Manitou MSI 50, MSI 40 Operator's Manual

MSI 40 MSI 50

BP 249 Z. I.

44 158 ANCENIS CEDEX FRANCE

TEL : 02 40 09 10 11

YOUR DEALER

OPERATOR'S MANUAL

REF : 47974 EN (06 / 07 / 2000)

1st DATE OF ISSUE

CATALOGUE

INFORMATION

DATE OF ISSUE OBSERVATIONS

03 / 1993

09 / 1993

12 / 1993

05 / 1994

19 / 09 / 1997

06 / 07 / 2000

- 1stISSUE

- ADDING "REPAIRS NOTICE"

- UP DATING : LIFTING CAB

- UP DATING

- UP DATING : LIFTING CAB

- UP DATING : REVISION OF THE OPERATOR'S MANUAL

- UP DATING

03 / 1993

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR

PARTLY.

1 - OPERATING AND SAFETY INSTRUCTIONS

– ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS – DRIVER'S OPERATING INSTRUCTIONS

• CAUTION

• GENERAL INSTRUCTIONS

• OPERATING INSTRUCTIONS

• HANDLING INSTRUCTIONS

• LOAD HANDLING

– MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK – BEFORE STARTING UP A NEW LIFT TRUCK

2 - DESCRIPTION

– IDENTIFICATION OF THE LIFT TRUCK – CHARACTERISTICS – MAST CHARACTERISTICS – DIMENSIONS AND LOAD CHART – INSTRUMENTS AND CONTROLS

Up to machine n° : 117 315 From machine n° : 117 316

– DESCRIPTION AND OPERATION OF ELECTRIC AND HYDRAULIC OPTIONS

3 - MAINTENANCE

– FILTERS CARTRIDGES AND BELTS – LUBRICANTS AND FUEL – SERVICING SCHEDULE

4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE

– INTRODUCTION – TECHNICAL SPECIFICATIONS OF ATTACHMENTS – ATTACHMENT SHIELDS

TABLE OF CONTENTS

1 - 1

1 - 3 1 - 4

1 - 4 1 - 6

1 - 8 1 - 12 1 - 14

1 - 18 1 - 20

2 - 1

2 - 4

2 - 6 2 - 16 2 - 18

2 - 20 2 - 30 2 - 41

3 - 1

3 - 3

3 - 4

3 - 6

4 - 1

4 - 3

4 - 4

4 - 8

1 - 1

1 - OPERATING

AND SAFETY INSTRUCTIONS

1 - OPERATING

AND SAFETY INSTRUCTIONS

1 - 2

1 - 3

BY ALLOWING NON-ORIGINAL PARTS TO BE USED,

YOU RUN THE RISK - Legally, of being liable in the event of an accident.

- Technically, of causing breakdowns to occur or of reducing your lift truck's service life.

Using counterfeit parts or components not approved by the manufacturer may put an end to contract warranty terms

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

BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS,

YOU ARE LEGALLY

- Any user who procures parts from another quarter does so at his own risk.

COVERING YOURSELF

- Any user who modifies his lift truck or has it modified by a service company, must consider that a new item of equipment has been brought onto the market and therefore takes liability for it.

- Any user who copies original parts or has them copied is taking a risk from the legal viewpoint.

- The certificate of compliance only binds the maker for parts chosen or produced under the maker's control.

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

YOU GET THE THE MANUFACTURER BRINGS TO THE USER, BENEFIT OF THE MANUFACTURER'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 best technological 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 DEALER NETWORK.

You can obtain the list of dealers by phoning the spare parts department on :

TEL : 02 40 09 10 21

ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS

1 - 4

DRIVER'S OPERATING INSTRUCTIONS

CAUTION

WHENEVER YOU SEE THIS SYMBOL IT MEANS :

WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK.

- Most accidents connected with the use, maintenance and repair of the lift truck are due to non application of the basic safety instructions. By being aware of the risks to which you are exposed and by taking the necessary preventive measures, you should be able to avoid accidents occurring.

