Manitou 80 VJR Operator's Manual
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Manitou 80 VJR Operator's Manual

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547397
EN (22/10/2020)
80 VJR / 80 VJR EVOLUTION
100 VJR / 100 VJR EVOLUTION
OPERATOR'S MANUAL
(ORIGINAL MANUAL)

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Summary of Contents for Manitou 80 VJR

  • Page 1 547397 EN (22/10/2020) 80 VJR / 80 VJR EVOLUTION 100 VJR / 100 VJR EVOLUTION OPERATOR'S MANUAL (ORIGINAL MANUAL)
  • Page 2 - Descriptions and figures are non-binding. - MANITOU reserves the right to change its models and their equipment without being required to update this manual. - The MANITOU network, consisting exclusively of qualified professionals, is available to answer all your questions.
  • Page 3 MANITOU BF. Any violation of the above is subject to civil and criminal penalties. The logos and visual identity of the company are property of MANITOU BF and may not be used without express formal authorization.
  • Page 4 1 - OPERATING AND SAFETY INSTRUCTIONS 2 - DESCRIPTION 3 - MAINTENANCE...
  • Page 5 1 - OPERATING AND SAFETY INSTRUCTIONS 1 - 1...
  • Page 6 1 - OPERATING AND SAFETY INSTRUCTIONS INSTRUCTIONS TO THE COMPANY MANAGER THE SITE THE OPERATOR PLATFORM A – SUITABILITY OF THE PLATFORM FOR THE TASK ........... . 1-4 B - ADAPTING THE PLATFORM TO USUAL ENVIRONMENTAL CONDITIONS .
  • Page 7 IF THE PLATFORM IS NOT TO BE USED FOR A LONG TIME 1-14 INTRODUCTION 1-14 PREPARING THE PLATFORM 1-14 PROTECTING THE ENGINE (DIESEL PLATFORM) 1-14 BATTERY CHARGING (ELECTRIC PLATFORM) 1-14 PROTECTING THE PLATFORM 1-14 BRINGING THE PLATFORM BACK INTO SERVICE 1-14 DISPOSING OF THE PLATFORM 1-15...
  • Page 8 A – SUITABILITY OF THE PLATFORM FOR THE TASK - 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 harmonised standard EN 280 for MPLP (Mobile Personnel Lifting Platforms).
  • Page 9 C - MODIFYING THE PLATFORM IMPORTANT It is strictly prohibited to replace platform components with components not approved by Manitou (batteries, wheels, basket, etc.). IMPORTANT It is strictly forbidden to change the structure and settings of the various components of your platform (hydraulic pressure, calibrating limiters, engine speed, sensors, addition of extra equipment, addition of counterweight, unapproved attachments, alarm systems, etc.) yourself.
  • Page 10 INSTRUCTIONS FOR THE OPERATOR INTRODUCTION IMPORTANT The risk of accident while using, servicing or repairing your platform can be reduced if you follow the safety instructions and preventive measures detailed in these instructions. Failure to respect the safety and operating instructions, or the instructions for repairing or servicing your platform may lead to serious, even fatal accidents.
  • Page 11 - Ensure that the guard rail and/or the access gate (according to model) is fully in the locked position before operating the platform from the basket. - MANITOU recommends a safety harness in the operator’s size be provided when the platform is in use (for the harness attachment in the basket,  2 - DESCRIPTION).
  • Page 12 C - ENVIRONMENT - Comply with site safety regulations. - The platform can be operated 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 Do not use this machine during lightning storms, snow storms, during frosty periods or in hazardous weather conditions. In case of strong wind exceeding 45 km/h, do not make any movement that may endanger the platform’s stability. - To visually recognise this wind speed, refer to the empirical wind evaluation scale below: BEAUFORT scale (wind speed at a height of 10 m on a flat site) Speed Speed...
  • Page 14 F - OPERATING THE PLATFORM SAFETY INSTRUCTIONS 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 15 INSTRUCTIONS FOR WELDING AND BLOW TORCH WORK ON AN 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 AN ELECTRICAL WELDING SET...
  • Page 16 PLATFORM MAINTENANCE INSTRUCTIONS GENERAL INSTRUCTIONS - Read the operator’s manual carefully. - Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie and protect your hair, if necessary. - DIESEL PLATFORM: • Make sure the area is adequately ventilated before starting up the platform. •...
  • Page 17 IMPORTANT Welding operations for the purposes of maintenance or repairs must only be carried out by persons authorised by MANITOU. WASHING THE PLATFORM - Clean the platform or at least the area concerned before any intervention.
  • Page 18 IF THE PLATFORM IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent the platform from being damaged when it is withdrawn from service for an extended period. IMPORTANT Procedures to follow if the platform is not to be used for a long time and for starting it up again afterwards must be performed by your dealership. This period of long-term stoppage must not exceed 12 months.
  • Page 19 • Glass items can be removed and collected for processing by glaziers. ENVIRONMENTAL PROTECTION By entrusting the maintenance of your platform to the MANITOU network, the risk of pollution is limited and the contribution to environmental protection is made. WORN OR DAMAGED PARTS •...
  • Page 20 1 - 16...
  • Page 21 2 - DESCRIPTION 2 - 1...
  • Page 22 IDENTIFICATION OF THE PLATFORM 2-22 SPECIFICATIONS 2-24 DIMENSIONS 2-26 DIAGRAM 2-27 80 VJR / 80 VJR EVOLUTION DIAGRAM 2-28 100 VJR / 100 VJR EVOLUTION SAFETY COMPONENTS 2-29 CONTROL PANEL AND SAFETY DEVICES AT GROUND LEVEL 2-30 CONTROL PANEL AND SAFETY DEVICES IN THE BASKET...
