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Opitec MANITOU 101.200 Manual

Fork lift truck
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F o r k
l i f t
t r u c k
" M A N I T O U "
101.200
Please Note
The OPITEC range of projects is not intended as play toys for young
children.They are teaching aids for young people learning the skills of
Craft, Design and Technology.These projects should only be underta-
ken and tested with the guidance of a fully qualified adult.
The finished projects are not suitable to give to children under 3
years old. Some parts can be swallowed. Danger of suffocation!

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Summary of Contents for Opitec MANITOU 101.200

  • Page 1 “ M A N I T O U ” 101.200 Please Note The OPITEC range of projects is not intended as play toys for young children.They are teaching aids for young people learning the skills of Craft, Design and Technology.These projects should only be underta- ken and tested with the guidance of a fully qualified adult.

  • Page 2: Table Of Contents

    Parts list It is recommended that you sort through and identify the various parts before starting this project. Please remove any ‘burr’ from the metal parts with a file or emery cloth before assembly! Quantity Description PartNo Material Size Chassis/base Holed metal 130 x 166mm Rear axle bearing...
  • Page 4 Chassis Part Nr: 2 Cut two holed metal strips to 60mm long, and round the sharp corners with a file. Mark out and drill the 2 diameter in the holed metal strip Hold the holed metal strip up to the bottom line in a vice ( See diagram) And twist the top half ( Upper line) with a pair of pliers, firstly turn it through 90 degrees and finally bend it...

  • Page 5: Machine Screws

    Part Nr.2 Mount both of the rear axle holders with machine screws M3x8 (Part Nr: 28) in the 11th row 3rd hole in from left and right. Use two M3 nuts (Part Nr:31)and contra tighten them so that the holders swivel. Part Nr.
  • Page 6 Part Nr:3 Form an eye in one end on the ends of the welding rod as shown. Join both welding rods together in a connector block ( lightly tighten) Hook the eye at the end of rod through the 2mm dia hole in the axle holder. Tighten the loop afterwards with a pair of pliers so that it cannot spring out.
  • Page 7 Part Nr 6 Mount the one motor and gearbox and wheel assembly with 2 machine screws ( Part No: 28) and nuts ( Part No:31).in the 10th row of holes and 3 holes from the edge 2. Carry out the same Procedure with the second motor and gearbox Part Nr.
  • Page 8 Finished chassis with wheels and gearboxes Fork lift truck “MANITOU” 101.200...
  • Page 9 Fork lift assembly Part Nr:20 Cut the fork carrier to length and drill the middle hole out to 6.5 mm diameter Round the ends with a file Part Nr:22 Cut the fork assembly to length. Use the machine screws M4x 8 (Part Nr:23) M4 nuts and domed nuts (Part Nr: 34 and 35) join them to part 20 (See sheet 9)
  • Page 10 Assembling the fork Machine screw M4 x 8 (Part Nr 33) Nuts M4 (Part Nr: 34) Domed nut (Part Nr:35) Front view Nuts M4 (Part Nr: 34) Machine screw View from behind M4 x 8 (Part Nr 33) Fork lift truck “MANITOU” 101.200...

  • Page 11: Fork Guides

    Part 27 Saw brass tube to length as shown, with a Junior hacksaw env. Part Nr: 18 In drive direction Mount the right hand fork guide (Part Nr: 18) in the first row of holes in the 3rd or fourth hole in from left. Fix with two nuts M4 (Part Nr: 34) as shown in diagram Z Mount the other fork guide ( Part Nr:18) at a distance of 90mm (Seen from centre to centre) and also in the first row of holes (See...

  • Page 12: Fork

    Part: 27 Place M4 nuts ( Part Nr: 4 ) on each fork guide ( Part Nr: 18) and then place a brass tube (Part Nr: 18) on each guide, finish with M4 nuts Adjust all the nuts so that the guides protrude 4mm on either side. Part Nr.

  • Page 13: Fork Drive

    Parts Nr: 24 and 26 Place the worm gear on the motor shaft Part Nr: 25 Mount the motor and gear so that the worm gear engages lightly with the Fork drive gear. Fix the motor in position with the metal loop holder (Part Nr: 25) and two machi- ne screws M3 x 8 (Part Nr: 28) and suitable nuts (Part Nr:31) to the holed metal sheet.
  • Page 14 Part Nr: 20 22 Mount the completed fork assembly. Turn the worm by hand so that the fork assembly lowers by about a centimetre Finally add a domed nut to the tops of the guide and drive ( Parts Nr: 35 and 35) Part Nr.
  • Page 15 Bodywork Parts Nr: 39-43 Cut out the patterns 1-6 (See page 23 & 24) and lay them out on the metal sheet, hold them in position with tape or glue Cut out the shapes with metal snips along the thicker lines. In patterns 1 and 4 along with the contour lines other inner cuts must be made.
  • Page 16 Part 39 After cutting out pattern 1 (Motor cover) fold the metal sheet along the broken lines Use folding bars or a vice for accuracy View from underneath Fork lift truck “MANITOU” 101.200...
  • Page 17 Part Nr:42 Once you have cut out the pattern Nr. 6 drill the 4mm holes Fold the edges as shown using vice or folding bars. The small short folds can be folded with pliers View from underneath Part Nr:43 Cut out the pattern 5 from the metal sheet. Bend using a vice (Use soft jaws) at an angle of 80 degrees Finally add the foam squab and back ( Part Nr :38 ) use contact glue Shape to suit with a file or sandpaper...
  • Page 18 Part No 41 Cut out pattern 4 . Centre punch and drill the holes. Finally cut out the slots with a Junior hacksaw. Clean up all edges of the slots with a needle file View from underneath Part Nr:40 Cut out the sides according to patterns No 2 and 3 and drill the 3mm holes Fold using a vice with soft jaws Fork lift truck “MANITOU”...

  • Page 19: Machine Screws

    Part : 40 Mount the side panels so that the wheels can turn without rubbing When you are happy with the position mount the panels with the M3 x 8 ( Part Nr: 28) machine screws and nuts Part Nr: 39 and 41 To fit the bodywork you will need to loosen the nuts on the fork guides where they join the chassis ( Holed metal sheet ) Now mount the bodywork ( Slide one part under the loosened nuts ) and adjust to fit.

  • Page 20: Nut

    Part Nr: 44 Mount the finished roof ( Part Nr 42 ) with hex.nuts and dome nuts on the 4 pillars ( Part Nr:44) Now hold the roof and pillars in position on the bodywork and mark the four holes. Centre punch an drill the four 4 mm holes Add another set of M4 (Part Nr:34 ) nuts to the bottoms of the pillars then mount the cabin on the holed chassis with M4 nuts...
  • Page 22 Electrics Part No: 45-51b 1. Mount the battery under the bodywork using the remaining double sided sticky pad 2 Insert a piece of cable in the joiner block 3 and 4. Solder or crimp a connector on the ends and join to the battery 3 Wire up the components according to the diagram 4,5 V...
  • Page 23 drill ø 7,5 mm Pattern A...
  • Page 24 D101200#1...