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  647732 US (31/10/2019) MT 625 H 75K ST5 S1 MT 625 H 75K COMFORT ST5 S1 OPERATOR’S MANUAL (ORIGINAL INSTRUCTIONS)
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  — Descriptions and figures are non binding. — MANITOU reserves the right to change its models and their equipment without being required to update this manual. — The MANITOU network, consisting exclusively of qualified professionals, is at your disposal to answer all your questions.
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  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…
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  1 — OPERATING AND SAFETY INSTRUCTIONS 2 — DESCRIPTION 3 — MAINTENANCE 4 — OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE…
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  1 —  OPERATING AND SAFETY INSTRUCTIONS 1 — 1…
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• Page 8: Table Of Contents

  1 —  OPERATING AND SAFETY INSTRUCTIONS INSTRUCTIONS TO THE COMPANY MANAGER THE SITE THE OPERATOR THE LIFT TRUCK A — SUITABILITY OF THE LIFT TRUCK FOR THE JOB ……….. . . 1-6 B — ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS .

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  LIFT TRUCK MAINTENANCE INSTRUCTIONS 1-30 GENERAL INSTRUCTIONS 1-30 PLACING THE BOOM SAFETY WEDGE 1-30 FITTING THE WEDGE …………..1-30 REMOVING THE WEDGE .

• Page 10: Instructions To The Company Manager

  A — SUITABILITY OF THE LIFT TRUCK FOR THE JOB — MANITOU 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 1.25 and a DYNAMIC TEST COEFFICIENT OF 1, as specified in harmonised standard EN 1459 for mast trucks.

• Page 11: C — Modification Of The Lift Truck

  Inflate the tyres in accordance with recommendations. • The seat is an essential way of reducing the vibrations transmitted to the operator. In the event of seat replacement, please contact MANITOU. • Ensure that the operators adapt their operating speed to suit the conditions on site.

• Page 12: Instructions

  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 or stickers which are no longer legible or are damaged, must be replaced immediately. MAINTENANCE — Maintenance or repairs other than those detailed in Part: 3 — MAINTENANCE must be carried out by qualified personnel (consult your dealer) and in the necessary safety conditions to preserve the health of the operator and any third party.

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• Page 14: Instructions For The Operator

  — At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself when you use it. IMPORTANT In order to reduce or prevent any danger with a MANITOU-approved attachment, follow the instructions in Paragraph: 4 — ADAPTABLE ATTACHMENTS AS OPTIONS ON THE RANGE: INTRODUCTION. GENERAL INSTRUCTIONS A — OPERATOR’S MANUAL…

• Page 15: E — Modification Of The Lift Truck

  Right-hand column • With a PLATFORM-fitted lift truck, people can only be lifted using platforms designed by MANITOU for the purpose. — MANITOU sells equipment specifically designed for lifting people (OPTION PLATFORM lift truck, contact your dealer). 1 — 11…

• Page 16: Operating Instructions Unladen And Laden

  OPERATING INSTRUCTIONS UNLADEN AND LADEN A — BEFORE STARTING THE LIFT TRUCK — Perform the daily maintenance operations (  3 — MAINTENANCE). — Make sure that the driver’s cab is clean, particularly the floor and floor mat. Check that no movable object may hinder the operation of the lift truck.

• Page 17: D — Visibility

  — Take into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passageway. — Never move onto a loading platform without having first checked: • That it is suitably positioned and made fast. •…

• Page 18: E — Starting The Lift Truck

  E — STARTING THE LIFT TRUCK SAFETY INSTRUCTIONS IMPORTANT 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 hauling it. Such an operation may cause severe damage to the transmission. If necessary, towing requires the transmission to be put in neutral (  3 — MAINTENANCE).

• Page 19: G — Stopping The Lift Truck

  — Never drive on the edge of a ditch or steep slope. — It is dangerous to use two lift trucks simultaneously to handle heavy or bulky loads, since this operation requires particular precautions to be taken. It must only be used exceptionally and after risk analysis. — The ignition switch has an emergency stop mechanism in case of an operating anomaly occurring in the case of lift trucks not fitted with a punch-operated cut-out.

• Page 20: H — Driving The Lift Truck On The Public Highway

  H — DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY (or see current legislation in other countries) FRENCH ROAD TRAFFIC RULES — The driving of non EC type-approved tractors on the public highway is subject to the provisions of the highway code relating to special machines, defined in article R311-1 of the highway code, in category B of the Equipment Order of 20 November 1969 that determines the procedures applicable to special machines.

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• Page 22: Instructions For Handling A Load

  INSTRUCTIONS FOR HANDLING A LOAD A — CHOICE OF ATTACHMENTS — Only attachments approved by MANITOU can be used on its lift trucks. — Make sure the attachment is suitable for the work to be done (  4 — ADAPTABLE ATTACHMENTS AS OPTIONS ON THE RANGE).

• Page 23: D — Transverse Attitude Of The Lift Truck

  D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK Depending on the model of lift truck The transverse attitude is the transverse slope of the chassis with respect to the horizontal. Raising the boom reduces the lift truck’s lateral stability. The transverse attitude must be set with the boom in down position as follows: 1 — …

• Page 24: F —  Picking Up And Putting Down A High Load On Tyres

  F —  PICKING UP AND PUTTING DOWN A HIGH LOAD ON TYRES IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:…

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  PUTTING DOWN A HIGH LOAD ON TYRES — Approach the load in the transport position in front of the stack (fig. F6). — Apply the parking brake and place the forward/reverse selector in neutral. — Raise and extend the boom (1) (2) until the load is above the stack, while monitoring the longitudinal stability indicator (  INSTRUCTIONS FOR HANDLING A LOAD: C — LONGITUDINAL STABILITY INDICATOR).

• Page 26: G —  Picking Up And Putting Down A High Load On Stabilisers

  G —  PICKING UP AND PUTTING DOWN A HIGH LOAD ON STABILISERS Depending on the model of lift truck IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:…

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  TAKING UP A HIGH LOAD ON STABILISERS — Ensure that the forks will easily pass under the load. — Check the position of the lift truck with respect to the load and make a test run, if necessary, without taking the load. — Raise and extend the boom (1) (2) until the forks are at the level of the load (fig. G5).

• Page 28: H — Picking Up And Putting Down A Suspended Load

  H — PICKING UP AND PUTTING DOWN A SUSPENDED LOAD IMPORTANT Failure to follow the above instructions may lead the lift truck to loose stability and overturn. MUST be used with a lift truck equipped with an operational hydraulic movement cut-out device. CONDITIONS OF USE — The length of the sling or the chain shall be as short as possible to limit swinging of the load.

• Page 29: Instructions For Use As A Loader

  INSTRUCTIONS FOR USE AS A LOADER For agricultural-type lift trucks (MLT range) A — LOADING IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:…

• Page 30: Platform Operating Instructions

  — MANITOU has ensured that this platform is suitable for use under the normal operating conditions provided in this operator’s manual, with a STATIC test coefficient of 1.25 and a DYNAMIC test coefficient of 1.1 as specified in harmonised European standard EN 280:2013+A1 for «mobile elevating work platforms».

• Page 31: E — Environment

  E — ENVIRONMENT IMPORTANT It is forbidden to use the platform close to electricity cables. Maintain the specified safe distances. RATED VOLTAGE SAFETY DISTANCE (METRES) 50 < U < 1,000 2,30 M 1,000 < U < 30,000 2,50 M 30000 < U < 45000 2,60 M 45000 <…

