Manitou MAN'GO 12 Operator's Manual
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Manitou MAN'GO 12 Operator's Manual

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MANITOU BF
BP 10249
44158 ANCENIS CEDEX - FRANCE
TEL: + 33 (0)2 40 09 10 11
YOUR DEALER
647533 EN (09/10/2015)
MAN' GO 12
OPERATOR'S MANUAL
(ORIGINAL INSTRUCTIONS MANUAL)

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  • Page 1 MANITOU BF BP 10249 44158 ANCENIS CEDEX - FRANCE TEL: + 33 (0)2 40 09 10 11 YOUR DEALER 647533 EN (09/10/2015) MAN' GO 12 OPERATOR’S MANUAL (ORIGINAL INSTRUCTIONS MANUAL)
  • Page 3 - Descriptions and figures are non binding. - MANITOU reserves the right to change its models and their equipment without being required to update this manual. - The MANITOU network, consisting exclusively of qualified professionals, is at your disposal to answer all your questions.
  • Page 4 1 - OPERATING AND SAFETY INSTRUCTIONS 2 - DESCRIPTION 3 - MAINTENANCE...

  • Page 5: Operating And Safety Instructions

    1 - OPERATING AND SAFETY INSTRUCTIONS 1 - 1...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS 1 - OPERATING AND SAFETY INSTRUCTIONS INSTRUCTIONS TO THE COMPANY MANAGER PREAMBLE THE SITE THE OPERATOR THE PLATFORM THE INSTRUCTIONS THE MAINTENANCE INSTRUCTIONS FOR THE OPERATOR PREAMBLE GENERAL INSTRUCTIONS A - OPERATOR'S MANUAL ............6 B - AUTHORISATION FOR USE IN FRANCE .
  • Page 7 SCRAPPING THE PLATFORM RECYCLING OF MATERIALS METALS..............18 PLASTICS.

  • Page 8: Instructions To The Company Manager

    The platform’s suitability for us MANITOU has ensured that this platform is suitable for use under the standard operating conditions defined in this operator’s manual, with an overload test coefficient of 1,25 and an operational test coefficient of 1,1, as stipulated in standardised norm EN 280 for MPLPs (Mobile Personnel Lifting Platforms).

  • Page 9: The Instructions

    IMPORTANT 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.

  • Page 10: Instructions For The Operator

    INSTRUCTIONS FOR THE OPERATOR PREAMBLE IMPORTANT The risk of accident while using, servicing or repairing your lifting platform can be restricted if you follow the safety instructions and safety measures detailed in these instruction. Failure to respect the safety and operating instructions, or the instructions for repairing or servicing your lifting platform may lead to serious, even fatal accident. - Only the operations and manœuvres described in these operator’s manual must be performed.

  • Page 11: E - Ic Platform Axles

    - Safety helmets must be worn. - MANITOU recommends a safety harness in the operator’s size be provided when the platform is in use (for the harness attachement in the basket , see chapter 2 - DESCRIPTION, CHECKING AND CONTROL INSTRUMENTS pages).

  • Page 12: C - Environment

    C - ENVIRONMENT - Comply with site safety regulations. - The platform can be manoeuvred from the ground: ensure that you forbid access. - If you have to use the platform in a dark area or at night, make sure it is equipped with working lights. - The platforms may not be used as cranes or elevators for the permanent transport of people or materials, nor as jacks or supports.
  • Page 13 IMPORTANT If the wind is in excess of 45Km/h, do not perform any movements liable to endanger the lifting platform’s stability. - To recognise this speed by eye, please refer to the empirical wind evaluation scale below: BEAUFORT scale (wind speed at a height of 10m over flat terrain) Speed Speed Speed...

  • Page 14: D - Visibility

    D - VISIBILITY - Maintain permanently good visibility throughout the route. To increase your visibility, you can move forwards with the pendular arm slightly raised (pay attention to the risk of falls in the basket from knocking into a low doorway, overhead electric wires, travelling cranes, highway bridges, tracks or any obstacle in the area in front of the platform).

  • Page 15: F - Driving The Platform

    F - DRIVING THE PLATFORM SAFETY NOTICE IMPORTANT Operators should be aware of the risks connected with using the platform, notably: - Risk of losing control. - Risk of losing lateral and frontal stability of the platform. The operator must remain in control of the platform. - Do not carry out operations which exceed the capacities of your platform.

  • Page 16: Instructions For Welding And Blow Torch Work On The External Structure

    INSTRUCTIONS FOR WELDING AND BLOW TORCH WORK ON THE EXTERNAL STRUCTURE IMPORTANT Ensure that there are no hydraulic or electrolyte leaks on the platform. IMPORTANT When welding, work in the opposite direction from the control console to avoid sparks damaging it. Any welding and cutting (blow torch) work from the basket on a building’s metallic structures requires the following precautions to be taken: A - WITH ELECTRIC WELDING EQUIPMENT...
  • Page 17 1 - 13...

