6°

2526

3255

7770

44

TRIPLE MAST WITHOUT FREE-ACTING LIFT MAST

HL

Z

Y

LL

H

H1

H2

3m30

3340

10°

12°

0

1845

4070

25

3m30

3340

10°

12°

0

1845

4070

25

3m30

3340

10°

12°

0

1830

4070

40

HL Z Y LL H H1 H2

➩ MSI 20 D with standard tyres ➩ MSI 25 D with standard tyres ➩ MSI 25 D with tyres 275/80 R20 XM27 MICHELIN

: Lift height in mm : Forward tilting : Backward tilting : Free-acting lift in mm : Overall height with folded mast in mm : Overall height with spreaded out mast in mm : Carriage overshooting in mm

2 - 14

CHARACTERISTICS OF MASTS MSI 30 D

MSI 30 D BUGGIE

DOUBLE MAST WITH ALL-ROUND VISION MAST

HL

Z

Y

LL

H

H1

H2

3m00

3035

10°

12°

135

2155

3895

290

3m30

3335

10°

12°

135

2305

4195

290

3m50

3535

10°

12°

135

2405

4395

290

3m70

3735

10°

12°

135

2565

4595

230

4m00

4035

10°

12°

135

2755

4895

190

4m50

4535

10°

12°

135

3005

5395

190

5m00

5035

6°

6°

135

3255

5895

190

5m50

5535

6°

6°

135

3505

6395

190

6m00

6035

6°

6°

135

3795

6895

190

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT MAST

HL

Z

Y

LL

H

H1

H2

3m00

3045

10°

12°

1400

2155

3800

154

3m30

3345

10°

12°

1550

2305

4100

154

3m50

3545

10°

12°

1650

2405

4300

154

3m70

3745

10°

12°

1810

2565

4500

154

4m00

4045

10°

12°

2000

2755

4800

154

4m50

4545

10°

12°

2250

3005

5300

154

TRIPLE MAST WITH TOTAL FREE-ACTING LIFT MAST

HL

Z

Y

LL

H

H1

H2

3m70

3745

10°

12°

1300

2055

4500

34

4m00

4045

10°

12°

1400

2155

4800

34

4m30

4345

10°

12°

1550

2305

5100

34

4m70

4745

10°

12°

1650

2405

5500

34

5m00

5045

6°

6°

1810

2565

5800

34

5m50

5545

6°

6°

2000

2755

6300

34

6m00

6045

6°

6°

2250

3005

6800

34

6m50

6545

6°

6°

2500

3255

7300

34

7m00

7045

6°

6°

2750

3505

7800

34

HL Z Y LL H H1 H2

: Lift height in mm : Forward tilting : Backward tilting : Free-acting lift in mm : Overall height with folded mast in mm : Overall height with spreaded out mast in mm : Carriage overshooting in mm

2 - 15

DIMENSIONS AND LOAD CHART

MSI 20 D MSI 20 D BUGGIE

MSI 25 D MSI 25 D BUGGIE

CAPACITE NOMINALE RATED CAPACITY NENNKAPAZITÄT CAPACIDAD NOMINAL CAPACITÀ NOMINALE

2000

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA 1-

2-

MAT VERTICAL VERTICAL MAST VERTIKALER MAST MASTIL VERTICAL RAMPA VERTICALE

2000

1830

1300

600

1100

500

D : mm

-

55F-SS-A931 55F-SS-A932 55F-SS-A933 -

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA

1

2000

218155

1830

-

-

Pour hauteur maximale de For maximum height of Für maximale Höhe Para altura máxima de Per altezza massima di

3300

MAT VERTICAL VERTICAL MAST VERTIKALER MAST MASTIL VERTICAL RAMPA VERTICALE

2500

2290

1630

600

1100

500

D D : mm

-

55F-SS-A931 55F-SS-A932 55F-SS-A933 -

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA

1300

Jusqu'à hauteur de levée Up to height of Bis zur hubhöhe Hasta altura de elevación Sino ad altezza di sollevamento

2-

Pour hauteur maximale de For maximum height of Für maximale Höhe Para altura máxima de Per altezza massima di

mm

MAT VERTICAL VERTICAL MAST VERTIKALER MAST MASTIL VERTICAL RAMPA VERTICALE

D : mm

1

2500 2

218136

2290

-

2 - 16

3300

mm

-

3000

2750

1960

500

600

1100

-

-

-

3000

2750

1960

60E-SS-B621 100E-SS-B551 100E-SS-B687 -

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA

1630

1

2

n°:

mm

-

2

D

-

1

Q : kg

EQUIPEMENT ATTACHMENT ZUBEHÖR EQUIPO ATTREZZATURA

kg

SUIVANT NORME EN 1726-1

1mm

-

2

3000

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA

1

Q : kg

n°:

CAPACITE NOMINALE RATED CAPACITY NENNKAPAZITÄT CAPACIDAD NOMINAL CAPACITÀ NOMINALE

kg

SUIVANT NORME EN 1726-1

Jusqu'à hauteur de levée Up to height of Bis zur hubhöhe Hasta altura de elevación Sino ad altezza di sollevamento

EQUIPEMENT ATTACHMENT ZUBEHÖR EQUIPO ATTREZZATURA

2

n°:

-

2

D

mm

1

Q : kg

mm 2-

3300

2500

CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA 1-

-

Pour hauteur maximale de For maximum height of Für maximale Höhe Para altura máxima de Per altezza massima di

EQUIPEMENT ATTACHMENT ZUBEHÖR EQUIPO ATTREZZATURA

CAPACITE NOMINALE RATED CAPACITY NENNKAPAZITÄT CAPACIDAD NOMINAL CAPACITÀ NOMINALE

kg

SUIVANT NORME EN 1726-1

Jusqu'à hauteur de levée Up to height of Bis zur hubhöhe Hasta altura de elevación Sino ad altezza di sollevamento

MSI 30 D MSI 30 D BUGGIE

218157

MSI 20 D

MSI 25 D

MSI 30 D

MSI 20 D BUGGIE

MSI 25 D BUGGIE

MSI 30 D BUGGIE

A

1100 mm

1100 mm

1100 mm

1100 mm

1100 mm

1100 mm

B

1800 mm

1800 mm

1800 mm

1800 mm

1800 mm

1800 mm

C

625 mm

625 mm

630 mm

625 mm

625 mm

630 mm

D

2945 mm

2945 mm

2980 mm

2945 mm

2945 mm

2980 mm

E

4045 mm

4045 mm

4080 mm

4045 mm

4045 mm

4080 mm

F

1046 mm

1046 mm

1046 mm

1046 mm

1046 mm

1046 mm

F1

1102 mm

1102 mm

1102 mm

1102 mm

1102 mm

1102 mm

G

275 mm

275 mm

275 mm

275 mm

275 mm

275 mm

G*

245 mm

245 mm

245 mm

245 mm

245 mm

245 mm

G1

260 mm

260 mm

260 mm

260 mm

260 mm

260 mm

G1*

260 mm

260 mm

260 mm

260 mm

260 mm

260 mm

G2

215 mm

215 mm

215 mm

215 mm

215 mm

215 mm

G2*

230 mm

230 mm

230 mm

230 mm

230 mm

230 mm

G3

270 mm

270 mm

270 mm

270 mm

270 mm

270 mm

H

2305 mm

2305 mm

2305 mm

2305 mm

2305 mm

2305 mm

H*

1955 mm

1955 mm

2055 mm

1955 mm

1955 mm

2055 mm

H1

4130 mm

4130 mm

4195 mm

4130 mm

4130 mm

4195 mm

H1*

4470 mm

4470 mm

4500 mm

4470 mm

4470 mm

4500 mm

I

520 mm

520 mm

550 mm

520 mm

520 mm

550 mm

J

1025 mm

1025 mm

1025 mm

1025 mm

1025 mm

1025 mm

K

1260 mm

1260 mm

1260 mm

1260 mm

1260 mm

1260 mm

L

40 mm

40 mm

45 mm

40 mm

40 mm

45 mm

N

1450 mm

1450 mm

1450 mm

1450 mm

1450 mm

1450 mm

O

100 mm

100 mm

100 mm

100 mm

100 mm

100 mm

P1

49,5 °

49,5 °

49,5 °

49,5 °

49,5 °

49,5 °

P2

40,5 °

40,5 °

40,5 °

40,5 °

40,5 °

40,5 °

P3

44 °

44 °

40 °

44 °

44 °

40 °

R

2310 mm

2310 mm

2310 mm

2310 mm

2310 mm

2310 mm

S

2545 mm

2545 mm

2580 mm

2545 mm

2545 mm

2580 mm

T

4525 mm

4525 mm

4560 mm

4525 mm

4525 mm

4560 mm

U-U*

2105 mm

2105 mm

2105 mm

1990 mm

1990 mm

1990 mm

V

2600 mm

2600 mm

2635 mm

2600 mm

2600 mm

2635 mm

V1

150 mm

150 mm

150 mm

150 mm

150 mm

150 mm

W

1323 mm

1323 mm

1323 mm

1323 mm

1323 mm

1323 mm

Y

12 °

12 °

12 °

12 °

12 °

12 °

Z

10 °

10 °

10 °

10 °

10 °

10 °

H - H1 H* - H1* G - G1 - G2 - G3 G* - G1* - G2*

= Standard mast DUPLEX 3M30 = Option mast TRIPLEX 3M70 = Unladen = Rated load

2 - 17

INSTRUMENTS AND CONTROLS OVERHEAD GUARD MODEL

16

1 6 3

8

4

13

7

2 13

11 5

17

12 1

7 5 15

2

11 9 10

14

2 - 18

DESCRIPTION 1 - DRIVER'S SEAT 2 - SAFETY BELT 3 - SIGNAL LAMP PANEL 4 - FUEL LEVEL AND HOURMETER 5 - SWITCH PANEL 6 - HORN SWITCH 7 - IGNITION SWITCH 8 - BATTERY CUT-OFF 9 - ACCELERATOR PEDAL 10 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF 11 - FUSES 12 - FORWARD/REVERSE LEVER 13 - HYDRAULIC CONTROLS 14 - DOCUMENT HOLDER NET 15 - DOCUMENT CLIP 16 - WINDSCREEN WASHER TANK 17 - OVERHEAD GUARD LIFTING

NOTE : All the terms such as : RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver's seat and looking in front of him.

2 - 19

1 - DRIVER'S

SEAT

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

2

E D

LONGITUDINAL ADJUSTMENT - Pull locking lever 1 towards the right.

- Slide the seat to the required position.

- Release the lever and be sure it returns to the lock position.

C B A

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 (50 kg).

Position B : Intermediate.

Position C : Middle-weight driver.

Position D : Intermediate.

Position E : Heavy-weight driver (120 kg).

1

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.

2 - SAFETY

3

4

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.

In no event should the lift truck be used if the seat belt is defective (Fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.

3 - SIGNAL

LAMP PANEL

When activating the electrical system of the lift truck, all the red lamps and the panel's buzzer must light to indicate their good working order. If one of the red lamps or the buzzer does not function, carry out the necessary repairs.