• Page 32: Instructions For Using The Radio-Control

  INSTRUCTIONS FOR USING THE RADIO-CONTROL For lift trucks with RC radio control HOW TO USE THE RADIO-CONTROL SAFETY INSTRUCTIONS — This radio-control consists of electronic and mechanical safety elements. It cannot receive commands from another transmitter because the internal encoding is unique to each radio-control. IMPORTANT If it is used improperly or incorrectly, there is a risk of danger to: — The physical and mental health of the user or others.
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  LIFT TRUCK MAINTENANCE INSTRUCTIONS GENERAL INSTRUCTIONS — Ensure the area is sufficiently ventilated before starting the lift truck. — Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie back and protect your hair, if necessary. — Stop the engine and remove the ignition key, when an intervention is necessary.
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  LUBRICANT AND FUEL LEVELS — Use the recommended lubricants (never use contaminated lubricants). — Do not fill the fuel tank when the 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. — Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
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  IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an extended period. IMPORTANT Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership. This period of long-term stoppage must not exceed 12 months.
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  BRINGING THE LIFT TRUCK BACK INTO SERVICE — Remove the waterproof adhesive tape from all the holes. — Refit and reconnect the battery. — Remove the protection from the cylinder rods. — Perform the daily maintenance operations (  3 — MAINTENANCE). — Put the handbrake on and remove the axle stands. — Drain and clean the fuel tank (  3 — MAINTENANCE).
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  • Glass items can be removed and collected for processing by glaziers. ENVIRONMENTAL PROTECTION By entrusting the maintenance of your lift truck to the MANITOU network, the risk of pollution is limited and the contribution to environmental protection contribution is made.
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  2 —  DESCRIPTION 2 — 1…
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  2 —  DESCRIPTION SAFETY PLATES AND STICKERS IDENTIFICATION OF THE LIFT TRUCK CHARACTERISTICS 2-10 TYRES 2-12 DIMENSIONS AND LOAD CHARTS 2-14 VISIBILITY 2-16 INSTRUMENTS AND CONTROLS 2-18 TOWING DEVICE 2-40 DESCRIPTION AND USE OF THE OPTIONS 2-42 2 — 3…
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  SAFETY PLATES AND STICKERS IMPORTANT Clean all stickers and safety plates so that they are legible. Any safety plates and stickers which are illegible or damaged must be replaced. Check that stickers and safety plates are present after replacing any spare parts. EXTERNAL PLATES AND STICKERS REF.
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  STICKERS AND PLATES UNDER THE ENGINE HOOD REF. PART NO. DESCRIPTION 244130 — Preheat rod (OPTION) 52506370 — Fuses 259398 — Water/diesel separator 52515083 — Anti-freeze 234797 MT 625 H COMFORT 75K ST5 — Air conditioning (OPTION) 52589959 — Rotating fan safety 110 -120 V ;…
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  PLATES AND STICKERS IN THE CAB REF. PART NO. DESCRIPTION 52611811 — Lubrication sheet 52509004 — Manipulator function sheet 241621 — Safety instruction sheet 52504055 MT 625 H COMFORT 75K ST5 — Fuse sheet 52515060 MT 625 H  — Fuse sheet 75K S 52533603 MT 625 H COMFORT 75K ST5 — Relay sheet…
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  75% handling cycle Maxi Kg CO2/hour 1,00m Maxi 3m Mini Tests carried out by Manitou following the EP-695 internal procedure as approved by DANGER Keep machine at least 25 feet from overhead power lines. Failure to comply may result…
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  IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement in our products, our range of lift trucks may undergo certain modifications, without any obligation for us to advise our customers. When you order parts, or when you require any technical information, always specify: NOTE: For the owner’s convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time of the delivery of the lift truck.
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  FRONT AXLE Type Serial number MANITOU part No. REAR AXLE Type Serial number MANITOU part No. «Constructeur» Manufacturer «Type Cabine» Cabin type «Numéro de série» Serial number BOOM MANITOU Part No. Date of manufacture and manufacturer FRAME Serial number/Product identification number ATTACHMENT MANUFACTURER’S PLATE «MODELE»…
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  CHARACTERISTICS ENGINE Type KUBOTA V3307 Fuel Diesel 4 in line Number of cylinders Supercharged Suction Injection system Direct Ignition sequence 1.3.4.2 Capacity cu.in (cm3) 203.27 (3331) 3.7 x 4.72 (94 x 120) Bore and stroke in (mm) 17,5 Compression ratio Nominal speed laden 2600 Min.
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  BRAKE SYSTEM Service brake Non-servo hydraulic brake — Type of brake Oil-immersed multi-disc brake — Type of control By foot on front axle Parking brake Low pressure hydraulic brake — Type of brake Oil-immersed multi-disc brake — Type of control Switch-operated electro-hydraulic HYDRAULIC CIRCUIT Hydraulic pump…
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  TYRES LOAD PER TYRE FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN PRESSURE 12-16,5 12PR 81,2 SKS 532 ALLIANCE 12-16,5 12PR 1100 2425 3250 7165 1250 2756 81,2 HAULER SKS 305/70 R16,5  MICHELIN 69,6 137A8 BIBSTEEL ALL TERRAIN GROUND CONTACT PRESSURE GROUND CONTACT AREA PRESSURE LOAD HARD GROUND…
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  DIMENSIONS AND LOAD CHARTS ft-in (mm) 3-11,2 (1200) ft-in (mm) 7-6,6 (2300) ft-in (mm) (991) ft-in (mm) 3-0,5 (928) ft-in (mm) 12-9,3 (3894) ft-in (mm) 12-6,8 (3831) ft-in (mm) 10-8,9 (3275) ft-in (mm) 16-8,6 (5094) ft-in (mm) 4-10,7 (1492) ft-in (mm) 4-10,7 (1492) (mm) 9,45…
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  MT625 68° 19ft1in 60° 50° 40° 30° 20° 10° 0° -2° 24in 0 Feet 11ft0in 8ft4in 5ft3in 3ft7in 9ft4in 6ft11in 4ft3in 0 Meters According norme ANSI/ITSDF B56-6-2011 2 — 15…
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  VISIBILITY We use European standard EN15830 relating to operator visibility. — Adhere to the instructions for optimising operator visibility in the immediate vicinity (  1 — OPERATING AND SAFETY INSTRUCTIONS: INSTRUCTIONS TO THE OPERATOR: DRIVING INSTRUCTIONS UNLADEN AND LADEN: D — VISIBILITY). DESCRIPTION AND ADJUSTMENT OF REAR-VIEW MIRRORS 1 — LEFT REAR-VIEW MIRROR 2 — MAIN RIGHT REAR-VIEW MIRROR 3 — CENTRAL RIGHT REAR-VIEW MIRROR…
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  INSTRUMENTS AND CONTROLS DESCRIPTION NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are as seen by an observer occupying the driver’s seat and looking straight ahead. 1 — DRIVER’S CAB ACCESS ………………… . . 2-20 2 — SEAT BELT .
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  MT 625 H COMFORT 75K ST5 MT 625 H 75K ST5 2 — 19…

• Page 58: Driver’s Cab Access

  1 — DRIVER’S CAB ACCESS Use the contact points 1 to get into or out of the driver’s cab. • Mounting at the front. • Descending at the rear. 2 — SEAT BELT IMPORTANT Under no circumstances must the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the safety belt.

• Page 59: Driver’s Seat

  3 — DRIVER’S SEAT DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS. WEIGHT ADJUSTMENT Adjust the weight when the driver is sitting on the seat. — Pull the weight adjustment lever 1 fully out. — Move the weight adjustment lever 1 upwards to increase the weight or downwards to reduce it.

• Page 60: Ignition Switch

  4 — IGNITION SWITCH This switch has 5 positions: • P — Not used. • O — Ignition cut-off and engine stopped. • I — Ignition + preheat. • II — Not used. • III — Starting and return to position I as soon as the key is released. 5 — EMERGENCY STOP In the event of danger, it enables the engine to be shut down, thereby cutting-off all hydraulic movements.

• Page 61: Man-Machine Interface (Mmi)

  8 — MAN-MACHINE INTERFACE (MMI) • A — INSTRUMENT CONTROL PANEL • B — SCREEN DISPLAYS A — INSTRUMENT CONTROL PANEL IMPORTANT A permanently lit or flashing warning lamp, with the engine running, is the sign of an operating fault. The lighting of some lamps may be accompanied by an audible signal. Do not ignore this warning, consult your dealer without delay.

• Page 62: Switches

  TRANSMISSION OIL TEMPERATURE WARNING INDICATOR LAMP The lamp and the buzzer come on when the transmission oil temperature is abnormally high. Stop the lift truck and seek the cause of this overheating. ENGINE FAULT INDICATOR LAMP If the indicator lamp comes on or flashes while the lift truck is in operation, a diagnostic fault has been detected. The lift truck will operate in reduced mode.

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  PARKING BRAKE FAULT INDICATOR LAMP The indicator lamp comes on when the parking brake is applied (  SWITCHES). BRAKING OIL LEVEL WARNING INDICATOR LAMP If the lamp comes on when the lift truck is running, stop the engine immediately and check the brake fluid level. In the event of an abnormal drop in the level, consult your dealer.
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  Rev counter Partial hour meter SETTING THE TIME — Display clock screen. — Press the button for 2 seconds, choose the «24 hour» or «12 hour am/pm» clock with the button and confirm — Set the hours with the button and confirm — Set the minutes with the button and confirm RESETTING THE PARTIAL HOUR METER…
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  9 — SWITCHES NOTE:  The location of the switches may vary depending on the options. HAZARD WARNING LIGHTS REAR FOG LIGHT (OPTION) ROTATING BEACON LIGHT FRONT AND REAR WORKING LIGHTS (OPTION) REAR WINDOW DEFROSTER (OPTION) MT 625 H COMFORT 75K ST5 HYDRAULIC MOVEMENT NEUTRALISATION When driving on the road, it is highly recommended (mandatory in Germany) that you cut-off all the hydraulic movements. The indicator lamp shows when it is in use.

• Page 66: Armrest And Storage

  PARKING BRAKE To connect the parking brake, press the bottom of the switch. The indicator lamp indicates when it is in use. To disconnect the parking brake, press the top of the switch. ATTACHMENT HYDRAULIC LOCKING (OPTION) BOOM HEAD ELECTROVALVE (OPTION) MT 625 H COMFORT 75K ST5 BOOOM HEAD ELECTROVALVE + ATTACHMENT HYDRAULIC LOCKING (OPTION)

• Page 67: Fuses And Relays

  12 — FUSES AND RELAYS A sticker on the inside of the access panel provides a quick indication of the use of the fuse plate’s components described below. — Remove the access panel 1 to access the fuses and relays. Replace a used fuse with a new fuse of the same quality and capacity.

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  2A Control instrument module power supply. * * MT 625 H 75K ST5 Not used. ** 2A Battery power supply (+). * Not used. ** Free. * Not used. ** Free. * Not used. ** 2A Control instrument module power supply. ** 2A Battery power supply (+).

• Page 69: Cigarette Lighter

  13 — CIGARETTE LIGHTER For 12 V appliance and max. amperage 15A. 14 — LIGHTING, HORN AND INDICATOR SWITCH The switch controls the visual and sound alarms. • A — All lights are off, the indicator lights do not flash. • B — The right hand indicator lights flash. •…

• Page 70: Hydraulic Controls

  17 — HYDRAULIC CONTROLS IMPORTANT Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve. In the event of suspected malfunction, contact your dealer. ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID. Use the hydraulic controls gently without jerking, to avoid incidents caused by shaking the lift truck. NOTE: When driving on the road, it is highly recommended (mandatory in Germany) that all the hydraulic movements are cut off (  SWITCHES).

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  ADJUSTMENT OF ATTACHMENT HYDRAULIC FLOW RATE — Switch on lift truck ignition. — Select the attachment circuit hydraulic flow screen with the scroll button . In turn the screen displays the hydraulic flow stored in the memory of circuit B (without «-» sign) and of circuit A (with «-» sign). — Press the button for two seconds, the screen will appear on the…

• Page 72: Accelerator Pedal

  18 — ACCELERATOR PEDAL 19 — SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF The pedal acts on the front wheels by means of a hydraulic brake system to slow down and stop the lift truck. During free travel it enables the transmission to be cut off progressively thus allowing a gradual approach (delicate handling) with all the engine power.

• Page 73: Steering Selection

  21 — STEERING SELECTION A — GREEN WHEEL ALIGNMENT INDICATOR LAMPS IMPORTANT Before selecting one of the three steering possibilities, align the 4 wheels in relation to the lift truck axis. Never change the steering mode whilst driving. These green indicator lamps come on to indicate the alignment of the wheels in relation to the lift truck.

• Page 74: Heater Control

  22 — HEATER CONTROL A — FAN CONTROL This 3-speed control allows the air to be ventilated through the air vents. B — TEMPERATURE CONTROL Adjusts the temperature inside the cab. • B1 — The fan pumps in the air at ambient temperature. • B2 — The fan pumps in warm air. The intermediate positions allow the temperature to be adjusted.