  • Page 18: Platform Maintenance Instructions

    PLATFORM MAINTENANCE INSTRUCTIONS GENERAL INSTRUCTIONS - Ensure the area is sufficiently ventilated before starting the platform. - Wear clothes suitable for the maintenance of the platform, avoid wearing jewellery and loose clothes. Tie and protect your hair, if necessary. - Stop the I.C. engine before conducting any work on the platform, remove the ignition key and disconnect the “Minus” battery terminal.

  • Page 19: Welding On The Access Platform

    IMPORTANT Welding operations on the structure for maintenance or repair operations must only be performed by MANITOU-certified personnel. WASHING THE PLATFORM - Clean the platform or at least the area concerned before any intervention.

  • Page 20: If The Platform Is Not To Be Used For A Long Time

    The following recommendations are intended to prevent the platform 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.

  • Page 21: Bringing The Platform Back Into Service

    BRINGING THE PLATFORM BACK INTO SERVICE - Remove the waterproof adhesive tape from all the holes. - Refit the intake hose. - Reconnect the engine cut-off solenoid. - Refit and reconnect the battery. - Remove the protection from the cylinder rods. - Perform the daily service (see : 3 - MAINTENANCE - Empty and replace the fuel and replace the fuel filter (see : 3 - MAINTENANCE).

  • Page 22: Scrapping The Platform

    SCRAPPING THE PLATFORM MANITOU complies with the regulations issued under the directive 2000/53/CE relating to the end of the life of the platform. This platform does not contain any substance or material forbidden by the directive 2000/53/CE. NOTE: Before scrapping the nacelle, consult your dealer.
  • Page 23 2 - DESCRIPTION 2 - 1...
  • Page 24 2 - 2...
  • Page 25 TABLE OF CONTENTS 2 - DESCRIPTION «EC» DECLARATION OF CONFORMITY SAFETY PLATES AND STICKERS LIFTING PLATFORM ID CHARACTERISTICS DIMENSIONS LIFTING PLATFORM OPERATION BASE CONTROL INSTRUMENTATION BASKET CONTROL INSTRUMENTATION GROUND MAINTENANCE AND EMERGENCY STATION BASKET CONTROL STATION SCREEN DISPLAY - DESCRIPTION OF THE PAGES DESCRIPTION OF THE SUB-MENUS USING THE LIFTING PLATFORM RESCUE PROCEDURE...

  • Page 26: Ec" Declaration Of Conformity

    430, rue de l’Aubinière - BP 10249 - 44158 - ANCENIS CEDEX - FRANCE Dossier technique, Technical file MANITOU BF - 430, rue de l’Aubinière BP 10249 - 44158 - ANCENIS CEDEX - FRANCE Constructeur de la machine décrite ci-après,...
  • Page 27 bg : 1) удостоверение за « СЕ » съответствие (oригинална), 2) Фирмата, 3) Адрес, 4) Техническо досие, 5) Фабрикант на описаната по-долу машина, 6) Обявява, че тази машина, 7) Отговаря на следните директиви и на тяхното съответствие национално право, 8) За машините към допълнение IV, 9) Номер...

  • Page 28: Safety Plates And Stickers

    SAFETY PLATES AND STICKERS IMPORTANT Clean all the safety plates and stickers to make them legible. It is essential to replace safety plates and stickers which are illegible or damaged. Check the presence of safety plates and stickers after replacing any spare parts. EXTERNAL PLATES AND STICKERS ITEM PART NO.
  • Page 29 1 - White arrow This indicates the translation direction when moving forward. IMPORTANT Identify the forward direction by looking at the arrows on the chassis and those on the basket control console. 2 - Black arrow This indicates the translation direction when reversing. IMPORTANT Identify the forward direction by looking at the arrows on the chassis and those on the basket control console.
  • Page 30 5 - Repairing travelling procedure This describes the procedure for towing the platform in case of failure. 6 - 6a - Safety advice Read and take note of the operating instructions and safety measures before starting the lifting platform. 6b - Towing This sticker states that the machine must not be towed if it breaks down.
  • Page 31 9 - Lifting hook This sticker shows the location of the attachment points for lifting the platform. 10 - Hydraulic oil This indicates that this reservoir is designed only to hold hydraulic oil. NB: see MAINTENANCE: LUBRICANTS 597652 11 - Diesel This indicates that this reservoir is designed only to hold fuel for diesel vehicles.
  • Page 32 13 - Danger, keep away It is strictly forbidden to walk under or park under the structure (arms, jib-mounted platform, basket...) and in the lifting platform’s operating area. 14 - Risk of burns This sticker indicates that there is a significant risk of your being burnt in this region (engine silencer, IC engine, etc.).
  • Page 33 17 - Made in France This sticker shows that the platform is manufactured in France. 18 - Anti-freeze This sticker indicates that there is anti-freeze in the engine. When protection is provided by anti-freeze with properties differing from the original, the -30°or - 40°C box must be ticked.
  • Page 34 21 - Moving parts This sticker shows the hazard relating to locating hands or fingers at this place; cutting of fingers in the blades of the cooling fan. 683108-A 22 - Battery location This sticker shows the location of the battery. 52509705-- 23 - Diagram of stability This sticker shows the platform capcity for inside and external use.
  • Page 35 2 - 13...