A - RED I.C. ENGINE OIL PRESSURE LAMP If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and look for the cause (See oil level in engine crankcase).

B - RED I.C. ENGINE WATER TEMPERATURE LAMP If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and investigate the cooling system for the cause of the malfunction.

2 - 20

A B C D E

F G H

I

J

C - RED HYDROSTATIC TRANSMISSION OIL FILTER CLOG LAMP This lamp informs the operator about the good working condition of the filter cartridge. If it is clogged, the red lamp and the buzzer light up (See replacement requirements in the chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 MAINTENANCE).

NOTE : Leave the lift truck run after a cold start, the lamp should go out once the hydraulic oil has reached its operating temperature.

D - RED AIR FILTER CLOGGED LAMP The lamp and buzzer come on when the air filter cartridge is clogged up. Stop the lift truck and carry out the necessary repairs (See cleaning and replacement requirements in chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 MAINTENANCE).

E - NOT USED F - RED ALTERNATOR CHARGE LAMP If the lamps B - C - D - E - F and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately and check the electrical circuit as well as the alternator belt.

G - RED PARKING BRAKE LAMP This lamp comes on when the parking brake is applied.

H - GREEN INDICATOR LAMP OPTION The lamp is illuminated when the indicators are on and indicates that they are functioning properly.

I - BLUE MAIN BEAM LAMP OPTION The lamp is illuminated when main beam lights are on.

J - NOT USED

4 - FUEL

LEVEL AND HOURMETER

B

A - FUEL LEVEL

A

B - HOURMETER It shows the number of hours the lift truck has run.

5 - SWITCH

PANEL

A - PARKING BRAKE SWITCH To connect the parking brake, lower the button 1 and press the bottom of the switch.

The signal lamp shows it is being used. To disconnect the parking brake, press the top of the switch.

B - FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER This two position switch, when set on the "down" position and simultaneously pressed, allows the windscreen-washer and the windscreen wiper to be operated, and when set on the "up" position, the windscreen wiper to be operated.

C - REAR WINDSCREEN WIPER OPTION or STANDARD as assembly.

2 - 21

A

B

C

F

E

G

H

I

J

K

1

D

D - HEATING FAN OPTION This two speed switch allows warm or cold air to pass through the heating vents.

A

B

C

F

E

G

H

I

J

K

1

E - OVERHEAD GUARD LIFTING See chapter : 17 - OVERHEAD GUARD LIFTING in paragraph : 2 - DESCRIPTION for operation of the switch.

F - WARNING LIGHTS OPTION This switch enables the L.H. and R.H. Indicators to be switched on simultaneously, with the ignition off. The signal light indicates that the switch is being used.

D

G - WORKING HEAD LIGHTS OPTION H - FLASHING LIGHT OPTION I - WORKING TAIL LIGHTS OPTION J - COLD COUNTRY HEATING FAN OPTION K - OPTION

6 - HORN

SWITCH

7 - IGNITION

SWITCH

The key switch has five positions : P - Ignition off, parking position.

O - Ignition switched off and engine stopped.

I - Ignition on.

II - Heating.

III - The engine starts, return to position i as soon as the key is released.

8 - BATTERY

CUT- OFF

Enables the battery to be rapidly cut off from the electric circuit in the event of a short circuit or a fire.

9 - ACCELERATOR 10 - SERVICE

PEDAL

BRAKE AND TRANSMISSION CUT- OFF PEDAL

This pedal operates in two steps : - First, the pedal acts upon an electric switch which puts the transmission into neutral so as to slow down the lift truck.

- Then, the pedal acts upon a hydraulic valve which progressively gives rise to a pressure drop in the brakes so as to stop the lift truck.

NOTE : A hydraulic transmission cut-off OPTION is available to allow the transmission to be cut progressively (See chapter : DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS in paragraph : 2 - DESCRIPTION).

2 - 22

11 - FUSES Remove the cover to have access to the fuses.

1 - OPTION Light switch power supply, horn and indicators (15A).

2 - OPTION Hazard warning lights power supply (10A).

3 - Rear windscreen wiper (10A). (OPTION or STANDARD as assembly) - OPTION Roof windscreen wiper (10A).

4 - OPTION Working tail lights (10A).

5 - OPTION Front working head lights (10A).

6 - OPTION Heating (15A).

- OPTION Cold country heating (15A).

7 - Panel of signal lights (5A).

- Fuel level (5A).

- Hourmeter (5A).

8 - Front windscreen wiper and windscreen washer (10A).

- OPTION Pneumatic seat (15A).

9 - OPTION Indicator power supply (10A).

10 - Gear reverser (10A).

- Transmission cut-off (10A).

- OPTION Reverse lights (10A).

- OPTION Reverse buzzer alarm (10A).

11 - Sound alarm (10A).

- Parking brake (10A).

- OPTION Stop switch (10A).

12 - OPTION Flashing light (7,5A).

13 - OPTION Right sidelight (5A).

- OPTION Sidelight indicator light (5A).

- OPTION Fuel level lighting (5A).

- OPTION Hourmeter lighting (5A).

14 - OPTION Left sidelights (5A).

15 - OPTION Right indicators (7,5A).

16 - OPTION Left indicators (7,5A).

17 - OPTION Low beam (10A).

- OPTION Low beam indicator light (5A).

18 - OPTION Main beam (10A).

- OPTION Main beam lamp (10A).

19 - OPTION Roof light (3A).

- OPTION (+)permanent (3A).

20 - OPTION. 21 - OPTION. 22 - OPTION. 23 - OPTION. 24 - Overhead guard lifting (5A).

13

14

15

22 7

9

19 2

3

LEVER

When operating this control, the lift truck should be travelling at slow speed and not accelerating. When the reverser is in the neutral position a mechanical lock prevents an accidental shifting movement.

A

C

FORWARD : Lift slightly and push the lever forwards (Position A).

REVERSE : Lift slightly and pull the lever backwards (Position B).

NEUTRAL : To start the lift truck, the lever must be in neutral (Position C).

NOTE : In OPTION, The reverse lights and the reverse buzzer alarm indicate that the lift truck is running in reverse motion.

2 - 23

B

18 24

10

11

20

NOTE : Replace a used fuse with a new fuse of the same quality and capacity. Never reuse a repaired fuse.

12 - FORWARD/REVERSE

17

23 8

1

16

12 21

4

5

6

13 - HYDRAULIC

CONTROLS A

Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve. In the event of suspected malfunction, contact your dealer. ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID.

B

LEVER A : Controls the load lifting and the mast tilting.

- The lever backwards for backward tilting of the mast.

- The lever forwards for forward tilting of the mast.

- The lever to the right for load lifting.

- The lever to the left for load lowering.

NOTE : The engine r.p.m. automatically increases when lifting the load.

LEVER B : Designed for additional equipment control.

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

14 - DOCUMENT

HOLDER NET

Make sure that the operator’s manual is in the right place, i.e. in the document holder net.

15 - DOCUMENT

CLIP

16 - WINDSCREEN

WASHER TANK

See chapter : B - EVERY 50 HOURS SERVICE in paragraph : 3 - MAINTENANCE. A

17 - OVERHEAD

GUARD LIFTING

Make sure that the mast is tilted forwards to a maximum and the engine is stopped before lifting the overhead guard.

B

1

UNLOCKING THE OVERHEAD GUARD - Keep the ignition on in the lift truck.

- Unlock the overhead guard by means of the lever 1 (Fig. A) in position A. A

LIFTING THE OVERHEAD GUARD - Press the top of the switch 2 (Fig. B) until complete lifting of the overhead guard.

- Put the lever 1 back into position B (Fig. A).

- Place the safety prop 3 (Fig. C) onto its stop 4 (Fig. C).

Check that any object left in the operator’s stand cannot impede the operation.

B 2

LOWERING THE OVERHEAD GUARD - Fold the safety prop back into its clip 5 (Fig. D).

- Lower the overhead guard into its initial position by pressing the bottom of the switch 2 (Fig. B).

- Ensure that the overhead guard is locked.

Check that nothing or nobody can impede the lowering of the overhead guard.

2 - 24

C

D

3

4

2 - 25

5

INSTRUMENTS AND CONTROLS CAB MODEL

12 14

7 5

11 1

15 8 9

10

16

6 17

3 8

4

20 7 20

13

11 10

5

20

13 20

20

18

22

22 24 19

21 23

21 25

2 - 26

DESCRIPTION 1 - DRIVER'S SEAT 2 - SAFETY BELT (NOT ILLUSTRATED) 3 - SIGNAL LAMP PANEL 4 - FUEL LEVEL AND HOURMETER 5 - SWITCH PANEL 6 - HORN SWITCH 7 - IGNITION SWITCH 8 - BATTERY CUT-OFF 9 - ACCELERATOR PEDAL 10 - SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF 11 - FUSES 12 - FORWARD/REVERSE LEVER 13 - HYDRAULIC CONTROLS 14 - DOCUMENT HOLDER NET 15 - DOCUMENT CLIP 16 - WINDSCREEN WASHER TANK 17 - STEERING WHEEL TILTING HANDLE 18 - ROOF LIGHT 19 - CAB HEATER CONTROL 20 - HEATING VENTS 21 - DOORS LOCKS 22 - LEFT SIDE WINDSCREEN OPENING HANDLES 23 - LOCKING HANDLE FOR UPPER HALF DOOR 24 - RELEASING BUTTON FOR UPPER HALF DOOR 25 - CAB LIFTING

NOTE : All the terms such as : RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver's seat and looking in front of him.

2 - 27

1 - DRIVER'S

SEAT

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

2

E D

LONGITUDINAL ADJUSTMENT - Pull locking lever 1 towards the right.

- Slide the seat to the required position.

- Release the lever and be sure it returns to the lock position.

C B A

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 (50 kg).

Position B : Intermediate.

Position C : Middle-weight driver.

Position D : Intermediate.

Position E : Heavy-weight driver (120 kg).

1

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.

2 - SAFETY

3

4

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.

In no event should the lift truck be used if the seat belt is defective (Fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.

3 - SIGNAL

LAMP PANEL

When activating the electrical system of the lift truck, all the red lamps and the panel's buzzer must light to indicate their good working order. If one of the red lamps or the buzzer does not function, carry out the necessary repairs.

A - RED I.C. ENGINE OIL PRESSURE LAMP If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and look for the cause (See oil level in engine crankcase).

B - RED I.C. ENGINE WATER TEMPERATURE LAMP If the lamp and the buzzer come on when the lift truck is running, stop the I.C. engine immediately and investigate the cooling system for the cause of the malfunction.

2 - 28

A B C D E

F G H

I

J

C - RED HYDROSTATIC TRANSMISSION OIL FILTER CLOG LAMP This lamp informs the operator about the good working condition of the filter cartridge. If it is clogged, the red lamp and the buzzer light up (See replacement requirements in the chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 MAINTENANCE).

NOTE : Leave the lift truck run after a cold start, the lamp should go out once the hydraulic oil has reached its operating temperature.