• Page 75: Heating Vents

  24 — HEATING VENTS These swivelling heating vents, which can be shut off, allow you to direct and adjust the flow inside the cab. 25 — DEMIST VENTS These vents allow the windscreen and side windows to be demisted. For optimum efficiency, close the heating vents. 26 — LEVEL INDICATOR Enables the operator to check that the lift truck is in the horizontal position.

• Page 76: Front Headlights

  34 — FRONT HEADLIGHTS • A — Left front indicator light. • B — Left front dipped beam headlight. • C — Left front main beam. • D — Left front side light. • E — Right front indicator light. • F — Right front dipped beam headlight. • G — Right front main beam headlight. •…

• Page 77: Boom Safety Wedge

  40 — BOOM SAFETY WEDGE IMPORTANT Only use the wedge supplied with the lift truck. The lift truck is equipped with a boom safety wedge which must be installed on the rod of the lifting cylinder when working beneath the boom (  1 — OPERATING AND SAFETY INSTRUCTIONS).

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  TOWING DEVICE 1 — TOWING PIN ………………….. . 2-41 2 — REAR ELECTRIC SOCKET (DEPENDING ON ASSEMBLY) .
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  1 — TOWING PIN IMPORTANT Be careful not to get your fingers caught or crushed during this operation. Do not forget to put the cotter pin back in place. When uncoupling, make sure that the trailer is supported independently. COUPLING AND UNCOUPLING THE TRAILER — To couple the trailer, position the lift truck as close as possible to the trailer ring.
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  DESCRIPTION AND USE OF THE OPTIONS 1 — PREHEAT ROD………………….. 2-42 2 — MODCOD ANTI-THEFT SYSTEM .

• Page 81: Modcle Anti-Start System

  3 — MODCLE ANTI-START SYSTEM OPERATION — Switch on lift truck ignition, red LED 1 will flash. — Apply key 2 to its base 3, and withdraw it as soon as the system emits a continuous sound signal, and LED 1 turns green. — Start the lift truck within the next 20 seconds; otherwise the anti-theft system will be reactivated and red LED 1 will flash.

• Page 82: Waterproof Document Holder

  7 — WATERPROOF DOCUMENT HOLDER 8 — WINDSCREEN GRILL DESCRIPTION The windscreen grill provides additional protection for the operator from any external elements spattered on the windscreen. This grill must be removable from inside the cab to enable an emergency exit. EMERGENCY EXIT — After breaking the windscreen with the emergency hammer, push (with force) on the windscreen grill at A to remove it.

• Page 83: Boom Head Electrovalve

  10 — BOOM HEAD ELECTROVALVE MT 625 H COMFORT 75K ST5 Enables use of two hydraulic functions on the attachment circuit. IMPORTANT To facilitate connection of the quick couplers, decompress the hydraulic circuit by pressing button 1 on the electrovalve. ATTACHMENT LINE A1/B1 CONTROL — Put switch 1 to position A (indicator lamp off ).

• Page 84: Attachment Hydraulic Control Forced Operation

  12 — ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION MT 625 H COMFORT 75K ST5 IMPORTANT This OPTION must only be used with an attachment requiring continuous hydraulic movement, such as a brush, feeder bucket, mixer, spray etc. It is strictly forbidden for use in handling operations and all other applications (winch, crane jib, crane jib with winch, hook, etc.).

• Page 85: Lifting Ring On Single Carriage

  15 — LIFTING RING ON SINGLE CARRIAGE CONDITIONS OF USE IMPORTANT Follow the instructions given in your lift truck’s instruction manual (  1 — OPERATING AND SAFETY INSTRUCTIONS FOR HANDLING LOADS), and in addition those given below. — The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS, but the angle of inclination of the carriage must be same as when the forks are used in the horizontal position.
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  3 — MAINTENANCE 3 — 1…
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  3 — MAINTENANCE ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FORKLIFT TRUCK MAINTENANCE DAILY AND WEEKLY MAINTENANCE MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE PERIODIC SERVICE OCCASIONAL MAINTENANCE AND OPERATION FILTER ELEMENTS AND BELTS LUBRICANTS AND FUEL 3-10 Ü  10H — DAILY SERVICE OR EVERY 10 HOURS OF SERVICE 3-12 Ü…
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  • Efficient help with diagnosis. • Improvements due to experience feedback. • Operator training. • Only the MANITOU network has detailed knowledge of the design of the lift truck and therefore the best technical ability to provide maintenance. IMPORTANT ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
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  This schedule enables the operator to keep up with the periodic service of the lift truck by notifying the total number of hours of operation and the date of the service performed by the professional approved by the MANITOU network.
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  MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE FIRST 500 HOURS BEFORE THE FIRST 6 MONTHS — If the lift truck has reached the first 500 hours of service before the first 6 months have expired, perform both the mandatory ÜŒ service and periodic 500 H service (  …
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  PERIODIC SERVICE MAINTENANCE SCHEDULE Þ Þ 500 H 1000 H 1500 H 2000 H Ü WHEN DUE FIRST 6 MONTHS FIRST 500 HOURS or 1 YEAR or 2 YEARS or 3 YEARS or 4 YEARS MANDATORY SERVICE Ü Œ Œ  Œ Œ  Ž PERIODIC SERVICE MANDATORY SERVICE Œ…
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  ܍  1000H — PERIODIC SERVICE — EVERY 1000 HOURS OF SERVICE OR 2 YEARS ALSO PERFORM THE 500 HOUR PERIODIC MAINTENANCE OPERATIONS. — CHECK Safety belt ………………3-24 — CLEAN Fuel tank .
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  Ü  3000H — PERIODIC SERVICE — EVERY 3000 HOURS OF SERVICE OR 6 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. — CHECK Turbocharger **………………3-33 — CHECK Exhaust gas recirculation system «EGR»…
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  FILTER ELEMENTS AND BELTS ÜŒ  500H — PERIODIC SERVICE — EVERY 500 HOURS OF SERVICE OR 1 YEAR ENGINE OIL FILTER HYDRAULIC RETURN OIL FILTER CARTRIDGE Part number: 279809 Part number: 750098 FUEL PRE-FILTER INTERIOR CAB VENTILATION FILTER Part number: 940729 Part number: 750306 FUEL FILTER HYDRAULIC FLUID TANK FILTER CAP Part number: 52630568 Part number: 794879 ܍…
• Page 96
  USE THE RECOMMENDED LUBRICANTS AND FUEL: — For topping up, oils may not be miscible. — For oil changes, MANITOU oils are perfectly appropriate. DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been set up with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use.
• Page 97
  PRODUCT 1.06 US qt 2.11 US qt 5.28 US qt 5.28 US gal 14.53 US gal 55.21 US gal 1 ℓ 2 ℓ 5 ℓ 20 ℓ 55 ℓ 209 ℓ — MANITOU EVOLOGY OIL 10W40 API CJ4 895837 895838 895839 895840 — MANITOU ISO VG 46 HYDRAULIC OIL 545500 582297 546108…

• Page 98: Daily Service Or Every 10 Hours Of Service

  Ü  10H — DAILY SERVICE OR EVERY 10 HOURS OF SERVICE CHECK Lift truck environment Carry out a general inspection around the lift truck: — Fluid leaks or stains on the ground. — Additional objects on the lift truck and in the cabin. — Mounting and locking of the attachment.

• Page 99: Clean

  CLEAN Cyclonic pre-filter (option) The cleaning interval is given as a guide, however the pre-filter must be emptied and cleaned as soon as impurities reach the MAX level on the tank. IMPORTANT When cleaning, take care not to let impurities into the dry air filter. — Loosen nut 1 remove cover 2 and empty the tank.

• Page 100: Weekly Service Or Every 50 Hours Of Service

  Ü  50H — WEEKLY SERVICE OR EVERY 50 HOURS OF SERVICE CHECK Alternator/crankshaft belt tension IMPORTANT If the belt is changed, check the tension again after the first 20 hours of service. — Open the engine cover. — Check the belt for signs of wear and cracks, and change if necessary (  FILTER ELEMENTS AND BELTS).

• Page 101: Check Front Axle Differential Seal

  — Telescope the boom several times in order to spread the lubricant evenly. — Remove the surplus lubricant. IMPORTANT If the lift truck is used in an abrasive environment (dust, sand, coal.) use lubricating varnish (MANITOU reference: 483536). Please consult your dealer. 3 — 15…

• Page 102: Check Hydraulic Oil Level

  CHECK Hydraulic oil level Place the lift truck on level ground with the engine stopped, and the boom retracted and lowered as far as possible. IMPORTANT Use a clean funnel and clean the underside of the oil drum before filling. — Check dipstick 1, the correct level must be at the level of the red dot.

• Page 103: Clean

  — Cleaning is completed when there is no more dust on the cartridge. — Clean the cartridge seal surface with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU part No.: 479292).

• Page 104: Lubricate General Lubrication

  LUBRICATE General lubrication To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week. IMPORTANT In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to 10 hours of service or every day. Clean, then lubricate the following points with grease (  LUBRICANTS AND FUEL) and remove the surplus.

• Page 105: Replace Engine Oil

  REPLACE Engine oil * REPLACE Engine oil filter * Place the lift truck on level ground, let the engine run at idling speed for a few minutes, then stop the engine. IMPORTANT Dispose of the drain oil in an ecological manner. Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.