  • Page 36: Lifting Platform Id

    LIFTING PLATFORM ID 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 platform.
  • Page 37 WHEEL REDUCING GEAR • Type • Serial No. FUSES • 2 fuses 60A, 32V • 1 relay 12V 2 - 15...

  • Page 38: Characteristics

    CHARACTERISTICS LOAD SPECIFICATIONS MAN' GO 12 TOL ± Platform Nominal capacity for use indoors (Wind 0 Km/h) Nominal capacity for use outdoors (Wind 45 Km/h) No. of people in the basket during indoor use No. of people in the basket during outdoor use Lifting platform unladen weight 4150 Max permissible tilt...
  • Page 39 TRANSMISSION MAN' GO 12 TOL ± Type MSE02 Supplier POCLAIN Cubic capacity Max service pressure 1950 Traction power Reduction ratio Number of steering wheels Front / Rear 2 / 0 Number of driven wheels 2 / 2 Front / Rear Front axle wheel Hydraulic Differential...
  • Page 40 ELECTRICAL CIRCUIT MAN' GO 12 TOL ± Battery Supplier (Initial mounting) Exide C5 capacity C20 capacity Nominal voltage Start-up 110 Amp Type EARL Cycle Alternator Type Intensité Tension Starter Type Electrical Power output Voltage DIMENSIONS MAN' GO 12 TOL ± Transport position Width 1800...
  • Page 41 EQUIPMENT MAN' GO 12 TOL ± Emergency pump Type Manual Cubic capacity Power output Voltage Intensity Audible beep on all movements Rotating flashing light / Revolving light Hour metre 230 V preconfiguration Diesel level proportional display Low fuel level / battery alarm Toolbox in the basket User interface (diagnostic help) Oscillating axle...

  • Page 42: Dimensions

    DIMENSIONS 5500 4500 2000 2015 2495 1800 1715 4115 2900 ° / % 36/73 2 - 20...
  • Page 43 Theorical Dimensions Designation 1940 mm Overhang max offset (dimension measured on the floor) 6190 mm Max offset 9905 mm Max height (dimension measured on the floor) 3100 mm Max offset height 5220 mm S4 = 4 m Platform offset and height for a building height = 4m 5830 mm 6620 mm S5 = 5 m...

  • Page 44: Lifting Platform Operation

    MANITOU lifting platforms are solely intended to be used to carry people, with their tools and supplies (up to the authorized weight limit: see the “SPECIFICATIONS” section), to the desired working height, to reach difficult to access areas over installations and buildings.
  • Page 45 SAFETY TILT When the lifting platform reaches the maximum authorised level of tilt (see the CHARACTERISTICS section), LED 30* on the basket console flashes regularly. Also the basket’s buzzer 37* sounds intermittently. All the “AGGRAVATING” movements of raising the arms, extending the telescope and translation are prohibited as a safety measure.

  • Page 46: Base Control Instrumentation

    BASE CONTROL INSTRUMENTATION 2 - 24...
  • Page 47 DESCRIPTION 1 - KEY-OPERATED IGNITION SWITCH 2 - STARTER BUTTON 3 - GROUND OR PLATFORM CONTROL SELECTRO SWITCH 4 - EMERGENCY STOP 5 - ENGINE START-UP ASSISTANCE SELECTOR SWITCH 6 - INTERFACE SCREEN 7 - INFORMATION VALIDATION SCREEN KEYS 8 - DEAD MAN’S BUTTON 9 - BASKET TILT DOWN / TILT UP BUTTON 10 - TURRET ROTATION KEYS 11 - LOWER ARM UP / DOWN BUTTONS...

  • Page 48: Basket Control Instrumentation

    BASKET CONTROL INSTRUMENTATION 2 - 26...
  • Page 49 19 - UPPER ARM UP / DOWN AND TURRET ROTATION CONTROL LEVER 20 - CONTROL LEVER FOR PLATFORM FORWARD/REVERSE MOVEMENT 21 - EMERGENCY STOP 22 - “PREHEATING” INDICATOR LIGHT 23 - START-UP CONTROL BUTTON 24 - DIFFERENTIAL LOCKING CONTROL BUTTON 25 - DIFFERENTIAL LOCKING CONTROL INDICATOR LIGHT 26 - BUZZER CONTROL BUTTON 27 - LOW FUEL LEVEL INDICATOR...

