Manitou 6-E3 Series Operator'S Manual Download

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3-3

TABLE OF CONTENTS

MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT

3-4

START-UP CHECKLIST

3-5

FILTERS CARTRIDGES AND BELTS

MLT 731 Turbo Série F-E3

3-6

FILTERS CARTRIDGES AND BELTS

MLT 634 Turbo LSU Série F-E3

MLT 735 Turbo LSU Série 6-E3
MLT 741 Turbo LSU Série 6-E3
MLT 1035 L Turbo LSU Série 6-E3

3-7

FILTERS CARTRIDGES AND BELTS

MLT 634 -120 LSU Série F-E3

MLT 634 -120 LSU POWERSHIFT Série F-E3
MLT 735 -120 LSU Série 6-E3
MLT 735 -120 LSU POWERSHIFT Série 6-E3
MLT 741 -120 LSU Série 6-E3
MLT 741 -120 LSU POWERSHIFT Série 6-E3

3-8

LUBRICANTS AND FUEL

3-10

SERVICING SCHEDULE

3-12

A - DAILY OR EVERY 10 HOURS SERVICE

3-14

B - EVERY 50 HOURS SERVICE

3-20

C - EVERY 250 HOURS SERVICE

3-26

D - EVERY 500 HOURS SERVICE

3-30

E - EVERY 1000 HOURS SERVICE

3-36

F - EVERY 2000 HOURS OF SERVICE

3-42

G - OCCASIONAL MAINTENANCE

3-44

Summary of Contents for 6-E3 Series

Page 1: ...0 LSU S rie 6 E3 MLT 735 120 LSU POWERSHIFT S rie 6 E3 MLT 741 Turbo LSU S rie 6 E3 MLT 741 120 LSU S rie 6 E3 MLT 741 120 LSU POWERSHIFT S rie 6 E3 MLT 1035 L Turbo LSU S rie 6 E3 YOUR DEALER OPERATO...

Page 2: ......

Page 3: ...TY INSTRUCTIONS 2 DESCRIPTION 3 MAINTENANCE 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE 5 SPECIFIC AUSTRALIA See also the operator s manual supplement 647065 AU 27 08 2010 18 10 2010 19 05 2011 1ST...

Page 4: ......

Page 5: ...1 1 1 OPERATING AND SAFETY INSTRUCTIONS...

Page 6: ...1 2...

Page 7: ...ENTRE OF GRAVITY C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE D TRANSVERSE ATTITUDE OF THE LIFT TRUCK E TAKING UP A LOAD ON THE GROUND F TAKING UP AND LAYING A HIGH LOAD ON TYRES G TAKING UP AN...

Page 8: ...ditions to define the lift truck s signalling and lighting equipment Contact your dealer Take into account climatic and atmospheric conditions of the site of utilisation Protection against frost see 3...

Page 9: ...e THE INSTRUCTIONS The operator s manual must always be in good condition and kept in the place provided on the lift truck and in the language used by the operator The operator s manual and any plates...

Page 10: ...shment with respect to the use of lift trucks and must be carried permanently by the operator The operator is not competent to authorise the driving of the lift truck by another person C MAINTENANCE T...

Page 11: ...uck is used The pictogram posted at the operator station reminds you that Left hand column It is forbidden to lift people with any kind of attachment using a non PLATFORM fitted lift truck Right hand...

Page 12: ...andle s provided for this purpose Do not jump out of the seat to get down Always pay attention when using the lift truck Do not listen to the radio or music using headphones or earphones Never operate...

Page 13: ...risk Regularly check the distance between the load or the attachment and the structure and readjust this if necessary If possible use the lift truck at an oil temperature as close as possible to ambie...

Page 14: ...erations F DRIVING THE LIFT TRUCK SAFETY INSTRUCTIONS Operators attention is drawn to the risks involved in using the lift truck in particular Risk of losing control Risk of losing lateral and frontal...

Page 15: ...n for a moment place the forks or attachment on the ground apply the parking brake and place the forward reverse selector in neutral Make sure that the lift truck is not stopped in any position that w...

Page 16: ...fitted with them Select the steering mode HIGHWAY TRAFFIC as model of lift truck see 2 DESCRIPTION INSTRUMENTS AND CONTROLS Retract entirely the jib and put the attachment at 300 mm from the ground P...

Page 17: ...e other obligations OPERATING THE LIFT TRUCK WITH A TRAILER For using a trailer observe the regulations in force in your country maximum travel speed braking maximum weight of trailer etc Do not forge...

Page 18: ...of gravity before any movement fig B2 and set it in the longitudinal axis of the lift truck It is forbidden to move a load heavier than the effective capacity defined on the lift truck load chart For...

Page 19: ...be between the two lines see 2 DESCRIPTION INSTRUMENTS AND CONTROLS In this position the two front wheels must be off the ground E TAKING UP A LOAD ON THE GROUND Approach the lift truck perpendicular...

Page 20: ...orks in front of the load by alternately extending and retracting the jib 1 or if necessary moving the lift truck forward 2 fig F2 Put the handbrake on and set the forward reverse selector to neutral...

Page 21: ...ILITY LIMITER AND WARNING DEVICE If necessary move the lift truck 3 forward fig F7 driving very slowly and carefully Place the load in a horizontal position and lay it down on the pile by lowering and...

Page 22: ...STABILIZERS WITH THE JIB UP UNLADEN AND LADEN This operation must be exceptional and performed with great care Raise the jib and retract the telescopes completely Set the lift truck in position in fro...

Page 23: ...E If it is overloaded set the load down in the place from where it was taken If possible lower the load without moving the lift truck Raise the jib 1 to release the load retract 2 and lower the jib 3...