D - RED AIR FILTER CLOGGED LAMP The lamp and buzzer come on when the air filter cartridge is clogged up. Stop the lift truck and carry out the necessary repairs (See cleaning and replacement requirements in chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 MAINTENANCE).

E - NOT USED F - RED ALTERNATOR CHARGE LAMP If the lamps B - C - D - E - F and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately and check the electrical circuit as well as the alternator belt.

G - RED PARKING BRAKE LAMP This lamp comes on when the parking brake is applied.

H - GREEN INDICATOR LAMP OPTION The lamp is illuminated when the indicators are on and indicates that they are functioning properly.

I - BLUE MAIN BEAM LAMP OPTION The lamp is illuminated when main beam lights are on.

J - NOT USED

4 - FUEL

LEVEL AND HOURMETER

B

A - FUEL LEVEL

A

B - HOURMETER It shows the number of hours the lift truck has run.

5 - SWITCH

PANEL

A - PARKING BRAKE SWITCH To connect the parking brake, lower the button 1 and press the bottom of the switch.

The signal lamp shows it is being used. To disconnect the parking brake, press the top of the switch.

B - FRONT WINDSCREEN WIPER AND WINDSCREEN WASHER This two position switch, when set on the "down" position and simultaneously pressed, allows the windscreen-washer and the windscreen wiper to be operated, and when set on the "up" position, the windscreen wiper to be operated.

C - REAR WINDSCREEN WIPER

2 - 29

A

B

C

F

E

G

H

I

J

K

1

D

D - HEATING FAN This two speed switch allows warm or cold air to pass through the heating vents.

A

B

C

F

E

G

H

I

J

K

1

E - CAB LIFTING See chapter : 25 - CAB LIFTING in paragraph : 2 - DESCRIPTION for operation of the switch.

F - WARNING LIGHTS OPTION This switch enables the L.H. and R.H. Indicators to be switched on simultaneously, with the ignition off. The signal light indicates that the switch is being used.

D

G - WORKING HEAD LIGHTS OPTION H - FLASHING LIGHT OPTION I - WORKING TAIL LIGHTS OPTION J - COLD COUNTRY HEATING FAN OPTION K - OPTION

6 - HORN

SWITCH

7 - IGNITION

SWITCH

The key switch has five positions : P - Ignition off, parking position.

O - Ignition switched off and engine stopped.

I - Ignition on.

II - Heating.

III - The engine starts, return to position i as soon as the key is released.

8 - BATTERY

CUT- OFF

Enables the battery to be rapidly cut off from the electric circuit in the event of a short circuit or a fire.

9 - ACCELERATOR 10 - SERVICE

PEDAL

BRAKE AND TRANSMISSION CUT- OFF PEDAL

This pedal operates in two steps : - First, the pedal acts upon an electric switch which puts the transmission into neutral so as to slow down the lift truck.

- Then, the pedal acts upon a hydraulic valve which progressively gives rise to a pressure drop in the brakes so as to stop the lift truck.

NOTE : A hydraulic transmission cut-off OPTION is available to allow the transmission to be cut progressively (See chapter : DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS in paragraph : 2 - DESCRIPTION).

2 - 30

11 - FUSES Remove the cover to have access to the fuses.

1 - OPTION Light switch power supply, horn and indicators (15A).

2 - OPTION Hazard warning lights power supply (10A).

3 - Rear windscreen wiper (10A).

- OPTION Roof windscreen wiper (10A).

4 - OPTION Working tail lights (10A).

5 - OPTION Front working head lights (10A).

6 - Heating (15A).

- OPTION Cold country heating (15A).

7 - Panel of signal lights (5A).

- Fuel level (5A).

- Hourmeter (5A).

8 - Front windscreen wiper and windscreen washer (10A).

- OPTION Pneumatic seat (15A).

9 - OPTION Indicator power supply (10A).

10 - Gear reverser (10A).

- Transmission cut-off (10A).

- OPTION Reverse lights (10A).

- OPTION Reverse buzzer alarm (10A).

11 - Sound alarm (10A).

- Parking brake (10A).

- OPTION Stop switch (10A).

12 - OPTION Flashing light (7,5A).

13 - OPTION Right sidelight (5A).

- OPTION Sidelight indicator light (5A).

- OPTION Fuel level lighting (5A).

- OPTION Hourmeter lighting (5A).

14 - OPTION Left sidelights (5A).

15 - OPTION Right indicators (7,5A).

16 - OPTION Left indicators (7,5A).

17 - OPTION Low beam (10A).

- OPTION Low beam indicator light (5A).

18 - OPTION Main beam (10A).

- OPTION Main beam lamp (10A).

19 - Roof light (3A).

- OPTION (+)permanent (3A).

20 - OPTION. 21 - OPTION. 22 - OPTION. 23 - OPTION. 24 - Cab lifting (5A).

13

14

15

22 7

9

19 2

3

LEVER

When operating this control, the lift truck should be travelling at slow speed and not accelerating. When the reverser is in the neutral position a mechanical lock prevents an accidental shifting movement.

A

C

FORWARD : Lift slightly and push the lever forwards (Position A).

REVERSE : Lift slightly and pull the lever backwards (Position B).

NEUTRAL : To start the lift truck, the lever must be in neutral (Position C).

NOTE : In OPTION, The reverse lights and the reverse buzzer alarm indicate that the lift truck is running in reverse motion.

2 - 31

B

18 24

10

11

20

NOTE : Replace a used fuse with a new fuse of the same quality and capacity. Never reuse a repaired fuse.

12 - FORWARD/REVERSE

17

23 8

1

16

12 21

4

5

6

13 - HYDRAULIC

CONTROLS A

Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve. In the event of suspected malfunction, contact your dealer. ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID.

B

LEVER A : Controls the load lifting and the mast tilting.

- The lever backwards for backward tilting of the mast.

- The lever forwards for forward tilting of the mast.

- The lever to the right for load lifting.

- The lever to the left for load lowering.

NOTE : The engine r.p.m. automatically increases when lifting the load.

LEVER B : Designed for additional equipment control.

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

14 - DOCUMENT

HOLDER NET

Make sure that the operator’s manual is in the right place, i.e. in the document holder net.

15 - DOCUMENT

CLIP

16 - WINDSCREEN

WASHER TANK

See chapter : B - EVERY 50 HOURS SERVICE in paragraph : 3 - MAINTENANCE.

17 - STEERING

WHEEL TILTING HANDLE

- Turn the lever 1 towards A for loosening.

- Tilt the steering wheel into the required position.

- Turn the lever 1 towards B for blocking.

A B

1

18 - ROOF 19 - CAB

LIGHT

HEATER CONTROL

Allows the temperature inside the cab to be adjusted.

B

A - With the valve closed, the blower delivers fresh air.

B - With the valve opened completely, the blower delivers warm air.

The intermediate positions allow the temperature inside the cab to be adjusted.

20 - HEATING

VENTS 2 - 32

A

21 - DOORS

LOCKS

Two keys are provided with the lift truck to enable the cab to be locked.

22 - LEFT

SIDE WINDSCREEN OPENING HANDLES

23 - LOCKING

HANDLE FOR UPPER HALF DOOR

24 - RELEASING 25 - CAB

BUTTON FOR UPPER HALF DOOR

LIFTING

A

Ensure that the mast is tilted forwards to a maximum, that the engine is stopped and that the two doors are shut before lifting the cab.

UNLOCKING THE CAB - Half-open the right door of the cab.

- Keep the ignition on in the lift truck.

- Unlock the cab by means of the lever 1 (Fig. A) in position A.

B

1

A

LIFTING THE CAB - Maintain the door half-open.

- Press the top of the switch 2 (Fig. B) until complete lifting of the cab.

- Put the lever 1 (Fig. A) back into position B. - Shut the door.

- Place the safety prop 3 (Fig. C) onto its stop 4 (Fig. C).

B

Check that any object left in the driver’s stand cannot impede the operation.

2

LOWERING THE CAB - Fold the safety prop back into its clip 5 (Fig. D).

- Half-open the right door of the cab.

- Lower the cab into its initial position by pressing the bottom of the switch 2 (Fig. B).

- Ensure that the cab is locked.

- Shut the door.

Check that nothing or nobody can impede the lowering of the cab.

C

D

3

4

2 - 33

5

TOWING PIN AND HOOK Located at the rear of the lift truck, this device is used to attach a trailer. Its capacity is limited for each lift truck by the Authorised Gross Vehicle Weight (A.G.V.W), tractive effort and maximum vertical force on the coupling point. This information is given on the manufacturer's plate fixed to each lift truck (See chapter : IDENTIFICATION OF THE LIFT TRUCK in paragraph : 2 - DESCRIPTION).

- To use a trailer, see current regulations in your country (Maximum running speed, braking, maximum weight of trailer, etc.).

- Verify the trailer's condition before using it (Tyre condition and pressures, electrical connection, hydraulic hose, braking system…).

Do not tow a trailer or accessory which is not in perfect working order. Using a trailer in poor condition may effect the lift truck's steering and braking, and hence safety.

If a third party helps in coupling or uncoupling the trailer, this person must be permanently visible to the driver and wait until the lift truck has stopped, the handbrake is on and the engine is switched off before performing the operation.

A - TOWING

PIN

(STANDARD) (FIG. A)

A

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

- Put the handbrake on and switch off the IC engine.

- Remove the clip 1, lift the trailer pin 2 and place or remove the trailer ring.

2

Be careful not to get your fingers caught or crushed during this operation.

Do not forget to put clip 1 back in place.

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

1

2 - 34

2 - 35

DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS 1 - REVOLVING

LIGHT

The revolving light is dismountable to make it possible, for example, to reduce the bulkiness of the lift truck or to avoid being stolen.

- Loosen nut 1 and remove the revolving light.

- Protect mounting 2 with cap 3.

3

2

1

2 - LIGHT

SWITCH , HORN AND INDICATOR SWITCH

The switch controls the visual and sound alarms.

A - All lights are off, the direction indicators do not flash.

B - The right hand direction indicators flash.

C - The left hand direction indicators flash.

D - The sidelights and the rear lights are on.

E - The dipped headlights and the rear lights are on.

F - The main beam headlights and the rear lights are on.

G - Headlight signal.

G

A D

C

E B

F

Pressing the switch sounds the horn.

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

3 - FRONT

LIGHTS

A - Left front indicator.

B - Left front sidelight.

C - Left front dipped headlight and main beam.

D - Right front sidelight.

E - Right front dipped headlight and main beam.

F - Right front indicator.

4 - REAR

LIGHTS

(OVERHEAD

F

D

B

E

C

A

GUARD MODEL )

A - Left rear indicator.

B - Left tail light.

C - Left rear stoplight.

D - Right rear stoplight.

E - Right tail light.

F - Right rear indicator.

A

2 - 36

B

C

D

E

F

5 - REAR

LIGHTS

(CAB

MODEL )

A - Left rear indicator.

B - Left tail light.

C - Left rear stoplight.

D - Right rear stoplight.

E - Right tail light.

F - Right rear indicator.

6 - REAR

REVERSE LIGHT

7 - REVERSE

8 - FUEL

A

BUZZER ALARM

REHEATING

2 - 37

B

C

D

E

F

9 - PUNCH

STOP BUTTON

This button enables all lift truck movements to be switched off by stopping the I.C. engine.