• Page 106
  CHECK Hydraulic oil MANITOU offers a hydraulic oil analysis kit which might make it possible to delay the recommended deadline in the periodic maintenance schedule (2000 hours). In this case we recommend an analysis of the hydraulic oil every 500 hours or 1 year of service.
• Page 107
  REPLACE Fuel filter IMPORTANT Carefully clean the outside of the filter and around it, to prevent dust from getting into the system. Tighten the filter by hand only and lock it by a quarter turn. — Switch off the lift truck’s ignition with the ignition key. — Unscrew the filter 1.
• Page 108
  REPLACE Front axle differential oil Place the lift truck on level ground with the engine stopped and the still warm differential oil. IMPORTANT Dispose of the drain oil in an ecological manner. — Place a container under drain plug 1 and unscrew the plug. — Remove level and filling plug 2 to ensure correct drainage.
• Page 109
  REPLACE Hydraulic fluid tank filter cap Place the lift truck on level ground with the engine stopped. — Unscrew plug 1, remove and replace the filter 2 with a new one (  FILTER ELEMENTS AND BELTS). — Refit and tighten the filter 2 (tightening torque 2,21 ±0,37 ft-lbs 3 ±0,5 N.m). — Refit the filler plug 1.
• Page 110
  ܍  1000H — PERIODIC SERVICE — EVERY 1000 HOURS OF SERVICE OR 2 YEARS ALSO PERFORM THE 500 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Safety belt IMPORTANT Under no circumstances must the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the safety belt. SEAT BELT WITH TWO ANCHORING POINTS — Check the following points: •…
• Page 111
  REPLACE Alternator belt IMPORTANT Check the belt tension again after the first 20 hours of service. REMOVING THE BELT — Undo screws 1 and remove radiator protection grill 2. — Loosen screws 3 by two to three thread turns. — Swivel the alternator assembly so as to free belt 4. — Pass belt 4 behind radiator propeller 5 to remove it and replace with a new one  FILTER ELEMENTS AND BELTS).
• Page 112
  REPLACE Dry air filter cartridge In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges,  FILTER ELEMENTS AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced (up to 250 hours in a very dusty atmosphere and with pre-filtration).
• Page 113
  REPLACE Rear axle differential oil Place the lift truck on level ground with the engine stopped and the still warm differential oil. IMPORTANT Dispose of the drain oil in an ecological manner. — Place a container under drain plug 1 and unscrew the plug. — Remove level and filling plug 2 to ensure correct drainage.
• Page 114
  CHECK Silentblocks ** CHECK Valve lash ** CHECK Injectors ** CHECK Exhaust gas recirculation cooler «EGR» ** CHECK Casing gas recycling valve ** CHECK Brake system pressure * CHECK Boom pad wear * CHECK Condition of wiring harnesses and cables * CHECK Lights and signals * CHECK…
• Page 115
  REPLACE Oil separator rubber hoses ** REPLACE Exhaust particle filter pressure sensor rubber hoses «DPF» ** REPLACE Intake hose ** REPLACE Pressure detection hoses for the oversupply sensor ** REPLACE Exhaust gas recirculation cooler hoses «EGR» ** REPLACE Water hose ** REPLACE Lubrication hose ** REPLACE…
• Page 116
  ÜŽ  2000H — PERIODIC SERVICE — EVERY 2000 HOURS OF SERVICE OR 4 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Wheel nut tightening torques — Check the condition of the tyres, to detect cuts, blisters, wear, etc. — Check the tightening torque of the wheel nuts with a torque wrench. •…
• Page 117
  REPLACE Hydraulic oil REPLACE Brake accumulator unit filter Place the lift truck on level ground with the engine stopped. IMPORTANT Raise the boom and place the boom safety wedge on the rod of the lifting cylinder (  1 — OPERATING AND SAFETY INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
• Page 118
  CHECK Radiator * CHECK Transmission pressures * CHECK Steering * CHECK Steering swivel joints * CHECK Brake pad and brake disk wear * CHECK Condition of boom assembly * CHECK Bearings and bushings * CHECK Condition of hoses and flexible pipes * CHECK Condition of cylinders (leakage, rods) * CHECK…

• Page 119: Check Turbocharger

  Ü  3000H — PERIODIC SERVICE — EVERY 3000 HOURS OF SERVICE OR 6 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Turbocharger ** CHECK Exhaust gas recirculation system «EGR» ** CLEAN Exhaust particle filter «DPF» ** ** Engine service, consult your dealer. 3 — 33…

• Page 120: Occasional Maintenance

  Ü OCCASIONAL MAINTENANCE CLEAN «Stationary lift truck» exhaust purification IMPORTANT Exhaust purification is an automated procedure activated by the operator when the following indicator lamps are displayed: — Park the lift truck in a safe and adequately ventilated place. — Check the following points: •…

• Page 121: Replace Wheels

  REPLACE Wheels For this operation, we advise you to use the MANITOU hydraulic jack Part No. 505507 and the MANITOU safety support prop Part No. 554772. IMPORTANT In the event of a wheel being changed on the public highway, secure the lift truck vicinity: — Stop the lift truck, if possible on firm, level ground.

• Page 122: Replace

  REPLACE Battery failure IMPORTANT Operate the battery cut-off for a minimum of 30 seconds after having switched off the ignition with the ignition key. 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.

• Page 123
  3 — 37…

• Page 124: Occasional Operation

  Ü OCCASIONAL OPERATION TOW OR WINCH Lift truck IMPORTANT If the lift truck is not on level ground, chock it so that it does not descend the slope. The lift truck must be towed very slowly (less than 5 km/h) and for as short a distance as possible (less than 100 m). For towing a lift truck, the high pressure limiters must be unlocked to avoid damaging the hydrostatic transmission, and the parking brake on the front axle must be released.

• Page 125
  TRANSPORT Lift truck IMPORTANT Ensure that the safety instructions associated with the flatbed are complied with before loading the lift truck and that the driver of the carrier vehicle is informed of the dimensions and the weight of the lift truck (  2 — DESCRIPTION: CHARACTERISTICS).
• Page 126
  3 — 40…
• Page 127
  4 —  OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE 4 — 1…
• Page 128
  4 — 2…
• Page 129
  INTRODUCTION — Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS. — A wide range of attachments is available, guaranteed by MANITOU and designed to fit your lift truck perfectly. IMPORTANT Only attachments approved by MANITOU can be used with their lift trucks (  TECHNICAL SPECIFICATIONS OF ATTACHMENTS).
• Page 130
  PICKING UP THE ATTACHMENTS 1 — ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE FITTING AN ATTACHMENT — Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessary precautions in order to move it safely. — Check that the locking pin is in position in the bracket (Fig.
• Page 131
  2 — HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE FITTING AN ATTACHMENT — Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessary precautions in order to move it safely. — Check that the locking pin is in position in the bracket (Fig.
• Page 132
  TECHNICAL SPECIFICATIONS OF ATTACHMENTS STANDARDISED TILTING FORK CARRIAGE PFB 25 N MT-1020 S2 PFB 25 N MT-1260 S2 PART NO. 571958 571959 Rated capacity 2300 kg 2300 kg Width 1020 mm 1260 mm Ground 71 kg 80 kg STANDARDISED SIDE-SHIFT CARRIAGE TDL 2T5 L1020 FEM2 TDL 2T5 L1260 FEM2 PART NO.
• Page 133
  FLOATING FORK CARRIAGE TFF 29 MT-1040 PART NO. 653340 Rated capacity 2900 kg Width 1040 mm Ground 285 kg FLOATING FORK PART NO. 211919 Section 125x40x1200 mm Ground 62 kg 4 — 7…
• Page 134
  BUILDING BUCKET CBC 650 L1850 PART NO. 654473 Rated capacity 676 l Width 1850 mm Ground 320 kg LOADING BUCKET CBR 730 L1850 PART NO. 571831 Rated capacity 735 l Width 1850 mm Ground 330 kg MULTIPURPOSE BUCKET DISPLAY CB4X1-700 L1950 PART NO.
• Page 135
  CONCRETE BUCKET (ADAPTABLE ON FORKS) BB 500 S4 PART NO. 654409 Rated capacity 500 l/1300 kg Width 1100 mm Ground 205 kg CONCRETE BUCKET WITH SPOUT (ADAPTABLE ON FORKS) BBHG 500 S4 PART NO. 751464 Rated capacity 500 l/1300 kg Width 1100 mm Ground…
• Page 136
  ATTACHMENT GUARDS FORK GUARD PART NO. 227801 FORK BLOCK FOR FLOATING FORK CARRIAGE PART NO. 261210 BUCKET PROTECTOR Always ensure that the width of the protector you choose is less than or equal to the width of the bucket. PART NO. 206734 206732 206730…

• Page 1
  647732 US (31/10/2019) MT 625 H 75K ST5 S1 MT 625 H 75K COMFORT ST5 S1 OPERATOR’S MANUAL (ORIGINAL INSTRUCTIONS)
• Page 2
  — Descriptions and figures are non binding. — MANITOU reserves the right to change its models and their equipment without being required to update this manual. — The MANITOU network, consisting exclusively of qualified professionals, is at your disposal to answer all your questions.
• Page 3
  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…
• Page 4
  1 — OPERATING AND SAFETY INSTRUCTIONS 2 — DESCRIPTION 3 — MAINTENANCE 4 — OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE…
• Page 5
  1 —  OPERATING AND SAFETY INSTRUCTIONS 1 — 1…
• Page 6
  1 — 2…
• Page 7
  1 — 3…

• Page 8: Table Of Contents

  1 —  OPERATING AND SAFETY INSTRUCTIONS INSTRUCTIONS TO THE COMPANY MANAGER THE SITE THE OPERATOR THE LIFT TRUCK A — SUITABILITY OF THE LIFT TRUCK FOR THE JOB ……….. . . 1-6 B — ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS .

• Page 9
  LIFT TRUCK MAINTENANCE INSTRUCTIONS 1-30 GENERAL INSTRUCTIONS 1-30 PLACING THE BOOM SAFETY WEDGE 1-30 FITTING THE WEDGE …………..1-30 REMOVING THE WEDGE .

• Page 10: Instructions To The Company Manager

  A — SUITABILITY OF THE LIFT TRUCK FOR THE JOB — MANITOU 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 1.25 and a DYNAMIC TEST COEFFICIENT OF 1, as specified in harmonised standard EN 1459 for mast trucks.

• Page 11: C — Modification Of The Lift Truck

  Inflate the tyres in accordance with recommendations. • The seat is an essential way of reducing the vibrations transmitted to the operator. In the event of seat replacement, please contact MANITOU. • Ensure that the operators adapt their operating speed to suit the conditions on site.

• Page 12: Instructions

  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 or stickers which are no longer legible or are damaged, must be replaced immediately. MAINTENANCE — Maintenance or repairs other than those detailed in Part: 3 — MAINTENANCE must be carried out by qualified personnel (consult your dealer) and in the necessary safety conditions to preserve the health of the operator and any third party.

