AEG | COMPETENCE 5003 F | Operator`s manual | AEG COMPETENCE 5003 F Operator`s manual

MANITOU BF
BP 10249
44158 ANCENIS CEDEX - FRANCE
TEL: + 33 (0)2 40 09 10 11
YOUR DEALER
647012 EN (11/03/2011)
MT 1440 E3
MT 1840 E3
OPERATOR’S MANUAL
THIS OPERATOR’S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.
1 - OPERATING AND SAFETY INSTRUCTIONS
2 - DESCRIPTION
3 - MAINTENANCE
4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE
21/01/2011
1ST DATE OF ISSUE
11/03/2011
UP DATING: 2-39
3-10 ; 3-11 ; 3-18 ; 3-21 ; 3-30 – 3-42
THE TEXTS AND ILLUSTRATIONS IN THIS DOCUMENT MUST NOT BE REPRODUCED EITHER WHOLLY OR IN PART.
1 - OPERATING
AND SAFETY
INSTRUCTIONS
1-1
1-2
TABLE OF CONTENTS
INSTRUCTIONS TO THE COMPANY MANAGER
1-4
THE SITE
THE OPERATOR
THE LIFT TRUCK
A - THE LIFT TRUCK’S SUITABILITY FOR THE JOB
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS
C - MODIFICATION OF THE LIFT TRUCK
D - FRENCH ROAD TRAFFIC RULES (or see current legislation in other countries)
THE INSTRUCTIONS
THE MAINTENANCE
1-4
1-4
1-4
1-4
1-4
1-5
1-5
1-5
1-5
INSTRUCTIONS FOR THE OPERATOR
1-6
PREAMBULE
GENERAL INSTRUCTIONS
A - OPERATOR’S MANUAL
B - AUTHORIZATION FOR USE IN FRANCE (or see current legislation in other countries)
C - MAINTENANCE
D - MODIFICATION OF THE LIFT TRUCK
E - LIFTING PEOPLE
OPERATING INSTRUCTIONS UNLADEN AND LADEN
A - BEFORE STARTING THE LIFT TRUCK
B - DRIVER’S OPERATING INSTRUCTIONS
C - ENVIRONMENT
D - VISIBILITY
E - STARTING THE LIFT TRUCK
F - DRIVING THE LIFT TRUCK
G - STOPPING THE LIFT TRUCK
H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY (or see current legislation in other countries)
INSTRUCTIONS FOR HANDLING A LOAD
A - CHOICE OF ATTACHMENTS
B - MASS OF LOAD AND CENTRE 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 AND LAYING A HIGH LOAD ON STABILIZERS
H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD
I - TRAVELLING WITH A SUSPENDED LOAD
PLATFORM OPERATING INSTRUCTIONS
A - AUTHORISATION FOR USE
B - SUITABILITY OF THE PLATFORM FOR THE JOB
C - PRECAUTIONS WHEN USING THE PLATFORM
D - USING THE PLATFORM
E - ENVIRONMENT
F - MAINTENANCE
INSTRUCTIONS FOR USING THE RADIO-CONTROL
1-6
1-6
1-6
1-6
1-6
1-6
1-7
1-8
1-8
1-8
1-9
1-9
1 - 10
1 - 10
1 - 11
1 - 12
1 - 14
1 - 14
1 - 14
1 - 14
1 - 15
1 - 15
1 - 16
1 - 18
1 - 20
1 - 20
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 21
1 - 22
1 - 23
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK
1 - 24
GENERAL INSTRUCTIONS
MAINTENANCE
LUBRICANT AND FUEL LEVELS
HYDRAULIC
ELECTRICITY
WELDING
WASHING THE LIFT TRUCK
1
1
1
1
1
1
1
IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME
1 - 26
INTRODUCTION
PREPARING THE LIFT TRUCK
PROTECTING THE I.C. ENGINE
PROTECTING THE LIFT TRUCK
BRINGING THE LIFT TRUCK BACK INTO SERVICE
1
1
1
1
1
1-3
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24
24
24
24
24
25
25
26
26
26
26
27
INSTRUCTIONS TO THE COMPANY MANAGER
THE SITE
- Proper management of lift truck’s area of travel will reduce the risk of accidents:
. ground not unnecessarily uneven or obstructed,
. no excessive slopes,
. pedestrian traffic controlled, etc.
THE OPERATOR
- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment with respect to the use of lift trucks and must be carried permanently by the operator.
On the basis of experience, there are a number of possible situations in which operating the lift truck is contra-indicated. Such foreseeable abnormal
uses, the main ones being listed below, are strictly forbidden.
- The foreseeable abnormal behaviour resulting from ordinary neglect, but does not result from any wish to put the machinery to any improper use.
- The reflex reactions of a person in the event of a malfunction, incident, fault, etc. during operation of the lift truck.
- Behaviour resulting from application of the «principle of least action» when performing a task.
- For certain machines, the foreseeable behaviour of such persons as: apprentices, teenagers, handicapped persons, trainees tempted to drive a
lift truck, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.
The person in charge of the equipment must take these criteria into account when assessing whether or not a person will makea suitable driver.
THE LIFT TRUCK
A - THE TRUCK’S SUITABILITY 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 OF 1.33 and a DYNAMIC test coefficient OF 1, as specified in harmonized norm EN 1459
for variable range trucks.
- Before commissioning, the company manager must make sure that the lift truck is appropriate for the work to be done, and
perform certain tests (in accordance with current legislation).
B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS
- In addition to series equipment mounted on your lift truck, many options are available, such as: road lighting, stop lights, flashing
light, reverse lights, reverse buzzer alarm, front light, rear light, light at the jib head, etc… (as model of lift truck).
- The operator must take into account the operating conditions 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 - MAINTENANCE: LUBRICANTS AND FUEL).
. Adaptation of lubricants (ask your dealer for information).
. I.C. engine filtration (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
For operation under average climatic conditions, i.e.: between - 15 °C and + 35 °C, correct levels of lubricants in all the circuits are checked in production.
For operation under more severe climatic conditions, before starting up, it is necessary to drain all the circuits, then ensure correct levels of lubricants
using lubricants properly suited to the relevant ambient temperatures. It is the same for the cooling liquid.
- A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are
solutions, consult your dealer.
Your lift truck is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated premises. It is prohibited
to use the lift truck in areas where there is a risk of fire or which are potentially explosive (e.g. Refineries, fuel or gas depots, stores of inflammable
products…). For use in these areas, specific equipment is available (ask your dealer for information).
- Our trucks comply with Directive 2004/108/EC concerning electromagnetic compatibility (EMC), and with the corresponding
harmonized norm EN 12895. Their proper operation is no longer guaranteed if they are used within areas in which the
electromagnetic fields exceed the limit specified by that norm (10 V/m).
- Directive 2002/44/EC requires company managers to not expose their employees to excessive vibration doses. There is no
recognized code of measurement for comparing the machines of different manufacturers. The actual doses received can therefore
be measured only under actual operating conditions at the user's premises.
- The following are some tips for minimizing these vibration doses:
• Select the most suitable lift truck and attachment for the intended use.
• Adapt the seat adjustment to the operator's weight (according to lift truck model) and maintain it in good condition, as
well as the cab suspension. Inflate the tires in accordance with recommendations.
• Ensure that the operators adapt their operating speed to suit the conditions on site.
• As far as possible, arrange the site in such a way as to provide a flat running surface and remove obstacles and harmful
potholes.
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C - MODIFICATION OF THE LIFT TRUCK
- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
D - FRENCH ROAD TRAFFIC RULES
(or see current legislation in other countries)
- Only one certificate of conformity is issued. It must be kept in a safe place.
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 or stickers which are no longer legible or are damaged, must be replaced immediately.
THE MAINTENANCE
- Maintenance or repairs other than those detailed in part: 3 - MAINTENANCE must be carried out by qualified personnel (consult
your dealer) and under the necessary safety conditions to maintain the health of the operator and any third party.
Your lift truck must be inspected periodically to ensure that it remains in compliance. The frequency of this inspection is defined by current legislation in
the country in which the lift truck is used.
1-5
INSTRUCTIONS FOR THE OPERATOR
PREAMBLE
WHENEVER YOU SEE THIS SYMBOL IT MEANS:
WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK.
The risk of accident while using, servicing or repairing your lift truck can be restricted if you follow the safety instructions and safety measures detailed
in these instruction.
- Only the operations and manœuvres described in these operator’s manual must be performed. The manufacturer cannot predict
all possible risky situations. Consequently, the safety instructions given in the operator’s manual and on the lift truck itself are
not exhaustive.
- 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.
Failure to respect the safety and operating instructions, or the instructions for repairing or servicing your lift truck may lead to serious, even fatal
accident.
GENERAL INSTRUCTIONS
A - OPERATOR’S MANUAL
- Read the operator’s manual carefully.
- The operator’s manual must always be in good condition and in the place provided for it on the lift truck.
- You must report any plates and stickers which are no longer legible or which are damaged.
B - AUTHORISATION FOR USE IN FRANCE
(or see current legislation in other countries)
- Only qualified, authorized personnel can use the lift truck. This authorization is given in writing by the appropriate person in the
establishment 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
- The operator must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety
notice.
- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He must
keep the lift truck properly cleaned if this is among his responsibilities.
- The operator must carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- The operator must ensure tyres are adapted to the nature of the ground (see area of the contact surface of the tyres in the
chapter: 2 - DESCRIPTION: FRONT AND REAR TYRES). There are optional solutions, consult your dealer.
. SAND tyres.
. LAND tyres.
. Snow chains.
Do not use the lift truck if the tyres are incorrectly inflated, damaged or excessively worn, because this could put your own safety or that of others at
risk, or cause damage to the lift truck itself. The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer, excepting prior
authorisation.
D - MODIFICATION OF THE LIFT TRUCK
- For your safety and that of others, you must not change the structure and settings of the various components used in your lift truck
(hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved
attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.
1-6
E - LIFTING PEOPLE
- The use of working equipment and load lifting attachments to lift people is:
• either forbidden
• or authorized exceptionally and under certain conditions (see current regulations
in the country in which the lift truck 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 PLATFORMfitted 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).
1-7
OPERATING INSTRUCTIONS UNLADEN AND LADEN
A - BEFORE STARTING THE LIFT TRUCK
- Carry out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Make sure the lights, indicators and windscreen wipers are working properly.
- Make sure the rear view mirrors are in good condition, clean and properly adjusted.
- Make sure the horn works.
B - DRIVER’S OPERATING INSTRUCTIONS
- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and
instruments before operating the lift truck.
- Wear clothes suited for driving the lift truck, avoid loose clothes.
- Make sure you have the appropriate protective equipment for the job to be done.
- Prolonged exposure to high noise levels may cause hearing problems. It is recommended to wear ear muffs to protect against
excessive noise.
- Always face the lift truck when getting into and leaving the driving seat and use the handle(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 the lift truck when hands or feet are wet or soiled with greasy substances.
- For increased comfort, adjust the seat to your requirements and adopt the correct position in the driver’s cab.
Under no circumstances must the seat be adjusted while the lift truck is moving.
- The operator must always be in his normal position in the driver’s cab. It is prohibited to have arms or legs, or generally any part
of the body, protruding from the driver’s cab of the lift truck.
- The safety belt must be worn and adjusted to the operator’s size.
- The control units must never in any event be used for any other than their intended purposes (e.g. climbing onto or down from the
lift truck, portmanteau, etc.).
- If the control components are fitted with a forced operation (lever lock) device, it is forbidden to leave the cab without first putting
these controls in neutral.
- It is prohibited to carry passengers either on the lift truck or in the cab.
1-8
C - ENVIRONMENT
- Comply with site safety regulations.
- If you have to use the lift truck in a dark area or at night, make sure it is equipped with working lights.
- During handling operations, make sure that no one is in the way of the lift truck and its load.
- Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load.
- When using the lift truck on a transverse slope, before lifting the jib, follow the instructions given in the paragraph: INSTRUCTIONS
FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK.
- Travelling on a longitudinal slope:
• Drive and brake gently.
• Moving without load: Forks or attachment facing downhill.
• Moving with load: Forks or attachment facing uphill.
- 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.
• That the unit to which it is connected (wagon, lorry, etc.) will not shift.
• That this platform is prescribed for the total weight of the lift truck to be loaded.
• That this platform is prescribed for the size of the lift truck.
- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the lift
truck to be loaded and without having checked that they are in sound working order.
- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.
- Make sure the ground is stable and firm under the wheels and/or stabilizers before lifting or removing the load. If necessary, add
sufficient wedging under the stabilizers.
- Make sure that the scaffolding, loading platform, pilings or ground is capable of bearing the load.
- Never stack loads on uneven ground, they may tip over.
If the load or the attachment must remain above a structure for a long time, there is the risk that it will rest on the structure because of the jib
descending owing to the oil in the cylinders cooling down.
To eliminate this 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 ambient temperature.
- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and
the aerial line.
You must consult your local electrical agency. You could be electrocuted or seriously injured if you operate or park the lift truck too close to power
cables.
In the event of high winds, do not carry out handling work that jeopardizes the stability of the lift truck and its load, particularly if the load catches the
wind badly.
D - VISIBILITY
- The safety of people within the lift truck’s working area, as well as that of the lift truck itself and the operator are depend on good
operator visibility of the lift truck’s immediate vicinity in all situations and at all times.
- This lift truck has been designed to allow good operator visibility (direct or indirect by means of rear-view mirrors) of the immediate
vicinity of the lift truck while traveling with no load and with the jib in the transport position.
- Special precautions must be taken if the size of the load restricts visibility towards the front:
- moving in reverse,
- site layout,
- assisted by a person directing the maneuver (while standing outside the truck’s area of travel), making sure to keep this
person clearly in view at all times.
- in any case, avoid reversing over long distances.
- Certain special accessories may require the truck to travel with the jib in the raised position. In such cases, visibility on the right
hand side is restricted, and special precautions must be taken:
- site layout,
- assisted by a person directing the maneuver (while standing outside the truck’s area of travel).
- If visibility of your road is inadequate, ask someone to assist by directing the maneuver (while standing outside the truck’s area
of travel), making sure to keep this person clearly in view at all times.
- Keep all components affecting visibility in a clean, properly adjusted state and in good working order (e.g. windscreens, windows,
windscreen wipers, windscreen washers, driving and work lights, rear-view mirrors).
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E - STARTING THE LIFT TRUCK
SAFETY INSTRUCTIONS
The lift truck must only be started up or maneuvered when the operator is sitting in the driver’s cab, with his seat belt adjusted and fastened.
- Never try to start the lift truck by pushing or towing it. Such operation may cause severe damage to the transmission. If necessary,
to tow the lift truck in an emergency, the transmission must be placed in the neutral position (see: 3 - MAINTENANCE: G OCCASIONAL MAINTENANCE).
- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connecting
it. Connect at first the positive terminals before the negative terminals.
Failure to respect polarity between batteries can cause serious damage to the electrical circuit. The electrolyte in the battery may produce an explosive
gas. Avoid flames and generation of sparks close to the batteries. Never disconnect a battery while it is charging.
INSTRUCTIONS
- Check the closing and locking of the hood(s).
- Check that the cab door is closed.
- Check that the forward/reverse selector is in neutral.
- Turn the ignition key to the position I to activate the electrical system and the preheat.
- Whenever you switch on the lift truck, perform the automatic check on the longitudinal stability limiter and warning device system
(see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS). Do not use the lift truck if it does not conform to the regulations.
- Check the fuel level on the indicator.
- Turn the ignition key fully: the I.C. engine should then start. Release the ignition key and let the I.C. engine run at idle.
- Do not engage the starter motor for more than 15 seconds and carry out the preheating between unsuccessful attempts.
- Make sure all the signal lights on the control instrument panel are off.
- Check all control instruments when the I.C. engine is warm and at regular intervals during use, so as to quickly detect any faults
and to be able to correct them without any delay.
- If an instrument does not show the correct display, stop the I.C. engine and immediately carry out the necessary operations.
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 stability of the lift truck.
The operator must remain in control of the lift truck.
In the event of the lift truck overturning, do not try to leave the cabin during the incident. YOUR BEST PROTECTION IS TO STAY FASTENED IN THE CABIN.
- Observe the company’s traffic regulations or, by default, the public highway code.
- Do not carry out operations which exceed the capacities of your lift truck or attachments.
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 300 mm from the ground, the jib retracted
and the carriage sloping backwards.
- Only carry loads which are balanced and properly anchored to avoid any risk of a load falling off.
- Ensure that palettes, cases, etc, are in good order and suitable for the load to be lifted.
- Familiarise yourself with the lift truck on the terrain where it will be used.
- Ensure that the service brakes are working properly.
- The loaded lift truck must not travel at speeds in excess of 12 km/h.
- Drive smoothly at an appropriate speed for the operating conditions (land configuration, load on the lift truck).
- Do not use the hydraulic jib controls when the lift truck is moving.
- Never change the steering mode whilst driving.
- Do not manoeuvre the lift truck with the jib in the raised position unless under exceptional circumstances and then with extreme
caution, at very low speed and using gentle braking. Ensure that visibility is adequate.
- Take bends slowly.
- In all circumstances make sure you are in control of your speed.
- On damp, slippery or uneven terrain, drive slowly.
- Brake gently, never abruptly.
- Only use the lift truck’s forward/reverse selector from a stationary position and never do so abruptly.
- Do not drive with your foot on the brake pedal.
- Always remember that hydrostatic type steering is extremely sensitive to movement of the steering wheel, so turn it gently and
not jerkily.
- Never leave the I.C. engine on when the lift truck is unattended.
- Do not leave the cab when the lift truck has a raised load.
- Look where you are going and always make sure you have good visibility along the route.
1-10
-
Use the rear-view mirrors frequently.
Drive round obstacles.
Never drive on the edge of a ditch or steep slope.
It is dangerous to use two lift trucks simultaneously to handle heavy or voluminous 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.
INSTRUCTIONS
- Always drive the lift truck with the forks or attachment to the transport position, i.e. at 300 mm from the ground, the jib retracted
and the carriage sloping backwards.
- For lift trucks with gearboxes, use the recommended gear (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
- Select the steering mode appropriate for its use and/or working conditions (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS)
(as model of lift truck).
- Release the parking brake.
- Shift the forward/reverse selector to the selected direction of travel and accelerate gradually until the lift truck moves off.
G - STOPPING THE LIFT TRUCK
SAFETY INSTRUCTIONS
- Never leave the ignition key in the lift truck during the operator’s absence.
- When the lift truck is stationary, or if the operator has to leave his cab (even 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 will interfere with the traffic flow and at less than one meter from
the track of a railway.
- In the event of prolonged parking on a site, protect the lift truck from bad weather, particularly from frost (check the level of
antifreeze), close and lock all the lift truck accesses (doors, windows, cowls…).
INSTRUCTIONS
- Park the lift truck on flat ground or on an incline lower than 15 %.
- Set the forward/reverse selector to neutral.
- Apply the parking brake.
- For lift trucks with gearboxes, place the gear lever in neutral.
- Retract entirely the jib.
- Lower the forks or attachment to rest on the ground.
- When using an attachment with a grab or jaws, or a bucket with hydraulic opening, close the attachment fully.
- Before stopping the lift truck after a long working period, leave the I.C. engine idling for a few moments, to allow the coolant liquid
and oil to lower the temperature of the I.C. engine and transmission. Do not forget this precaution, in the event of frequent stops
or warm stalling of the I.C. engine, or else the temperature of certain parts will rise significantly due to the stopping of the cooling
system, with the risk of badly damaging such parts.
- Stop the I.C. engine with the ignition switch.
- Remove the ignition key.
- Lock all the accesses to the lift truck (doors, windows, cowls…).
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H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY
(or see current legislation in other countries)
SAFETY INSTRUCTIONS
- Operators driving on the public highway must comply with current highway code legislation.
- The lift truck must comply with current road legislation. If necessary, there are optional solutions. Contact your dealer.
INSTRUCTIONS
- Make sure the revolving light is in place, switch it on and verify its operation.
- Make sure the lights, indicators and windscreen wipers are working properly.
- Switch off the working headlights if the lift truck is 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.
- Place the slope correctors in the central position, i.e. the transverse shaft of the axles parallel to the chassis (as model of lift truck).
- Lift up the stabilizers to the maximum and turn the blocks inwards (as model of lift truck).
Never move in neutral (forward/reverse selector or gear lever in neutral or transmission cut-off button pressed) to preserve the lift truck engine brake.
Failure to respect this instruction on a slope will lead to excessive speed which may make the lift truck uncontrollable (steering, brakes) and cause
serious mechanical damage.
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DRIVING THE LIFT TRUCK WITH A FRONT-MOUNTED ATTACHMENT
- You must comply with current regulations in your country, covering the possibility of driving on the public highway with a frontmounted attachment on your lift truck.
- If road legislation in your country authorizes circulation with a front-mounted attachment, you must at least:
• Protect and report any sharp and/or dangerous edges on the attachment (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION
ON THE RANGE: ATTACHMENT SHIELDS).
• The attachment must not be loaded.
• Make sure that the attachment does not mask the lighting range of the forward lights.
• Make sure that current legislation in your country does not require 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 forget to connect the trailer’s electrical equipment to that of the lift truck.
- The trailer’s braking system must comply with current legislation.
- If pulling a trailer with assisted braking, the tractor lift truck must be equipped with a trailer braking mechanism. In this case, do
not forget to connect the trailer braking equipment to the lift truck.
- The vertical force on the towing hook must not exceed the maximum authorised by the manufacturer (consult the manufacturer’s
plate on your lift truck).
- The authorised gross vehicle weight must not exceed the maximum weight authorised by the manufacturer (see: 2 - DESCRIPTION:
CHARACTERISTICS).
IF NECESSARY, CONSULT YOUR DEALER.
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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 appropriate for the work to be done (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE).
- If the lift truck is equipped with the Single side-shift carriage OPTION (TSDL), use only the authorised attachments (see: 4 - ADAPTABLE
ATTACHMENTS IN OPTION ON THE RANGE).
- Make sure the attachment is correctly installed and locked onto the lift truck carriage.
- Make sure that your lift truck attachments work properly.
- Comply with the load chart limits for the lift truck for the attachment used.
- Do not exceed the rated capacity of the attachment.
- Never lift a load in a sling without the attachment provided for the purpose, as the sling risks to slip (see: INSTRUCTIONS FOR
HANDLING A LOAD: H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD).
B - MASS OF LOAD AND CENTRE OF GRAVITY
- Before taking up a load, you must know its mass and its centre of gravity.
- The load chart for your lift truck is valid for a load in which the longitudinal position of the
centre of gravity is 500 mm from the base of the forks (fig. B1). For a higher centre of
gravity, contact your dealer.
- For irregular loads, determine the transverse centre of gravity before any movement (fig.
B2) and set it in the longitudinal axis of the lift truck.
B1
500 mm
It is forbidden to move a load heavier than the effective capacity defined on the lift truck load chart.
For loads with a moving centre of gravity (e.g. liquids), take account of the variations in the centre of
gravity in order to determine the load to be handled and be vigilant and take extra care to limit these
variations as far as possible.
B2
C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
This device gives an indication of the longitudinal stability of the lift truck, and limits
hydraulic movements in order to ensure this stability, at least under the following operating
conditions:
• when the lift truck is at a standstill,
• when the lift truck is on firm, stable and consolidated ground,
• when the lift truck is performing handling and placing operations.
- Move the jib very carefully when approaching the authorized load limit (see: 2 - DESCRIPTION:
INSTRUMENTS AND CONTROLS).
- Always watch this device during handling operations.
- In the event that "AGGRAVATING" hydraulic movements are cut-off, only perform
de-aggravating hydraulic movements in the following order (fig. C): if necessary, raise the
jib (1), retract the jib as far as possible (2) and lower the jib (3) to set down the load.
The instrument reading may be erroneous when the steering is at its maximum limit or the rear axle
oscillated to its limit. Before lifting a load, make sure that the lift truck is not in either of these
situations.
1-14
C
1
2
3
D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK
Depending on the model of lift truck
D1
The transverse attitude is the transverse slope of the chassis with respect to the
horizontal.
Raising the jib reduces the lift truck’s lateral stability. The transverse attitude must be set
with the jib in down position as follows:
1 - LIFT TRUCK WITHOUT SLOPE CORRECTOR USED ON TYRES
- Position the lift truck so that the bubble in the level is between the two lines (see: 2 DESCRIPTION: INSTRUMENTS AND CONTROLS).
2 - LIFT TRUCK WITH SLOPE CORRECTOR USED ON TYRES
- Correct the slope using the hydraulic control and verify the horizontality via the level. The
bubble in the level must be between the two lines (see: 2 - DESCRIPTION: INSTRUMENTS
AND CONTROLS).
D2
3 - LIFT TRUCK USED ON STABILIZERS
- Set the two stabilizers on the ground and raise the two front wheels of the lift truck (fig. D1).
- Correct the slope using the stabilizers (fig. D2) and make sure the truck is horizontal
by checking the level. The bubble of the level must 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 to the load, with the jib retracted and the forks in a horizontal position (fig. E1).
- Adjust the fork spread and centering in connection with the load (fig. E2) (optional solutions
exist, consult your dealer).
E1
- Never lift a load with a single fork.
Beware of the risks of trapping or squashing limbs when manually adjusting the forks.
- Move the lift truck forward slowly (1) and bring the forks to stop in front of the load (fig.
E3), if necessary, slightly lift the jib (2) while taking up the load.
- Bring the load into the transport position.
- Tilt the load far enough backwards to ensure stability (loss of load on braking or going
downhill).
FOR A NON-PALLETIZED LOAD
- Tilt the carriage (1) forwards and move the lift truck slowly forwards (2), to insert the fork
under the load (fig. E4) (block the load if necessary).
- Continue to move the lift truck forwards (2) tilting the carriage (3) (fig. E4) backwards to
position the load on the forks and check the load’s longitudinal and lateral stability.
E4
E3
1
2
2
3
1
1-15
E2
F - TAKING UP AND LAYING A HIGH LOAD ON TYRES
F1
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see:
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
(see: OPERATIONS INSTRUCTIONS UNLADEN AND LADEN: D - VISIBILITY).
2
1
TAKING UP A HIGH LOAD ON TYRES
- Ensure that the forks will easily pass under the load.
- Lift and extend the jib (1) (2) until the forks are level with the load, moving the lift truck (3)
forward if necessary (fig. F1), moving very slowly and carefully.
