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Manitou MLT 961-145 V PLUS L JD ST4 S1, Operator'S Manual

The Manitou MLT 961-145 V PLUS L JD ST4 S1 is a powerful and efficient machine designed for heavy-duty lifting and material handling. Its Operator's Manual is essential for safe and proper usage. Download the manual for free at 88.208.23.73:8080, ensuring you have all the necessary instructions at your fingertips.

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MANDATORY FIRST 500 HOURS OR 6 MONTH SERVICE

FIRST 500 HOURS BEFORE THE FIRST 6 MONTHS

 -If the lift truck completes its first 500 hours of service before the first 6 months are up, carry out the mandatory service 

and the 500 hour periodic maintenance (

e

 

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 500 HOUR - PERIODIC MAINTENANCE - EVERY 500 HOURS OF SERVICE)

FIRST 6 MONTHS BEFORE THE FIRST 500 HOURS

 -If the lift truck has not completed 500 hours of service in the first 6 months, just carry out the mandatory service.

Ü

 MANDATORY SERVICE

 -CHECK  

Gearbox oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16

 -CHECK  

Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16

 -CHECK  

Wheel nut torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-16

 -CHECK  

Waterproofing on front axle differential  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

 -CHECK  

Waterproofing on rear axle differential  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

 -CHECK  

Waterproofing of front wheel reducing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

 -CHECK  

Waterproofing of rear wheel reducing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

 -CHECK  

 Brake oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17

 -CHECK  

Hydraulic oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18

 -CHECK  

Windscreen washer liquid level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18

 -CLEAN  

Radiator grilles  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19

 -CLEAN/CHECK  

Condenser grille (OPTIONAL air conditioning)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19

 -LUBRICATE  

General lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-20

 -CHECK  

Fork wear * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-26

 -CHECK  

Seat belt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-28

 -CHECK  

I.C. engine silent blocks *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Gearbox silent blocks *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Gearbox controls *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Brake circuit pressure *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Wear of boom pads *  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Condition of wiring harness and cables * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Lighting and signalling * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Indicators * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Side rear-view mirror conditions * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Cab structure *  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Structure of the chassis *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Attachment holder table * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

 -CHECK  

Attachment conditions * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-33

* Consult your dealer

* Contact your dealer

Summary of Contents for MLT 961-145 V PLUS L JD ST4 S1

Page 1: ...OPERATOR S MANUAL ORIGINAL INSTRUCTIONS MLT 961 145 V PLUS L JD ST4 S1 649100 EN US AU 20 05 2019 ...

Page 2: ...t 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 This manual is an integral part of the telehandler It is to be kept in its storage space at all times for ease of reference Hand this manual to the new owner if the telehandler is resold CALIFO...

Page 3: ...logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization All rights are reserved 30 05 2018 Update 10 09 2018 1st ISSUE SILICADUSTHAZARD Exposure to crystalline silica found in sand soil and rocks has been associated with silicosis a debilitating and often fatal lung disease Comply with all applicable rules and ...

Page 4: ...RATING AND SAFETY INSTRUCTIONS 2 DESCRIPTION 3 MAINTENANCE 4 OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE 5 LOAD CHARTS FOR INTERCHANGEABLE EQUIPMENT 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 5: ...1 1 1 O P E R AT I N G AND SAFET Y INSTRUCTIONS ...

Page 6: ...1 2 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 7: ...1 3 ...

Page 8: ... 12 E STARTING THE TELEHANDLER 1 13 F DRIVING THE TELEHANDLER 1 13 G STOPPING THE TELEHANDLER 1 14 H DRIVING THE TELEHANDLER ON THE PUBLIC HIGHWAY 1 15 INSTRUCTIONS FOR HANDLING A LOAD 1 16 A CHOICE OF ATTACHMENTS 1 16 B WEIGHT OF LOAD AND CENTRE OF GRAVITY 1 16 C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE 1 16 D TRANSVERSE ATTITUDE OF THE TELEHANDLER 1 17 E TAKING UP A LOAD ON THE GROUND 1...

Page 9: ...C SYSTEM 1 29 ELECTRICITY 1 29 WELDING 1 29 WASHING THE TELEHANDLER 1 29 TRANSPORTING THE TELEHANDLER 1 29 IFTHETELEHANDLERISNOTTOBEUSEDFORALONGTIME 1 30 INTRODUCTION 1 30 PREPARING THE TELEHANDLER 1 30 DEF Diesel Exhaust Fluid TANK 1 30 PROTECTING THE ENGINE 1 30 PROTECTING THE TELEHANDLER 1 30 BRINGING THE TELEHANDLER BACK INTO SERVICE 1 31 TELEHANDLERDISPOSAL 1 32 RECYCLING OF MATERIALS 1 32 ME...

Page 10: ...lights reverse buzzer alarm front light rear light light at the jib head etc according to the telehadler model The operator must take into account the operating conditions to specify the telehadler s signaling and lighting equipment Contact your dealer Take into account climatic and atmospheric conditions of the site of utilisation Protection against frost e 3 MAINTENANCE LUBRICANTS AND FUEl Adapt...

Page 11: ...MLT range that are EC type approved tractors agricultural tractor typeT1a point 5 1 1 of Article R311 1 of the French Highway Code The truckmustberegistered SPECIAL INSTRUCTION APPLYING TO EC TRACTOR TYPE APPROVED TELEHANDLERS All EC tractor type approved telehadlers are supplied with an EC tractor certificate complying with directive 2003 37 EC to be retained by the owner and a page of administra...

Page 12: ...sonnel e your dealer and under the necessary safety conditions to maintain the health of the operator and any third party tIMPORTANT t Yourtelehadlermustbeinspectedperiodicallytoensurethatitremainsincompliance Thefrequencyofthisinspectionisdefinedbycurrentlegislationinthecountryinwhichthetelehadlerisused Example for France The manager in charge of the establishment using a telehadler must open and...

Page 13: ...1 9 Page intentionally left blank ...

Page 14: ...f the telehadler by another person C MAINTENANCE The operator must immediately advise his superior if his telehadler is not in good working order or does not comply with the safety notice The operator is prohibited from carrying out any repairs or adjustments himself unless he has been trained for this purpose He must keep the telehadler properly cleaned if this is among his responsibilities The o...

Page 15: ... wear ear muffs to protect against excessive noise Always face the telehadler when getting into and leaving the driving seat and use the handle s provided for this purpose Do not jump out of the seat to get down Always pay attention when using the telehadler Do not listen to the radio or music using headphones or earphones Never operate the telehadler when hands or feet are wet or soiled with grea...

Page 16: ...alelectricalagency Youcouldbeelectrocutedorseriouslyinjuredifyouoperateorparkthetelehadlertooclosetopowercables Intheeventofhighwinds donotcarryouthandlingworkthatjeopardisesthestabilityofthetelehadleranditsload particularlyiftheloadcatchesthewindbadly Prevent fire risks associated with use in dusty and flammable conditions e g straw flour sawdust organic waste etc D VISIBILITY The safety of peopl...

Page 17: ...rrect display stop the engine and immediately carry out the necessary operations F DRIVING THE TELEHANDLER SAFETY INSTRUCTIONS tIMPORTANT t Operators attentionisdrawntotherisksinvolvedinusingtheforktelehadler inparticular Riskoflosingcontrol Riskoflosinglateralandfrontalstabilityoftheforktelehadler Theoperatormustremainincontrolofthetelehadler Intheeventofthetelehadleroverturning donottrytoleaveth...