Page 24: ...ive and stop the lift truck gently and smoothly to minimise swinging of the load Carry the load a few centimetres above the ground max 30 cm the shortest possible jib length Do not exceed the offset i...

Page 25: ...out Do not pile these materials to the point where it is necessary to step over them D USING THE PLATFORM However experienced they may be operators must acquaint themselves with the emplacement and o...

Page 26: ...e waves begin to form white foam crests probably spray 7 Near gale 28 33 50 61 13 9 17 1 Whole trees sway it is difficult to walk against the wind Sea heaps up and white foam blown in streaks along th...

Page 27: ...button from the transmitter or locking it in an inaccessible place The user must ensure that the instruction manual is accessible at all times and that operators have read and understood it INSTRUCTI...

Page 28: ...uals or companies having performed them the type of operation and its frequency if applicable The part numbers of any lift truck items replaced shall also be indicated LUBRICANT AND FUEL LEVELS Use th...

Page 29: ...ol unit disconnect this before starting to weld to avoid the risk of causing irreparable damage to electronic components WASHING THE LIFT TRUCK Clean the lift truck or at least the area concerned befo...

Page 30: ...e protective product to the engine oil Run the I C 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 af...

Page 31: ...ENANCE D EVERY 500 HOURS SERVICE Refit and set the tension in the drive belts see 3 MAINTENANCE C EVERY 250 HOURS SERVICE Turn the I C engine using the starter to allow the oil pressure to rise Reconn...

Page 32: ...1 28...

Page 33: ...2 1 2 DESCRIPTION...

Page 34: ...2 2...

Page 35: ...741 120 LSU S rie 6 E3 2 28 CHARACTERISTICS MLT 741 120 LSU POWERSHIFT S rie 6 E3 2 30 CHARACTERISTICS MLT 1035 L Turbo LSU S rie 6 E3 2 32 FRONT AND REAR TIRES 2 34 DIMENSIONS AND LOAD CHART MLT 634...

Page 36: ...SHIFT S rie 6 E3 MLT 741 Turbo LSU S rie 6 E3 MLT 741 120 LSU S rie 6 E3 MLT 741 120 LSU POWERSHIFT S rie 6 E3 MLT 1035 L Turbo LSU S rie 6 E3 6 D clare que cette machine Declares that this machine 7...

Page 37: ...RG WDV UHQJLQLR JDPLQWRMDV 3DUHL NLD NDG LV UHQJLQ V WLWLQND WROLDX QXURG WDV GLUHNW YDV LU QDFLRQDOLQLXV WHLV V DNWXV SHUNHOWDV M QXRVWDWDV 9 SULHGDV G O PD LQ 6HUWLILNDWR 1U 3DVNHOEWRML VWDLJD VXGHU...

Page 38: ...ce illegible or damaged plates Contact your dealer 1 EXTERNAL PLATES AND STICKERS REF PART NUMBER DESCRIPTION 1 9 24653 Securing and slinging point 2 289013 Towing instruction 3 207525 Hydraulic trail...

Page 39: ...tion according to model 2 293887 Anti freeze 3 Consult your dealer Cooling fluid 4 Consult your dealer High pressure system instruction for 120 only 5 Consult your dealer Engine adjustment instruction...

Page 40: ...braking Massa rimorchiabile non frenata Peso remolcable sin frenado Nichtgebremste Anh ngemasse Masse remorquable avec freinage ind pendant Towable mass with independent braking Massa rimorchiabile c...

Page 41: ...7 5A 7 5Amax 15Amax 5A 10A 15Amax 15A 10A OPT OPT ECU HYD OPT OPT STOP LSU OPT OPT DIAG 8 9 10 11 12 13 14 15 1 2 N 240805 16 SUIVANT NORME EN 1459 annexe B N MLT 1600kg 1300kg 2000kg 2500kg 1150kg 35...

Page 42: ...e pressure Bar Pressione per pneumatici Bar Presion de los neum ticos Bar kW daN Avant Front Anteriore Adelante Arri re Rear Posteriore Trasero kg kg daN MANITOU BF 44158 ANCENIS CEDEX FRANCE Type Typ...

Page 43: ...erial Nr MANITOU reference REAR AXLE FIG F Type Serial Nr MANITOU reference CAB FIG G Type Serial Nr BOOM FIG H MANITOU reference Date of manufacture PLATE MANUFACTURER OF THE ATTACHMENT FIG I Model S...

Page 44: ...ermanent Switch for 2 4 drive wheels No Front tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 Rear tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 ELECTRIC CIRCUIT Battery Standa...

Page 45: ...vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 5820 At rated...

Page 46: ...reverse speeds 4 Angle gear box TURNER Front axle DANA Differential Limited slip Rear axle DANA Differential Without locking Drive wheels 4RM Permanent Switch for 2 4 drive wheels No Front tyres MICHE...

Page 47: ...vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 5600 At rated...

Page 48: ...r of reverse speeds 3 Angle gear box TURNER Front axle DANA Differential Limited slip Rear axle DANA Differential Without locking Drive wheels 4RM Permanent Switch for 2 4 drive wheels No Front tyres...

Page 49: ...gross vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 5400 At...

Page 50: ...manent Switch for 2 4 drive wheels No Front tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 Rear tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 ELECTRIC CIRCUIT Battery Standard...

Page 51: ...daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 6100 At rated load transmiss...

Page 52: ...ermanent Switch for 2 4 drive wheels No Front tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 Rear tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 ELECTRIC CIRCUIT Battery Standa...

