) MC 40 POWERSHIFT S2,MC 50 POWERSHIFT S2,MC 60 …

WICHTIG

BESTELLUNG VON TEILEN :

Bei Ihrer Bestellung bitte immer folgende Daten angeben :

- Nr. des Ersatzteiles- komplette Bezeichnung- Menge- Typ der Maschine- Seriennummer der Maschine- Identifikationsnummer des Bestandteiles(Mast, Ausleger, Kabine, Motor, usw.)

ACHTUNG :

Bestimmte in diesem Katalog illustrierte Teile oder Montagen von Teilen werden ausschließlich als Option geliefert und nicht mit der Maschine in ihrer Standardausführung.

SYMBOLISIERUNG :

: Ab (Maschine, Motor, Datum, usw.) : Bis (Maschine, Motor, Datum, usw.)

: Bei (Maschine, Motor, Datum, usw.) : Außer bei (Maschine, Motor, Datum, usw.) : siehe Tafel

, , , , , , : Bis , , , , , , : Ab

IMPORTANT

PARTS ORDER :

When placing an order, always state :

- Spare part ref. number- Complete description- Quantity- Type of machine- Machine serial number.- Component identification number(mast, jib, cab, engine, etc

CAUTION :

Certain parts, or part assemblies illustrated in this catalogue are only supplied as options, and not with the standard machine.

SYMBOLS :

: From (machine, engine, date, etc.) : Up to (machine, engine, date, etc.)

: For (machine, engine, date, etc.) : Except for (machine, engine, date, etc.) : See drawing

, , , , , , : Up to , , , , , , : From } machine N°,

N° moteur, cabine,transmission, etc.

} Maschine N°, Motor Nr, kabine,Transmission, usw.}

machine N°, N° engine, cab,transmission, etc.

IMPORTANT

COMMANDES DE PIECES :

Pour passer vos commandes, préciser toujours :

- N° de pièce rechange- Désignation complète- Quantité- Type de machine- N° dans la série de la machine- N° d’identification du composant(mât, flèche, cabine, moteur, etc.)

ATTENTION :

Certaines pièces ou montages de pièces illustrés dans ce catalogue sont livrés seulement en option et non avec la machine standard.

SYMBOLISATION :

: A partir de (machine, moteur, date, etc.) : Jusqu’à (machine, moteur, date, etc.)

: Pour (machine, moteur, etc.) : Sauf pour (machine, moteur, etc.) : Voir planche

, , , , , , : Jusqu’à , , , , , , : A partir

La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou autre, partiellement ou en totalité, sous quelque format que ce soit est interdite. Les schémas, les dessins, les vues, les commentaires les indications, l’organisation même du document qui sont rapportés dans la présente documentation, sont la propriété intellectuelle de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation exprès et formelle. Tous droits réservés.

This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization. All rights are reserved.

Die vorliegende Broschüre dient allein zur Beratung. Nachdruck, Fotokopieren, Vervielfältigung, Darstellung, Erfassung, Überlassung, Verbreitung oder Sonstiges (ganz oder teilweise) in jeglicher Form sind verboten. Die Entwürfe, Zeichnungen, Bilder, Darstellungen, Ansichten, Kommentare, Hinweise und der Aufbau der Druckschrift selbst, die in der vorliegenden Dokumentation enthalten sind, sind geistiges Eigentum von MANITOU BF. Alle Verstöße gegen das Vorstehende können zu straf- oder zivilrechtlicher Verfolgung führen. Die Logos und Markenzeichen sowie Unternehmens- und Produktbezeichnungen sind Eigentum von MANITOU BF und dürfen ohne ausdrückliche Genehmigung nicht verwendet werden. Alle Rechte vorbehalten.

IMPORTANTE

PEDIDOS DE PIEZAS :

Cuando efectúe sus pedidos, indique siempre :

- N° de pieza de recambio- Designación completa- Cantidad- Tipo de máquina- N° en la serie de la máquina- N° de identificación del componente(mástil, pluma, cabina, motor, etc.)

ATENCIÓN

Ciertas piezas o montajes de piezas ilustrados en este catálogo se suministran únicamente como opción y no con la máquina estándar.

SÍMBOLOS :

: A partir de (máquina, motor, fecha, etc.) : Hasta (máquina, motor, fecha, etc.)

: Para (máquina, motor, etc.) : Salvo para (máquina, motor, etc.) : Ver la lámina

, , , , , , : Hasta , , , , , , : A partir

IMPORTANTE

ORDINE DI PEZZI :

Per passare i vostri ordini, precisare sempre :

- N° pezzo di ricambio- Descrizione completa- Quantità- Tipo di macchina- N° di serie della macchina- N° d’identificazione componente(rampa, braccio, cabina,motore, ecc.)

ATTENZIONE :

Alcuni pezzi o montaggio di pezzi illustrati in questo catalogo vengono spediti solamente come optional e non con la macchina standard.

SIMBOLI :

: A partire da (macchina, motore, data, ecc.) : Fino a ( macchina, motore, data, ecc.)

: Per (macchina, motore, ecc.) : Escluso per (macchina, motore, ecc) : Vedere tavola

, , , , , , : Fino a , , , , , , : A partire da}

máquina N°, N° motor, cabina,transmisión, etc.

}macchina N°, N° motore, cabina,trasmissione, ecc.

Este folleto se ofrece a título meramente informativo y queda prohibida su reproducción, copia, representación, captación, cesión, distribución y demás, parcial o total, en el formato que sea. Los esquemas, dibujos, vistas, comentarios, indicaciones, la organización misma del documento aportado en esta documentación son propiedad intelectual de MANITOU BF. Cualquier infracción a lo antedicho puede acarrear condenas civiles y penales. Los logotipos y la identidad visual de la empresa son propiedad de MANITOU BF y no pueden utilizarse sin su autorización expresa y formaL. Reservados todos los derechos.

Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione, acquisizione, cessione, distribuzione o altro, parziale o totale, e in qualsivoglia formato. Gli schemi, i disegni, le viste, i commenti, le indicazioni e l’organizzazione stessa del documento, riportati nella presente documentazione, sono proprietà intellettuale di MANITOU BF. Qualsiasi violazione a quanto riportato sopra è passibile di condanna civile e penale. I loghi e l’identità visiva dell’azienda sono di proprietà di MANITOU BF e non possono essere utilizzati senza previa autorizzazione espressa e formale. Tutti i diritti sono riservati.

Contents

Safety instructions and advice 1Forklift truck identification plate 20General characteristics 22Description of the driving and control instruments 45Description of the towing pins and hooks 56Description and use of the hydraulic and electrical options 57Maintenance of the filters, belts and lubricants 58Maintenance intervals or periodic maintenance (0 to 500 hours) 61Maintenance intervals or periodic maintenance (1000 hours to +) 78General characteristics of the accessories 90

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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 andlead the maker to withdraw the lift truck's certificate of compliance.

BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS,

YOU ARE LEGALLY - Any user who procures parts from another quarter does so at his own risk.COVERINGYOURSELF - 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'scontrol.

- The practicalities of maintenance terms are set out by the maker. The maker is in no way liable in theevent of the user not complying with such terms.

YOU GET THE THE MANUFACTURER BRINGS TO THE USER,BENEFIT OF THEMANUFACTURER'S - His know-how and skill.KNOW-HOW

- 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 besttechnological capability to carry out maintenance.

ALL MAINTENANCE ON OUR LIFT TRUCKS MUST BE CARRIED OUT USING ORIGINAL PARTS.

ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALERNETWORK.

The dealer network list is available on MANITOU web site www.manitou.com

ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS

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 safetyinstructions. By being aware of the risks to which you are exposed and by taking the necessary preventive measures, youshould be able to avoid accidents occurring.

- Any operation or manœuvre not described in the operator's manual is theoretically prohibited, but anyone using a differentmethod 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 theuser 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 inserious, 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 themachinery 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 ownpersonal experience.The person in charge of the equipment must take these criteria into account when assessing whether or not a person willmake a suitable driver.

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DRIVER'S OPERATING INSTRUCTIONS

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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 normEN 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 appropriatemanager 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 agent or 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 yourlift truck yourself (Hydraulic pressure, relief valve calibration, I.C. engine running speed, addition of extra equipment etc.). Thesame holds with regard to any suppression or modification of the safety systems, in which case the maker would no longer beliable.

Regular inspection of your lift truck is mandatory if it is to be kept in conforming condition. The frequency of such checks aredefined by the current legislation of the country in which the lift truck is being operated. Maintenance or repairs other thanthose detailed in part : 3 - MAINTENANCE must be carried out by qualified personnel (Consult your agent or dealer) and underthe 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 agent or 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 thecircuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessary todrain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambienttemperatures. 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 andventilated 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 availableon option.

IF NECESSARY, CONSULT YOUR DEALER.

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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 anypart 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.

. Transmission oil.

. Cooling liquid.

. Braking oil.- Also check for possible leakage of oil, fuel or liquid from the lift truck.- Check the closing and locking of the hood(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 TRUCKSAFETY NOTICE

The lift truck must only be started up or manoeuvred when the operator is sitting in the driver’s cab, with his seat beltadjusted 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, thetransmission 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 whenconnecting 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 batterymay produce an explosive gas. Avoid flames and generation of sparks close to the batteries.

Never disconnect a battery while it is charging.

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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 unsuccessfulattempts.

- 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 TRUCKSAFETY 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 agent

or 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- Check the transmission oil level.- Raise the forks or attachment to the transport position approximately 300 mm from the ground.- Engage the gear required (See chapter : INSTRUMENTS AND CONTROLS in paragraph : 2 - DESCRIPTION).- 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 TRUCKSAFETY 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 ofcertain 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 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 safetyand the safety of others.

F - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAYSAFETY 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 withequipment in accordance with regulations or else dismounted.

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INSTRUCTIONS- Ensure that the flashing light is in position and that it is working.- Check the good working order and cleanness of lights, indicators and windscreen wiper.- 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.- On the road, set off in 3rd gear and go into 4th (As model of lift truck) when the conditions and state of the road allow. In hilly

areas, set off in 2nd gear and go into 3rd when the conditions and state of the road allow.

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).- When driving with a trailer, set off in 2nd gear and go into 3rd when the conditions and state of the road allow.

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.


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 stronglyadvised to ensure that the safety rules on the site conform to the local regulations in force regarding all types of work carriedout 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 theweight.

- Ensure the stability and solidity of the ground before depositing a load.- Never stack loads on uneven ground, they may tip over.

1 - 12

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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 toguide 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 buzzeralarm, front light, rear light, etc. Consult your agent or dealer.


1 - 14

INSTRUCTIONS FOR HANDLING A LOAD

A - WEIGHT OF LOAD AND CENTRE OF GRAVITY

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

- 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 highercentre of gravity, consult your agent or dealer.

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

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

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).

Beware of the risks of trapping or squashing limbs when manually adjusting theforks. Always maintain an equal distance between the forks and the centre of thecarriage 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).

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

500 mm

A

B

C

D

12

E

21

F

1 - 15

C - TAKING UP A HIGH LOAD ON TYRES

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 inthe chapter : INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLINGOPERATIONS for visibility of the road).

- Bring the forks to stop in front of the load (Fig. H). Apply the parking brake and placethe 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.

- Manoeuvring very gently and carefully (See paragraph : E - VISIBILITY in the chapter :INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLINGOPERATIONS 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).

G

H

2

1

I

1

J

1 - 16

D - LAYING A HIGH LOAD ON TYRES

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 thechapter : INSTRUCTIONS FOR MOVING THE LIFT TRUCK DURING HANDLINGOPERATIONS for visibility of the road). Apply the parking brake and place theforward/reverse lever in neutral.

- Place the load in a horizontal position by tilting the mast forwards (1) and lay it downon 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 HANDLINGOPERATIONS for visibility of the road). Then bring the forks into the transport position.

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.

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 islaterally horizontal.

2

1

3

N

3

2

1

M

1

2

L

K

1 - 18

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 canbe dangerous. A balancing valve must only be removed when the cylinder concerned is without load and the hydraulic circuitis 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 causingirreparable 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 tomove 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.

MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK

1 - 19

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 - 20

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 willbe 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 thelift 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 thecircuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessary todrain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambienttemperatures. 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 SYSTE- Check that all fuel lines are secured.- If necessary drain the fuel filter and bleed the fuel system of air.

BEFORE STARTING UP A NEW LIFT TRUCK

1 - 21

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.


1 - 22

INTRODUCTION

The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service foran 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 performedby your agent or 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 1600 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 400 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.

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

1 - 23

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 400 HOURS SERVICE in paragraph : 3 -

MAINTENANCE).- Refit and set the tension in the drive belts (See chapter : C - EVERY 200 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 inparagraph : 1 - OPERATING AND SAFETY INSTRUCTIONS).