Page 18: ...ingandno oneobstructingthetelehadler spath Releasetheservicebrakepedalandincreasetheenginerevs Theriskisincreasedifthetelehadlerisladenortowingatrailer requiringextremevigilance G STOPPING THE TELEHANDLER SAFETY INSTRUCTIONS Never leave the ignition key in the telehadler during the operator s absence When the telehadler is stationary or if the operator has to leave his cab even for a moment place ...

Page 19: ...telehadler e 2 DESCRIPTION CONTROL AND COMMAND INSTRUMENTS Fully retract the jib and set the attachment approximately 300 mm 11 8 in off the ground Place the roll corrector in the central position i e the transverse axis of the axles parallel to the chassis as model of telehadler Fully raise the stabilizers and turn the blocks inwards according to model of telehadler tIMPORTANT t Nevermoveinneutra...

Page 20: ...vity e g liquids takeaccountofthevariationsinthecentreofgravityinorder todeterminetheloadtobehandledandbeextravigilantandcarefultolimitthesevariationsasfaraspossible C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE This device gives an indication of the longitudinal stability of the telehadler and limits hydraulic movements in order to ensure this stability at least under the following operatin...

Page 21: ... two lines e2 DESCRIPTION CONTROL AND COMMAND INSTRUMENTS In this position the two front wheels must be off the ground E TAKING UP A LOAD ON THE GROUND Approach the telehadler perpendicular to the load with the jib retracted and the forks in a horizontal position fig E1 Adjust the fork spread and centering relative to the load to ensure stability fig E2 optional solutions exist consult your dealer...

Page 22: ...l go by alternately extending and lowering the jib 1 or if necessary moving the telehadler forward 2 fig F2 Apply the handbrake and place the forward reverse selector in neutral Slightly raise the load 1 and tilt the carriage 2 backwards to stabilize the load fig F3 Tilt the load sufficiently backwards to ensure its stability Monitor the longitudinal stability limiter and warning device eINSTRUCTI...

Page 23: ...ITY LIMITER ANDWARNING DEVICE If necessary move the telehadler 3 forward fig F7 driving very slowly and carefully Place the load in a horizontal position and lay it down on the pile by lowering and retracting the jib 1 2 in order to position the load correctly fig F8 If possible release the fork by alternately retracting and raising the jib 1 fig F9 Then set the forks into transport position If th...

Page 24: ...PORTANT t Thisoperationmustbeexceptionalandperformedwithgreatcare Raise the jib and retract the telescopes completely Set the telehadler in position in front of the elevation fig G2 moving very slowly and carefully Apply the parking brake and place the forward reverse selector in neutral Move the stabilizers very slowly and gradually as soon as they are close to the ground or in contact with it Lo...

Page 25: ... If it is overloaded set the load back down in the place from which it was taken If possible lower the load without moving the telehadler Raise the jib 1 to release the load retract 2 and lower the jib 3 to set the load into transport position fig G8 SETTING DOWN A HIGH LOAD ON STABILISERS Raise and extend the jib 1 2 until the load is above the elevation fig G9 while monitoring the longitudinal s...

Page 26: ...er gently and smoothly to minimise swinging of the load Carry the load a few centimetres above the ground max 30 cm 11 8 in the shortest possible jib length Do not exceed the offset indicated on the load chart If the load begins to swing excessively do not hesitate to stop and lower the jib to set down the load Before moving the telehadler check the longitudinal stability limiter and warning devic...

Page 27: ...toavoidspillingproductandensureitsstability lossofproductunderbraking LOADING A TRAILER Approach the side of the trailer in the transport position fig A3 Raise and extend the boom 1 2 until the bucket is above the trailer while monitoring the longitudinal stability limiter and warning device eINSTRUCTIONS FOR HANDLING A LOAD C LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE fig A4 Drive the tele...

Page 28: ...h the emplacement and operation of all control instruments prior to operating the platform Check before use that the platform has been correctly assembled and locked onto the telehadler Check before operating the platform that the access gate has been properly locked The platform should be operated in an area free of any obstructions or danger when it is lowered to the ground The operator using th...

Page 29: ...sdifficult Largerwavesforming whitecapseverywhere somespray 7 Neargale 28 33 50 61 13 9 17 1 Wholetreesinmotion inconveniencefeltwhen walkingagainstthewind Seaheapsup whitefoamfrombreakingwaves beginstobeblowninstreaksalongthedirection ofthewind 8 Gale 34 40 62 74 17 2 20 7 Windbreakstwigsofftrees impedesprogress Moderatelyhighwavesofgreaterlength edges ofcrestsbegintobreakintospindrift 9 Strongga...

Page 30: ...sible place The user must ensure that the instruction manual is accessible at all times and that operators have read and understood it INSTRUCTIONS Take up position in a stable place with no risk of slipping Before using the transmitter make sure there is nobody within the working area Only use the transmitter with its carrying device or installed correctly on the platform tIMPORTANT t Whenyouremo...

Page 31: ...1 27 ...

Page 32: ...the rod of the lifting cylinder and secure with the rod 2 and the pin 3 Slowly lower the jib then stop the hydraulic movements before it comes into contact with the wedge REMOVING THE WEDGE Fully raise the jib Remove the pin and the rod Return the safety wedge to the storage location provided on the telehadler tIMPORTANT t Onlyusethewedgesuppliedwiththetelehadler MAINTENANCE Perform the periodic s...

Page 33: ...ttery Disconnect the battery before working on the electrical circuit WELDING Disconnect the battery before any welding operations on the telehadler When carrying out electric welding work on the telehadler 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 of...

Page 34: ...up to the bottom of the filler neck Start up the telehadler to pressurise the circuit and bring it up to working temperature then shut down the engine If necessary top up the tank PROTECTINGTHEENGINE Contact your dealer to obtain the procedure for protecting the inside of the engine use of protection product Fill the fuel tank Empty and replace the cooling liquid e3 MAINTENANCE 2000 HOUR PERIODIC ...

Page 35: ...OUR PERIODIC MAINTENANCE EVERY 500 HOURS OF SERVICE OR EVERY 1 YEAR according to model of telehadler Drain and rinse the DEF tank according to model of telehadler Slowly fill the tank with new DEF Diesel Exhaust Fluid up to the bottom of the filler neck according to model of telehadler Refit and set the tension in the drive belts e 3 MAINTENANCE FILTER CARTRIDGES AND BELTS Turn the engine over wit...

Page 36: ...TECTION By entrusting the maintenance of your telehadler to the MANITOU network the risk of pollution is limited and the contribution to environmental protection contribution is made WORN OR DAMAGED PARTS Do not dump them in the countryside MANITOU and its network have signed up to a scheme of environmental protection through recycling USED OIL The MANITOU network organizes the collection and proc...

Page 37: ...2 1 2 DESCRIPTION ...

Page 38: ...2 2 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 39: ...ATIONOFCONFORMITY 4 SAFETYPLATESANDSTICKERS 6 IDENTIFICATIONOFTHETELEHANDLER 10 TECHNICALFEATURES 14 FRONTANDREARTYRES 17 DIMENSIONS 18 LOADCHART 19 VISIBILITY 20 INSTRUMENTSANDCONTROLS 22 TOWINGDEVICES 56 DESCRIPTIONANDUSEOFOPTIONS 62 ...

Page 40: ... T T TI I I I I I I I I IO O O O O O O O O ON N N N N N N N N N O O O O O O O O O OF F F F F F F F F F C C C C C C C C C CO O O O O O O O O ON N N N N N N N N NF F F F F F F F F FO O O O O O O O O OR R R R R R R R R RM M M M M M M M M MI I I I I I I I I IT T T T T T T T T TY Y Y T TY Y TY TY Y Y Y Y Y Y o o o o o o o o o or r r r r r r r r ri i i i i i i i i ig g g g g g g g g gi i i g gi i gi gi ...