- Always think about keeping the distance necessary to fit the forks under the load, between
the pile and the lift truck (fig. F1) and use the shortest possible length of jib.
- Stop the forks 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.
- Slightly lift the load (1) and incline the carriage (2) backwards to stabilize the load (fig. F3).
- Tilt the load sufficiently backwards to ensure its stability.
- Watch the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR
HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE). If it is
overloaded, replace the load in the place from which it was taken.
- If possible lower the load without shifting the lift truck. Lift the jib (1) to release the load,
retract (2) and lower the jib (3) to bring the load into the transport position (fig. F4).
- If this is not possible, back up the lift truck (1), manoeuvring very gently and carefully to
release the load. Retract (2) and lower the jib (3) to bring the load into the transport position
(fig. F5).
3
F2
1
2
F3
2
1
F4
1
2
3
F5
2
3
1
1-16
LAYING A HIGH LOAD ON TYRES
- Approach the load in the transport position in front of the pile (fig. F6).
- Put the handbrake on and set the forward/reverse selector to neutral.
- Lift and extend the jib (1) (2) until the load is above the pile, while keeping an eye on the
longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR HANDLING A
LOAD: C - LONGITUDINAL STABILITY 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 retracting
the jib (1) (2) in order to position the load correctly (fig. F8).
- If possible, release the fork by alternately retracting and raising the jib (1) (fig. F9). Then set
the forks into transport position.
- If this is not possible, reverse the lift truck (1) very slowly and carefully to release the
forks (fig. F10). Then set them into transport position.
F6
F7
2
1
3
F8
1
2
F9
1
F10
1
1-17
G - TAKING UP AND LAYING A HIGH LOAD ON STABILIZERS
Depending on the model of lift truck
You must not raise the jib if you have not checked the transverse attitude of the lift truck (see: 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 (see: OPERATIONS INSTRUCTIONS UNLADEN
AND LADEN: D - VISIBILITY).
USING THE STABILIZERS
The stabilizers are used to optimise the lift truck’s lifting performances (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS).
POSITION THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION (UNLADEN AND LADEN)
- Set the forks in transport position in front of the elevation.
- Stay far enough away to have room for the jib to be raised.
- Put the handbrake on and put the gearshift lever into neutral.
- Set the two stabilizers on the ground and lift the two front wheels of the lift truck (fig. G1),
while maintaining its transverse stability.
G1
RAISE THE STABILIZERS WITH THE FORKS IN TRANSPORT POSITION (UNLADEN AND LADEN)
- Raise both stabilizers fully and at the same time.
SETTING THE STABILIZERS WITH THE JIB UP (UNLADEN AND LADEN)
G2
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 front of the elevation (fig. G2) moving very slowly and
carefully.
- Put the handbrake on and put the gearshift lever into neutral.
- Move the stabilizers very slowly and gradually as soon as they are close to the ground or
in contact with it.
- Lower the two stabilizers and lift the two front wheels of the lift truck (fig. G3). During this
operation, transverse attitude must be permanently maintained: the bubble in the level
must be kept between the two lines.
SETTING THE STABILIZERS WITH THE JIB UP (UNLADEN AND LADEN)
G3
This operation must be exceptional and performed with great care.
- Keep the jib up and retract the telescopes completely (fig. G3).
- Move the stabilizers very slowly and gradually as soon as they are in contact with the
ground and when they leave the ground. During this operation, the transverse attitude
must be permanently maintained: the bubble in the level must be kept between the two
lines.
- Raise both stabilizers completely.
- Release the parking brake and reverse the lift truck (1) very slowly and carefully, to
release it and lower the forks (2) into transport position (fig. G4).
G4
2
1
1-18
TAKING UP A HIGH LOAD ON STABILIZERS
- Make sure the forks will fit easily 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 jib (1) (2) until the forks are at the level of the load (fig. G5).
- Block the forks in front of the load by alternately using the controls to extend and lower
the jib (1) (fig. G6).
- Lift the load slightly (1) and tilt the carriage (2) backwards to stabilise the load (fig. G7).
- Monitor the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR
HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE). 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) to set the load into transport position (fig. G8).
G5
2
1
G6
1
G8
G7
2
1
2
1
3
LAYING A HIGH LOAD ON STABILIZERS
- Raise and extend the jib (1) (2) until the load is above the elevation (fig. G9), while
monitoring the longitudinal stability limiter and warning device (see: INSTRUCTIONS FOR
HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE).
- Position the load horizontally and release it by lowering and retracting the jib (1) (2) to
position the load correctly (fig. G10).
- Release the forks by alternating retracting and raising the jib (3) (fig. G11).
- If possible, set the jib in transport position without moving the lift truck.
G10
1
G9
2
1
G11
3
2
1-19
H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD
WARNING: 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.
- Lift the load vertically along its axis, never by pulling sideways or lengthways.
HANDLING WITHOUT MOVING THE LIFT TRUCK
- Whether on stabilisers or on tyres, the lateral attitude must not exceed 1 % and the longitudinal attitude must not exceed 5%, the
bubble of the level must be held at “0”.
- Ensure that the wind speed is not higher than 10 m/s.
- Ensure that there is no one between the load and the lift truck.
I - TRAVELLING WITH A SUSPENDED LOAD
- Before moving, inspect the terrain in order to avoid excessive slopes and cross-falls, bumps and potholes, or soft ground.
- Ensure that the wind speed is not higher than 10 m/s.
- The lift truck must not travel at more than 0.4 m/s (1.5 km/h, i.e., one quarter walking speed).
- Drive 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
indicated on the load chart. If the load begins to swing excessively, do not hesitate to stop and lower the jib to set down the
load.
- Before moving the lift truck, check the longitudinal stability limiter and warning device (see: 2 - DESCRIPTION: INSTRUMENTS AND
CONTROLS), only the green LEDs and possibly the yellow LEDs should be lit.
- During transport, the lift truck operator must be assisted by a person on the ground (standing a minimum of 3 m from the load),
who will limit swinging of the load using a bar or a rope. Ensure that this person is always clearly in view.
- The lateral attitude must not exceed 5%, the bubble in the level must be kept between the two “MAX.” marks
- The longitudinal attitude must not exceed 15%, with the load facing uphill, and 10%, with the load facing downhill.
- The jib angle must not exceed 45°.
- If the first red LED of the longitudinal stability limiter and warning device (see: 2 - DESCRIPTION: INSTRUMENTS AND CONTROLS)
comes on while travelling, gently bring the lift truck to a stop and stabilise the load. Retract the telescope to reduce the offset of
the load.
1-20
PLATFORM OPERATING INSTRUCTIONS
For PLATFORM-fitted lift trucks
Installation of the platform on the lift truck is only possible if the shields “operating the platform” of the lift truck and the platform are identical (see: 2
- DESCRIPTION: OPERATING THE PLATFORM).
A - AUTHORISATION FOR USE
- Operation of the platform requires further authorisation in addition to that of the lift truck.
B - SUITABILITY OF THE TRUCK FOR USE
- 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 of 1.25 and a DYNAMIC test coefficient of 1.1, as specified in harmonised standard
EN 280 for “mobile elevating work platforms”.
- Before commissioning, the company manager must make sure that the platform is appropriate for the work to be done, and
perform certain tests (in accordance with current legislation).
C - PRECAUTIONS WHEN USING THE PLATFORM
- Wear clothes suited for operating the platform, avoid loose clothes.
- Never operate the platform when hands or feet are wet or soiled with greasy substances.
- Always pay attention when using the platform. Do not listen to the radio or music using headphones or earphones.
- For increased comfort, adopt the correct position at the platform’s operator station.
- The platform’s guard rail exempts the operator from wearing a safety harness under normal operating conditions. As a result, you
are responsible deciding whether to wear a safety harness.
- The controls must not be used for any other than their intended purpose (e.g. getting in and out of the lift truck, coat hanger etc.).
- Safety helmets must be worn.
- The operator must always be in the normal operator’s position. It is prohibited to have arms or legs, or generally any part of the
body, protruding from the basket.
- Ensure that any materials loaded onto the platform (pipes, cables, containers, etc.) cannot fall 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 operation of all control
instruments prior to operating the platform.
- Check before operating that the platform has been correctly assembled and locked onto the lift truck.
- Check before operating the platform that the access gate has been properly locked.
- The platform should be operated in an area free of any obstructions or danger when it is lowered to the ground.
- The operator using the platform must be aided on the ground by a person with adequate training.
- You should stay within the limits set out in the platform load chart.
- The lateral stresses are limited pressure (see: 2 - DESCRIPTION: CHARACTERISTICS).
- It is strictly forbidden to hand a load from the platform or the lift truck jib without a specially designed attachment (see: INSTRUCTIONS
FOR HANDLING A LOAD: H - TAKING UP AND LAYING DOWN A SUSPENDED LOAD).
- The platform cannot be used as a crane or a lift for permanently transporting people or materials, nor as jacks or supports.
- The lift truck must not be moved with one (or more) person(s) in the platform.
- It is forbidden to transport people on the platform using the hydraulic controls in the lift truck’s driver’s cab (except in case of rescue).
- The operator must not get in or out of the platform when it is not on ground level (jib retracted and in the down position).
- The platform must not be fitted with attachments that increase the unit’s wind load.
- Do not use ladders or improvised structures in the platform to gain extra height.
- Do not climb onto the sides of the platform to gain extra height.
E - ENVIRONMENT
NOMINAL VOLTAGE
Operating the platform close to electricity cables is forbidden. Maintain the specified
safe distances.
1-21
50 < U < 1000
1000 < U < 30000
30000 < U < 45000
45000 < U < 63000
63000 < U < 90000
90000 < U < 150000
150000 < U < 225000
225000 < U < 400000
400000 < U < 750000
DISTANCE ABOVE THE
GROUND OR THE FLOOR
IN METRES
2,30 M
2,50 M
2,60 M
2,80 M
3,00 M
3,40 M
4,00 M
5,30 M
7,90 M
Operation of the platform is strictly forbidden in the event of wind speeds of over 45 km/h.
- The following scale is given for an empiric evaluation of the wind speed:
BEAUFORT scale (wind speed at a height of 10 m from flat ground)
Force
Type of wind
Speed
(knots)
Speed
(kph)
Speed
(m/s)
0
1
Calm
Light air
0-1
1-3
0-1
1-5
< 0,3
0,3 - 1,5
2
Light breeze
4-6
6 - 11
1,6 - 3,3
7 - 10
12 - 19
3,4 - 5,4
11 - 16
20 - 28
5,5 - 7,9
29 - 38
8 - 10,7
3
4
Gentle
breeze
Moderate
breeze
5
Fresh breeze
17 - 21
6
Strong
breeze
22 - 27
7
Near gale
28 - 33
8
Gale
34 - 40
9
Strong gale
41 - 47
10
Storm
48 - 55
11
Violent
storm
56 - 63
12
Hurricane
64 +
Effects on Land
Smoke rises vertically.
The wind bends the smoke.
The wind can be felt on the face,
shakes the leaves.
The wind continuously shakes the
leaves and twigs.
The wind raises dust and scraps of
paper, shakes the twigs.
Leafy shrubs sway.
Sea condition
Sea like a mirror.
Ripples but without foam crests.
Small but evident wavelets.
Large wavelets Perhaps scattered
white horses.
Small waves. Fairly frequent white
horses.
Small waves form on inland waters.
Moderate waves, many white
horses.
Shakes thick branches, metal wires
Large waves begin to form, white
10,8 - 13,8 hum, it becomes difficult to keep an
foam crests, probably spray.
umbrella open.
Sea heaps up and white foam blown
Whole trees sway, it is difficult to
50 - 61 13,9 - 17,1
in streaks along the direction of the
walk against the wind.
wind.
Breaks the branches of trees, it is
Moderately high waves, crests begin
62 - 74 17,2 - 20,7 almost impossible to walk against
to break into spindrift.
the wind.
High waves. Dense foam along
Causes slight damage to buildings the direction of the wind. Crests of
75 - 88 20,8 - 24,4
(stacks, tiles, etc..).
waves begin to roll over. Spray may
affect visibility.
Rare inland, uproots trees, causes Very high waves with long overhanging
89 - 102 24,5 - 28,4
considerable damage to buildings.
crests. Visibility affected.
Exceptionally high waves that may
Very
rare,
causes
extensive
hide medium sized ships. Visibility
103 - 117 28,5 - 32,6
devastation.
affected.
The air is filled with foam and
spray. Sea completely white with
118 +
32,7 + Causes very serious catastrophes.
driving spray. Visibility very seriously
affected.
39 - 49
F - MAINTENANCE
Your platform must be periodically inspected to ensure its continued compliance. The inspection frequency is defined by the current legislation in the
country in which the platform is used.
1-22
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.
If it is used improperly or incorrectly, there is a risk of danger to:
- The physical and mental health of the user or others.
- The lift truck and other neighbouring items.
Everyone working with this radio-control:
- Must be qualified in line with current regulations and therefore appropriately trained.
- Must follow this instruction manual as closely as possible.
- The system is used to control the lift truck remotely via radio waves. Commands are also transmitted if the lift truck is out of sight
(behind an obstacle or a building for example), this is why:
• After stopping the truck and removing the key button (only possible when it is stationary), always place the transmitter in
a safe, dry place.
• Before performing any installation, servicing or repair work, always switch off power sources (in particular, electric welding
devices and electric head units on hydraulic distributors must be disconnected at each section).
• Never remove or alter the safety devices (such as the hand-guard frame, key, emergency stop button, etc.).
Never drive the lift truck if it is not continuously and perfectly within view of the operator!
- Before leaving the transmitter, the operator must make sure that it cannot be used by an unauthorized third person: either by
removing the key 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.
INSTRUCTIONS
- Take up position in a stable place with no risk of slipping.
- Before using the transmitter, make sure there is nobody within the working area.
- Only use the transmitter with its carrying device or installed correctly on the platform.
When you remove the transmitter, remove the accumulator and key button so that it cannot be used accidentally or deliberately by anyone else.
PROTECTIVE DEVICES
- The lift truck will be immobilised within 450 milliseconds (approx. 0.5 second) at most:
• If the transmitter emergency stop button (50 milliseconds), or the one on the lift is pressed.
• If the transmission distance of the radio waves is exceeded.
• If the transmitter is faulty.
• If an interfering radio signal is received from elsewhere.
• If the accumulator is removed from its housing in the transmitter.
• If the accumulator reaches the end of its autonomy.
• If the transmitter is switched off by turning the key button to stop.
- These protective devices are provided for the safety of personnel and property and must never be altered, removed or bypassed
in any way whatsoever!
- The hand-guard frame prevents external action on a manipulator (if the transmitter falls, for example, or if the operator leans on
a guard-rail).
- An electronic safety device prevents radio transmission from being initiated if the manipulators are not mechanically and electrically
at rest and if the internal combustion engine speed selector is not set to idle.
In an emergency, press the transmitter emergency stop button immediately ; then follow the manual’s instructions (see: 2 - DESCRIPTION: INSTRUMENTS
AND CONTROLS).
1-23
MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK
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 and protect your hair,
if necessary.
- Stop the I.C. engine and remove the ignition key, when an intervention is necessary.
- Read the operator’s manual carefully.
- Carry out all repairs immediately, even if the repairs concerned are minor.
- Repair all leaks immediately, even if the leak concerned is minor.
- Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.
- Be careful of the risk of burning and splashing (exhaust, radiator, I.C. engine, etc.).
MAINTENANCE
- Perform the periodic service (see: 3 - MAINTENANCE) to keep your lift truck in good working conditions. Failure to perform the periodic
service may cancel the contractual guarantee.
MAINTENANCE LOGBOOK
- The maintenance operations carried out in accordance with the recommendations given in part: 3 - MAINTENANCE and the other
inspection, servicing or repair operations or modifications performed on the lift truck or its attachments shall be recorded in a
maintenance logbook. The entry for each operation shall include details of the date of the works, the names of the individuals 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 the recommended lubricants (never use contaminated lubricants).
Do not fill the fuel tank when the I.C. engine is running.
Only fill up the fuel tank in areas specified for this purpose.
Do not fill the fuel tank to the maximum level.
Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
HYDRAULIC
- Any work on the load handling hydraulic circuit is forbidden except for the operations described in part: 3 - MAINTENANCE.
- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.
BALANCING VALVE: It is dangerous to change the setting and remove the balancing valves or safety valves which may be fitted to your lift truck cylinders.
These operations must only be performed by approved personnel (consult your dealer).
The HYDRAULIC ACCUMULATORS that may be fitted on your lift truck are pressurized units. Removing these accumulators and their pipework is a
dangerous operation and must only be performed by approved personnel (consult your dealer).
ELECTRICITY
- Do not short-circuit the starter relay to start the IC engine. If the forward/reverse selector is not in neutral and the parking brake is
not engaged, the lift truck may suddenly start to move.
- Do not drop metallic items on the battery.
- Disconnect the battery before working on the electrical circuit.
1-24
WELDING
- Disconnect the battery before any welding operations on the lift truck.
- When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being
welded, so as to avoid high tension current passing through the alternator.
- Never carry out welding or work which gives off heat on an assembled tyre. The heat would increase the pressure which could
cause the tyre to explode.
- If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing
irreparable damage to electronic components.
WASHING THE LIFT TRUCK
-
Clean the lift truck or at least the area concerned before any intervention.
Remember to close and lock all accesses to the lift truck (doors, windows, cowls…).
During washing, avoid the articulations and electrical components and connections.
If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged,
particularly electrical components and connections and the injection pump.
- Clean the lift truck of any fuel, oil or grease trace.
FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT YOUR DEALER.
1-25
IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME
INTRODUCTION
The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from service for an
extended period.
For these operations, we recommend the use of a MANITOU protective product, reference 603726.
Instructions for using the product are given on the packaging.
Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership.
PREPARING THE LIFT TRUCK
-
Clean the lift truck thoroughly.
Check and repair any leakage of fuel, oil, water or air.
Replace or repair any worn or damaged parts.
Wash the painted surfaces of the lift truck in clear and cold water and wipe them.
Touch up the paintwork if necessary.
Shut down the lift truck (see: OPERATING INSTRUCTIONS UNLADEN AND LADEN).
Make sure the jib cylinder rods are all in retracted position.
Release the pressure in the hydraulic circuits.
PROTECTING THE I.C. ENGINE
- Fill the tank with fuel (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
- Empty and replace the cooling liquid (see: 3 - MAINTENANCE: F - EVERY 2000 HOURS SERVICE).
- Leave the I.C. engine running at idling speed for a few minutes, then switch off.
- Replace the I.C. engine oil and oil filter (see: 3 - MAINTENANCE: D - EVERY 500 HOURS SERVICE).
- Add the 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, after charging it to a maximum.
- Remove the injectors and spray the protective product into each cylinder for two seconds with the piston in low neutral position.
- Turn the crankshaft once slowly and refit the injectors (see I.C. engine REPAIR MANUAL).
- Remove the intake hose from the manifold or turbocharger and spray the protective product into the manifold or turbocharger.
- Cap the intake manifold or turbocharger hole with waterproof adhesive tape.
- Remove the exhaust pipe and spray the protective product into the exhaust manifold or turbocharger.
- Refit the exhaust pipe and block the outlet with waterproof adhesive tape.
NOTE: The spray time is noted on the product packaging and must be increased by 50 % for turbo engines.
- Open the filler plug, spray the protective product around the rocker arm shaft and refit the filler plug.
- Cap the fuel tank using waterproof adhesive tape.
- Remove the drive belts and store them in a safe place.
- Disconnect the engine cut-off solenoid on the injection pump and carefully insulate the connection.
PROTECTING THE LIFT TRUCK
- Set the lift truck on axle stands so that the tyres are not in contact with the ground and release the handbrake.
- Protect cylinder rods which will not be retracted, from corrosion.
- Wrap the tyres.
NOTE: If the lift truck is to be stored outdoors, cover it with a waterproof tarpaulin.
1-26
BRINGING THE LIFT TRUCK BACK INTO SERVICE
-
Remove the waterproof adhesive tape from all the holes.
Refit the intake hose.
Refit and reconnect the battery.
Remove the protection from the cylinder rods.
Perform the daily service (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).
Put the handbrake on and remove the axle stands.
Empty and replace the fuel and replace the fuel filter (see: 3 - MAINTENANCE: 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.
Reconnect the engine cut-off solenoid.
Lubricate the lift truck completely (see: 3 - MAINTENANCE: SERVICING SCHEDULE).
Make sure the area is adequately ventilated before starting up the lift truck.
- Start up the lift truck, following the safety instructions and regulations (see: OPERATING INSTRUCTIONS UNLADEN AND LADEN).
- Run all the jib’s hydraulic movements, concentrating on the ends of travel for each cylinder.
1-27
1-28
2 - DESCRIPTION
2-1
2-2
TABLE OF CONTENTS
«EC» DECLARATION OF CONFORMITY
2-4
IDENTIFICATION OF THE LIFT TRUCK
2-6
CHARACTERISTICS
MT 1440 E3
2-8
CHARACTERISTICS
MT 1840 E3
2-10
FRONT AND REAR TIRES
2-12
DIMENSIONS AND LOAD CHART
MT 1440 E3
2-14
DIMENSIONS AND LOAD CHART
MT 1840 E3
2-16
INSTRUMENTS AND CONTROLS
2-18
TOWING PIN AND HOOK
2-46
DESCRIPTION AND USE OF THE OPTIONS
2-48
2-3
«EC» DECLARATION OF CONFORMITY
1)
DÉCLARATION «CE» DE CONFORMITÉ (originale)
«EC» DECLARATION OF CONFORMITY (original)
2)
La société, The company : MANITOU BF
3)
Adresse, Address : 430, rue de l’Aubinière - BP 10249 - 44158 - ANCENIS CEDEX - FRANCE
4)
Dossier technique,Technical file : MANITOU BF - 430, rue de l’Aubinière
BP 10249 - 44158 - ANCENIS CEDEX - FRANCE
5)
Constructeur de la machine décrite ci-après, Manufacturer of the machine described below :
MT 1440 E3
MT 1840 E3
6)
Déclare que cette machine, Declares that this machine :
7)
Est conforme aux directives suivantes et à leurs transpositions en droit national,
Complies with the following directives and their transpositions into national law :
2006/42/CE
8)
Pour les machines annexe IV , For annex IV machines :
9) Numéro d’attestation, Certificate number :
10) Organisme notifié, Notified body :
15)
Normes harmonisées utilisées, Harmonised standards used :
16)
Normes ou dispositions techniques utilisées, Standards or technical provisions used :
17)
Fait à, Done at : Ancenis
19)
Nom du signataire, Name of signatory : Christian CALECA
20)
Fonction, Function : Directeur Général Adjoint
21)
Signature, Signature :
18)
Date, Date : 21/01/2011
2-4
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2-5
IDENTIFICATION OF THE LIFT TRUCK
As our policy is to promote a constant improvement of our products, our range of telescopic lift trucks may undergo certain modifications,
without obligation for us to advise our customers.
When you order parts, or when you require any technical information, always specify:
NOTE: For the owner’s convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time
of the delivery of the lift truck.
LIFT TRUCK MANUFACTURER’S PLATE (FIG. A)
-
A
Model
Series
Serial Nr
Year of manufacture
MANITOU BF 44158 ANCENIS CEDEX FRANCE
MODELE
MODEL
MODELLO
MODELO
SERIE
SERIES
SERIE
SERIE
N° de série
Serial Nr
Année de fabrication
Year of manufacture
Anno di fabbricazione
Año de fabricacion
Numero di serie
Número de serie
Masse à vide
Unladen mass
For any further technical information regarding your lift truck refer to chapter: 2 - DESCRIPTION:
CHARACTERISTICS.