  • Page 23 2 - 3...
  • Page 24 44158 - ANCENIS - CEDEX - FRANCE Le constructeur déclare que la machine décrite ci-après, The manufacturer declares that the machine : 80 VJR EVOLUTION - 100 VJR EVOLUTION described below - Est conforme aux directives suivantes et à leurs transpositions en droit national (si...
  • Page 25 2 - 5...
  • Page 26 44158 - ANCENIS - CEDEX - FRANCE Le constructeur déclare que la machine décrite ci-après, The manufacturer declares that the machine : 80 VJR EVOLUTION - 100 VJR EVOLUTION described below - Est conforme aux directives suivantes et à leurs transpositions en droit national (si...
  • Page 27 2 - 7...
  • Page 28 44158 - ANCENIS - CEDEX - FRANCE Le constructeur déclare que la machine décrite ci-après, The manufacturer declares that the machine : 80 VJR described below - Est conforme aux directives suivantes et à leurs transpositions en droit national (si...
  • Page 29 2 - 9...
  • Page 30 CE DECLARATION OF CONFORMITY VJR 100 11/2020 DECLARATION “CE” DE CONFORMITE (originale) “EC” DECLARATION OF CONFORMITY (original) Constructeur, : Manitou BF manufacturer Adresse, : 430, RUE DE L’AUBINIERE - B.P 10249 Address 44158 - ANCENIS - CEDEX - FRANCE Titulaire du dossier technique,...
  • Page 31 2 - 11...
  • Page 32 STICKERS 1 - WHITE ARROW ...............Part No. 498327 ....2-16 2 - BLACK ARROW .
  • Page 33 VERSION 1 *: DEPENDING ON FITTING 2 - 13...
  • Page 34 VERSION 2 - 14...
  • Page 35 VERSION 2 - 15...
  • Page 36 1 - WHITE ARROW Part No. 498327 Indicates forward driving direction, PLATFORM OPERATION: TRANSPORT/WORKING POSITION. 2 - BLACK ARROW Part No. 498326 Indicates reverse driving direction, PLATFORM OPERATION: TRANSPORT/WORKING POSITION. 3 - INSTRUCTIONS LOCATION Part No. 52562839 DEPENDING ON FITTING Indicates location of the instructions for use. 4 - BASKET INSTRUCTIONS AND LOAD CAPACITY Part No. 830096 Indicates:...
  • Page 37 5 - GROUND SAFETY INSTRUCTIONS Part No. 830102 VERSION Indicates: : The safety and operating instructions must be read before starting the platform. : Platform transportation procedures. : It is strictly forbidden to direct a pressure washer nozzle over the control panels and electrical components.
  • Page 38 10 - DANGER WARNING Part No. 830871 Indicates a nearby hazard. 11 - HARNESS ATTACHMENT POINT Part No. 834438 Indicates the location of safety harness attachment points,  SAFETY COMPONENTS: HARNESS ATTACHMENT POINTS. 12 - SAFETY VALVE Part No. 830123 Indicates the location of the jib safety valve.  RESCUE PROCEDURE.
  • Page 39 15 - MANUAL CONTROL PROCEDURE Part No. 830099 Indicates the procedure to be followed for using the emergency controls for the jib, turntable and steering,  RESCUE PROCEDURE. 830099-C 16 - ANCHORING POINT Part No. 598895 VERSION Indicates the location of the platform's anchoring points,  PLATFORM OPERATION: TRANSPORTING THE PLATFORM.
  • Page 40 80 VJR = 640 mm NOTE: Each platform has its own lifting procedure; refer to this sticker to see the values. 100 VJR = 690 mm 80 VJR = 2250 kg (4960 lbs) TOTAL MASS 100 VJR = 2650 kg (5840 lbs)
  • Page 41 25 - BATTERY SAFETY Part No. 830119 Indicates: : The "OFF" off position of the emergency stop/battery cut-off button. : The following hazards: • Explosion when charging. • Possibility of explosion caused by a flame, spark or short-circuit. • Risk of gas emissions. Charge the battery in a well-ventilated area. : The type of socket required when recharging the battery.
  • Page 42 IDENTIFICATION OF THE PLATFORM In view of our policy of constantly improving our products, we may make certain modifications to our access platform range without notifying our customers in advance. NOTE: In order to have all these numbers on hand when needed, it is recommended that they are noted in the spaces provided, at the time of the delivery of the access platform.
  • Page 43 2 - 23...
  • Page 44 SPECIFICATIONS 80 VJR / 100 VJR / LOAD SPECIFICATIONS ± 80 VJR EVOLUTION 100 VJR EVOLUTION Platform - Maximum load capacity of the basket - Maximum wind speed when operating outside km/h - Number of people in the basket in indoor use...
  • Page 45 80 VJR / 100 VJR / HYDRAULIC CIRCUIT ± 80 VJR EVOLUTION 100 VJR EVOLUTION Hydraulic pump - Type Mini unit - HYDAC - Maximum cylinder capacity 4.2* / 2 x 4.2* - Maximum unladen flow rate L/min 18* / 23.5*...
  • Page 46 DIMENSIONS 80 VJR / 100 VJR / 80 VJR EVOLUTION 100 VJR EVOLUTION 2,956 2,824 1,200 1,200 1,995 1,994 2,022 2,022 1,636 1,636 2 - 26...
  • Page 47 DIAGRAM 80 VJR / 80 VJR EVOLUTION 1,760 5,650 2,620 4,213 1,623 2,020 2 - 27...
  • Page 48 DIAGRAM 100 VJR / 100 VJR EVOLUTION 1,855 7,900 2,537 6,669 1,623 1,888 2 - 28...
  • Page 49 SAFETY COMPONENTS GUARDRAIL IMPORTANT Do not attach the guardrail with a clamp, twine or any device that could prevent it from functioning properly. - Raise the guardrail and keep it raised to get in and out of the basket. HARNESS ATTACHMENT POINTS IMPORTANT Only one operator is permitted to use each attachment point.
  • Page 50 CONTROL PANEL AND SAFETY DEVICES AT GROUND LEVEL IMPORTANT The left and right are defined in PLATFORM OPERATION: TRANSPORT/WORKING POSITION. 1 - EMERGENCY STOP/BATTERY CUT-OFF BUTTON................2-32 2 - IGNITION SWITCH .