Page 41: ...to 6 Dichiara che questa macchina 7 È conforme alle direttive seguenti e alle relative trasposizioni nel diritto nazionale 8 Per le macchine Allegato IV 9 Numero di Attestazione 10 Organismo notificato 15 norme armonizzate applicate 16 altre norme e specifiche tecniche applicate 17 Stabilita a 18 Data 19 Nome del firmatario 20 Funzione 21 Firma lt 1 CE atitikties deklaracija originalas 2 Bendrovė ...

Page 42: ...terreplacinganyspareparts EXTERNALPLATESANDSTICKERS REFERENCE CODE DESCRIPTION 1 296740 towing instructions 2 934233 towing point 3 52588111 rear centralised greasing points 4 52588086 rear centralised greasing points 6 52567646 emergency exit 7 296741 non walking surface 8 53017705 rim tightening torque 9 024653 lifting points 10 52563320 fixing points 649100 EN US AU 20 05 2019 MLT 961 145 V PLU...

Page 43: ...ctrocution 6 307508 battery disconnecting switch 7 932067 hydraulic oil level point 8 52514555 hydraulic oil level gauge 9 52518323 battery maintenance 15 53017705 rim tightening torque 16 52563320 fixing points 17 024653 lifting points 18 234805 instructions for the hydraulic coupling 19 296998 do not stand under or over the forks 21 932084 DEF tank ...

Page 44: ...ke 15 52518186 PowerBox fuse plate 16 288430 repair instructions 17 716925 Pressurised fluid hazard 18 716906 danger of hand shearing 19 52518323 electrical danger 20 52501046 engine coolant 21 716905 Danger hot surface 22 716926 Risk of leakage of the coolant 23 259398 water fuel separator 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 45: ...l position for the exclusion of the anti tilting system of the telehandler 14 52619897 fuse box functions 15 932117 do not drill and weld telehandler parts 16 239594 sound power 17 268491 Instructions brake circuit oil 18 261307 operator instructions sheet 19 52569941B joystick function According to equipment 19 52623222 joystick function According to equipment 20 52586309 load chart tyre Alliance...

Page 46: ...ther technical information regarding your telehandler refer to chapter 2 DESCRIPTION CHARACTERISTICS TELEHANDLERMANUFACTURER SPLATE Designation Series Yearofmanufacture Modelyear SerialNumber ProductIdentificationNumber Unladenmass Power Authorizedgrossvehicleweight Ratedcapacity Maxverticalforce ontrailerhook Dragstrain TRACTORAPPROVALPLATE Category HomologationN ProductIdentificationNumber Total...

Page 47: ... 11 GEARBOX Type SerialNo MANITOUReference FRONTAXLE Type SerialNo MANITOUReference REARAXLE Type SerialNo MANITOUReference CAB Manufacturer Cabintype Serialnumber BOOM MANITOUReference Dateofmanufacture ...

Page 48: ...Number ProductIdentificationNumber ATTACHMENTMANUFACTURER SPLATE MODEL Serialnumber Yearofmanufacture Unladenweight Centreofgravity Ratedcapacity Pressionservice 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

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Page 50: ...SION Hydrostatic pump Type Variable displacement pistons Displacement cm3 L 85 0 085 Max flow rate l min 280 Operating pressure bar psi 450 6526 71 Hydrostatic motor 1 Type Variable volume Capacity min max cm3 rev 0 to 115 Hydrostatic motor 2 Type Variable volume Capacity min max cm3 rev 20 to 60 Gearbox Type Mechanical with hydraulic drive Number of forward speeds 1 Number of reverse speeds 1 Spe...

Page 51: ...hydraulic NOISE AND VIBRATION Sound pressure level at the driver s seat LpA compliantwithNFEN12053 dB A 80 cab closed Sound pressure accordingtodirective2009 76 dB A cab closed cab open Sound pressure level ensured in the environment LwA accordingtodirective2000 14 ECmodifiedbydirective2005 88 EC dB A 104 measured 104 guaranteed Sound level in motion accordingtodirective2009 63 dB A Average weight...

Page 52: ... Weight with forks kg lb 200 440 92 Weight of forks each kg lb 78 171 96 Rated capacity with standard attachment kg lb 6000 13227 73 Capacity at maximum height with standard attachment with tyre MICHELIN500 70 R24164A8 164BINDTLBIBLOAD kg lb 5000 11023 1 Capacity at maximum reach with standard attachment kg lb 1400 11023 1 Distance from centre of gravity of the load to fork base mm in 600 23 62 St...

Page 53: ... 4 5 65 26 ALLIANCE 600 55R26 5 380 5 72 51 MITAS 17 5 R25EM60171B 7 101 52 SOLIDAIR TLH14 R24 PRESSURE bar psi WITHLOAD kg lb PRESSURETOTHEGROUND kg cm2 GROUNDCONTACTSURFACE cm2 COMPACTSOIL CRUMBLINGSOIL COMPACTSOIL CRUMBLINGSOIL ALLIANCE 500 70 R24AGRO IND RADIALR 4 580 4 4 63 81 MICHELIN 500 70 R24INDTL 164A8 BXMCL 4 4 63 81 TRELLEBORG 500 70 R24164A8 164B TH400 4 4 63 81 MICHELIN 500 70 R24164...

Page 54: ...490 19 29 H 7 H1 7 I 1459 57 44 J 995 39 17 L 60 2 36 N 1891 74 45 O 200 7 87 P2 42 P3 23 R 4050 159 45 S 8654 340 71 T 4168 164 09 U1 2530 99 61 U2 2670 105 12 V 5492 216 22 V1 1325 52 17 V2 4303 169 41 W 2482 97 72 Y 12 Z 138 DIMENSIONS D2 B G2 G1 P2 D C C1 D1 A E I N G L Z Y U1 U2 P 3 F1 F W J S V T V 1 V2 R O K H H1 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 55: ...2 19 LOAD CHART ...

Page 56: ...TIONANDADJUSTMENTOFREAR VIEWMIRRORS 1 LEFT REAR VIEW MIRROR 2 MAIN RIGHT REAR VIEW MIRROR 3 CENTRAL RIGHT REAR VIEW MIRROR 4 UPPER RIGHT REAR VIEW MIRROR 5 REAR REAR VIEW MIRROR Place the telehandler on level ground with the I C engine stopped and the telescopic boom retracted and lowered as far as possible Note the position of the reference points in the illustrations to e and correctly adjust th...

Page 57: ...INDSPOTZONES In accordance with EN15830 the two diagrams indicate blind spot zones on the visibility test circle r 12m and the 1m rectangular zone around the telehandler r 12 m 9 5 m 45 45 A F E D B C C 2200 50 600 mm 1 m 1000 50 r 12 m 9 5 m 45 45 A F E D B C A F E D B C A F E D B C ...

Page 58: ...10 24 22 INSTRUMENTS AND CONTROLS 18 18a 13 23 14 26 8 11 8 9 25 25 26 29 30 31 31 28 37 3 35 25 6 7 6 25 17 1 2 20 20 22 22 12 51 21 41 4 39 39 25 15 19 16 37 38 43 44 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 59: ...OLS 45 21 I C ENGINE SPEED REGULATOR 46 22 HYDRAULIC FLOW ADUSTMENT CONTROL 46 23 HEATER AND CONDITIONER CONTROLS OPTIONAL 47 24 PARKING BRAKE LEVER 47 25 HEATING VENTS 47 26 DEMIST VENTS 47 27 STEERING SELECTION LEVER 48 28 DOOR OPEN LEVER 48 29 DOOR CLOSE HANDLE 48 30 WINDOW REGULATOR SWITCH 48 31 SIDE STORAGE SPACE 48 32 CEILING LIGHT 48 33 HANDLE FOR REAR WINDOW OPENING 48 34 HANDLE FOR REAR W...