• Page 13
  1 — 9…

• Page 14: Instructions For The Operator

  — At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself when you use it. IMPORTANT In order to reduce or prevent any danger with a MANITOU-approved attachment, follow the instructions in Paragraph: 4 — ADAPTABLE ATTACHMENTS AS OPTIONS ON THE RANGE: INTRODUCTION. GENERAL INSTRUCTIONS A — OPERATOR’S MANUAL…

• Page 15: E — Modification Of The Lift Truck

  Right-hand column • With a PLATFORM-fitted lift truck, people can only be lifted using platforms designed by MANITOU for the purpose. — MANITOU sells equipment specifically designed for lifting people (OPTION PLATFORM lift truck, contact your dealer). 1 — 11…

• Page 16: Operating Instructions Unladen And Laden

  OPERATING INSTRUCTIONS UNLADEN AND LADEN A — BEFORE STARTING THE LIFT TRUCK — Perform the daily maintenance operations (  3 — MAINTENANCE). — Make sure that the driver’s cab is clean, particularly the floor and floor mat. Check that no movable object may hinder the operation of the lift truck.

• Page 17: D — Visibility

  — Take into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passageway. — Never move onto a loading platform without having first checked: • That it is suitably positioned and made fast. •…

• Page 18: E — Starting The Lift Truck

  E — STARTING THE LIFT TRUCK SAFETY INSTRUCTIONS IMPORTANT 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 hauling it. Such an operation may cause severe damage to the transmission. If necessary, towing requires the transmission to be put in neutral (  3 — MAINTENANCE).

• Page 19: G — Stopping The Lift Truck

  — Never drive on the edge of a ditch or steep slope. — It is dangerous to use two lift trucks simultaneously to handle heavy or bulky loads, since this operation requires particular precautions to be taken. It must only be used exceptionally and after risk analysis. — The ignition switch has an emergency stop mechanism in case of an operating anomaly occurring in the case of lift trucks not fitted with a punch-operated cut-out.

• Page 20: H — Driving The Lift Truck On The Public Highway

  H — DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY (or see current legislation in other countries) FRENCH ROAD TRAFFIC RULES — The driving of non EC type-approved tractors on the public highway is subject to the provisions of the highway code relating to special machines, defined in article R311-1 of the highway code, in category B of the Equipment Order of 20 November 1969 that determines the procedures applicable to special machines.

• Page 21
  1 — 17…

• Page 22: Instructions For Handling A Load

  INSTRUCTIONS FOR HANDLING A LOAD A — CHOICE OF ATTACHMENTS — Only attachments approved by MANITOU can be used on its lift trucks. — Make sure the attachment is suitable for the work to be done (  4 — ADAPTABLE ATTACHMENTS AS OPTIONS ON THE RANGE).

• Page 23: D — Transverse Attitude Of The Lift Truck

  D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK Depending on the model of lift truck The transverse attitude is the transverse slope of the chassis with respect to the horizontal. Raising the boom reduces the lift truck’s lateral stability. The transverse attitude must be set with the boom in down position as follows: 1 — …

• Page 24: F —  Picking Up And Putting Down A High Load On Tyres

  F —  PICKING UP AND PUTTING DOWN A HIGH LOAD ON TYRES IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:…

• Page 25
  PUTTING DOWN A HIGH LOAD ON TYRES — Approach the load in the transport position in front of the stack (fig. F6). — Apply the parking brake and place the forward/reverse selector in neutral. — Raise and extend the boom (1) (2) until the load is above the stack, while monitoring the longitudinal stability indicator (  INSTRUCTIONS FOR HANDLING A LOAD: C — LONGITUDINAL STABILITY INDICATOR).

• Page 26: G —  Picking Up And Putting Down A High Load On Stabilisers

  G —  PICKING UP AND PUTTING DOWN A HIGH LOAD ON STABILISERS Depending on the model of lift truck IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:…

• Page 27
  TAKING UP A HIGH LOAD ON STABILISERS — Ensure that the forks will easily pass under the load. — Check the position of the lift truck with respect to the load and make a test run, if necessary, without taking the load. — Raise and extend the boom (1) (2) until the forks are at the level of the load (fig. G5).

• Page 28: H — Picking Up And Putting Down A Suspended Load

  H — PICKING UP AND PUTTING DOWN A SUSPENDED LOAD IMPORTANT Failure to follow the above instructions may lead the lift truck to loose stability and overturn. MUST be used with a lift truck equipped with an operational hydraulic movement cut-out device. CONDITIONS OF USE — The length of the sling or the chain shall be as short as possible to limit swinging of the load.

• Page 29: Instructions For Use As A Loader

  INSTRUCTIONS FOR USE AS A LOADER For agricultural-type lift trucks (MLT range) A — LOADING IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D — TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:…

• Page 30: Platform Operating Instructions

  — MANITOU has ensured that this platform is suitable for use under the normal operating conditions provided in this operator’s manual, with a STATIC test coefficient of 1.25 and a DYNAMIC test coefficient of 1.1 as specified in harmonised European standard EN 280:2013+A1 for «mobile elevating work platforms».

• Page 31: E — Environment

  E — ENVIRONMENT IMPORTANT It is forbidden to use the platform close to electricity cables. Maintain the specified safe distances. RATED VOLTAGE SAFETY DISTANCE (METRES) 50 < U < 1,000 2,30 M 1,000 < U < 30,000 2,50 M 30000 < U < 45000 2,60 M 45000 <…

• Page 32: Instructions For Using The Radio-Control

  INSTRUCTIONS FOR USING THE RADIO-CONTROL For lift trucks with RC radio control HOW TO USE THE RADIO-CONTROL SAFETY INSTRUCTIONS — This radio-control consists of electronic and mechanical safety elements. It cannot receive commands from another transmitter because the internal encoding is unique to each radio-control. IMPORTANT If it is used improperly or incorrectly, there is a risk of danger to: — The physical and mental health of the user or others.

• Page 33
  1 — 29…
• Page 34
  LIFT TRUCK MAINTENANCE INSTRUCTIONS GENERAL INSTRUCTIONS — Ensure the area is sufficiently ventilated before starting the lift truck. — Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie back and protect your hair, if necessary. — Stop the engine and remove the ignition key, when an intervention is necessary.
• Page 35
  LUBRICANT AND FUEL LEVELS — Use the recommended lubricants (never use contaminated lubricants). — Do not fill the fuel tank when the 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. — Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
• Page 36
  IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an extended period. IMPORTANT Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership. This period of long-term stoppage must not exceed 12 months.
• Page 37
  BRINGING THE LIFT TRUCK BACK INTO SERVICE — Remove the waterproof adhesive tape from all the holes. — Refit and reconnect the battery. — Remove the protection from the cylinder rods. — Perform the daily maintenance operations (  3 — MAINTENANCE). — Put the handbrake on and remove the axle stands. — Drain and clean the fuel tank (  3 — MAINTENANCE).
• Page 38
  • Glass items can be removed and collected for processing by glaziers. ENVIRONMENTAL PROTECTION By entrusting the maintenance of your lift truck to the MANITOU network, the risk of pollution is limited and the contribution to environmental protection contribution is made.
• Page 39
  2 —  DESCRIPTION 2 — 1…
• Page 40
  2 — 2…
• Page 41
  2 —  DESCRIPTION SAFETY PLATES AND STICKERS IDENTIFICATION OF THE LIFT TRUCK CHARACTERISTICS 2-10 TYRES 2-12 DIMENSIONS AND LOAD CHARTS 2-14 VISIBILITY 2-16 INSTRUMENTS AND CONTROLS 2-18 TOWING DEVICE 2-40 DESCRIPTION AND USE OF THE OPTIONS 2-42 2 — 3…
• Page 42
  SAFETY PLATES AND STICKERS IMPORTANT Clean all stickers and safety plates so that they are legible. Any safety plates and stickers which are illegible or damaged must be replaced. Check that stickers and safety plates are present after replacing any spare parts. EXTERNAL PLATES AND STICKERS REF.
• Page 43
  STICKERS AND PLATES UNDER THE ENGINE HOOD REF. PART NO. DESCRIPTION 244130 — Preheat rod (OPTION) 52506370 — Fuses 259398 — Water/diesel separator 52515083 — Anti-freeze 234797 MT 625 H COMFORT 75K ST5 — Air conditioning (OPTION) 52589959 — Rotating fan safety 110 -120 V ;…
• Page 44
  PLATES AND STICKERS IN THE CAB REF. PART NO. DESCRIPTION 52611811 — Lubrication sheet 52509004 — Manipulator function sheet 241621 — Safety instruction sheet 52504055 MT 625 H COMFORT 75K ST5 — Fuse sheet 52515060 MT 625 H  — Fuse sheet 75K S 52533603 MT 625 H COMFORT 75K ST5 — Relay sheet…
• Page 45
  75% handling cycle Maxi Kg CO2/hour 1,00m Maxi 3m Mini Tests carried out by Manitou following the EP-695 internal procedure as approved by DANGER Keep machine at least 25 feet from overhead power lines. Failure to comply may result…
• Page 46
  IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement in our products, our range of lift trucks may undergo certain modifications, without any obligation for us to advise our customers. When you order parts, or when you require any technical information, always specify: NOTE: For the owner’s convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time of the delivery of the lift truck.
• Page 47
  FRONT AXLE Type Serial number MANITOU part No. REAR AXLE Type Serial number MANITOU part No. «Constructeur» Manufacturer «Type Cabine» Cabin type «Numéro de série» Serial number BOOM MANITOU Part No. Date of manufacture and manufacturer FRAME Serial number/Product identification number ATTACHMENT MANUFACTURER’S PLATE «MODELE»…
• Page 48
  CHARACTERISTICS ENGINE Type KUBOTA V3307 Fuel Diesel 4 in line Number of cylinders Supercharged Suction Injection system Direct Ignition sequence 1.3.4.2 Capacity cu.in (cm3) 203.27 (3331) 3.7 x 4.72 (94 x 120) Bore and stroke in (mm) 17,5 Compression ratio Nominal speed laden 2600 Min.
• Page 49
  BRAKE SYSTEM Service brake Non-servo hydraulic brake — Type of brake Oil-immersed multi-disc brake — Type of control By foot on front axle Parking brake Low pressure hydraulic brake — Type of brake Oil-immersed multi-disc brake — Type of control Switch-operated electro-hydraulic HYDRAULIC CIRCUIT Hydraulic pump…
• Page 50
  TYRES LOAD PER TYRE FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN PRESSURE 12-16,5 12PR 81,2 SKS 532 ALLIANCE 12-16,5 12PR 1100 2425 3250 7165 1250 2756 81,2 HAULER SKS 305/70 R16,5  MICHELIN 69,6 137A8 BIBSTEEL ALL TERRAIN GROUND CONTACT PRESSURE GROUND CONTACT AREA PRESSURE LOAD HARD GROUND…
• Page 51
  2 — 13…
• Page 52
  DIMENSIONS AND LOAD CHARTS ft-in (mm) 3-11,2 (1200) ft-in (mm) 7-6,6 (2300) ft-in (mm) (991) ft-in (mm) 3-0,5 (928) ft-in (mm) 12-9,3 (3894) ft-in (mm) 12-6,8 (3831) ft-in (mm) 10-8,9 (3275) ft-in (mm) 16-8,6 (5094) ft-in (mm) 4-10,7 (1492) ft-in (mm) 4-10,7 (1492) (mm) 9,45…
• Page 53
  MT625 68° 19ft1in 60° 50° 40° 30° 20° 10° 0° -2° 24in 0 Feet 11ft0in 8ft4in 5ft3in 3ft7in 9ft4in 6ft11in 4ft3in 0 Meters According norme ANSI/ITSDF B56-6-2011 2 — 15…
• Page 54
  VISIBILITY We use European standard EN15830 relating to operator visibility. — Adhere to the instructions for optimising operator visibility in the immediate vicinity (  1 — OPERATING AND SAFETY INSTRUCTIONS: INSTRUCTIONS TO THE OPERATOR: DRIVING INSTRUCTIONS UNLADEN AND LADEN: D — VISIBILITY). DESCRIPTION AND ADJUSTMENT OF REAR-VIEW MIRRORS 1 — LEFT REAR-VIEW MIRROR 2 — MAIN RIGHT REAR-VIEW MIRROR 3 — CENTRAL RIGHT REAR-VIEW MIRROR…
• Page 55
  2 — 17…
• Page 56
  INSTRUMENTS AND CONTROLS DESCRIPTION NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are as seen by an observer occupying the driver’s seat and looking straight ahead. 1 — DRIVER’S CAB ACCESS ………………… . . 2-20 2 — SEAT BELT .
• Page 57
  MT 625 H COMFORT 75K ST5 MT 625 H 75K ST5 2 — 19…

