Manitou MT 1440 E3 Operator's Manual
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Manitou MT 1440 E3 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
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.

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Summary of Contents for Manitou MT 1440 E3

  • Page 1 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.
  • Page 3 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.
  • Page 5 1 - OPERATING AND SAFETY INSTRUCTIONS...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS INSTRUCTIONS TO THE COMPANY MANAGER 1 - 4 THE SITE 1 - 4 THE OPERATOR 1 - 4 THE LIFT TRUCK 1 - 4 A - THE LIFT TRUCK’S SUITABILITY FOR THE JOB 1 - 4 B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS 1 - 4 C - MODIFICATION OF THE LIFT TRUCK 1 - 5...

  • Page 8: Instructions To The Company Manager

    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.

  • Page 9: C - Modification Of The Lift Truck

    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.

  • Page 10: Instructions For The Operator

    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.

  • Page 11: E - Lifting People

    • 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).

  • Page 12: Operating Instructions Unladen And Laden

    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.

  • Page 13: C - Environment

    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.

  • Page 14: E - Starting The Lift Truck

    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).

  • Page 15: G - Stopping The Lift Truck

    - 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.

  • Page 16: H - Driving The Lift Truck On The Public Highway (Or See Current Legislation In Other Countries)

    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.
  • Page 17 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 front- mounted attachment on your lift truck. - If road legislation in your country authorizes circulation with a front-mounted attachment, you must at least: •...

  • Page 18: 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).

  • Page 19: D - Transverse Attitude Of The Lift Truck

    D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK Depending on the model of lift truck The transverse attitude is the transverse slope of the chassis with respect to the horizontal. Raising the 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 -...

  • Page 20: F - Taking Up And Laying A High Load On Tyres

    F - TAKING UP AND LAYING A HIGH LOAD ON TYRES 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).
  • Page 21 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).

  • Page 22: G - Taking Up And Laying A High Load On Stabilizers

    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).
  • Page 23 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.

  • Page 24: H - Taking Up And Laying Down A Suspended Load

    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.

  • Page 25: Platform Operating Instructions

    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”.

  • Page 26: F - Maintenance

    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) Speed Speed Speed...

  • Page 27: Instructions For Using The Radio-Control

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

  • Page 28: Maintenance Instructions Of The Lift Truck

    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.

  • Page 29: Welding

    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.

  • Page 30: If The Lift Truck Is Not To Be Used For A Long Time

    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.