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

2 - 4

D

As our policy is to promote a constant improvement of our products, our range oftelescopic lift trucks may undergo certain modifications, without obligation for us toadvise 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 ismade in the spaces provided, at the time of the delivery of the lift truck.

PLATE MANUFACTURER OF THE LIFT TRUCK (FIG. A)

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

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

I.C. ENGINE (FIG. B)

- Engine Nr

TRANSMISSION (FIG. C)

- Type- MANITOU reference- Serial Nr

FRONT AXLE (FIG. D)

- Type- Serial Nr- MANITOU reference

IDENTIFICATION OF THE LIFT TRUCK

B

C

44158 ANCENIS CEDEXFRANCE

daN

AR.AV.

daNkg

daNkW

MANITOU BF

(sur accrochage remorque)Effort vertical max.

P.T.R.A.

Ann e de fabrication

SERIE

Pression des pneumatiques (Bar)

Masse vide

N¡ de chassis

N¡ dans la s rie

MODELE

Effort de tractionPuissance ISO/TR14396

N¡240130

A

2 - 5

CAB (FIG. E)

- Type- Serial Nr

MAST (FIG. F)

- Mast identification Nr

PLATE MANUFACTURER OF THE ATTACHMENT (FIG. G)

- Model- Serial Nr- Year of manufacture

E

F

FMC 40/50 POWERSHIFT Série 2

MC 60/70 POWERSHIFT Série 2 + Turbo

Pression de service

Cap. Nominale

Année fabrication

C d G / Tablier

MODELE

N° dans la série

Masse à vide

44158 ANCENIS CEDEXFRANCE

MANITOU BF

AVERTISSEMENT : RESPECTEZLA CAPACITE DE L'ENSEMBLE"CHARIOT ET EQUIPEMENT"

207701N°

A vide / En charge : mm

kg

G

2 - 6

PERKINS 1004.42 AR 81268PERKINS 1004.42 AR 81268PERKINS 1004.42 AR 81268PERKINS 1004.42 AR 81268PERKINS 1004.40 T AK 81289PERKINS 1004.40 T AK 81289

1004.42 AR 81268 1004.40T AK 812894 in line 4 in line

4 4Natural Compressed turboDirect Direct

1.3.4.2. 1.3.4.2.

0,20 mm 0,20 mm0,45 mm 0,45 mm4233 cm3 3990 cm3103 mm 103 mm127 mm 127 mm18.5 : 1 17.25 : 1

2200 rpm 2300 rpm825 rpm 825 rpm

2500 rpm 2500 rpm80 cv / 60 kw 106,5 cv / 78,5 kw

290 Nm at 1400 rpm 394 Nm at 1400 rpmDry 3 µ Dry 3 µ

By waterBlowing6

457 mm

77 °C to 85 °C92 °C to 98 °C

Negative12 V - 105 Ah - 680 A EN12 V - 65 A

Magneti Marelli A127Incorporated into the alternator

12 VMagneti Marelli M127

CLARK-HURTHCLARK-HURTH

Electrohydraulic43Electrohydraulic

ENGINE

- TypeMC 40 POWERSHIFT Série 2MC 50 POWERSHIFT Série 2MC 60 POWERSHIFT Série 2MC 70 POWERSHIFT Série 2MC 60 Turbo POWERSHIFT Série 2MC 70 Turbo POWERSHIFT Série 2

- 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 CIRCUIT

- Type- Fan

. Number of blades

. Diameter- Thermostat

. Start opening

. Full opening

ELECTRIC CIRCUIT

- Earth- Battery- Alternator

. Type

. Tension regulator- Starter

. Type

TRANSMISSION

- Type- Torque converter- Gear box

. Gear shifting

. Number of forward speeds

. Number of reverse speeds- Gear reverser

CHARACTERISTICS

2 - 7

DANAEpicyclicFoot button. Electrohydraulic

Foot pedal. Hydraulic brake, applied on the frontwheels.Multidisc brake immersed in oil.Mechanical hand lever applied on the front wheels.Multidisc brake immersed in oil.

FRONT AXLE

- Type- Hub reducers- Differential lock

BRAKE

- Service brake

. Type- Parking brake

. Type

2 - 8

HYDRAULIC CIRCUIT

- Type of pump. Capacity

- Lifting, tilting, attachment circuit. Flow rate at full speed. Pressure

- Steering circuit. Flow rate at full speed. Pressure

- Filtration. Return. Suction

- Hydraulic shock absorber. Capacities. Pressure

Gear pump with flow divider37 cm3

87 L/min210 Bar

Load control system145 Bar

10 µ100 µ

1,4 L120 Bar

MC 40 POWERSHIFT Série 2

STANDARD

DIMENSIONS PRESSURE TYRE LOAD PRESSURE ON THE CONTACT SURFACE AREA OF THE CONTACT SURFACEHARD GROUND LIGHT GROUND HARD GROUND LIGHT GROUND

445/65R19,5 XZY TL 165K 4 Bar 1250 kg 3 kg/cm2 kg/cm2 415 cm2 cm2MICHELIN 4700 kg 4,1 kg/cm2 kg/cm2 1143 cm2 cm2

UnladenLaden

OPTION 18-19,5 ML224 18 PR Tubeless 6,5 Bar 1250 kg 6,5 kg/cm2 kg/cm2 192 cm2 cm2ALLIANCE 4700 kg 6,5 kg/cm2 kg/cm2 723 cm2 cm2

UnladenLaden

OPTION 18R19,5 XF Tubeless *PR 6,5 Bar 1250 kg 2,8 kg/cm2 1,32 kg/cm2 439 cm2 947 cm2MICHELIN 4700 kg 4,1 kg/cm2 1,89 kg/cm2 1150 cm2 2481 cm2

UnladenLaden


STANDARD 10R17,5 134M G291 8,5 Bar 2100 kg 8,8 kg/cm2 6,6 kg/cm2 240 cm2 320 cm2GOODYEAR 700 kg 5 kg/cm2 3,8 kg/cm2 140 cm2 185 cm2

UnladenLaden

FRONT TYRES

REAR TYRES

CHARACTERISTICS

OPTION 10R17,5 LSR Tubeless 134/132L 5 Bar 2100 kg kg/cm2 kg/cm2 cm2 cm2CONTINENTAL 700 kg kg/cm2 kg/cm2 cm2 cm2

10R17,5 LDR Tubeless 134/132L 6,5 Bar 2100 kg kg/cm2 kg/cm2 cm2 cm2CONTINENTAL 700 kg kg/cm2 kg/cm2 cm2 cm2

UnladenLadenUnladenLaden

OPTION 285/70 R19,5 XZY TL 140/137L 5,5 Bar 2100 kg 5,2 kg/cm2 kg/cm2 405 cm2 cm2MICHELIN 700 kg 5,2 kg/cm2 kg/cm2 134 cm2 cm2

UnladenLaden

2 - 9

dB

105 dB

24 km/h24 km/h

3700 mm (DUPLEX mast)

4000 kg

500 mm

105 kg

0,50 m/s0,47 m/s0,41 m/s0,50 m/s

6660 kg10660 kg

2475 kg9330 kg4185 kg1330 kg

3230 daN7160 daN

daN

SPECIFICATIONS

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

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

- Travel speed of the lift truck. Forward. Reverse

- Standard lift height

- Rated capacity with standard mast

- Load center

- Weight of forks (Each)

- Lifting motions (With standard mast). Unladen lifting. Rated load lifting. Unladen lowering. Rated load lowering

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

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

rated load. Rear unladen

rated load

- Tensible strain at coupling hook. Unladen. Rated load

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

2 - 10


STANDARD


445/65R19,5 XZY TL 165K 5,75 Bar 1250 kg 3,9 kg/cm2 kg/cm2 323 cm2 cm2MICHELIN 5500 kg 5,4 kg/cm2 kg/cm2 1012 cm2 cm2

UnladenLaden

OPTION 18-19,5 ML224 18 PR Tubeless 6,5 Bar 1250 kg 6,5 kg/cm2 kg/cm2 192 cm2 cm2ALLIANCE 5500 kg 6,5 kg/cm2 kg/cm2 846 cm2 cm2

UnladenLaden


UnladenLaden

FRONT TYRES

CHARACTERISTICS

HYDRAULIC CIRCUIT







87 L/min210 Bar


10 µ100 µ

1,4 L120 Bar


STANDARD 10R17,5 134M G291 9,5 Bar 2650 kg 10 kg/cm2 7,6 kg/cm2 265 cm2 350 cm2GOODYEAR 850 kg 6,3 kg/cm2 4,7 kg/cm2 135 cm2 180 cm2

UnladenLaden

REAR TYRES

OPTION 10R17,5 LSR Tubeless 134/132L 6 Bar 2650 kg kg/cm2 kg/cm2 cm2 cm2CONTINENTAL 850 kg kg/cm2 kg/cm2 cm2 cm2

10R17,5 LDR Tubeless 134/132L 8 Bar 2650 kg kg/cm2 kg/cm2 cm2 cm2CONTINENTAL 850 kg kg/cm2 kg/cm2 cm2 cm2


OPTION 285/70 R19,5 XZY TL 140/137L 6 Bar 2650 kg 5,9 kg/cm2 kg/cm2 541 cm2 cm2MICHELIN 850 kg 6,3 kg/cm2 kg/cm2 134 cm2 cm2

UnladenLaden

2 - 11

dB

105 dB

24 km/h24 km/h


5000 kg

600 mm

134 kg

0,44 m/s0,38 m/s0,41 m/s0,50 m/s

7620 kg12620 kg

2405 kg10925 kg5215 kg1695 kg

2660 daN7680 daN

daN

SPECIFICATIONS






- Load center






rated load



2 - 12

HYDRAULIC CIRCUIT







87 L/min230 Bar


10 µ100 µ

1,4 L150 Bar



STANDARD 18R19,5 XF Tubeless *PR 6,5 Bar 1750 kg 3,3 kg/cm2 1,54 kg/cm2 526 cm2 1135 cm2MICHELIN 6800 kg 4,5 kg/cm2 2,1 kg/cm2 1500 cm2 3236 cm2

UnladenLaden

OPTION 18R22,5 XF Tubeless *PR 7 Bar 1750 kg 2,2 kg/cm2 1,01 kg/cm2 800 cm2 1726 cm2MICHELIN 6800 kg 4,4 kg/cm2 2,03 kg/cm2 1550 cm2 3344 cm2

445/65R19,5 XZY TL 165K 7 Bar 1750 kg 4,3 kg/cm2 kg/cm2 405 cm2 cm2MICHELIN 6800 kg 6,7 kg/cm2 kg/cm2 1021 cm2 cm2



OPTION 285/70 R19,5 XZY 140/137L 6,5 Bar 2800 kg 6,2 kg/cm2 kg/cm2 455 cm2 cm2MICHELIN 800 kg 6 kg/cm2 kg/cm2 133 cm2 cm2

UnladenLaden

STANDARD 9,5R19,5 Tubeless XZY 134/131K 6,5 Bar 2800 kg 6,2 kg/cm2 kg/cm2 452 cm2 cm2MICHELIN 800 kg 4,4 kg/cm2 kg/cm2 181 cm2 cm2

UnladenLaden

FRONT TYRES

REAR TYRES

CHARACTERISTICS

2 - 13

dB

105 dB

24 km/h24 km/h


6000 kg

600 mm

176 kg

0,40 m/s0,36 m/s0,43 m/s0,50 m/s

9055 kg15055 kg

3480 kg13540 kg5575 kg1515 kg

1900 daN8800 daN

daN

SPECIFICATIONS






- Load center






rated load



2 - 14

HYDRAULIC CIRCUIT







92,5 L/min230 Bar


10 µ100 µ

1,4 L150 Bar

MC 60 Turbo POWERSHIFT Série 2


STANDARD 18R19,5 XF Tubeless *PR 6,5 Bar 1750 kg 3,3 kg/cm2 1,54 kg/cm2 526 cm2 1135 cm2MICHELIN 6800 kg 4,5 kg/cm2 2,1 kg/cm2 1500 cm2 3236 cm2

UnladenLaden

OPTION 18R22,5 XF Tubeless *PR 7 Bar 1750 kg 2,2 kg/cm2 1,01 kg/cm2 800 cm2 1726 cm2MICHELIN 6800 kg 4,4 kg/cm2 2,03 kg/cm2 1550 cm2 3344 cm2

445/65R19,5 XZY TL 165K 7 Bar 1750 kg 4,3 kg/cm2 kg/cm2 405 cm2 cm2MICHELIN 6800 kg 6,7 kg/cm2 kg/cm2 1021 cm2 cm2



OPTION 285/70 R19,5 XZY 140/137L 6,5 Bar 2800 kg 6,2 kg/cm2 kg/cm2 455 cm2 cm2MICHELIN 800 kg 6 kg/cm2 kg/cm2 133 cm2 cm2