Page 53: ...e of gravity from the load to the lug of the forks mm 500 Standard lifting height mm 6860 Lift truck weight without attachment kg 6835 Lift truck weight with standard attachment Unladen kg 7075 At rat...

Page 54: ...reverse speeds 4 Angle gear box TURNER Front axle DANA Differential Limited slip Rear axle DANA Differential Without locking Drive wheels 4RM Permanent Switch for 2 4 drive wheels No Front tyres MICHE...

Page 55: ...vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 5465 At rated...

Page 56: ...r of reverse speeds 3 Angle gear box TURNER Front axle DANA Differential Limited slip Rear axle DANA Differential Without locking Drive wheels 4RM Permanent Switch for 2 4 drive wheels No Front tyres...

Page 57: ...gross vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 4975 At...

Page 58: ...ermanent Switch for 2 4 drive wheels No Front tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 Rear tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 4 ELECTRIC CIRCUIT Battery Standa...

Page 59: ...e of gravity from the load to the lug of the forks mm 500 Standard lifting height mm 6840 Lift truck weight without attachment kg 7120 Lift truck weight with standard attachment Unladen kg 7475 At rat...

Page 60: ...reverse speeds 4 Angle gear box TURNER Front axle DANA Differential Limited slip Rear axle DANA Differential Without locking Drive wheels 4RM Permanent Switch for 2 4 drive wheels No Front tyres MICHE...

Page 61: ...s vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 6550 At rate...

Page 62: ...r of reverse speeds 3 Angle gear box TURNER Front axle DANA Differential Limited slip Rear axle DANA Differential Without locking Drive wheels 4RM Permanent Switch for 2 4 drive wheels No Front tyres...

Page 63: ...d gross vehicle weight daN 28000 Contact pressure on the ground for the whole surface of each stabilizer at maximum load when tilting kg cm2 Drag strain on the coupling hook Unladen sliding daN 6200 A...

Page 64: ...M Permanent Switch for 2 4 drive wheels No Front tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 Rear tyres MICHELIN Size 460 70 R24 159A8 XMCL Pressure bar 3 ELECTRIC CIRCUIT Battery Standar...

Page 65: ...om the load to the lug of the forks mm 500 Standard lifting height mm 9600 Lift truck weight without attachment kg 8135 Lift truck weight with standard attachment Unladen kg 8375 At rated load kg 1187...

Page 66: ...nladen 1900 1850 1900 2100 2050 2100 2400 Rear laden 650 600 600 700 700 750 1100 15 5R25 XHA TUBELESS PRESSURE 2 75 2 75 2 75 2 75 2 75 2 75 2 75 3 5 3 5 3 5 3 5 Front unladen 1550 1550 1600 1750 170...

Page 67: ...445 70R24 MPT IT510 151G TUBELESS PRESSURE 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 Front unladen 1550 1550 1600 1750 1700 1750 1750 1700 1750 1750 1800 Front laden 4450 4450 4550 4600 4650 4700 4...

Page 68: ...55 2 22 128 495 1550 8 61 2 25 180 690 1600 8 65 2 25 185 710 1700 8 41 2 28 202 744 1750 8 57 2 31 204 758 1800 8 73 2 33 206 772 1850 8 89 2 35 208 786 1900 9 05 2 38 210 800 1950 9 05 2 36 216 825...

Page 69: ...0 520 1100 5 05 1 74 214 620 1550 5 64 1 94 275 800 1600 5 71 1 98 280 810 1750 5 79 2 02 302 866 1800 5 84 2 03 308 884 1950 6 05 2 09 323 935 2050 6 21 2 14 330 960 2100 6 27 2 16 335 970 2400 6 73...

Page 70: ...0 3 06 1 64 1702 3167 5150 3 07 1 66 1715 3186 500 70R24 XMCL 164A8 TUBELESS 2 6 600 650 700 750 1100 1700 1750 1800 1850 1900 2050 2100 2400 4650 4700 4750 4900 5100 5150 15 5R25 XHA TUBELESS 2 75 60...

Page 71: ...400 4650 4700 4750 4900 5100 5150 1200R20 X MINE D2 5 5 600 850 1550 1600 1750 1950 2050 2100 4450 4550 4600 ALLIANCE 17 5 LR 24 150 A8 A570 TUBELESS 3 2 600 650 700 750 850 1100 1550 1600 1700 1750 1...

Page 72: ...ie F E3 A mm 1200 B mm 2560 C mm 1142 C1 mm 1245 D mm 4579 D1 mm 4682 D2 mm 4003 E mm 5779 F mm 1935 F1 mm 1935 G mm 450 G1 mm 435 G2 mm 435 I mm 877 J mm 980 K mm 1260 L mm 45 N mm 1715 O mm 125 P2 4...

Page 73: ...2 41 3400kg 2500kg 2000kg 1500kg 2800kg MLT634 6 05 0m 1 2 3 4 5 6 7 0m 1 2 3 4 2 05 1 45 1 80 1 19 2 55 3 25 63 5 60 50 40 30 20 10 0 3 5 SUIVANT NORME EN 1459 annexe B 0 5m N 244374...

Page 74: ...142 C1 mm 1537 D mm 4879 D1 mm 4974 D2 mm 4003 E mm 6079 F mm 1935 F1 mm 1935 G mm 450 G1 mm 435 G2 mm 435 I mm 877 J mm 980 K mm 1260 L mm 45 N mm 1715 O mm 125 P2 47 5 P3 53 R mm 3535 S mm 7690 T mm...