- Press the button 1 so as to stop the I.C. engine.

- Turn the button to the right so as to reset it.

IImmobilize the lift truck before using the punch stop.

10 - ADAPTATION

CONTROLS LIFTING

/

TILTING REVERSED A

LEVER A : Controls the load lifting and the mast tilting.

- The lever backwards for load lifting.

- The lever forwards for load lowering.

- The lever to the right for backward mast tilting.

- The lever to the left for forward mast tilting.

11 - A D A P TAT I O N 4 T H

SINGLE-ACTING

OR

DOUBLE-ACTING

DISTRIBUTOR ELEMENT

A

LEVER A : Intended for controlling a single or double acting additional equipment.

12 - ADAPTATION 3

ON LINE DISTRIBUTOR ELEMENTS

LEVER A : Controls the mast tilting.

- The lever backwards for backward mast tilting.

- The lever forwards for forward mast tilting.

LEVER B : Controls the load lifting.

- The lever backwards for load lifting.

- The lever forwards for load lowering.

NOTE : The engine r.p.m. automatically increases when lifting the load.

LEVER C : Designed for additional equipment control.

2 - 38

A

B

C

13 - ADAPTATION 4

ON LINE DISTRIBUTOR ELEMENTS A

LEVER A : Controls the mast tilting.

- The lever backwards for backward mast tilting.

- The lever forwards for forward mast tilting.

LEVER B : Controls the load lifting.

- The lever backwards for load lifting.

- The lever forwards for load lowering.

NOTE : The engine r.p.m. automatically increases when lifting the load.

LEVER C : Designed for additional equipment control.

LEVER D : Designed for additional equipment control.

14 - ADAPTATION "INCHING"

B

C

D

HYDRAULIC TRANSMISSION CUT- OFF

This pedal operates in two steps : - First, the pedal acts upon a hydraulic valve which progressively cuts off the hydrostatic transmission so as to carry out a slow approach with all the I.C. engine output.

- Then, the pedal acts upon a hydraulic valve which progressively makes the pressure in the brakes drop so as to immobilize the lift truck.

15 - FOOT

ADAPTATION GEAR REVERSER

The lift truck must be stationary when operating the forward / reverse lever.

FORWARD : Press the pedal 1 on the right.

REVERSE : Press the pedal 2 on the left.

NEUTRAL : To start the lift truck, do not press the reverser pedals.

2 - 39

1

2

2 - 40

3 - MAINTENANCE

3-1

3-2

FILTERS CARTRIDGES AND BELTS

1

2

3

9

4

10

DESIGNATION

5

6

7

8

11

PART NUMBER

CLEAN

CHANGE

1 - I.C. engine oil filter

211384

2 - Dry air filter cartridge

227959

3 - Safety dry air filter cartridge

227960

1000 H *

4 - Fuel filter cartridge

49660

500 H

5 - Hydrostatic transmission oil filter cartridge

46028

1000 H

6 - Hydraulic return oil filter cartridge + Oil tank breather

217031

500 H

7 - Suction strainer for hydraulic oil tank

77402

8 - Fan belt

138175

9 - Automatic vacuum-cleaning pre-filter (OPTION) (1st ASSEMBLY)

160945

10 - Cyclonic pre-filter (OPTION) (2nd ASSEMBLY)

588330

11 - Automatic vacuum-cleaning pre-filter (OPTION)

240334

500 H 50 H *

500 H *

1000 H

10 H

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

3-3

LUBRICANTS AND FUEL I.C. ENGINE ORGANS TO BE LUBRICATED I.C. ENGINE

CAPACITY 5 Liters

RECOMMENDATION MANITOU Oil API CG4

COOLING CIRCUIT

11 Liters

Cooling liquid (Protection - 30 °C) Cooling liquid (Protection - 25 °C)

FUEL TANK

PACKAGING 20 L. 55 L. 209 L. 2 L. 5 L. 20 L. 210 L. 2 L. 5 L. 20 L. 210 L.

PART NUMBER 582 357 582 358 582 359 473 076 470 077 470 078 470 079 554 002 554 003 554 004 554 005

73,5 Liters

Diesel fuel (*)

CAPACITY 1,1 Liters

RECOMMENDATION MANITOU Oil Mechanical transmission for axles and boxes SAE 80W90

PACKAGING 2 L. 25 L. 55 L. 209 L.

PART NUMBER 499 237 161 585 546 221 546 220

RECOMMENDATION Engine oil MANITOU Grease Multipurpose HD NLGI 2

PACKAGING

PART NUMBER

1 Kg. 5 Kg.

554 973 554 974

1 Kg.

161 590

RECOMMENDATION MANITOU Oil Hydraulic ISO 46

PACKAGING 25 L. 55 L. 209 L.

PART NUMBER 161 588 546 108 546 109

RECOMMENDATION Windscreen washer fluid

PACKAGING 1 L. 5 L. 30 L. 225 L.

PART NUMBER 490 402 486 424 505 527 490 432

RECOMMENDATION MANITOU Grease Multipurpose HD NLGI 2 Windscreen washer fluid

PACKAGING 1 Kg. 5 Kg. 1 L. 5 L. 30 L. 225 L.

PART NUMBER 554 973 554 974 490 402 486 424 505 527 490 432

RECOMMENDATION MANITOU Grease Multipurpose HD NLGI 2 MANITOU Grease Multipurpose HD NLGI 2 MANITOU GREASE Multipurpose HD NLGI 2

PACKAGING 1 Kg. 5 Kg. 1 Kg. 5 Kg. 1 KG. 5 Kg.

PART NUMBER 554 973 554 974 554 973 554 974 554 973 554 974

TRANSMISSION ORGANS TO BE LUBRICATED FRONT WHEELS REDUCERS

MAST ORGANS TO BE LUBRICATED MAST LIFTING CHAINS GREASING OF THE MAST Except : Tilt cylinders foot Articulation at the foot of the mast TILT CYLINDERS FOOT ARTICULATION AT THE FOOT OF THE MAST

MANITOU Grease Multipurpose NLGI 2

HYDRAULICS ORGANS TO BE LUBRICATED HYDRAULIC OIL TANK

CAPACITY 95 Liters

OVERHEAD GUARD ORGANS TO BE LUBRICATED WINDSCREEN WASHER TANK

CAB (OPTION) ORGANS TO BE LUBRICATED CAB DOOR WINDSCREEN WASHER TANK

REAR AXLE ORGANS TO BE LUBRICATED REAR AXLE OSCILLATION STEERING CONNECTING ROD SWIVEL PINS

3-4

USE THE RECOMMENDED LUBRICANTS : - For topping up, oils do not necessarily have to be miscible.

- For oil changes, MANITOU oils are perfectly suitable.

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. (*) FUEL SPECIFICATION CETANE RATING : 45 minimum VISCOSITY : 2 - 4,5 Centistokes at 40° C DENSITY : 0,820 - 0,860 kg/litre SULPHUR : 0,2 % mass maximum DISTILLATION : 85 % at 350° C - The cetane rating is a measure of the ignition quality of a diesel fuel. A fuel with a low cetane index may cause problems with cold starts and affect combustion.

- Viscosity is the resistance to flow. If the viscosity is outside the limits, I.C. engine performance may be affected.

- A low density reduces the power of the I.C. engine, a high density increases the power of the I.C. engine and the exhaust fumes.

- A high sulphur content (Not usually found in europe, north america or australasia) may cause wear to the I.C. engine. If only fuels with a high sulphur content are available, it is necessary to use a highly alkaline greasing oil in the I.C. engine or to replace the greasing oil more frequently.

- Distillation : this indicates the mixture of different hydrocarbons in the fuel. A high ratio of light hydrocarbons can affect the characteristics of combustion.

- Fuels for low temperatures : special winter fuels may be available for use in the I.C. engine at temperatures below 0°C. These fuels have a lower viscosity and thus reduce the formation of paraffin in the fuel at low temperatures. The formation of paraffin can prevent filtration of the fuel.

3-5

SERVICING SCHEDULE A = AJUST C = CHECK D = DESCALE G = GREASE

N = CLEAN P = BLEED R = CHANGE V = DRAIN

I.C. ENGINE I.C. engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling liquid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cyclonic prefilter (OPTION) . . . . . . . . . . . . . . . . . . . . . .

Dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator/fan/crankshaft belt tension . . . . . . . . . . . . . .

I.C. engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I.C. engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . .

I.C. engine silent blocks . . . . . . . . . . . . . . . . . . . . . . . . .

I.C. engine rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump and the thermostat . . . . . . . . . . . . . . . . . .

Alternator and the starter motor . . . . . . . . . . . . . . . . . . .

Bleed the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION Front wheels reducers oil level . . . . . . . . . . . . . . . . . . .

Hydrostatic transmission oil filter cartridge . . . . . . . . . .

Front wheels reducers oil . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic transmission circuit pressures . . . . . . . . . . .

Governing start of the hydrostatic transmission . . . . . . .

Working order of the hydraulic valves for the transmission cut-off and accelerator Wearing of brake discs . . . . . . . . . . . . . . . . . . . . . . . . .

After Day 1 year 1 year the or 50 250 or or 2000 4000 first 50 10 hours hours 500 1000 hours hours hours hours hours hours

C/N N C C/A V R R

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

C*

3-24

V N/D* C* C*

3-26 3-11 3-21 3-25

C R V

R V C* C* C* C*

TYRES Tyres pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel nuts torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition of wheels and tyres . . . . . . . . . . . . . . . . . . . .

Change a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9 3-9

C C C*

3-27

MAST Tension and alignment of the mast lifting chains . . . . . .

Tilt cylinders head . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt cylinders foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Articulation at the foot of the mast . . . . . . . . . . . . . . . . .

Mast lifting chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition of mast unit . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast guide rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mast bearing rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thickness of the mast wearing plates . . . . . . . . . . . . . .

HYDRAULICS Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic return oil filter cartridge . . . . . . . . . . . . . . . . .

Oil tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suction strainer for hydraulic oil tank . . . . . . . . . . . . . . .

Speeds of hydraulic movements . . . . . . . . . . . . . . . . . .

Hydraulic pump pipe filter . . . . . . . . . . . . . . . . . . . . . . .

Condition of hoses and flexibles pipes . . . . . . . . . . . . . .

Condition of cylinders (leakage, shafts) . . . . . . . . . . . . .

Hydraulic circuit pressures . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic circuit outputs . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 3-8 3-8 3-9 3-9 3-10/3-17 3-10 3-10 3-14 3-16 3-16 3-17 3-20 3-20

C C C N

C/A G G G N/C/G

C* C* C* C* C* C*

3-12 3-18 3-18 3-21 3-21

C R R

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

3-6

3-11 3-11 3-11 3-12 3-18

A = AJUST C = CHECK D = DESCALE G = GREASE

N = CLEAN P = BLEED R = CHANGE V = DRAIN

After Day 1 year 1 year the or 50 250 or or 2000 4000 first 50 10 hours hours 500 1000 hours hours hours hours hours hours

BRAKE Brake circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake solenoid valve filter . . . . . . . . . . . . . . . . . . . . . . .