UnladenLaden

STANDARD 9,5R19,5 Tubeless XZY 134/131K 6,5 Bar 2800 kg 6,2 kg/cm2 kg/cm2 452 cm2 cm2MICHELIN 800 kg 4,4 kg/cm2 kg/cm2 181 cm2 cm2

UnladenLaden

FRONT TYRES

REAR TYRES

CHARACTERISTICS

2 - 15

dB

105 dB

25,8 km/h25,8 km/h


6000 kg

600 mm

176 kg

0,44 m/s0,38 m/s0,43 m/s0,50 m/s

9055 kg15055 kg

3480 kg13540 kg5575 kg1515 kg

1900 daN8800 daN

daN

SPECIFICATIONS



- Travel speed of the lift truck(Except particular conditions)

. Forward

. Reverse



- Load center






rated load



2 - 16


HYDRAULIC CIRCUIT







87 L/min230 Bar


10 µ100 µ

1,4 L150 Bar


STANDARD 18R19,5 XF Tubeless *PR 7 Bar 1850 kg 3,6 kg/cm2 1,69 kg/cm2 507 cm2 1094 cm2MICHELIN 7100 kg 4,7 kg/cm2 2,19 kg/cm2 1500 cm2 3236 cm2

UnladenLaden





OPTION 285/70 R19,5 XZY 140/137L 6,5 Bar 3050 kg 6,1 kg/cm2 kg/cm2 499 cm2 cm2MICHELIN 1300 kg 9,3 kg/cm2 kg/cm2 140 cm2 cm2

UnladenLaden

STANDARD 9,5R19,5 Tubeless XZY 134/131K 8 Bar 3050 kg 7,3 kg/cm2 kg/cm2 416 cm2 cm2MICHELIN 1300 kg 7,2 kg/cm2 kg/cm2 180 cm2 cm2

UnladenLaden

FRONT TYRES

REAR TYRES

CHARACTERISTICS

2 - 17

dB

105 dB

24 km/h24 km/h


7000 kg

600 mm

176 kg

0,38 m/s0,33 m/s0,37 m/s0,43 m/s

9700 kg16700 kg

3615 kg14145 kg6085 kg2555 kg

2400 daN8300 daN

daN

SPECIFICATIONS






- Load center






rated load



2 - 18


HYDRAULIC CIRCUIT







92,5 L/min230 Bar


10 µ100 µ

1,4 L150 Bar


STANDARD 18R19,5 XF Tubeless *PR 7 Bar 1850 kg 3,6 kg/cm2 1,69 kg/cm2 507 cm2 1094 cm2MICHELIN 7100 kg 4,7 kg/cm2 2,19 kg/cm2 1500 cm2 3236 cm2

UnladenLaden





OPTION 285/70 R19,5 XZY 140/137L 6,5 Bar 3050 kg 6,1 kg/cm2 kg/cm2 499 cm2 cm2MICHELIN 1300 kg 9,3 kg/cm2 kg/cm2 140 cm2 cm2

UnladenLaden

STANDARD 9,5R19,5 Tubeless XZY 134/131K 8 Bar 3050 kg 7,3 kg/cm2 kg/cm2 416 cm2 cm2MICHELIN 1300 kg 7,2 kg/cm2 kg/cm2 180 cm2 cm2

UnladenLaden

FRONT TYRES

REAR TYRES

CHARACTERISTICS

2 - 19

dB

105 dB

25,8 km/h25,8 km/h


7000 kg

600 mm

176 kg

0,40 m/s0,35 m/s0,37 m/s0,43 m/s

9700 kg16700 kg

3615 kg14145 kg6085 kg2555 kg

2400 daN8300 daN

daN

SPECIFICATIONS



- Travel speed of the lift truck(Except particular conditions)

. Forward

. Reverse



- Load center






rated load



2 - 20

HL : Lift height in mmZ : Forward tiltingY : Backward tiltingLL : Free-acting lift in mmH : Overall height with folded mast in mmH1 : Overall height with spreaded out mast in mmH2 : Carriage overshooting in mm

CHARACTERISTICS OF MASTS WITH ROLLERS

DOUBLE MAST WITH ALL-ROUND VISION

MAST HL Z Y LL H H1 H2

3m00 3050 15° 15° 0 2505 4050 45

3m30 3350 15° 15° 0 2655 4350 45

3m50 3550 15° 15° 0 2755 4550 45

3m70 3750 15° 15° 0 2855 4750 45

4m00 4050 15° 15° 0 3005 5050 45

4m50 4550 15° 15° 0 3250 5550 45

5m00 5050 15° 15° 0 3505 6050 45


TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


3m70 3750 15° 15° 1255 2255 4750 45

4m00 4050 15° 15° 1355 2355 5050 45

4m30 4350 15° 15° 1455 2455 5350 45

4m50 4550 15° 15° 1530 2530 5550 20

4m70 4750 15° 15° 1590 2590 5750 40

5m00 5050 10° 15° 1705 2705 6050 15

5m50 5550 10° 15° 1855 2855 6550 45

6m00 6050 10° 15° 2030 3030 7050 20

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


3m00 3050 15° 15° 1518 2530 4062 32

3m30 3350 15° 15° 1668 2680 4362 32

3m50 3550 15° 15° 1768 2780 4562 32

3m70 3750 15° 15° 1868 2880 4762 32

4m00 4050 15° 15° 2018 3030 5062 32

2 - 21




3m00 3060 15° 15° 0 2505 4050 45

3m30 3360 15° 15° 0 2655 4350 45

3m50 3560 15° 15° 0 2755 4550 45

3m70 3760 15° 15° 0 2855 4750 45

4m00 4060 15° 15° 0 3005 5050 45

4m50 4560 15° 15° 0 3250 5550 45

5m00 5060 15° 15° 0 3505 6050 45


TRIPLE MAST WITH TOTAL FREE-ACTING LIFT


3m70 3760 15° 15° 1265 2255 4750 45

4m00 4060 15° 15° 1365 2355 5050 45

4m30 4360 15° 15° 1465 2455 5350 45

4m50 4560 15° 15° 1540 2530 5550 20

4m70 4760 15° 15° 1600 2590 5750 40

5m00 5060 10° 15° 1715 2705 6050 15

5m50 5560 10° 15° 1865 2855 6550 45

6m00 6060 10° 15° 2040 3030 7050 20

DOUBLE MAST WITH TOTAL FREE-ACTING LIFT


3m00 3060 15° 15° 1528 2530 4062 32

3m30 3360 15° 15° 1678 2680 4362 32

3m50 3560 15° 15° 1778 2780 4562 32

3m70 3760 15° 15° 1878 2880 4762 32

4m00 4060 15° 15° 2028 3030 5062 32

2 - 22



3m60 3670 15° 15° 0 3205 5005 45

4m00 4070 15° 15° 0 3405 5405 45

4m50 4570 15° 15° 0 3655 5905 45



2 - 24

DIMENSIONS AND LOAD CHART

MC 40/50 POWERSHIFT Série 2

DD : mm

mm

kg

mm

1

2

1

2

CAPACITE NOMINALERATED CAPACITYNENNKAPAZIT TCAPACIDAD NOMINALCAPACIT¸ NOMINALE

CAPACITES EFFECTIVESACTUAL CAPACITIESEFFEKTIVE KAPAZIT TCAPACIDAD EFECTIVACAPACIT¸ EFFETTIVA


n°:

1 - Jusqu’ hauteur de lev eUp to height ofBis zur hubh heHasta altura de elevaci nSino ad altezza di sollevamento

2 - Pour hauteur maximale deFor maximum height ofF r maximale H hePara altura m xima dePer altezza massima di

MAT VERTICALVERTICAL MASTVERTIKALER MASTMASTIL VERTICALRAMPA VERTICALE

EQUIPEMENTATTACHMENTZUBEH REQUIPOATTREZZATURA

Q : kg

3700

4000

-

- - -4000 3710 2590

500 600 1200

- - -3600 3340 2330

TDLA40N 1670TDLA40N 2000

--

197211

SUIVANT NORME EN 1726-1

DD : mm

mm

kg

mm

1

2

1

2

CAPACITE NOMINALERATED CAPACITYNENNKAPAZIT TCAPACIDAD NOMINALCAPACIT¸ NOMINALE



n°:

1 - Jusqu’ hauteur de lev eUp to height ofBis zur hubh heHasta altura de elevaci nSino ad altezza di sollevamento

2 - Pour hauteur maximale deFor maximum height ofF r maximale H hePara altura m xima dePer altezza massima di


EQUIPEMENTATTACHMENTZUBEH REQUIPOATTREZZATURA

Q : kg

3700

5000

-

- - -5000 3800 3400

600 1000 1200

- - -4700 3600 3200

TDLA50N 1670TDLA50N 2000

--

239178


MC 40 POWERSHIFT Série 2 MC 50 POWERSHIFT Série 2

2 - 25


A 1200 mm

B 2063 mm

C 762 mm

D 3745 mm

E 4945 mm

F 1590 mm

F1 1640 mm

G 265 mm

G* 210 mm

G1 365 mm

G1* 345 mm

G2 290 mm

G2* 315 mm

G3 360 mm

H 2855 mm

H* 2455 mm

H1 4750 mm

H1* 5350 mm

I 920 mm

J 1380 mm

K 1670 mm

L 50 mm

N 1840 to 1900 mm

O 150 mm

P1 33,5 °

P2 44 °

P3 37 °

R 2970 mm

S 3255 mm

T 5560 mm

U 2420 mm

V 3395 mm

V1 200 mm

W 2040 mm

Y 15 °

Z 15 °


1200 mm

2063 mm

772 mm

3755 mm

4955 mm

1590 mm

1640 mm

265 mm

210 mm

365 mm

345 mm

290 mm

315 mm

360 mm

2855 mm

2455 mm

4750 mm

5350 mm

920 mm

1380 mm

1670 mm

60 mm

1840 to 1900 mm

150 mm

33,5 °

44 °

37 °

2970 mm

3255 mm

5570 mm

2420 mm

3395 mm

200 mm

2040 mm

15 °

15 °

H - H1 = Standard mast DUPLEX 3M70 with rollersH* - H1* = Option mast TRIPLEX 4M30 with rollersG - G1 - G2 - G3 = UnladenG* - G1* - G2* = Rated load

2 - 26


MC 60 POWERSHIFT Série 2 + Turbo

DD : mm

mm

kg

mm

1

2

1

2

CAPACITE NOMINALERATED CAPACITYNENNKAPAZITÄTCAPACIDAD NOMINALCAPACITÀ NOMINALE

CAPACITES EFFECTIVESACTUAL CAPACITIESEFFEKTIVE KAPAZITÄTCAPACIDAD EFECTIVACAPACITÀ EFFETTIVA


n°:

1 - 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


EQUIPEMENTATTACHMENTZUBEHÖREQUIPOATTREZZATURA

Q : kg

4000

6000

-

- - -6000 4680 4210

600 1000 1200

- - -5400 4210 3790

TDLA100N 2000TDLA100N 1750

--

203062


DD : mm

mm

kg

mm

1

2

1

2




n°:





Q : kg

3600

6000

-

- - -6000 4680 4210

600 1000 1200

- - -5400 4210 3790

TDLA100N 2000TDLA100N 1750

--

203061


DD : mm

mm

kg

mm

1

2

1

2




n°:





Q : kg

4500

6000

4000

6000 4680 42105500 4285 3860

600 1000 1200

5400 4210 37904950 3860 3470

TDLA100N 2000TDLA100N 1750

--

203063


2 - 27


A 1500 mm

B 2293 mm

C 803 mm

D 3960 mm

E 5460 mm

F 1700 mm

F1 1580 mm

G 320 mm

G* 285 mm

G1 390 mm

G1* 370 mm

G2 305 mm

G2* 330 mm

G3 390 mm

H 3405 mm

H* 3655 mm

H1 5405 mm

H1* 5905 mm

I 864 mm

J 1390 mm

K 1750 mm

L 70 mm

N 1860 to 1920 mm

O 150 mm

P1 38 °

P2 42,5 °

P3 45 °

R 3625 mm

S 3460 mm

T 6500 mm

U 2440 mm

V 3995 mm

V1 760 mm

W 2150 mm

Y 15 °

Z 15 °


1500 mm

2293 mm

803 mm

3960 mm

5460 mm

1700 mm

1580 mm

320 mm

285 mm

390 mm

370 mm

305 mm

330 mm

390 mm

3405 mm

3655 mm

5405 mm

5905 mm

864 mm

1390 mm

1750 mm

70 mm

1860 to 1920 mm

150 mm

38 °

42,5 °

45 °

3625 mm

3460 mm

6500 mm

2440 mm

3995 mm

760 mm

2150 mm

15 °

15 °

H - H1 = Standard mast DUPLEX 4M00 with rollersH* - H1* = Option mast DUPLEX 4M50 with rollersG - G1 - G2 - G3 = UnladenG* - G1* - G2* = Rated load