Page 60: ...ng First check on a hidden area how the fabric reacts to normal fabric and plastic detergents DRIVER SPNEUMATICSEAT PREMIUM FOR GREATER COMFORT THIS SEAT ALLOWS SEVERAL ADJUSTMENTS SEAT WEIGHT AND HEIGHT ADJUSTMENT ADJUSTING THE WEIGHT Adjust the seat for the driver s weight by sitting on it Switch on lift truck ignition Lift or press lever 1 until the green light of indicator light 2 appears indi...

Page 61: ... travel HORIZONTAL DAMPER In certain conditions e g driving with a trailer it is advised to use the horizontal shock absorber 2 The driver seat will be able to dampen shocks in the travelling direction better Position A damper disengaged Position B horizontal damper engaged EXTENDING THE BACK REST The height of the back rest 3 can be adjusted by pulling it upwards the notches will click up to the ...

Page 62: ...eatbeltisdefective fixing locking cuts tears etc Repairorreplacetheseatbeltimmediately Sit correctly on the seat Check that 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 3 IGNITIONSWITCH tIMPORTANT t THEI C enginecanbestartedonlyiftheoperatorissittingon...

Page 63: ...ights F GREEN WARNING LIGHTS FOR WHEEL ALIGNMENT E 2 DESCRIPTION 22 STEERING SELECTION G DIGICODE INDICATOR LIGHT This light flashes when the digicode is enabled e 2 DESCRIPTION 6D DISPLAY H I C ENGINE WATER LEVEL AND TEMPERATURE LIGHT COLD ENGINE If the H1 light comes on when the telehandler is running this means that the cooling liquid level is too low Immediately stop the I C engine and check t...

Page 64: ...C engine immediately and look for the cause possible leak etc BRAKE FLUID LEVEL OR BRAKING FAULT INDICATOR LIGHT If the light comes on when the telehandler is running stop the I C engine immediately and search for the cause check proper brake oil level pressure of the braking circuit or any leaks servobrake fault front axle brake fault rear axle brake fault brake accumulator fault brake booster fa...

Page 65: ...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 light remains on stop the telehandler and contact your dealer NOTE Abnormal heating of the oil may be linked to an incorrect use of the gear box ratios e 2 DESCRIPTION 21 GEAR SELECTOR PARKING BRAKE INDICATOR...

Page 66: ...e air flow The button is constantly lit as soon as automatic mode is activated tIMPORTANT t Duringoperation payattentiontotheriskofmaterialbeingprojectedwhencleaningthegrilles Wearsuitableprotectivegoggles A short press on the button launches an individual fan reversal cycle The screen i appears when there is insufficient time between two individual ventilation fan reversal cycle requests Holding ...

Page 67: ... SCREEN System initialising A beep is sounded when this screen appears If the screen remains permanently displayed contact your dealer DIGIC 0 0 _ _ DIGICODE SCREEN The digicode is disabled by default It can be enabled from the OPT menu on the menu screen A beep is sounded when this screen appears Switch on the telehandler ignition Enter the code default 0000 using the keys on the keyboard and con...

Page 68: ...ter treatment system Flashingindicator additivelevel 10 e HELPSCREEN FAULTSCREEN 1 Whitescreen Nofunctionreleasedandatleastafunctionlocked edefault screen Atleastonefunctionreleased edefaultscreen 2 Whitescreen Attachmentcircuitlocked Flashingscreen Requiredattachmentincontinuousmodecircuitnotactive Steadyscreen Attachmentincontinuousmodecircuitactive 3 Whitescreen Flashingscreen Requestedboomsusp...

Page 69: ...modeoftheexhaust particulatefilteractive e 2 DESCRIPTION 8 SWITCHES i AUTO OFF Highsootlevelinautomaticregenerationmodeoftheexhaust particulatefilterinactive e 2 DESCRIPTION 8 SWITCHES i Moderatesootlevelinautomaticregenerationmodeofthe exhaustparticulatefilteractive e 2 DESCRIPTION 8 SWITCHES i AUTO OFF Moderatesootlevelinautomaticregenerationmodeofthe exhaustparticulatefilterinactive e 2 DESCRIP...

Page 70: ...ion of the telehandler safer e g unlocking the fault condition of the hydraulic valve to withdraw and lower the boom This unlock remains temporarily active the function is locked again when power supply to the I C engine is cut off Forbiddenboomliftingfault Hydrauliccontrolfault Fuelindicatorfault STOP Exhaustparticulatefiltercloggedfault ExhaustgasemissioncontrolsystemandSCRsystemderating Level2 ...

Page 71: ...al in the DEF tank lower than the minimum limit FluidtemperaturesignalintheDEFtankhigherthanthemaximumlimit FluidtemperaturesignalintheDEFtanklowerthantheminimumlimit Loss of communication with after treatment inlet NOx sensor Fault of the after treatment inlet NOx sensor Loss of communication with after treatment outlet NOx sensor Fault of the after treatment outlet NOx sensor DEF dosing injector...

Page 72: ...ed Overview DEF LEVEL INDICATOR Warning Description 100 50 75 25 DEF level OK DEF level low DEF level depleted Warnings and indicators for the DEF level status and relevant SCR derating Overview SCR DERATING DEF level Indicators Consequences Warning Limitation to diesel emissions 1 Engine performance limitations 50 decrease of torque 50 decrease of engine speed Limitation to diesel emissions 2 Eng...

Page 73: ...OW Forced operation without driver presence permitted or not permitted by default LLMC Disabling of aggravating hydraulic movement cut off permitted by default or not permitted PASS Fault override permitted or not permitted by default UNIT Speed of travel displayed in MPH or Km h by default DIGI1 Digicode enabled or not enabled by default DIGI2 Change the 4 figure digicode telehandler start up CUS...

Page 74: ...forward tip over when making aggravating movements is ensured except when the telescopic boom is retracted and or the telehandler is moving DEVICESTATUS HALTED SLOWSPEED1to5km h SPEED 5km h TELESCOPICBOOM S INRETRACTED POSITION A4 A5 Veryslowintermittentsound alarm A6 Slowintermittentsoundalarm A7 Fastintermittentsoundalarm A8 Veryfastintermittentsoundalarm A7 Fastintermittentsoundalarm A8 Veryfas...

Page 75: ...tip over when making aggravating movements is ensured except when the telescopic boom is retracted DEVICESTATUS HALTED SLOWSPEED1to5km h SPEED 5km h TELESCOPICBOOM S INRETRACTED POSITION BUCKET mode is disabled if the telehandler remainsstationary A6 Anaudiblesignalonpassingintothered zone Hydraulicmovementsareadjusted Nosoundalarm Hydraulicmovementsareadjusted Nosoundalarm WarninglightA9lit A9 Kg...

Page 76: ...elybythedynamicstabilityofthetelehandler Authorization of this function can be configured from the OPT menu in the menu screen In some cases to get out of a delicate situation the operator can bypass this safety feature Selector C1 and C2 temporarily disables the cut off of AGGRAVATING hydraulic movements Keep pressed or rotated the selector C1 or C2 timer of 60 seconds indicator lamp A9 lamp will...

Page 77: ...m is lower than 21 e 7D DISPLAY The telehandlers are provided with a device for levelling the chassis in relation to the ground in order to allow the levelling of the telehandler and therefore the lifting of the boom to the maximum height in complete safety and stability This device allows to correct the level by 7 to the right and 7 to the left Use of the device Checking the relevant spirit level...