C* A* N*

OVERHEAD GUARD Windscreen washer liquid level . . . . . . . . . . . . . . . . . . .

Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition of the rear view mirrors . . . . . . . . . . . . . . . . .

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift the overhead guard in case of electric failure . . . . .

Lift the overhead guard in case of hydraulic failure . . . .

Lift the overhead guard in case of mechanical failure . .

C

3-12 3-22

C C* C*

3-30 3-31 3-32

CAB (OPTION) Windscreen washer liquid level . . . . . . . . . . . . . . . . . . .

Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition of the rear view mirrors . . . . . . . . . . . . . . . . .

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift the cab in case of electric failure . . . . . . . . . . . . . . .

Lift the cab in case of hydraulic failure . . . . . . . . . . . . . .

Lift the cab in case of mechanical failure . . . . . . . . . . . .

3-12 3-12 3-22

C G C C* C*

3-30 3-31 3-32

ELECTRICITY Battery electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . .

Battery electrolyte density . . . . . . . . . . . . . . . . . . . . . . .

Condition of wiring harness and cables . . . . . . . . . . . . .

Lights and signals (OPTION) . . . . . . . . . . . . . . . . . . . . .

Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjust the front headlamps (OPTION) . . . . . . . . . . . . . .

3-13 3-18

C C C* C* C*

3-32

REAR AXLE Swivel pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering connecting rod . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G G G

3-13 3-13 3-13

G/C* C* C*

CHASSIS Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearings and articulation rings . . . . . . . . . . . . . . . . . . . .

C* C*

ATTACHMENTS Forks wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attachment carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition of attachments . . . . . . . . . . . . . . . . . . . . . . . .

C* C* C*

LIFT TRUCK Tow the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sling the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transport the lift truck on a platform . . . . . . . . . . . . . . .

3-28 3-28 3-29

(*) : Consult your dealer.

3-7

A - DAILY OR EVERY 10 HOURS SERVICE A1 - I.C.

ENGINE OIL LEVEL

A1/1 CHECK

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

1

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Remove the dipstick 1 (Fig. A1/1).

- Clean the dipstick and check the level between the two MAXI and MINI notches.

- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 MAINTENANCE) by the filler port 2 (Fig. A1/2).

A2 - COOLING

LIQUID LEVEL A1/2

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

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 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).

2

When the expansion pan is empty, check the level in the radiator before filling the expansion pan.

- Disassemble the cover plate 3 (Fig. A2/2).

- Slowly bring the radiator cap 4 (Fig. A2/3) up to the safety stop.

- Allow the pressure and the steam to escape.

- Press down and turn the cap so as to release it.

- Add cooling liquid through the filler port 5 (Fig. A2/3) (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE).

- Slightly lubricate the filler plug to facilitate the fitting and removal of the radiator cap.

A2/1

If the cooling liquid is very hot, add only hot cooling liquid (80°C). In an emergency, you can use water as a cooling liquid, then change the cooling circuit liquid as soon as possible (See chapter : F1 - COOLING LIQUID in paragraph : 3 - MAINTENANCE).

2

1

A2/3

A2/2

3 4

5

3-8

A3 - FUEL

LEVEL

A3 CHECK

Keep the fuel tank full, to reduce as much as possible any condensation due to the atmospheric conditions.

1 2

- Remove cap 1 (Fig. A3).

- Fill the fuel tank with clean fuel (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE), filtered through a strainer or a clean, lint free cloth, through filler port 2 (Fig. A3).

- Put the cap back 1 (Fig. A3).

Never smoke or approach with a flame during filling operations or when the tank is open. Never refill while I.C. engine is running.

The fuel tank is degassed via the filler plug. When changing it, always use an original part, with degassing hole.

NOTE : A locking tank cap is available as an OPTION.

A4 - CYCLONIC

PREFILTER

(OPTION)

A4 CLEAN 1

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

2

- Loosen nut 1 (Fig. A4), remove cover 2 (Fig. A4) and empty the tank.

- Clean the prefilter unit with a clean dry cloth and reassemble the unit.

When cleaning, take care not to let impurities into the dry air filter.

A5 - TYRES

PRESSURE AND WHEEL NUTS TORQUE

A5 CHECK

- Check the condition of the tyres, to detect cuts, protuberances, wear, etc.

- Check the torque load of the wheel nuts (Fig. A5). Non compliance with this instruction can cause damage and rupture to the wheel bolts and distortion to the wheels.

- Check and adjust the tyre pressures if necessary (See chapter : CHARACTERISTICS paragraph : 2 - DESCRIPTION).

Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation. Respect the recommended tyre pressures given.

3-9

WHEEL NUTS TIGHTENING TORQUE

FRONT TYRES

400 ± 15 % N.m

REAR TYRES

200 ± 15 % N.m

B - EVERY 50 HOURS SERVICE Carry out the operations described previously as well as the following operations.

B1 - DRY

AIR FILTER CARTRIDGE CHECK - CLEAN

In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE). Also, the checking and cleaning periodicity of the cartridge must be reduced.

If the clogging indicator light comes on, this operation must be carried out as quickly as possible (1 hour maximum). The cartridge must not be cleaned more than seven times, after which the cartridge must be changed.

- For the disassembly and reassembly of the cartridge, see chapter : D3 - DRY AIR FILTER CARTRIDGE in paragraph : 3 MAINTENANCE. - Clean the filter cartridge using a compressed air jet (Max. pressure 3 bar) directed from the top to the bottom and from the inside towards the outside at a minimum distance of 30 mm from the cartridge wall.

- Cleaning is completed when there is no more dust on the cartridge.

Respect the safety distance of 30 mm between the air jet and the cartridge to avoid tearing or making a hole in the cartridge.

The cartridge must not be blown anywhere near the air filter box. Never clean the cartridge by tapping it against a hard surface. Your eyes must be protected during this intervention.

- Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU Reference : 479 292).

Do not clean the dry air filter cartridge by washing it in liquid. Do not clean by any means the safety cartridge located inside the filter cartridge, change it for a new one if it is dirty or damaged.

B2 - RADIATOR

CORE CLEAN

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

In order to prevent the radiator becoming clogged, clean the radiator with a compressed air jet directed from inside to outside.

This is the only way to clean the core of debris.

When handling straw, grain or cereal, clean the radiator core daily. Do not use water jet or high pressure steam as this could damage the radiator fins.

B3 - FUEL

FILTER

B3 CHECK

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Visually check for the presence of water in tank 1 (Fig. B3) and drain if necessary.

- Place a receptacle under the tank and loosen drain plug 2 (Fig. B3) by two of three turns.

- Leave the diesel fuel to flow out until it is free from impurities and water.

- Tighten the drain plug while the diesel fuel is running out.

3 - 10

1

2

B4 - FRONT

WHEELS REDUCERS OIL LEVEL

B4 CHECK

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

- Check the oil level on each front wheel reducer.

- Place the level plugs 1 (Fig. B4) into a horizontal position.

- Remove one of the level plugs, the oil must flush with the port.

- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 MAINTENANCE) through the same port.

- Replace the level plug 1 and tighten it (Fig. B4) (Tightening torque 60 à 70 N.m)

B5 - TENSION

1

1

AND ALIGNMENT OF THE MAST LIFTING CHAINS CHECK - ADJUST B5

Place the lift truck on level ground with the mast in a vertical position and the forks lifted at approximately 200 mm.

- 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 as following while ensuring that the carriage is perpendicular to the mast.

- Untighten the nut 1 (Fig. B5).

- Untighten the lock nut 2 (Fig. B5) of the chain tension adjuster.

- Adjust the tension by tightening or untightening the nut 3 (Fig. B5) while checking the alignment of the lifting chains.

- Then block the lock nut 2 (Fig. B5) and the nut 3 (Fig. B5).

- Retighten the nut 1 (Fig. B5).

1

3 2

These checks are important for the good working operation of the mast. In case of technical faults, consult your dealer.

B6

B6 - TILT

CYLINDERS HEAD

1

GREASE - Clean and lubricate the points 1 (2 lubricators) (Fig. B6) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

B7 - TILT

CYLINDERS FOOT

B7 GREASE

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Clean and lubricate the points 1 (2 lubricators) (Fig. B7) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

3 - 11

1

B8 - ARTICULATION

AT THE FOOT OF THE MAST

B8 GREASE

- Clean and lubricate the points 1 (2 lubricators) (Fig. B8) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

1

B9 - HYDRAULIC

OIL LEVEL

B9 CHECK

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

1 2 3

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Refer to gauge 1 (Fig. B9).

- The level is correct when it is equidistant between the lower and the upper marks.

- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 MAINTENANCE).

- Unscrew the cover 2 (Fig. B9).

- Add oil by filler port 3 (Fig. B9).

B10

Use a clean funnel and clean the underside of the oil drum before filling.

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

B10 - WINDSCREEN

1

WASHER LIQUID LEVEL CHECK

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Check visually the level.

- If necessary add windscreen washer liquid (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) by filler port 1 (Fig. B10).

B11 - CAB

B11

DOOR GREASE

1

Clean and lubricate the points 1 (8 lubricators) (Fig. B11) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

3 - 12

B12 - BATTERY

ELECTROLYTE LEVEL

B12 CHECK

Check the electrolyte level in each cell of the battery.

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

1

1

1

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Remove caps 1 (Fig. B12) from each cell of the battery.

- The level is correct when it is 1,5 cm above the top of the plates in the battery.

- If necessary, top up the cells with clean distilled water that has been stored in a glass container.

- Clean and dry caps 1 (Fig. B12) and refit in place and screw in firmly.

- Check the terminal connections and lightly smear them with petroleum jelly to prevent the formation of verdigris.

1

1

1

B13 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 a naked flame.

- Work in a well-ventilated area.

- In the event of electrolyte being spilled onto the skin or splashed in the eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.

1

B13 - SWIVEL

PINS GREASE

Clean and lubricate the points 1 (4 lubricators) (Fig. B13) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

B14 - STEERING

B14

CONNECTING ROD GREASE

Clean and lubricate the points 1 (2 lubricators) (Fig. B14) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

B15 - REAR

AXLE OSCILLATION

1

B15 GREASE

Clean and lubricate the points 1 (2 lubricators) (Fig. B15) with grease (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

1

3 - 13

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

C1 - ALTERNATOR /

FAN

/

CRANKSHAFT BELT TENSION

C1

CHECK - ADJUST 1

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Check the belt for signs of wear and cracks and change if necessary (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

- Check the belt tension between the pulleys of the crankshaft and of the alternator.

- Under a normal pressure exerted with the thumb (45N), the tension should be approximately 10 mm.

- Carry out adjustments if necessary.

- Untighten screws 1 (Fig. C1) by two to three thread turns.

- Swivel the alternator assembly so as to obtain the belt tension required.

- Retighten screws 1 (Fig. C1).

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

3 - 14

1 1

3 - 15

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

D1 - I.C.