2 - 28


MC 70 POWERSHIFT Série 2 + Turbo

DD : mm

mm

kg

mm

1

2

1

2




n°:





Q : kg

4000

7000

-

- - -7000 5460 4920

600 1000 1200

- - -6300 4915 4430

TDLA100N 1750TDLA100N 2000

--

182581


DD : mm

mm

kg

mm

1

2

1

2




n°:





Q : kg

3600

7000

-

- - -7000 5460 4920

600 1000 1200

- - -6300 4915 4430

TDLA100N 1750TDLA100N 2000

--

230060


DD : mm

mm

kg

mm

1

2

1

2




n°:





Q : kg

4500

7000

4000

7000 5460 49206500 5070 4570

600 1000 1200

6300 4915 44305850 4565 4115

TDLA100N 1750TDLA100N 2000

--

220950


2 - 29


A 1500 mm

B 2493 mm

C 803 mm

D 4160 mm

E 5660 mm

F 1700 mm

F1 1580 mm

G 320 mm

G* 270 mm

G1 385 mm

G1* 375 mm

G2 305 mm

G2* 335 mm

G3 390 mm

H 3405 mm

H* 3655 mm

H1 5405 mm

H1* 5905 mm

I 864 mm

J 1390 mm

K 1750 mm

L 70 mm

N 1860 to 1920 mm

O 150 mm

P1 38 °

P2 38,5 °

P3 45 °

R 3840 mm

S 3510 mm

T 6715 mm

U 2440 mm

V 4210 mm

V1 995 mm

W 2150 mm

Y 15 °

Z 15 °


1500 mm

2493 mm

803 mm

4160 mm

5660 mm

1700 mm

1580 mm

320 mm

270 mm

385 mm

375 mm

305 mm

335 mm

390 mm

3405 mm

3655 mm

5405 mm

5905 mm

864 mm

1390 mm

1750 mm

70 mm

1860 to 1920 mm

150 mm

38 °

38,5 °

45 °

3840 mm

3510 mm

6715 mm

2440 mm

4210 mm

995 mm

2150 mm

15 °

15 °

H - H1 = Standard mast DUPLEX 4M00 with rollersH* - H1* = Option mast DUPLEX 4M50 with rollersG - G1 - G2 - G3 = UnladenG* - G1* - G2* = Rated load

2 - 30

INSTRUMENTS AND CONTROLS

2

8

10

17

18

1

22

23

24

21

9

19

12

13

14

20

16

6

27

9 5

7

4

3

1413

12

2020

20

15

11

2 - 31

DESCRIPTION

1 - DRIVER'S SEAT2 - SAFETY BELT3 - SIGNAL LAMP PANEL4 - FUEL LEVEL AND HOURMETER5 - SWITCH PANEL6 - LIGHT SWITCH, HORN AND INDICATOR SWITCH7 - IGNITION SWITCH8 - BRAKING OIL TANK9 - FUSES

10 - ROOF LIGHT11 - WINDSCREEN WASHER TANK12 - ACCELERATOR PEDAL13 - SERVICE BRAKE PEDAL14 - TRANSMISSION CUT-OFF PEDAL (INCHING)15 - FORWARD/REVERSE LEVER AND SPEED SELECTOR16 - PARKING BRAKE LEVER17 - HYDRAULIC CONTROLS18 - CAB HEATER CONTROL19 - HEATING VENTS20 - DOORS LOCKS21 - DOORS UNLOCKING BUTTONS22 - DOCUMENT HOLDER23 - DOCUMENT HOLDER NET24 - FRONT LIGHTS (NOT ILLUSTRATED)25 - REAR LIGHTS (NOT ILLUSTRATED)26 - ADJUSTMENT HANDLE OF THE STEERING WHEEL

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

1 - DRIVER'S SEAT

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

LONGITUDINAL ADJUSTMENT- Pull the locking lever 1 upwards.- Slide the seat to the required position.- Release the lever and ensure it returns to the lock position.

SEAT SUSPENSION ADJUSTMENT- Pull and lift up the locking lever 2 so as to place it into one of these five positions.

Position A : Light-weight driver (50 kg).Position B : Intermediate.Position C : Middle-weight driver.Position D : Intermediate.Position E : Heavy-weight driver (120 kg).

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

ANGLE ADJUSTMENT OF THE WHOLE SEAT- Lift up the locking lever 4.- Tilt the seat forwards or backwards.- Release the lever and ensure it returns to the lock position.

A B C D E

1

24

3

2 - 32

1 - PNEUMATIC DRIVER'S SEAT (OPTION)

DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED ASFOLLOWS.

WEIGHT AND SEAT HEIGHT ADJUSTMENT

WEIGHT ADJUSTMENT (FIG. A)It is advised that you adjust the seat according to your weight when sitting.- Switch on lift truck ignition.- Push or pull lever 1 until green appears in display 2 indicating correct adjustment

according to your weight.NOTE : To avoid any health problems, it is recommended that the weight should be

checked and adjusted before starting up the lift truck.

SEAT HEIGHT ADJUSTMENT (FIG. B)When weight adjustment has been carried out, you can then modify seat height.- Keep the ignition switched on.- Push or pull lever 1 until green appears and adjust the height of the seat while

checking that the green in display 2 remains visible.

To avoid causing any damage, do not activate the compressor for over 1 minute.

SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C)The back-rest angle of the seat may be adjusted to suit the individual.- Press the left-hand button while pushing on the seat or relaxing pressure on the seat to

find a comfortable position.

SEAT DEPTH ADJUSTMENT (FIG. D)The depth of the seat may be adjusted to suit the individual.- Press the right-hand button while raising or lowering the seat to find the desired

position.

EXTENDING THE HEAD-REST (FIG. E)- The height of the back-rest can be adjusted by pulling it upwards (The notches will

click) up to the stop.- The head-rest can be removed by applying sufficient pressure to pull it off the stop.

LUMBAR ADJUSTMENT (FIG. F)This increases the comfort of the seat and the driver’s freedom of movement.- Turn the handle either left or right to adjust the height or depth of the lumbar support.

A

B

C

D

E F

2 - 33

ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)- Support the back-rest, pull the lever and position the back-rest to find the desired

position.

If you do not support the back-rest when making adjustments, it swings completelyforwards.

HORIZONTAL SHOCK ABSORBER (FIG. H)In certain conditions (e.g. driving with a trailer) it is advised that a horizontal shockabsorber be used. The driver’s seat is thus better able to absorb jerks in the direction oftravel.

- Position 1 : Horizontal shock absorber fitted.- Position 2 : Horizontal shock absorber removed.

LONGITUDINAL ADJUSTMENT (FIG. I)- Adjust the locking lever until you reach the position required. This then locks and the

seat will not shift into another position.

MAINTENANCE (FIG. J)Dirt may adversely affect the correct functioning of the seat. For this reason, make sureyour seat is always clean.- To clean or change the cushions, simply remove them from the seat frame.

A rocking head-rest increases the risk of an accident !

Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on asmall hidden area before using any fabric or plastic cleaner.

2 - SAFETY BELT

- Sit correctly on the seat.- Check that seat belt is not twisted.- Place the seat belt at hip level and not across the stomach.- Attach the seat belt and check that it locks.- Adjust the seat belt to your body shape without squeezing your hip.

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.

G

H

I

J

2 - 34

3 - SIGNAL LAMP PANEL

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

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

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

C - NOT USED

D - RED AIR FILTER CLOGGED LAMPThe 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 - RED TRANSMISSION OIL TEMPERATURE LAMPThe lamp and the buzzer come on when the converter oil temperature is abnormally high. Stop the lift truck and look for thecause of this overheating.

F - RED ALTERNATOR CHARGE LAMPIf the lamps B - C - D - E - F - J and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately andcheck the electrical circuit as well as the alternator belt.

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

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

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

J - RED BRAKING OIL LEVEL LAMPIf the lamp and the buzzer come on, when the lift truck is running, stop the I.C. engine immediately and check the braking oillevel. In the event of an abnormal dropping of the level, consult your dealer.

4 - FUEL LEVEL AND HOURMETER

A - FUEL LEVEL

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

A B C D E

F G H I J

AB

2 - 35

5 - SWITCH PANEL

A - FRONT WINDSCREEN WIPER AND WINDSCREEN WASHERThis 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 seton the "up" position, the windscreen wiper to be operated.

B - HEATING FANThis two speed switch allows warm or cold air to pass through the heating vents.

C - OPTION

D - WARNING LIGHTSThis switch enables the L.H. and R.H. Indicators to be switched on simultaneously, with the ignition off. The signal lightindicates that the switch is being used.

E - REAR WINDSCREEN WIPER + ROOF WIPER OPTION

F - DIFFERENTIAL LOCK SIGNAL LIGHTThis orange signal light goes out when you push the differential lock button.

G - FLASHING LIGHT OPTION

H - WORKING HEAD LIGHT OPTION

I - WORKING TAIL LIGHT OPTION

J - OPTION

6 - 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.

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

A B C D

E F G H I J

F

D

G

C

B

E

A

2 - 36

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 - BRAKING OIL TANK

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

9 - FUSES

Remove the cover to have access to the fuses.1 - Light switch power supply, horn and indicators (15A).2 - Hazard warning lights power supply (10A).3 - Rear windscreen wiper (10A).

- OPTION Roof windscreen wiper (10A).4 - OPTION Working tail light (10A).5 - OPTION Front working head light (10A).6 - Heating (15A).7 - Panel of signal lights (5A).

- Fuel level (5A).- Hourmeter (5A).

8 - Front windscreen wiper and windscreen washer (10A).9 - 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).- Stop switch (10A).

12 - OPTION Flashing light (7,5A).13 - Right sidelight (5A).

- Sidelight indicator light (5A).- Fuel level lighting (5A).- Hourmeter lighting (5A).

14 - Left sidelights (5A).15 - Right indicators (7,5A).16 - Left indicators (7,5A).17 - Low beam (10A).

- Low beam indicator light (5A).18 - Main beam (10A).

- Main beam lamp (10A).19 - Roof light (3A).

- OPTION (+)permanent (3A).20 - OPTION Anti-theft device provision (10A).21 - Differential lock (10A).22 - OPTION Pneumatic seat (15A).

- OPTION Fuel reheating (15A).23 - OPTION Anti-theft device provision (10A).24 - OPTION.

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

7 8 9 10 11 12

1 2 3 4 5 6

13

22 2423

19 2120

14 15 16 17 18

2 - 37

10 - ROOF LIGHT

11 - WINDSCREEN WASHER TANK

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

12 - ACCELERATOR PEDAL

When idling, the transmission is automatically cut.- As soon as you accelerate, the transmission is switched on again.- When you release the accelerator pedal, the transmission remains on until the engine falls to idling speed.

13 - SERVICE BRAKE PEDAL

The pedal acts on the front wheels by means of a hydraulic brake system enabling the slowing down and stopping of the lifttruck.

14 - TRANSMISSION CUT-OFF PEDAL (INCHING)

This pedal is used to gradually cut transmission, making it easier to use a slow approach for careful handling jobs.- When you press the transmission cut-off pedal, you first gradually cut transmission and then use the service brake pedal to

stop the machine.

15 - DIFFERENTIAL LOCK PUSH BUTTON

The differential lock allows the main wheels to turn at the same speed whatever the ground condition. In order to engage it, fullypress the push button.

- Maintain this position during the time required for locking. To interrupt its use, simply remove the foot from the top of the pushbutton which returns to its initial position automatically.

When the differential lock is engaged, always drive in straight line and in first gear.

2 - 38

16 - FORWARD/REVERSE LEVER AND SPEED SELECTOR

DESCRIPTION

FORWARD/ REVERSE LEVER

When operating this control, the lift truck should be travelling at low speed and notaccelerating. During this operation, the selected speed remains the same, except for the4th gear in forward motion which becomes 3rd gear in reverse motion.

FORWARD : Push the lever forwards (Position A).REVERSE : Pull the lever backwards (Position B).NEUTRAL : To start the truck, the lever must be in neutral (Position C). On

starting up, 3rd gear is automatically selected.

SPEED SELECTORThe selected speed is indicated on dial 1 by a signal light.

SPEED IN FORWARD MOTION : The gear can be changed successively from the 1st to the 4th by turning the lever forwardsand retrograded from the 4th to the 1st by turning the lever backwards.

SPEED IN REVERSE MOTION : The gear can be changed successively from the 1st to the 3rd by turning the lever forwardsand retrograded from the 3rd to the 1st by turning the lever backwards.

USING THE GEARS ON THE GEARBOX- On these lift trucks with a torque converter, it is not necessary to automatically start up in 1st speed and progress up the

gears.