  • Page 31: Bringing The Lift Truck Back Into Service

    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.
  • Page 32 1-28...
  • Page 33 2 - DESCRIPTION...
  • Page 35 TABLE OF CONTENTS «EC» DECLARATION OF CONFORMITY IDENTIFICATION OF THE LIFT TRUCK CHARACTERISTICS MT 1440 E3 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...
  • Page 36 430, 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 37 bg : 1) cs : 1) da : 1) de : 1) el : 1) es : 1) et : 1) fi : 1) ga : 1) hu : 1) is : 1) it : 1) lt : 1) lv : 1) mt : 1) nl : 1) no : 1)
  • Page 38 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) - Model - Series MANITOU BF 44158 ANCENIS CEDEX FRANCE MODELE MODELLO SERIE SERIE...
  • Page 39 REAR AXLE (FIG. E) - Type - Serial Nr - MANITOU reference CAB (FIG. F) - Type - Serial Nr JIB (FIG. G) - MANITOU reference - Date of manufacture PLATE MANUFACTURER OF THE ATTACHMENT (FIG. H) - Model MANITOU BF...
  • Page 40 CHARACTERISTICS MT 1440 E3 I.C. ENGINE Type PERKINS 1104D-44TA RP52117 Fuel Diesel Number of cylinders 4 in line Suction Supercharged Injection system Direct Ignition sequence 1.3.4.2 Capacity 4400 Bore and stroke 105 x 127 Compression ratio 18,2/1 Nominal rating loaded...
  • Page 41 HYDRAULIC CIRCUIT Hydraulic pump Type Gear pump with flow divider on 2nd casing 1st casing 2nd casing Capacity Max. rating capacity unladen l/mn Flow rate at 1600 rpm l/mn Filtration Return μm Suction μm Maximum service pressure Telescoping circuit 270 / 270 Lifting circuit 270 / 210 Tilt circuit...
  • Page 42 CHARACTERISTICS MT 1840 E3 I.C. ENGINE Type PERKINS 1104D-44TA RP52117 Fuel Diesel Number of cylinders 4 in line Suction Supercharged Injection system Direct Ignition sequence 1.3.4.2 Capacity 4400 Bore and stroke 105 x 127 Compression ratio 18,2/1 Nominal rating loaded 2200 Rating slow unladen Max.
  • Page 43 HYDRAULIC CIRCUIT Hydraulic pump Type Gear pump with flow divider on 2nd casing 1st casing 2nd casing Capacity Max. rating capacity unladen l/mn Flow rate at 1600 rpm l/mn Filtration Return μm Suction μm Maximum service pressure Telescoping circuit 270 / 270 Lifting circuit 270 / 210 Tilt circuit...
  • Page 44 FRONT AND REAR TIRES TYRE LOAD (kg) PRESSURE MT 1440 E3 (bar) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN DUNLOP 440/80-24 T37 158B TUBELESS GALAXY 15.5-25 16PR GIRAFFE L2 2700 6300 2900 1250 MICHELIN 400/80-24 162A8 TUBELESS MITAS 15.5-25 12PR EM-20 TUBELESS...
  • Page 45 2-13...
  • Page 46 DIMENSIONS AND LOAD CHART MT 1440 E3 1200 3070 1905 1790 6135 6020 4872 7335 1960 1960 ° ° 1160 1040 1855 ° ° 3779 8615 4183 2452 2640 5468 1285 3975 2351 3793 1134 2422 ° ° 2-14...
  • Page 47 SUIVANT NORME EN 1459 annexe B. 50° 60° 70° 71.3° 13.53 40° 30° 20° 10° MT 1440 0° -1.2° 0.5m 9.38 6.20 5.10 1.86 N°261552 N°261549 50° 60° 62° 40° 12.3 30° 20° 10° MT 1440 0° 0.5m -6.2° 9.46 7.75 5.85 4.25 3.10 1.91...
  • Page 48 DIMENSIONS AND LOAD CHART MT 1840 E3 1200 3070 2043 1929 6274 6159 4894 7474 1960 1960 ° ° 1160 1040 1908 ° ° 3779 8788 4307 2505 2693 5592 1285 4009 2420 3793 1134 2422 ° ° 2-16...
  • Page 49 2-17...
  • Page 50 INSTRUMENTS AND CONTROLS 2-18...
  • Page 51 DESCRIPTION 1 - DRIVER’S SEAT 2 - SAFETY BELT 3 - IGNITION SWITCH 4 - EMERGENCY STOP BUTTON 5 - BATTERY CUT-OFF 6 - 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...
  • Page 52 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. SEAT CUSHION ADJUSTMENT The front and the back of the seat cushion can be adjusted separately.
  • Page 53 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. 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.
  • Page 54 1 - DRIVER’S SEAT (OPTION) DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS. 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.
  • Page 55 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. 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.
  • Page 56 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.).
  • Page 57 6 - MAN-MACHINE INTERFACE (MMI) 6A - DRIVER PRESENCE 6B - INSTRUMENT CONTROL PANEL 6C - PANEL FOR BUTTONS AND KEYBOARD 6D - SCREEN DISPLAY 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.
  • Page 58 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.
  • Page 59 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.
  • Page 60 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 The indicator will light when it is in use. By default, the attachment circuit in continuous mode is disabled as soon as the operator leaves the cab.
  • Page 61 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 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).
  • Page 62 Cancel 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...
  • Page 63 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.
  • Page 64 Driver presence. LOCKING SCREEN Transmission fault. By default, the operator is not permitted to unlock the functions (see: 2 - DESCRIPTION: 6D - SCREEN DISPLAY: MENU SCREEN). Retracting stabilizer. One of these screens appears when the system detects an operating defect on the lift truck. A beep is sounded when this Tilt.
  • Page 65 < INFO CLOCK > 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).
  • Page 66 ERROR ERROR COMPONENT FAULT TYPE DETECTED BY COMPONENT FAULT TYPE DETECTED BY CODE CODE A00003 I.C. engine Fault 30028 Hydraulic control valve Short circuit Computer MP1 A00006 Gear box Fault 30029 Hydraulic control valve Short circuit Computer MP1 A00007 Air filter Fault 30030 Low speed electrovalve...
  • Page 67 ERROR ERROR COMPONENT FAULT TYPE DETECTED BY COMPONENT FAULT TYPE DETECTED BY CODE CODE Short circuit 50069 Left-hand sidelight Disconnected wire Computer MP1 40080 Right-hand main beam headlight Computer MP1 50078 Rotating light Disconnected wire Computer MP1 50080 Right-hand main beam headlight Disconnected wire Computer MP1 40081 Trailer left-hand indicator light Short circuit...
  • Page 68 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.
  • Page 69 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.
  • Page 70 8 - SWITCHES A - OPTION WORKING TAIL LIGHTS B - OPTION WORKING LIGHTS ON JIB 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”...
  • Page 71 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).
  • Page 72 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.
  • Page 73 17 - HYDRAULIC CONTROLS Authorisation for using the hydraulic controls is given by the validation of the driver’s presence (see: 2 - DESCRIPTION: 6 - MAN- MACHINE 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.
  • Page 74 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.
  • Page 75 23 - HEATER CONTROL A - FAN CONTROL This 3-speed control allows the air to be ventilated through the air vents. 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.
  • Page 76 26 - LEVEL INDICATORS A - TILT INDICATOR When the two marks are aligned, the chassis is parallel with the front axle. B - SPIRIT LEVEL Enables the operator to check that the lift truck is in the horizontal position. 27 - DOOR OPEN LEVER 28 - DOOR CLOSE HANDLE 29 - WINDOW REGULATOR SWITCH...
  • Page 77 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.
  • Page 78 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).
  • Page 79 2-47...
  • Page 80 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...
  • Page 81 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 MT 1840 E3 2-49...
  • Page 82 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.
  • Page 83 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.
  • Page 84 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. ATTACHMENT LINE L2 CONTROL - Hold down button 3 and push button 2 forwards or backwards.
  • Page 85 14 - LIFTING RING ON SINGLE CARRIAGE CONDITIONS OF USE 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. - The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS, but the angle of inclination of the carriage must be same as when the forks are used in the horizontal position.
  • Page 86 2-54...
  • Page 87 3 - MAINTENANCE...
  • Page 89 TABLE OF CONTENTS MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT START-UP CHECKLIST FILTERS CARTRIDGES AND BELTS LUBRICANTS AND FUEL 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...