  • Page 51: Table Of Contents

    CONTROL PANEL AND SAFETY DEVICES IN THE BASKET IMPORTANT Drive forwards, drive backwards, the left and right are defined in PLATFORM OPERATION: TRANSPORT/WORKING POSITION. 14 - EMERGENCY STOP BUTTON....................2-37 15 - HORN BUTTON .
  • Page 52 1 - EMERGENCY STOP/BATTERY CUT-OFF BUTTON IMPORTANT In all cases this control takes priority, even if the movements are executed from the basket control panel. Movements may stop suddenly if the emergency stop is activated. 2 positions: - OFF (locked): Press the button to cut off movements and stop the platform. - ON (unlocked): Turn the knob to power the platform up.
  • Page 53 3 - ACTIVATION BUTTONS AND CONTROL BUTTONS FIRST VERSION SECOND VERSION RAISE THE JIB - Press and hold down the jib activation button - Press and hold down the control button to raise the jib. - Release it or release the activation button to stop. LOWER THE JIB - Press and hold down the jib activation button - Press and hold down the control button...
  • Page 54 4 - MULTI-FUNCTION DISPLAY It displays: - The battery charge level. - The hour counter. - The maintenance warning. - The fault codes. NOTE:  MULTI-FUNCTION DISPLAY - DESCRIPTION. 5 - FAULT INDICATOR LIGHT  MULTI-FUNCTION DISPLAY - DESCRIPTION. 6 - TILT ALARM LIGHT Illustrations:  = first version,  = second version.
  • Page 55 7 - OVERLOAD ALARM LIGHT Illustrations:  = first version,  = second version. The overload alarm is activated when the load in the basket has reached maximum capacity: - The indicator lamp flashes. - The horn and the audible warning sound continuously. - All controls are locked,  PLATFORM OPERATION: LOCKED CONTROLS.
  • Page 56 10 - TILT SENSOR A light on the tilt sensor indicates its operating status: - On: the chassis has not reached maximum tilt. - Off: the chassis has reached maximum tilt. 11 - HORN The horn sounds: - When the horn button is pressed. - Once after the platform has been powered up.