ENGINE OIL

D1/1 DRAIN

D2 - I.C.

ENGINE OIL FILTER CHANGE

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

1

DRAINING THE OIL - Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Place a container under drain plug 1 (Fig. D1/1) and unscrew the plug.

- Remove filler cap 2 (Fig. D1/2) in order to ensure that the oil is drained properly.

Dispose of the drain oil in an ecological manner.

D1/2

REPLACEMENT OF THE FILTER - Remove I.C. engine oil filter 3 (Fig. D1/1) ; discard the filter and the filter seal.

- Clean the filter bracket with a clean, lint-free cloth.

- Lightly grease the seal of the new oil filter (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

- Refit the oil filter on the filter bracket.

2 4

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

FILLING UP THE OIL - Refit and tighten drain plug 1 (Fig. D1/1) (Tightening torque 30 to 40 N.m).

- Fill up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 MAINTENANCE) by filler port 4 (Fig. D1/2).

- Wait a few minutes to allow the oil to flow into the sump.

- Start the I.C. engine and let it run for a few minutes.

- Check for possible leaks at the drain plug and the oil filter.

- Stop the I.C. engine, wait a few minutes and check the level between the two MAXI and MINI notches on dipstick 5 (Fig. D1/3).

- Top up the level if necessary.

D1/3

5 3

3 - 16

D3 - DRY

AIR FILTER CARTRIDGE

D3 CHANGE

In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges, see chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE. Also, the checking and cleaning periodicity of the cartridge must be reduced (up to 250 hours in a heavily laden dust atmosphere and with pre-filtration).

1 2

Change the cartridge in a clean location, with the I.C. engine stopped. Never run the I.C. engine with the air filter removed or damaged.

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Loosen the bolts and remove cover 1 (Fig. D3).

- Gently remove the cartridge 2 (Fig. D3), taking care to avoid spilling the dust.

- Leave the safety cartridge in place.

- The following parts must be cleaned with a damp, clean lint-free cloth.

• The inside of the filter and cover.

• The inside of the filter inlet hose.

• The gasket surfaces in the filter and in the cover.

- Check pipes and connections between the air filter and the I.C. engine and the connection and state of the clogging indicator on the filter.

- Before mounting check the state of the new cartridge (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.

- Reassemble the cover, guiding the valve downwards.

D4 - FUEL

FILTER CARTRIDGE

D4/1 CHANGE

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Carefully clean the exterior of the filter and this bracket to prevent the dust from entering the system.

- Place a receptacle under the tank and empty using drain plug 1 (Fig. D4/1).

- Unscrew locking screw 2 (Fig. D4/2).

- Remove housing 3 (Fig. D4/2) and discard cartridge 4 (Fig. D4/2) as well as the seals of the cartridge.

- Clean the inside of the filter head and the housing, using a brush immersed in clean diesel oil.

- Refit the assembly with a new cartridge and new seals (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

- If necessary, bleed the fuel circuit (See chapter : G1 - FUEL SYSTEM in paragraph : 3 - MAINTENANCE).

1

D4/2

2

4

3

3 - 17

D5 - MAST

LIFTING CHAINS

D5 CLEAN - CHECK - GREASE

- Wipe the mast lifting chains 1 (Fig. D5) with a clean, lint-free cloth, then examine them closely so as to detect any signs of wear.

- Vigorously brush the chains to get rid of any foreign matter, with a hard nylon brush and clean diesel fuel.

- Rinse the chains by means of a paint brush impregnated with clean diesel fuel and dry them with a compressed air jet.

- Moderately lubricate the chains with a paint brush impregnated with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE).

- Remove the excess of oil with a clean cloth on the full length of the mast lifting chains.

1

In case of technical faults, consult your dealer.

D6 - HYDRAULIC

RETURN OIL FILTER CARTRIDGE

D6 CHANGE

D7 - OIL

TANK BREATHER CHANGE

Thoroughly clean the outside of the filter and its surroundings before any intervention in order to prevent any risk of polluting the hydraulic circuit.

2 1

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Unscrew the cover.

- Remove the hydraulic return oil filter cartridge 1 (Fig. D6) and replace it by a new one (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 MAINTENANCE).

- Disassemble the cover 2 (Fig. D6) and change the oil tank breather 3 (Fig. D6).

- Ensure that the cartridge and the breather are correctly positioned and refit the covers.

D8 - BATTERY

3

ELECTROLYTE DENSITY

D8 CHECK 1.240

The electrolyte density varies depending on the temperature concerned, but a minimum of 1260 at 16°C must be maintained. In the shaded area (Fig. D8), 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.

1.250 1.260 1.270 1.280 1.290

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Check the electrolyte density in each battery cell using a hydrometer.

- Do not carry out this check immediately after topping up with distilled water. Recharge the battery for at least an hour before checking the battery electrolyte density.

Handling and servicing a battery can be dangerous, take the following precautions : - Wear protective goggles.

- Keep the battery horizontal.

- Never smoke or work near a naked flame.

- Work in a well-ventilated area.

- In the event of electrolyte being spilled onto the skin or splashing in the eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.

3 - 18

1.300 °C -18 -10 0 10 20 30 40 °F 0 14 32 50 68 86 104

3 - 19

E - EVERY 1000 HOURS SERVICE Carry out the operations described previously as well as the following operations.

E1 - FUEL

TANK

E1/1 CLEAN

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

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

- Inspect the parts susceptible to leaks in the fuel circuit and in the tank.

- In the event of a leak, contact your dealer.

1

Never try to carry out a weld or any other operation by yourself, this could provoke an explosion or a fire.

- Place a container under drain plug 1 (Fig. E1/1) and unscrew the plug.

- Remove cap 2 (Fig. E1/2).

- Let the fuel flow and clean with 10 litres of clean fuel by filler port 3 (Fig. E1/2).

- Refit and tighten drain plug 1 (Fig. E1/1) (Tightening torque 29 to 39 N.m).

- Fill the fuel tank with clean fuel (See chapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) filtered through a strainer or a clean, lint-free cloth and refit the filler plug 2 (Fig. E1/2).

- Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Re-prime the system by activating fuel feed pump 4 (Fig. E1/3).

- If necessary, bleed the system (See chapter : G1 - FUEL SYSTEM in paragraph : 3 MAINTENANCE).

E1/2

2 3

E1/3

4

E2 - SAFETY

DRY AIR FILTER CARTRIDGE CHANGE

- For the disassembly and reassembly of the cartridge, see chapter : D3 - DRY AIR FILTER CARTRIDGE in paragraph : 3 - MAINTENANCE. - Gently remove the dry air filter safety cartridge 1 (Fig. E2), taking care to avoid spilling the dust.

- Clean the gasket surface on the filter with a damp, clean lint-free cloth.

- Before mounting check the state of the new safety cartridge (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.

NOTE : The periodicity for changing the safety cartridge is given for information only.

The safety cartridge must be changed for every two changes of the air filter cartridge.

3 - 20

E2

1

E3 - HYDRAULIC

OIL

E3/1 DRAIN

E4 - SUCTION

STRAINER FOR HYDRAULIC OIL TANK CLEAN

E5 - HYDROSTATIC

TRANSMISSION OIL FILTER CARTRIDGE CHANGE

Put the lift truck on level ground, the I.C. engine stopped and the mast lowered as far as possible.

1

Before any intervention, thoroughly clean the area surrounding the drain plug, the hydraulic return oil filter and the hydrostatic transmission oil filter on the hydraulic tank.

DRAINING THE OIL - Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Place a container under drain plug 1 (Fig. E3/1) and unscrew the plug.

- Unscrew the cover 2 (Fig. E3/2) to ensure that the oil is drained properly.

E3/2

10 2

Dispose the drain oil in an ecological manner.

9

CLEANING THE STRAINER - Disconnect the clogging indicator 3 (Fig. E3/3).

- Disconnect the hose 4 (Fig. E3/3) at the level of the hydrostatic transmission oil filter 5 (Fig. E3/3).

- Unscrew the four screws 6 (Fig. E3/3) and remove the complete filter 5 (Fig. E3/3).

- Unscrew 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 (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).

- Reassemble the strainer, the filter and re-connect the clogging indicator.

E3/3 HYDROSTATIC TRANSMISSION OIL FILTER CARTRIDGE CHANGE - Unscrew the cover 7 (Fig. E3/4).

- Remove the hydrostatic transmission oil filter cartridge 8 (Fig. E3/4) and replace it by a new one (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph : 3 MAINTENANCE).

- Ensure that the cartridge is correctly positioned and refit the cover.

Do not operate the lift truck without a cartridge. This would immediately lead to the deterioration of the hydraulic transmission circuit, the hydrostatic pump and the wheel reducers to get damaged.

5 4

3

6 6

FILLING UP THE OIL - Clean and refit drain plug 1 (Fig. E3/1) (Tightening torque 29 to 39 N.m).

- Fill up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 MAINTENANCE) by filler port 9 (Fig. E3/2).

Use a clean container and funnel and clean the underside of the oil drum before filling.

- Observe the oil level on dipstick 10 (Fig. E3/2), the oil should be equidistant between the lower and the upper marks.

- Check for any possible leaks at the drain plug.

- Refit the cover 2 (Fig. E3/2).

IIt may be necessary to bleed the system at the inlet of the pumps, if any air bubbles have formed during the draining; if so, consult your dealer.

3 - 21

E3/4

7

8

POLLUTION ABATEMENT OF THE HYDRAULIC CIRCUIT - Let the engine run (Accelerator pedal at halfway travel) for 5 minutes without using anything on the lift truck, then for 5 more minutes while using completely the hydraulic movements (Except the steering system).

- Accelerate the engine at full speed for 1 minute, then activate the steering system.

- This operation makes a pollution abatement of the circuit possible through the hydraulic return oil filter.

E6 - SEAT

BELT CHECK

SEAT BELT WITH TWO ANCHORING POINTS - Check the following points : • Fixing of the anchoring points on the seat.

• Cleanness of the strap and the locking mechanism.

• Triggering of the locking mechanism.

• Condition of the strap (cuts, curled edges).

REELED SEAT BELT WITH TWO ANCHORING POINTS - Check the points listed above together with the following points : • The correct winding of the belt.

• Condition of the reel guards.

• Roller locking mechanism when the strap is given a sharp tug.

NOTE : After an accident, replace the seat belt.

Under no circumstances should you use the lift truck if the seat belt is faulty (fixing, locking, it has cuts or tears, etc). Repair or replace the seat belt immediately.

3 - 22

3 - 23

F - EVERY 2000 HOURS SERVICE Carry out the operations described previously as well as the following operations.

F1 - COOLING

LIQUID

F1/1 DRAIN

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

DRAINING THE LIQUID - Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

- Disassemble the lower hose 1 (Fig. F1/1) of the radiator.

- Untighten the drain plug 2 (Fig. F1/2) of the engine block.

- Unscrew the filler plug 3 (Fig. F1/3) of the expansion pan and empty the latter.

- Disassemble the cover plate 4 (Fig. F1/4).

- Remove the filler plug 5 (Fig. F1/5) of the radiator.