Page 75: ...44389 SUIVANT NORME EN 1459 annexe B 6 90 8 7 6 5 4 3 2 1 0m 2 50 1 60 4 16 3 10 2 05 1 40 5 4 3 2 1 0m 1000kg 1500kg 2000kg 2500kg 3100kg 62 5 60 50 4 0 10 40 30 20 0 5m NOTE For Australia see 5 SPEC...

Page 76: ...rie 6 E3 A mm 1200 B mm 2810 C mm 1192 C1 mm 1287 D mm 4791 D1 mm 4886 D2 mm 4165 E mm 5991 F mm 1935 F1 mm 1935 G mm 450 G1 mm 435 G2 mm 435 I mm 789 J mm 980 K mm 1260 L mm 45 N mm 1715 O mm 125 P2...

Page 77: ...9 annexe B N 254433 MLT735 1600kg 1300kg 2000kg 2500kg 1150kg 3500kg 3 5 0 0 k g 50 40 30 20 10 0 4 0m 0 5m 1 23 1 70 2 55 3 90 3 55 2 05 1 45 1 2 3 4 5 1 2 3 4 5 6 7 8 6 86 60 61 5 NOTE For Australia...

Page 78: ...ie 6 E3 A mm 1200 B mm 2810 C mm 1232 C1 mm 1288 D mm 4919 D1 mm 4975 D2 mm 4253 E mm 6119 F mm 1935 F1 mm 1935 G mm 450 G1 mm 435 G2 mm 435 I mm 877 J mm 980 K mm 1260 L mm 50 N mm 1715 O mm 125 P2 3...

Page 79: ...1 MLT741 1300Kg 3000Kg 4100Kg 2500Kg 2000Kg 1500Kg 1 86 1 25 3 93 2 78 8 7 6 5 4 3 2 1 0m 5 4 3 2 1 0m 6 84 2 22 1 40 3 49 0 5m 62 60 50 5 40 30 20 10 0 NOTE For Australia see 5 SPECIFIC AUSTRALIA Onl...

Page 80: ...C1 mm 1325 D mm 5093 D1 mm 5025 D2 mm 4267 E mm 6293 F mm 1935 F1 mm 1935 G mm 450 G1 mm 435 G2 mm 435 H H1 I mm 890 J mm 980 K mm 1260 L mm 45 N mm 1715 O mm 125 P2 38 P3 45 R mm 3570 S mm 7802 T mm...

Page 81: ...0kg 3500kg 2500kg 550kg 600kg 900kg N 256053 SUIVANT NORME EN 1459 annexe B 5 5 0 10 20 30 40 50 60 60 5 0m 1 2 3 4 5 6 7 6 80 1 43 2 75 5 60 3 30 4 80 7 06 9 60 1 0m 1 2 3 4 5 6 7 8 9 10 NOTE For Aus...

Page 82: ...22 34 11 7 23 37 39 38 MLT LSU 16 22 22 MLT 1035 L Turbo LSU S rie 6 E3 13 MLT 120 17 24 6 19 20 18 1 4 20 9 14 15 21 26 29 26 19 7 30 11 25 10 3 8 MLT LSU POWERSHIFT 28 18 27 2 39 23 26 39 5 26 7 16...

Page 83: ...3 22 LEVEL INDICATORS only for MLT 1035 L Turbo LSU S rie 6 E3 23 HEATER CONTROL 23 AIR CONDITIONING CONTROLS OPTION AIR CONDITIONING 24 CAB FILTER VENTILATORS 25 WINDSCREEN DEMISTER VENTS 26 HEATING...

Page 84: ...se the seat above the last notch stop the seat drops down to the lowest position SEAT BACK REST ANGLE ADJUSTMENT FIG C The back rest angle of the seat may be adjusted to suit the individual Press the...

Page 85: ...wings completely forwards LONGITUDINAL ADJUSTMENT FIG H Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position MAINTENANCE FIG...

Page 86: ...ll 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...

Page 87: ...USTMENT FIG I Adjust the locking lever until you reach the position required This then locks and the seat will not shift into another position SERVICING FIG J Dirt may adversely affect the correct fun...

Page 88: ...itions When activating the electrical system of the lift truck all the red and orange lamps and the panel s buzzer must light to indicate their good working order If one of the red lamps or the buzzer...

Page 89: ...the cause gear box oil level possible leak radiator etc RED BRAKING OIL LEVEL WARNING INDICATOR LIGHT If the lamp and the buzzer come on when the lift truck is running stop the I C engine immediately...

Page 90: ...may automatically slow before cut off Only make de aggravating hydraulic movements in the following order retract and raise the jib NOTE When the jib is retracted the function for cutting off AGGRAVA...

Page 91: ...off of AGGRAVATING hydraulic movements Hold down button D lamp D1 will light and simultaneously perform the necessary AGGRAVATING hydraulic movement with extreme care The combined use of these two act...

Page 92: ...SELF CLEANING FAN OPTION See 2 DESCRIPTION DESCRIPTION AND USE OF THE OPTIONS G STEERING SELECTION H TRANSMISSION CUT OFF The switch selects transmission cut off to the service brake pedal or the hydr...

Page 93: ...ended mandatory in Germany that you cut off all the hydraulic movements The lamp shows when it is in use S TILTING CORRECTOR MLT 1035 L Turbo LSU S rie 6 E3 See 2 DESCRIPTION 20 HYDRAULIC CONTROLS AND...

Page 94: ...off B Front windscreen wiper low speed setting C Front windscreen wiper high speed setting D Front windscreen wiper intermittent setting REAR WINDSCREEN WIPER E Rear windscreen wiper off F Rear winds...