The choice of gear ratio should be made carefully according to the nature of the work being carried out. A poor choice mayresult in the extremely rapid elevation of the transmission oil temperature through excessive slipping of the converter, whichcould lead to serious damage to the transmission (it is essential to stop and change the working conditions if thetransmission oil temperature indicator light comes on). This poor choice may also result in a reduction in the lift truck'sperformance in forward speed. When the forward force increases, the forward speed in the r gear (for example 3rd gear) maybe lower than the forward speed that could be obtained with the r-1 gear (in 2nd instead of the 3rd).

In general, we would advise you to use the following gears according to the nature of the work being carried out.• On the road : Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it. In hilly areas, set off in 2nd

gear and go up to 3rd if the conditions and state of the road permit it.• With a trailer on the road : Set off in 2nd gear and go up to 3rd if the conditions and state of the road permit it.• Handling : 3rd gear.

2nd gear in restricted spaces.• Earth moving : 1st gear.• Loading (reclaiming with bucket, manure fork, etc.) : 2nd gear.

LED

1

N NF RT

2 3 4 5 6 7 8

Forward

Neutral

(Green) LED in forwardgear

(Green) LED lightswhen the machine isstationary

LED lights in "test"mode (see repairmanual)

"T" LED lights in "test"mode (yellow) (seerepair manual)

(Red) "N" neutral LED (lightswhen the reverse lever is inneutral)

Reverse

ColoursRED

GREENYELLOW

Reverse leverNEUTRAL

FORWARD GEARREVERSE GEAR

C

A

B

1

2 - 39

17 - PARKING BRAKE LEVER

To prevent accidental loosening or release, the lever is fitted with safety locking.

- To apply the parking brake, pull the lever backwards (Position A).- To loosen the parking brake, release and push the lever forwards (Position B).

18 - HYDRAULIC CONTROLS

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

LEVER A : Controls the load lifting.- The lever backwards for load lifting.- The lever forwards for load lowering.

LEVER B : Controls the mast tilting.- The lever backwards for backward mast tilting.- The lever forwards for forward mast tilting.

LEVER C : Controls the additional attachment.

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

19 - CAB HEATER CONTROL

Allows the temperature inside the cab to be adjusted.

A - With the valve closed, the fan delivers fresh air.B - With the valve opened completely, the fan delivers warm air.

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

20 - HEATING VENTS

21 - DOORS LOCKS

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

22 - DOORS UNLOCKING BUTTONS

23 - DOCUMENT HOLDER

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

24 - DOCUMENT HOLDER NET

A

B

A

BC

B

A

2 - 40

25 - 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.

26 - REAR LIGHTS

A - Left rear indicator.B - Left rear stoplight.C - Left tail light.D - Right tail light.E - Right rear stoplight.F - Right rear indicator.

27 - STEERING WHEEL REGULATING HANDLE

This handle enables the angle and height of the steering wheel to be adjusted.

- Turn handle 1 towards A to loosen and adjust steering wheel.- Turn handle 1 towards B to lock steering wheel in the position required.

AB CF D E

F

E

D

A

B

C


F

D

E

A

C

B


A

B

2 - 42

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 theAuthorised Gross Vehicle Weight (A.G.V.W), tractive effort and maximum vertical force on the coupling point. This informationis 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 lifttruck'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 untilthe lift truck has stopped, the handbrake is on and the engine is switched off before performing the operation.

A - TOWING PIN (STANDARD) (FIG. 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.

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.

TOWING PIN AND HOOK

1

A

2


1

A

2


2 - 44

1 - REVOLVING LIGHT

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

- Loosen nut 1 and remove the revolving light.- Protect mounting 2 with cap 3.

2 - REVERSE BUZZER ALARM

3 - BATTERY CUT-OFF

4 - DIGICODE ANTI-THEFT SYSTEM

5 - ADAPTATION 4TH DISTRIBUTOR ELEMENT

LEVER A : Intended for controlling a additional equipment.

DESCRIPTION AND USE OF ELECTRIC AND HYDRAULIC OPTIONS

1

2

3

A

3 - 3

FILTERS CARTRIDGES AND BELTS

21 5 6 7 8 943

1211

10

DESIGNATION PART NUMBER CLEAN CHANGE

1 - I.C. engine oil filter 133755 400 H

2 - Dry air filter cartridge 563416 50 H * 400 H *

3 - Safety dry air filter cartridge 563415 800 H *

4 - Transmission oil filter 550145 400 H

5 - Fuel filter cartridge 49660 400 H

6 - Hydraulic return oil filter cartridge 221174 400 H

7 - Suction strainer for hydraulic oil tank 77402 800 H

8 - Filter cap for hydraulic oil tank 62415 800 H

9 - Fan belt 474948

9 - Fan belt (Adaptation warm countries) 473557

10 - Cab ventilation filter 562185 400 H

11 - Cyclonic pre-filter (OPTION) 224713 10 H

12 - Automatic vacuum-cleaning pre-filter (OPTION) 226611

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

3 - 4

LUBRICANTS AND FUEL

ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBERI.C. ENGINE 7,75 Liters MANITOU Oil 20 L. 582 357

API CG4 55 L. 582 358209 L. 582 359

COOLING CIRCUIT 19 Liters Cooling liquid 2 L. 473 076(Protection - 30 °C) 5 L. 470 077

20 L. 470 078210 L. 470 079

Cooling liquid 2 L. 554 002(Protection - 25 °C) 5 L. 554 003

20 L. 554 004210 L. 554 005

FUEL TANK Diesel fuel (*)MC 40/50 POWERSHIFT Série 2 85 LitersMC 60/70 POWERSHIFT Série 2 + Turbo 115 Liters

I.C. ENGINE

ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBERTRANSMISSION 12,5 Liters MANITOU Oil 1 L. 62 148

Automatic transmission 25 L. 487 65555 L. 546 217209 L. 546 195

TRANSMISSION UNIVERSAL JOINT MANITOU Grease 1 Kg. 554 973Multipurpose HD NLGI 2 5 Kg. 554 974

TRANSMISSION

ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBERMAST LIFTING CHAINS Engine oilGREASING OF THE MAST MANITOU Grease 1 Kg. 161590

Multipurpose NLGI 2GREASING MAST GUIDE ROLLER MANITOU Grease 1 Kg. 161590MC 40/50 POWERSHIFT Série 2 Multipurpose NLGI 2GREASING MAST GUIDE ROLLER MANITOU Grease 1 Kg. 554 973MC 60/70 POWERSHIFT Série 2 + Turbo Multipurpose HD NLGI 2 5 Kg. 554 974

MAST

ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBERBRAKE CIRCUIT MANITOU Oil 1 L. 490 408

Mineral brake fluid

BRAKE

ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBERHYDRAULIC OIL TANK MANITOU Oil 25 L. 161 588MC 40/50 POWERSHIFT Série 2 80 Liters Hydraulic ISO 46 55 L. 546 108MC 60/70 POWERSHIFT Série 2 + Turbo 108 Liters 209 L. 546 109

HYDRAULICS

ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBERCAB DOOR MANITOU Grease 1 Kg. 554 973

Multipurpose HD NLGI 2 5 Kg. 554 974WINDSCREEN WASHER TANK Windscreen washer fluid 1 L. 490 402

5 L. 486 42430 L. 505 527

225 L. 490 432

CAB

ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBERFRONT AXLE DIFFERENTIAL 6,2 Liters MANITOU Oil 25 L. 545 608

Special immersed brakesFRONT WHEELS REDUCERS 0,75 Liter MANITOU Oil 2 L. 499 237

Mechanical transmission for 25 L. 161 585axles and boxes SAE 80W90 55 L. 546 221

209 L. 546 220

FRONT AXLE

3 - 5

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 OILIn the event of a maintenance or service contract with the dealer you may be requested to provide a sample of a selectedcomponent's oil, for diagnostic analysis.

(*) FUEL SPECIFICATIONCETANE RATING : 45 minimumVISCOSITY : 2 - 4,5 Centistokes at 40° CDENSITY : 0,820 - 0,860 kg/litreSULPHUR : 0,2 % mass maximumDISTILLATION : 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 problemswith 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 toreplace the greasing oil more frequently.

- Distillation : this indicates the mixture of different hydrocarbons in the fuel. A high ratio of light hydrocarbons can affect thecharacteristics 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 ofparaffin can prevent filtration of the fuel.

ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBERSWIVEL PINS MANITOU Grease 1 Kg. 554 973

Multipurpose HD NLGI 2 5 Kg. 554 974REAR AXLE OSCILLATION MANITOU Grease 1 Kg. 554 973

Multipurpose HD NLGI 2 5 Kg. 554 974

REAR AXLE

3 - 6

SERVICING SCHEDULE

I.C. ENGINEI.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 feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Safety dry air filter cartridge . . . . . . . . . . . . . . . . . . . . . .I.C. engine silent blocks . . . . . . . . . . . . . . . . . . . . . . . . .I.C. engine rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Valves clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water pump and the thermostat . . . . . . . . . . . . . . . . . .Alternator and the starter motor . . . . . . . . . . . . . . . . . . .Turbocompressor (Only for the "Turbo") . . . . . . . . . . . . . . .Bleed the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSIONTransmission oil level . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission controls . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission pressures . . . . . . . . . . . . . . . . . . . . . . . . .Converter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TYRESTyres pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel nuts torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Condition of wheels and tyres . . . . . . . . . . . . . . . . . . . .Change a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MASTTension and alignment of the mast lifting chains . . . . . .Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mast guide rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mast uprights (MC 40/50 POWERSHIFT Série 2) . . . . . . . . .Mast lifting chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Condition of mast unit . . . . . . . . . . . . . . . . . . . . . . . . . .Chain rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mast guide rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Mast bearing rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULICSHydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic return oil filter cartridge . . . . . . . . . . . . . . . . .Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Suction strainer for hydraulic oil tank . . . . . . . . . . . . . . .Filter cap 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CCCN

N RNC

A AV VR RR R

NNR

C**C**

C** C**V

N/D**C**C**C**

CR RV V

C**C**C**

CC

C**

C/AGG

G*G G/C**

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

CR R

VNR

C**N**C**C**

C**C**N**

PAGE3-83-83-83-9

3-10/3-193-103-103-163-183-183-193-203-243-24

3-28

3-30

3-93-203-25

3-93-9

3-31

3-113-113-123-163-21

3-133-213-263-263-26

Afterthe

first 50hours

Dayor10

hours

50hours

200hours

1 yearor

400hours

1 yearor

800hours

1600hours

3200hours

A = AJUSTC = CHECKD = DESCALEG = GREASE

N = CLEANP = BLEEDR = CHANGEV = DRAIN

3 - 7

BRAKEBrake oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parking brake mechanism . . . . . . . . . . . . . . . . . . . . . . .Brake oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . .Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABWindscreen washer liquid level . . . . . . . . . . . . . . . . . . .Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cab ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Condition of the rear view mirrors . . . . . . . . . . . . . . . . .Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lift the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICITYBattery electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . .Battery electrolyte density . . . . . . . . . . . . . . . . . . . . . . .Condition of wiring harness and cables . . . . . . . . . . . . .Lights and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjust the front headlamps . . . . . . . . . . . . . . . . . . . . . .

FRONT AXLETransmission universal joint . . . . . . . . . . . . . . . . . . . . . .Front axle differential oil level . . . . . . . . . . . . . . . . . . . .Front wheels reducers oil level . . . . . . . . . . . . . . . . . . .Front axle differential oil . . . . . . . . . . . . . . . . . . . . . . . . .Front wheels reducers oil . . . . . . . . . . . . . . . . . . . . . . . .Wearing of front axle brake discs . . . . . . . . . . . . . . . . . .Front wheels reducers clearance . . . . . . . . . . . . . . . . . .

REAR AXLESwivel pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

ATTACHMENTSForks wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Attachment carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . .Condition of attachments . . . . . . . . . . . . . . . . . . . . . . . .

LIFT TRUCKTow the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sling the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transport the lift truck on a platform . . . . . . . . . . . . . . .

CA

GV**P**C**A**

CG

NC

C**C**

CC

C*C*C*

G G/C**CC

V VV V

C**C**

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

C**C**

C**C**

C**C**C**

3-133-163-21

3-143-143-223-27

3-34

3-143-22

3-35

3-153-173-173-233-27

3-153-15

3-323-323-33

(*) : To be done before starting up the new lift truck and a last time after 200 hours service.(**) : Consult your dealer.