- Allow the cooling circuit to drain completely while ensuring that the ports do not get clogged.

- Check the condition of the hoses as well as the fastening devices and change the hoses if necessary.

- Rinse the circuit with clean water and use a cleaning product if necessary.

LIQUID FILLING - Reassemble the lower hose 1 (Fig. F1/1).

- Retighten the drain plug 2 (Fig. F1/2) (tightening torque 8 to 12 N.m).

- Slowly fill the circuit with the cooling liquid (see chapter : LUBRICANTS AND FUEL in the section : 3 - MAINTENANCE) through the filler port 6 (Fig. F1/5).

- Fill the expansion pan to the maximum level.

- Allow the engine to run at idle for a few minutes.

- Check for possible leaks.

- Check the level and top up if necessary.

- Refit the filler plug 5 (Fig. F1/5).

- Reassemble the cover plate 4 (Fig. F1/4).

- Retighten the filler plug 3 (Fig. F1/3).

1

F1/2

2

F1/3

The I.C. engine does not contain any corrosion resistor and must be filled during the whole year with a mixture containing 25 % of ethylene glycol-based antifreeze.

3

F1/4

F1/5

4

5

6

3 - 24

F2 - FRONT

WHEELS REDUCERS OIL

F2 DRAIN

This operation should be carried out once a year if the lift truck has not reached 2000 hours service within the year.

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

B 1

Dispose the drain oil in an ecological manner.

- Drain and change each front wheel reducer.

- Place drain plug 1 (Fig. F2) in position A. - Place a container under the drain plug and unscrew the plug.

- Let the oil drain fully.

- Place the drain port in position B, i.e. in a level port.

- Fill up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 MAINTENANCE) by level port 1 (Fig. F2).

- The level is correct when the oil level is flush with the edge of the hole.

- Refit and tighten the drain plug 1 (Fig. F2) (Tightening torque 60 to 70 N.m).

3 - 25

A

G - OCCASIONAL MAINTENANCE G1 - FUEL

SYSTEM

G1/1 BLEED 1

These operations are to be carried out only in the following cases : - A component of the fuel system replaced or drained.

- A drained tank.

- Running out of fuel.

Ensure that the level of fuel in the tank is sufficient, turn the ignition key to notch I to establish electrical contact and bleed in the following order : - Lift up the overhead guard or the cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

BLEEDING THE FUEL FILTER - Loosen bleed screw 1 (Fig. G1/1).

- Activate feed pump 2 (Fig. G1/2) until the diesel fuel flows out free from air 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 the diesel fuel is flowing out.

G1/2

2

BLEEDING THE HEATER PLUG - Loosen connection 3 (Fig. G1/3) on the heater plug.

- Activate feed pump 2 (Fig. G1/2) until the diesel fuel is flowing out free from air at the connection.

- Tighten the connection while the diesel fuel is flowing out.

G1/3

3

Immobilise the heater plug with a spanner before loosening connection 3 (Fig. G1/3).

BLEEDING THE INJECTORS - Loosen high pressure connectors 4 (Fig. G1/4) of two of the injectors.

- Activate the starter until the diesel fuel flows out free of air at connections 4 (Fig. G1/4).

- Tighten the connection while the diesel fuel is flowing out (Tightening torque 22 N.m).

The I.C. engine is then ready to be started up.

G1/4

4

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

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

3 - 26

4

4

G2 - WHEEL

G2/1 CHANGE

In the event of a wheel being changed on the public highway, make sure of the following points : - Stop the lift truck, if possible on even and hard ground.

- To pass on stop of lift truck (See chapter : DRIVING INSTRUCTIONS in paragraph : 1 - OPERATING AND SAFETY INSTRUCTIONS).

- Put the warning lights on.

- Immobilise the lift truck in both directions on the axle opposite to the wheel to be changed.

- Unlock the nuts of the wheel to be changed.

REAR WHEEL NOTE : For this operation, we advise you to use the hydraulic jack MANITOU Reference 505 507.

G2/2

- Place the jack under the counterweight (It must be situated in the middle and under the flat part of the counterweight).

- Lift the rear of the truck and place wedges (Approximately 260 mm) under the axle on the side of the wheel to be changed (Fig. G2/1).

- Completely untighten the wheel nuts and remove them.

- Release the wheel by reciprocating movements and roll it on the side.

- Slide the new wheel onto the hub.

- Manually screw the nuts, if necessary lubricate them.

- Remove the wedges under the axle and lower the lift truck with the help of the jack.

- Tighten the wheel nuts by means of a torque wrench (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE for tightening torque).

FRONT WHEEL - Lift the carriage and tilt the mast backwards.

- Put wedges under the foot of the mast on the side of the wheel to be changed (Fig. G2/2).

- Tilt the mast forwards so as to lift the wheel.

- Place wedges under the chassis (Approximately 300 mm) as near as possible to the wheel (Fig. G2/3).

- Completely untighten the wheel nuts and remove them.

- Release the wheels by reciprocating movements and roll it on the side.

- Slide the new wheel onto the hub.

- Manually screw the nuts, if necessary lubricate them.

- Remove the wedges under the axle and lower the lift truck.

- Tighten the wheel nuts by means of a torque wrench (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE for tightening torque).

3 - 27

G2/3

G3 - LIFT

TRUCK

G3/1 TOWING

To start up the lift truck, never try to push or pull it. Such a manoeuvre would cause serious damage to the hydrostatic transmission.

You must unlock the wheel reducers before any movement. Towing the lift truck must be carried out by means of a rigid drawbar, because the lift truck is uncoupled from its braking system after unlocking the wheel reducers.

2 1

UNLOCKING THE FRONT WHEEL REDUCERS Carry out this operation on both front wheel reducers.

- Place a container under the reducer.

- Disassemble the retaining ring 1 (Fig. G3/1).

- Remove the plug 2 (Fig. G3/1), a little oil will then escape.

- Put a screw HM 6 x .. onto the threading of the drive shaft 3 (Fig. G3/2).

- Remove the drive shaft and protect it with a clean cloth.

- Reassemble the plug 2 (Fig. G3/1) and the retaining ring 1 (Fig. G3/1) so as to protect the wheel reducers during the towing.

- After the towing, proceed in the reverse order.

G3/2

NOTE : When reassembling, ensure that the drive shaft grooves and the gears coincide without forcing.

3

Top up the level of oil in the wheel reducers.(See chapter : B4 - FRONT WHEELS REDUCERS OIL LEVEL in paragraph : 3 - MAINTENANCE).

TOWING THE LIFT TRUCK Do not tow the lift truck at a speed exceeding 24 km/h.

- Put the forward/ reverser lever in neutral.

- Untighten the hand brake.

- Turn up the warning lights (OPTION).

- As the steering booster is lacking, operate slowly and energetically the steering wheel.

Avoid abrupt movements and jerks.

G4 - LIFT

TRUCK

G4/1 SLING

- Take into account the position of the lift truck gravity center for lifting (Fig. G4/1).

- Place the hooks in the fastening points provided (Fig. G4/2 and G4/3).

A = 921 mm A = 999 mm A = 1084 mm

B = 879 mm B = 801 mm B = 716 mm

A

3 - 28

MSI 20 D + BUGGIE MSI 25 D + BUGGIE MSI 30 D + BUGGIE

B

G4/2

G5 - LIFT

G4/3

TRUCK ON A PLATFORM

G5/1 TRANSPORT

Ensure that the safety instructions connected to the platform are respected before the loading of the lift truck and that the driver of the means of transport is informed about the dimensions and the weight of the lift truck (See chapter : CHARACTERISTICS in paragraph : 2 - DESCRIPTION).

Ensure that the platform has got dimensions and a load capacity sufficient for transporting the lift truck. Check also the pressure on the contact surface allowable for the platform in connection with the lift truck.

LOAD THE LIFT TRUCK - Block the wheels of the platform.

- Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck.

- Load the lift truck parallel to the platform.

- Stop the lift truck (See chapter : DRIVING INSTRUCTIONS in paragraph : 1 OPERATING AND SAFETY INSTRUCTIONS).

G5/2

STOW THE LIFT TRUCK - Fix the chocks to the semitrailer at the front and at the back of each tyre (Fig. G5/1).

- Fix also the chocks to the semitrailer in the inside of each tyre (Fig. G5/2).

- Stow the lift truck onto the semi-trailer with sufficiently resistant ropes. To the front by passing above the articulation fittings 1 (Fig. G5/3) of the mast and to the back onto the towing pin 2 (Fig. G5/4).

- Tighten the ropes (Fig. G5/5).

G5/3

1

G5/4

G5/5

1

2

3 - 29

G6 - OVERHEAD

GUARD OR THE CAB IN CASE OF ELECTRIC FAILURE

G6/1

LIFT - Bring a floating battery of the same type as the one used for the lift truck and battery cables.

- Unlock the overhead guard or the cab with the lever 1 (Fig. G6/1) into position A. - Turn on the ignition in the lift truck.

- Disassemble the panel 2 (Fig. G6/2) to access to the electric pump relay.

- Connect the negative cable onto the battery and take a good earth on the lift truck (Fig. G6/3).

- Connect the positive cable onto the battery and excite the terminal 3 (Fig. G6/4) (Terminal fed by a red wire).

NOTE : The overhead guard or the cab will start to rise as soon as the terminal 3 (Fig. G6/4) is excited.

- Lift the overhead guard or the cab until reaching a dimension of 140 mm between the hood and the cowling (Fig. G6/5). (Above this dimension, risk of interference between the windscreen and the mast if the latter is tilted backwards).

- Disconnect the earth in the lift truck.

- Access to the lift truck battery from the back between the hood and the cowling and connect the floating battery while respecting the polarity (Fig. G6/6).

- Then, carry out the lifting of the overhead guard or cab (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).

1

A

G6/2

2

G6/3

G6/4

G6/5

3

140 mm

3 - 30

G6/6

G7 - OVERHEAD

GUARD OR THE CAB IN CASE OF HYDRAULIC FAILURE

G7/1

IN THE LIFTING SYSTEM LIFT - Tilt the mast backwards to the maximum.

- Unlock the overhead guard or the cab with the lever 1 (Fig. G7/1) into position A. - With the cab model, close the doors.

- Remove the screws 2 (Fig. G7/2) from the roof.

- Pass a sling around the upper belt of the mobile column (Fig. G7/3) and fasten the sling ends onto the roof with screws H, M 14 (Length 50 mm minimum) (Fig. G7/3).

- Start the I.C. engine.

- Smoothly lift the mast so as to stretch the sling.

- Slowly tilt the mast forwards until you can fit the safety stay 3 (Fig. G7/4) onto its stop 4 (Fig. G7/4).

- Lower the mast so as to release and remove the sling and the screws.

- Reinstall and tighten the screws 2 (Fig. G7/2).

1

A

G7/2

2

2

G7/3

G7/4

3

4

3 - 31

G8 - O V E R H E A D

GUARD OR THE CAB IN CASE OF MECHANICAL

G8/1

FAILURE IN THE LIFTING SYSTEM LIFT PROCEDURE IN THE EVENT OF AN UNLOCKING CABLE BREAKAGE - Unlock the overhead guard or the cab with the lever 1 (Fig. G8/1) into position A. - Remove the air pre-filter (If mounted).