Page 95: ...movement control unit 20A F16 Diagnostic socket 5A OPTION F17 OPTION CLEANFIX self cleaning fan 10A OPTION FINTRONIC anti start system 10A OPTION MODCOD MODCL Anti theft system 10A OPTION Rear hydrau...

Page 96: ...ccess to fuse F33 Hydraulic control unit 1A MLT LSU Remove the les casings 3 and 4 of the hydraulic control for access to relays K10 OPTION Jib suspension cut off K11 OPTION Jib suspension supply F32...

Page 97: ...rol unit 30A MLT 120 F42 Preheating I C engine 80A F43 Alternator 80A MLT Turbo Alternator 100A MLT 120 F47 OPTION Fuel decongealant 15A MLT Turbo K15 OPTION Diesel decongealant MLT Turbo K16 Engine p...

Page 98: ...io should be made carefully according to the nature of the work being carried out A poor choice may result in the extremely rapid rise of the transmission oil temperature through excessive slipping of...

Page 99: ...an the forward speed that could be obtained with the r 1 gear in 2nd instead of 3rd In general we would advise you to use the following gears according to the nature of the work being carried out ON T...

Page 100: ...e if he wishes to continue moving 19 STEERING SELECTION A GREEN WHEEL ALIGNMENT LAMPS These lamps come on to indicate the alignment of the wheels in relation to the lift truck Lamp A1 for the front wh...

Page 101: ...C forwards or backwards OPTION ELECTRIC PREDISPOSITION ON ELECTROVALVE JIB AT HEAD JIB Button D see 2 DESCRIPTION DESCRIPTION AND USE OF ELECTRICAL AND HYDRAULIC OPTIONS MLT 1035 L Turbo LSU S rie 6 E...

Page 102: ...R When the two marks are aligned the chassis is parallel with the front axle B SPIRIT LEVEL Enables the operator to check that the lift truck is in the horizontal position 23 HEATER CONTROL A HEATING...

Page 103: ...When this control is set to 0 the air conditioning system will not work NOTE Possible losses of water under the lift truck are due to condensate discharges caused by the drying effect of the installa...

Page 104: ...ll handle 1 to adjust the steering wheel Push in handle 1 to lock the steering wheel in the desired position 29 DOOR LOCK Two keys are provided with the lift truck to enable the cabin to be locked 30...

Page 105: ...2 73 33 DOCUMENT HOLDER Ensure that the operator s manual is in its place in the document holder 34 SUN VISOR 35 OVERHEAD LIGHT 36 HOOK 37 CIGAR LIGHTER For 12 V appliance and max amperage 10A 36 35...

Page 106: ...AGE Lift the armrest 1 to access the storage 39 CAR RADIO OPTION 40 INSIDE REAR VIEW MIRROR OPTION 41 TOOL BOX Except for MLT 1035 L Turbo LSU S rie 6 E3 42 NUMBER PLATE 43 NUMBER PLATE LIGHTING 44 RE...

Page 107: ...rse light E Left rear fog light F Right rear fog light G Right rear reverse light H Right tail light I Right rear stoplight J Right rear indicator 47 REVOLVING LIGHT STANDARD The revolving light pivot...

Page 108: ...truck has stopped the handbrake is on and the I C engine is switched off before performing the operation NOTE A rear view mirror allows the lift truck to approach more closely to the trailer ring A C...

Page 109: ...AND UNCOUPLING THE TRAILER To couple the trailer position the lift truck as close as possible to the trailer ring Put the handbrake on and switch off the I C engine ON THE FIXED PIN Remove pin 1 remo...

Page 110: ...pendently Raise the trailer hook by pressing the upper part of switch 2 and then lower the hook to verify that the lock pin is in proper contact with hook 1 lock G AUTOMATIC TRAILER HOOK OPTION COUPLI...

Page 111: ...2 79...

Page 112: ...VALVE 13 HYDRAULIC ATTACHMENT LOCKING 14 JIB HEAD ELECTROVALVE HYDRAULIC ATTACHMENT LOCKING 15 MACH2 QUICK RELEASE COUPLER ON ACCESSORY CIRCUIT 16 QUICK RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT HYD...

Page 113: ...o the preheating system is Effected with a cable that conforms to the installation standards in force and contains a protective earth conductor Contains an appropriate sectioning system Incorporate an...

Page 114: ...ANTI START SYSTEM OPERATION Switch on the lift truck and set the black key A next to the antenna B maximum 80 mm Wait a few seconds for red led C to go out before starting the lift truck NOTE You can...

Page 115: ...arting the lift truck make sure the potentiometer is set to 0 NOTE If the operator leaves the driver s cab the continuous hydraulic movement will automatically stop and must be restarted 9 BOOM SUSPEN...

Page 116: ...osition B indicator light on Hold button 2 down and button 3 forwards or backwards NOTE Set switch 1 to position A indicator light off controls the hydraulic attachment line see 2 DESCRIPTION 20 HYDRA...

Page 117: ...se two options on the attachment line allows two hydraulic functions to be used and locks the attachment onto the carriage To make connection of the rapid connectors easier decompress the hydraulic ci...

Page 118: ...ECTING A HYDRAULIC ATTACHMENT Lower lever 1 and disconnect the MACH2 quick release couplers from the attachment Lift up lever 1 16 MACH2 QUICK RELEASE COUPLER MACH2 ON ATTACHMENT CIRCUIT HYDRAULIC ATT...

Page 119: ...chains and slings shall have a minimum capacity of 3000 kg with a factor of safety against breakage of 4 LOAD CHARTS AND FUNCTION SHEETS MLT 731 The load charts are given for use without forks and wi...