Afterthe

first 50hours

Dayor10

hours

50hours

200hours

1 yearor

400hours

1 yearor

800hours

1600hours

3200hours

A = AJUSTC = CHECKD = DESCALEG = GREASE

N = CLEANP = BLEEDR = CHANGEV = DRAIN

3 - 8

A1 - I.C. ENGINE OIL LEVEL

CHECK

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

- Open the I.C. engine bonnet.- 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

CHECK

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

- Open the I.C. engine bonnet.- Slowly turn the cap of the radiator 1 (Fig. A2) anticlockwise up to the safety stop.- Allow the pressure and vapour to escape.- Press down and turn the cap so as to release the cap.- If necessary, add cooling liquid (See chapter : LUBRICANTS AND FUEL in paragraph :

3 - MAINTENANCE) in order to top up the level to 12 mm below the filler port 2 (Fig. A2).- Lubricate slightly the filler neck in order to facilitate the setting and the removal of the

radiator cap.

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 soonas possible (See chapter : F1 - COOLING LIQUID in paragraph : 3 - MAINTENANCE).

A3 - FUEL LEVEL

CHECK

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

- 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 fillerport 2 (Fig. A3).

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

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

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

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

A - DAILY OR EVERY 10 HOURS SERVICE

A1/1

A1/2

A2

A3

1

2

1

2

1

2

3 - 9

A5/2

A5/1

A4 - CYCLONIC PREFILTER (OPTION)CLEAN

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

- Loosen nut 1 (Fig. A4), remove cover 2 (Fig. A4) and empty the tank.- Clean the prefilter unit with a clean dry cloth and reassemble the unit.

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

A5 - TRANSMISSION OIL LEVEL

CHECK

Place the lift truck on level ground with the I.C. engine cold and at idle.

- Disassemble the access panel 1 (Fig. A5/1).- Remove the dipstick 2 (Fig. A5/2).- Check the level of the lower notch.- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by the filler port 3 (Fig. A5/2).

NOTE : OIL LEVEL WHEN COLD (Between 15 °C and 20 °C).Oil level must be at lower notch.OIL LEVEL WHEN WARM (Between 82 °C and 93 °C).Oil level must be at upper notch.

Too much oil in the transmission may have a detrimental effect on the functioning ofthe lift truck.

A6 - TYRES PRESSURE AND WHEEL NUTS TORQUE

CHECK

- Check the condition of the tyres, to detect cuts, protuberances, wear, etc.- Check the torque load of the wheel nuts (Fig. A6). 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 andkeep all persons at a distance during inflation. Respect the recommended tyrepressures given.

A4

340 ± 15 %N. m

630 ± 15 %N. m

A6

WHEEL NUTSTIGHTENING TORQUE

FRONT TYRES

REAR TYRES

1

2

3

1

2

3 - 10

B - EVERY 50 HOURS SERVICECarry 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 CARTRIDGESAND 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). Thecartridge 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 theinside 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 hardsurface. 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 insidethe filter cartridge, change it for a new one if it is dirty or damaged.

B2 - RADIATOR CORE

CLEAN

- Open the I.C. engine bonnet.- Remove the inspection panel 1 (Fig. B2).

In order to prevent the radiator becoming clogged, clean the radiator with a compressedair jet directed from outside to inside. 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 waterjet or high pressure steam as this could damage the radiator fins.

B3 - FUEL FILTER

CHECK

- Open the I.C. engine bonnet.- 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.

B3

B2

1

2

1

3 - 11

B4 - TENSION AND ALIGNMENT OF THE MAST LIFTING CHAINS

CHECK - ADJUST

Place the lift truck on level ground with the mast in a vertical position and the forks liftedat 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 lock nut 1 (Fig. B4) of the chain tension adjuster.- Adjust the tension by tightening or untightening the nut 2 (Fig. B4) while checking the

alignment of the lifting chains.- Then block the lock nut 1 (Fig. B4) and the nut 2 (Fig. B4).

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

B5 - MAST

GREASE

Clean and lubricate the following points with grease (See chapter : LUBRICANTS ANDFUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

1 - Lubricators of the articulation axles at the foot of the mast (2 lubricators) (Fig.B5/1).

2 - Lubricators of the tilt cylinders foot axles (2 lubricators) (Fig. B5/2).3 - Lubricators of the tilt cylinders head axles (2 lubricators) (Fig. B5/3).

B5/1

1

B4MC 40/50 POWERSHIFT Série 2

B4MC 60/70 POWERSHIFT Série 2 + Turbo

1

2

1

2

B5/2

2

B5/3

3

B5/3MC 40/50 POWERSHIFT Série 2 MC 60/70 POWERSHIFT Série 2 + Turbo

3

B6 - MAST GUIDE ROLLERS

GREASEMC 40/50 POWERSHIFT Série 2

Place the lift truck on level ground with the mast in vertical position and the forksunused.Clean and lubricate the following points with grease (See chapter : LUBRICANTS ANDFUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

1 - Lubricators of upper guide rollers on mast (2 lubricators) (Fig. B6/1).2 - Lubricators of lower guide rollers on mast (2 lubricators) (Fig. B6/2).

NOTE : With wide tyres OPTION, lift the forks by approximately 2 m so as to grease thelower guide rollers of the mast through the port 3 (Fig. B6/3).

In case of technical faults, consultyour dealer.

B7 - MAST GUIDE ROLLERS

GREASE MC 60/70 POWERSHIFT Série 2 + Turbo

Place the lift truck on level ground with the mast in a vertical position and the forks liftedat approximately 200 mm.Clean and lubricate the following points with grease (See chapter : LUBRICANTS ANDFUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

1 - Lubricators of guide rollers on carriage (4 lubricators) (Fig. B7/1).2 - Lubricators of upper guide rollers on mast (2 lubricators) (Fig. B7/2).3 - Lubricators of lower guide rollers on mast (2 lubricators) (Fig. B7/3).

In case of technical faults, consult your dealer.

3 - 12

B7/1

B7/3

B6/1

B6/3

1

23

B6/2

B7/2

1

1

23

3 - 13

B9/1

B9/2

B8 - HYDRAULIC OIL LEVEL

CHECK

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

- Refer to gauge 1 (Fig. B8/1).- 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).- Remove cap 2 (Fig. B8/2).- Add oil by filler port 3 (Fig. B8/2).

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

- Put the cap back.

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

B9 - BRAKE OIL LEVEL

CHECK

Place the lift truck on level ground.

- Remove the front sheet metal plate 1 (Fig. B9/1).- The level is correct when it is at the MAXI level on the tank.- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by the filler port 2 (Fig. B9/2).- Reassemble the front sheet metal plate 1 (Fig. B9/1).

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

B8/1

B8/2

1

2

3

1

2

3 - 14

B10

B12

B10 - WINDSCREEN WASHER LIQUID LEVEL

CHECK

- Open the I.C. engine bonnet.- 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 DOOR

GREASE

Clean and lubricate the points 1 (4 lubricators) (Fig. B11) with grease (See chapter :LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove the surplusof grease.

B12 - BATTERY ELECTROLYTE LEVEL

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 morefrequently than every 50 hours service.

- Open the I.C. engine bonnet.- 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.

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.

B11

1

1

1

3 - 15

B13 - FRONT AXLE TRANSMISSION UNIVERSAL JOINT

GREASE

Clean and lubricate the points 1 (3 lubricators) (Fig. B13/1 and B13/2) with grease (Seechapter : LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE) and remove thesurplus of grease.

B14 - REAR AXLE

GREASE

Clean and lubricate the following points with grease (See chapter : LUBRICANTS ANDFUEL in paragraph : 3 - MAINTENANCE) and remove the surplus of grease.

1 - Lubricators of the swivel pins (6 lubricators) (Fig. B14/1).2 - Lubricators of the rear axle oscillation pin (2 lubricators) (Fig. B14/2).

B14/1

B14/2

B13/1

B13/2

1

1 1

1

1

2

3 - 16

C - EVERY 200 HOURS SERVICECarry out the operations described previously as well as the following operations.

C1 - ALTERNATOR / FAN / CRANKSHAFT BELT TENSION

CHECK - ADJUST

- Open the I.C. engine bonnet.- 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 20hours of operation.

C2 - MAST UPRIGHTS

CLEAN / GREASEMC 40/50 POWERSHIFT Série 2

OPERATION TO BE DONE BEFORE OPERATING A NEW LIFT TRUCK AND ONCEAT 250 HOURS SERVICE.

- Clean and remove the grease on all the lenght of the mast uprights (Fig. C2) Be verycareful when the lift truck is used in very dusty atmosphere.

- Check carefully the differents rollers to discover any traces of wear and change it ifnecessary.

- Lubricate very slightly with grease (See chapter : LUBRICANTS AND FUEL inparagraph : 3 - MAINTENANCE) all the lenght of mast uprights.


C3 - PARKING BRAKE

CHECK - ADJUST

Place the lift truck on a slope less than 15 % with the rated load in the transport position.- Check the tightening adjustment by locking the parking brake in position A (Fig. C3/1).- The adjustment is correct when the lift truck is held stationary on a slope.- Carry out adjustments if necessary.

ADJUSTMENT OF THE PARKING BRAKE CABLE ON THE FRONT AXLE- Press and release the brake pedal, then release the parking brake, putting it in position

B (Fig. C3/1).- Unscrew nuts 1 (Fig. C3/2).- Adjust the cable by untightening nuts 1 (Fig. C3/2), until a clearance of 1.5 mm

between cams 2 (Fig. C3/3) and stops 3 (Fig. C3/3) is obtained.

C1

C2

C3/1

11

A

B

4

3 - 17

The adjustment of the stops performed by the manufacturer must notbe modified under any circumstances.

ADJUSTMENT OF THE PARKING BRAKE- Leave the parking brake in position B (Fig. C3/1).- Progressively tighten the end piece of the lever 4 (Fig. C3/1) and

recheck braking.- Repeat the operation until the correct braking adjustment is obtained.

C4 - FRONT AXLE DIFFERENTIAL OIL LEVEL

CHECK

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

- Remove level plug 1 (Fig. C4). The oil should be flush with the edge of the hole.- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by the filler port 2 (Fig. C4).- Replace and tighten the level plug 1 (Fig. C4) (Tightening torque 34 to 49 N.m).

C5 - FRONT WHEELS REDUCERS OIL LEVEL

CHECK


- Check the level on each front wheel reducer.- Place level plug 1 (Fig. C5) in the horizontal position.- Remove the level plug ; the oil should be flush with the edge of the hole.- If necessary, add oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by the same hole.- Replace and tighten the level plug 1 (Fig. C5) (Tightening torque 34 to 49 N.m).

C3/3

22

C3/2

C5

C4

1

1

2

11

3 3

3 - 18

D - EVERY 400 HOURS SERVICECarry out the operations described previously as well as the following operations.

D1 - I.C. ENGINE OIL

DRAIN

D2 - I.C. ENGINE OIL FILTER

CHANGE

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

DRAINING THE OIL- Open the I.C. engine bonnet.- Remove the two inspection panels 1 (Fig. D1/1).- Place a container under drain plug 2 (Fig. D1/2) and unscrew the plug.- Remove filler cap 3 (Fig. D1/3) in order to ensure that the oil is drained properly.

Dispose of the drain oil in an ecological manner.

REPLACEMENT OF THE FILTER- Remove I.C. engine oil filter 4 (Fig. D1/2) ; discard the filter and the filter seal.- Clean the filter bracket with a clean, lint-free cloth.- Fill the new oil filter (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph

: 3 - MAINTENANCE) with I.C. engine oil and lightly grease the seal.- Refit the oil filter on the filter bracket.

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

FILLING UP THE OIL- Refit and tighten drain plug 2 (Fig. D1/2) (Tightening torque 29 to 39 N.m).- Fil l up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by filler port 5 (Fig. D1/3).NOTE : For this operation we recommend to use a funnel with a hose.- 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 6 (Fig. D1/4).- Top up the level if necessary.- Refit the two inspection panels 1 (Fig. D1/1).

D1/2

D1/4

D1/1

1

1

2

4

6

3

5

D1/3

3 - 19

D3 - DRY AIR FILTER CARTRIDGE

CHANGE

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

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

- Open the I.C. engine bonnet.- Loosen the bolts and remove cover 1 (Fig. D3).- Gently remove the cartridge 2 (Fig. D3), taking care to avoid spilling the dust.- Leave the safety cartridge in place.- The following parts must be cleaned with a damp, clean lint-free cloth.

• The inside of the filter and cover.• The inside of the filter inlet hose.• The gasket surfaces in the filter and in the cover.

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

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

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

- Reassemble the cover, guiding the valve downwards.

D4 - FUEL FILTER CARTRIDGE

CHANGE

- Open the I.C. engine bonnet.- 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).- Unscrew locking screw 2 (Fig. D4).- Remove housing 3 (Fig. D4) and discard cartridge 4 (Fig. D4) 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).