Puissance ISO/TR14396
Power ISO/TR14396
Potenza ISO/TR14396
Potencia ISO/TR14396
Massa a vuoto
Masa en vacio
kg
Numéro d'homologation
Homologation number
Numero d'omologazione
Contraseña homologacion
kW
Effort vertical max. (sur accrochage remorque)
Vertical max. effort (on trailer hook)
Carico max. verticale (sul gancio di traino)
Esfuerzo vertical max. (sobre el gancho de remolque)
daN
Pression des pneumatiques (Bar)
Tyre pressure (Bar)
Pressione per pneumatici (Bar)
Presion de los neumáticos (Bar)
Avant
Anteriore
Arrière Posteriore
Front
Adelante
Rear
Trasero
Capacité maxi nominale
Nominal maximum capacity
Capacità maxi nominale
Capacidad máximo nominal
kg
Effort de traction
Tractive effort
Forza di traino
Esfuerzo de traccion
daN
N°283688
I.C. ENGINE (FIG. B)
B
- I.C. engine Nr
GEAR BOX (FIG. C)
C
- Type
- MANITOU reference
- Serial Nr
FRONT AXLE (FIG. D)
D
- Type
- Serial Nr
- MANITOU reference
2-6
REAR AXLE (FIG. E)
E
- Type
- Serial Nr
- MANITOU reference
CAB (FIG. F)
F
- Type
- Serial Nr
JIB (FIG. G)
G
- MANITOU reference
- Date of manufacture
PLATE MANUFACTURER OF THE ATTACHMENT (FIG. H)
H
- Model
- Serial Nr
- Year of manufacture
MANITOU BF
44158 ANCENIS CEDEX
FRANCE
MODELE
N$ dans la série
Année fabrication
Masse à vide
kg
C d G / Tablier
A vide / En charge : mm
Cap. Nominale
Pression de service
AVERTISSEMENT : RESPECTEZ
LA CAPACITE DE L'ENSEMBLE
"CHARIOT ET EQUIPEMENT"
N$207701
2-7
CHARACTERISTICS
MT 1440 E3
I.C. ENGINE
Type
Fuel
Number of cylinders
Suction
Injection system
Ignition sequence
Capacity
Bore and stroke
Compression ratio
Nominal rating loaded
Rating slow unladen
Max. rating unladen
Power ISO/TR 14396
Power SAE J 1995
Maximum torque ISO/TR 14396
Air cleaner
Type of cooling
Fan
cm3
mm
rpm
rpm
rpm
cv- kW
cv- kW
Nm
μm
TRANSMISSION
Gear box
Type
Forward/reverse selector
Torque converter
Number of forward speeds
Number of reverse speeds
Angle gear box
Front axle
Differential
Rear axle
Differential
Drive wheels
Switch for 2/4 drive wheels
Front tyres
Size
Pressure
Rear tyres
Size
Pressure
bar
bar
ELECTRIC CIRCUIT
Battery
Alternator
Type
Starter
Type
PERKINS 1104D-44TA RP52117
Diesel
4 in line
Supercharged
Direct
1.3.4.2
4400
105 x 127
18,2/1
2200
850
2350
101 - 74,5
101 - 74,5
400 to 1400 rpm
3
By water
Puller
DANA
Mechanical
Electro-hydraulic
DANA
4
4
DANA
Without locking
DANA
Without locking
4RM Permanent
No
MICHELIN
400/80-24 162A8 TUBELESS
5
MICHELIN
400/80-24 162A8 TUBELESS
5
12 V - 110 Ah - 900 A EN
12 V - 85 A
DENSO A115i
12 V - 3,2 kW
ISKRA AZE
BRAKE CIRCUIT
Service brake
Type of brake
Type of control
Parking brake
Type of brake
Type of control
Hydraulic power brake
Multidisk brake immersed in oil
Foot-operated for the front and rear axles
Low pressure brake
Disk on gear-box output
Electro-hydraulic
SOUND AND VIBRATION
Level of sound pressure in the driver’s cab LpA
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on driver’s body
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the driver’s hand/arm system
(according to standard ISO 5349-2)
2-8
dB
82 (cab closed)
dB
105 (measured)
106 (ensured)
m/s2
0,985
m/s2
< 2,5
HYDRAULIC CIRCUIT
Hydraulic pump
Type
Gear pump with flow divider on 2nd casing
Capacity
Max. rating capacity unladen
Flow rate at 1600 rpm
Filtration
Return
Suction
Maximum service pressure
Telescoping circuit
Lifting circuit
Tilt circuit
Stabilizers Circuit
Tilting corrector circuit
Attachment circuit
Steering circuit
cm3
l/mn
l/mn
μm
μm
bar
bar
bar
bar
bar
bar
bar
bar
HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device
Lifting motions (jib retracted)
Unladen lifting
Laden lifting
Unladen lowering
Laden lowering
Telescoping motions (jib raised)
Unladen extending
Laden extending
Unladen retracting
Laden retracting
Tilting movements
Unladen digging
Forward tilting unladen
1st casing
45
106
72
2nd casing
27
64
44
16
135
16
135
270
270 / 270
270 / 210
280 / 200
270
270
270
140
Electronic
s
s
s
s
-
m/mn
m/mn
m/mn
m/mn
s - m/mn
s - m/mn
s - m/mn
s - m/mn
SPECIFICATIONS AND WEIGHTS
Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen
1
2
3
4
Rear unladen
1
2
3
4
Standard attachment
Weight with forks
Weight of forks (each one)
Rated capacity with standard attachment
Tipping load at maximum reach on stabilisers
Distance from the centre of gravity from the load to the lug of the forks
Standard lifting height
Lift truck weight without attachment
Lift truck weight with standard attachment
Unladen
At rated load
Weight per axle with standard attachment (transport position)
Front unladen
Rear unladen
Front rated load
Rear rated load
Weight per axle with standard attachment (jib extended)
Front rated load
Rear rated load
Contact pressure on the ground for the whole surface of each stabilizer
at maximum load when tilting
Authorised gross vehicle weight
Drag strain on the coupling hook
Unladen (sliding)
At rated load (transmission setting)
Pull strain with open carrier (according to standard ISO 8313)
2-9
15,49
14,97
11,58
11,16
-
24,1
29,4
32,3
33,5
16,45 - 27,7
16,47 - 27,7
11,89 - 38,4
11,82 - 38,6
s - °/s
s - °/s
3,92 - 32,1
3,97 - 31,7
km/h
km/h
km/h
km/h
km/h
km/h
km/h
km/h
5,1
8,1
15,2
25,7
5,1
8,1
15,2
25,7
TFF 45 MT1040
228
71
4000
1950
500
13530
10745
kg
kg
kg
kg
mm
mm
kg
kg
kg
11115
15115
kg
kg
kg
kg
5355
5760
12615
2500
kg
kg
10995
420
kg/cm2
5,57
daN
20000
daN
daN
daN
6235
8240
5340
CHARACTERISTICS
MT 1840 E3
I.C. ENGINE
Type
Fuel
Number of cylinders
Suction
Injection system
Ignition sequence
Capacity
Bore and stroke
Compression ratio
Nominal rating loaded
Rating slow unladen
Max. rating unladen
Power ISO/TR 14396
Power SAE J 1995
Maximum torque ISO/TR 14396
Air cleaner
Type of cooling
Fan
cm3
mm
rpm
rpm
rpm
cv- kW
cv- kW
Nm
μm
TRANSMISSION
Gear box
Type
Forward/reverse selector
Torque converter
Number of forward speeds
Number of reverse speeds
Angle gear box
Front axle
Differential
Rear axle
Differential
Drive wheels
Switch for 2/4 drive wheels
Front tyres
Size
Pressure
Rear tyres
Size
Pressure
bar
bar
ELECTRIC CIRCUIT
Battery
Alternator
Type
Starter
Type
PERKINS 1104D-44TA RP52117
Diesel
4 in line
Supercharged
Direct
1.3.4.2
4400
105 x 127
18,2/1
2200
850
2350
101 - 74,5
101 - 74,5
400 to 1400 rpm
3
By water
Puller
DANA
Mechanical
Electro-hydraulic
DANA
4
4
DANA
Without locking
DANA
Without locking
4RM Permanent
No
MICHELIN
440/80-24 168A8 TUBELESS
4,5
MICHELIN
440/80-24 168A8 TUBELESS
4,5
12 V - 110 Ah - 900 A EN
12 V - 85 A
DENSO A115i
12 V - 3,2 kW
ISKRA AZE
BRAKE CIRCUIT
Service brake
Type of brake
Type of control
Parking brake
Type of brake
Type of control
Hydraulic power brake
Multidisk brake immersed in oil
Foot-operated for the front and rear axles
Low pressure brake
Disk on gear-box output
Electro-hydraulic
SOUND AND VIBRATION
Level of sound pressure in the driver’s cab LpA
(according to standard NF EN 12053)
Level of sound power ensured in the LwA environment
(according to directive 2000/14/EC modified by directive 2005/88/EC)
Average weighted acceleration on driver’s body
(according to standard NF EN 13059)
The average weighted acceleration transmitted to the driver’s hand/arm system
(according to standard ISO 5349-2)
2-10
dB
82 (cab closed)
dB
105 (measured)
106 (ensured)
m/s2
0,985
m/s2
< 2,5
HYDRAULIC CIRCUIT
Hydraulic pump
Type
Gear pump with flow divider on 2nd casing
Capacity
Max. rating capacity unladen
Flow rate at 1600 rpm
Filtration
Return
Suction
Maximum service pressure
Telescoping circuit
Lifting circuit
Tilt circuit
Stabilizers Circuit
Tilting corrector circuit
Attachment circuit
Steering circuit
cm3
l/mn
l/mn
μm
μm
bar
bar
bar
bar
bar
bar
bar
bar
HYDRAULIC MOVEMENTS
Longitudinal stability limiter and warning device
Lifting motions (jib retracted)
Unladen lifting
Laden lifting
Unladen lowering
Laden lowering
Telescoping motions (jib raised)
Unladen extending
Laden extending
Unladen retracting
Laden retracting
Tilting movements
Unladen digging
Forward tilting unladen
1st casing
45
106
72
2nd casing
27
64
44
16
135
16
135
270
270 / 270
270 / 210
280 / 200
270
270
270
140
Electronic
s
s
s
s
SPECIFICATIONS AND WEIGHTS
Speed of movement for lift truck in standard configuration on flat
ground (except particular conditions)
Front unladen
1
2
3
4
Rear unladen
1
2
3
4
Standard attachment
Weight with forks
Weight of forks (each one)
Rated capacity with standard attachment
Tipping load at maximum reach on stabilisers
Distance from the centre of gravity from the load to the lug of the forks
Standard lifting height
Lift truck weight without attachment
Lift truck weight with standard attachment
Unladen
At rated load
Weight per axle with standard attachment (transport position)
Front unladen
Rear unladen
Front rated load
Rear rated load
Weight per axle with standard attachment (jib extended)
Front rated load
Rear rated load
Contact pressure on the ground for the whole surface of each stabilizer
at maximum load when tilting
Authorised gross vehicle weight
Drag strain on the coupling hook
Unladen (sliding)
At rated load (transmission setting)
Pull strain with open carrier (according to standard ISO 8313)
2-11
-
m/mn
m/mn
m/mn
m/mn
17,29 - 23,3
17,3 - 23,2
12,72 - 31,6
12,62 - 31,9
s - m/mn
s - m/mn
s - m/mn
s - m/mn
16,06 - 13,6
16,5 - 13,9
15,6 - 14,3
15 - 14,9
s - °/s
s - °/s
5,03 - 25
3,98 - 31,6
km/h
km/h
km/h
km/h
km/h
km/h
km/h
km/h
5,4
8,5
16
27,1
5,4
8,5
16
27,1
TFF 45 MT1040
228
71
4000
1110
500
17530
11260
kg
kg
kg
kg
mm
mm
kg
kg
kg
11630
15630
kg
kg
kg
kg
5480
6150
12930
2700
kg
kg
11450
580
kg/cm2
4,97
daN
20000
daN
daN
daN
7380
10023
7447
FRONT AND REAR TIRES
440/80-24 T37 158B TUBELESS
15.5-25 16PR GIRAFFE L2
400/80-24 162A8 TUBELESS
15.5-25 12PR EM-20 TUBELESS
PRESSURE
(bar)
4,5
5,2
5
4,6
440/80-24 T37 158B TUBELESS
15.5-25 16PR GIRAFFE L2
440/80-24 168A8 TUBELESS
15.5-25 12PR EM-20 TUBELESS
PRESSURE
(bar)
4,5
5,2
4,5
4,6
MT 1440 E3
DUNLOP
GALAXY
MICHELIN
MITAS
MT 1840 E3
DUNLOP
GALAXY
MICHELIN
MITAS
PRESSION
(bar)
DUNLOP
440/80-24 T37 158B TUBELESS
4,5
GALAXY
15.5-25 16PR GIRAFFE L2
5,2
400/80-24 162A8 TUBELESS
5
440/80-24 168A8 TUBELESS
4,5
15.5-25 12PR EM-20 TUBELESS
4,6
MICHELIN
MITAS
FRONT UNLADEN
TYRE LOAD (kg)
FRONT LADEN
REAR UNLADEN
2700
6300
FRONT UNLADEN
CHARGE
(kg)
1250
1350
2700
2750
2900
3050
6300
6450
1250
1350
2700
2750
2900
3050
6300
6450
1250
2700
2900
6300
1350
2750
3050
6450
1250
1350
2700
2750
2900
3050
6300
6450
2-12
1250
2900
TYRE LOAD (kg)
FRONT LADEN
REAR UNLADEN
2750
6450
6,84
6,99
8,71
8,73
8,92
8,97
12,86
12,97
1,89
1,84
2,41
2,42
2,47
2,50
3,54
3,58
REAR LADEN
1350
3050
PRESSION DE CONTACT AU SOL
(kg/cm2)
SOL DUR
SOL MEUBLE
REAR LADEN
SURFACE DE CONTACT AU SOL
(cm2)
SOL DUR
SOL MEUBLE
180
190
310
315
325
340
490
498
650
686
1120
1135
1173
1220
1780
1803
2-13
DIMENSIONS AND LOAD CHART
MT 1440 E3
D1
C1
N
G2
G
G1
Y
L
P2
D2
B
C
A
I
D
E
W3
J
H
G3
F1
K
V
F
W
W1
O
R
V2
V1
T
S
2-14
U2
U1
W2
H1
1200
3070
1905
1790
6135
6020
4872
7335
1960
1960
384
367
380
355
9
9
1160
892
1040
50
1855
125
34
33
3779
8615
4183
2452
2640
5468
1285
3975
2351
3793
1134
2422
12
114
P3
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
°
°
mm
mm
mm
mm
mm
mm
°
°
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
°
°
Z
A
B
C
C1
D
D1
D2
E
F
F1
G
G1
G2
G3
H
H1
I
J
K
L
N
O
P2
P3
R
S
T
U1
U2
V
V1
V2
W
W1
W2
W3
Y
Z
SUIVANT NORME EN 1459 annexe B.
15
50°
60°
70° 71.3°
14
13.53
13
40°
12
11
10
30° 9
8
7
3000KG
2000KG
2
1500KG
10° 3
2500KG
4
4000KG
20° 6
5
1
0°
-1.2° 0
0.5m
-1 10 9
9.38
8
7
6
5
6.20 5.10
4
3
2 1
1.86
MT 1440
0m
N°261552
N°261549
50°
60° 62°
14
40°
12.3
13
12
11
10
30° 9
8
2
1
0°
300KG
900KG
10° 3
400KG
4
600KG
5
4000KG
20° 6
1200KG
1500KG
2000KG
2500KG
3000KG
7
MT 1440
0
-6.2° -1
0.5m
10 9 8 7 6 5 4 3 2
1
9.46
7.75
5.85 4.25 3.10 1.91
8.80
6.70 5.10 3.60 2.40
0m
SUIVANT NORME EN 1459 annexe B.
2-15
DIMENSIONS AND LOAD CHART
MT 1840 E3
A
B
C
C1
D
D1
D2
E
F
F1
G
G1
G2
G3
H
H1
I
J
K
L
N
O
P2
P3
R
S
T
U1
U2
V
V1
V2
W
W1
W2
W3
Y
Z
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
°
°
mm
mm
mm
mm
mm
mm
°
°
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
°
°
1200
3070
2043
1929
6274
6159
4894
7474
1960
1960
437
420
433
302
9
9
1160
892
1040
50
1908
125
37
34
3779
8788
4307
2505
2693
5592
1285
4009
2420
3793
1134
2422
12
114
2-16
2-17
INSTRUMENTS AND CONTROLS
6
25
24
7
25
25
27
24
24
23
24
29
14
15
3
34
20
28
24
4
17
17
19
18
30
17
17
2
1
35
2
8
12
9
31
5
8
13
11
37
16
26
10
26
21
22
41
32
36
35
33
2-18
DESCRIPTION
1
2
3
4
5
6
-
DRIVER’S SEAT
SAFETY BELT
IGNITION SWITCH
EMERGENCY STOP BUTTON
BATTERY CUT-OFF
MAN-MACHINE INTERFACE (MMI)
6A - DRIVER PRESENCE
6B - INSTRUMENT CONTROL PANEL
6C - PANEL FOR BUTTONS AND KEYBOARD
6D - SCREEN DISPLAY
7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
8 - SWITCHES
9 - FUSES AND RELAYS IN THE CAB
10 - FUSES AND RELAYS UNDER THE ENGINE HOOD
11 - DOOR PRESENCE SENSORS
12 - LIGHTER
13 - HANDLE FOR OPENING ENGINE HOOD
14 - SWITCH FOR LIGHTING, HORN AND INDICATORS
15 - FRONT AND REAR WINDSCREEN WIPER SWITCH
16 - FUNCTION FILES
17 - HYDRAULIC CONTROLS
18 - ACCELERATOR PEDAL
19 - SERVICE BRAKE PEDAL
20 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
21 - GEAR LEVER
22 - STEERING SELECTION
23 - HEATER CONTROL
23 - AIR CONDITIONING CONTROLS (AIR CONDITIONING OPTION)
24 - HEATING VENTS
25 - DEMIST VENTS
26 - LEVEL INDICATORS
27 - DOOR OPEN LEVER
28 - DOOR CLOSE HANDLE
29 - WINDOW REGULATOR SWITCH
30 - SIDE STORAGE SPACE
31 - ROOF LIGHT
32 - HANDLE FOR REAR WINDOW OPENING
33 - HANDLE FOR REAR WINDOW CLOSING
34 - STEERING WHEEL ADJUSTMENT LEVER
35 - DOCUMENT HOLDER NET
36 - STORAGE COMPARTMENT
37 - ASHTRAY
38 - FRONT LIGHTS (NOT ILLUSTRATED)
39 - REAR LIGHTS (NOT ILLUSTRATED)
40 - FLASHING LIGHT (NOT ILLUSTRATED)
41 - INSIDE REAR-VIEW MIRROR (OPTION)
NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are meant for an observer seated on driver’s seat and looking in front of
him.
2-19
1 - DRIVER’S SEAT (STANDARD)
DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
LONGITUDINAL ADJUSTMENT
- Pull the locking lever 1 upwards.
- Slide the seat to the desired position.
- Release the lever and be sure it returns to the lock position.
3
4
2
SEAT CUSHION ADJUSTMENT
The front and the back of the seat cushion can be adjusted separately.
- To adjust the front, push the lever 2 downwards.
- Release it into one of the five possible positions.
- Same procedure to adjust the back by pulling the lever 2 upwards.
1
SEAT SUSPENSION ADJUSTMENT
- Turn the button 3 and adjust according to your weight.
ANGLE ADJUSTMENT OF THE BACK-REST
- Lean the back against the back-rest.
- Pull the lever 4 and place the back-rest into one of the possible positions.
1 - DRIVER’S SEAT (OPTION)
A
DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
WEIGHT ADJUSTMENT (FIG. A)
It is advised that the weight be adjusted when the driver is not sitting in the cab.
- Refer to graduation 1 of the seat.
- Turn handle 2 depending on the driver’s weight.
NOTE: To avoid any health problems, it is recommended that the weight should be checked
and adjusted before starting up the lift truck.
2
1
SEAT HEIGHT ADJUSTMENT (FIG. B)
Raise the seat to the desired position, until you hear the ratchet click. If you raise 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 left-hand button while pushing on the seat or relaxing pressure on the seat to
find a comfortable position.
B
C
2-20
SEAT DEPTH ADJUSTMENT (FIG. D)
The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired position.
D
EXTENDING THE HEAD-REST (FIG. E)
- The height of the back-rest can be adjusted by pulling it upwards (the notches will click)
up to the stop.
- The head-rest can be removed by applying sufficient pressure to pull it off the stop.
LUMBAR ADJUSTMENT (FIG. F)
This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.
ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)
- Support the back-rest, pull the lever and position the back-rest to find the desired
position.
E
If you do not support the back-rest when making adjustments, it swings 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. I)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure your
seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.
A rocking head-rest increases the risk of an accident !
F
Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a small
hidden area before using any fabric or plastic cleaner.
G
H
2-21
I
1 - DRIVER’S SEAT (OPTION)
DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
1
LONGITUDINAL ADJUSTMENT
- Release lever 1.
- Slide the seat to the desired position.
- Release the lever and be sure it returns to the lock position.
SEAT SUSPENSION ADJUSTMENT
- Refer to the seat’s graduation.
- Turn handle 2 depending on the driver’s weight.
ANGLE ADJUSTMENT OF THE BACK-REST
- Pull locking lever 3 upwards.
- Slide the back-rest to the required position.
- Release the lever and be sure it returns to the lock position.
2
3
1 - PNEUMATIC DRIVER’S SEAT (OPTION)
A
DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
WEIGHT AND SEAT HEIGHT ADJUSTMENT
WEIGHT ADJUSTMENT (FIG. A)
It is advised that you adjust the seat according to your weight when sitting.
- Switch on lift truck ignition.
- Push or pull lever 1 until green appears in display 2 indicating correct adjustment according
to your weight.
NOTE: To avoid any health problems, it is recommended that the weight should be checked
and adjusted before starting up the lift truck.
SEAT HEIGHT ADJUSTMENT (FIG. B)
When weight adjustment has been carried out, you can then modify seat height.
- Keep the ignition on in the lift truck.
- Push or pull lever 1 until green appears and adjust the height of the seat while checking
that the green in display 2 remains visible.
B
To avoid causing any damage, do not activate the compressor for over 1 minute.
SEAT BACK-REST ANGLE ADJUSTMENT (FIG. C)
The back-rest angle of the seat may be adjusted to suit the individual.
- Press the left-hand button while pushing on the seat or relaxing pressure on the seat to find
a comfortable position.
C
2-22
SEAT DEPTH ADJUSTMENT (FIG. D)
The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired position.
D
EXTENDING THE HEAD-REST (FIG. E)
- The height of the back-rest can be adjusted by pulling it upwards (the notches will click)
up to the stop.
- The head-rest can be removed by applying sufficient pressure to pull it off the stop.
LUMBAR ADJUSTMENT (FIG. F)
This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.
ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)
- Support the back-rest, pull the lever and position the back-rest to find the desired
position.
E
If you do not support the back-rest when making adjustments, it swings completely forwards.
HORIZONTAL SHOCK ABSORBER (FIG. H)
In certain conditions (e.g. driving with a trailer) it is advised that a horizontal shock absorber
be used. The driver’s seat is thus better able to absorb jerks in the direction of travel.
- Position 1: Horizontal shock absorber fitted.
- Position 2: Horizontal shock absorber removed.
LONGITUDINAL ADJUSTMENT (FIG. I)
- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
SERVICING (FIG. J)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure your
seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.
F
A rocking head-rest increases the risk of an accident !
Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a small
hidden area before using any fabric or plastic cleaner.
G
H
I
2-23
J
2 - SAFETY BELT
-
Sit correctly on the seat.
Check that the seat belt is not twisted.
Place the seat belt at hip level.
Attach the seat belt and check that it locks.
Adjust the seat belt to your body shape without squeezing your hip and without over-slack.
In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.
3 - IGNITION SWITCH
The key switch has five positions:
P - Ignition off, parking position.
O - Ignition switched off and engine stopped.
I - Ignition on.
II - Heating.
III - The engine starts, and returns to position I as soon as the key is released.
4 - EMERGENCY STOP BUTTON
- In the event of danger, it lets you stop the I.C. Engine and thereby cut out all hydraulic
movements.
- Pull the button to disable it before restarting the lift truck.
Be ready for hydraulic movements suddenly stopping when you press this button.
Warning, when driving, the lift truck will be brought to a sudden stop if actuating the parking brake. If
possible, stop the lift truck before using the emergency stop.
5 - BATTERY CUT-OFF
- For quickly disconnecting the battery when working on the electric circuit or when soldering,
for example.
2-24
6 - MAN-MACHINE INTERFACE (MMI)
6A - DRIVER PRESENCE
6B - INSTRUMENT CONTROL PANEL
6C - PANEL FOR BUTTONS AND KEYBOARD
6D - SCREEN DISPLAY
6B
UPDATED: In order to gain maximum advantage from the Man-Machine
Interface of your lift truck, contact your dealer to receive the most
recent available version of the software.
6A
6D
6C
6A - DRIVER PRESENCE
The driver’s presence is validated when the following are performed.
1 - The cab door is closed.
2 - The engine is started and the accelerator pedal is pressed.
It is only as from this time that the lift truck will be operational.
When driving (at speeds of less than 3 km/h), as soon as the door is opened and the accelerator is released, the system detects the operator’s absence
and immediately activates the parking brake which may cause a sudden stop for the lift truck.
6B - INSTRUMENT CONTROL PANEL
E
E
G
C
B
A
B1
D
F
A - REV COUNTER
B - FUEL LEVEL
When the yellow warning light B1 comes on it means that you are in reserve and that your running time is limited.
C - LONGITUDINAL STABILITY WARNING LIGHT
See: 2 - DESCRIPTION: 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE.
D - FORWARD/NEUTRAL/REVERSE LIGHT
See: 2 - DESCRIPTION: 20 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION.
E - GREEN STEERING LIGHTS
A continuous beeping sound on and off at the same time as the steering lights when using flashing lights or hazard warning
lights.
F - GREEN WARNING LIGHTS FOR WHEEL ALIGNMENT
See: 2 - DESCRIPTION: 22 - STEERING SELECTION.
G - DIGICODE INDICATOR LAMP
This light flashes when the digicode is enabled (see: 2 - DESCRIPTION: 6D - SCREEN DISPLAY).
2-25
MAJOR FAULT WARNING LIGHT
When this light is on it indicates that there is a major fault that may affect the safety for the lift truck or the driver (see:
2 - DESCRIPTION: 6D - SCREEN DISPLAY).
GREEN LIGHT FOR LOW BEAM
BLUE LIGHT FOR MAIN BEAM
I.C. ENGINE WATER LEVEL AND TEMPERATURE LAMP
COLD ENGINE: If the lamp comes on when the lift truck is running, this means that the coolant level is too low. Immediately
stop the engine and check the coolant level.
HOT ENGINE: If the lamp comes on when the lift truck is running, this means that the coolant temperature is too high.
Immediately stop the engine immediately and seek the cause of the cooling system malfunction.
AIR FILTER CLOGGING LAMP
The lamp comes on when the air filter cartridge is clogged up. When this lamp remains continuously lit, the cartridge needs
changing. Stop the lift truck and carry out the necessary repairs (see cleaning and replacement requirements in chapter:
3 - MAINTENANCE: SERVICING SCHEDULE).
HYDRAULIC RETURN OIL FILTER CARTRIDGE CLOGGING LAMP
The lamp come on when the hydraulic return oil filter cartridge is clogged up. When this lamp remains continuously lit
the cartridge needs changing. Stop the lift truck and carry out the necessary repairs (see cleaning and replacement
requirements in chapter: 3 - MAINTENANCE: SERVICING SCHEDULE).
NOTE: This lamp comes on by cold weather or when starting the fork lift truck, it goes off when the hydraulic oil reaches its
operating temperature.
POWER-ASSISTED STEERING FAULT INDICATOR LAMP
If the lamp comes on when the lift truck is running, stop the I.C. engine immediately and look for the cause (possible leak,
etc.).
BRAKE FLUID LEVEL OR POWER-ASSISTED BRAKING FAULT INDICATOR LAMP
If the lamp comes on, when the lift truck is running, stop the I.C. engine immediately and check the braking oil level. In the
event of an abnormal drop in the level, consult your dealer.
WARNING LAMP NOT AVAILABLE
WATER IN FUEL PRE-FILTER LAMP
This lamp will come on when there is water in the fuel pre-filter. Stop the lift truck and carry out the necessary repairs (see:
3 - MAINTENANCE: SERVICING SCHEDULE).
ENGINE PREHEATING LAMP
This lamp comes on when the lift truck’s ignition is switched on and should go out as soon as pre-heating is ended. If it
comes on while the lift truck is in operation, immediately stop the I.C engine and find the cause.
I.C. ENGINE OIL PRESSURE LAMP
If the lamp comes on when the lift truck is running, stop the I.C. engine immediately and look for the cause (see oil level
in I.C. engine crankcase).