- Disassemble the cowling 2 (Fig. G8/2).

- By means of a tool (For example screwdriver), push the lock 3 (Fig. G8/3) on the side of the damaged cable while another operator carries out the procedure of overhead guard or cab lifting (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 DESCRIPTION).

1

A

G8/2

G8/3

2

3

G9 - FRONT

HEADLAMPS ADJUST

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

ADJUSTING PROCEDURE - Place the lift truck unloaded and in the transport position and perpendicular to a white wall on flat, level ground (Fig. G9).

- Check the tyre pressures (See chapter : A5 - TYRES PRESSURE AND WHEEL NUTS TORQUE in paragraph : 3 - MAINTENANCE).

- Put the gear reverser lever in neutral and release the parking brake.

G9 h2 = h1 - (l x 2 / 100)

h1 +% -% h2

-2%

h1

MADE IN FRANCE

l

CALCULATING THE HEIGHT OF THE DIPPED BEAM (h2) • h1 = Height of the dipped beam in relation to the ground.

• h2 = Height of the adjusted beam.

• l = Distance between the dipped beam and the white wall.

3 - 32

4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE

4-1

4-2

INTRODUCTION - A wide range of attachments studied and perfectly adapted to your lift truck is available and guaranteed by the manufacturer.

- The attachments are delivered with a load chart concerning your lift truck. The operator's manual and the load chart should be kept in the places provided in the lift truck. For standard attachments, their use is governed by the instructions contained on this notice.

- Some particular uses require the adaptation of the attachment which is not provided in the price-listed options. Optional solutions exist, consult your dealer.

It is COMPULSORY for all ATTACHMENTS WITH SUSPENDED LOAD (Hoist, crane jib, crane jib with winch, hook, etc.) to be used with a fork lift fitted with AUTOMATIC HYDRAULIC MOVEMENT CUT-OFF. Only attachments approved by the manufacturer are to be used on our lift trucks (See chapter : TECHNICAL SPECIFICATIONS OF ATTACHMENTS in paragraph : 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE). The manufacturer's liability will be denied in case of modification or of attachment adaptation carried out without his knowing it.

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

4-3

TECHNICAL SPECIFICATIONS OF ATTACHMENTS LOAD

BACK REST

MSI 20/25 D + BUGGIE Reference : 556005 Width : 1260 mm Weight : 38 Kg

Reference Width Weight

: 555323 : 1470 mm : 42 Kg

Reference Width Weight

: 555325 : 1470 mm : 41 Kg

MSI 20/25 D + BUGGIE Reference : 415689 Section : 100 x 40 x 1100 mm Weight : 43 Kg

Reference Section Weight

: 415691 : 100 x 40 x 1200 mm : 44 Kg

Reference Section Weight

: 415692 : 100 x 40 x 1500 mm : 60 Kg

Reference Section Weight

: 415330 : 125 x 45 x 1200 mm : 65 Kg

MSI 30 D + BUGGIE Reference Section Weight

: 415690 : 100 x 45 x 1100 mm : 55 Kg

Reference Section Weight

: 415693 : 100 x 45 x 1200 mm : 58 Kg

Reference Section Weight

: 415694 : 100 x 45 x 1500 mm : 72 Kg

Reference Section Weight

: 415449 : 150 x 50 x 1200 mm : 100 Kg

Reference Width Weight

: 556007 : 1580 mm : 44 Kg

MSI 30 D + BUGGIE Reference Width Weight

: 556008 : 1260 mm : 39 Kg

Reference Width Weight

: 556010 : 1580 mm : 42 Kg

STANDARDISED

FORKS

FORK

EXTENSION

- RF 30-1700 Reference : 570426 Nominal load capacity : 1500 Kg Length : 1700 mm Section : 140 x 60 mm Weight : 32 Kg

- RF 30-2000 Reference : 570427 Nominal load capacity : 1500 Kg Length : 2000 mm Section : 140 x 60 mm Weight : 38 Kg

- RF 30-2300 Reference : 570428 Nominal load capacity : 1500 Kg Length : 2300 mm Section : 140 x 60 mm Weight : 42 Kg

- RF 30-2500 Reference : 570429 Nominal load capacity : 1500 Kg Length : 2500 mm Section : 140 x 60 mm Weight : 48 Kg

4-4

STANDARDISED

SIDE - SHIFT CARRIAGE

MSI 20/25 D + BUGGIE - TDL 55F-SS-A931 - 1260 Reference : 571456 * : 571457 ** : 571458 *** Nominal load capacity : 2500 Kg Side-shift : 2x100 mm Width : 1260 mm Weight : 85 Kg - TDL 55F-SS-A933 - 1580 Reference : 571464 * : 571465 ** : 571466 *** Nominal load capacity : 2500 Kg Side-shift : 2x100 mm Width : 1580 mm Weight : 105 Kg

- TDL 55F-SS-A932 - 1470 Reference : 571460 * : 571461 ** : 571462 *** Nominal load capacity : 2500 Kg Side-shift : 2x100 mm Width : 1470 mm Weight : 101 Kg * : Double mast with all-round vision ** : Double mast with free-acting lift *** : Triple mast with free-acting lift

MSI 30 D + BUGGIE - TDL 60E-SS-B621 - 1260 Reference : 556254 * : 570197 ** : 570194 *** Nominal load capacity : 3000 Kg Side-shift : 2x100 mm Width : 1260 mm Weight : 110 Kg - TDL 100E-SS-B687 - 1580 Reference : 556256 * : 570199 ** : 570196 *** Nominal load capacity : 3000 Kg Side-shift : 2x100 mm Width : 1580 mm Weight : 200 Kg

- TDL 100E-SS-B686 - 1470 Reference : 556386 * : 570198 ** : 570195 *** Nominal load capacity : 3000 Kg Side-shift : 2x100 mm Width : 1470 mm Weight : 192 Kg * : Double mast with all-round vision ** : Double mast with free-acting lift *** : Triple mast with free-acting lift

4-5

GRAIN

BUCKET

MSI 20/25 D + BUGGIE - BA 1000 S2 25N Reference : 555777 Nominal load capacity : 1000 L / 1200 Kg Width : 2022 mm Weight : 470 Kg

- BA 1500 S2 25N Reference : 555778 Nominal load capacity : 1500 L / 1800 Kg Width : 2022 mm Weight : 600 Kg

- BA 2000 S2 25N Reference : 555779 Nominal load capacity : 2000 L / 2000 Kg Width : 2022 mm Weight : 700 Kg MSI 30 D + BUGGIE - BA 1000 S2 30N Reference : 555780 Nominal load capacity : 1000 L / 1200 Kg Width : 2022 mm Weight : 480 Kg

- BA 1500 S2 30N Reference : 555781 Nominal load capacity : 1500 L / 1800 Kg Width : 2022 mm Weight : 610 Kg

- BA 2000 S2 30N Reference : 555782 Nominal load capacity : 2000 L / 2000 Kg Width : 2022 mm Weight : 700 Kg

BUILDING

BUCKET

MSI 20/25 D + BUGGIE - SP 500 N S2 Reference : 555784 Nominal load capacity : 500 L / 900 Kg Width : 1648 mm Weight : 420 Kg

- SP 500 NL S2 Reference : 555788 Nominal load capacity : 500 L / 900 Kg Width : 2022 mm Weight : 450 Kg

MSI 30 D + BUGGIE - SP 500 N S2 Reference : 555786 Nominal load capacity : 500 L / 900 Kg Width : 1648 mm Weight : 420 Kg

- SP 500 NL S2 Reference : 555790 Nominal load capacity : 500 L / 900 Kg Width : 2022 mm Weight : 450 Kg

4-6

NORMALIZED

TILTING FORK CARRIAGE

- PFB 25 N TI 1260 Reference : 570513 Nominal load capacity : 2500 Kg Width : 1260 mm Weight : 87 Kg

STANDARDISED

(ON

TILTABLE CARRIAGE

- PFB 25 N TI 1470 Reference : 570514 Nominal load capacity : 2500 Kg Width : 1470 mm Weight : 104 Kg

SIDE - SHIFT CARRIAGE

- TDL 55F-SS-A931 - 1260 Reference : 571545 Nominal load capacity : 2500 Kg Side-shift : 2x100 mm Width : 1260 mm Weight : 85 Kg

(ON

TILTABLE CARRIAGE

- TDL 55F-SS-A932 - 1470 Reference : 571546 Nominal load capacity : 2500 Kg Side-shift : 2x100 mm Width : 1470 mm Weight : 101 Kg

- TDL 55F-SS-A933 - 1580 Reference : 571547 Nominal load capacity : 2500 Kg Side-shift : 2x100 mm Width : 1580 mm Weight : 105 Kg

STANDARDISED Reference Section Weight

LOAD

FORK

(ON

TILTABLE CARRIAGE

T I)

: 415689 : 100 x 40 x 1100 mm : 43 Kg

BACK REST

(ON

TILTABLE CARRIAGE

Reference Width Weight

: 570518 : 1260 mm : 38 Kg

Reference Width Weight

: 556007 : 1580 mm : 44 Kg

T I)

T I)

Reference Width Weight

: 570519 : 1470 mm : 42 Kg

4-7

T I)

GRAIN

BUCKET

(ON

TILTABLE CARRIAGE

T I)

- CBA 900 S3 L1500 Reference : 570543 Nominal load capacity : 878 L Width : 1500 mm Weight : 367 Kg

LOADING

BUCKET

(ON

TILTABLE CARRIAGE

T I)

- CBR 500 L1500 Reference : 571991 Nominal load capacity : 496 L Width : 1500 mm Weight : 254 Kg

BUILDING

BUCKET

(ON

TILTABLE CARRIAGE

T I)

- CBC 500 L1500 Reference : 570610 Nominal load capacity : 519 L Width : 1500 mm Weight : 276 Kg

BUCKET

WITH GRAB

(ON

TILTABLE CARRIAGE

T I)

- CBG 1500 S3 Reference : 571549 Nominal load capacity : 0,7 m3 Width : 1500 mm Grab :6 Weight : 440 Kg

4-8

4

X

1

MULTIPURPOSE BUCKET

(ON

TILTABLE CARRIAGE

- CB4X1-450 L1500 Reference : 469880 Nominal load capacity : 450 L Width : 1500 mm Weight : 467 Kg

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T I)

ATTACHMENT SHIELDS FORK

PROTECTOR

Reference

BUCKET

: 227801

PROTECTOR

NOTE : Always ensure that the width of the protector you choose is less than or equal to the width of the bucket.

Reference Reference Reference Reference Reference

: 206734 (1375 mm) : 206732 (1500 mm) : 206730 (1650 mm) : 235854 (1850 mm) : 206728 (1950 mm)

Reference Reference Reference Reference Reference Reference Reference

: 206726 (2000 mm) : 223771 (2050 mm) : 223773 (2100 mm) : 206724 (2150 mm) : 206099 (2250 mm) : 206722 (2450 mm) : 223775 (2500 mm)

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