- Any operation or manoeuvre not described in the instructions is prohibited a priori, however, any person who does use another method must first ensure that he is not putting himself, another person or the lift truck in danger.

- The manufacturer is not able to anticipate all possible risk situations. Therefore the safety instructions and notices given in the user manual and on the lift truck are not exhaustive.

Any bending of the rules in safety notices or the user, maintenance or repair instructions for your lift truck may result in

serious, or even fatal, accidents.

We would remind users of the risks in driving at excessive speed with regard to traffic conditions, particularly :

- Risk of loss of control on a poor-quality track.

- Increased stopping distance. The user must remain in full control of his lift truck and should :

- Adapt his speed to each situation in order to be maintain his own safety, that of others and of his

equipment.

- Always be aware of his stopping distance.

On the basis of experience, there are a number of possible situations in which operating the lift truck is contra-indica-

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

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

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

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

- For certain machines, the foreseeable behaviour of such persons as : apprentices, teenagers, handicapped persons and trainees tempted to drive a lift truck. Truck drivers tempted to operate a truck to win a bet, in competition or for their own personal experience.

The person in charge of the equipment must take these criteria into account when assessing whether or not a person

will make a suitable driver.

1 - 5

1 - 6

GENERAL INSTRUCTIONS

A - DRIVER’S OPERATING INSTRUCTIONS

- Read the operator's manual carefully, making sure you understand it.

- The operator’s manual must always be kept in the lift truck, in the place provided and in the language understood by the operator.

- Respect the safety notices and instructions given on the lift truck.

- It is compulsory to replace all plates or stickers which are no longer legible or which have become worn or damaged.

B - AUTHORISATION TO OPERATE (LEGISLATION IN FORCE FOR FRANCE)

(Or refer to the legislation for each particular country)

- Only qualified personnel may use the lift truck. Its use is subject to authorisation to operate being given by the appropriate manager in the user establishment.

- The user should always carry this authorisation to operate with him while he is using the lift truck.

- 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.

C - MAINTENANCE

- The user must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety notice.

- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He must keep the lift truck properly cleaned if this is among his responsibilities.

- Carry out daily maintenance (See 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 your lift truck yourself (Hydraulic pressure, relief valve calibration, I.C. engine running speed, addition of extra equipment etc.). The same holds with regard to any suppression or modification of the safety systems, in which case the maker would no longer be liable.

Regular inspection of your lift truck is mandatory if it is to be kept in conforming condition. The frequency of such

checks are defined by the current legislation of the country in which the lift truck is being operated.

Maintenance or repairs other than those detailed in part : 3 - MAINTENANCE must be carried out by qualified person-

nel (Consult your agent or dealer) and under the necessary safety conditions to maintain the health of the operator and

any third party.

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D - ENVIRONMENT

- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are optional solutions, consult your agent or dealer.

- Take into account climatic and atmospheric conditions of the site of utilisation.

For operation under average climatic conditions, i.e. : between -15 °C and + 35 °C, correct levels of lubricants in all the

circuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessa-

ry to drain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient

temperatures. It is the same for the cooling liquid.

. 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.

Use of a lift truck is prohibited in protected areas (e.g. refinery, explosive atmosphere). For use in these areas,

specific equipment is available as an option. Consult your dealer.

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.

- Never operate the vehicle when hands or feet are wet or soiled with greasy substances.

- For increased comfort, adjust the driver’s seat to your requirements and adopt the correct position in the driver’s cab.

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

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

- Check the closing and locking of the hood.

- Whatever his experience as a truck driver is, the operator is advised to familiarize himself with the position and operation of all the controls and instruments before operating the lift truck.

C - STARTING THE LIFT TRUCK

SAFETY NOTICE

The lift truck must only be started up or manoeuvred when the operator is sitting in the driver’s cab, with his seat belt

adjusted and fastened.

- Never try to start the lift truck by pushing or towing it.

Such operation may cause severe damage to the transmission. If necessary, to tow the lift truck in an emergency, the transmission must be placed in the neutral position (See chapter : H - OCCASIONAL MAINTENANCE in paragraph : 3

- MAINTENANCE).