I.C. ENGINE PREHEATING FAULT INDICATOR LAMP
If the lamp comes on when the lift truck is running, stop the I.C. engine immediately and look for the cause (possible leak,
etc.).
BATTERY LOAD LAMP
If this lamp comes on when the lift truck is running, switch off the I.C engine immediately and check the electric circuit and
the alternator belt.
GREEN PROGRESSIVE INCHING TRANSMISSION MODE INDICATOR LAMP
This lamp comes on when using the progressive transmission “INCHING” mode (see: 2 - DESCRIPTION: 6C - PANEL FOR
BUTTONS AND KEYBOARD).
GEAR BOX OIL PRESSURE LAMP
This lamp comes on when there is an abnormal drop in gear box pressure. Stop the lift truck and look for the cause (e.g.,
Low oil level in the transmission, internal leak in the transmission, etc.).
2-26
GEAR BOX OIL TEMPERATURE LAMP
This lamp comes on when the temperature of the gear box oil is abnormally high. In this case, place the forward/reverse
selector in neutral and let the I.C. engine running at idle for a few minutes. If the lamp remains on, stop the lift truck and
contact your dealer.
NOTE: Abnormal heating of the oil may be linked to an incorrect use of the gear box ratios (see: 2 - DESCRIPTION: 21 - GEAR
LEVER).
PARKING BRAKE LAMP
This lamp comes on when the parking brake is applied.
HYDRAULIC MOVEMENT NEUTRALISATION LAMP
The lamp lights when the hydraulic controls are neutralised and when a forbidden hydraulic movement is requested.
6C - PANEL FOR BUTTONS AND KEYBOARD
A beep is sounded each time one of the buttons is pressed.
“BUCKET” MODE (NOT USED)
See: 2 - DESCRIPTION: 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE.
OPTION PROGRESSIVE TRANSMISSION “INCHING” MODE
STANDARD TRANSMISSION MODE (default mode)
OPTION PROGRESSIVE TRANSMISSION “INCHING” MODE IN FORWARD AND REVERSE GEAR (OPTION)
on the instrument control panel will light when it is in use.
The indicator
- The operating screen displays the enabled mode. Press the button to display the other available mode(s).
CHANGE MODE
88°
88
Press
Confirm
88°
88
Cancel
88°
88
Confirm
88°
88
Cancel
88°
88
1
ON TYRES
88°
88
Press
1
ON TYRES
“SUSPENDED LOAD” MODE
See: 2 - DESCRIPTION: 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE.
2-27
ATTACHMENT CIRCUIT
ATTACHMENT CIRCUIT UNLOCKED (by default)
ATTACHMENT CIRCUIT LOCKED
It is recommended to use this function when the lift truck is not fitted with hydraulic attachment.
ATTACHMENT CIRCUIT IN CONTINUOUS MODE
will light when it is in use.
The indicator
By default, the attachment circuit in continuous mode is disabled as soon as the operator leaves the cab. This condition can be changed from the OPT
menu on the menu screen.
- The operating screen displays the enabled mode. Press the button to display the other available mode(s).
NOTE: On stabilizers, the display in zone 2 on the operating screen switches to zone 6/7.
CHANGE MODE
1
2
88°
88
88°
88
1
2
1
2
88°
88
88°
88
Confirm
88°
88
1
2
1
2
ON TYRES
Cancel
Press
ON TYRES
88°
88
Confirm
Press
ON TYRES
88°
88
88°
88
Cancel
88°
88
88°
88
Confirm
Press
88°
88
1
2
Cancel
88°
88
ADJUSTING THE ATTACHMENT CIRCUIT HYDRAULIC FLOW RATE IN CONTINUOUS MODE
i
XX%
flashes, and switches to the setting screen
as soon as
- The pictogram
hydraulic flow rate is selected using button A on the attachment hydraulic control lever.
- Button A forward for positive percentage (+ XX %), backward for negative percentage
(XX %).
- Hold button A in the same position for 2 seconds to confirm the chosen hydraulic flow
A
rate
+XX%
.
- Press the button
, or actuate button A, or switch off the I.C. engine to return to the
88°
88
and thus disable continuous mode.
screen with the flashing pictogram
2-28
OPTION JIB SUSPENSION (NOT AVAILABLE)
ATTACHMENT EASY CONNECTION
For easily connecting and disconnecting the attachment.
- Press for two seconds on the push-button to release the attachment circuit hydraulic pressure. Screens
and
will be alternately displayed.
- Connect or disconnect the rapid connectors of the hydraulic attachment (see: 4 - OPTIONAL ATTACHMENTS FOR USE WITH THE
RANGE: PICKING UP THE ATTACHMENTS).
OPTION REAR FOG LIGHT
Only works when the low beam or main beam lights are switched on. The indicator will light when in use.
OPTION FRONT WORKING HEAD LIGHTS
ROTATING BEACON LIGHT
MENU SCREEN DISPLAY
See: 2 - DESCRIPTION: 6D - SCREEN DISPLAY.
CANCEL OR BACK
CONFIRM
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
See: 2 - DESCRIPTION: 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE.
OPTION SELF-CLEANING FAN (NOT AVAILABLE)
HAND-OPERATED PARKING BRAKE
The hand-operated parking brake can be configured from the OPT menu in the menu screen.
HAZARD WARNING LIGHTS
This switch enables the L.H. and R.H. Indicators to be switched on simultaneously, with the ignition off.
2-29
LOCKING HYDRAULIC CONTROLS
HYDRAULIC CONTROLS AVAILABLE (by default)
TILT CONTROL LOCKED
HYDRAULIC CONTROLS LOCKED
When driving on the road, it is strongly recommended that you lock all hydraulic movements.
- Press the button to display the other available mode(s), the first screen displayed is the opposite of the enabled mode.
CHANGE MODE
1
2
Confirm
Press
Cancel
1
2
1
2
Confirm
Press
Cancel
1
2
1
2
Confirm
Press
Cancel
1
2
6D - SCREEN DISPLAY
SCREEN OFF
Lift truck parked, with ignition off and without the driver.
MANITOU
LOGO SCREEN
System initialising. A beep is sounded when this screen appears. If the screen remains permanently displayed, contact your
dealer.
DIGIC
00__
DIGICODE SCREEN
The digicode is disabled by default. It can be enabled from the OPT menu on the menu screen. A beep is sounded when this screen
appears.
- Switch on the lift truck ignition. Enter the code (default 0000) using the keys on the keyboard and confirm with the confirm button
. Automatically moves to the next character.
2-30
HOUR METER SCREEN
Operator present in the cab. The screen displays the total number of hours worked [888888h], the number of hours for that working
day [888.88h] and the number of hours before the next major maintenance [888h].
RESETTING THE DAILY WORKING HOURS COUNTER BACK TO ZERO
- Authorization of this function can be configured from the OPT menu in the menu screen.
RESETTING THE MAINTENANCE COUNTER TO 500H
- Reset the maintenance counter to 500h from the XPRT menu in the menu screen.
ECO
AUTOMATIC STANDBY SCREEN
In ECO mode the lift truck stops the IC engine after 1 minute at standstill. Switch off the ignition before restarting the lift truck.
88°
88
OPERATING SCREEN
Lift truck is operational (different screen depending on the operating mode).
1
2
3
5
6
1
4
88°
88
7
2
3
4
88°
LIFT TRUCK ON TIRES
5
8
6
7
Blank screen.
Blank screen.
If no function is unlocked and at least one function is
locked (see unlocking screen).
If at least one function is unlocked (see unlocking
screen).
1
If no function is unlocked and at least one function is
locked (see unlocking screen).
If at least one function is unlocked (see unlocking
screen).
1
Blank screen.
Blank screen.
2/3
Attachment circuit unlocked.
2
LIFT TRUCK ON STABILIZERS
8
88°
Jib lifting angle in degrees.
--°
Lifting angle sensor fault (contact your dealer).
4
Attachment circuit in continuous mode.
Blank screen.
3
Blank screen.
5
88°
Jib lifting angle in degrees.
Maintenance key.
--°
Lifting angle sensor fault (contact your dealer).
Blank screen.
4
Blank screen.
6/7
Attachment circuit unlocked.
5
Maintenance key.
Attachment circuit in continuous mode.
Blank screen.
6
Blank screen.
7
88
8
--
8
Transmission locked in neutral, driver presence not
validated
OPTION Progressive INCHING transmission mode in
forward and reverse gear.
Travelling speed of the lift truck whatever the gear ratio
in km/h.
Lift truck speed sensor fault (contact your dealer).
2-31
Stabilizers fitted on the ground
To validate the
and under pressure.
information, the last
Left stabilizer fitted on the ground
movement of the
and under pressure.
stabiliser must be
Right stabilizers fitted on the
lowering.
ground and under pressure.
Driver presence.
LOCKING SCREEN
By default, the operator is not permitted to unlock the functions
(see: 2 - DESCRIPTION: 6D - SCREEN DISPLAY: MENU SCREEN).
One of these screens appears when the system detects an
operating defect on the lift truck. A beep is sounded when this
screen appears.
These defects cause certain functions to be prohibited in order to
ensure safety. However it is possible for the operator and under
his own responsibility (and/or that of the person in charge of the
!
establishment) to override the prohibition in order to secure the
parking of the lift truck (e.g., unlocking the hydraulic distributor fault
in order to retract and lower the jib).
The unlocking is activated temporarily, the function will be locked again as soon as the engine is
Transmission fault.
Retracting stabilizer.
Tilt.
Telescoping jib.
Hydraulic distributor.
switched off.
UNLOCKING THE FUNCTION
- Move the triangles
using the button
to the open padlock and confirm with the button
.
In any event, stop the lift truck and contact your dealer.
i
i
!
!
HELP SCREEN
One of these screens appears to inform the operator about the
operations to be carried out in the present configuration (e.g., if the
operator wants to lower the stabilizers, he must first lower the jib).
A beep is sounded when this screen appears.
i
Set down the stabilizers.
i
Lower the jib before lowering the stabilizers.
i
Driver presence not validated, close the door and press
the accelerator pedal.
Driver presence not validated, press the accelerator
pedal.
Overspeed, reduce the speed.
or
i
i
XX%
Transmission default, The visual alarm
is triggered
at the same time. Immediately stop the lift truck and
find the cause.
Retract and/or lower the jib before raising up the
stabilizers.
Raise the stabilizers and/or lower the jib before
correcting the tilt.
Using the attachment circuit in continuous mode and
indicating the hydraulic capacity.
NR
Reset the forward/reverse selector via neutral.
i
i
i
i
i
2-32
Major maintenance interval exceeded.
F
Jib chain tension default.
< INFO
CLOCK
LCD
OPT
>
09:35
10/06/2010
MENU SCREEN
- Press the
button to display the menu screen with the time and date. Navigate horizontally between menus using the
buttons and vertically in the sub-menus using the buttons
.
INFO
Time and date (by default).
Lift truck in degraded mode and/or fault detected (see error code table).
“Check Maintenance” appears for a few seconds if maintenance is necessary.
CLOCK
HOUR: Change the hour.
DATE: Change the date.
FORM: Change the time or date format.
LCD
BACKL: Backlight.
CONTR: Contrast.
OPT
The contents of this menu can be accessed by means of a customer password.
RST H: Resetting of daily hour counter to zero, permitted (by default) or not permitted.
PARK: Hand-operated parking brake or automatic (by default).
CFLOW: Forced operation without driver presence permitted or not permitted (by default).
LLMC: Disabling of aggravating hydraulic movement cut-off permitted (by default) or not permitted.
PASS: Fault override permitted or not permitted (by default).
UNIT: Speed of travel displayed in MPH or Km/h (by default).
DIGI1: Digicode enabled or not enabled (by default).
DIGI2: Change the 4 figure digicode (lift truck start-up).
CUST: Change the customer code.
DIAG
The contents of this menu enables your dealer to perform a diagnosis on the Man-Machine Interface.
XPRT
RESET > HOURM: Reset the partial hour meter to zero.
MAINT: Reset the maintenance interval to 500 hours.
ADMIN > ADMIN: Change the administrator code.
ERASE > MC: Clear faults from the computer of the Man-Machine Interface.
MP1: Clear faults from computer MP1.
MP2: Clear faults from computer MP2.
CALIB > SECU: Calibration of jib angle and strain gauge.
GAUGE: Recalibration of strain gauge.
2-33
ERROR
COMPONENT
CODE
A00003
I.C. engine
A00006
Gear box
A00007
Air filter
A00008
Hydraulic filter
A00009
I.C. engine
A003F1
Gear box
A10002
I.C. engine
A10004
Brake system
A10005
Gear box
A10051
Alternator
A1046A
Power-assisted steering
A1048A
Power assisted braking
A20000
Strain gauge
A203E8
Hydraulic controls
A203EC
Accelerator
A203EF
Jib angle
A203F0
Door switch
A203F4
Jib retracted switch
A203FE
Hydraulic controls
A203FF
Hydraulic controls
A20408
Hydraulic control valve
Hydraulic controls (unit)
2D003C
Hydraulic controls (unit)
2D003D
2D003E
Hydraulic controls
2D003F
Hydraulic controls
2D0011
Jib angle
2D0012
Jib angle
2D0024
Accelerator
Hydraulic controls (unit)
2D0045
Hydraulic controls (unit)
2D0046
20010
Hydraulic control valve
20012
Hydraulic control valve
20014
Hydraulic control valve
20017
Hydraulic control valve
22001E
Gear box
28000B
Speed sensor
220020
Gear box
220026
Slope sensor
220028
Fuel gauge
230130
Jib chain sensors
230131
Jib chain sensors
240130
Jib chain sensors
240131
Jib chain sensors
3000A
Gear box
3000B
Gear box
3000C
Flow controller
3001B
Hydraulic control valve
3001D
Right stabiliser electrovalve
3001F
Left stabiliser electrovalve
3002A
Unloading electrovalve
3002B Rear axle blocking electrovalve
3002D
Jib suspension electrovalve
3002E
Jib suspension electrovalve
3002F
Fast gear 2 electrovalve
3003A
Hydraulic control valve
3006A
Right-hand sidelight
Left-hand dipped beam
3006B
headlight
3006C Left-hand main beam headlight
3006D
Left-hand indicator lights
3006E
Right-hand indicator lights
3007A Rear axle blocking electrovalve
3007B
Trailer stop lights
3007C
Front working lights
3007D
Trailer reversing light
3007E
Trailer fog light
Right-hand dipped beam
3007F
headlight
Parking brake
3008F
Reversing sound alarm
30001
30002
Horn
30026
Hydraulic control valve
30027
Hydraulic control valve
FAULT TYPE
DETECTED BY
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Inconsistency
inconsistency
inconsistency
inconsistency
inconsistency
inconsistency
inconsistency
inconsistency
Fault
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
Calibration
PVG error
PVG error
PVG error
PVG error
Fault
Fault
Fault
Calibration
Calibration
Fault
Fault
Fault
Fault
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
MMI
MMI
MMI
MMI
MMI
Computer MP1
MMI
MMI
MMI
MMI
Computer MP1
Computer MP1
MMI
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP2
MMI
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Short circuit
Computer MP1
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Short circuit
Computer MP1
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
ERROR
CODE
30028
30029
30030
30031
30032
30039
30064
30065
30066
30067
30068
30069
30078
30080
30081
30082
400CA
400CD
4000A
4000B
4000C
4001A
4001B
4001D
4001F
4002A
4002B
4002D
4002E
4002F
4003A
4003B
4006A
4006B
4006C
4006D
4006E
4007A
4007B
4007C
4007D
4007E
4007F
4008C
4008D
4008E
4008F
40001
40002
40011
40013
40016
40019
40026
40027
40028
40029
40030
40031
40032
40039
40064
40065
40066
40067
40068
40069
40078
2-34
COMPONENT
FAULT TYPE
DETECTED BY
Hydraulic control valve
Hydraulic control valve
Low speed electrovalve
Forward/reverse selector
electrovalve
High speed 1 electrovalve
Jib head electrovalve
Stop lights
Front working lights
Reversing light
Rear fog light
Ceiling light
Left-hand sidelight
Rotating light
Right-hand main beam headlight
Trailer left-hand indicator light
Trailer right-hand indicator light
Fuel electrovalve
Windscreen wiper
Gear box
Gear box
Flow controller
Hydraulic control valve
Hydraulic control valve
Right stabiliser electrovalve
Left stabiliser electrovalve
Unloading electrovalve
Rear axle blocking electrovalve
Jib suspension electrovalve
Jib suspension electrovalve
Fast gear 2 electrovalve
Hydraulic control valve
Transmission computer power
supply
Right-hand sidelight
Left-hand dipped beam
headlight
Left-hand main beam headlight
Left-hand indicator lights
Right-hand indicator lights
Rear axle blocking electrovalve
Trailer stop lights
Front working lights
Trailer reversing light
Trailer fog light
Right-hand dipped beam
headlight
Engine speed relay
Engine starting relay
Parking brake
Parking brake
Reversing sound alarm
Horn
Hydraulic control valve
Hydraulic control valve
Hydraulic control valve
Hydraulic control valve
Hydraulic control valve
Hydraulic control valve
Hydraulic control valve
Hydraulic control valve
Low speed electrovalve
Forward/reverse selector
electrovalve
Electrovalve Fast gear 1
Jib head electrovalve
Stop lights
Front working lights
Reversing light
Rear fog light
Ceiling light
Left-hand sidelight
Rotating light
Short circuit
Short circuit
Shortcircuit
Computer MP1
Computer MP1
Computer MP2
Short circuit
Computer MP2
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
MMI
MMI
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP1
Short circuit
Computer MP1
Short circuit
Computer MP1
Short circuit
Computer MP1
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Short circuit
Computer MP1
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Short circuit
Computer MP2
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Short circuit
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
ERROR
CODE
COMPONENT
40080 Right-hand main beam headlight
40081
40082
42000A
42000B
42000D
42000E
420006
420007
420015
420016
440001
440011
440014
450001
450011
450014
500CA
500CD
5000A
5000B
5000C
5001A
5001B
5001D
5001F
5002A
5002B
5002D
5002E
5002F
5003A
5003B
5006A
5006B
5006C
5006D
5006E
5007A
5007C
5007F
5008C
5008D
5008E
5008F
50001
50002
50026
50027
50028
50029
50030
50031
50032
50039
50064
50065
50066
50067
Trailer left-hand indicator light
Trailer right-hand indicator light
FAULT TYPE
Short circuit
Short circuit
Short circuit
Power supply
Gear box
fault
Power supply
Hydraulic controls (unit)
fault
Power supply
Hydraulic controls
fault
Power supply
Hydraulic controls (unit)
fault
Power supply
Frequency sensor
fault
Power supply
Jib angle
fault
Power supply
Jib chain sensors
fault
Power supply
Jib chain sensors
fault
Wheel alignment sensor
Short circuit
Gear box
Short circuit
Parking brake
Short circuit
Disconnected wire
Wheel alignment sensor
Disconnected wire
Gear box
Parking brake
Disconnected wire
Disconnected wire
Fuel electrovalve
Windscreen wiper
Disconnected wire
Disconnected wire
Gear box
Disconnected wire
Gear box
Disconnected wire
Flow controller
Disconnected wire
Hydraulic control valve
Hydraulic control valve
Disconnected wire
Right stabiliser electrovalve Disconnected wire
Left stabiliser electrovalve Disconnected wire
Disconnected wire
Unloading electrovalve
Rear axle blocking electrovalve Disconnected wire
Jib suspension electrovalve Disconnected wire
Jib suspension electrovalve Disconnected wire
Disconnected wire
Fast gear 2 electrovalve
Disconnected wire
Hydraulic control valve
Transmission computer power
Disconnected wire
supply
Disconnected wire
Right-hand sidelight
Left-hand dipped beam
Disconnected wire
headlight
Left-hand main beam headlight Disconnected wire
Disconnected wire
Left-hand indicator lights
Disconnected wire
Right-hand indicator lights
Rear axle blocking electrovalve Disconnected wire
Disconnected wire
Front working lights
Right-hand dipped beam
Disconnected wire
headlight
Disconnected wire
Engine speed relay
Engine starting relay
Disconnected wire
Parking brake
Disconnected wire
Disconnected wire
Parking brake
Reversing sound alarm
Disconnected wire
Horn
Disconnected wire
Disconnected wire
Hydraulic control valve
Hydraulic control valve
Disconnected wire
Hydraulic control valve
Disconnected wire
Disconnected wire
Hydraulic control valve
Disconnected wire
Low speed electrovalve
Forward/reverse selector
Disconnected wire
electrovalve
High speed 1 electrovalve
Disconnected wire
Disconnected wire
Jib head electrovalve
Disconnected wire
Stop lights
Disconnected wire
Front working lights
Disconnected wire
Reversing light
Disconnected wire
Rear fog light
ERROR
COMPONENT
CODE
50069
Left-hand sidelight
50078
Rotating light
50080 Right-hand main beam headlight
DETECTED BY
Computer MP1
Computer MP1
Computer MP1
7303E8
Man-machine interface
7303E9
Network
7307D0
Man-machine interface
7307D1
Radio control
7307D2
Platform control console
730000
Man-machine interface
8003E8
8007D0
8203E9
8203EC
8207D1
8207D4
8303ED
8307D3
8307D5
8403ED
8407D5
8703EA
8707D2
800000
820001
820002
820003
820004
820005
Computer MP1
Computer MP2
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP1
Computer MP2
Computer MP2
Computer MP1
Computer MP2
Computer MP1
Computer MP2
Man-machine interface
Man-machine interface
Strain gauge
Strain gauge
Strain gauge
Strain gauge
Computer MP1
Computer MP2
Computer MP1
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
MMI
MMI
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
2-35
FAULT TYPE
DETECTED BY
Disconnected wire
Disconnected wire
Disconnected wire
Communication
error
Communication
error
Communication
error
Communication
error
Communication
error
Communication
error
Overheating
Overheating
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Fault
Overheating
Fault
Fault
Fault
Fault
Fault
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP2
MMI
Computer MP1
Computer MP2
Computer MP1
Computer MP1
Computer MP2
Computer MP2
Computer MP1
Computer MP2
Computer MP2
Computer MP1
Computer MP2
Computer MP1
Computer MP2
MMI
MMI
MMI
MMI
MMI
MMI
7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
This device warns the operator of the lift truck’s longitudinal stability limits. However, lateral stability can reduce the load chart
in the upper part, and this reduction is not detected by the device.
According to the type of work required, the longitudinal stability limiter and warning device allows the operator to operate the lift
truck in complete safety.
The operator must respect the lift truck’s load chart, and the operating mode according to the attachment.
“HANDLING”
MODE
“SUSPENDED LOAD”
MODE
A - “HANDLING” MODE
Use on forks (TFF, PFB, TDL), adjustable attachments on forks (BB, GL) and with buckets
(CBC, CBR, CBG, CB4x1).
- By default, the device is in “HANDLING” MODE when the lift truck is started-up, except
if the “SUSPENDED LOAD” MODE has been selected before shutting-down the engine.
A8
A7
A6
A5
D1
A1 - A2 - A3: There is a significant reserve of longitudinal stability.
A4
A4 - A5: The lift truck is nearing the limit of longitudinal stability. The alarm sounds
A3
simultaneously with a very slow intermittent sound. Move with care.
A2
A6: The lift truck is near at the limit of longitudinal stability. The alarm sounds with
a slow intermittent sound. Move with care.
A1
A7: The lift truck is very near at the limit of longitudinal stability. The alarm sounds
with a fast intermittent sound. Move with extreme care.
A8: The lift truck is at the authorized limit of longitudinal stability. The alarm sounds
with a very fast intermittent sound. All “AGGRAVATING” hydraulic movements
are cut-off. Cut-off may be preceded by an automatic slowing of the hydraulic movement. 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 “AGGRAVATING” hydraulic movements is disconnected.
B - “BUCKET” MODE (NOT USED)
C - “SUSPENDED LOAD” MODE
Providing a higher margin of safety, use with a crane jib (P, PT, PO), hoist and hoisting
eye.
- Place the lift truck in the transport position.
A8
A7
A6
- Press the button
for 2 seconds , “SUSPENDED LOAD” MODE is validated by an
audible beep and the lighting of the lamp.
A5
D1
A4
A3
- Return to “HANDLING” MODE by pressing the button
A2
.
A1
A1 - A2 - A3: There is a significant reserve of longitudinal stability.
A4 - A5: The lift truck is nearing the limit of longitudinal stability. The alarm sounds
simultaneously with a very slow intermittent sound. Move with care.
A6: The lift truck is near at the limit of longitudinal stability. The alarm sounds with
a slow intermittent sound. Move with care.
A7: The lift truck is very near at the limit of longitudinal stability. The alarm sounds with a fast intermittent sound. Move
with extreme care.
A8: The lift truck is at the authorized limit of longitudinal stability. The alarm sounds with a very fast intermittent sound.
All “AGGRAVATING” hydraulic movements are cut-off. Cut-off may be preceded by an automatic slowing of the hydraulic
movement. 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 “AGGRAVATING” hydraulic movements is disconnected.
2-36
D - DISABLING “AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF
Authorization of this function can be configured from the OPT menu in the menu screen.
In certain cases, in order to get out of a difficult situation, the operator can bypass this
safety system. Button D temporarily disables the cutting-off of “AGGRAVATING” hydraulic
movements.
- Hold down button D, lamp D1 will light (60 second time delay), and simultaneously perform
the necessary ”AGGRAVATING” hydraulic movement with extreme care.
Remain very vigilant during this operation. The only information available to the operator is the lift truck’s
dynamic stability.
D
E - TESTING OF THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
A8
A7
- Short press the button
to verify at any time that the longitudinal stability alarm
is working.
• Correct operation: All the LEDs A1 to A8 light for two seconds and an audible
beep is sounded.
NOTE: This test does not check the proper adjustment of the longitudinal stability limiter that
must be inspected daily or after every 10 hours of service (see: 3 - MAINTENANCE:
A - DAILY OR EVERY 10 HOURS SERVICE).
A6
D1
A5
A4
A3
A2
A1
F - STRAIN GAUGE
Disassembly or calibration of the strain gauge is prohibited, this must only be done by specially trained
personnel, consult your dealer.
F
2-37
8 - SWITCHES
A - OPTION WORKING TAIL LIGHTS
B
B - OPTION WORKING LIGHTS ON JIB
D
C - OPTION FOR ROOF WINDSCREEN WIPER AND WINDSCREEN WIPER
This switch, when set in the “high” position, allows the windscreen wiper to be worked and
with the “down” position pressed, the windscreen-washer to be operated.