  • Page 50: Ground Maintenance And Emergency Station

    GROUND MAINTENANCE AND EMERGENCY STATION 1 - KEY-OPERATED IGNITION SWITCH This key-operated contactor has two positions. POSITION 1 - Engine stop and electrical circuit supply off. POSITION 2 - Electrical circuit supply on and automatic engine preheating. 2 - STARTER BUTTON Engine start-up.
  • Page 51 5 - LOW-TEMPERATURE ENGINE START-UP AID This selector switch has two positions to be selected according to the ambient air temperature. 1 : SUN POSITION - If the temperature is over - 10°C, start the engine at tickover rpm. 2 : SNOW POSITION - If the temperature is less than around - 10°C, set the selector switch to this position before starting: the engine will be held at maximum rpm (only for the first start of the day).
  • Page 52 8 - "DEAD MAN'S" FUNCTION The button must be held down in the Dead Man’s position (position 2) to provide power to the base control, at the same time as holding down the lifting and rotation keys. 9 - BASKET TILT DOWN / TILT UP BUTTON Using these keys at the same time as pressing button 8 to the Dead Man’s position, control correction of the basket’s horizontality or the complete folding back of the basket in Transport position.
  • Page 53 13 - PENDULAR ARM LIFTING AND LOWERING KEYS Using these keys at the same time as pressing button 8 to the Dead Man’s position enables the pendular arm to be lifted and lowered. A : LIFTING THE PENDULAR ARM - Hold down the Dead Man’s function 8 and press key 13A. B : LOWERING THE PENDULAR ARM - Hold down the Dead Man’s function 8 and press key 13B.
  • Page 54 18 - FUEL COCK - The fuel cock (18) located on the diesel filter must be in the “ON” position as shown opposite before starting the engine. - The “OFF” position on the fuel cock shuts off the fuel supply to the engine. 2 - 32...

  • Page 55: Basket Control Station

    BASKET CONTROL STATION 19 - UPPER ARM UP / DOWN AND TURRET ROTATION CONTROL LEVER Lever 19 enables you to raise the upper arm and rotate the turret. NB: This is a progressive control lever, which provides you with great accuracy in approach.
  • Page 56 22 - “PREHEATING” INDICATOR LIGHT - This indicator light illuminates when the machine is supplied with power: - Either by turning the ignition key on the base (the timing is identical to that shown on the bar graph on the screen). - Or by rearming the Emergency Stop on the basket console in the lifting platform.
  • Page 57 27 - LOW FUEL LEVEL INDICATOR This indicator light illuminates when the fuel level is low and the basket buzzer is activated : • Level 1 of alarm: 3 beeps every 10 minutes • Level 2 of alarm: 3 beeps the every 1 minute • Level 3 of alarm: 3 beeps every 10 seconds and blocking of the movements rises after 5 seconds of activation.
  • Page 58 32 - BASKET INCLINATION CONTACTOR This contactor enables you to correct the basket’s horizontality or to fold the basket back completely in Transport position. CORRECTING THE BASKET UPWARDS - Push the contactor up. CORRECTING THE BASKET DOWNWARDS - Pull the contactor down. 33 - BASKET ROTATION CONTACTOR This contactor enables you to rotate the basket left and right RIGHT ROTATION...
  • Page 59 37 - “DEAD MAN'S” PEDAL - This pedal is fixed on the platform’s floor. - This pedal must be pressed to perform movements from the basket console. - When the pedal is released, no control can be used. 38 - BUZZER - This buzzer is activated when the machine reaches the maximum authorised level of tilt or is overloaded.
  • Page 60 42 - REARMING BUTTON (SAFEMANSYSTEM OPTION) See the chapter “DESCRIPTION AND USE OF OPTIONS” page 2-50. 43 - SENSITIVE EDGE (SAFEMANSYSTEM OPTION) See the chapter “DESCRIPTION AND USE OF OPTIONS” page 2-50. 44 - BLUE WARNING LIGHT (SAFEMANSYSTEM OPTION) See the chapter “DESCRIPTION AND USE OF OPTIONS” page 2-50. 2 - 38...
  • Page 61 2 - 39...

  • Page 62: Screen Display - Description Of The Pages

    SCREEN DISPLAY - DESCRIPTION OF THE PAGES 1 - PRESENTATION PAGE When you switch on, an initialisation page appears briefly on the screen and then the pre-heating page is displayed. 2 - PRE-HEATING PAGES The Pre-heating page is displayed for the whole of the adjustable pre-heating period and the bar graph increases in increments in proportion to the pre-heating time elapsed.
  • Page 63 5 - MENU DISPLAY After switching power on,press on to display the page of proposed menus and selesct the chosen menu using the arrows the validate with 6 - TO MODIFY A SUB-MENU After having chosen the menu, select the various choices of modifications, if required, using the arrows Use the buttons to change the value of the selected option, then validate for a first...