Page 120: ...for use without forks and without attachments MLT7 TS AS 3T MLT7 TS AS 3T N 285324 MLT1035 TS AS 3 5T kg 3000KG 700KG 900KG 1200KG 1600KG 2000KG 2500KG 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1 0 1 0m 7 6 3 20...

Page 121: ...ULIC CONTROL PREDISPOSITION Enables the use of a hydraulic attachment at the rear of the lift truck e g a trailer with hydraulic tipping SINGLE EFFECT HYDRAULIC CONTROL L1 Press switch 1 downwards to...

Page 122: ...witch 2 upwards or downwards to supply the rear hydraulic attachment SINGLE EFFECT ATTACHMENT L2 Set switch 1 to position B indicator light on Press switch 2 downwards to supply the rear hydraulic att...

Page 123: ...DESCRIPTION TRAILER PIN AND HOOK F HYDRAULIC TRAILER HOOK SINGLE EFFECT ATTACHMENT L2 Set switch 1 to position B indicator light on Press switch 2 downwards to supply the rear hydraulic attachment HY...

Page 124: ...2 92...

Page 125: ...3 1 3 MAINTENANCE...

Page 126: ...3 2...

Page 127: ...ILTERS CARTRIDGES AND BELTS MLT 634 120 LSU S rie F E3 MLT 634 120 LSU POWERSHIFT S rie F E3 MLT 735 120 LSU S rie 6 E3 MLT 735 120 LSU POWERSHIFT S rie 6 E3 MLT 741 120 LSU S rie 6 E3 MLT 741 120 LSU...

Page 128: ...USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS YOU BENEFIT Through its network MANITOU provides the user with EXPERTISE Know how and competence The guarantee of high quality work Original rep...

Page 129: ...cing valve 104 BRAKE SYSTEM 01 Service brake and parking brake operation 02 Brake fluid level 105 LUBRICATION AND GREASING 106 JIB MANISCOPIC MANIACCESS ASSEMBLY 01 Beam and telescope s 02 Skid 03 Hin...

Page 130: ...R Part number 476954 Change 500 H ALTERNATOR BELT Part number 702974 DRY AIR FILTER CARTRIDGE Part number 563416 Clean 50 H Change 500 H FAN BELT Part number 257524 SAFETY DRY AIR FILTER CARTRIDGE Par...

Page 131: ...lean 50 H Change 250 H I C ENGINE I C ENGINE OIL FILTER Part number 476954 Change 500 H ALTERNATOR BELT Part number 702974 MLT 634 T MLT 735 T Part number 291467 MLT 1035 L T DRY AIR FILTER CARTRIDGE...

Page 132: ...0 H CAB VENTILATION FILTER WITH AIR CONDITIONING Part number 282619 Clean 50 H Change 250 H I C ENGINE I C ENGINE OIL FILTER Part number 476954 Change 500 H ALTERNATOR BELT Part number 291467 DRY AIR...

Page 133: ...3 9...

Page 134: ...UEL SPECIFICATION Use a high quality fuel to obtain optimal performance of the I C engine N590 diesel fuel type Auto C0 C1 C2 C3 C4 BS2869 Class A2 ASTM D975 91 Class 2 2DA US DF1 US DF2 US DFA JIS K2...

Page 135: ...ransmission 2 l 5 l 20 l 55 l 209 l 499237 720184 546330 546221 546220 REAR WHEELS REDUCERS PIVOTS REAR AXLE OSCILLATION MANITOU Grease BLACK multi purpose 400 g 1 kg 5 kg 545996 161590 499235 CHASSIS...

Page 136: ...or filter OPTION 3 33 R R Fuel tank 3 36 N Safety dry air filter cartridge 3 36 R I C engine silent blocks C I C engine rates C Valves clearances C C Cooling liquid 3 42 V Radiator C Water pump and th...

Page 137: ...ness and cables C Lights and signals C Warning indicators C Front headlights 3 45 A FRONT AXLE Front wheels reducers pivots 3 24 G G G C Front axle oscillation 3 24 G G G C Front axle differential oil...

Page 138: ...2 If necessary add cooling liquid see 3 MAINTENANCE LUBRICANTS AND FUEL Slowly turn the cap of the radiator 2 fig A2 up to the safety stop Allow the pressure and the steam to escape Press down and tur...

Page 139: ...r the drain plug 2 fig A4 1 and loosen it in two to three thread turns Allow the diesel fuel to flow out until it is free from impurities and water Retighten the drain plug while the diesel fuel is fl...

Page 140: ...necessary add oil see 3 MAINTENANCE E3 GEAR BOX OIL Check visually that there is no leakage or seepage of oil in the transmission A7 TYRES PRESSURE AND WHEEL NUTS TORQUE CHECK Check the condition of t...

Page 141: ...conds and an audible beep will be sounded TEST NOT OK Fault warning light comes on Exit test mode Go to stage 4 STAGE 4 The fault warning light remains permanently on until the error is repaired The f...

Page 142: ...ain gauge fault Jib angle sensor fault Telescope or attachment control fault Telescope retracted senor fault Computer earth output fault Aggravating hydraulic movement cut off disable fault Stability...

Page 143: ...3 19...

Page 144: ...cartridge seal surfaces with a damp clean lint free cloth and grease with a silicone lubricant MANITOU reference 479292 Check visually the outer condition of the air filter and its mounts Verify the c...

Page 145: ...ig B4 1 2 Lubricators of the carriage axle 2 lubricators fig B4 2 3 Lubricator of the tilt cylinder foot axle 1 lubricator fig B4 3 4 Lubricator of the tilt cylinder head axle 1 lubricator fig B4 4 5...