  • Page 57: Emergency Stop Button

    14 - EMERGENCY STOP BUTTON Illustrations:  = first version,  = second version. FIRST VERSION IMPORTANT In all cases this control takes priority, even if the movements are executed from the basket control panel or the box. Movements may stop suddenly if the emergency stop is activated. 2 positions: - OFF (locked): Press the knob to cut off the movements.
  • Page 58 16 - ACTIVATION BUTTON AND INDICATOR LAMP - JIB Illustrations:  = first version,  = second version. - Press and release the button NOTE: the control handle and the trigger on the control handle must be released. Result: the indicator lamp comes on.

  • Page 59: Activation Button And Indicator Lamp - Jib

    18 - ACTIVATION BUTTON AND INDICATOR LAMP - DRIVING/STEERING Illustrations:  = first version,  = second version. - Press and release the button NOTE: the control handle and the trigger on the control handle must be released. Result: the indicator lamp comes on.

  • Page 60: Activation Button And Indicator Lamp - Turntable And Mast

    RAISE THE MAST - Activate the turntable and mast functions,  ACTIVATION BUTTON AND INDICATOR LAMP – TURNTABLE AND MAST. - Press and hold down trigger - Push and hold the control handle forward. - Release it or release the trigger to stop. LOWER THE MAST - Activate the turntable and mast functions,  ACTIVATION BUTTON AND INDICATOR LAMP –...

  • Page 61: Not Used

    20 - NOT USED 21 - TILT ALARM LIGHT Illustrations:  = first version,  = second version. The tilt alarm is activated when the platform is on a steep slope: - The indicator lamp flashes. - The horn and the audible warning sound intermittently (only when the platform is in WORKING position,  PLATFORM OPERATION: TRANSPORT/WORKING POSITION.

  • Page 62: Reset Button Sps (Option)

    23 - RESET BUTTON SPS (OPTION) Illustrations:  = first version,  = second version.  OPTIONS: SECONDARY PROTECTION SYSTEM SPS - FIRST VERSION "SAFEMANSYSTEM"  OPTIONS: SECONDARY PROTECTION SYSTEM SPS - SECOND VERSION. 24 - SAFETY EDGE SPS (OPTION)  OPTIONS: SECONDARY PROTECTION SYSTEM SPS - FIRST VERSION "SAFEMANSYSTEM". 25 - SAFETY CABLE SPS (OPTION)  OPTIONS: SECONDARY PROTECTION SYSTEM SPS - SECOND VERSION.
  • Page 63 2 - 43...

  • Page 64: Multi-Function Display

    MULTI-FUNCTION DISPLAY BATTERY CHARGE LEVEL The bar graph indicates the battery charge level from 0% to 100%, with each segment representing 10%. It is recommended to load the battery when the charge level is 30%,  CHARGE THE BATTERY. = 100%: - The battery is fully charged.

  • Page 65: The Maintenance Warning

    MAINTENANCE WARNING IMPORTANT The hour counter and the key are displayed when a maintenance warning occurs, a maintenance operation could be necessary. Always consult the maintenance personnel when a maintenance warning occurs. The maintenance warning is displayed after every 50 hours of service. Maintenance can be carried out before the alert depending on how much the platform has been used, for example: - Maintenance is required every 50 hours of service or every 3 months.
  • Page 66 PLATFORM OPERATION IMPORTANT Part 1 - INSTRUCTIONS AND SAFETY INSTRUCTIONS must be read and understood before operating the platform. TRANSPORT/WORKING POSITION RIGHT TRANSPORT POSITION The platform is in TRANSPORT position when: - The mast is fully retracted. FRONT REAR - The jib is in the range as shown in the illustration.
  • Page 67 OPERATION FROM THE GROUND LEVEL CONTROL PANEL IMPORTANT  CONTROL PANEL AND SAFETY DEVICES ON THE GROUND for detailed information about the ground controls. SWITCH THE PLATFORM ON - Ensure that the basket's emergency stop button is in the ON position. - Pull out the battery cut-off/emergency stop button (ON position).
  • Page 68 CONTROLS LOCKED Some controls are locked (refer to the tables below): - When the basket load has reached maximum capacity (OVERLOAD ALARM). - When the platform is on a steep slope (TILT ALARM). TRANSPORT POSITION GROUND CONTROLS OVERLOAD ALARM TILT/OSCILLATION ALARM RAISE THE MAST LOCKED RAISE/LOWER THE JIB...

  • Page 69: Battery Charger Status Indicator Lamp

    CHARGE THE BATTERY IMPORTANT It is recommended to charge the battery at the end of each day's use. Always charge the battery in a well-ventilated area, protected from sunlight and rain. Do not charge the battery during a lightning storm. Do not charge the battery if the electrolyte temperature is over 40 °C.