INSTRUCTIONS

- Open the LPG bottle.

- 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.

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

unsuccessful attempts.

1 - 9

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

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

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

D - DRIVING THE LIFT TRUCK

SAFETY NOTICE

- Always drive the lift truck with the forks or attachment at approximately 300 mm from the ground, i.e. In the transport position.

- 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 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 move onto a loading platform without having first checked :

. That it is suitably positioned and made fast. . That the unit to which it is connected (Wagon, lorry, etc.) will not shift. . That this platform is prescribed for the total weight of the lift truck to be loaded. . That this platform is prescribed for the width of the lift truck.

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

Take extreme care with loading platforms, trenches, scaffolding, recently dug and/or backfilled ground.

- The loaded lift truck must not travel at speeds in excess of 12 km/h.

INSTRUCTIONS

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

- Shift the forward/reverse lever to the selected direction of travel.

- Release the parking brake and accelerate gradually until the lift truck moves off.

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E - STOPPING THE LIFT TRUCK

SAFETY NOTICE

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

Do not forget this precaution, in the event of frequent stops of the engine, or else the temperature of certain parts will

rise significantly due to the stopping of the cooling system, with the risk of badly damaging such parts.

- Never leave the ignition key in the lift truck when the lift truck is unattended.

- When the lift truck is stationary, place the forks or attachment on the ground, apply the parking brake and put the forward/reverse lever in neutral.

- If the driver has to leave his cab, even for a moment, it is essential 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 the rear windows, lock the cab doors and ensure that the hood is properly secured.

INSTRUCTIONS

- Park the lift truck on flat ground or on an incline 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 engine with the ignition switch.

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

- Remove the ignition key.

- Check the closing and locking of doors, windows and hood.

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

safety and the safety of others.

F - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY

SAFETY INSTRUCTIONS

- When driving a lift truck on roads open to public traffic, observe the provisions of the Highway Code.

- Lift truck drivers, driving on the public highway, must abide by the general provisions relative to highway traffic.

- The lift truck must conform to the provisions of the Highway Code. If necessary, optional solutions exist, consult your dealer.

Transport of loads on the public highway is forbidden and attachments mounted on the lift truck must be fitted with

equipment in accordance with regulations or else dismounted.

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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.

- Check the adjustment of the rear view mirrors.

- Ensure that the fuel level is sufficient.

- Put the attachment at 300 mm from the ground.

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.

- Do not use a non-braked trailer if the unit weight of a load exceeds that imposed by the highway code.

- Do not use a non-braked trailer without braking equipment for the trailer on the lift truck.

- Do not forget to connect the lift truck’s braking equipment to that of the trailer.

- The maximum vertical pull on the trailer hook must not exceed 1500 daN.

- The authorised total towed weight (A.T.T.W.) must not exceed the maximum weight authorised by the manufacturer (Consult the manufacturer’s plate on your lift truck).

H - OPERATING THE LIFT TRUCK WITH A FRONT-END ATTACHMENT ON A PUBLIC HIGHWAY

- For driving with an attachment, check the regulations currently applicable in your country.

- The attachment must not exceed the overall width of the lift truck.

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

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

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

IF NECESSARY, CONSULT YOUR DEALER.

HANDLING INSTRUCTIONS

A - GENERAL

- Ensure the correct functioning of your lift truck’s attachments.

- Do not attempt to carry out operations which exceed the capacities of your lift truck or attachments.

- It is prohibited to increase the counterweight value in any way.

- It is strictly prohibited to carry or to lift up persons using the lift truck, unless the vehicle is specially equipped for this purpose and has the corresponding certificate of conformance for lifting people.

- Avoid travelling for a long distance in reverse.

B - ATTACHMENTS

- Ensure that the attachment is correctly fitted and locked to its frame.

- Conform to the limits on the load chart for the lift truck and/or attachment.

- Ensure that palettes, cases, etc, are in good order and suitable for the load to be lifted.

- Position the forks perpendicular to the load to be lifted, taking account of the load’s 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 hydraulic controls.