  • Page 90: Manitou Original Spare Parts And Equipment

    - 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.

  • Page 91: Start-Up Checklist

    START-UP CHECKLIST 0 = OK 1 = Missing 2 = Incorrect ENGINE ATTACHMENTS 01 Air filter 01 Fitting on machine 02 Fuel tank 02 Hydraulic couplings 03 Fuel lines - Filter CABIN/PROTECTOR/ELECTRIC CIRCUIT 04 Injection or carburetion system 01 Seat 05 Radiator and cooling system 02 Dashboard and radio 06 Belts...

  • Page 92: Filters Cartridges And Belts

    FILTERS CARTRIDGES AND BELTS I.C. ENGINE I.C. ENGINE OIL FILTER ALTERNATOR BELT Part number: 476954 Part number: 702974 Change: 500 H DRY AIR FILTER CARTRIDGE ALTERNATOR BELT Part number: 563416 (OPTION AIR CONDITIONING) Clean: 50 H* Part number: 286931 Change: 500 H* SAFETY DRY AIR FILTER CARTRIDGE COMPRESSOR BELT Part number: 563415...

  • Page 94: 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.
  • Page 95 BRAKE ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER MANITOU Oil BRAKE CIRCUIT 490408 Mineral brake fluid ORGANS TO BE LUBRICATED RECOMMENDATION PACKAGING PART NUMBER 490402 WINDSCREEN WASHER TANK Windscreen washer fluid 486424 FRONT AXLE ORGANS TO BE LUBRICATED CAPACITY...