  • Page 64: Description Of The Sub-Menus

    DESCRIPTION OF THE SUB-MENUS User Dealer / Renters Icons Menu Sub-menu Parameters Access codes Without **** Platform locking (option) Settings immobilizer (option) Screen settings Settings codes platform locking Return default locking code Screen setting: Contrast, Brightness. Screen settings Date, time, screen beep deactivation View program and equipment codes Coding View history of Machine N°...
  • Page 65 User Dealer / Renters Icons Menu Sub-menu Parameters Display of the “CALIBRATION” icon after entry of a code. 1 - Engine rpm calibration 2 - Joystick calibration Max raising speed for lower arms Max lowering speed for lower arms Max raising speed for upper arm Max lowering speed for upper arm Max telescope extension speed Max telescope retraction speed...

  • Page 66: Using The Lifting Platform

    USING THE LIFTING PLATFORM BEFORE STARTING THE LIFTING PLATFORM Check the following levels: • Engine oil • Oil in the hydraulic reservoir • Coolant STARTING THE LIFTING PLATFORM Turn the ignition key 1 to notch to make the electrical contact. Press button 2 to start up the IC engine. IMPORTANT Do not operate the starter for more than 30 seconds and run a pre-heating cycle between all failed attempts to start.
  • Page 67 Work mode : one or more of the lifting platform’s arms are raised and/or the telescope is extended. In this mode, translations are made at slow speed and the safety systems for tilt and overload are active. NB: You must use Ramp speed (full power with the speed restricted) to cross over steep slopes or move over very broken ground.
  • Page 68 SAFETY SYSTEMS - When the lifting platform is overloaded, the buzzer sounds continuously and all movements are blocked. • Solution : unburden the basket. LOWERING - When the work is complete: retract the telescope and lower the arms to bring the lifting platform back to Transport position. IMPORTANT Pay attention to the people on the ground when you are descending.
  • Page 69 LOADING / UNLOADING THE LIFTING PLATFORM IMPORTANT Check that the safety instructions relating to the truck bed have been correctly applied before loading the lifting platform and ensure that the transport vehicle’s driver is aware of the lifting platform’s dimensional characteristics and its weight. (see the CHARACTERISTICS section).

  • Page 70: Rescue Procedure

    RESCUE PROCEDURE This paragraph describes the procedures to follow, the controls to use in the event of a problem (breakdown of the lifting platform or someone trapped in the basket) while the lifting platform is working. When taking over the machine and regularly afterwards, the details of this procedure must be read and fully understood by the operator and everyone whose duties are centred on activities in contact with the machine.
  • Page 71 For turret rotation - Press button 1 and turn a quarter clockwise to block it. - Pump with the lever. - The turret turn to the left. - Pull the button to "neutral" position. - Pull the button 1 and turn a quarter anti-clockwise to block it. - Pump with the lever.

  • Page 72: Description And Use Of The Options

    DESCRIPTION AND USE OF THE OPTIONS 1 - SAFEMANSYSTEM The SafeManSystem option is a system used to disable all of the basket control panel controls when activated by the lifting platform user. OPERATION • Each time the lifting platform is switched on, a system test is performed: there is a beep and the blue warning light flashes.
  • Page 73 3 - MAINTENANCE 3 - 1...
  • Page 74 3 - 2...
  • Page 75 TABLE OF CONTENTS 3 - MAINTENANCE ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FILTERS CARTRIDGES AND BELTS LUBRICANTS AND FUEL MAINTENANCE TABLE A - DAILY OR EVERY 10 HOURS OF OPERATION B - EVERY 50 HOURS OF OPERATION C - EVERY 250 HOURS OF OPERATION...

  • Page 76: Original Manitou Spare Parts And Equipment

    IMPORTANT THE USE OF COUNTERFEIT PARTS OR COMPONENTS NOT APPROVED BY THE MANUFACTURER, WILL CAUSE YOU TO LOSE THE BENEFIT OF THE CONTRACTUAL GUARANTEE. BY USING ORIGINAL MANITOU PARTS FOR MAINTENANCE OPERATIONS, YOU BENEFIT FROM OUR KNOW-HOW Through its network, MANITOU provides the user with, • Know-how and competence. • The guarantee of high-quality work.

  • Page 77: Filters Cartridges And Belts

    FILTERS CARTRIDGES AND BELTS ENGINE ENGINE OIL FILTER ALTERNATOR BELT Part number: 894022 Part number: 942079 Change: 500 H Change: 500 H DRY AIR FILTER CARTRIDGE FUEL FILTER CARTRIDGE Part number: 942077 Part number: 781909 Clean: 50 H Change: 500 H Change: 500 H SAFETY DRY AIR FILTER CARTRIDGE FUEL PRE-FILTER Part number: 942078 Part number: 734146 Change: 1000 H HYDRAULIC SYSTEM HYDRAULIC RETURN OIL FILTER CARTRIDGE SUCTION STRAINER FOR HYDRAULIC OIL TANK Part number: 942081 Part number: 52513197 Change: 500 H Clean: 1000 H AUXILIARY HYDRAULIC RETURN OIL FILTER  HYDRAULIC RESERVOIR FILLING STRAINER CARTRIDGE Part number: 259499 Part number: 518251 Change: 500 H ELECTRICAL COMPONENTS CAPTEUR DE DEVERS DEAD MAN’S PEDAL Part number: 52524733 Part number: 831136...