C - ENVIRONMENT

- Take care when raising the load that no object or person is in the way of movement and do not make any incorrect manoeuvres.

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

You must consult your local electrical agency.

You could be electrocuted or seriously injured if you operate or park the lift truck too close to power cables. You are

strongly advised to ensure that the safety rules on the site conform to the local regulations in force regarding all types

of work carried out close to power cables.

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

- When using the lift truck on a slope, before raising the mast, ensure that the ground is horizontal (See paragraph : F HORIZONTAL POSITION OF THE LIFT TRUCK in the chapter : LOAD HANDLING).

- Travelling on a longitudinal slope :

• Drive and brake gently.

• Moving without load : Forks or attachment facing downhill.

• Moving with load : Forks or attachment facing uphill.

- Ensure that scaffolding, loading platform or pile is capable of bearing the weight.

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

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1 - 13

D - HANDLING

- Always consider safety and only transport balanced and correctly secured loads to avoid any risk of tipping.

- Fully engage forks under the load and move it in the transport position (The forks 300 mm from the ground and the mast sloping backwards).

- For obvious reasons regarding the lift truck’s stability and clear visibility of the surrounding environment, only move the lift truck when the mast is in the transport position.

- Do not manoeuvre the lift truck with the mast in the raised position unless under exceptional circumstances and then with extreme caution, at very low speed and using gentle braking. Ensure that visibility is adequate and get another person to guide you along if necessary.

- Never shift the position of the load while the lift truck is in motion.

- The simultaneous use of two lift trucks to handle heavy or bulky loads is a dangerous manoeuvre, requiring specific precautions to be taken. This should only be done in exceptional circumstances and in the presence of a handling manager.

- Never drive too fast or brake abruptly when carrying a load.

- During handling, drive at low speed.

- Check the load, particularly when turning corners and especially if it is very bulky.

- Secure unstable loads.

- Handle loads with caution, at slow speed, without sudden jerks when moving them at significant heights and 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

- Constantly keep clear visibility of the road, either direct view (looking backwards when reversing) or indirect view using the panoramic rear view mirrors to check for people, animals, holes, obstacles, change of slope, etc.

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

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

- 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, a certain number of options are available, such as : road lighting, stop lights, flashing light, reverse lights, reverse buzzer alarm, front light, rear light, etc. Consult your agent or dealer.

IF NECESSARY, CONSULT YOUR DEALER.

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LOAD HANDLING

A - WEIGHT OF LOAD AND CENTRE OF GRAVITY

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

attachment is prohibited.

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

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

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

For loads with a moving centre of gravity (e.g. liquids), take account of the

variations in the centre of gravity in order to determine the load to be hand-

led (Consult your agent or dealer) and be vigilant and take extra care to limit

these variations as far as possible.

B - TAKING UP A LOAD ON THE GROUND

- Approach the lift truck perpendicular to the load, with the forks in a horizontal position (Fig. C).

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

Beware of the risks of trapping or squashing limbs when manually adjusting

the forks. Always maintain an equal distance between the forks and the

centre of the carriage in order to keep the load completely stable.

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

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

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

Tilt the load sufficiently backwards to ensure its stability (loss of load on bra-

king) without upsetting the balance of the load in so doing.

500 mm

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C - TAKING UP A HIGH LOAD ON TYRES

Under no circumstances should you pick up a load if the lift truck is not a

horizontal position. (See paragraph : F - HORIZONTAL POSITION OF THE

LIFT TRUCK in the chapter : LOAD HANDLING).

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

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

- Bring the forks to stop in front of the load (Fig. H). Apply the parking brake and place the forward/reverse lever in neutral.

- Slightly lift the load (1) and incline the mast (2) backwards to stabilize the load (Fig. I).

Tilt the load sufficiently backwards to ensure its stability (loss of load on bra-

king) without upsetting the balance of the load in so doing.

- Manoeuvring very gently and carefully (See paragraph : E - VISIBILITY in the chapter : HANDLING INSTRUCTIONS 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).