A
C
F
E
D - OPTION FOR SIDE WINDSHIELD WIPER AND WINDSHIELD WASHER
This switch, when set in the “high” position, allows the windscreen wiper to be worked and
with the “down” position pressed, the windscreen-washer to be operated.
E - OPTION REAR WINDOW DE-ICING
F - OPTION
G - OPTION
G
H
J
K
I
H - OPTION SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
See: 2 - DESCRIPTION: DESCRIPTION AND USE OF THE OPTIONS.
I - OPTION
L
J - OPTION
K - OPTION
L - DISABLING OF “AGGRAVATING” HYDRAULIC MOVEMENTS
See: 2 - DESCRIPTION: 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE.
9 - FUSES AND RELAYS IN THE CAB
A sticker on the inside of the access panel gives a clear display of the use of the components
described below.
1
- Remove access panel 1 to gain access to the fuses and relays, Replace a used fuse with
a new fuse of the same quality and capacity. Never reuse a repaired fuse.
K1
K2
K3
K4
K5
K6
K11
K12
-
OPTION.
Front windshield wiper intermittence relay.
OPTION Air conditioning fan relay.
OPTION.
Safety system starting switch relay.
OPTION Air conditioning compressor relay.
OPTION.
OPTION Air conditioning timer relay.
K12
F1
F2
F3
F4
F5
-
OPTION.
OPTION Single or dual effect hydraulic predisposition (7,5A).
OPTION.
Heating and ventilation (20A).
Disabling “AGGRAVATING” hydraulic movement cut-off + seat switch
(2A).
F6 - OPTION Jib head electrical provision (5A).
F7 - OPTION Engine immobilizer (2A).
F8 - OPTION Pneumatic seat (10A).
F9 - Ignition (2A).
F10 - OPTION Car radio (2A).
2-38
OPT.
K3
K6
OPT.
OPT.
K2
F40
F30
OPT.
20A
F20
15A
F10
F39
F29
OPT.
7.5A
F19
7.5A
F9
F38
F28
5A
F18
15A
F8
2A
2A
K5
EV
K11
Diagn
Pn
10A
1
4
A.S.
K1
K4
A.S.
A.S.
F37
F27
10/15A
F17
F36
2A
F26
7.5A
F16
F35
2A
F25
F7
OPT.
F6
2A
F15
OPT.
15A max.
F5
F34
2A
F24
15A
F14
OPT.
10A max.
F4
5A
F23
2A
F13
10A
F3
OPT.
10A max.
7.5A
F22
10A
F21
3A
F12
15A
F2
OPT.
7.5A
3A
F11
10A
F1
OPT.
10A
1
4
F33
Diagn
F32
2
3
5
7
6
8
*
0
9
#
EV
F31
N°273735
2
15A
15A max.
3
5
7
8
*
0
6
9
#
OPT.
2A
15A max.
15A
20A
F11 - Cigar lighter (10A).
F12 - Front windscreen wiper and windscreen washer (15A).
F13 - Rear windscreen wiper and windscreen washer (10A).
F14 - OPTION.
F15 - OPTION.
F16 - OPTION Working lights on jib (15A).
F17 - OPTION Working tail light (15A).
F18 - OPTION Rear window de-icing (15A).
F19 - OPTION Roof windscreen wiper and windscreen washer (7,5A).
F20 - Window winder (15A).
F21 - Roof light + door switch (3A).
F22 - Man-Machine Interface (MMI) (3A).
F23 - OPTION.
F24 - Front windscreen wiper motor (15A).
F25 - OPTION Immobiliser (2A).
F26 - OPTION Car radio (7.5A).
F27 - Rear windscreen wiper motor (10A).
- OPTION Roof windscreen wiper motor (10A).
- OPTION Roof windscreen wiper motor + side windscreen wiper motor (15A).
F28 - Diagnostic socket (5A).
F29 - OPTION Air conditioning compressor (7,5A).
F30 - OPTION Air conditioning fan (20A).
F31 - Starter system safety (10A).
F32 - OPTION Side windscreen wiper and windscreen washer (7,5A).
F33 - Diagnostic socket (5A).
F34 - OPTION.
F35 - OPTION.
F36 - OPTION.
F37 - OPTION.
F38 - Not used.
F39 - Not used.
F40 - Not used.
10 - FUSES AND RELAYS UNDER THE ENGINE HOOD
- Open engine hood 1 in order to gain access to the fuses and relays. Replace a used fuse
with a new fuse of the same quality and capacity. Never reuse a repaired fuse.
K20
K21
K22
K23
K24
K25
K26
-
1
Pre-heating relay.
Engine starter relay.
OPTION Diesel decongealant relay.
OPTION.
Not used.
Not used.
Not used.
MAXIFUSE F41 TO F46
F41 - Electronic box MP2 (40A).
F42 - Ignition switch (50A).
F43 - Alternator (80A).
F44 - Electronic box MP1 (40A).
F45 - Power supply for fuses in the cab (40A).
F46 - Preheating I.C. engine (80A).
N°298080
K20
K23
MP2
K26
RC
K22
K25
F60
F55
F59
F54
F58
F53
30A
RC
MINIFUSE F51 TO F60
F51 - Not used.
F52 - OPTION Diesel decongealant (20A).
F53 - Not used.
F54 - OPTION.
F55 - Engine start-up (30A).
F56 - Not used.
F57 - Not used.
F58 - Not used.
F59 - Not used.
F60 - Not used.
F41
40A
F42
50A
F43
30A
80A
MP1
F44
K21
K24
F57
F52
F56
F51
RC
2-39
40A
F45
40A
CAB
F46
80A
11 - DOOR PRESENCE SENSORS
See: 2 - DESCRIPTION: 6 - MAN-MACHINE INTERFACE (MMI)
12 - LIGHTER
13 - HANDLE FOR OPENING ENGINE HOOD
14 - SWITCH FOR LIGHTING, HORN AND INDICATORS
The switch controls the visual and sound alarms.
A - All lights are off, the direction indicators do not flash.
B - The right hand direction indicators flash.
C - The left hand direction indicators flash.
D - The sidelights and the rear lights are on.
E - The dipped headlights and the rear lights are on.
F - The main beam headlights and the rear lights are on.
G - Headlight signal.
Pressing the switch sounds the horn.
NOTE: Positions D - E - F - G can be used without the ignition being on.
F
E
G
B
D
G
C
A
G
15 - FRONT AND REAR WINDSCREEN WIPER
SWITCH
FRONT WINDSCREEN WIPER
A - Front windscreen wiper stop.
B - Slow speed for front windscreen wiper.
C - Fast speed for front windscreen wiper.
D - Front windscreen wiper intermittent
control.
E - Front windscreen washer, pulse-driven.
REAR WINDSCREEN WIPER
F - Rear windscreen wiper stop.
G - Rear windscreen wiper.
H - Rear windscreen washer, pulse-driven.
E
A
A
E
B
D
E
C
C
G
F
H
16 - FUNCTION FILES
These files contain the description of the hydraulic controls and the load charts for the attachments used on the lift truck.
2-40
17 - HYDRAULIC CONTROLS
Authorisation for using the hydraulic controls is given by the validation of the driver’s presence (see: 2 - DESCRIPTION: 6 - MANMACHINE INTERFACE (MMI)) and if the conditions for using the hydraulic control are followed.
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 carefully without jerking, to avoid accidents caused by shaking the lift truck.
A - Lifting and tilting control lever.
B - Telescoping control button.
C - Left stabilizer control lever.
D - Right stabilizer control lever.
E - Tilting corrector control lever.
F - Attachment control button.
B
A
F
LIFTING THE LOAD
- The lever A backwards when lifting.
- The lever A forwards when lowering.
TILT OF CARRIAGE
- The lever A to the left for reverse tilt.
- The lever A to the right for forward tilt.
TELESCOPING
- Button B forwards for extending.
- Button B backwards for retracting.
NOTE: When completely retracting the telescopes, insistently operate the control so as to
allow all the telescopes to retract fully.
MT 1840 E3
NOTE: The completely extending of the telescopes can only be
extended if the stabilisers are lowered and bearing on the
ground.
L.H. STABILIZER
- Move lever C forwards to lower.
- Move lever C backwards for lifting.
R.H. STABILIZER
- Move lever D forwards for lowering.
- Move lever D backwards for lifting.
NOTE: The stabilisers can only be raised if the telescopic sections
are retracted and the lifting angle of the jib is less than 62°.
TILTING CORRECTOR
- Move lever E to the left to tilt the lift truck to the left.
- Move lever E to the right to tilt the lift truck to the right.
NOTE: The tilt correction may only be performed if the lifting angle for
the jib is less than 30°.
ATTACHMENT
- Button F forwards or backwards.
C
E
D
N°261550
18 - ACCELERATOR PEDAL
19 - SERVICE BRAKE PEDAL
The pedal acts on the front and rear wheels by a power assisted hydraulic brake system, and allows the lift truck to be slowed
down and stopped.
2-41
20 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION
When operating this control, the lift truck should be travelling at slow speed and not
accelerating.
FORWARD: Push the switch forward (position A).
REVERSE: Push the switch backward (position B). Reversing lights and an acoustic reversing
alarm indicate that the lift truck is running in reverse.
NEUTRE: Parking brake applied (position C).
C
B
A
21 - GEAR LEVER
2
In order to change gear, it is necessary to cut the transmission by pressing button 1 on
the lever.
1st gear: To the left, backwards.
2nd gear: To the left, forwards.
3rd gear: To the right, backwards.
4th gear: To the right, forwards.
4
1
1
3
CONDITION FOR USING THE TRANSMISSION GEAR RATIOS
- On these lift trucks with a torque converter, it is not necessary to automatically start up
in 1st speed and progress up the gears.
The choice of transmission gear ratio 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 the converter, which could lead to serious damage to the transmission (it is essential to stop and change the working
conditions if the transmission oil temperature indicator light comes on). This poor choice may also result in a reduction in the lift truck’s performance
in forward gear. When the forward force increases, the forward speed in the r gear (for example, in 3rd gear) may be lower than 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 the road: Set off in 3rd gear and go up to 4th if the conditions and state of the road permit it. In hilly areas, set off in 2nd
gear and go up to 3rd if the conditions and state of the road permit it.
• With a trailer on the road: Set off in 2nd gear and switch to 3rd if the conditions and state of the road permit it.
• In handling mode: 3rd gear.
2nd gear in restricted spaces.
• Earth moving: 1st gear.
• Loading (reclaiming with bucket, manure fork, etc.): 2nd gear.
22 - 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 wheels and lamp A2 for the rear wheels.
Before selecting one of the three possible steering positions, bring all 4 wheels into alignment with
regards to the lift truck axle. Never change the steering mode whilst driving.
A1
B - STEERING SELECTION LEVER
A2
B1 - Front drive wheels (highway traffic).
B2 - Front and rear drive wheels in opposite direction (short steering lock).
B3 - Front and rear drive wheels in the same direction (crab steering).
CONTROL FOR ALIGNMENT OF THE WHEELS
- Shift the steering selection lever B into position B2 (short steering lock).
- Turn the steering wheel and bring the rear wheels into alignment until lamp A2 lights up.
- Shift the steering selection lever B into position B1 (highway traffic).
- Turn the steering wheel and bring the front wheels into alignment until lamp A1 lights
up.
Before driving on roads, it is necessary to check the alignment of the rear wheels and to drive in front
wheel steer. The control of the alignment of the rear wheels must be regularly done with the help of the
green lamps, while driving the lift truck. In case of anomalies, consult your dealer.
2-42
B3
B1
B2
23 - HEATER CONTROL
A - FAN CONTROL
This 3-speed control allows the air to be ventilated through the air vents.
A
B
B - TEMPERATURE CONTROL
Allows the temperature inside the cab to be adjusted.
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.
B1
B2
23 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
The air conditioning only works if the lift truck has been started up. When using your air conditioning unit you must work with the cab closed.
In winter: So as to ensure correct operation and complete efficiency of the air conditioning unit, start up the compressor once a week, if only for a
short spell, so as to lubricate the internal seals.
In cold weather: Warm the I.C. engine before switching on the compressor, so as to allow the coolant that has collected in a liquid state at
the lowest point of the compressor circuit to turn into gas under the effect of the heat given off by the I.C. engine, as the compressor is liable to be
damaged by coolant in a liquid state.
If your air conditioning does not seem to be working regularly, have it examined by your dealer (see: 3 - MAINTENANCE: F - EVERY 2000 HOURS OF
SERVICE). Never try to repair any anomalies yourself.
A - FAN CONTROL
This 3-speed control allows the air to be ventilated through the air vents.
A
B
B - TEMPERATURE CONTROL
Allows the temperature inside the cab to be adjusted.
B1 - The fan pumps in cold air.
B2 - The fan pumps in warm air.
The intermediate positions allow the temperature to be adjusted.
C - AIR CONDITIONING CONTROL
This control with a pilot light allows the air conditioning unit to be switched on.
B1
B2
C
HEATING MODE
The controls must be adjusted in the following way:
C - Control with pilot light off.
B - At the required temperature.
A - At the desired speed: 1, 2 or 3.
CONDITIONED AIR MODE
The controls must be adjusted in the following way:
C - Control with pilot light on.
B - At the required temperature.
A - At the desired speed: 1, 2 or 3.
DEMISTING MODE
The controls must be adjusted in the following way:
C - Control with pilot light on.
B - At the required temperature.
A - At speed 2 or 3.
For optimum effectiveness, close the heating ventilators.
24 - HEATING VENTS
These swiveling heating vents, which can be shut off, allow you to direct and adjust the flow rate inside the cab.
25 - DEMIST VENTS
These vents allow the front windscreen and side windows to be demisted. For optimum efficiency, shut off the heating vents.
2-43
26 - LEVEL INDICATORS
A - TILT INDICATOR
When the two marks are aligned, the chassis is
parallel with the front axle.
B
A
B - SPIRIT LEVEL
Enables the operator to check that the lift truck is
in the horizontal position.
27 - DOOR OPEN LEVER
28 - DOOR CLOSE HANDLE
29 - WINDOW REGULATOR SWITCH
30 - SIDE STORAGE SPACE
31 - ROOF LIGHT
32 - HANDLE FOR REAR WINDOW OPENING
EMERGENCY EXIT
Use the rear window as an emergency exit, if it is impossible to leave the cab by the door.
33 - HANDLE FOR REAR WINDOW CLOSING
34 - STEERING WHEEL ADJUSTMENT LEVER
This handle enables the angle and height of the steering wheel to be adjusted.
- Pull the knob 1 backwards.
- Adjust the steering wheel to the desired position.
- Push the knob back to lock the steering wheel in position.
1
2-44
35 - DOCUMENT HOLDER NET
Make sure that the operator’s manual is in the right place, i.e. in the document holder net.
NOTE: An OPTION waterproof document-holder exists.
36 - STORAGE COMPARTMENT
37 - ASHTRAY
38 - FRONT HEADLIGHTS
A - Left front indicator.
B - Left front dipped headlight.
C - Left front main beam.
D - Left front sidelight.
E - Right front indicator.
F - Right front dipped headlight.
G - Right front main beam.
H - Right front sidelight.
G
E
C
H
D
A
B
F
39 - REAR LIGHTS
A - Left rear indicator.
B - Left rear stoplight.
C - Left tail light.
D - Rear fog light.
E - Rear reversing light.
F - Right tail light.
G - Right rear stoplight.
H - Right rear indicator.
H
A
B
D
E
G
C
F
40 - REVOLVING LIGHT
The magnetic revolving light must be clearly visible
on the roof of the cab and plugged-in to socket 1.
1
41 - INSIDE REAR-VIEW MIRROR (OPTION)
2-45
TOWING PIN AND HOOK
Located at the rear of the lift truck, this device is used to attach a trailer. Its capacity is limited for each lift truck by the
authorized gross vehicle weight, tractive effort and maximum vertical force on the coupling point. This information is given on the
manufacturer’s plate fixed to each lift truck (see: 2 - DESCRIPTION: IDENTIFICATION OF THE LIFT TRUCK).
- To use a trailer, see current regulations in your country (maximum running speed, braking, maximum weight of trailer, etc.).
- Verify the trailer’s condition before using it (tyre condition and pressures, electrical connection, hydraulic hose, brake system…).
Do not tow a trailer or attachment which is not in perfect working order. Using a trailer in poor condition may affect the lift truck’s steering and braking,
and hence safety.
If a third party helps in coupling or uncoupling the trailer, this person must be permanently visible to the driver and wait until the lift truck has stopped,
the handbrake is on and the I.C. engine is switched off before performing the operation.
NOTE: There is an OPTIONAL rear-view mirror which allows the lift truck to be approached more closely to the trailer ring.
A - TOWING PIN
COUPLING AND UNCOUPLING THE TRAILER
- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- Switch off the I.C. engine.
- Remove the pin 1, lift the trailer pin 2 and place or remove the trailer ring.
2
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put pin 1 back in place.
When uncoupling, make sure that the trailer is supported independently.
1
B - ADJUSTABLE PROJECTING HOOK (OPTION)
COUPLING AND UNCOUPLING THE TRAILER
- To couple the trailer, position the lift truck as close as possible to the trailer ring.
- Switch off the I.C. engine.
- Set the coupling fitting 1 according to the height of the trailer ring.
3
Do not forget to put rods and pin back in place.
1
- Remove pin 2, lift the trailer pin 3 and place or remove the trailer ring.
Be careful not to get your fingers caught or crushed during this operation.
Do not forget to put pin 2 back in place.
When uncoupling, make sure that the trailer is supported independently.
2
C - REAR ELECTRIC SOCKET (OPTION)
1
- Connect the male plug to the female socket 1 on the lift truck and make sure the lights of
the trailer or the light bar are working properly.
A - Left rear indicator.
B - OPTION Rear fog lights.
C - Earth.
D - Right rear indicator.
E - Right tail light.
F - Rear stoplight.
G - Left rear light + number plate.
A
F
B
G
E
C
D
2-46
2-47
DESCRIPTION AND USE OF THE OPTIONS
1 - NUMBER PLATE LIGHTING
2 - PREHEATING ELEMENT
3 - FINTRONIC ANTI-START SYSTEM
4 - MODCLE ANTI-START SYSTEM
5 - ELECTRICAL PROVISION ON JIB
6 - QUICK-RELEASE COUPLER ON ATTACHMENT CIRCUIT
7 - ANGULAR SECTOR ON JIB
8 - EXTERIOR DRAIN-BACK
9 - HYDRAULIC ATTACHMENT LOCKING
10 - JIB HEAD ELECTROVALVE
11 - JIB HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING
12 - SINGLE SIDE-SHIFT CARRIAGE (TSDL)
13 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
14 - LIFTING RING ON SINGLE CARRIAGE
1 - NUMBER PLATE LIGHTING
2 - PREHEATING ELEMENT
Enables the engine to be kept warm during prolonged periods of stoppage and thus
improves engine starting.
SUPPLY CHARACTERISTICS OF PREHEATING SYSTEM:
• Rated range of power: 220-240V; 50-60Hz
• Current consumed: 4,5A
• Equipment in class 1
• Equipment connectable only on feeder circuit TT or TN
• Category of insulation 2
ENVIRONMENTAL CONDITIONS FOR USE:
• Maximum ambient temperature for using preheating: +25°C
• Pollution level 2
CONDITIONS FOR CONNECTION AND USE OF PREHEATING:
- The preheating system should not be used for an external ambient temperature higher than + 25°C.
- It is essential that the power supply to 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 appropriate safety system against short circuits (fuses or circuit breaker) and a differential circuit breaker
with 30 mA sensitivity.
- Only connect to and disconnect from the power supply while the unit is off and the I.C. engine is stopped.
2-48
3 - FINTRONIC 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 restart the lift truck within 20 seconds of stopping it: after this time, the
anti-start system reacts and red LED C flashes.
4 - MODCLE ANTI-START SYSTEM
OPERATION
- Switch on lift truck ignition, red led 1 will flash.
- Apply key 2 to its base 3, and withdraw the moment the system emits a continuous beep,
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.
NOTE: You can restart the lift truck within 20 seconds of stopping it: after this time, the
anti-start system reacts and red LED C flashes.
5 - ELECTRICAL PROVISION ON JIB
Enables an electrical function to be used at the head of the jib.
OPERATION
- Set switch 1 to position A to enable the electrical provision. The indicator light will come
on when it is enabled.
6 - QUICK-RELEASE COUPLER ON ATTACHMENT CIRCUIT
7 - ANGULAR SECTOR ON JIB
The angular sector displays the jib angle, and thus
improves the reading of the load charts.
MT 1440 E3
2-49
MT 1840 E3
8 - EXTERIOR DRAIN-BACK
Enables connection of an attachment for which
drain-back is required.
MT 1440 E3
A - Fixed position, drain back not connected.
B - Movable position, drain back connected.
MT 1440 E3
MT 1840 E3
9 - HYDRAULIC ATTACHMENT LOCKING
Enables the attachment to be locked onto the carriage and a hydraulic attachment to be
used by the same hydraulic circuit.
ATTACHMENT LINE CONTROL
- Set valve 1 to position A.
- Push button 2 forward or backward.
B
1
ATTACHMENT LOCKING CONTROL
- Set valve 1 to position B.
- Push button 2 forward to lock the attachment and backward to release it.
A
Once the attachment is locked, return valve 1 to position A to prevent accidental release of the
attachment.
2
10 - JIB HEAD ELECTROVALVE
Enables use of two hydraulic functions on the attachment circuit.
L2
L1
ATTACHMENT LINE L1 CONTROL
- Push button 1 forward or backward.
L2
L1
ATTACHMENT LINE L2 CONTROL
- Hold down button 2 and push button 1 forwards or backwards.
2
1
2-50
11 - JIB HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING
The addition of these two options on the attachment line allows two hydraulic functions
to be used and locks the attachment onto the carriage.
ATTACHMENT LINE L1 CONTROL
- Set valve 1 to position A.
- Push button 2 forward or backward.
L1
L1
A
L2
L2
1
ATTACHMENT LINE L2 CONTROL
- Set valve 1 to position A.
- Hold down button 3 and push button 2 forwards or backwards.
B
ATTACHMENT LOCKING CONTROL
- Set valve 1 to position B.
- Hold down button 3 and push button 2 forward to lock the attachment and backward
to release it.
Once the attachment is locked, return valve 1 to position A to prevent accidental release of the
attachment.
3
2
12 - SINGLE SIDE-SHIFT CARRIAGE (TSDL)
The single side-shift carriage (TSDL) is only compatible with the following
attachments:
• floating fork carriage (TFF)
• tilting fork carriage (PFB)
• loading bucket (CBR)
• concrete bucket (BB, BBG)
• chute bucket (GL)
• crane jib and crane jib with winch (P, PT, PO, PC)
• winch (H)
• fixed platform, swivelling platform, roofer’s platform.
The use of any other attachment on the TSDL is forbidden.
TSDL
N°272186
If it is being used with a loading bucket (CBR), the single side-shift carriage MUST
be centred and no side-shift operations performed.
WITH JIB HEAD COUPLER
ATTACHMENT LINE CONTROL
- Set valve 1 to position A.
- Push button 2 forward or backward.
1
TSDL CONTROL
- Set valve 1 to position B.
- Push button 2 forward to move sideways to the right, and backward to move sideways to
the left.
A
2
2-51
B
WITH JIB HEAD ELECTROVALVE
TSDL LINE L1 CONTROL
- Push button 2 forward to move sideways to the
right, and backward to move sideways to the left.
L2
L1
L1
3
L2
ATTACHMENT LINE L2 CONTROL
- Hold down button 3 and push button 2 forwards
or backwards.
2
WITH JIB HEAD ELECTROVALVE + PREARRANGED HYDRAULIC ATTACHMENT
LOCKING
L1
L1
TSDL LINE L1 CONTROL
- Push button 2 forward to move sideways to the right, and backward to move sideways to
the left.
A
L2
ATTACHMENT LINE L2 CONTROL
- Set valve 1 to position A.
- Hold down button 3 and push button 2 forwards or backwards.
L2
1
B
ATTACHMENT LOCKING CONTROL
- Set valve 1 to position B.
- Hold down button 3 and push button 2 forward to lock the attachment and backward to
release it.
Once the attachment is locked, return valve 1 to position A to prevent accidental release of the
attachment.
3
2
13 - SINGLE OR DUAL EFFECT REAR HYDRAULIC CONTROL PREDISPOSITION
Enables the use of a hydraulic attachment at the rear of the lift truck (e.g. a trailer with
hydraulic tipping).
REAR HYDRAULIC CONTROL
- Press down on switch 1 (indicator lamp lit) to power the hydraulic control at the rear of the
lift truck.
- Push button 2 forward or backward.
2
2-52
14 - LIFTING RING ON SINGLE CARRIAGE
Kg
CONDITIONS OF USE
Kg
Follow the instructions given in your lift truck’s instruction manual (see:
1 - OPERATING AND SAFETY INSTRUCTIONS ON HANDLING LOADS), in
addition to those given below.
N°265284
- 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.
- Check the maximum authorized angle, which is 45°, on the
screen.
- Do not change the angle of the carriage while using the lifting
ring.
- The lifting hook, the chains and slings shall have a minimum
capacity of 3000 kg with a factor of safety against breakage of 4.
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
Kg
LOAD CHARTS AND FUNCTION SHEETS
The load charts are given for use without forks and without attachments.