D4

D3

21

2

1

4

3

3 - 20

D5 - FUEL FEED PUMP

CLEAN

- Open the I.C. engine bonnet.- Disassemble the left side panel 1 (Fig. D5/1) (3 fastening screws).- Loosen connection 2 (Fig. D5/2), lift hose 3 (Fig. D5/2) and protect the aperture.- Remove connection 4 (Fig. D5/3) and lift strainer 5 (Fig. D5/3).- Carefully clean the strainer and connection using a brush soaked in clean diesel fuel

and dry them with a low pressure jet of compressed air.- Reassemble connection 4 (Fig. D5/3) ensuring that the watertight seal is in the correct

position (Tightening torque 20 N.m).- Reconnect hose 3 (Fig. D5/2) and check that the feed pump is watertight.- Reprime the circuit by activating the feed pump.- If necessary, bleed the fuel circuit (See chapter : G1 - FUEL SYSTEM in paragraph : 3

- MAINTENANCE).- Reassemble the left side panel 1 (Fig. D5/1).

D6 - TRANSMISSION OIL FILTER

CHANGE

- Disassemble the access panel 1 (Fig. D6/1).- Unscrew and discard the transmission oil filter 2 (Fig. D6/2).- Carefully clean the filter head with a clean, lint-free cloth.- Slightly lubricate the new seal and fit the seal on the filter (See chapter : FILTERS

CARTRIDGES AND BELTS in paragraph : 3 - MAINTENANCE).- Refit the filter, making sure that the seal is correctly positioned and tightened.

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

- Reassemble the access panel 1 (Fig. D6/1).

D5/2 D5/3

54

23

D5/1

D6/1

D6/2

1

2

1

3 - 21

D7 - MAST LIFTING CHAINS

CLEAN - CHECK - GREASE

- Wipe the mast lifting chains 1 (Fig. D7) with a clean, lint-free cloth, then examine themclosely so as to detect any signs of wear.

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

- Rinse the chains by means of a paint brush impregnated with clean diesel fuel and drythem 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.


D8 - HYDRAULIC RETURN OIL FILTER CARTRIDGE

CHANGE

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

- Open the I. C. engine bonnet.- Unscrew the locking screws of the cover 1 (Fig. D8).- Remove the hydraulic return oil filter cartridge 2 (Fig. D8), and fit new replacement

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

- Make sure that the cartridge is correctly positioned and refit cover 1 (Fig. D8).

D9 - PARKING BRAKE MECHANISM

GREASE

- Release the protective boot 1 (Fig. D9).- Clean and grease articulation axles 2 (Fig. D9) with grease (See chapter :

LUBRICANTS AND FUEL in paragraph : 3 - MAINTENANCE).- Refit the protective boot 1 (Fig. D9).

D8

D9

D7

1

1

2

1

2

2

2

3 - 22

D10/1

D10/2

2

1

D10 - CAB VENTILATION FILTER

CLEAN

- Remove the cover plate 1 (Fig. D10/1).- Lift out cabin ventilation filter 2 (Fig. D10/2).- Clean the filter with a compressed air jet.- Check its condition and change if necessary (See chapter : FILTERS CARTRIDGES

AND BELTS in paragraph : 3 - MAINTENANCE).- Put back the cover plate 1(Fig. D10/1).

NOTE : For air conditioned cabs, refer to the air conditioner operator's manual.

D11 - BATTERY ELECTROLYTE DENSITY

CHECK

The electrolyte density varies depending on the temperature concerned, but a minimumof 1260 at 16°C must be maintained. In the shaded area (Fig. D11), the battery is in anormal charge condition. Readings above this zone indicate that the battery needs to berecharged.The density should not vary more than 0.025 units between cells.

- 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.

D12 - FRONT AXLE DIFFERENTIAL OIL

DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the differential oilstill warm.

Dispose the drain oil in an ecological manner.

- Place a container under drain plugs 1 (Fig. D12) and unscrew the plugs.- Remove level plug 2 (Fig. D12) and filler plug 3 (Fig. D12) in order to ensure that the

oil is drained properly.- Refit and tighten drain plugs 1 (Fig. D12) (Tightening torque 34 to 49 N.m).- Fil l up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by filler port 3 (Fig. D12).- The level is correct when the oil level is flush with the edge of port 2 (Fig. D12).- Check for any possible leaks at the drain plugs.- Refit and tighten level plug 2 (Fig. D12) (Tightening torque 34 to 49 N.m) and filler plug

3 (Fig. D12) (Tightening torque 34 to 49 N.m).

D11

1.240

1.250

1.260

1.270

1.280

1.290

1.300

-1014

-180

°C°F

032

1050

2068

3086

40104

D12

1

1

1

32

3 - 24

E - EVERY 800 HOURS SERVICECarry out the operations described previously as well as the following operations.

E1 - FUEL TANK

CLEAN

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


- Inspect the parts susceptible to leaks in the fuel circuit and in the tank.- In the event of a leak, contact your dealer.

Never try to carry out a weld or any other operation by yourself, this could provokean 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 thefiller plug 2 (Fig. E1/2).

- Open the I.C. engine bonnet.- Disassemble the left side panel 4 (Fig. E1/3) (3 fastening screws).- Re-prime the system by activating fuel feed pump 5 (Fig. E1/4).- If necessary, bleed the system (See chapter : G1 - FUEL SYSTEM in paragraph : 3 -

MAINTENANCE).- Reassemble the left side panel 4 (Fig. E1/3).

E2 - SAFETY DRY AIR FILTER CARTRIDGE

CHANGE

- For the disassembly and reassembly of the cartridge, see chapter : D3 - DRY AIRFILTER CARTRIDGE in paragraph : 3 - MAINTENANCE.

- Gently remove the dry air filter safety cartridge 1 (Fig. E2), taking care to avoid spillingthe 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 filtercartridge.

E1/1

E1/2

E1/4

E2

1

3

2

1

5

E1/3

4

3 - 25

E3 - TRANSMISSION OIL

DRAIN

Place the lift truck on level ground with the I.C. engine stopped, the transmission oil stillwarm.

DRAINING THE OIL- Place a container under drain plug 1 (Fig. E3/1) and unscrew the plug.- Disassemble the access panel 2 (Fig. E3/2).- Remove dipstick 3 (Fig. E3/3) in order to ensure that the oil is drained properly.


FILLING UP THE OIL- Refit and tighten drain plug 1 (Fig. E3/1) (Tightening torque 54 à 61 N. m).- Fil l up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by filler port 4 (Fig. E3/3) and refit the plug.- Run the engine at idle speed, check the oil level (See chapter : A5 - Check the

transmission oil level in paragraph : 3 - MAINTENANCE) and any possible leaks.- Reassemble the access panel 2 (Fig. E3/2).

E3/1

E3/2

E3/3

1

2

3

4

3 - 26

E4 - HYDRAULIC OIL

DRAIN

E5 - SUCTION STRAINER FOR HYDRAULIC OIL TANK

CLEAN

E6 - FILTER CAP FOR HYDRAULIC OIL TANK

CHANGE

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

Before any intervention, thoroughly clean the area surrounding the drain plug andthe suction cover on the hydraulic tank.

DRAINING THE OIL- Place a container under drain plug 1 (Fig. E4/1) and unscrew the plug.- Open the I.C. engine bonnet.- Remove filler cap 2 (Fig. E4/2) in order to ensure that the oil is drained properly and

get rid of it.


CLEANING THE STRAINER- Disassemble the side panel 3 (Fig. E4/3) (3 fastening screws).- Disconnect the hose 4 (Fig. E4/4).- Remove the hydraulic return oil filter 5 (Fig. E4/4).- Unscrew and clean the strainer using a compressed air jet, check its condition and

replace if necessary (See chapter : FILTERS CARTRIDGES AND BELTS in paragraph: 3 - MAINTENANCE).

- Refit the strainer and tighten the hydraulic return oil filter 5 (Fig. E4/4) (Tighteningtorque 81 N.m).

- Connect the hose 4 (Fig. E4/4).- Reassemble the side panel 3 (Fig. E4/3).

FILLING UP THE OIL- Clean and refit drain plug 1 (Fig. E4/1) (Tightening torque 29 to 39 N.m).- Fil l up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by filler port 6 (Fig. E4/2).

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

- Observe the oil level on dipstick 7 (Fig. E4/5), the oil should be equidistant between thelower and the upper marks.

- Check for any possible leaks at the drain plug.- Replace a new filler plug 2 (Fig. E4/2) (See chapter : FILTERS CARTRIDGES AND

BELTS in paragraph : 3 - MAINTENANCE).

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 hydraulicmovements (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.

E4/2

E4/1

E4/3

E4/4

1

2

6

3

4

5

3 - 27

E7 - 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.

E8 - FRONT WHEELS REDUCERS OIL

DRAIN

Place the lift truck on level ground with the I.C. engine stopped and the reducers oil stillwarm.


- Drain and change each front wheel reducer.- Place drain plug 1 (Fig. E8) in position A.- Place a container under the drain plug and unscrew the plug.- Let the oil drain fully.- Place the drain port in position B, i.e. in a level port.- Fil l up with oil (See chapter : LUBRICANTS AND FUEL in paragraph : 3 -

MAINTENANCE) by level port 1 (Fig. E8).- The level is correct when the oil level is flush with the edge of the hole.- Refit and tighten the drain plug 1 (Fig. E8) (Tightening torque 34 to 49 N.m).

E4/5

7

E8

A

B

1

3 - 28

F1 - COOLING LIQUID

DRAINMC 40/50 POWERSHIFT Série 2

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

DRAINING THE LIQUID- Open the I.C. engine bonnet.- Remove the casing 1 (Fig. F1/1) on the right hand side of the truck.- Place a tray under the radiator and under drain plug 2 (Fig. F1/2) in the engine unit.- Disconnect water hose 3 (Fig. F1/3) on the radiator side and remove drain plug 2 (Fig. F1/2).- Remove filler cap 4 (Fig. F1/4) of the radiator.- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.- Check the condition of the hoses as well as the fastening devices and change the

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

FILLING THE LIQUID- Tighten drain plug 2 (Fig. F1/2) (Tightening torque 7.4 to 12.2 Nm).- Reconnect water hose 3 (Fig. F1/3).- Refit casing 1 (Fig. F1/1).- Slowly fill up the cooling circuit (See chapter : LUBRICANTS AND FUEL in paragraph :

3 - MAINTENANCE) to 12 mm under filler port 5 (Fig. F1/4).- Put back filler cap 4 (Fig. F1/4).- Run the I.C. engine at idle for a few minutes.- Check for any possible leaks.- Check the level and refill if necessary.

The I.C. engine does not contain any corrosion resistor and must be filled during thewhole year with a mixture containing 25 % of ethylene glycol-based antifreeze.

F1/2

F1/1

F1/3

F1/4

F - EVERY 1600 HOURS SERVICECarry out the operations described previously as well as the following operations.

2

3

4

5

1

3 - 29


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

DRAINING THE LIQUID- Open the I.C. engine bonnet.- Disassemble the protective guard 1 (Fig. F1/1) on the right side (Only for MC 60

POWERSHIFT + Turbo).- Place a container under drain plug 2 (Fig. F1/2) of the radiator and under drain plug 3

(Fig. F1/3) of the I.C. engine block.- Unscrew the plugs.- Remove filler cap 4 (Fig. F1/4) of the radiator.- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.- Check the condition of the hoses as well as the fastening devices and change the

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

FILLING THE LIQUID- Retighten drain plug 2 (Fig. F1/2) (Tightening torque 20 N.m) and 3 (Fig. F1/3)

(Tightening torque 7 to 12 N.m).- Reassemble the protective guard 1 (Fig. F1/1) (Only for MC 60 POWERSHIFT + Turbo).- Slowly fill up the cooling circuit (See chapter : LUBRICANTS AND FUEL in paragraph :

3 - MAINTENANCE) to 12 mm under filler port 5 (Fig. F1/4).- Put back filler cap 4 (Fig. F1/4).- Run the I.C. engine at idle for a few minutes.- Check for any possible leaks.- Check the level and refill if necessary.

The I.C. engine does not contain any corrosion resistor and must be filled during thewhole year with a mixture containing 25 % of ethylene glycol-based antifreeze.

F1/2

F1/1

F1/4

F1/3

3

4

5

1

2

3 - 30

G - OCCASIONAL MAINTENANCE

G1 - FUEL SYSTEM

BLEED

These operations are to be carried out only in the following cases :- A component of the fuel system replaced 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 1 toestablish electrical contact and bleed in the following order :

- Open the I.C. engine bonnet.- Disassemble the left side panel 1 (Fig. G1/1) (3 fastening screws).

BLEEDING THE FUEL FILTER- Loosen bleed screw 2 (Fig. G1/2).- Activate feed pump 3 (Fig. G1/3) 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.

BLEEDING THE HEATER PLUG- Loosen connection 4 (Fig. G1/4) on the heater plug.- Activate feed pump 3 (Fig. G1/3) until the diesel fuel is flowing out free from air at the

connection.- Tighten the connection while the diesel fuel is flowing out.