  • Page 70: 3-Maintenance: Occasional Operation: Tow/Winch

    TRANSPORTING THE PLATFORM IMPORTANT Check that the safety instructions associated with the flatbed have been correctly applied before loading the platform and ensure that the driver of the vehicle has been informed of the dimensional characteristics and total weight of the platform. Ensure that the flatbed has adequate dimensions and load capacity for transporting the platform,  SPECIFICATIONS and STICKERS.
  • Page 71 CONFIGURE THE PLATFORM FOR TRANSPORT IMPORTANT Turntable rotation is prohibited once on the transport vehicle. The platform should be in TRANSPORT position with the jib arm completely lowered and the turntable in NEUTRAL position,  PLATFORM OPERATION: TRANSPORT/ WORKING POSITION. NOTE: The platform is switched on. The platform is in TRANSPORT position.
  • Page 72 SECURING THE PLATFORM BY THE CHASSIS (FOR VERSIONS 1, 2 AND 3) 80 VJR 100 VJR 80 VJR EVOLUTION 100 VJR EVOLUTION 2,955 mm 2,825 mm 2,000 mm 2,000 mm 1,000 mm 1,000 mm D "LOAD ON 2 WHEELS" LOAD ON 2 WHEELS 1,320 kg (2,910 lbs) 1,580 kg (3,480 lbs) E "LOAD ON 2 WHEELS" LOAD ON 2 WHEELS 930 kg (2,050 lbs) 1,070 kg (2,360 lbs) F "TOTAL MASS"...
  • Page 73 SECURING THE PLATFORM BY THE MAST (FOR VERSIONS 2 AND 3) 80 VJR 100 VJR 80 VJR EVOLUTION 100 VJR EVOLUTION 2,955 mm 2,825 mm 2,000 mm 2,000 mm 1,000 mm 1,000 mm D "LOAD ON 2 WHEELS" LOAD ON 2 WHEELS 1,320 kg (2,910 lbs) 1,580 kg (3,480 lbs) E "LOAD ON 2 WHEELS" LOAD ON 2 WHEELS 930 kg (2,050 lbs) 1,070 kg (2,360 lbs) F "TOTAL MASS"...
  • Page 74 RESCUE PROCEDURE IMPORTANT This procedure should be read and fully understood by the operator and any other persons likely to be involved with working on the platform in the event of a breakdown or someone getting trapped in the basket. SHOULD THE USER FEEL ILL - PRIORITY CONTROLS Illustrations:  = first version,...
  • Page 75 830123-B 830099-C 2 - 55...
  • Page 76 RETRACT THE MAST 1 - Turn the valve counterclockwise until it stops. 2 - Press and hold down the valve button , then release it when the desired position is reached. 3 - Turn the valve clockwise until it stops. LOWER THE JIB NOTE: The mast must be retracted in order to be able to lower the jib.
  • Page 77 STEER TO THE RIGHT 1 - Turn the valve clockwise until it stops. 2 - Place the pump lever on the manual backup pump 3 - Press and hold down button 4 - Pump to steer the platform, stop when the desired position is reached.
  • Page 78 OPTIONS OPTIONS THAT CAN BE ACTIVATED/DEACTIVATED Illustrations:  = first version,  = second version. - Switch on the platform - Turn the ignition switch to position (depending on version) to activate the controls from the basket. - Get into the basket. - Press and hold down the buttons - Release the buttons when the audible alarm sounds once and when the indicator lamps...
  • Page 79 SECONDARY PROTECTION SYSTEM SPS - FIRST VERSION "SAFEMANSYSTEM" IMPORTANT Operate the controls extremely carefully during attempts at clearance. If the audible alarm sounds intermittently and rapidly and the flashing light SPS flashes rapidly: The platform can be used, but the secondary protection system "SAFEMANSYSTEM" is deactivated; consult the maintenance personnel. NOTE: The audible alarm sounds once and the flashing light SPS flashes several times when the platform is powered up.
  • Page 80 SECONDARY PROTECTION SYSTEM SPS - SECOND VERSION IMPORTANT Activate the platform controls extremely carefully during attempts at clearance. If the audible alarm sounds intermittently and rapidly and the flashing light SPS flashes rapidly: The platform can be used, but the secondary protection system SPS is deactivated; consult the maintenance personnel. NOTE: The audible alarm sounds once and the flashing light SPS flashes several times when the platform is powered up.
  • Page 81 3 - MAINTENANCE 3 - 1...
  • Page 82 3 - MAINTENANCE INTRODUCTION ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT DAILY AND WEEKLY MAINTENANCE MANDATORY SERVICING AND PERIODIC MAINTENANCE OCCASIONAL MAINTENANCE AND OPERATION FILTERS AND CARTRIDGES LUBRICANTS Ü  DAILY MAINTENANCE 3-10 Ü  WEEKLY MAINTENANCE 3-19 ÜŒ 50H - MAINTENANCE EVERY 50 HOURS OF SERVICE OR EVERY 3 MONTHS 3-21 ܍...
  • Page 83 • Efficient help with diagnosis. • Improvements due to experience feedback. • Operator training. • Only the MANITOU network has detailed knowledge of the design of the access platform and therefore the best technical ability to provide maintenance. IMPORTANT ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
  • Page 84 DAILY AND WEEKLY MAINTENANCE IMPORTANT DAILY MAINTENANCE MUST BE CARRIED OUT BY THE OPERATOR BEFORE USING THE PLATFORM. WEEKLY MAINTENANCE MUST BE CARRIED OUT BY THE MAINTENANCE PERSONNEL. Ü  DAILY MAINTENANCE - CHECK General inspection................. . 3-10 - CHECK Hydraulic oil level .
  • Page 85 MANDATORY SERVICING AND PERIODIC MAINTENANCE IMPORTANT THE MANDATORY SERVICE AND THE PERIODIC MAINTENANCE MUST BE CARRIED OUT BY AN APPROVED PROFESSIONAL FROM THE MANITOU NETWORK. MAINTENANCE SCHEDULE This schedule enables the periodic maintenance on the platform to be kept up to date by reporting the total number of hours worked and the date of the service.
  • Page 86 1400 H 1350 H 1450 H 1500 H 1550 H Ü SCHEDULE or 7 YEARS Ü Œ Œ  Ž Œ Œ  Œ PERIODIC MAINTENANCE Ü MACHINE COUNTER Ü DATE OF SERVICING 1600 H 1800 H 1650 H 1700 H 1750 H Ü SCHEDULE or 8 YEARS or 9 YEARS Ü...
  • Page 87 Ü  MANDATORY SERVICE - FIRST 50 HOURS This service must be carried out in the first 50 hours of service. - CHECK Tightening of the fixing screws for the wheel reduction gears ........3-25 - CHECK Tightening of the mast fixing screws.
  • Page 88 ÜŒ 50H - MAINTENANCE EVERY 50 HOURS OF SERVICE OR EVERY 3 MONTHS ALSO PERFORM THE DAILY AND WEEKLY MAINTENANCE. - CHECK Tightening of the wheel nuts and bolts (depending on version) ........3-21 - CHECK Battery electrolyte specific gravity .
  • Page 89 USE THE RECOMMENDED LUBRICANTS AND FUEL: - For topping up, oils may not be miscible. - For oil changes, MANITOU oils are perfectly appropriate. DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been set up with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use.