Page 78: ...has been re enabled MANAGEMENTOFEXHAUSTPARTICLEFILTERREGENERATION INDICATIONS ACTIONS i 1shortbeep Moderatesootlevel The screen appears on the operating display the switching on of the indicator light andthespeedingupoftheengineidlingspeedindicatesthatautomaticregeneration isinprogress NOTE Preferablywaituntilautomaticregenerationiscompletedbeforeswitchingofftheignition i AUTO OFF 1shortbeep Moder...

Page 79: ...nd rear option power supply F15 CSS control power supply F16 Boom working headlight control cabin option control power supply F17 Rear working headlight control power supply F18 Rear window defrosting control power supply F19 Roof windscreen wiper windscreen washer spray nozzle F20 Power windows F21 Ceiling light door closed contact operator on driving seat contact F22 Dashboard power supply F23 T...

Page 80: ... ECM computer 30A MINIFUSE F51 Diagnostic socket 10A 13 DOORPRESENCESENSORS e 2 DESCRIPTION 6 HUMAN MACHINE INTERFACE HMI 14 CIGARETTELIGHTER move the emergency brake release and push the lever forward position B 15 EMERGENCYBRAKELEVER To prevent accidental loosening or release the lever is fitted with safety locking The emergency brake lever is used in case of malfunction of the parking brake at ...

Page 81: ...ds the horn NOTE Positions D E F G can be activated without the contact being activated 17 FRONTANDREARWINDSCREENWIPERSWITCH FRONT WINDSCREEN WIPER A Front windscreen wiper stop B Slow speed for front windscreen wiper C Fast speed for front windscreen wiper D Front windscreen wiper intermittent control E Front windscreen washer pulse driven REAR WINDSCREEN WIPER F Rear windscreen wiper stopped G R...

Page 82: ...when using the telescopic handler If necessary reactivate the hydraulic movements by pressing the hydraulic movements enable button LIFTING THE LOAD Move lever A backward to lift Move lever A forward to lower TILTING THE LOAD Move lever A to the left to tilt the load upward Move lever A to the right to tilt the load downward TELESCOPIC MOVEMENTS Move button B forward to extend the load Move button...

Page 83: ...tion of driver presence e 2 DESCRIPTION 6 HUMAN MACHINE INTERFACE HMI When operating this control the telehandler should be travelling at slow speed and not accelerating FORWARD GEAR Push the switch forward position A indicator light A1 will flash then remain steady the moment you press on the accelerator pedal REVERSE GEAR Push the switch backward position B indicator light B1 will flash then rem...

Page 84: ...e operating mode that meets his needs The handling mode allows having the maximum progression and torque performance for all heavy duty handling and loading operations The road travel mode which is much more dynamic and fast is ideal for all other uses where speed is important In both modes the maximum travel speed is 40 km h Select the operating mode press the key briefly LED on to enable the han...

Page 85: ...ows achieving the full hydraulic flow in the attachment circuit 25 STEERINGSELECTION A WHEEL ALIGNMENT GREEN INDICATOR LIGHTS tIMPORTANT t Beforeselectingoneofthethreepossiblesteeringpositions bringall4wheelsintoalignmentwithregardstothe telehandleraxle Neverchangedirectionmodewhiletravelling These green lights come on to indicate the alignment of the wheels in relation to the telehandler Indicato...

Page 86: ...urown A FAN KNOB This 4 speed control allows the air to be ventilated through the air vents B TEMPERATURE ADJUSTMENT KNOB Adjusts the temperature inside the cab B1 The fan pumps in cold air B2 The fan pumps in warm air Middle positions are used to adjust the temperature C AIR CONDITIONING CONTROL This control with a pilot light allows the air conditioning unit to be switched on HEATING MODE The co...

Page 87: ...ot possible to exit from the cab door 37 HANDLEFORREARWINDOWCLOSING 38 STEERINGWHEELADJUSTMENTKNOB This handle enables the angle and height of the steering wheel to be adjusted Pull the knob backwards Adjust the steering wheel to the desired position Push the knob back to lock the steering wheel in position 30 LEVELINDICATOR Enables the operator to check that the telehandler is in the horizontal p...

Page 88: ...light H Right rear indicator tIMPORTANT t Whendrivingontheroad widentherearlightsbymeansofthe thumbscrews 39 DOCUMENTHOLDERNET Make sure that the operator s manual is in the right place i e in the document holder net NOTE An OPTIONAL waterproof document holder exists 40 STORAGECOMPARTMENT 41 ARMRESTADJUSTMENT The armrest adjustment positions the controller tIMPORTANT t Makesurethatthearmrest sposi...

Page 89: ...T EMERGENCY HAMMER Use the emergency hammer to break one of the windows in the event that it is impossible to exit the cab by the door or by opening the rear window 46 BOOMSAFETYLOCK tIMPORTANT t Onlyusethewedgesuppliedwiththetelehandler The telehandler is equipped with a boom safety wedge that must be installed on the rod of the lifting cylinder when working beneath the boom e 1 OPERATING AND SAF...

Page 90: ...ionwithatankcontaininglittleornofluidmayhaveconsequences fortheI C engineperformance If necessary add diesel exhaust fluid e3 MAINTENANCE LUBRICANTS AND FUEL Remove the plug 1 Slowly fill the tank to the bottom of the filling chute Always keep a proper level to limit the alteration of the product Refit the cap DEF Diesel Exhaust Fluid QUALITY The quality of diesel exhaust fluid can be measured wit...

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Page 92: ...ustremainpermanentlyvisibletothedriverandwaituntilthetelehandlerhasstopped the handbrakeisonandtheI Cengineisswitchedoffbeforeperformingtheoperation Located at the rear of the telehandler this device is used to attach a trailer Its capacity is limited for each telehandler by the authorized gross vehicle weight tractive effort and maximum vertical force on the coupling point This information is giv...

Page 93: ... the trailer 3 AUTOMATICTOWINGHOOK OPTIONAL tIMPORTANT t Whenreleased ensurethatthetrailerstandsonitsown COUPLING THE TRAILER Remove the automatic towing pin using lever 1 Move the lift truck backwards so that the trailer ring slots into the automatic hook NOTE The pin closes automatically when the trailer ring touches the end of the yoke The pin can be lowered by hand using lever 1 UNCOUPLING THE...

Page 94: ...er touches the bottom part of the hook The hook can be lowered by hand using lever 3 UNCOUPLING THE TRAILER Lift the hook using lever 3 to uncouple the trailer 6 AUTOMATICTOWINGJOINTONCOUPLINGLADDER OPTIONAL tIMPORTANT t Payattentiontotheriskofpinchingorcrushingduringthisoperation Whenreleased ensurethatthetrailerstandsonitsown Position the lift truck as near as possible to the trailer ring ADUSTI...

Page 95: ...tion or remove the hook of the trailer on the fixed pin Refit block 4 pin 3 and pin 2 8 FIXEDTOWINGHOOK HOOKONCOUPLINGLADDER OPTIONAL tIMPORTANT t Payattentiontotheriskofpinchingorcrushingduringthisoperation Donotforgettoputpinbackinplace Whenreleased ensurethatthetrailerstandsonitsown COUPLING AND UNCOUPLING THE TRAILER Position the lift truck as near as possible to the trailer ring Apply the han...

Page 96: ...ate the roller 1 on the joystick forward to release the locking pin of hook 2 Pull lever 3 and keep this position Actuate the roller 1 on the joystick backward to lower the towing hook Release lever 3 Couple or uncouple the trailer Actuate the roller 1 on the joystick forward to fully lift the towing hook Then actuate the roller 1 on the joystick backward to bring the locking pin on hook 2 3 2 4 1...