Immobilise the heater plug with a spanner before loosening connection 4 (Fig. G1/4).

BLEEDING THE INJECTION PUMP- Loosen connection 5 (Fig. G1/5) of the low pressure fuel return circuit on the regulator

housing.- Activate feed pump 3 (Fig. G1/3) until the diesel fuel is flowing out free from air at the

connection.- Tighten the connection while the diesel fuel is flowing out.

G1/2

G1/3

G1/4 G1/5

4

3

2

5

G1/1

1

3 - 31

BLEEDING THE INJECTORS- Loosen high pressure connectors 6 (Fig. G1/6) of two of the injectors.- Activate the starter until the diesel fuel flows out free of air at connections 6 (Fig. G1/6).- Tighten the connection while the diesel fuel is flowing out (Tightening torque 22 N.m).- Reassemble the left side panel 1 (Fig. G1/1).The I.C. engine is then ready to be started up.

Turn the I.C. engine over slowly for 5 minutes immediately after bleeding the fuel feedcircuit, 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 functionsirregularly, check for possible leaks in the low pressure circuit. If in doubt,contact your dealer.

G2 - WHEEL

CHANGE

In the event of a wheel being changed on the public highway, make sure of thefollowing 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 MANITOUReference 505 507.

- Fit the jack under the rear axle, as near as possible to the wheel to be changed andadjust the jack (Fig. G2/1).

- Lift the wheel until it lifts off the ground and fit security wedges under the rear axle (Fig.G2/2).

- Completely unscrew the wheel nuts and remove them.- Free the wheel by reciprocating movements and roll it to the side.- Slip the new wheel on the wheel hub.- Refit the nuts by hand, if necessary grease them.- Remove the security wedges and lower the lift truck with the jack.- Tighten the wheel nuts with a torque wrench (See chapter : A - DAILY OR EVERY 10

HOURS SERVICE in paragraph : 3 - MAINTENANCE for tightening torque).

G1/6

6 6 6 6

G2/1

G2/2

FRONT WHEEL

NOTE : For this operation, we advise you to use the hydraulic jack MANITOUReference 505 507 and the safety support MANITOU Reference 554 772.

- Place the jack under the flared axle tube, as near as possible to the wheel and adjustthe jack (Fig. G2/3).

- Lift the wheel until it comes off the ground and put in place the safety support under thechassis (Fig. G2/4).

- Completely unscrew the wheel nuts and remove them.- Free the wheel by reciprocating movements and roll it to the side.- Slip the new wheel on the wheel hub.- Refit the nuts by hand, if necessary grease them.- Remove the safety support and lower the lift truck with the jack.- Tighten the wheel nuts with a torque wrench (See chapter : A - DAILY OR EVERY 10

HOURS SERVICE in paragraph : 3 - MAINTENANCE for tightening torque).

G3 - LIFT TRUCK

TOW

Do not tow the lift truck at more than 25 km/h.

- Put the forward/reverse lever and the gear shift in neutral.- Release the parking brake.- Put the warning lights on.- If the I.C. engine is not running there will be no steering or braking assistance. Operate

the steering and pedal slowly avoiding sudden jerkymovements.

G4 - LIFT TRUCK

SLING

- Take into account the position of the lift truck gravitycenter for lifting (Fig. G4/1).

- Place the hooks in the fastening points provided (Fig. G4/2and G4/3).

MC 40 POWERSHIFT Série 2A = 1296 mm B = 767 mm

MC 50 POWERSHIFT Série 2A = 1412 mm B = 651 mm

MC 60 POWERSHIFT Série 2 + TurboA = 1412 mm B = 881 mm

MC 70 POWERSHIFT Série 2 + TurboA = 1564 mm B = 929 mm

3 - 32

G4/3G4/2

G2/3

G2/4

A B

G4/1

G5 - LIFT TRUCK ON A PLATFORM

TRANSPORT

Ensure that the safety instructions connected to the platform are respected beforethe loading of the lift truck and that the driver of the means of transport is informedabout 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 fortransporting the lift truck. Check also the pressure on the contact surface allowablefor the platform in connection with the lift truck.

For lift trucks equipped with a turbo-charged I.C. engine, block off the exhaust outletto avoid rotation of the turbo shaft without lubrication when transporting the vehicle.

LOAD THE LIFT TRUCK- Block the wheels of the platform.- Fix the loading ramps so that you obtain an angle as little as possible to lift the lift

truck.- Load the lift truck parallel to the platform.- Stop the lift truck (See chapter : DRIVING INSTRUCTIONS in paragraph : 1 -

OPERATING AND SAFETY INSTRUCTIONS).

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 thetowing pin 2 (Fig. G5/4).

- Tighten the ropes (Fig. G5/5).

3 - 33

G5/2

G5/3

G5/1

G5/5G5/4

1

2

3 - 34

G6/4 G6/5

G6 - CAB

LIFT

To be done in the event of major intervention on the lift truck.

PLACING THE LIFT TRUCK- Place the lift truck on level ground.- Untighten the parking brake.- Tilt the mast backwards to a maximum and if necessary lift the

mast so as to bring it approximately 50 cm above the cab.

FITTING THE CABLE- Unscrew the two screws 1 (Fig. G6/1) on the roof and replace

them by two rings 2 (Fig. G6/2) Ref : 72422.- Pass the cable onto the upper belt of the mobile upright and

fasten the cable onto the rings (Fig. G6/3).UNLOCKING THE CAB- Disassemble the side panels 3 (Fig. G6/4) (3 fastening screws).- Unscrew the fastening screws of the silent blocks 4 (Fig. G6/5)

and only remove the nuts.- Close the left cab door.- Open and immobilize the right door.

G6/1

G6/2

G6/3

1 1

2

3 3

4 4

3 - 35

G6/7

G6/6

G6/8

LIFTING THE CAB

Check that there is no object in the driver stand which canimpede the manoeuvre.

- Slowly and slightly tilt the mast forwards and unlock the supportstay 5 (Fig. G6/6).

- Keep lifting the cab and fit the support stay into its stops 6 (Fig.G6/7) as soon as possible.

Do not lift the cab more than necessary.

- Slightly lower the cab so as to ensure its stability (Fig. G6/8).

LOWERING THE CAB- Slightly tilt the mast forwards in order to unlock the support stay

and fit it back into its clip.- Slowly lower the cab and check that there is nothing impeding

the manoeuvre.- Refit and tighten the fastening screws of the silent blocks.- Reassemble the side panels.- Remove the cable, the rings and refit both screws onto the roof.

G7 - 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 ofthe headlamp.

ADJUSTING PROCEDURE- Place the lift truck unloaded and in the transport position and

perpendicular to a white wall on flat, level ground (Fig. G7).- Check the tyre pressures (See chapter : A6 - TYRES

PRESSURE AND WHEEL NUTS TORQUE in paragraph : 3 -MAINTENANCE).

- Put the gear reverser lever in neutral and release the parkingbrake.

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.

MADE IN FRANCE

h1

+%

-%

h1h2

-2%

h2 = h1 - (l x 2 / 100)

l

G7

5

66

4 - 3

- 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 bekept in the places provided in the lift truck. For standard attachments, their use is governed by the instructions contained onthis notice.

- Some particular uses require the adaptation of the attachment which is not provided in the price-listed options. Optionalsolutions exist, consult your dealer.

It is COMPULSORY for all ATTACHMENTS WITH SUSPENDED LOAD (Hoist, crane jib, crane jib with winch, hook, etc.) to beused 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 SPECIFICATIONSOF ATTACHMENTS in paragraph : 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE). The manufacturer's liabilitywill 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. Inthe event of the attachment having less capacity than the lift truck, never exceed this limit.

INTRODUCTION

4 - 4

TECHNICAL SPECIFICATIONS OF ATTACHMENTS

- RF 50 -Reference : 34584Nominal load capacity : 2500 KgLength : 2000 mmSection : 200 x 75 mmWeight : 65 Kg

- RF 70 -Reference : 570430Nominal load capacity : 3500 KgLength : 2500 mmSection : 200 x 75 mmWeight : 80 Kg

- RF 50-2500 -Reference : 468586Nominal load capacity : 2500 KgLength : 2500 mmSection : 200 x 75 mmWeight : 70 Kg

Reference : 560858Width : 1750 mmWeight : 210 Kg



LOAD BACK REST (6T - 7T)

Reference : 572788Width : 1670 mmWeight : Kg

Reference : 572790Width : 2000 mmWeight : Kg

LOAD BACK REST (4T - 5T)


Reference : 415494Section : 150 x 60 x 1200 mmWeight : 124 Kg


MC 50 POWERSHIFT Série 2Reference : 415495Section : 150 x 60 x 1200 mmWeight : 134 Kg

MC 60/70 POWERSHIFT Série 2 + TurboReference : 415702Section : 150 x 70 x 1500 mmWeight : 176 Kg

STANDARDISED FORK

FORKS EXTENSION

4 - 5

- TDLA 40N 1670 -Reference : 572303 *

572069 **572069 ***

Nominal load capacity : 4000 KgSide-shift : 2 x 100 mmWidth : 1670 mmWeight : 335 Kg

- TDLA 40N 2000 -Reference : 572304 *

572071 **572071 ***


- TDLA 50N 1670 -Reference : 572305 *

572070 **572070 ***


- TDLA 50N 2000 -Reference : 572306 *

572072 **572072 ***


STANDARDISED SIDE-SHIFT CARRIAGE (4T - 5T)

* : Double mast with all-round vision** : Double mast with total free-acting lift

*** : Triple mast with total free-acting lift

- TDLA 100N 1750 -Reference : 572307Nominal load capacity : 9000 KgSide-shift : 2 x 150 mmWidth : 1750 mmWeight : 520 Kg

- TDLA 100N 2000 -Reference : 572308Nominal load capacity : 9000 KgSide-shift : 2 x 150 mmWidth : 2000 mmWeight : 565 Kg

STANDARDISED SIDE-SHIFT CARRIAGE (6T - 7T)

4 - 6

- DOUBLE TDLA40N -Reference : 572401Nominal load capacity : 2 x 2000 KgSide-shift : 2 x 150/100 mmWidth : 2 x 985 mmWeight : 2 x 132 Kg

- DOUBLE TDLA50N -Reference : 572404Nominal load capacity : 2 x 2500 KgSide-shift : 2 x 150/100 mmWidth : 2 x 985 mmWeight : 2 x 165 Kg

DOUBLE STANDARDISED SIDE-SHIFT CARRIAGE (4T - 5T)



STANDARDISED FORK (DOUBLE TDL)



4 - 7

- SP 700 50N SD -Reference : 556306Nominal load capacity : 700 L / 1260 KgWidth : 2100 mmWeight : 580 Kg

LOADING BUCKET (4T)




LOADING BUCKET (5T)


LOADING BUCKET (6T - 7T)

4 - 8

- SP 700 50N AD -Reference : 556307Nominal load capacity : 700 L / 1260 KgWidth : 2100 mmTeeth : 6Weight : 605 Kg

EARTHMOVING BUCKET (4T)




EARTHMOVING BUCKET (5T)

- SP 1200 70N AD -Reference : 556313Nominal load capacity : 1200 L / 2160 KgWidth : 2200 mmWeight : 785 Kg

EARTHMOVING BUCKET (6T - 7T)

4 - 9

- BCE 1500 40N -Reference : 556296Nominal load capacity : 1500 L / 1800 KgWidth : 2100 mmWeight : 775 Kg


- BCE 2500 40N -Référence : 556298Nominal load capacity : 2500 L / 3000 KgWidth : 2100 mmWeight : 950 Kg



- BCE 2500 50N -Référence : 556301Nominal load capacity : 2500 L / 3000 KgWidth : 2100 mmWeight : 925 Kg

GRAIN AND FERTILIZER BUCKET (4T - 5T)

4 - 10

- GL 800 S2 -Reference : 174246Nominal load capacity : 800 L / 1760 KgWeight : 308 Kg




SPOUT OPENNING HYDRAULIC KITReference : 202747

SPOUT BUCKET (ADAPTABLE ON FORKS)

4 - 11

4 - 12

Reference : 227801

FORK PROTECTOR

Reference : 206734 (1375 mm)Reference : 206732 (1500 mm)Reference : 206730 (1650 mm)Reference : 235854 (1850 mm)Reference : 206728 (1950 mm)

Reference : 206726 (2000 mm)Reference : 223771 (2050 mm)Reference : 223773 (2100 mm)Reference : 206724 (2150 mm)Reference : 206099 (2250 mm)Reference : 206722 (2450 mm)Reference : 223775 (2500 mm)

BUCKET PROTECTOR

NOTE : Always ensure that the width of the protector you choose is less than or equal tothe width of the bucket.

ATTACHMENT SHIELDS

Documents

) MC 40 POWERSHIFT S2,MC 50 POWERSHIFT S2,MC 60 …