  • Page 78: Lubricants And Fuel

    LUBRICANTS AND FUEL IMPORTANT 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 engine. • Type of diesel fuel EN590 • Type of diesel fuel ASTM D975...
  • Page 79 3 - 7...

  • Page 80: Maintenance Table

    MAINTENANCE TABLE IMPORTANT (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). (2): The internal-combustion engine oil and its oil filter must be replaced after the first 50 hours of operation, and subsequently every 500 hours of operation. (3): Contact your dealer.
  • Page 81 A = RÉGLER, C = CONTRÔLER, G = GRAISSER, N = NETTOYER, PAGE P = PURGER, R = REMPLACER, V = VIDANGER ELECTRICITY 3-12   - Condition of the joystick bellows 3-14   - Level of electrolyte in the battery 3-21   - Arm position sensors 3-21   - Tilt sensor 3-21  ...

  • Page 82: A - Daily Or Every 10 Hours Of Operation

    A - DAILY OR EVERY 10 HOURS OF OPERATION A1 – GENERAL INSPECTION CHECK Scrupulously inspect the machine and check that there are no cracked welds, corrosion or structural damage, loose or missing  nuts and bolts, hydraulic leaks, damaged control cables or loose electrical connections. Inspect the safety harness hook-up points in the basket and check that there are no cracked welds, corrosion and structural  damage. Inspect the "dead man's" pedal in the platform and check that there is no object in the platform that could stop the good  functionning of the pedal. A2 – FUNCTIONAL CHECKS CHECK IMPORTANT Any malfunction of the platform must be detected every day before putting it into service. Identify any malfunction and take the platform out of service if any malfunction is detected.
  • Page 83 TILT SENSOR Fold back the arms for this operation.   - Set the lifting platform in such a position that it is tilting more than the authorized amount. • Result: the raising and telescope extension movements should be blocked. The Tilt light is lit in the basket and the  buzzer is ON intermittently in the basket. OVERLOAD SENSOR Fold the arms into transport position for this operation.   - Place a weight in the basket that is heavier than that indicated. • Result: all movements should be blocked. The Overload light is lit in the basket and the buzzer is ON continuously in  the basket. A3 – IC ENGINE OIL LEVEL CHECK Set the lifting platform on a horizontal surface with the engine switched off and let the  oil drain back into the sump.   - Open the rear cover.   - Remove the dipstick 1   - Wipe the dipstick and check that the oil level is between the two upper notches.   - If necessary, add oil (see the LUBRICANTS section) via the filling hole 2. A4 – COLLANT LEVEL CHECK Set the platform on a horizontal surface with the engine off and wait for the engine to ...
  • Page 84 A6 – HYDRAULIC OIL LEVEL CHECK   - Set the platform on a horizontal surface in transport position with the engine  switched off.   - The oil level should be in the middle of the visual indicator 1.   - Make a 90° turret rotation on the left.   - Remove the front cover.   - If necessary, top up the oil (See the “LUBRICANTS section) via the filling hole 2. IMPORTANT There may be a difference in the oil level of 10 to 20mm between warm and cold oil. It is advisable to top up the oil when the oil is warm.
  • Page 85 3 - 13...

  • Page 86: B - Every 50 Hours Of Operation

    B - EVERY 50 HOURS OF OPERATION Perform the operations described above as well as the following operations. B1 – LEVEL OF BATTERY ELECTROLYTE CHECK Check the electrolyte level in each battery. If the ambient temperature is high, check the level more often than every 50 hours of  operation.   - Release the caps over the elements 2.   - The level should be 1cm above the battery plates.   - If necessary, top up with distilled water, kept in a glass container.   - Clean and dry the caps 2 (Fig. B1/2) and refit them.  ...
  • Page 87 B4 – ALTERNATOR/CRANKSHAFT/FAN BELT TENSION CONTROL / ADJUST   - Open the rear cover.   - Check the condition of the belt for any signs of wear or cracking and replace it, if  necessary (see: 3 - MAINTENANCE: FILTER ELEMENTS AND BELTS).   - Check the tension between the crankcase and alternator pulleys.   - Under thumb pressure (98 N), the tension A must be 7 to 9 mm   - Adjust, if necessary.   - Loosen the bolts 1 two or three turns.   - Swivel the alternator assembly to obtain the requisite belt tension.   - Retighten the bolts 1. IMPORTANT When changing an alternator belt, recheck the tension after the first 20 hours of operation. B5 –...
  • Page 88 B7 – FUEL FILTER REPLACE   - Open the chassis left cover.   - Carefully clean the exterior of the filter and its holder to prevent dust from entering  the system.   - Close the fuel tap 1 to the OFF position.   - Unscrew the retaining ring 2, remove the container 3 and clean the interior with a  paintbrush impregnated with clean diesel.   - Remove the filter cartridge 4 and plunge it in diesel to rinse it.   - Reinstall the assembly with a new filter (see 3 – MAINTENANCE: FILTER ELEMENTS  AND BELTS section).   - Open the fuel tap 1 to the ON position. 3 - 16...
  • Page 89 3 - 17...