Page 97: ...SL Connect the brake pipe to the line CL 1 of the truck Connect the brake release pipe to the line SL 2 of the truck Check proper operation of the trailer brakes and familiarise yourself with the effects of braking before using it on public roads 12 TRAILERBRAKESYSTEM COMPRESSEDAIR OPTIONAL TRAILER BRAKE WITH SINGLE LINE CL Connect the brake pipe to the line CL 1 of the truck Check proper operatio...

Page 98: ...LIGNMENT 63 4 EXTERNALLOSSRETURN 64 5 EASYATTACHMENTHYDRAULICCONNECTION ECS 64 6 FORCEDMODEOFTHEATTACHMENTCIRCUIT 65 7 BOOMSUSPENSION 66 8 ATTACHMENTHYDRAULICLOCK 66 9 BOOMHEADSOLENOIDVALVE 67 10 BOOMHEADSOLENOIDVALVE LOCKINGHYDRAULICATTACHMENT 68 11 FORSINGLE ACTINGREARHYDRAULICCONTROLFITTING 69 12 DUAL ACTINGREARHYDRAULICCONTROLFITTING 69 13 INTELLIGENTHYDRAULICS 70 14 COMFORTSTEERINGSYSTEM 70 1...

Page 99: ...ngethesteeringmodeabove11km h Incaseoffaults contactyourdealer WHEEL ALIGNMENT GREEN INDICATOR LIGHTS These green lights come on to indicate the alignment of the wheels in relation to the telehandler Indicator light A1 is for the front wheels and indicator light A2 for the rear wheels CHANGING THE STEERING MODE Directional front wheels road travel Directional front and rear wheels in opposite dire...

Page 100: ...asily connecting and disconnecting the attachment hydraulically OPERATION Switch on telehandler ignition Press on the button for two seconds to release the attachment circuit hydraulic pressure screens i i i i will be alternately displayed Connect or disconnect the rapid connectors of the hydraulic attachment e 4 OPTIONALATTACHMENTSFORUSEWITHTHERANGE PICKINGUPTHEATTACHMENTS B A 649100 EN US AU 20 ...

Page 101: ...HMENT CIRCUIT HYDRAULIC FLOW RATE IN CONTINUOUS MODE The pictogram flashes and switches to the setting screen XX as soon as hydraulic flow rate is selected using button A on the attachment hydraulic control lever Button A forward for positive percentage XX backward for negative percentage XX Hold button A in the same position for 4 seconds to confirm the chosen hydraulic flow rate i XX Press butto...

Page 102: ...cel AUTOMATIC Confirm FORCED 2 1 F o r c e d Activation permanent Press 1 2 O F F Cancel FORCED Confirm OFF 1 2 A u t o m a t i c Cancel FORCED Confirm AUTOMATIC Note in FORCED mode it returns to AUTOMATIC mode if contact is interrupted with the key switch 8 ATTACHMENTHYDRAULICLOCK Enables the attachment to be locked onto the TS and a hydraulic attachment to be used by the same hydraulic circuit t...

Page 103: ...lic functions on the attachment circuit ATTACHMENT LINE L1 CONTROL Move button 1 forward or backward ATTACHMENT LINE L2 CONTROL Accordingtoequipment Keep pressed button 2 and operate button 1 forward or backward L1 L1 L2 L2 2 1 OK OK 2 1 Accordingtoequipment ...

Page 104: ...t on the table ATTACHMENT LINE L1 CONTROL Bring cock 3 to position A Press button 1 forward or backward ATTACHMENT LINE L2 CONTROL Bring cock 3 to position A Keep pressed button 4 and operate button 1 forward or backward ATTACHMENT LOCKING CONTROL Bring cock 3 to position B Keep button 4 pressed and move button 2 forward to lock the attachment and backward to release it L2 L1 L1 L2 3 4 1 OK OK 4 1...

Page 105: ...ulic control Press button 2 forward or backward 12 DUAL ACTINGREARHYDRAULICCONTROLFITTING DOUBLE ACTING L1 L2 AND DOUBLE ACTING L3 L4 REAR HYDRAULIC CONTROL DUAL EFFECT ATTACHMENT L1 L2 Press the switch 2 light on to I to power the hydraulic control Press button 1 forward or backward DUAL EFFECT ATTACHMENT L3 L4 Press the switch 2 light on to II to power the hydraulic control Press button 1 forwar...

Page 106: ...tensity is reached at an engine speed greater than 1600 rpm Press the button to activate it the indicator light shows its operation Push the joystick A fully and keep it to the right to unload and shake the bucket RETURNTOLOAD This allows bringing the bucket back to the loading position e g loading the trailer Position the telehandler in the transport position Adjust the bucket in loading position...

Page 107: ...ng the front key switch before restarting the telehandler tIMPORTANT t The EcoSTOP functiondoesnotreplacethestopofthetelehandler thetelehandlermustbestoppedattheendoftheoperatingcycleortheday e1 SAFETY INSTRUCTIONSANDREGULATIONS INSTRUCTIONSTOTHEOPERATOR DRIVINGINSTRUCTIONSUNLADENANDLADEN G STOPPINGTHETELEHANDLER 16 TRAILERBRAKETESTBUTTON This test is used to check whether the parking brake system...

Page 108: ... grille provides additional protection for the operator from any external elements spattered on the windscreen This grille must be removable from inside the cab to enable an emergency exit EMERGENCY EXIT After breaking the windscreen with the emergency hammer push with force on the grille at A to remove it A 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 109: ...3 1 3 MAINTENANCE ...

Page 110: ...OFSERVICE 3 12 Ü50HOUR DAILYMAINTENANCEOREVERY50HOURSOFSERVICE 3 16 Ü 500HOUR PERIODICMAINTENANCE EVERY500HOURSOFSERVICE 3 22 Ü 1000HOUR PERIODICMAINTENANCE EVERY1000HOURSOFSERVICEOR2YEARS 3 28 Ü 2000HOUR PERIODICMAINTENANCE EVERY2000HOURSOFSERVICEOR4YEARS 3 34 Ü 3000HOUR PERIODICMAINTENANCE EVERY3000HOURSOFSERVICEOR6YEARS 3 38 Ü 4000HOUR PERIODICMAINTENANCE EVERY4000HOURSOFSERVICEOR8YEARS 3 39 ÜO...

Page 111: ...GINALMANITOUPARTSFORMAINTENANCEOPERATIONS YOUWILLBENEFITFROMOURADVANCEDEXPERTISE Through its network MANITOU offers to the user Know how and competence Guarantee of high quality work Original spare parts Help with preventive maintenance Efficient help with diagnostics Improvements due to experience feedback Operator training Only the MANITOU network has a detailed knowledge of the design of the li...

Page 112: ...erations are carried out as required to ensure the safety and correct maintenance of the lift truck DAILYANDWEEKLYMAINTENANCE Ü10HOUR DAILYMAINTENANCEOREVERY10HOURSOFSERVICE CHECK Area around the lift truck 3 12 CHECK I C engine oil level 3 12 CHECK Coolant level 3 12 CHECK Fuel pre filter 3 13 LUBRICATE Boom pads 3 13 Every10hoursduringthefirst50hours thenalasttimeafter250hours CHECK Signalling d...

Page 113: ...17 CHECK Waterproofing of front wheel reducing gears 3 17 CHECK Waterproofing of rear wheel reducing gears 3 17 CHECK Brake oil level 3 17 CHECK Hydraulic oil level 3 18 CHECK Windscreen washer liquid level 3 18 CLEAN Radiator grilles 3 19 CLEAN CHECK Condenser grille OPTIONAL air conditioning 3 19 LUBRICATE General lubrication 3 20 CHECK Fork wear 3 26 CHECK Seat belt 3 28 CHECK I C engine silent...