13
45°
12
11
3000KG
MAXI
10
40°
9
30°
7
6
5
20°
3
P
10°
2
200KG
400KG
600KG
900KG
1200KG
1600KG
10°
2
20°
4
3000KG
0KG
3
200KG
400KG
600KG
900KG
1200KG
1600KG
2000KG
4
0KG
5
3000KG
6
P
1
1
0°
0
-1
-2
0KG
8
30°
MT1840
45°
40°
9
0KG
8
7
100KG
9.80 10
2500KG
3000KG
MAXI
100KG
11
2500KG
MT1440
12
2000KG
13
-1
-5.2°
10
9
8
8.77
0°
0
0km/h
7 6 5 4
3 2 1
6.75 5.80 4.45 3.30 2.45 1.17
6.45 5.25 3.80 2.85 2.10
-2
0m
0km/h
-5.51°
10
9 8 7 6 5 4
3 2 1
7.80 6.65
4.65 3.65 2.95 1.40
8.77 7.45 6.10
4.20 3.30
0m
N°272014
N°272016
75.5°
N°272013
18
71.4°
14
14
50°
12
10
40°
11
40°
10
8
9
10°
2
6
4
3 10°
2
1
MT1440
0
1
0°
10
0
9 8 7 6 5 4
8.67 7.45 6.05 4.70
8.15
6.40 5.35
3
2
1
1.10
-1
0m
MT1840
0.3m Maxi
0.3m Maxi
1,5km/h Maxi (0,4m/s)
5
4
3
2
1
1.30
0m
MT1840
1,5km/h Maxi (0,4m/s)
2.40m Maxi
3m Mini
1.40m Maxi
kg
kg
kg
15% maxi
6
3000KG
MAXI
kg
5% maxi
9 8 7
8.45
7.65
45° Maxi
36km/h Maxi
(10m/s)
3000KG
MAXI
3m Mini
0KG
-0.7°
13 12 11 10
11.65
12.43 10.60
MT1440
45° Maxi
36km/h Maxi
(10m/s)
20°
5
3000KG
7
600KG
900KG
3
8
300KG
20°
4
0KG
3000KG
750KG
5
1200KG
30°
6
2000KG
2500KG
7
30°
1600KG
2000KG
2500KG
9
-1
50°
13
1200KG
11
60°
15
3000KG
MAXI
60°
900KG
12
70°
16
70°
13
1600KG
13.35
3000KG
MAXI
N°272015
17.30
17
15
10% maxi
kg
kg
5% maxi
5% maxi
N°272013
kg
15% maxi
10% maxi
kg
5% maxi
N°272015
2-53
2-54
3 - MAINTENANCE
3-1
3-2
TABLE OF CONTENTS
MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT
3-4
START-UP CHECKLIST
3-5
FILTERS CARTRIDGES AND BELTS
3-6
LUBRICANTS AND FUEL
3-8
SERVICING SCHEDULE
3-10
A - DAILY OR EVERY 10 HOURS SERVICE
3-12
B - EVERY 50 HOURS SERVICE
3-16
C - EVERY 250 HOURS SERVICE
3-20
D - EVERY 500 HOURS SERVICE
3-24
E - EVERY 1000 HOURS SERVICE
3-28
F - EVERY 2000 HOURS OF SERVICE
3-34
G - EVERY 4000 HOURS OF SERVICE
3-36
H - OCCASIONAL MAINTENANCE
3-38
3-3
MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT
OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS.
IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS,
YOU RISK
- Legally - to be held responsible in the event of an accident.
- Technically - to generate operating failure or shorten the life of the lift truck.
THE USE OF COUNTERFEIT PARTS OR COMPONENTS NOT APPROVED BY THE MANUFACTURER,
MEANS YOU LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE.
BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS,
YOU BENEFIT
EXPERTISE
Through its network, MANITOU provides the user with
- Know-how and competence.
- The guarantee of high-quality work.
- Original replacement components.
- Help with preventive maintenance.
- 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.
ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
the dealer network list is available on manitou web site www.manitou.com
3-4
START-UP CHECKLIST
0 = OK
100
ENGINE
108
01 Air filter
1 = Missing
ATTACHMENTS
01 Fitting on machine
02 Fuel tank
02 Hydraulic couplings
03 Fuel lines - Filter
109
CABIN/PROTECTOR/ELECTRIC CIRCUIT
04 Injection or carburetion system
01 Seat
05 Radiator and cooling system
02 Dashboard and radio
06 Belts
03 Sound and visual alarm/safety system
07 Hoses
04 Heating/Air conditioning
101
TRANSMISSION
05 Windscreen wiper/windscreen washer
01 Direction reversal system
06 Road horn
02 Gear shift
07 Reversing horn
03 Cut-off pedal
08 Road lights
04 Clutch
09 Additional lights
102
AXLES/TRANSFER GEAR BOX
10 Rotating beacon light
01 operation and seal
11 Battery
02 Stop settings
103
110
HYDRAULIC/HYDROSTATIC CIRCUIT
WHEEL
01 Rims
01 Tank
02 Tyre/Pressure
02 Pumps and couplings
111
SCREWS
03 Tightening of connections
112
FRAME AND BODYWORK
04 Lift cylinder(s)
113
PAINTING
05 Tilt cylinder(s)
114
GENERAL OPERATION
06 Attachment cylinder(s)
115
OPERATOR’S MANUAL
07 Telescope cylinder(s)
116
CUSTOMER INSTRUCTIONS
08 Compensation cylinder(s)
09 Steering cylinder(s)
10 Control Valve
11 Balancing 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 Hinges
04 Carriage
05 Forks
107
2 = Incorrect
MAST ASSEMBLY
01 Fixed and mobile uprights
02 Carriage
03 Chains
04 Rollers
05 Forks
3-5
FILTERS CARTRIDGES AND BELTS
I.C. ENGINE
I.C. ENGINE OIL FILTER
Part number: 476954
Change: 500 H
ALTERNATOR BELT
Part number: 702974
DRY AIR FILTER CARTRIDGE
Part number: 563416
Clean: 50 H*
Change: 500 H*
ALTERNATOR BELT
(OPTION AIR CONDITIONING)
Part number: 286931
SAFETY DRY AIR FILTER CARTRIDGE
Part number: 563415
Change: 1000 H*
COMPRESSOR BELT
(OPTION AIR CONDITIONING)
Part number: 216125
FUEL FILTER CARTRIDGE
Part number: 605013
Change: 500 H
CYCLONIC PRE-FILTER
Part number: 224713
Clean: 10 H
FUEL PRE-FILTER CARTRIDGE
Part number: 706497
Change: 500 H
AUTOMATIC VACUUM-CLEANING
(OPTION)
Part number: 226611
PRE-FILTER
FUEL TANK BREATHER
Part number: 266219
Change: 1000 H
*: This periodicity is given for information only (see: 3 - MAINTENANCE: SERVICING SCHEDULE) for cleaning and changing.
TRANSMISSION
GEAR BOX OIL FILTER
Part number: 745878
Change: 1000 H
HYDRAULIC
HYDRAULIC RETURN OIL FILTER CARTRIDGE
Part number: 289920
Change: 500 H
SUCTION STRAINER FOR HYDRAULIC OIL TANK
Part number: 259500
Clean: 1000 H
BREATHER FOR THE HYDRAULIC OIL TANK
Part number: 261487
Change: 1000 H
BRAKE ACCUMULATOR UNIT FILTER
Part number: 746308
Change: 1000 H
EXTERNAL CAB VENTILATION FILTER
Part number: 261971
Clean: 50 H
Change: 250 H
INTERNAL CAB VENTILATION FILTER
Part number: 746106
Clean: 50 H
Change: 250 H
CABINE
3-6
3-7
LUBRICANTS AND FUEL
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 organized with the dealer, a diagnostic analysis of engine, transmission and axle oils
may be requested depending on the rate of use.
(*) RECOMMENDED FUEL 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 K2204 (1992) Grades 1, 2, 3 and Special Grade 3.
I.C. ENGINE
ORGANS TO BE LUBRICATED
I.C. ENGINE
CAPACITY
10,9 Liters
RECOMMENDATION
MANITOU Oil
API CH4
Cooling liquid
(protection - 25°)
COOLING CIRCUIT
20 Liters
Cooling liquid
(protection - 35°)
FUEL TANK
140 Liters
TRANSMISSION
ORGANS TO BE LUBRICATED
CAPACITY
GEAR BOX
23 Liters
PART NUMBER
661706
582357
582358
582359
490205
788245
788246
788247
788248
788249
788250
788251
PACKAGING
1l
20 l
55 l
209 l
1000 l
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
62148
546332
546217
546195
720148
161589
720683
554974
499233
489670
PACKAGING
400 g
1 kg
5 kg
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
545996
161590
499235
161589
720683
554974
499233
489670
400 ml
554271
PACKAGING
5l
20 l
55 l
209 l
PART NUMBER
545500
582297
546108
546109
Diesel fuel (*)
RECOMMENDATION
MANITOU Oil
Automatic transmission
MANITOU Grease
BLUE multi-purpose
TRANSMISSION UNIVERSAL JOINT
PACKAGING
5l
20 l
55 l
209 l
1000 l
2l
5l
20 l
210 l
20 l
210 l
1000 l
JIB
ORGANS TO BE LUBRICATED
RECOMMENDATION
JIB PADS
MANITOU Grease
BLACK multi-purpose
GREASING OF THE JIB
MANITOU Grease
BLUE multi-purpose
MT 1840 E3
JIB CHAINS
MANITOU Lubricant
Chain special
HYDRAULIC
ORGANS TO BE LUBRICATED
HYDRAULIC OIL TANK
CAPACITY
135 Liters
RECOMMENDATION
MANITOU Oil
Hydraulic ISO VG 46
3-8
BRAKE
ORGANS TO BE LUBRICATED
BRAKE CIRCUIT
RECOMMENDATION
MANITOU Oil
Mineral brake fluid
PACKAGING
PART NUMBER
1l
490408
RECOMMENDATION
PACKAGING
1l
5l
PART NUMBER
490402
486424
PACKAGING
5l
20 l
209 l
1000 l
2l
5l
20 l
55 l
209 l
400 g
1 kg
5 kg
PART NUMBER
545976
582391
546222
720149
499237
720184
546330
546221
546220
545996
161590
499235
PACKAGING
5l
20 l
209 l
1000 l
2l
5l
20 l
55 l
209 l
400 g
1 kg
5 kg
PART NUMBER
545976
582391
546222
720149
499237
720184
546330
546221
546220
545996
161590
499235
PACKAGING
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
161589
720683
554974
499233
489670
PACKAGING
400 g
1 kg
5 kg
20 kg
50 kg
PART NUMBER
161589
720683
554974
499233
489670
CAB
ORGANS TO BE LUBRICATED
WINDSCREEN WASHER TANK
Windscreen washer fluid
FRONT AXLE
ORGANS TO BE LUBRICATED
CAPACITY
FRONT AXLE DIFFERENTIAL
7,6 Liters
MANITOU Oil
Special immersed brakes
FRONT WHEELS REDUCERS
0,8 Liter
MANITOU Oil
SAE80W90
Mechanical transmission
FRONT WHEELS REDUCERS PIVOTS
FRONT AXLE OSCILLATION
RECOMMENDATION
MANITOU Grease
BLACK multi-purpose
REAR AXLE
ORGANS TO BE LUBRICATED
CAPACITY
REAR AXLE DIFFERENTIAL
7,6 Liters
MANITOU Oil
Special immersed brakes
REAR WHEELS REDUCERS
0,8 Liter
MANITOU Oil
SAE80W90
Mechanical transmission
REAR WHEELS REDUCERS PIVOTS
REAR AXLE OSCILLATION
RECOMMENDATION
MANITOU Grease
BLACK multi-purpose
CHASSIS
ORGANS TO BE LUBRICATED
TILTING CORRECTOR
STABILIZERS
RECOMMENDATION
MANITOU Grease
BLUE multi-purpose
ATTACHMENT
ORGANS TO BE LUBRICATED
SINGLE SIDE-SHIFT CARRIAGE (TSDL) (OPTION)
RECOMMENDATION
MANITOU Grease
BLUE multi-purpose
3-9
SERVICING SCHEDULE
EVERY 4000 HOURS
SERVICE
C
C
C
C
N
<<<
<<<
<<<
<<<
<<<
N
N
C/N
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C/A
C/A
C/A
<<<
<<<
<<<
<<<
<<<
R
<<<
<<<
<<<
<<<
<<<
V
R
R
R
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
N
R
R
C**
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
V
C**
C**
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
3-34
3-38
P
3-13
3-18
3-29
3-29
C
G
V
R
C
<<<
G
<<<
<<<
<<<
<<<
<<<
<<<
V
R
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
<<<
G/C**
<<<
<<<
<<<
<<<
<<<
<<<
C**
3-13
3-13
C
C
C
C
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
<<<
<<<
<<<
<<<
<<<
<<<
3-38
3-13
3-18
3-21
OCCASIONALLY
EVERY 2000 HOURS
SERVICE OR 2
YEARS
C
C
C
C
N
R
N
C/N
C/A
C/A
C/A
V
R
R
R
EVERY 1000 HOURS
SERVICE OR 1 YEAR
3-12
3-12
3-12
3-12
3-13
3-16/25
3-16
3-16
3-20
3-20
3-22
3-24
3-24
3-25
3-25
3-28
3-28
3-28
EVERY 500 HOURS
SERVICE OR 6
MONTHS
(1)
EVERY 250 HOURS
SERVICE
I.C. ENGINE
I.C. engine oil level
Cooling liquid level
Fuel level
Fuel pre-filter
Cyclonic pre-filter (OPTION)
Dry air filter cartridge
Radiator core
Condenser core (OPTION Air conditioning)
Alternator belt tension
Compressor belt tension (OPTION Air conditioning)
Alternator belt tension (air conditioning OPTION)
I.C. engine oil
I.C. engine oil filter
Fuel pre-filter cartridge
Fuel filter cartridge
Fuel tank
Fuel tank breather
Safety dry air filter cartridge
I.C. engine silent blocks
I.C. engine rates
Valves clearances
Cooling liquid
Radiator
Water pump and the thermostat
Alternator and the starter motor
Turbocompressor
Fuel circuit
TRANSMISSION
Gear box oil level
Transmission universal joint
Gear box oil
Gear box oil filter
Silentblocks in the gear box
Gear box controls
Gear box pressures
Converter pressure
Wear of the brake pads and the brake disk
TYRES
Tyres pressure
Wheel nuts torque
Condition of wheels and tyres
Wheel
JIB
Jib pads
Jib
Outer jib chains MT 1840 E3
Jib pads wear
Outer jib chain wear MT 1840 E3
Condition of jib unit
Bearings and articulation rings
Inner jib chain wear MT 1840 E3
HYDRAULIC
Hydraulic oil level
Hydraulic return oil filter cartridge
Hydraulic oil
Breather for the hydraulic oil tank
Suction strainer for hydraulic oil tank
Brake accumulator unit filter
Speeds of hydraulic movements
Hydraulic pump tubular filter
Condition of hoses and flexibles pipes
Condition of cylinders (leakage, shafts)
Hydraulic circuit pressures
Hydraulic circuit outputs
Hydraulic oil tank
PAGE
EVERY 50 HOURS
SERVICE
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,
P = BLEED, R = REPLACE, V = DRAIN
DAILY OR EVERY 10
HOURS SERVICE
(1): MANDATORY 500 HOUR OR 6 MONTH SERVICE
This service must be carried out after approximately the first 500 hours of operation or within the 6 months following the start-up of the machine
(whichever occurs first).
R
G*
G
N/G/C
<<<
G
<<<
<<<
N/G/C
<<<
<<<
<<<
<<<
<<<
<<<
C**
C
<<<
<<<
<<<
<<<
<<<
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C
C
<<<
<<<
R
<<<
<<<
V
R
N
R
C**
N**
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
N**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
3-30
3-36
3-17
3-26
3-31
3-31
3-31
3-31
C
R
3-10
3-17
3-18/22
3-32
C
R
EVERY 2000 HOURS
SERVICE OR 2
YEARS
EVERY 4000 HOURS
SERVICE
C
<<<
<<<
<<<
V**
P**
C**
A**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C
C
<<<
C**
C
N
<<<
R
<<<
<<<
<<<
<<<
C
C**
C**
<<<
<<<
<<<
<<<
<<<
N/C
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
3-35
3-14/39
C**
3-40
3-40
OCCASIONALLY
EVERY 1000 HOURS
SERVICE OR 1 YEAR
C
EVERY 500 HOURS
SERVICE OR 6
MONTHS
3-17
EVERY 250 HOURS
SERVICE
(1)
EVERY 50 HOURS
SERVICE
BRAKE
Brake oil level
Brake oil
Brake system
Brake system pressure
Brake
STEERING
Steering
Steering swivel joints
CAB
Windscreen washer liquid level
Cab ventilation filters
Seat belt
Condition of the rear view mirrors
Structure
Air conditioning (OPTION)
ELECTRICITY
Longitudinal stability limiter and warning device
Condition of wiring harness and cables
Lights and signals
Warning indicators
Front headlights
Battery failure
FRONT AXLE
Front wheels reducers pivots
Front axle oscillation
Front axle differential oil level
Front wheels reducers oil level
Front axle differential oil
Front wheels reducers oil
Wear of front axle brake discs
Front wheels reducers universal joint
Front wheels reducers clearance
REAR AXLE
Rear wheels reducers pivots
Rear axle oscillation
Rear axle differential oil level
Rear wheels reducers oil level
Rear axle differential oil
Rear wheels reducers oil
Wearing of rear axle brake discs
Rear wheels reducers universal joint
Rear wheels reducers clearance
CHASSIS
Tilting corrector
Stabilizers
Structure
Bearings and articulation rings
ATTACHMENTS
Single side-shift carriage (TSDL) (OPTION)
Forks wear
Attachment carriage
Condition of attachments
LIFT TRUCK
Tow the lift truck
Sling the lift truck
Transport the lift truck on a platform
PAGE
DAILY OR EVERY 10
HOURS SERVICE
A = ADJUST, C = CHECK, G = GREASE, N = CLEAN,
P = BLEED, R = REPLACE, V = DRAIN
XXX
A
R
3-18
3-18
3-22
3-22
3-27
3-32
G
G
C
C
V
V
G
G
<<<
<<<
C
C
<<<
<<<
<<<
<<<
V
<<<
<<<
<<<
<<<
<<<
V
<<< G/C**
G/C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
C**
3-18
3-18
3-22
3-22
3-27
3-32
G
G
C
C
V
V
G
G
<<<
<<<
C
C
<<<
<<<
<<<
<<<
V
<<<
<<<
<<<
<<<
<<<
V
<<< G/C**
G/C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
C**
C**
C**
3-18
3-18
G
G
G
G
<<<
<<<
<<<
<<<
<<<
<<<
C**
<<<
<<<
<<<
C**
<<<
<<<
<<<
<<<
3-18
G
C**
G
<<<
<<<
C**
<<<
<<<
C**
C**
<<<
<<<
<<<
<<<
<<<
<<<
<<<
<<<
3-41
3-41
3-42
XXX
XXX
XXX
(*): Every 10 hours during the first 50 hours, then once at 250 hours.
(**): Consult your dealer.
3-11
A - DAILY OR EVERY 10 HOURS SERVICE
A1 - I.C. ENGINE OIL LEVEL
A1
CHECK
Place the lift truck on level ground with the I.C. engine stopped, and let the oil drain into
the sump.
1
-
Open the I.C. engine bonnet.
Remove the dipstick 1 (fig. A1).
Clean the dipstick and check the correct level between the two notches.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port 2
(fig. A1).
- Check visually that there is no leakage or seepage of oil in the I.C. engine.
2
A2 - COOLING LIQUID LEVEL
A2
CHECK
Place the lift truck on level ground with the I.C. engine stopped, and allow the I.C. engine
to cool.
2
- Open the I.C. engine bonnet.
- The liquid must be at the MAXIMUM level on the expansion pan 1 (fig. A2).
- If necessary, add cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through
the filler port 2 (fig. A2).
- Check visually that there is no leakage in the radiator and pipes.
1
To avoid any risk of spraying or burning, wait until the I.C. engine has cooled down before removing
the cooling circuit filler plug. If the cooling liquid is very hot, add only hot cooling liquid (80°C). In an
emergency, you can use water as a cooling liquid, then change the cooling circuit liquid as soon as
possible (see: 3 - MAINTENANCE: F1 - COOLING LIQUID).
A3 - FUEL LEVEL
A3
CHECK
Keep the fuel tank full, to reduce as much as possible any condensation due to the
atmospheric conditions.
1
2
-
Check the dipstick level on the instrument panel.
If necessary, add cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
Remove cap 1 (fig. A3) using the switch key.
Fill the fuel tank with clean diesel and filtered through filler port 2 (fig. A3).
Put the cap back.
Check visually that there is no leakage in the tank and pipes.
Never smoke or approach with a flame during filling operations or when the tank is open. Never refill
while I.C. engine is running.
A4 - FUEL PRE-FILTER
A4
CHECK
- Open the I.C. engine bonnet.
- Check for the presence of water in the pre-filter bowl 1 (fig. A4) and empty it out
if necessary.
- Place a receptacle under the drain plug 2 (fig. A4) and loosen it in two to three thread
turns.
- Allow the diesel fuel to flow out until it is free from impurities and water.
- Tighten the drain plug while the diesel fuel is running out.
1
2
3-12
A5 - CYCLONIC PRE-FILTER
A5
CLEAN
The cleaning interval is given as a guide, however the prefilter must be emptied as soon as
impurities reach the MAXI level on the tank.
1
2
- Loosen nut 1 (fig. A5), remove cover 2 (fig. A5) and empty the tank.
- Clean the prefilter unit with a clean dry cloth and reassemble the unit.
When cleaning, take care not to let impurities into the dry air filter.
A6/1
A6 - GEAR BOX OIL LEVEL
CHECK
1
Park the lift truck on level ground with the jib raised, the I.C. engine cold and stopped. Carry
out the control within 5 minutes of the I.C. engine being stopped.
-
Raise the jib and remove protective guard back 1 (fig. A6/1).
Remove dipstick 2 (fig. A6/2) by unscrewing it.
Wipe the dipstick and check the correct level against the MAX mark.
If necessary, add oil (see: 3 - MAINTENANCE: E4 - GEAR BOX OIL) through filler port 3
(fig. A6/2).
- Screw the dipstick back in whilst pressing it down so as to ensure its hold and its
airtightness.
- Check visually that there is no leakage or seepage of oil in the transmission.
A6/2
2
3
A7 - TYRES PRESSURE AND WHEEL NUTS TORQUE
CHECK
- Check the condition of the tyres, to detect cuts, protuberances, wear, etc.
- Check the torque load of the wheel nuts. Non compliance with this instruction can cause
damage and rupture to the wheel bolts and distortion to the wheels.
Wheel nuts tightening torque
• Front tyres: 630 N.m ± 15%
• Rear tyres: 630 N.m ± 15%
- Check and adjust the tyre pressures if necessary (see: 2 - DESCRIPTION: FRONT AND REAR TYRES).
Check that the air hose is correctly connected to the tyre valve before inflating and keep all persons at a distance during inflation. Respect the
recommended tyre pressures given.
NOTE: There is an OPTIONAL wheel toolkit.
A8 - JIB PADS
A8
CLEAN - GREASE
To be carried out every 10 hours during the first 50 hours service,
then once at 250 hours.
- Extend the jib completely.
- With a brush, apply a coat of grease (see: 3 - MAINTENANCE:
LUBRICANTS AND FUEL) on the 4 sides of the telescope(s) (fig. A8).
- Telescope the jib several times in order to spread the coat of grease
evenly.
- Remove the surplus of grease.
If the lift truck is used in an abrasive environment (dust, sand, coal…) Use
lubricating varnish (MANITOU reference: 483536). In this respect, consult
your dealer.
3-13
A9 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
CHECK
- These tests are essential for checking the correct operation and adjustment of the different components of the device.
- Place the lift truck on flat, level ground with the wheels straight.
In case of doubt during the test procedure, exit by pressing the cancel button briefly
.
Long press on the test button.
STAGE
1
1
- Place the lift truck with no attachments,
with the left and right-hand stabilizers
on the ground, the front wheels off
the ground and the jib fully retracted
and raised.
- First green led flashing.
- Test button lit.
TEST
- Screen display.
- An audible beep.
Retract Telescope, Put
Boom to Maximum Angle
Then Press OK
2
STAGE
2
1
- Lower the jib with the engine running
at full revs and the hydraulic control
at the maximum setting. Lowering
slows until movement is cut-off.
- First green led continuously lit.
- Second green led flashing.
- Test button lit.
TEST
Short
press on
the test
button
- Go to stage 2.
.
Short
press on
the test
button
- Go to stage 3.
.
Lower the Boom
at Full Speed
(1/2)
- Screen display.
TEST OK
3
2
STAGE
3
1
- First and second green
continuously lit.
- Third green led flashing.
- Test button lit.
LEDs
- Continue to lower the jib with the
engine running at full revs and the
hydraulic control at the maximum
setting. Lowering slows until
movement is next cut-off.
Short
press on
the test
button
TEST
STAGE
4
warning light remains
- The fault
flashing on until the error is repaired.
TEST
- Screen display.
Security Test
Procedure NOK
111110
TEST
.
Security Test
Procedure OK
- Screen display.
- Press the button
To exit test mode.
TEST NOT OK
- See stage 4.
Lower the Boom
at Full Speed
(2/2)
- Screen display.
- First 5 LEDs lit.
- The combination is the result of tests carried out in the following order:
1st digit
2nd digit
3rd digit
4th digit
5th digit
Telescope
Right or left
Jib angle
Strain gauge
Safety valve
retracted
stabilizer
sensor fault.
fault.
fault.
sensor fault.
sensor fault.
1 = Test OK
0 = Fault detected
- Consult your dealer and provide the combination.
- Press the button
to exit test mode.
3-14
6th digit
Governing
fault.
3-15
B - EVERY 50 HOURS SERVICE
Carry out the operations described previously as well as the following operations.
B1 - DRY AIR FILTER CARTRIDGE
CLEAN
In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges (see: 3 - MAINTENANCE: FILTERS CARTRIDGES
AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced.
If the clogging indicator light comes on, this operation must be carried out as quickly as possible (1 hour maximum). The cartridge must not be cleaned
more than seven times, after which the cartridge must be changed.
- For the disassembly and reassembly of the cartridge, see: 3 - MAINTENANCE: D3 - DRY AIR FILTER CARTRIDGE.
- Clean the filter cartridge using a compressed air jet (max. pressure 3 bar) directed from the top to the bottom and from the inside
towards the outside at a minimum distance of 30 mm from the cartridge wall.
- Cleaning is completed when there is no more dust on the cartridge.
Respect the safety distance of 30 mm between the air jet and the cartridge to avoid tearing or making a hole in the cartridge. The cartridge must
not be blown anywhere near the air filter box. Never clean the cartridge by tapping it against a hard surface. Your eyes must be protected during this
intervention.
- Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU reference:
479292).
- Check visually the outer condition of the air filter and its mounts. Verify the condition of the hoses and their mounts also.
Do not clean the dry air filter cartridge by washing it in liquid. Do not clean by any means the safety cartridge located inside the filter cartridge, change
it for a new one if it is dirty or damaged.
B2 - RADIATOR CORE
B2
CLEAN
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure
steam as this could damage the radiator fins.
-
Open the I.C. engine bonnet.