Page 146: ...re is no leakage in the tank and pipes Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank B6 BRAKE OIL LEVEL CHECK Place the lift truck on level ground Loo...

Page 147: ...fig B7 2 B8 CAB DOOR GREASE Clean and lubricate the points 1 4 lubricators fig B8 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease B9 CAB VENTILATION FILTER OPTION AI...

Page 148: ...ve the surplus of grease B12 REAR AXLE OSCILLATION GREASE Clean and lubricate the points 1 2 lubricators fig B12 with grease see 3 MAINTENANCE LUBRICANTS AND FUEL and remove the surplus of grease B13...

Page 149: ...3 25...

Page 150: ...one and a half turns having allowed the I C engine to idle for 30 minutes C2 ALTERNATOR CRANKSHAFT BELT TENSION CHECK ADJUST MLT 634 Turbo LSU S rie F E3 MLT 731 Turbo S rie F E3 MLT 735 Turbo LSU S r...

Page 151: ...t adjustments if necessary Untighten screws 4 fig C2 3 by two to three thread turns Swivel the alternator assembly so as to obtain the belt tension required Retighten screws 4 fig C2 3 tightening torq...

Page 152: ...pin with a minimum force of 3500 daN The wheels of the lift truck must not rotate Carry out adjustments if necessary Progressively tighten the end piece of the lever 1 fig C5 and recheck the braking R...

Page 153: ...N m Repeat this operation for the rear axle differential C9 FRONT AND REAR WHEELS REDUCERS OIL LEVEL CHECK Place the lift truck on level ground with the I C engine stopped Check the level on each fron...

Page 154: ...C engine oil filter 7 fig D1 2 discard the filter and the filter seal Clean the filter bracket with a clean lint free cloth Lightly grease the new oil filter seal and refit the oil filter see 3 MAINT...

Page 155: ...ased if the lift pump is on Open the I C engine bonnet Carefully clean the outside of the filter and its holder to prevent dust from getting into the system Place a container under the pre filter and...

Page 156: ...it with a quarter turn Close drain plug 3 fig D5 2 and remove the container Before starting the I C engine leave the ignition on for three minutes on the lift truck to give the lift pump time to relea...

Page 157: ...D7 1 Unscrew and discard gear box oil filter 2 fig D7 2 Carefully clean the filter head with a clean lint free cloth Slightly lubricate the new seal and fit the seal on the filter Fill up the new gear...

Page 158: ...GES AND BELTS Make sure that the cartridge is correctly positioned and refit the body of the filter Tighten the body of the filter by hand pressure only and lock the body of the filter in place by a q...

Page 159: ...g D11 in order to ensure proper emptying Refit and tighten drain plugs 1 fig D11 tightening torque 34 to 49 N m Fill up with oil see 3 MAINTENANCE LUBRICANTS AND FUEL through filler port 3 fig D11 The...

Page 160: ...fit and tighten the drain plug tightening torque 29 to 39 N m Fill the fuel tank with clean diesel filtered through the filler port Refit the filling cap If necessary bleed the fuel circuit see 3 MAIN...

Page 161: ...manner CLEANING THE STRAINER Remove cover 2 fig E3 2 and set aside the O ring joint and sealing washer Allow the rest of the oil to drain away Remove and clean the strainer using a compressed air jet...

Page 162: ...d set aside the O ring joint and sealing washer Allow the rest of the oil to drain away Remove and clean the strainer using a compressed air jet Clean the magnetic section on the plate Refit the assem...

Page 163: ...K CLEAN E8 FILTER CAP FOR HYDRAULIC OIL TANK CHANGE E9 DISTRIBUTOR CONTROL HEAD FILTER CHANGE Place the lift truck on level ground with the I C engine stopped and telescope boom retracted and lowered...

Page 164: ...CE FILTERS CARTRIDGES AND BELTS HYDRAULIC CIRCUIT DECONTAMINATION MLT 731 Turbo S rie F E3 Let the I C engine run accelerator pedal at halfway travel for 5 minutes without using anything on the lift t...

Page 165: ...is defective fixing locking cuts tears etc Repair or replace the seat belt immediately E11 FRONT AND REAR WHEELS REDUCERS OIL DRAIN Place the lift truck on level ground with the I C engine stopped and...

Page 166: ...le 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...

Page 167: ...ot open the circuit under any circumstances as this would cause the coolant to be lost The cooling circuit contains a gas which can be dangerous under certain conditions This gas coolant R 134a is col...

Page 168: ...ble leaks in the low pressure circuit If in doubt contact your dealer G1 FUEL SYSTEM BLEED MLT 634 120 LSU S rie F E3 MLT 634 120 LSU POWERSHIFT S rie F E3 MLT 735 120 LSU S rie 6 E3 MLT 735 120 LSU P...

Page 169: ...h the jack Tighten the wheel nuts with a torque wrench see 3 MAINTENANCE A DAILY OR EVERY 10 HOURS SERVICE for tightening torque NOTE There is an OPTIONAL wheel toolkit and anti puncture kit G3 FRONT...

Page 170: ...sufficient for transporting the lift truck Check also the pressure on the contact surface allowable for the platform in connection with the lift truck For lift trucks equipped with a turbo charged I...

Page 171: ...button Without attachments Carriage tilted fully backward Jib fully retracted and in the down position a few centimetres off the ground Short press the test button STAGE 3 2 1 First green led continu...

Page 172: ...3 48...

Page 173: ...4 1 4 OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE...

Page 174: ...4 2...