• Page 58: Driver’s Cab Access

  1 — DRIVER’S CAB ACCESS Use the contact points 1 to get into or out of the driver’s cab. • Mounting at the front. • Descending at the rear. 2 — SEAT BELT IMPORTANT Under no circumstances must the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the safety belt.

• Page 59: Driver’s Seat

  3 — DRIVER’S SEAT DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS. WEIGHT ADJUSTMENT Adjust the weight when the driver is sitting on the seat. — Pull the weight adjustment lever 1 fully out. — Move the weight adjustment lever 1 upwards to increase the weight or downwards to reduce it.

• Page 60: Ignition Switch

  4 — IGNITION SWITCH This switch has 5 positions: • P — Not used. • O — Ignition cut-off and engine stopped. • I — Ignition + preheat. • II — Not used. • III — Starting and return to position I as soon as the key is released. 5 — EMERGENCY STOP In the event of danger, it enables the engine to be shut down, thereby cutting-off all hydraulic movements.

• Page 61: Man-Machine Interface (Mmi)

  8 — MAN-MACHINE INTERFACE (MMI) • A — INSTRUMENT CONTROL PANEL • B — SCREEN DISPLAYS A — INSTRUMENT CONTROL PANEL IMPORTANT A permanently lit or flashing warning lamp, with the engine running, is the sign of an operating fault. The lighting of some lamps may be accompanied by an audible signal. Do not ignore this warning, consult your dealer without delay.

• Page 62: Switches

  TRANSMISSION OIL TEMPERATURE WARNING INDICATOR LAMP The lamp and the buzzer come on when the transmission oil temperature is abnormally high. Stop the lift truck and seek the cause of this overheating. ENGINE FAULT INDICATOR LAMP If the indicator lamp comes on or flashes while the lift truck is in operation, a diagnostic fault has been detected. The lift truck will operate in reduced mode.

• Page 63
  PARKING BRAKE FAULT INDICATOR LAMP The indicator lamp comes on when the parking brake is applied (  SWITCHES). BRAKING OIL LEVEL WARNING INDICATOR LAMP If the lamp comes on when the lift truck is running, stop the engine immediately and check the brake fluid level. In the event of an abnormal drop in the level, consult your dealer.
• Page 64
  Rev counter Partial hour meter SETTING THE TIME — Display clock screen. — Press the button for 2 seconds, choose the «24 hour» or «12 hour am/pm» clock with the button and confirm — Set the hours with the button and confirm — Set the minutes with the button and confirm RESETTING THE PARTIAL HOUR METER…
• Page 65
  9 — SWITCHES NOTE:  The location of the switches may vary depending on the options. HAZARD WARNING LIGHTS REAR FOG LIGHT (OPTION) ROTATING BEACON LIGHT FRONT AND REAR WORKING LIGHTS (OPTION) REAR WINDOW DEFROSTER (OPTION) MT 625 H COMFORT 75K ST5 HYDRAULIC MOVEMENT NEUTRALISATION When driving on the road, it is highly recommended (mandatory in Germany) that you cut-off all the hydraulic movements. The indicator lamp shows when it is in use.

• Page 66: Armrest And Storage

  PARKING BRAKE To connect the parking brake, press the bottom of the switch. The indicator lamp indicates when it is in use. To disconnect the parking brake, press the top of the switch. ATTACHMENT HYDRAULIC LOCKING (OPTION) BOOM HEAD ELECTROVALVE (OPTION) MT 625 H COMFORT 75K ST5 BOOOM HEAD ELECTROVALVE + ATTACHMENT HYDRAULIC LOCKING (OPTION)

• Page 67: Fuses And Relays

  12 — FUSES AND RELAYS A sticker on the inside of the access panel provides a quick indication of the use of the fuse plate’s components described below. — Remove the access panel 1 to access the fuses and relays. Replace a used fuse with a new fuse of the same quality and capacity.

• Page 68
  2A Control instrument module power supply. * * MT 625 H 75K ST5 Not used. ** 2A Battery power supply (+). * Not used. ** Free. * Not used. ** Free. * Not used. ** 2A Control instrument module power supply. ** 2A Battery power supply (+).

• Page 69: Cigarette Lighter

  13 — CIGARETTE LIGHTER For 12 V appliance and max. amperage 15A. 14 — LIGHTING, HORN AND INDICATOR SWITCH The switch controls the visual and sound alarms. • A — All lights are off, the indicator lights do not flash. • B — The right hand indicator lights flash. •…

• Page 70: Hydraulic Controls

  17 — HYDRAULIC CONTROLS IMPORTANT Do not attempt to alter the hydraulic system pressure by interfering with the pressure regulating valve. In the event of suspected malfunction, contact your dealer. ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID. Use the hydraulic controls gently without jerking, to avoid incidents caused by shaking the lift truck. NOTE: When driving on the road, it is highly recommended (mandatory in Germany) that all the hydraulic movements are cut off (  SWITCHES).

• Page 71
  ADJUSTMENT OF ATTACHMENT HYDRAULIC FLOW RATE — Switch on lift truck ignition. — Select the attachment circuit hydraulic flow screen with the scroll button . In turn the screen displays the hydraulic flow stored in the memory of circuit B (without «-» sign) and of circuit A (with «-» sign). — Press the button for two seconds, the screen will appear on the…

• Page 72: Accelerator Pedal

  18 — ACCELERATOR PEDAL 19 — SERVICE BRAKE PEDAL AND TRANSMISSION CUT-OFF The pedal acts on the front wheels by means of a hydraulic brake system to slow down and stop the lift truck. During free travel it enables the transmission to be cut off progressively thus allowing a gradual approach (delicate handling) with all the engine power.

• Page 73: Steering Selection

  21 — STEERING SELECTION A — GREEN WHEEL ALIGNMENT INDICATOR LAMPS IMPORTANT Before selecting one of the three steering possibilities, align the 4 wheels in relation to the lift truck axis. Never change the steering mode whilst driving. These green indicator lamps come on to indicate the alignment of the wheels in relation to the lift truck.

• Page 74: Heater Control

  22 — HEATER CONTROL A — FAN CONTROL This 3-speed control allows the air to be ventilated through the air vents. B — TEMPERATURE CONTROL Adjusts the temperature inside the cab. • B1 — The fan pumps in the air at ambient temperature. • B2 — The fan pumps in warm air. The intermediate positions allow the temperature to be adjusted.

• Page 75: Heating Vents

  24 — HEATING VENTS These swivelling heating vents, which can be shut off, allow you to direct and adjust the flow inside the cab. 25 — DEMIST VENTS These vents allow the windscreen and side windows to be demisted. For optimum efficiency, close the heating vents. 26 — LEVEL INDICATOR Enables the operator to check that the lift truck is in the horizontal position.

• Page 76: Front Headlights

  34 — FRONT HEADLIGHTS • A — Left front indicator light. • B — Left front dipped beam headlight. • C — Left front main beam. • D — Left front side light. • E — Right front indicator light. • F — Right front dipped beam headlight. • G — Right front main beam headlight. •…

• Page 77: Boom Safety Wedge

  40 — BOOM SAFETY WEDGE IMPORTANT Only use the wedge supplied with the lift truck. The lift truck is equipped with a boom safety wedge which must be installed on the rod of the lifting cylinder when working beneath the boom (  1 — OPERATING AND SAFETY INSTRUCTIONS).

• Page 78
  TOWING DEVICE 1 — TOWING PIN ………………….. . 2-41 2 — REAR ELECTRIC SOCKET (DEPENDING ON ASSEMBLY) .
• Page 79
  1 — TOWING PIN IMPORTANT Be careful not to get your fingers caught or crushed during this operation. Do not forget to put the cotter pin back in place. When uncoupling, make sure that the trailer is supported independently. COUPLING AND UNCOUPLING THE TRAILER — To couple the trailer, position the lift truck as close as possible to the trailer ring.
• Page 80
  DESCRIPTION AND USE OF THE OPTIONS 1 — PREHEAT ROD………………….. 2-42 2 — MODCOD ANTI-THEFT SYSTEM .