If necessary, clean the suction grid on the engine bonnet.
Using a soft cloth, clean the radiator in order to remove as much dirt as possible.
Clean the radiator using a compressed air jet aimed in the same direction as the cooling
air flow (fig. B2).
- So as to enhance the cleaning, carry out this operation with the fan running.
B3 - CONDENSER CORE (OPTION AIR CONDITIONING)
B3
CHECK - CLEAN
In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure
steam as this could damage the condenser fins.
- Visually check whether the condenser (fig. B3) is clean and clean it if necessary.
- Clean the condenser using a compressed air jet aimed in the same direction as the air flow.
- So as to enhance the cleaning, carry out this operation with the fans running.
3-16
B4 - HYDRAULIC OIL LEVEL
B4/1
CHECK
Place the lift truck on level ground with the I.C. engine stopped, and the jib retracted and
lowered as far as possible.
-
Check dipstick 1 (fig. B4/1). The correct level must stand at the level of the red point.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
Lift up protective casing 2 (fig. B4/1).
Remove cap 3 (fig. B4/2).
Add oil by filler port 4 (fig. B4/2).
2
1
Use a clean funnel and clean the underside of the oil drum before filling.
- Put the cap back.
- Check visually that there is no leakage in the tank and pipes.
- Refit the protective casing.
B4/2
3
4
B5 - BRAKE OIL LEVEL
B5/1
CHECK
Place the lift truck on level ground.
1
-
Remove protective casing 1 (fig. B5/1) using the switch key.
Check tank 2 (fig. B5/2). The correct level must stand at the MAX. level in the tank.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL).
Remove cap 3 (fig. B5/2).
Add oil by filler port 4 (fig. B5/2).
Put the cap back.
Check visually that there is no leakage in the tank and pipes.
If the braking oil level is abnormally low, consult your dealer.
B5/2
3
4
2
B6 - WINDSCREEN WASHER LIQUID LEVEL
B6
CHECK
- Visually check the level in tank 1 (fig. B6).
- If necessary add windscreen washer liquid (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL).
- Remove cap 2 (fig. B6).
- Add windscreen washer liquid through filler port 3 (fig. B6).
- Put the cap back.
2
3
1
3-17
B7 - CAB VENTILATION FILTER
B7/1
B7/2
CLEAN
EXTERNAL CAB VENTILATION FILTER
- Lift out cabin ventilation filter 1 (fig. B7/1).
- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see: 3
- MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Put the filter back into place.
- Put the protective guard back 2 (fig. B7/2).
2
1
INTERNAL CAB VENTILATION FILTER
- Lift out protective grid 3 (fig. B7/3).
- Lift out cabin ventilation filter 4 (fig. B7/4).
- Clean the filter with a compressed air jet.
- Check its condition and change if necessary (see: 3
- MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- Put the filter back into place.
- Put the protective grid back into place.
B7/3
3
B7/4
4
B8 - GENERAL GREASING
GREASE
To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week.
In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to 10 working hours or every day.
Clean and lubricate the following points with grease (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) and remove the surplus of
grease.
TRANSMISSION UNIVERSAL JOINT
1 - Lubricators of the universal joint Transmission/Front axle (3 lubricators).
2 - Lubricators of the universal joint Transmission/Rear axle (3 lubricators).
JIB
3 - Lubricators of the jib axle (2 lubricators).
4 - Lubricators of the carriage axle (2 lubricators).
5 - Lubricator of the tilt cylinder foot axle (1 lubricator).
6 - Lubricator of the tilt cylinder head axle (1 lubricator).
7 - Lubricator of the lifting cylinder foot axle (1 lubricator).
8 - Lubricator of the lifting cylinder head axle (1 lubricator).
9 - Lubricator of the compensation cylinder foot axle (1 lubricator).
10 - Lubricator of the compensation cylinder head axle (1 lubricator).
MT 1840 E3
11 - Lubricator of the chain pulley axle of telescope 2 at the top of the jib (1 lubricator).
12 - Lubricator of the chain pulley axle of telescope 1 at the top of the jib (1 lubricator).
13 - Lubricator of the chain pulley axle of telescope 1 at the bottom of the jib (1 lubricator).
14 - Lubricator of the hose pulley axle at the bottom of the jib (1 lubricator).
FRONT AND REAR WHEELS REDUCER PIVOTS
15 - Lubricators of the wheel reduction gear pivots (8 lubricators).
AXLE OSCILLATION
16 - Front axle oscillation lubricators (2 lubricators).
17 - Rear axle oscillation lubricators (2 lubricators).
ROLL CORRECTOR
18 - Lubricator of the roll corrector cylinder foot axle (1 lubricator).
19 - Lubricator of the roll corrector cylinder head axle (1 lubricator).
STABILISERS
20 - Lubricators of the stabiliser cylinders’ foot axle (2 lubricators).
21 - Lubricators of the stabiliser cylinders’ head axle (2 lubricators).
22 - Lubricators of the stabiliser axles (2 lubricators).
SINGLE SIDE-SHIFT CARRIAGE (TSDL) (OPTION)
23 - Wear plate lubricators (8 lubricators).
3-18
23
5
4
6
23
23
23
23
23
4
11
23
23
12
9
17
17
21
7
8
21
18
20
19
10
22
3
3
15
16
13
14
16
2
2
1
2
3-19
1
1
C - EVERY 250 HOURS SERVICE
Carry out the operations described previously as well as the following operations.
C1 - ALTERNATOR BELT TENSION
C1/1
CHECK - ADJUST
-
Open the I.C. engine bonnet.
Unscrew the fastening screws 1 (fig. C1/1).
Lay down the protective guard 2 (fig. C1/1).
Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
Check the belt tension between the pulleys of the crankshaft and of the alternator.
Under a normal pressure exerted with the thumb (45 N), the belt should move approximately
10 mm.
Carry out adjustments if necessary.
Untighten screws 3 (fig. C1/2) with two to three thread turns.
Swivel the alternator assembly so as to obtain the belt tension required.
Retighten screws 3 (fig. C1/2) (tightening torque 22 N.m).
Refit the protective casing.
2
1
1
C1/2
3
If the alternator belt has to be changed, check the tension again after the first 20 hours of operation.
3
3
C2 - COMPRESSOR BELT TENSION (OPTION AIR CONDITIONING)
CHECK - ADJUST
C3 - ALTERNATOR BELT TENSION (AIR CONDITIONING OPTION)
CHECK - ADJUST
C2/1
- Open the I.C. engine bonnet.
- Unscrew the fastening screws 1 (fig. C2/1).
- Lay down the protective guard 2 (fig. C2/1).
After adjusting the compressor belt, you must carry out the adjustment of the alternator belt.
COMPRESSOR BELT
- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the crankshaft and of the compressor.
- Under a normal pressure exerted with the thumb (45 N), the belt should move approximately
10 mm.
- Carry out adjustments if necessary.
- Untighten screws 3 (fig. C2/2) by two to three thread turns.
- Swivel the compressor assembly so as to obtain the belt tension required.
- Retighten screws 3 (fig. C2/2) (tightening torque 22 N.m).
ALTERNATOR BELT
- Check the belt for signs of wear and cracks and change if necessary (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
- Check the belt tension between the pulleys of the alternator and the compressor
- Under a normal pressure exerted with the thumb
(45 N), the belt should move approximately
C2/3
10 mm.
- Carry out 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
4
torque 22 N.m).
4
- Refit the protective casing.
4
If the compressor belt has to be changed, check the
tension again after the first 20 hours of operation.
3-20
2
1
1
1
C2/2
3
3
C4 - OUTER JIB CHAINS
C4/1
1
CLEAN - GREASE - CHECK
MT 1840 E3
CLEAN AND GREASE
- Set the lift truck on its stabilizers, with the jib horizontal.
- Fully extend the telescopes.
- Protect the underside of the telescopes.
- Wipe the chains on the outside of the jib 1 (fig. C4/1) with a clean, lint-free
cloth, then examine them closely so as to detect any signs of wear.
- Vigorously brush the chains to get rid of any foreign matter, with a hard
nylon brush and clean diesel fuel.
- Rinse the chains by means of a paint brush impregnated with clean diesel
fuel and dry them with a compressed air jet.
- Lightly lubricate the chains (see: 3 - MAINTENANCE: LUBRICANTS AND
FUEL), and perform a number of telescoping movements to check the behaviour of the chains.
1
In case of technical faults, consult your dealer.
CHECK THE TENSION
- Fully extend the telescopes, then retract the jib 200 mm.
- At the centre of both telescopes (T1) and (T2) (fig. C4/2), use a ruler to
measure the perpendicular distance between the top of the telescope and
the underside of the chain (fig. C4/2), this distance must be identical for
both chains.
C4/2
T1
T2
Telescope (T1): between 117 mm and 97 mm
- If necessary, adjust with the tensioners 2 (fig. C4/3).
- Loosen the locknuts 3 (fig. C4/3), tighten nut 4 (fig. C4/3) until the required distance is
obtained.
- Retighten the locknuts 3 (fig. C4/3) while restraining the nut 4 (fig. C4/3).
C4/3
2
2
4
4
Telescope (T2): between 85 mm and 65 mm
- If necessary, adjust with the tensioners 5 (fig. C4/4).
- Loosen the locknuts 6 (fig. C4/4), tighten nut 7 (fig. C4/4) until the required distance is
obtained.
- Retighten the locknuts 6 (fig. C4/4) while restraining the nut 7 (fig. C4/4).
These checks are important for the proper operation of the jib. In case of technical faults, consult your
dealer.
If the chains are too long to allow tension to be adjusted, replace them in pairs. If one of the chains is
broken, replace the chains in pairs also.
3-21
3
3
C4/4
5
5
7
6
7
6
C5 - CAB VENTILATION FILTERS
C5/1
C5/2
CHANGE
EXTERNAL CAB VENTILATION FILTER
- Remove protective casing 1 (fig. C5/1) using the switch
key.
- Lift out cab ventilation filter 2 (fig. C5/2) and replace
it with a new one (see: 3 - MAINTENANCE: FILTERS
AND BELTS).
- Refit the protective casing.
1
2
INTERNAL CAB VENTILATION FILTER
- Lift up protective casing 3 (fig. C5/3).
- Lift out cab ventilation filter 4 (fig. C5/4) and replace
it with a new one (see: 3 - MAINTENANCE: FILTERS
AND BELTS).
- Put the protective grid back into place.
C5/3
C5/4
3
4
C6
C6 - FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL
CHECK
2
Place the lift truck on level ground with the I.C. engine stopped.
- Remove level plug 1 (fig. C6). The oil should be flush with the edge of the hole.
- If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the filler port 2
(fig. C6).
- Replace and tighten the level plug 1 (fig. C6) (tightening torque 34 to 49 N.m).
1
C7
C7 - 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 wheel reducer.
Place level plug 1 (fig. C7) in the horizontal position.
Remove the level plug ; the oil should be flush with the edge of the hole.
If necessary, add oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by the same hole.
Refit and tighten the level plug (tightening torque 34 to 49 N.m).
3-22
1
3-23
D - EVERY 500 HOURS SERVICE
Carry out the operations described previously as well as the following operations.
D1 - I.C. ENGINE OIL
D1/1
DRAIN
D2 - I.C. ENGINE OIL FILTER
CHANGE
Place the lift truck on level ground, let the I.C. engine run at idle for a few minutes, then
stop the I.C. engine.
1
DRAINING THE OIL
- Open the I.C. engine bonnet.
- Remove access panel 1 (fig. D1/1).
- Place a container under the drain plug and unscrew the drain plug 2 (fig. D1/2).
- Take drain hose 3 (fig. D1/3).
- Place the end of the drain hose in the tank and screw the hose fully to the drain connector
2 (fig. D1/2).
- Remove filler cap 4 (fig. D1/4) in order to ensure that the oil is drained properly.
D1/2
Dispose of the drain oil in an ecological manner.
5
REPLACEMENT OF THE FILTER
- Unscrew and discard the engine oil filter 5 (fig. D1/2) as well as its seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly grease the new seal before refitting the new oil filter (see: 3 - MAINTENANCE:
FILTERS AND BELTS) on its bracket.
2
Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.
FILLING UP THE OIL
- Remove, clean and refit drain hose 3 (fig. D1/3).
- Refit and tighten drain plug 2 (fig. D1/2).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 6
(fig. D1/4).
- Wait a few minutes to allow the oil to flow into the sump.
- Start the I.C. engine and let it run for a few minutes.
- Check for possible leaks from the drain plug and the oil filter.
- Stop the engine, wait a few minutes and check the correct level on the dipstick 7 (fig. D1/4)
between the two level marks.
- Top up the level if necessary.
- Refit access panel 1 (fig. D1/1).
D1/3
3
D1/4
7
4
6
3-24
D3 - DRY AIR FILTER CARTRIDGE
D3
CHANGE
In case of use in a heavily dust laden atmosphere, there are pre-filtration cartridges, see:
3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS. Also, the checking and cleaning
periodicity of the cartridge must be reduced (up to 250 hours in a heavily laden dust
atmosphere and with pre-filtration).
Change the cartridge in a clean location, with the I.C. engine stopped. Never operate the lift truck with
the air filter removed or damaged.
2
-
Open the I.C. engine bonnet.
Loosen the bolts and remove cover 1 (fig. D3).
1
Gently remove the cartridge 2 (fig. D3), taking care to avoid spilling the dust.
Leave the safety cartridge in place.
The following parts must be cleaned with a damp, clean lint-free cloth.
• The inside of the filter and cover.
• The inside of the filter inlet hose.
• The gasket surfaces in the filter and in the cover.
- Check pipes and connections between the air filter and the I.C. engine and the connection and state of the clogging indicator on
the filter.
- Before mounting, check the state of the new filter cartridge (see: 3 - MAINTENANCE: FILTERS AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the middle.
- Reassemble the cover, guiding the valve downwards.
D4 - FUEL PRE-FILTER CARTRIDGE
D4
CHANGE
2
3
Make sure the electrical contact on the lift truck is cut, otherwise fuel will be released if the lift pump
is on.
5
- Open the I.C. engine bonnet.
- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
4
the system.
- Place a container under the pre-filter and drain it using drain plug 1 (fig. D4).
- Remove bleeder screw 2 (fig. D4) in order to ensure that the oil is drained properly.
1
- Unscrew locking screw 3 (fig. D4).
- Remove container 4 (fig. D4) and discard cartridge 5 (fig. D4) as well as its seals.
- Clean the inside of the filter head and the housing, using a brush immersed in clean
diesel oil.
- Refit the assembly with a new cartridge and new seals (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS).
- If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: H1 - FUEL SYSTEM).
3-25
D5 - FUEL FILTER CARTRIDGE
D5/1
CHANGE
Make sure the electrical contact on the lift truck is cut, otherwise fuel will be released if the lift pump
is on.
- Open the engine hood.
- Carefully clean the outside of the filter and its holder, to prevent dust from getting into
the system.
- Place a container under the filter and drain it through drain plug 1 (fig. D5/1).
- Loosen the body of filter 2 (fig. D5/1).
- Remove the filter cartridge by pressing cartridge 3 (fig. D5/2) down against the pressure
of the spring and turn it to the left to extract it.
- Insert a new cartridge (see: 3 - MAINTENANCE: FILTERS AND BELTS), by pressing cartridge
3 (fig. D5/2) down against the pressure of the spring and turn it to the right to lock it into
the body of the filter.
- Place the new seal 4 (fig. D5/2) onto the body of the filter and lightly lubricate the contact
surface of the seal using clean motor oil.
- Remount the body of the filter onto its holder, hand-tighten it only and lock it with a
quarter-turn.
- Close drain plug 1 (fig. D5/1).
- Before starting the I.C. engine, leave the ignition on for three minutes on the lift truck, to
give the lift pump time to release air from the filter.
- Start up the I.C. engine and make sure there is no leakage.
- If necessary, bleed the fuel circuit (see: 3 - MAINTENANCE: H1 - FUEL SYSTEM).
D6 - HYDRAULIC RETURN OIL FILTER CARTRIDGE
2
1
D5/2
3
4
D6/1
CHANGE
Stop the I.C. engine and remove the pressure from the circuits by acting on the hydraulic
controls.
Thoroughly clean the outside of the filter and its surroundings before any intervention in order to prevent
any risk of polluting the hydraulic circuit.
- Remove protective casing 1 (fig. D6/1).
- Remove the filler plug 2 (fig. D6/2) and unscrew cover 3 (fig. D6/2) by two or three thread
turns.
- Wait a few moments while the oil flows into the tank.
- Remove the cover and take out filter cartridge assembly 4 (fig. D6/3).
- Place the assembly in a clean container.
- Pinch the head 5 and separate it from the tank 6 (fig. D6/4).
- Replace the cartridge 7 (fig. D6/5) with a new one (see: 3 - MAINTENANCE: FILTERS
CARTRIDGES AND BELTS).
- Put back the assembly then retighten the cover.
- Refit the filling cap.
- Refit the protective casing.
1
D6/2
3
2
D6/3
D6/4
D6/5
5
4
7
6
3-26
D7 - FRONT AND REAR AXLE DIFFERENTIAL OIL
D7
DRAIN
3
Place the lift truck on level ground with the I.C. engine stopped and the differential oil still
warm.
2
Dispose of the drain oil in an ecological manner.
-
Place a container under drain plugs 1 (fig. D7) and unscrew the plugs.
Remove level plug 2 (fig. D7) and filler plug 3 (fig. D7) in order to ensure proper emptying.
Refit and tighten drain plugs 1 (fig. D7) (tightening torque 34 to 49 N.m).
Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 3 (fig. D7).
The level is correct when the oil level is flush with the edge of port 2 (fig. D7).
Check for any possible leaks at the drain plugs.
Refit and tighten level cap 2 (fig. D7) (tightening torque 34 to 49 N.m) and filler plug 3 (fig.
D7) (tightening torque 34 to 49 N.m).
- Repeat this operation for the rear axle differential.
3-27
1
1
1
E - EVERY 1000 HOURS SERVICE
Carry out the operations described previously as well as the following operations.
E1 - FUEL TANK
E1/1
CLEAN
E2 - FUEL TANK BREATHER
CHANGE
While carrying out these operations, do not smoke or work near a flame.
Place the lift truck on level ground with the I.C. engine stopped.
1
- Inspect the parts susceptible to leaks in the fuel circuit and in the tank.
- In the event of a leak, contact your dealer.
Never try to carry out a weld or any other operation by yourself, this could provoke an explosion or a fire.
-
Place a container under drain plug 1 (fig. E1/1) and unscrew the plug.
Remove filling plug 2 (fig. E1/2) in order to ensure that the oil is drained properly.
Rinse out with ten liters of clean diesel through filler port 3 (fig. E1/2).
Refit and tighten the drain plug (tightening torque 29 to 39 N.m).
Open the storage compartment 4 (fig. E1/3).
Unscrew the breather 5 (fig. E1/4) and replace with a new one (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS) (tightening torque 5 ±2 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 - MAINTENANCE: H1 - FUEL SYSTEM).
E1/2
2
3
E1/3
E1/4
4
5
E3 - SAFETY DRY AIR FILTER CARTRIDGE
E3
CHANGE
- For the disassembly and reassembly of the dry air filter cartridge, see: 3 - MAINTENANCE:
D3 - AIR FILTER CARTRIDGE.
- Gently remove the dry air filter safety cartridge 1 (fig. E3), taking care to avoid spilling
the dust.
- Clean the gasket surface on the filter with a damp, clean lint-free cloth.
- Before mounting, check the state of the new safety cartridge (see: 3 - MAINTENANCE:
FILTERS AND BELTS).
- Introduce the cartridge into the filter axis and push it in, pressing the edges and not the
middle.
NOTE: The periodicity for changing the safety cartridge is given for information only. It must
be changed for every two changes of the dry air filter cartridge.
3-28
1
E4 - GEAR BOX OIL
E4/1
DRAIN
E5 - GEAR BOX OIL FILTER
CHANGE
1
Place the lift truck on level ground with the I.C. engine stopped, the gear box oil still warm.
DRAINING THE OIL
- Remove clutch housing cover 1(fig. E4/1).
- Place a container under drain plug 2 (fig. E4/2) and unscrew it.
- Remove dipstick 3 (fig. E4/3) in order to ensure proper emptying.
Dispose of the drain oil in an ecological manner.
REPLACEMENT OF THE FILTER
- Unscrew and discard gear box oil filter 4 (fig. E4/4) as well as its seal.
- Clean the filter bracket with a clean, lint-free cloth.
- Lightly grease the new seal before refitting the new oil filter (see: 3 - MAINTENANCE:
FILTERS AND BELTS) on its bracket.
E4/2
Tighten the oil filter by hand pressure only and lock the filter in place by a quarter turn.
2
FILLING UP THE OIL
- Refit and tighten drain plug 2 (fig. E4/2) (tightening torque 34 to 54 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) through filler port 5
(fig. E4/3) and refit dipstick 3 (fig. E4/3).
- Start the I.C. engine and let it run for a few minutes.
- Check for possible leaks from the drain plug and the oil filter.
- Stop the I.C. engine, and within 5 minutes of the engine being stopped, check on dipstick
3 (fig. E4/3) the correct level against the MAX. mark.
- Top up the level if necessary.
- Put back the cover plate 1 (fig. E4/1).
E4/3
3
5
E4/4
4
3-29
E6 - JIB OUTER CHAIN WEAR
CHECK
MT 1840 E3
Chain wear occurs at a number of locations.
On the articulations, which leads to elongation of the chain.
On the edge of link plates through contact with the pulleys.
On the face of the plates and the extended pins through contact with the pulley flanges.
On the alignment of the flats of the extended pins.
CHAIN ELONGATION
We recommend that you perform this operation using the chain checking gauge (fig. E6)
(MANITOU part No.: 161583).
- Set the lift truck on its stabilizers, with the jib horizontal.
- Fully extend the telescopes and continue operating the control for a few moments to
properly tension the chains.
- As the chain will likely wear unevenly over its length, divide the chain into 4 equal sections
and check with the gauge at the centre of each section.
25,4 mm x 9 = 228,6 mm
E6
19,05 mm x 12 = 228,6 mm
25,4 mm
19,05 mm
=
=
=
=
=
=
=
=
If the maximum dimension is exceeded (228.6 mm +2% = 233.2 mm), replace the pair of chains (contact your dealer).
24 mm
15,5 mm
SIDE WEAR OF PLATES
As for chain elongation, perform a check in the middle of each section using a calliper gauge.
If the dimension is less than the minimum dimension (24 mm - 2% = 23.5 mm and 15.5 mm -2% = 15.2 mm), replace the pair of chains (contact your
dealer).
53,6 mm
42,25 mm
EXTENDED PIN WEAR
As for chain elongation, perform a check in the middle of each section using a calliper gauge.
If the dimension is less than the minimum dimension (53.6 mm - 2% = 52.5 mm and 42.25 mm -2% = 41.4 mm), replace the pair of chains (contact your
dealer).
- In addition to wear, the high pressures between the side of the plates and the pulleys may force out material, causing the
articulations to seize. Replace the pair of chains in this case also.
ALIGNMENT OF EXTENDED PIN FLATS
Check the chains over their entire length.
- High friction between the plates and the extended pins may cause the pins to turn in the outer plates and thus come out of their
housing.
NON OK
OK
If the flats are not aligned in the longitudinal direction of the chain, replace the pair of chains (contact your dealer).
3-30
E7 - HYDRAULIC OIL
E7/1
DRAIN
E8 - HYDRAULIC OIL TANK BREATHER
CHANGE
E9 - SUCTION STRAINER FOR HYDRAULIC OIL TANK
CLEAN
E10 - BRAKE ACCUMULATOR UNIT FILTER
CHANGE
1
Place the lift truck on level ground with the I.C. engine stopped and telescope jib retracted
and lowered as far as possible.
Before any intervention, thoroughly clean the area surrounding the drain plug and the suction strainer
on the hydraulic tank.
E7/2
DRAINING THE OIL
- Remove protective casing 1 (fig. E7/1).
- Place a container under drain plug 2 (fig. E7/2) and unscrew the plug.
- Remove filling plug 3 (fig. E7/3) in order to ensure that the oil is drained properly.
Dispose of the drain oil in an ecological manner.
2
REPLACING THE BREATHER
- Unscrew the breather 4 (fig. E7/3) and replace with a new one (see: 3 - MAINTENANCE:
FILTERS CARTRIDGES AND BELTS).
CLEANING THE STRAINER
- Disconnect hose 5 (fig. E7/4).
- Unscrew suction strainer 6 (fig. E7/4), clean it using a compressed air jet, check its
condition and replace it, if necessary (see: 3 - MAINTENANCE: FILTERS AND BELTS).
- Refit the suction strainer making sure the seal is in the correct position.
E7/3
4
REPLACING THE BRAKE ACCUMULATOR UNIT FILTER
- Unscrew plug 7 (fig. E7/5), remove the filter and replace with a new one.
- Refit and tighten plug 7 (fig. E7/5) (tightening torque 70 to 80 N.m).
3
8
FILLING UP THE OIL
- Refit and tighten drain plug 2 (fig. E7/2) (tightening torque 29 to 39 N.m).
- Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by filler port 8 (fig. E7/3).
Use a clean container and funnel and clean the underside of the oil drum before filling.
- Observe the oil level on dipstick 9 (fig. E7/6), the oil level should be at the level of the red point.
- Check for any possible leaks at the drain plug.
- Refit the filler plug 3 (fig. E7/3).
HYDRAULIC CIRCUIT DECONTAMINATION
- Let the I.C. engine run (accelerator pedal at halfway travel) for 5 minutes without using
anything on the lift truck, then for 5 more minutes while using completely the hydraulic
movements (except the steering system and the service brakes).
- Accelerate the I.C. engine at full speed for 1 minute, then activate the steering system
and the service brakes.
- This operation makes a pollution abatement of the circuit possible through the hydraulic
return oil filter.
E7/5
E7/4
5
6
E7/6
7
9
3-31
E11 - SEAT BELT
CHECK
SEAT BELT WITH TWO ANCHORING POINTS
- Check the following points:
• Fixing of the anchoring points on the seat.
• Cleanness of the strap and the locking mechanism.
• Triggering of the locking mechanism.
• Condition of the strap (cuts, curled edges).
REELED SEAT BELT WITH TWO ANCHORING POINTS
- Check the points listed above together with the following points:
• The correct winding of the belt.
• Condition of the reel guards.
• Roller locking mechanism when the strap is given a sharp tug.