Page 114: ...00H OR17YEARS 9000H OR18YEARS PERIODICMAINTENANCEÜ MACHINECOUNTERÜ SERVICEDATEÜ Ü 500HOUR PERIODICMAINTENANCE EVERY500HOURSOFSERVICE CHECK Hydraulic oil 3 22 REPLACE I C engine oil 3 22 REPLACE I C engine oil filter 3 22 CHECK Automatic tensioner of the alternator belt 3 23 REPLACE Transmission oil filter hydrostatic pump 3 24 REPLACE Front axle differential oil 3 24 REPLACE Rear axle differential...

Page 115: ...DICMAINTENANCE EVERY2000HOURSOFSERVICEOR4YEARS INADDITION CARRYOUTPERIODICMAINTENANCEFOR500HOURSOFSERVICEAND1000HOURSOFSERVICE CHECK Tightening torque of the wheel nuts 3 34 REPLACE Hydraulic oil 3 34 CLEAN Suction strainer for hydraulic oil tank 3 34 REPLACE Hydraulic oil tank breather 3 34 CHECK Radiator 3 36 CHECK Transmission pressures 3 36 CHECK Steering 3 36 CHECK Steering swivel joints 3 36...

Page 116: ...ity signalling device 3 41 REPLACE Alternator belt 3 42 CLEANING DEF Diesel Exhaust Fluid 3 43 Contactyourdealer ÜOCCASIONALOPERATION TOW OR COUPLE Telehandler 3 46 HARNESSING Telehandler 3 47 TRANSPORT Telehandler 3 48 OCCASIONALMAINTENANCEANDOPERATION 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 117: ...796022 Ü 2000HOUR PERIODICMAINTENANCE EVERY2000HOURSOFSERVICEOR4YEARS ADDFILTERELEMENTSOFPERIODICMAINTENANCEOF500HOURSAND1000HOURSOFSERVICE HYDRAULIC OIL TANK BREATHER Reference 278288 FILTER CARTRIDGE FOR HYDRAULIC OIL TANK Reference 922903 FILTER CARTRIDGE FOR HYDRAULIC OIL TANK Reference 259500 Ü 3000HOUR PERIODICMAINTENANCE EVERY3000HOURSOFSERVICEOR6YEARS ADDFILTERELEMENTSOFPERIODICMAINTENANCE...

Page 118: ...ction glovesandgoggles RECOMMENDEDLUBRICANTS I C ENGINE PARTSTOLUBRICATE CAPACITY RECOMMENDEDPRODUCTS I C ENGINE 13L 3 4USgal SAE 0W40 SAE 5W30 MANITOU EVOLOGY 10W40 API CJ4 SAE 10W30 SAE 15W40 40 C 30 20 10 0 10 20 30 40 50 C COOLING CIRCUIT 23L 6USgal COOLANT 35 C 40 C 30 20 10 0 10 20 30 40 50 C FUEL TANK 135L 35 6USgal FUEL DEF Diesel Exhaust Fluid TANK 8 7L 2 2USgal DEF TRANSMISSION PARTSTOLU...

Page 119: ...XLE OSCILLATION REAR WHEEL FINAL DRIVE PIVOTS MANITOUGREASEBLUEMULTI PURPOSE 40 C 30 20 10 0 10 20 30 40 50 C REAR AXLE OSCILLATION MANITOUGREASEBLUEMULTI PURPOSE FRAME PARTSTOLUBRICATE CAPACITY RECOMMENDEDPRODUCTS 40 C 30 20 10 0 10 20 30 40 50 C TILT CORRECTOR MANITOUGREASEBLUEMULTI PURPOSE PACKAGING OIL PRODUCT PACKAGE REFERENCE 1L 0 26USgal 2L 0 52USgal 5L 1 32USgal 20L 5 28USgal 55L 14 5USgal...

Page 120: ...he whole lift truck particularly the engine housing and the central area of the chassis should be made to establish the cleaning frequency required to prevent potential build up of material or spillages CHECK I C engineoillevel Place the lift truck on level ground with the I C engine stopped and let the oil settle in the crankcase Open the engine bonnet Pull out the dipstick 1 Clean the dipstick a...

Page 121: ...e the diesel fuel is running out LUBRICATE Boompads Operation to be carried out every 10 hours during the first 50 hours of service then a last time after 250 hours tIMPORTANT t Incaseofuseinabrasiveatmospheres sand dust coal useaprotectivepaint MANITOU reference 483536 Formoreinformation contactyourdealer Completelyextendtheboom Apply the grease with a brush e LUBRICANTS AND FUEL to the 4 sides o...

Page 122: ... t Te l e s c o p e O K B o o m S e n s o r N O K S t r a i n G a u g e N O K TEST display Contactyourdealer STAGE 3 TEST L o w e r t h e b o o m a t f u l l s p e e d PerformadescentatfullI C enginespeedwithhydrauliccontrol tothemaximum Slowdownthedescentuntilthemovement stops TESTOK Gotostage4 TESTNOTOK Screen TEST Re g u l a t i o n N O K S e c u r i t y V a l v e O K display Contactyourdealer ...

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Page 124: ...hten the level plug 1 tightening torque 35 to 50 Nm Visually check that there is no leakage or seepage of oil in the gearbox CHECK Tyrepressure CHECK Wheelnuttorque tIMPORTANT t Checkthattheairhoseiscorrectlyconnectedtothetyrevalvebeforeinflatingandkeepeveryoneatadistanceduringinflation Check the condition of the tyres to detect cuts protuberances wear etc Check the torque load of the wheel nuts N...

Page 125: ...rmalconsultyourdealer Open the protective casing 1 with the ignition key Check tank 2 The level is correct when it is situated at the MAX level on the tank Visually check the tank and pipes for leaks If necessary add oil e LUBRICANTS AND FUEL Remove the plug 3 Add oil through filler port Refit the cap CHECK Waterproofingonfrontaxledifferential CHECK Waterproofingonrearaxledifferential Place the li...

Page 126: ...l e LUBRICANTS AND FUEL Visually check the tank and pipes for leaks Remove the filler cap lock 2 Remove the plug 3 Add oil through the filler hole 4 Refit the cap and its lock CHECK Windscreenwasherliquidlevel Open the protective casing 1 with the ignition key Visually check the level in tank 2 If necessary add windscreen washer liquid e LUBRICANTS AND FUEL Remove the plug 3 Add windscreen washer ...

Page 127: ...e direction of the air flow To optimise the cleaning carry out this operation with the fans switched on CLEAN Radiatorgrilles tIMPORTANT t Inpollutingenvironments cleantheradiatorgrilledaily Donotuseahighpressurewaterorsteamjetasthiscoulddamagetheradiatorfins Open the engine bonnet If necessary clean the suction grille on the engine cover Clean grid 1 Using a soft cloth clean the radiator in order...

Page 128: ...der base axis 1 lubricator 5 Lubricators of the attachment quick coupler con rod axes 3 lubricators 6 Lubricator of the lifting cylinder base axis 1 lubricator 7 Lubricator of the lifting cylinder head axis 1 lubricator 8 Lubricator of the compensation cylinder base axis 1 lubricator 9 Lubricator of the compensation cylinder head axis 1 lubricator FRONT AND REAR WHEEL FINAL DRIVE PIVOTS 10 Lubrica...