• Page 81: Modcle Anti-Start System

  3 — MODCLE ANTI-START SYSTEM OPERATION — Switch on lift truck ignition, red LED 1 will flash. — Apply key 2 to its base 3, and withdraw it as soon as the system emits a continuous sound signal, and LED 1 turns green. — Start the lift truck within the next 20 seconds; otherwise the anti-theft system will be reactivated and red LED 1 will flash.

• Page 82: Waterproof Document Holder

  7 — WATERPROOF DOCUMENT HOLDER 8 — WINDSCREEN GRILL DESCRIPTION The windscreen grill provides additional protection for the operator from any external elements spattered on the windscreen. This grill must be removable from inside the cab to enable an emergency exit. EMERGENCY EXIT — After breaking the windscreen with the emergency hammer, push (with force) on the windscreen grill at A to remove it.

• Page 83: Boom Head Electrovalve

  10 — BOOM HEAD ELECTROVALVE MT 625 H COMFORT 75K ST5 Enables use of two hydraulic functions on the attachment circuit. IMPORTANT To facilitate connection of the quick couplers, decompress the hydraulic circuit by pressing button 1 on the electrovalve. ATTACHMENT LINE A1/B1 CONTROL — Put switch 1 to position A (indicator lamp off ).

• Page 84: Attachment Hydraulic Control Forced Operation

  12 — ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION MT 625 H COMFORT 75K ST5 IMPORTANT This OPTION must only be used with an attachment requiring continuous hydraulic movement, such as a brush, feeder bucket, mixer, spray etc. It is strictly forbidden for use in handling operations and all other applications (winch, crane jib, crane jib with winch, hook, etc.).

• Page 85: Lifting Ring On Single Carriage

  15 — LIFTING RING ON SINGLE CARRIAGE CONDITIONS OF USE IMPORTANT Follow the instructions given in your lift truck’s instruction manual (  1 — OPERATING AND SAFETY INSTRUCTIONS FOR HANDLING LOADS), and in addition those given below. — The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS, but the angle of inclination of the carriage must be same as when the forks are used in the horizontal position.

• Page 86
  2 — 48…
• Page 87
  3 — MAINTENANCE 3 — 1…
• Page 88
  3 — MAINTENANCE ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FORKLIFT TRUCK MAINTENANCE DAILY AND WEEKLY MAINTENANCE MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE PERIODIC SERVICE OCCASIONAL MAINTENANCE AND OPERATION FILTER ELEMENTS AND BELTS LUBRICANTS AND FUEL 3-10 Ü  10H — DAILY SERVICE OR EVERY 10 HOURS OF SERVICE 3-12 Ü…
• Page 89
  • Efficient help with diagnosis. • Improvements due to experience feedback. • Operator training. • Only the MANITOU network has detailed knowledge of the design of the lift truck and therefore the best technical ability to provide maintenance. IMPORTANT ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
• Page 90
  This schedule enables the operator to keep up with the periodic service of the lift truck by notifying the total number of hours of operation and the date of the service performed by the professional approved by the MANITOU network.
• Page 91
  MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE FIRST 500 HOURS BEFORE THE FIRST 6 MONTHS — If the lift truck has reached the first 500 hours of service before the first 6 months have expired, perform both the mandatory ÜŒ service and periodic 500 H service (  …
• Page 92
  PERIODIC SERVICE MAINTENANCE SCHEDULE Þ Þ 500 H 1000 H 1500 H 2000 H Ü WHEN DUE FIRST 6 MONTHS FIRST 500 HOURS or 1 YEAR or 2 YEARS or 3 YEARS or 4 YEARS MANDATORY SERVICE Ü Œ Œ  Œ Œ  Ž PERIODIC SERVICE MANDATORY SERVICE Œ…
• Page 93
  ܍  1000H — PERIODIC SERVICE — EVERY 1000 HOURS OF SERVICE OR 2 YEARS ALSO PERFORM THE 500 HOUR PERIODIC MAINTENANCE OPERATIONS. — CHECK Safety belt ………………3-24 — CLEAN Fuel tank .
• Page 94
  Ü  3000H — PERIODIC SERVICE — EVERY 3000 HOURS OF SERVICE OR 6 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. — CHECK Turbocharger **………………3-33 — CHECK Exhaust gas recirculation system «EGR»…
• Page 95
  FILTER ELEMENTS AND BELTS ÜŒ  500H — PERIODIC SERVICE — EVERY 500 HOURS OF SERVICE OR 1 YEAR ENGINE OIL FILTER HYDRAULIC RETURN OIL FILTER CARTRIDGE Part number: 279809 Part number: 750098 FUEL PRE-FILTER INTERIOR CAB VENTILATION FILTER Part number: 940729 Part number: 750306 FUEL FILTER HYDRAULIC FLUID TANK FILTER CAP Part number: 52630568 Part number: 794879 ܍…
• Page 96
  USE THE RECOMMENDED LUBRICANTS AND FUEL: — For topping up, oils may not be miscible. — For oil changes, MANITOU oils are perfectly appropriate. DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been set up with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use.
• Page 97
  PRODUCT 1.06 US qt 2.11 US qt 5.28 US qt 5.28 US gal 14.53 US gal 55.21 US gal 1 ℓ 2 ℓ 5 ℓ 20 ℓ 55 ℓ 209 ℓ — MANITOU EVOLOGY OIL 10W40 API CJ4 895837 895838 895839 895840 — MANITOU ISO VG 46 HYDRAULIC OIL 545500 582297 546108…

• Page 98: Daily Service Or Every 10 Hours Of Service

  Ü  10H — DAILY SERVICE OR EVERY 10 HOURS OF SERVICE CHECK Lift truck environment Carry out a general inspection around the lift truck: — Fluid leaks or stains on the ground. — Additional objects on the lift truck and in the cabin. — Mounting and locking of the attachment.

• Page 99: Clean

  CLEAN Cyclonic pre-filter (option) The cleaning interval is given as a guide, however the pre-filter must be emptied and cleaned as soon as impurities reach the MAX level on the tank. IMPORTANT When cleaning, take care not to let impurities into the dry air filter. — Loosen nut 1 remove cover 2 and empty the tank.

• Page 100: Weekly Service Or Every 50 Hours Of Service

  Ü  50H — WEEKLY SERVICE OR EVERY 50 HOURS OF SERVICE CHECK Alternator/crankshaft belt tension IMPORTANT If the belt is changed, check the tension again after the first 20 hours of service. — Open the engine cover. — Check the belt for signs of wear and cracks, and change if necessary (  FILTER ELEMENTS AND BELTS).

• Page 101: Check Front Axle Differential Seal

  — Telescope the boom several times in order to spread the lubricant evenly. — Remove the surplus lubricant. IMPORTANT If the lift truck is used in an abrasive environment (dust, sand, coal.) use lubricating varnish (MANITOU reference: 483536). Please consult your dealer. 3 — 15…

• Page 102: Check Hydraulic Oil Level

  CHECK Hydraulic oil level Place the lift truck on level ground with the engine stopped, and the boom retracted and lowered as far as possible. IMPORTANT Use a clean funnel and clean the underside of the oil drum before filling. — Check dipstick 1, the correct level must be at the level of the red dot.

• Page 103: Clean

  — Cleaning is completed when there is no more dust on the cartridge. — Clean the cartridge seal surface with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU part No.: 479292).

• Page 104: Lubricate General Lubrication

  LUBRICATE General lubrication To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week. IMPORTANT In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to 10 hours of service or every day. Clean, then lubricate the following points with grease (  LUBRICANTS AND FUEL) and remove the surplus.

• Page 105: Replace Engine Oil

  REPLACE Engine oil * REPLACE Engine oil filter * Place the lift truck on level ground, let the engine run at idling speed for a few minutes, then stop the engine. IMPORTANT Dispose of the drain oil in an ecological manner. Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.

• Page 106
  CHECK Hydraulic oil MANITOU offers a hydraulic oil analysis kit which might make it possible to delay the recommended deadline in the periodic maintenance schedule (2000 hours). In this case we recommend an analysis of the hydraulic oil every 500 hours or 1 year of service.
• Page 107
  REPLACE Fuel filter IMPORTANT Carefully clean the outside of the filter and around it, to prevent dust from getting into the system. Tighten the filter by hand only and lock it by a quarter turn. — Switch off the lift truck’s ignition with the ignition key. — Unscrew the filter 1.
• Page 108
  REPLACE Front axle differential oil Place the lift truck on level ground with the engine stopped and the still warm differential oil. IMPORTANT Dispose of the drain oil in an ecological manner. — Place a container under drain plug 1 and unscrew the plug. — Remove level and filling plug 2 to ensure correct drainage.
• Page 109
  REPLACE Hydraulic fluid tank filter cap Place the lift truck on level ground with the engine stopped. — Unscrew plug 1, remove and replace the filter 2 with a new one (  FILTER ELEMENTS AND BELTS). — Refit and tighten the filter 2 (tightening torque 2,21 ±0,37 ft-lbs 3 ±0,5 N.m). — Refit the filler plug 1.
• Page 110
  ܍  1000H — PERIODIC SERVICE — EVERY 1000 HOURS OF SERVICE OR 2 YEARS ALSO PERFORM THE 500 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Safety belt IMPORTANT Under no circumstances must the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the safety belt. SEAT BELT WITH TWO ANCHORING POINTS — Check the following points: •…
• Page 111
  REPLACE Alternator belt IMPORTANT Check the belt tension again after the first 20 hours of service. REMOVING THE BELT — Undo screws 1 and remove radiator protection grill 2. — Loosen screws 3 by two to three thread turns. — Swivel the alternator assembly so as to free belt 4. — Pass belt 4 behind radiator propeller 5 to remove it and replace with a new one  FILTER ELEMENTS AND BELTS).
• Page 112
  REPLACE Dry air filter cartridge In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges,  FILTER ELEMENTS AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced (up to 250 hours in a very dusty atmosphere and with pre-filtration).
• Page 113
  REPLACE Rear axle differential oil Place the lift truck on level ground with the engine stopped and the still warm differential oil. IMPORTANT Dispose of the drain oil in an ecological manner. — Place a container under drain plug 1 and unscrew the plug. — Remove level and filling plug 2 to ensure correct drainage.
• Page 114
  CHECK Silentblocks ** CHECK Valve lash ** CHECK Injectors ** CHECK Exhaust gas recirculation cooler «EGR» ** CHECK Casing gas recycling valve ** CHECK Brake system pressure * CHECK Boom pad wear * CHECK Condition of wiring harnesses and cables * CHECK Lights and signals * CHECK…
• Page 115
  REPLACE Oil separator rubber hoses ** REPLACE Exhaust particle filter pressure sensor rubber hoses «DPF» ** REPLACE Intake hose ** REPLACE Pressure detection hoses for the oversupply sensor ** REPLACE Exhaust gas recirculation cooler hoses «EGR» ** REPLACE Water hose ** REPLACE Lubrication hose ** REPLACE…
• Page 116
  ÜŽ  2000H — PERIODIC SERVICE — EVERY 2000 HOURS OF SERVICE OR 4 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Wheel nut tightening torques — Check the condition of the tyres, to detect cuts, blisters, wear, etc. — Check the tightening torque of the wheel nuts with a torque wrench. •…
• Page 117
  REPLACE Hydraulic oil REPLACE Brake accumulator unit filter Place the lift truck on level ground with the engine stopped. IMPORTANT Raise the boom and place the boom safety wedge on the rod of the lifting cylinder (  1 — OPERATING AND SAFETY INSTRUCTIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).
• Page 118
  CHECK Radiator * CHECK Transmission pressures * CHECK Steering * CHECK Steering swivel joints * CHECK Brake pad and brake disk wear * CHECK Condition of boom assembly * CHECK Bearings and bushings * CHECK Condition of hoses and flexible pipes * CHECK Condition of cylinders (leakage, rods) * CHECK…