  • Page 90: Check General Inspection

    Ü  DAILY MAINTENANCE CHECK General inspection IMPORTANT Consult the maintenance personnel if there is doubt about the condition of the platform. NOTE: The turntable covers must be opened and removed to carry out the general inspection of the platform. They must be put back in place and closed once the inspection has finished.

  • Page 91: Check Battery Fluid Level

    CHECK Battery fluid level IMPORTANT At all times, make sure that: - The positive terminals cannot come into contact with the negative terminals. - The positive terminals cannot come into contact with metallic parts of the platform. Do not add distilled water if the battery charge level is not 100%. The battery contains a highly corrosive liquid.

  • Page 92: Platform Controls

    CHECK Platform controls Illustrations:  = first version,  = second version. IMPORTANT e 2 - DESCRIPTION for more information on the control panels on the ground and in the basket. Select a test area on a firm, level surface that is free of any obstacles. Look around and above you when maneuvering the platform (lifting, rotation, etc.).
  • Page 93 EMERGENCY CONTROLS NOTE: The platform is switched on. The platform is in TRANSPORT position, the jib is completely lowered and the turntable is in NEUTRAL position. - Press the emergency stop button on the basket control panel (OFF position). - Activate all the platform controls one by one using the ground level control panel. Result: •...
  • Page 94 OVERLOAD ALARM NOTE: The platform is switched on. The platform is in TRANSPORT position, the jib is completely lowered and the turntable is in NEUTRAL position. - Place a uniformly distributed load in the basket = between 220 kg and 250 kg. Result: •...

  • Page 95: Working Position

    CONTROLS: DRIVING/BRAKING/STEERING (TRANSPORT POSITION) NOTE: The platform is switched on. The platform is in TRANSPORT position, the jib is completely lowered and the turntable is in NEUTRAL position. NOTE: • ORANGE FLASHING LIGHT option activated: the orange FLASHING LIGHT must come on while the platform is being driven/steered.
  • Page 96 DRIVING ON A SLOPE AND TILT ALARM NOTE: The platform is switched on. The platform is in TRANSPORT position, the jib is in the range and the turntable is in NEUTRAL position. TEST NO. 1 Select a slope between 10% (5.7°) and 20% (11.3°). - Drive the platform forwards slowly on the slope, facing it, with the basket at the bottom of the slope.