  • Page 90: C - Every 250 Hours Of Operation

    C - EVERY 250 HOURS OF OPERATION Perform the operations described above as well as the following operations. C1 – WHEELS NUTS TIGHTENING CHECK Check the tightness of the wheel nuts: 25 daNm ± 10% IMPORTANT Failure to observe this instruction may cause the wheel pins to be damaged and break, as well as the wheels to deform. C2 –...
  • Page 91 C5 – TURRET ORIENTATION CROWN GREASE The bearing raceways and the teeth must be lubricated every 250 hours of operation  and after a long stoppage period.   - Grease to be used: See the LUBRICANTS section.   - Open the left hood of the turret.   - Find the 2 grease points1 and grease thoroughly.   - Close the chassis left cover.   - Spread lubricant over the crown’ s  teeth and the pinion with a paint brush 1.   - Lubricant to be used: See the LUBRICANTS section. 3 - 19...
  • Page 92 C6 – AXLES GREASE Clean and then grease the following points (see the LUBRICANTS section for details of the grease) and remove the surplus. LEGEND : AXLE JOINT 3 - 20...
  • Page 93 C7 – TIGHTNESS OF THE HYDRAULIC ENGINE FIXING BOLTS ON THE CHASSIS CHECK   - The tightness of these bolts must be checked, at the latest, after 50 hours of operation. This check must then be repeated  after every 250 hours of operation.   - The bolts’ tightening torque is 11,1 daN.m ± 10 %.   - 1 daN = 1 Kg. C8 – ARM POSITION SENSORS CHECK For this operation, fold the arms into transport position.   - Make a translation movement at transport speed   - Raise the arm and the telescope   - Move forward   - The platform should switch to Work speed IMPORTANT If a malfunction occurs, prohibit use of the platform.
  • Page 94 C12 – FUEL FILTER CLEAN   - Set the lifting platform on a horizontal surface, with the engine switched off.   - Open the turret's left cover.   - Close the fuel tap 1 to the OFF position (B).   - Carefully clean the exterior of the filter and its holder to prevent dust from entering  the system.   - Unscrew the retaining ring 2, remove the container 3 and clean the interior with a  paintbrush impregnated with clean diesel.   - Remove the filter cartridge 4 and plunge it in diesel to rinse it.   - Refit the assembly.   - Open the fuel tap 1 to the ON position. (A).   - Bleed the fuel supply circuit (see: 3 - MAINTENANCE: G1 – FUEL SUPPLY CIRCUIT). C13 – ALTERNATOR/FAN/CRANKSHAFT BELT TENSION CHECK / ADJUST (see: 3 - MAINTENANCE: B4).
  • Page 95 C16 – STOPPING DISTANCE CHECK stopping distance on horizontal ground :   - The stopping distance is tested on flat ground with 1.1 times the nominal load in the basket.   - Reach maximum speed and then release the control. Expected result: On horizontal ground Stopping distance Transport speed 1400 mm +or- 40 mm Working speed 160 mm +or- 40 mm Check brake holding on a slope Place the nacelle on a nominal 25% slope static with 1.1 times the nominal load in the basket. Expected result: no slipping of the nacelle must be detected after one minute. 3 - 23...