• Page 119: Check Turbocharger

  Ü  3000H — PERIODIC SERVICE — EVERY 3000 HOURS OF SERVICE OR 6 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Turbocharger ** CHECK Exhaust gas recirculation system «EGR» ** CLEAN Exhaust particle filter «DPF» ** ** Engine service, consult your dealer. 3 — 33…

• Page 120: Occasional Maintenance

  Ü OCCASIONAL MAINTENANCE CLEAN «Stationary lift truck» exhaust purification IMPORTANT Exhaust purification is an automated procedure activated by the operator when the following indicator lamps are displayed: — Park the lift truck in a safe and adequately ventilated place. — Check the following points: •…

• Page 121: Replace Wheels

  REPLACE Wheels For this operation, we advise you to use the MANITOU hydraulic jack Part No. 505507 and the MANITOU safety support prop Part No. 554772. IMPORTANT In the event of a wheel being changed on the public highway, secure the lift truck vicinity: — Stop the lift truck, if possible on firm, level ground.

• Page 122: Replace

  REPLACE Battery failure IMPORTANT Operate the battery cut-off for a minimum of 30 seconds after having switched off the ignition with the ignition key. 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.

• Page 123
  3 — 37…

• Page 124: Occasional Operation

  Ü OCCASIONAL OPERATION TOW OR WINCH Lift truck IMPORTANT If the lift truck is not on level ground, chock it so that it does not descend the slope. The lift truck must be towed very slowly (less than 5 km/h) and for as short a distance as possible (less than 100 m). For towing a lift truck, the high pressure limiters must be unlocked to avoid damaging the hydrostatic transmission, and the parking brake on the front axle must be released.

• Page 125
  TRANSPORT Lift truck IMPORTANT Ensure that the safety instructions associated with the flatbed are complied with before loading the lift truck and that the driver of the carrier vehicle is informed of the dimensions and the weight of the lift truck (  2 — DESCRIPTION: CHARACTERISTICS).
• Page 126
  3 — 40…
• Page 127
  4 —  OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE 4 — 1…
• Page 128
  4 — 2…
• Page 129
  INTRODUCTION — Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS. — A wide range of attachments is available, guaranteed by MANITOU and designed to fit your lift truck perfectly. IMPORTANT Only attachments approved by MANITOU can be used with their lift trucks (  TECHNICAL SPECIFICATIONS OF ATTACHMENTS).
• Page 130
  PICKING UP THE ATTACHMENTS 1 — ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE FITTING AN ATTACHMENT — Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessary precautions in order to move it safely. — Check that the locking pin is in position in the bracket (Fig.
• Page 131
  2 — HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE FITTING AN ATTACHMENT — Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessary precautions in order to move it safely. — Check that the locking pin is in position in the bracket (Fig.
• Page 132
  TECHNICAL SPECIFICATIONS OF ATTACHMENTS STANDARDISED TILTING FORK CARRIAGE PFB 25 N MT-1020 S2 PFB 25 N MT-1260 S2 PART NO. 571958 571959 Rated capacity 2300 kg 2300 kg Width 1020 mm 1260 mm Ground 71 kg 80 kg STANDARDISED SIDE-SHIFT CARRIAGE TDL 2T5 L1020 FEM2 TDL 2T5 L1260 FEM2 PART NO.
• Page 133
  FLOATING FORK CARRIAGE TFF 29 MT-1040 PART NO. 653340 Rated capacity 2900 kg Width 1040 mm Ground 285 kg FLOATING FORK PART NO. 211919 Section 125x40x1200 mm Ground 62 kg 4 — 7…
• Page 134
  BUILDING BUCKET CBC 650 L1850 PART NO. 654473 Rated capacity 676 l Width 1850 mm Ground 320 kg LOADING BUCKET CBR 730 L1850 PART NO. 571831 Rated capacity 735 l Width 1850 mm Ground 330 kg MULTIPURPOSE BUCKET DISPLAY CB4X1-700 L1950 PART NO.
• Page 135
  CONCRETE BUCKET (ADAPTABLE ON FORKS) BB 500 S4 PART NO. 654409 Rated capacity 500 l/1300 kg Width 1100 mm Ground 205 kg CONCRETE BUCKET WITH SPOUT (ADAPTABLE ON FORKS) BBHG 500 S4 PART NO. 751464 Rated capacity 500 l/1300 kg Width 1100 mm Ground…
• Page 136
  ATTACHMENT GUARDS FORK GUARD PART NO. 227801 FORK BLOCK FOR FLOATING FORK CARRIAGE PART NO. 261210 BUCKET PROTECTOR Always ensure that the width of the protector you choose is less than or equal to the width of the bucket. PART NO. 206734 206732 206730…

ERROR CODES

The appearance of the maintenance key

indicate that an anomaly has been detected by one of the lift truck’s Electronic Control Units (ECU).

— Press the button

to display the information

— If there are several error codes, press the button

— Press the button

once more to return to the hour meter screen, the maintenance key

repairs have not been carried out.

— Contact your dealer, stating the error code or codes.

NOTE: A faulty fuse can generate several error codes. When «error codes» and «maintenance interval» are displayed together, the maintenance

reminder time will appear at the end of the list.

ERROR CODE

HYDROSTATIC TRANSMISSION

520201

Hydraulic transmission electronic control unit voltage fault.

520214

Hydraulic transmission electronic control unit fault.

520215

Hydrostatic motor regulator control fault.

520217

Stop light control fault.

520224

Hydrostatic motor operating solenoid valve control fault.

520225

Hydraulic transmission electronic control unit fault.

520226

Hydraulic transmission electronic control unit fault.

520227

Hydraulic transmission electronic control unit fault.

520273

Forward/reverse selector error.

520274

Inching sensor error.

520275

Hydrostatic pump reverse operation control fault.

520276

Hydrostatic pump forward operation control fault.

520277

Hydraulic pump speed sensor fault.

520281

Temperature outside operating range.

ERROR CODE

190

Engine speed data fault.

520400

Network link fault.

520401

Fuel gauge fault.

520402

Engine temperature sensor fault.

520404

Man-Machine Interface fault.

520405

Man-Machine Interface fault.

520406

Man-Machine Interface fault.

520407

Man-Machine Interface fault.

520408

Man-Machine Interface fault.

520409

Man-Machine Interface fault.

520410

Man-Machine Interface fault.

520411

Man-Machine Interface fault.

520412

Hydrostatic transmission network link fault.

520413

Electronic handling controller network connection fault.

on the hour meter screen

to loop through the error codes.

MAN-MACHINE INTERFACE

together with the sounding of an audible beep,

on the upper screen and error code

remains displayed as long the as the required

ERROR CODE

2662

Telescope control setting fault.

2663

Attachment control setting fault.

520300

Seat sensor fault.

520307

Proportional telescope control fault.

520310

Proportional attachment control fault.

520315

Telescope control ON/OFF fault.

520318

Attachment control ON/OFF fault.

520336

Electronic handling controller fault.

520337

Electronic handling controller fault.

520338

Electronic handling controller temperature fault.

520352

Attachment forced operation control fault.

520362

Electronic handling controller 10V output fault.

520363

Attachment forced operation indicator fault.

520364

Attachment hydraulic control button fault.

520365

Attachment easy hydraulic connection button.

520366

Solenoid valve on jib head fault.

520370

Telescope retracted sensor fault (fault detected during test).

520371

Electronic handling controller temperature fault.

520376

Stability indicator fault.

520382

Aggravating hydraulic movement cut-off disable fault

520383

Computer earth output fault.

520384

Telescope retracted senor fault.

520386

Jib angle sensor fault.

520387

Strain gauge fault.

520388

Network communication fault.

520391

Inclination cut-off valve fault.

520392

Angle calibration fault (fault detected during test).

520393

Gauge calibration fault (fault detected during test).

520394

Safety valve fault.

520395

Safety valve cut-off fault (fault detected during test).

520396

Lowering regulating valve fault.

520397

Regulating fault (fault detected during test).

520398

Raising regulating valve fault.

2-22

.

TELESCOPE/ATTACHMENT

Play in Fork Loose bushings Resize bushings or replace with new ones if damaged Loose Compression Rod bolt Tighten bolt to specified torque Loose Rebound damping shaft Tighten
Shaft to specified torque Loose press fit tolerances Call Answer Products Customer Service Air Assist Problems Various See Air Assist Troubleshooting Guide Lock Out Problems Various See Lock Out
Troubleshooting Remote Lockout Problems Various See Remote Lockout Section