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D - LAYING A HIGH LOAD ON TYRES

Under no circumstances should you lay down a load if the lift truck is not a

horizontal position. (See paragraph : F - HORIZONTAL POSITION OF THE

LIFT TRUCK in the chapter : LOAD HANDLING).

- Approach the load in the transport position in front of the pile (Fig. K).

- Lift the mast (1) until the load is above the pile, and move the lift truck forward (2) (Fig. L) manoeuvring very gently and carefully (See paragraph : E - VISIBILITY in the chapter : HANDLING INSTRUCTIONS for visibility of the road). Apply the parking brake and place the forward/reverse lever in neutral.

- Place the load in a horizontal position by tilting the mast forwards (1) and lay it down on the pile (2) while checking the correct positioning of the load (Fig. M).

- To drive very gently and carefully.

- Free the forks by reversing the lift truck (3) (Fig. M) (See paragraph : E VISIBILITY in the chapter : HANDLING INSTRUCTIONS 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 - HORIZONTAL POSITION OF THE LIFT TRUCK

Apart from the transverse slope of the ground, several parameters can upset the horizontal position of the lift truck.

• The tyre pressure.

• The stability of the ground.

• The balance of the load.

• Strong wind or stormy conditions.

Before any handling work, check the points above and ensure that the lift

truck is completely horizontal.

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MAINTENANCE INSTRUCTIONS

A - GENERAL

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

- Stop the I.C. engine, when an intervention is necessary.

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

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

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

and in a ecological way.

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

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

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

The handling and removal of the balancing valves or safety valves which may be fitted to the cylinders of your lift truck

can be dangerous. A balancing valve must only be removed when the cylinder concerned is at rest and the hydraulic

circuit is depressurised.

This operation can only be carried out by authorised staff.

- 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.

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 engine without air filter, or with oil, water or fuel leaks.

Wait for the I. C engine to cool before removing the radiator cap or expansion pan (Pressurised system).

- 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

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D - WASHING

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

- Remember to close the doors and the windows of the cab.

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

If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being dama-

ged, 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.

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INTRODUCTION

- Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the mechanic.

- However, before commencing to operate the lift truck, the user should carefully read and understand the various chapters of this manual which has been provided to solve driving and maintenance problems. By following these instructions the user will be able to take full advantage of the versatility of this lift truck.

- The operator must familiarize himself with the positions and functions of all the controls and instruments before operating the lift truck.

Do not attempt to start a new lift truck before the following checks have been carried out :

LUBRICATION

- Check that all the correct grades of oils and greases that are required are available ; see chapter : SERVICING SCHEDULE in paragraph : 3 - MAINTENANCE and top up if necessary.

For operation under average climatic conditions, i.e. : between -15 °C and + 35 °C, correct levels of lubricants in all the

circuits are checked in production. For operation under more severe climatic conditions, before starting up, it is necessa-

ry to drain all the circuits, then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient

temperatures. It is the same for the cooling liquid (Contact your dealer for information, if necessary).

DRY AIR FILTER

- Ensure that the air filter is undamaged and not blocked.

- Tighten the fastening devices if necessary.

Never run the engine with the air filter removed or damaged.

COOLING SYSTEM

- Do not start the lift truck without checking the radiator coolant level or if the fan belt is damaged or broken.

HYDRAULIC SYSTEM

- Check by a visual examination that there are no leaks or oil oozing in the hoses, connections and unions. If necessary, tighten or repair the defective connections.

- Also check that the tank oil level is correct.

BRAKING SYSTEM

- Check by a visual examination that there are no leaks or oil oozing in the hoses, connections and unions. If necessary, tighten or repair the defective connections.

- Also check the oil level in the tank.

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

TYRES

- Make sure that the wheel nuts are correctly tightened (See chapter : A - DAILY OR EVERY 10 HOURS SERVICE in paragraph : 3 - MAINTENANCE) and that the tyre pressures are correct (See chapter : CHARACTERISTICS in paragraph : 2 - DESCRIPTION).

FUEL SYSTEM

- Check that all fuel lines are secured.

- If necessary drain the fuel filter and bleed the fuel system of air.

BEFORE STARTING UP A NEW LIFT TRUCK