  • Page 96: D - Every 500 Hours Of Operation

    D - EVERY 500 HOURS OF OPERATION Perform the operations described above as well as the following operations. D1 – DRY AIR FILTER CARTRIDGE REPLACE The air used for combustion is purified by a dry air filter. It is therefore forbidden to use  the lifting platform with the cartridge removed or damaged.   - Open the right-hand cowl.   - Unclip the clips 1 and remove the cover.   - Carefully remove the cartridge 2 to reduce any dust falling as much as possible.   - Leave the safety cartridge in place.   - Carefully clean the following parts with a clean, damp, lint-free cloth. • The interior of the filter and the cover.
  • Page 97 D5 – AUXILIARY HYDRAULIC OIL FILTER CARTRIDGE REPLACE   - With the machine stopped and the battery cutout in the OFF position.   - Unscrew the filter body 1.   - Remove the filter cartridge and replace it with a new one (see “FILTER ELEMENT”  section). NB: Pay attention to the direction for fitting.   - Refit the filter body 1. IMPORTANT Carefully clean the exterior of the filter and its surroundings before performing any work in order to avoid any risk of pollution getting into the hydraulic circuit.
  • Page 98 D8 – TIGHTENING THE TURRET ROTATION MOTOR’S BOLTS CHECK Set the lifting platform on a horizontal surface with the engine switched off.   - Check the tightness of the nine screws 1 : the screws’ tightening toque 1 is 8 daN.m  ± 10%. D9 – TIGHTENING THE BOLTS ON THE TURRET ORIENTATION CROWN GEAR CHECK   - The tightness of the screws must be checked at the latest after 50 hours of operation. This check must then be repeated  every 500 hours of operation.   - The tightening torque for the screws is 12 daN.m ± 10 %. D10 – BRAKING CHECK   - Check the braking system by disconnecting the coil EV100 from the hydraulic unit  on the chassis (to access the unit, remove the casing on the front side of the chassis) ...
  • Page 99 D13 – IC ENGINE OIL FILTER REPLACE IMPORTANT The internal-combustion engine oil and its oil filter must be replaced after the first 50 hours of operation, and subsequently every 500 hours of operation. Set the platform on a horizontal surface, leave the engine running at idling speed for a  few minutes and then switch it off. DRAINING THE OIL   - Open the rear cover and the chassis right and left cover.  ...
  • Page 100 D15 – TURRET MOTOR REDUCER BRAKE REDUCER DRAIN / REPLACE Set the lifting platform on a horizontal surface with the engine switched off.   - Open the left turret cover.   - The motor reducer is presented with the valve unit to the rear.   - Remove the sniffler/filling cap 1 to ensure good drainage.   - Note the drain plug 2 located on the right-hand side reducer unit’s sole plate.   - Place a (small) receptacle to catch the oil.   - Unscrew the drain plug. IMPORTANT Dispose of the drained oil in an environmentally friendly manner.  ...
  • Page 101 3 - 29...

  • Page 102: E - Every 1000 Hours Of Operation

    E - EVERY 1000 HOURS OF OPERATION Perform the operations described above as well as the following operations. E1 – FUEL TANK DRAIN / CLEAN IMPORTANT Never smoke or approach the machine with a naked flame during this operation. Set the lifting platform on a horizontal surface with the engine off.  ...
  • Page 103 E5 – HYDRAULIC CIRCUIT RACK CLEAN   - Drain the oil (see CHAPTER D6). E6 – ENGINE SILENTBLOCKS (*) CHECK E7 – ENGINE SPEEDS (*) CHECK E8 – HYDROSTATIC TRANSMISSION CIRCUIT PRESSURES (*) CHECK E9 – START OF HYDROSTATIC TRANSMISSION CONTROL (*) CHECK - ADJUST E10 –...

  • Page 104: F - Every 2000 Hours Of Operation Or Two Years

    F - EVERY 2000 HOURS OF OPERATION OR TWO YEARS Perform the operations described above as well as the following operations. F1 – COOLANT DRAIN - REPLACE This series of operations must only be performed as necessary or once a year, on the  approach of winter. Set the lifting platform on a horizontal surface with the engine  switched off and cold. IMPORTANT Do not remove the radiator cap when the engine is hot. Then, gently loosen the cap up to the stop to release any excessive pressure before removing the cap completely.
  • Page 105 F8 – INJECTION PUMP (*) CHECK F9 – INJECTORS (*) CONTACT YOUR DEALER F10 – RADIATOR (*) CHECK - DESCALE *Contact your dealer 3 - 33...

  • Page 106: G - Occasional Maintenance

    CHANGE   - Stop the lifting platform on a firm, horizontal surface if possible.   - Proceed to switch off the machine (see: 1 – SAFETY INSTRUCTIONS AND ADVICE:  DRIVING INSTRUCTIONS WHILE UNLADEN AND LOADED).   - Chock the lifting platform in both directions on the axle opposite the wheel to be  changed. Reminder : Load on one wheel : 2700 kg Recommandations : For using the MANITOU hydraulic jack Ref. 505507 and the MANITOU safety stay Ref.  554772:   - You are recommended to replace the rear wheels then, after turning the turret half a turn, to replace the front wheels.  This operation enables you to distribute the load on the axles by positioning the counterweight on the axle opposite  the wheel change.   - Unlock the nuts on the wheel to be changed.   - Set a jack under the axle housing as close as possible to the wheel and adjust the jack.   - Raise the wheel until it is slightly off the ground and place the safety stay under the axle. IMPORTANT The weight of one wheel is 96 kg.
  • Page 107 G4 – FREEWHEELING MODE ACTIVATION In the event that the lifting platform must be towed, follow the instructions below. IMPORTANT The lifting platform may only be towed a short distance and necessarily by a machine with significant braking power in order to hold it and with a connection bar between the two machines. 1 - WEDGE THE LIFTING PLATFORM IN PLACE 2 - HYDROSTATIC DECLUTCHING IMPORTANT...
  • Page 108 G5 – LIFTING PLATFORM HOISTING WITH A SLING Note the position of the lifting platform’s centre of gravity for lifting it. Place hooks on the anchoring points provided for this purpose. Chain 4 legs : 2 legs 1720mm long on the front of the lifting platform 1. 2 legs 1520mm long on the rear of the platform. (A) Centre of gravity (B) Axis line slinging rings 1103 2000 2185 1103 2000 3 - 36...

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