  • Page 97: Check Secondary Protection System Sps - First Version "Safemansystem

    CHECK Secondary protection system SPS - first version "SafeManSystem" IMPORTANT Select a test area on a firm, level surface that is free of any obstacles. Shut the platform down if a malfunction is detected. NOTE: The flashing light SPS can be blue or red depending on the country. - Switch the platform on.

  • Page 98: Check Secondary Protection System Sps - Second Version

    - Check the condition of the safety cable SPS ; if there is any doubt about its condition, have it replaced by an approved professional from the Manitou network. - Turn the turntable to the right or left, at the same time pushing the safety cable forward, then release it.

  • Page 99: Check Tightening Of The Wheel Nuts And Bolts (Depending On Version)

    Ü  WEEKLY MAINTENANCE CHECK Tightening of the wheel nuts and bolts (depending on version) IMPORTANT Failure to follow this instruction may result in the platform tipping over. - Check the tightening torque of all the wheel bolts and all the wheel nuts (depending on version): •...

  • Page 100: Lubricate Front Wheel Hubs (Depending On Version)

    LUBRICATE Front wheel hubs (depending on version) - Switch the platform on. - Steer fully to the left. - Locate the lubricator connector on the left wheel hub. If necessary, drive forward/ backward to locate it. - Remove the cap from the lubrication connector. - Inject the lubricant into the lubrication connectors,  LUBRICANTS.

  • Page 101: Battery Electrolyte Specific Gravity

    ÜŒ 50H - MAINTENANCE EVERY 50 HOURS OF SERVICE OR EVERY 3 MONTHS ALSO PERFORM THE DAILY AND WEEKLY MAINTENANCE. CHECK Tightening of the wheel nuts and bolts (depending on version) e WEEKLY MAINTENANCE CHECK Battery electrolyte specific gravity e WEEKLY MAINTENANCE LUBRICATE Front wheel hubs (depending on version) e WEEKLY MAINTENANCE...

  • Page 102: Fully Lower The Mast

    LUBRICATE Mast IMPORTANT Always secure the raised jib and the raised mast using a suitable lifting device. Lubricate the mast more often when the platform is operating in a dusty environment. NOTE: The jib is fully raised and secured. - Switch the platform on. - Raise the mast until the tube is completely visible.

  • Page 103: Clean Electric Motor Brushes According To Model

    CLEAN Electric motor brushes according to model - Remove the right turntable cover by lifting it off. - Remove the two screws and the metal collar. - Remove the screw and clean the brushes of the mini-unit. 3 - 23...
  • Page 104 RESET Maintenance warning NOTE: It is not possible to reset the maintenance warning if it is not displayed. It may be necessary to reset even if no maintenance has been performed. e 2 - DESCRIPTION: MULTI-FUNCTION DISPLAY. NOTE: The platform is switched on. - Activate the basket controls from the ground level control panel - Get into the basket.

  • Page 105: Check Tightening Of The Fixing Screws For The Wheel Reduction Gears

    ܍  100 H - MAINTENANCE EVERY 100 HOURS OF SERVICE OR EVERY 6 MONTHS ALSO PERFORM THE DAILY AND WEEKLY MAINTENANCE AND THE PERIODIC MAINTENANCE AT 50 HOURS OF SERVICE. CHECK Tightening of the fixing screws for the wheel reduction gears IMPORTANT Failure to follow this instruction may result in the platform tipping over.

  • Page 106: Check Overload Alarm

    CHECK Overload alarm IMPORTANT Failure to follow this instruction may result in the platform tipping over. Refer to the platform repair manual if the overload system is not correctly calibrated. NOTE: The platform is switched on. The platform is in TRANSPORT position with the jib lowered completely. The turntable is in NEUTRAL position.

  • Page 107: Check Stopping Distance And Braking On A Slope

    CHECK Stopping distance and braking on a slope IMPORTANT Failure to follow this instruction may result in the platform tipping over. PLACING IN FREEWHEEL MODE NOTE: The platform is switched on. The platform is in TRANSPORT position with the jib lowered completely. The turntable is in NEUTRAL position.

  • Page 108: Mast Setting

    CHECK Mast setting IMPORTANT Failure to follow this instruction may result in the platform tipping over. Refer to the platform repair manual if the dimension measured is greater than 1,700 mm. The platform must be on a level surface and must be anchored to the ground to perform this procedure. NOTE: The platform is switched on.