Page 175: ...4 3 TABLE OF CONTENTS INTRODUCTION 4 5 PICKING UP THE ATTACHMENTS 4 6 TECHNICAL SPECIFICATIONS OF ATTACHMENTS 4 8 ATTACHMENT SHIELDS 4 18...

Page 176: ...4 4...

Page 177: ...SAFETY INSTRUCTIONS LOAD HANDLING INSTRUCTIONS H TAKING UP AND SETTING DOWN A SUSPENDED LOAD Only attachments approved by MANITOU are to be used on our lift trucks see 4 ADAPTABLE ATTACHMENTS IN OPTIO...

Page 178: ...fig B Bring the carriage under the locking tube of the attachment slightly lift the boom incline the carriage backwards in order to position the attachment fig C Lift the attachment off the ground to...

Page 179: ...Take the locking pin and the clip on the bracket fig A and lock the attachment fig D Do not forget to refit the clip Stop the I C engine and keep the ignition on the lift truck Remove the pressure of...

Page 180: ...MBER 751545 751546 Rated capacity 4500 kg 4500 kg Side shift 2x100 mm 2x100 mm Width 1040 mm 1300 mm Weight 410 kg 450 kg FLOATING FORK CARRIAGE MLT 741 Turbo LSU S rie 6 E3 MLT 741 120 LSU S rie 6 E3...

Page 181: ...25x50x1200 mm Weight 71 kg FLOATING FORK MLT 634 Turbo LSU S rie F E3 MLT 634 120 LSU S rie F E3 MLT 634 120 LSU POWERSHIFT S rie F E3 MLT 731 Turbo S rie F E3 MLT 735 Turbo LSU S rie 6 E3 MLT 735 120...

Page 182: ...U S rie F E3 MLT 634 120 LSU POWERSHIFT S rie F E3 MLT 731 Turbo S rie F E3 MLT 735 Turbo LSU S rie 6 E3 MLT 735 120 LSU S rie 6 E3 MLT 735 120 LSU POWERSHIFT S rie 6 E3 MLT 1035 L Turbo LSU S rie 6 E...

Page 183: ...634 120 LSU S rie F E3 MLT 634 120 LSU POWERSHIFT S rie F E3 MLT 731 Turbo S rie F E3 MLT 735 Turbo LSU S rie 6 E3 MLT 735 120 LSU S rie 6 E3 MLT 735 120 LSU POWERSHIFT S rie 6 E3 MLT 1035 L Turbo LSU...

Page 184: ...g GRAIN BUCKET REVERSING AND DISMOUNTABLE CUTTING EDGE Except for MLT 1035 L Turbo LSU S rie 6 E3 CBA 1500 L2450 LDR S3 CBA 2000 L2450 LDR S3 CBA 2500 L2450 LDR S3 PART NUMBER 570548 570552 570554 Rat...

Page 185: ...50 LDR S5 PART NUMBER 752195 Rated capacity 1 03 m3 Width 2450 mm Grab 11 Weight 790 kg BUCKET 4X1 CB4x1 700 L1950 CB4x1 850 L2300 CB4x1 900 L2450 PART NUMBER 751402 751401 751465 Rated capacity 700 l...

Page 186: ...653016 653018 653020 Rated capacity 1 m3 1 2 m3 1 26 m3 Width 1950 mm 2300 mm 2450 mm Grab 7 8 8 Weight 678 kg 740 kg 767 kg GRAB BUCKET GRAB CLOSED CBG 2300 GF S4 PART NUMBER 653008 Rated capacity 1...

Page 187: ...ADAPTABLE ON FORKS GL 300 S2 GL 400 S2 PART NUMBER 174371 174372 Rated capacity 300 l 725 kg 400 l 969 kg Weight 150 kg 166 kg HYDRAULIC KIT TO OPEN THE SPOUT PART NUMBER 653750 SPOUT BUCKET ADAPTABLE...

Page 188: ...FFGR 30 MT 2100 S5 FFGR 30 MT 2400 S5 FFGR 30 MT 2100 DR PART NUMBER 556843 570594 570728 Rated capacity 1700 Kg 1700 Kg 1700 Kg Width 2100 mm 2400 mm 2100 mm Finger 10 12 10 round finger Grab 7 8 7 W...

Page 189: ...eight 210 kg CRANE JIB WITH WINCH PT 600 MT S6 PART NUMBER 708538 Rated capacity 600 kg Weight 288 kg 15 15 MULTI DIRECTIONAL CRANE JIB PO 600 L2500 S2 PO 1000 L1500 S2 PO 2000 L1000 S2 PART NUMBER 75...

Page 190: ...dth of the bucket PART NUMBER 206734 206732 206730 Width 1375 mm 1500 mm 1650 mm PART NUMBER 235854 206728 206726 Width 1850 mm 1950 mm 2000 mm PART NUMBER 223771 223773 206724 Width 2050 mm 2100 mm 2...

Page 191: ...5 1 5 SPECIFIC AUSTRALIA See also the operator s manual supplement 647065 AU...

Page 192: ...5 2...

Page 193: ...ndard used AS 1418 19 36km h Maxi 10m s Ground conditions solid surface 0 3m Maxi 3100kg MAXI 12km h Maxi 3 33m s kg 15 maxi kg 10 maxi kg 5 maxi kg 5 maxi MLT735 N 283823 0 6m Standard used AS 1418 1...

Page 194: ...ed AS 1418 19 36km h Maxi 10m s Ground conditions solid surface 0 3m Maxi 4100kg MAXI 12km h Maxi 3 33m s kg 15 maxi kg 10 maxi kg 5 maxi kg 5 maxi Standard used AS 1418 19 MLT1035LT 900kg 600kg 550kg...

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