  • Page 96: Servicing Schedule

    SERVICING SCHEDULE (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). A = ADJUST, C = CHECK, G = GREASE, N = CLEAN, PAGE P = BLEED, R = REPLACE, V = DRAIN I.C.
  • Page 97 A = ADJUST, C = CHECK, G = GREASE, N = CLEAN, PAGE P = BLEED, R = REPLACE, V = DRAIN BRAKE Brake oil level 3-17 <<< <<< <<< <<< <<< Brake oil <<< <<< Brake system <<< <<< Brake system pressure <<<...

  • Page 98: A - Daily Or Every 10 Hours Service

    A - DAILY OR EVERY 10 HOURS SERVICE A1 - I.C. ENGINE OIL LEVEL CHECK Place the lift truck on level ground with the I.C. engine stopped, and let the oil drain into the sump. - Open the I.C. engine bonnet. - Remove the dipstick 1 (fig.
  • Page 99 - 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...
  • Page 100 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.
  • Page 101 3-15...

  • Page 102: B - Every 50 Hours Service

    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).
  • Page 103 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).
  • Page 104 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).
  • Page 105 3-19...

  • Page 106: C - Every 250 Hours Service

    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.
  • Page 107 C4 - OUTER JIB CHAINS C4/1 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.
  • Page 108 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).
  • Page 109 3-23...

  • Page 110: D - Every 500 Hours Service

    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.
  • Page 111 D3 - DRY AIR FILTER CARTRIDGE 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).
  • Page 112 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.
  • Page 113 D7 - FRONT AND REAR AXLE DIFFERENTIAL OIL DRAIN Place the lift truck on level ground with the I.C. engine stopped and the differential oil still warm. 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.

  • Page 114: E - Every 1000 Hours Service

    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.
  • Page 115 E4 - GEAR BOX OIL E4/1 DRAIN E5 - GEAR BOX OIL FILTER CHANGE 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.
  • Page 116 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.
  • Page 117 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 Place the lift truck on level ground with the I.C. engine stopped and telescope jib retracted and lowered as far as possible.
  • Page 118 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. •...
  • Page 119 3-33...

  • Page 120: F - Every 2000 Hours Of Service

    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.
  • Page 121 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).

  • Page 122: G - Every 4000 Hours Of Service

    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.
  • Page 123 3-37...

  • Page 124: H - Occasional Maintenance

    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.
  • Page 125 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.
  • Page 126 H4 - FRONT HEADLAMPS 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. ADJUSTING PROCEDURE - Place the lift truck unloaded and in the transport position and h2 = h1 - (l x 2 / 100) perpendicular to a white wall on flat, level ground (fig.
  • Page 127 - Take into account the position of the lift truck centre of gravity for lifting (fig. H7/1). A = 1590 mm B = 1480 mm MT 1440 E3 A = 1625 mm B = 1445 mm MT 1840 E3 - Place the hooks in the fastening points provided (fig. H7/2 and...
  • Page 128 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).
  • Page 129 4 - OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE...
  • Page 131 TABLE OF CONTENTS INTRODUCTION PICKING UP THE ATTACHMENTS TECHNICAL SPECIFICATIONS OF ATTACHMENTS ATTACHMENT SHIELDS 4-14...
  • Page 133 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.
  • Page 134 PICKING UP THE ATTACHMENTS A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE 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.
  • Page 135 B - HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE 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.
  • Page 136 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...
  • Page 137 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 751542 Rated capacity 4300 kg Side-shift 2x100 mm...
  • Page 138 BUILDING BUCKET Use is prohibited with the optional single side-shift carriage (TSDL). MT 1440 E3 CBC 700 L1950 S2 CBC 800 L2250 S3 CBC 900 L2450 S3 PART NUMBER 654472 654471 654470 Rated capacity 697 l 814 l 893 l...
  • Page 139 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...
  • Page 140 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...
  • Page 141 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...
  • Page 142 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 206734 206732...

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