  • Page 109: Hydraulic Hoses

    CHECK Hydraulic hoses IMPORTANT Always secure the raised jib using a suitable lifting device. Always use a piece of paper or cardboard to check there are no hydraulic oil leaks. Replace any damaged hydraulic hoses. NOTE: The platform is switched on. - Fully raise the jib and secure it using a suitable lifting device.

  • Page 110: Check Tightening Of The Mast Fixing Screws

    ÜŽ  200H - PERIODIC MAINTENANCE - EVERY 200 HOURS OF SERVICE OR 1 YEAR ALSO PERFORM THE DAILY AND WEEKLY MAINTENANCE AND THE PERIODIC MAINTENANCE AT 50 HOURS AND 100 HOURS OF SERVICE. CHECK Tightening of the mast fixing screws IMPORTANT Failure to follow this instruction may result in the platform tipping over and the basket falling.

  • Page 111: Tightening Of The Fixing Screws For The Crown Gear

    CHECK Tightening of the fixing screws for the crown gear IMPORTANT Failure to follow this instruction may result in the platform tipping over. Always secure the raised jib using a suitable lifting device. Always use an inspection pit or a suitable hydraulic ramp to carry out any maintenance operations under the platform chassis.

  • Page 112: First Version

    CHECK Counterweight fixing screw tightening FIRST VERSION: COUNTERWEIGHT WITHOUT FORK POCKET IMPORTANT Failure to follow this instruction may result in the platform tipping over. NOTE: The left and right turntable covers have been removed. - Check the tightening torques for all the fixing screws , left and right-hand sides: •...
  • Page 113 REPLACE Hydraulic fluid REPLACE Hydraulic filter CLEAN Suction strainer IMPORTANT It is recommended that the oil is slightly warm before being changed. Clean the oil can before adding oil to the hydraulic oil tank. Use a clean funnel to add oil to the hydraulic oil tank. NOTE: The left and right turntable covers have been removed.

  • Page 114: Check Condition Of Cylinders

    - CHECK Clearance of slewing ring gear * CHECK Condition of cylinders * CHECK Condition of electric wiring * RESET Maintenance warning e 50H - PERIODIC MAINTENANCE - EVERY 50 HOURS OF SERVICE OR 3 MONTHS. * Consult your dealer. 3 - 34...
  • Page 115 Ü  OCCASIONAL MAINTENANCE REPLACE Wheels IMPORTANT  2 - DESCRIPTION: SPECIFICATIONS and refer to the applicable stickers for information about the total weight of the platform and wheel load. When lifting the platform with a mechanical or hydraulic jack: - Bear in mind that only the rear wheels are braked. - Always use a suitable jack for lifting the platform.
  • Page 116 REAR WHEELS - Loosen the wheel nut slightly - Lift the platform. - Remove the wheel nut and the locking washer - Remove the wheel. - Check that the key is in place. - Put the new wheel in place. - Refit the locking washer , positioning the tabs to the outside of the wheel.
  • Page 117 REPLACE Battery IMPORTANT Replace the battery with a model of the same capacity and the same mass to retain the original performance of the platform. The battery is heavy (215 kg) and must be extracted using a lifting device. SAFETY INSTRUCTIONS - Disconnect the battery in the following order: Negative, then positive.

  • Page 118: First Version

    Ü  OCCASIONAL OPERATION TOW/WINCH Platform IMPORTANT Never tow or winch the platform in WORKING position. Always use an appropriate traction bar to tow the platform. Always use a suitable winch for winching the platform. Before putting the platform into freewheel: - The platform must be on a level surface.
  • Page 119 LIFT Platform Depending on the version, the platform can be lifted using either a lift truck or a crane. VERSION 1: Platform without fork pockets and without anchoring points on the mast. VERSION 2: Platform without fork pockets and with anchoring points on the mast. VERSION 3: Platform with fork pockets and with anchoring points on the mast.
  • Page 120 LIFTING THE PLATFORM USING A LIFT TRUCK (FOR VERSIONS 1 AND 2) IMPORTANT Never lift the platform more than 20 cm from the ground. It is forbidden to use this lifting method to load the platform onto a flatbed or to unload it. This lifting method should only be used on level, even ground.
  • Page 121 LIFTING THE PLATFORM USING A LIFT TRUCK (FOR VERSION 3) IMPORTANT Make sure that the forks are suitable and are solid enough to take the weight of platform. Make sure that the lifting capacity of the lift truck is sufficient to take the weight of the platform. 80 VJR 100 VJR 80 VJR EVOLUTION...
  • Page 122 LIFTING THE PLATFORM USING A CRANE (FOR VERSIONS 1, 2 AND 3) IMPORTANT Make sure that the straps and/or chains are solid enough to take the weight of the platform. Make sure that the lifting capacity of the crane is sufficient to take the weight of the platform. 80 VJR 100 VJR 80 VJR EVOLUTION...

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