NOTE: After an accident, replace the seat belt.
In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Repair or replace the seat belt immediately.
E12 - FRONT AND REAR WHEELS REDUCERS OIL
E12
DRAIN
Place the lift truck on level ground with the I.C. engine stopped and the reducers oil still
warm.
1
Dispose of the drain oil in an ecological manner.
-
B
Drain and change the oil of each wheel reducer.
Place drain plug 1 (fig. E12) in position A.
Place a container under the drain plug and unscrew the plug.
Let the oil drain fully.
Place the drain port in position B, i.e. in a level port.
Fill up with oil (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL) by level port 1 (fig. E12).
The level is correct when the oil level is flush with the edge of the hole.
Refit and tighten the drain plug (tightening torque 34 to 49 N.m).
3-32
A
3-33
F - EVERY 2000 HOURS OF SERVICE
Carry out the operations described previously as well as the following operations.
F1 - COOLING LIQUID
F1/1
DRAIN
These operations are to be carried out if necessary or every two years at the beginning
of winter. Place the lift truck on level ground with the I.C. engine stopped and cold.
DRAINING THE LIQUID
- Open the I.C. engine bonnet.
- Remove the shroud 1 (fig. F1/1).
- Set a container under drain valve 2 (fig. F1/2) on the radiator and drain plug 3 (fig. F1/3)
of the engine block and loosen them.
- Remove filler port 4 (fig. F1/4) from the expansion pan and open the heating control
to the maximum in order to ensure proper emptying.
- Let the cooling circuit drain entirely while ensuring that the ports do not get clogged.
- Check the condition of the hoses as well as the fastening devices and change the hoses
if necessary.
- Rinse the circuit with clean water and use a cleaning agent if necessary.
1
F1/2
FILLING THE LIQUID
- Tighten the drain valve 2 (fig. F1/2) and drain plug 3 (fig. F1/3) (tightening torque 40
N.m).
- Slowly fill up the circuit with cooling liquid (see: 3 - MAINTENANCE: LUBRICANTS AND FUEL)
up to the middle of the expansion pan 5 (fig. F1/4) through filler port 6 (fig. F1/4).
- Put back filling plug 4 (fig. F1/4).
- Run the I.C. engine at idle for a few minutes.
- Check for any possible leaks.
- Put back the shroud 1 (fig. F1/1).
- Check the level and refill if necessary.
2
The I.C. engine does not contain any corrosion resistor and must be filled during the whole year with
a mixture containing 25 % of ethylene glycol-based antifreeze.
F1/3
3
F1/4
4
6
5
3-34
F2 - AIR CONDITIONING (OPTION)
CLEANING - INSPECTION
CLEANING CONDENSER AND EVAPORATOR COILS (*)
CLEANING CONDENSATE TRAY AND RELIEF VALVE (*)
COLLECTING COOLANT TO REPLACE FILTER-DRIER (*)
REFILLING WITH COOLANT AND CHECKING THE THERMOSTATIC CONTROL AND PRESSURE SWITCHES (*)
NOTE: When opening the evaporator unit, remember to replace the cover seal.
(*): (CONSULT YOUR DEALER).
CAUTION: DO NOT ATTEMPT TO REPAIR ANY PROBLEMS YOURSELF. ALWAYS REFER TO YOUR DEALER WHEN REFILLING CIRCUITS, AS THEY HOLD THE
CORRECT SPARE PARTS, AS WELL AS HAVING THE NECESSARY TECHNICAL KNOWLEDGE AND TOOLS.
- Do not 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 colourless, odourless
and heavier than air.
• If this gas is inhaled, take the victim into fresh air, give oxygen or artificial respiration if necessary and call a doctor.
• If the gas is in contact with the skin, wash it immediately under running water and remove any contaminated garments.
• If the gas is in contact with the eyes, rinse them in clear water for 15 minutes and call a doctor.
- The compressor has an oil level gauge (fig. F2). Never unscrew this gauge because it
would depressurizes the installation. The oil level is only checked when changing the oil
in the circuit.
3-35
F2
G - EVERY 4000 HOURS OF SERVICE
Carry out the operations described previously as well as the following operations.
G1 - JIB INNER CHAIN WEAR
CHECK
MT 1840 E3
THE CHECKING OF THE JIB INNER CHAINS REQUIRES THE TELESCOPES TO BE DISASSEMBLED (CONTACT YOUR DEALER).
Chain wear occurs at a number of locations.
On the articulations, which leads to elongation of the chain.
On the edge of link plates through contact with the pulleys.
On the face of the plates and the extended pins through contact with the pulley flanges.
On the alignment of the flats of the extended pins.
CHAIN ELONGATION
We recommend that you perform this operation using the chain checking gauge (fig. G1)
(MANITOU part No.: 161583).
- As the chain will likely wear unevenly over its length, divide the chain into 4 equal sections
and check with the gauge at the centre of each section.
G1
19,05 mm x 12 = 228,6 mm
19,05 mm
If the maximum dimension is exceeded (228.6 mm +2% = 233.2 mm), replace the pair of chains (contact your dealer).
15,5 mm
SIDE WEAR OF PLATES
As for chain elongation, perform a check in the middle of each section using a calliper gauge.
If the dimension is less than the minimum dimension (15.5 mm -2% = 15.2 mm), replace the chain or the pair of chains (contact your dealer).
42,25 mm
EXTENDED PIN WEAR
As for chain elongation, perform a check in the middle of each section using a calliper gauge.
If the dimension is less than the minimum dimension (42.25 mm -2% = 41.4 mm), replace the chain or the pair of chains (contact your dealer).
- In addition to wear, the high pressures between the side of the plates and the pulleys may force out material, causing the
articulations to seize. Replace the pair of chains in this case also.
ALIGNMENT OF EXTENDED PIN FLATS
Check the chains over their entire length.
- High friction between the plates and the extended pins may cause the pins to turn in the outer plates and thus come out of their
housing.
NON OK
OK
If the flats are not aligned in the longitudinal direction of the chain, replace the chain or the pair of chains (contact your dealer).
3-36
3-37
H - OCCASIONAL MAINTENANCE
H1 - FUEL SYSTEM
H1/1
BLEED
These operations are to be carried out only in the following cases:
• A component of the fuel system replaced.
• A drained tank.
• Running out of fuel.
1
Ensure that the level of fuel in the tank is sufficient and bleed in the following order:
- Open the I.C. engine bonnet.
- Put the ignition on for three minutes on the lift truck, to give the lift pump time to release
air from the filter.
- Switch off the ignition with the ignition key.
BLEEDING THE INJECTORS
- Remove the injectors cover 1 (fig. H1/1).
- Loosen high pressure connectors 2 (fig. H1/2) of all the injectors.
- Activate the starter until the diesel fuel flows out free of air at high pressure connectors 2
(fig. H1/2).
Do not engage the starter motor on a continual basis for more than 30 seconds and let it cool between
unsuccessful attempts.
- Tighten the connections while the diesel fuel is flowing out (tightening torque 30 N.m).
H1/2
2
2
2
2
- So the I.C. engine is ready to be started up.
- Turn the I.C. engine over slowly for 5 minutes immediately after bleeding the fuel feed
circuit, in order to ensure that the injection pump has been bled thoroughly.
NOTE: If the I.C. engine functions correctly for a short time then stops or functions
irregularly, check for possible leaks in the low pressure circuit. If in doubt, contact your dealer.
H2 - WHEEL
H2/1
CHANGE
In the event of a wheel being changed on the public highway, make sure of the following points:
For this operation, we advise you to use the hydraulic jack MANITOU reference 505507 and
the safety support MANITOU reference 554772.
- Stop the lift truck, if possible on even and hard ground.
- To pass on stop of lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING
INSTRUCTIONS UNLADEN AND LADEN).
- Put the warning lights on.
- Immobilise the lift truck in both directions on the axle opposite to the wheel to be changed.
- Unlock the nuts of the wheel to be changed.
- Place the jack under the flared axle tube, as near as possible to the wheel and adjust the
jack (fig. H2/1).
- Lift the wheel until it comes off the ground and put in place the safety support under the
axle (fig. H2/2).
- Completely unscrew the wheel nuts and remove them.
- Free the wheel by reciprocating movements and roll it to the side.
- Slip the new wheel on the wheel hub.
- Refit the nuts by hand, if necessary grease them.
- Remove the safety support and lower the lift truck with the jack.
- Tighten the wheel nuts with a torque wrench (see: 3 - MAINTENANCE: A - DAILY OR EVERY
10 HOURS SERVICE for tightening torque).
3-38
H2/2
H3 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
RESET
According to the use of the lift truck, the device may require to be periodically reset.
This operation can be easily performed by means of the following procedure.
- Provide a fork carrier or a bucket and a load corresponding to at least half the lift truck’s rated capacity.
- Preferably perform the reset when the lift truck is still cold (before it is used) or ensure that the temperature of the rear axle is
not more than 50°C.
- Place the lift truck on flat, level ground with the wheels straight.
RESET ADMIN ERASE
SECU
GAUGE
- Display the GAUGE “reset strain gauge” menu
validate
CALIB
Press
to
Enter Security
Calibration Mode
(see: 2 - DESCRIPTION: 6D - SCREEN DISPLAY: MENU SCREEN) and
.
CODE
00__
and validate
- Enter the CUSTOMER code
.
GAUGE
Calibration incomplete or failed
Scrupulously follow the jib positioning instructions. The appearance of the
cancellation request or a late response. If in doubt, consult your dealer.
screen indicates a failure to obey an instruction, a
GAUGE
STAGE 1
GAUGE
Lift the boom to max position,
fully retract the boom
then press
Fully extend the stabilizers
then press
2/6
1/6
Fully extend the stabilizers.
Completely raise the jib with the telescopes fully retracted.
GAUGE
STAGE 2
Wait…
Calibration in progress
Calibration in progress…
GAUGE
Completly lower the
boom on the frame,
then press
GAUGE
Rise stabilizers,
then press
3/6
STAGE 3
Fully lower the jib with the engine running
at full revs and the hydraulic control at the
maximum setting.
4/6
Completely raise the stabilizers.
GAUGE
Use override switch to
extend the boom until rear
axle is lifted then wait 5s
and press
5/6
STAGE 4
/
With the fork carriage or the bucket and
a load. Jib fully retracted in the lowered
position, approximately 20 centimetres
from the ground.
/
Wait 5
seconds
and
validate
Keep the load as close to the ground as possible throughout this
operation.
- Hold down the disable the “aggravating” hydraulic movement cut-off
button
(indicator lamp lit), and telescope the jib until the rear wheels
are off the ground.
GAUGE
Retract the boom then
press
to store
new calibration
6/6
FINISH
Retract the telescopes to restore the situation, and press the
button to record the new parameters.
When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see: 3 - MAINTENANCE: A - DAILY OF EVERY
10 HOURS SERVICE).
3-39
H4 - FRONT HEADLAMPS
H4
ADJUST
RECOMMENDED SETTING
(as per standard ECE-76/756 76/761 ECE20)
Set to - 2 % of the dipped beam in relation to the horizontal line of
the headlamp.
h1
+%
-%
-2%
ADJUSTING PROCEDURE
- Place the lift truck unloaded and in the transport position and
perpendicular to a white wall on flat, level ground (fig. H4).
- Check the tire pressures (see: 2 - DESCRIPTION: FRONT AND REAR
TIRES).
- Put the gearshift lever into neutral.
h1
h2
h2 = h1 - (l x 2 / 100)
l
Calculating the height of the dipped beam (h2)
• h1 = Height of the dipped beam in relation to the ground.
• h2 = Height of the adjusted beam.
• l = Distance between the dipped beam and the white wall.
H5 - BREAKDOWN OF BATTERY
H5/1
CHANGE
- Open the engine hood.
- Bring a floating battery of the same type as the one used for the lift truck and battery
cables.
- Connect the floating battery while respecting the polarity (fig. H5/1).
- Start the lift truck and remove the cables as son as the I.C engine is running.
- Raise the jib.
- Lift out protective casing 1 (fig. H5/2).
- Replace battery 2 (fig. H5/3).
+
-
Handling and servicing a battery can be dangerous, take the following precautions:
- Wear protective goggles.
- Keep the battery horizontal.
- Never smoke or work near a naked flame.
- Work in a well-ventilated area.
- In the event of electrolyte being spilled onto the skin or splashed in the eyes, rinse thoroughly
with cold water for 15 minutes and call a doctor.
H5/2
1
H5/3
2
3-40
H6 - LIFT TRUCK
H6/1
TOWING
Do not tow the lift truck at more than 6 km/h over a maximum distance of 5 km.
This manoeuvre is dangerous. Carefully chock the lift truck before towing, as the parking brake system
is inoperative.
-
Put the reversing lever in neutral and the gear shift into dead centre.
Chock the lift truck.
Remove the cap 1 (fig. H6/1).
Loosen screw 2 (fig. H6/2) with a pin wrench 3 (fig. H6/3) to release the brake disk.
Leave a minimum clearance of 5 mm between the disk 4 (fig. H6/4) and the brake pads
5 (fig. H6/4).
- Put the towing device into place.
- Remove the chocks.
- Switch on the warning lights.
NOTE: Since there will be no steering or braking assistance, operate these controls slowly.
Avoid sudden jerky movements.
1
H6/2
2
For adjusting the parking brake, please contact your dealer.
H6/3
H6/4
3
5
5
5 mm
4
H7 - LIFT TRUCK
H7/1
SLINGING
- Take into account the position of the lift truck centre of gravity for
lifting (fig. H7/1).
A = 1590 mm
A = 1625 mm
B = 1480 mm
B = 1445 mm
MT 1440 E3
MT 1840 E3
- Place the hooks in the fastening points provided (fig. H7/2 and
H7/3)
A
H7/2
3-41
B
H7/3
H8 - LIFT TRUCK ON A PLATFORM
H8/1
TRANSPORT
Ensure that the safety instructions connected to the platform are respected before the loading of the lift
truck and that the driver of the means of transport is informed about the dimensions and the weight of
the lift truck (see: 2 - DESCRIPTION: CHARACTERISTICS).
Ensure that the platform has got dimensions and a load capacity sufficient for transporting the lift truck.
Check also the pressure on the contact surface allowable for the platform in connection with the lift
truck.
For lift trucks equipped with a turbo-charged I.C. engine, block off the exhaust outlet to avoid rotation of
the turbo shaft without lubrication when transporting the vehicle.
LOAD THE LIFT TRUCK
- Block the wheels of the platform.
- Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck.
- Load the lift truck parallel to the platform.
- Stop the lift truck (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: DRIVING INSTRUCTIONS
UNLADEN AND LADEN).
H8/2
STOW THE LIFT TRUCK
- Fix the chocks to the platform at the front and at the back of each tyre (fig. H8/1).
- Fix also the chocks to the platform in the inside of each tyre (fig. H8/2).
- Secure the lift truck to the platform with sufficiently strong ropes. At the front of the lift
truck, attach the ropes to the fastening points (fig. H8/3) and at the rear to the towing
pin (fig. H8/4).
- Tighten the ropes (fig. H8/5).
H8/3
H8/4
H8/5
3-42
4 - OPTIONAL
ATTACHMENTS
FOR USE WITH
THE RANGE
4-1
4-2
TABLE OF CONTENTS
INTRODUCTION
4-5
PICKING UP THE ATTACHMENTS
4-6
TECHNICAL SPECIFICATIONS OF ATTACHMENTS
4-8
ATTACHMENT SHIELDS
4-14
4-3
4-4
INTRODUCTION
- Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS.
- A wide range of attachments, specially designed and perfectly suitable for your lift truck is available and guaranteed by
MANITOU.
Only attachments approved by MANITOU are to be used on our lift trucks (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE: TECHNICAL
SPECIFICATIONS OF ATTACHMENTS). The manufacturer’s liability will be denied in case of modification or of attachment adaptation carried out without
his knowing it.
- The attachments are delivered with a load chart concerning your lift truck. The operator’s manual and the load chart should be
kept in the places provided in the lift truck. For standard attachments, their use is governed by the instructions contained on this
notice.
Maximum loads are defined by the capacity of a lift truck taking account of the attachment’s mass and centre of gravity. In the event of the attachment
having less capacity than the lift truck, never exceed this limit.
- Some particular uses require the adaptation of the attachment which is not provided in the price-listed options. Optional solutions
exist, consult your dealer.
Depending on their size, certain attachments may, when the jib is lowered and retracted, come into contact with the front tyres and cause damage
to them, if reverse tilt is activated in the forward tilt direction. TO REMOVE THIS RISK, EXTEND THE TELESCOPE TO A SUFFICIENT EXTENT FOR THE
PARTICULAR LIFT TRUCK AND ATTACHMENT SO THAT THIS CONTACT IS NOT POSSIBLE.
SUSPENDED LOAD
Suspended load MUST be handled with a lift truck designed for that purpose (see: 1 - OPERATING AND SAFETY INSTRUCTIONS: LOAD HANDLING
INSTRUCTIONS: H - TAKING-UP AND SETTING-DOWN A SUSPENDED LOAD).
USE THE SINGLE SIDE-SHIFT CARRIAGE
The single side-shift carriage (TSDL) is only compatible with the following attachments:
• floating fork carriage (TFF)
• tilting fork carriage (PFB)
• loading bucket (CBR)
• concrete bucket (BB, BBG)
• spout bucket (GL)
• crane jib and crane jib with winch (P, PT, PO, PC)
• winch (H)
• fixed platform, swivelling platform, roofer’s platform.
It is prohibited to use any other attachments on the TSDL.
Attachments authorised for use on the TSDL must comply strictly with the applications for which they are designed.
It is prohibited to use them for any other application (for example, earth moving, excavation, desurfacing, back scraping, etc. for the loading bucket
CBR) or any application placing abnormal stress on the structure of the TSDL: risk of deformation which could cause the load to fall.
USE THE BUCKETS
The MT 1440/1840 E3, are lift trucks essentially intended for handling. Occasional use with the buckets CBC/CBR/CB4x1 is authorised (only with the
jib completely retracted, in order to reduce stress on the jib head), but under no circumstances is intensive use for difficult applications (quarry, waste,
cereals, agriculture, etc) permissible. In addition, on the MT 1840 E3 the back scraping is forbidden to reduce additional stress on the inner jib chains.
4-5
PICKING UP THE ATTACHMENTS
A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE
A
TAKING UP 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 and the clip are in position in the bracket (fig. A).
- Place the lift truck with the jib fully lowered in front of and parallel to the attachment, tilt
the carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the jib, incline the
carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.
HAND LOCKING
- 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.
B
HAND RELEASING
- Proceed in the reverse order of paragraph HAND LOCKING while making sure you put back
the locking pin and the clip in the bracket (fig. A).
LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.
C
D
4-6
B - HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE
A
TAKING UP 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 and the clip are in position in the bracket (fig. A).
- Place the lift truck with the jib fully lowered in front of and parallel to the attachment, tilt
the carriage forwards (fig. B).
- Bring the carriage under the locking tube of the attachment, slightly lift the jib, incline the
carriage backwards in order to position the attachment (fig. C).
- Lift the attachment off the ground to facilitate locking.
MANUAL LOCKING AND CONNECTION OF THE ATTACHMENT
- 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.
- Press for two seconds on the push-button
B
to release the attachment circuit hydraulic
and
will be alternately displayed.
pressure. Screens
- Connect the rapid connectors according to the logic of the attachment’s hydraulic
movements.
Make sure that the rapid connectors are clean and protect the holes which are not used, with the caps
provided.
HAND RELEASING AND DISCONNECTING THE ATTACHMENT
- Proceed in the reverse order of paragraph HAND LOCKING AND CONNECTING THE ATTACHMENT
while making sure you put back the locking pin and the clip in the bracket (fig. A).
C
LAYING AN ATTACHMENT
- Proceed in the reverse order of paragraph TAKING UP AN ATTACHMENT while making sure
you place the attachment flat on the ground and in closed position.
D
4-7
TECHNICAL SPECIFICATIONS OF ATTACHMENTS
FLOATING FORK CARRIAGE
TFF 45 MT-1040
TFF 45 MT-1300
PART NUMBER
653344
653345
Rated capacity
4500 kg
4500 kg
Width
1040 mm
1300 mm
Weight
370 kg
400 kg
FLOATING FORK SIDE-SHIFT CARRIAGE
Use is prohibited with the optional single side-shift carriage (TSDL).
TFF 45 MT-1040 DL
TFF 45 MT-1300 DL
PART NUMBER
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
PART NUMBER
211922
Section
125x50x1200 mm
Weight
71 kg
4-8
STANDARDISED TILTING FORK CARRIAGE
PFB 45 N MT-1260 S2
PFB 45 N MT-1670 S2
PFB 45 N MT-2000 S2
PART NUMBER
654407
653747
653748
Rated capacity
4500 kg
4500 kg
4500 kg
Width
1260 mm
1670 mm
2000 mm
Weight
200 kg
255 kg
300 kg
STANDARDISED SIDE-SHIFT CARRIAGE
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
TDLA 40 N MT-1670
PART NUMBER
Rated capacity
751542
4300 kg
Side-shift
2x100 mm
Width
1670 mm
Weight
265 kg
STANDARDISED FORK
PART NUMBER
415652
Section
125x50x1200 mm
Weight
78 kg
LOAD BACK REST
PART NUMBER
727035
572788
572790
Width
1260 mm
1670 mm
2000 mm
Weight
46 kg
56 kg
63 kg
4-9
BUILDING BUCKET
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
PART NUMBER
Rated capacity
CBC 700 L1950 S2
CBC 800 L2250 S3
CBC 900 L2450 S3
654472
654471
654470
697 l
814 l
893 l
Width
1950 mm
2250 mm
2450 mm
Weight
330 kg
385 kg
410 kg
CBR 900 L2250 S2
CBR 1000 L2450 S2
PART NUMBER
653749
654716
Rated capacity
904 l
990 l
Width
2250 mm
2450 mm
Weight
390 kg
410 kg
LOADING BUCKET
BUCKET 4X1
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
PART NUMBER
Rated capacity
CB4x1-700 L1950
CB4x1-850 L2300
CB4x1-900 L2450
751402
751401
751465
700 l
850 l
900 l
Width
1950 mm
2300 mm
2450 mm
Weight
640 kg
735 kg
765 kg
4-10
GRAB BUCKET
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
CBG 1950 S4
CBG 2300 S4
CBG 2450 S4
PART NUMBER
751407
751414
751418
Rated capacity
1 m3
1,2 m3
1,26 m3
Width
1950 mm
2300 mm
2450 mm
Grab
7
8
8
555 kg
615 kg
635 kg
Weight
GRAB BUCKET (NON-HAZARDOUS INDUSTRIAL WASTE)
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
PART NUMBER
Rated capacity
Width
CBG 1950 DIB S4
CBG 2300 DIB S4
CBG 2450 DIB S4
653016
653018
653020
1 m3
1,2 m3
1,26 m3
1950 mm
2300 mm
2450 mm
Grab
Weight
7
8
8
678 kg
740 kg
767 kg
GRAB BUCKET (GRAB CLOSED)
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
CBG 2300 GF S4
PART NUMBER
Rated capacity
653008
1,2 m3
Width
2300 mm
Grab
8
Weight
637 kg
GRAB BUCKET (CLOSED JAWS AND REVERSIBLE REMOVABLE BLADE)
Use is prohibited with the optional single side-shift carriage (TSDL).
MT 1440 E3
PART NUMBER
Rated capacity
Width
Grab
Weight
CBG 1950 JFD-LDR S4
CBG 2300 JFD-LDR S4
CBG 2450 JFD-LDR S4
653003
653006
653009
1 m3
1,2 m3
1,26 m3
1950 mm
2300 mm
2450 mm
7
8
8
655 kg
715 kg
742 kg
4-11
CONCRETE BUCKET (ADAPTABLE ON FORKS)
BB 500 S4
BBH 500 S4
PART NUMBER
654409
751462
Rated capacity
500 l/1300 kg
500 l/1300 kg
Width
1100 mm
1100 mm
Weight
205 kg
220 kg
CONCRETE BUCKET WITH SPOUT (ADAPTABLE ON FORKS)
BBG 500 S4
BBHG 500 S4
PART NUMBER
654411
751464
Rated capacity
500 l/1300 kg
500 l/1300 kg
Width
1100 mm
1100 mm
Weight
220 kg
235 kg
SPOUT BUCKET (ADAPTABLE ON FORKS)
GL 300 S2
GL 400 S2
PART NUMBER
174371
174372
Rated capacity
300 l/725 kg
400 l/969 kg
150 kg
166 kg
Weight
HYDRAULIC KIT TO OPEN THE SPOUT
PART NUMBER
653750
SPOUT BUCKET (ADAPTABLE ON FORKS)
GL 600 S2
GL 800 S2
PART NUMBER
174373
174374
Rated capacity
600 l/1440 kg
800 l/1920 kg
290 kg
325 kg
Weight
HYDRAULIC KIT TO OPEN THE SPOUT
PART NUMBER
653750
SPOUT BUCKET (ADAPTABLE ON FORKS)
GL 1000 S2
GL 1500 S2
PART NUMBER
174375
174376
Rated capacity
1000 l/2440 kg
1500 l/3591 kg
360 kg
409 kg
Weight
HYDRAULIC KIT TO OPEN THE SPOUT
PART NUMBER
653750
4-12
CRANE JIB
P 600 MT S3
PART NUMBER
653228
Rated capacity
600 kg
Weight
170 kg
CRANE JIB
P 4000 MT S2
PART NUMBER
653226
Rated capacity
4000 kg/1200 kg
Weight
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
751547
751548
751549
Rated capacity
600 kg
1000 kg
2000 kg
Weight
320 kg
275 kg
255 kg
WINCH
H4T S4
PART NUMBER
708535
Rated capacity
4000 kg
Weight
420 kg
4-13
ATTACHMENT SHIELDS
FORK PROTECTOR
PART NUMBER
227801
FORK BLOCK FOR FLOATING FORK CARRIAGE
PART NUMBER
261210
BUCKET PROTECTOR
NOTE: Always ensure that the width of the protector you choose is less than or equal to the width of the bucket.
PART NUMBER
Width
PART NUMBER
Width
PART NUMBER
Width
PART NUMBER
Width
206734
206732
206730
1375 mm
1500 mm
1650 mm
235854
206728
206726
1850 mm
1950 mm
2000 mm
223771
223773
206724
2050 mm
2100 mm
2150 mm
206099
206722
223775
2250 mm
2450 mm
2500 mm
4-14
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