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Page 130: ...nlybyhand andlockitbyafourthofaturn DRAINING OIL Open the engine bonnet Remove access door 1 Place a container under the drain hole and unscrew the drain plug 2 Take drain hose 3 Place the end of the drain hose in the container and screw the hose fully to the drain connector 2 Remove filler plug 4 to facilitate draining REPLACING THE FILTER Unscrew and dispose of the engine oil filter 5 and releva...

Page 131: ... tensioner spring tension if the alternator belt tension is correct In case of doubts contact your dealer AUTOMATIC TENSIONER SPRING TENSION IF NECESSARY Place a 1 2 socket wrench in the square of the automatic tensioner 5 to slacken the belt and remove it Release the force and remove the socket wrench Make a mark A on the pivoting arm measure a distance of 21 mm 0 8 in from this point and make an...

Page 132: ...CE Rearaxledifferentialoil Place the lift truck on level ground with the I C engine off and differential oil still warm tIMPORTANT t Disposeofthedrainoilinanecologicalmanner Place a container under drain plugs 1 and unscrew them Remove level plug 2 and filling plug 3 to facilitate draining Fit the drain plugs 1 back on and tighten them tightening torque 34 to 49 Nm Fill up with oil e LUBRICANTS AN...

Page 133: ...hydraulic return oil filter cartridge 3 and fit new replacement cartridge see 3 MAINTENANCE FILTER ELEMENTS AND BELTS Make sure that the cartridge is correctly positioned and refit the cover 2 Reassemble the guard 1 REPLACE Cabventilationfilters CAB EXTERNAL VENTILATION FILTER Remove the guard 1 using a contact wrench Removethecabventilationfilter2andreplace it with a new one e 3 MAINTENANCE FILTE...

Page 134: ...3 MAINTENANCE FILTER ELEMENTS AND BELTS Retighten tank 2 tightening torque 14 N m REPLACE Fuelfilter tIMPORTANT t Wipetheoutsideoftheprefilteraswellasitssupportthoroughlytopreventdustfrompenetratingthesystem Open the engine bonnet Wipe the outside of the filter as well as its support thoroughly to prevent dust from penetrating the system Place a receptacle under the filter and empty using drain pl...

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Page 136: ...less than 5 I C engine temperature greater than 60 C Check that there is sufficient fuel Start the telehandler and run the I C engine for a few minutes to bring it up to its operating temperature Press down on the top of switch 1 for more than two seconds to begin the regeneration procedure The help screen i P will be displayed the indicator light will come on then a beep will sound to confirm tha...

Page 137: ... possible leaks of the fuel circuit and tank may occur In case of leaks contact your dealer Place a container under drain plug 1 and unscrew the plug Open the fuel filler access panel with the ignition key Remove filler plug 2 to facilitate draining Rinse out with ten liters of clean diesel through filler port 3 Fit the drain plug back on and tighten it tightening torque 72 to 88 Nm Fill the tank ...

Page 138: ...ing to full to facilitate draining Let the cooling circuit drain entirely while ensuring that the ports do not get clogged Check the condition of the hoses as well as the fastening devices and change the hoses if necessary Rinse the circuit with clean water and use a cleaning agent if necessary FILLING WITH FLUID Remove clean and refit drain hose 3 Refit and tighten the radiator drain plug 2 Slowl...

Page 139: ...position it by pressing on the edge of the cartridge and not in the centre Refit the cover and check to make sure the clips are secured correctly It must be possible to install the cover easily if necessary check the correct positioning of the filter cartridge 2 1 A B 1 1 REPLACE VentilationcircuitintheI C engineguard Open the engine bonnet Wipe the outside of the filter as well as its support tho...

Page 140: ...osen the screw and remove the speed sensor 5 2 E11 1 Install the speed sensor Loctite 270 and tighten the screw to a torque of 9 5 11 N m 5 3 E11 1 Install the speed sensor Loctite 270 and tighten the screw to a torque of 9 5 11 N m 5 4 E11 1 Fill the cup with the right quantity of new hydraulic oil see 3 MAINTENANCE LUBRICANTS AND FUEL through the filler hole 3 E11 Refit the filler plug 2 E11 35 ...

Page 141: ...CHECK Wearofboompads CHECK Conditionofwiringharnessandcables CHECK Lightingandsignalling CHECK Indicators CHECK Siderear viewmirrorconditions CHECK Cabstructure CHECK Structureofthechassis CHECK Attachmentholdertable CHECK Attachmentconditions REPLACE Brakeoil PURGE Brakecircuit ADJUST Brake Consultyourdealer ...

Page 142: ...fthefilter aroundthedrainplugsandthesuctionpanelonthe hydraulictank Disposeofthedrainoilinanecologicalmanner Useacleancontainerandfunnel Cleanthetopoftheoildrumbeforefilling DRAINING OIL Remove the guard 1 Place a container under drain plug 2 and unscrew the plug Open the hydraulic oil filler access panel with the ignition key Remove the filler cap lock 12 Remove filler plug 3 to facilitate draini...

Page 143: ...Refit the filler hole 3 HYDRAULIC CIRCUIT DECONTAMINATION Leave the I C engine running accelerator pedal at halfway travel for 5 minutes without using anything on the telehandler then for 5 more minutes while fully using the hydraulic movements except the steering system and the service brakes Accelerate the I C engine at full speed for 1 minute then activate the steering system and the service br...

Page 144: ...WAYSCONTACTTHEDEALERWHOHASTHESUITABLESPAREPARTS TECHNICALKNOW HOWANDTHENECESSARYTOOLS Ineventofthefollowing contactadoctor Incaseofinhalation movetofreshair Incaseofskincontact washimmediatelywithplentyofwater Incaseoffrostbite applyasteriledressing Incaseofcontactwitheyes rinsewithclearwaterfor15minutes IMPORTANT INFORMATION ABOUT THE COOLANT USED This product contains fluorinated greenhouse gase...

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Page 146: ...educe leakage of dust to the minimum Carefully clean the seat of the filter gaskets with a wet clean cloth that does not leave lint Before the assembly check the state of the new safety cartridge see 3 MAINTENANCE FILTER ELEMENTS AND BELTS Insert the cartridge in the filter and position it by pressing on the edge of the filter not in the center NOTE The safety cartridge replacement frequency is pu...

Page 147: ...it for the pump to stop Remove the guard 1 Unscrew the cover of pump 2 remove and discard compensation element 3 Insert the end of tool 4 for the DEF supply filter into the filter 5 until it clicks to indicate that tool 4 is fully inserted Pull out tool 4 and filter 5 from the DEF supply pump Remove filter 5 Lubricate the O rings of the DEF filter Replace filter 5 with a new filter see 3 MAINTENAN...

Page 148: ... nuts and remove them Free the wheel by reciprocating movements and roll it to the side Slip the new wheel on the wheel hub Refit the nuts by hand if necessary grease them Remove the safety support and lower the lift truck with the jack Tighten the wheel nuts with a torque wrench e 2000 HOUR PERIODIC MAINTENANCE EVERY 2000 HOURS OF SERVICE OR 4YEARS for tightening torque ADJUST Frontheadlights REC...

Page 149: ...ain gauge Press to Enter Fast Calibration Mode RESET ADMIN CALIB ERASE GAUGE M THR SECU BRAKE menu and confirm with Enter the CUSTOMER code CODE 0 and validate STAGE1 TEST Re t r a c t t e l e s c o p e l i f t t h e b o o m t o m a x p o s i t i o n t h e n p r e s s Fullyraisetheboomwiththetelescopicboomsfullyretracted Confirm STAGE2 GAUGE W a i t c a l i b r a t i o n i n p r o g r e s s Calibr...

Page 150: ...ove the socket wrench Refit a new alternator belt see 3 MAINTENANCE FILTER ELEMENTS AND BELTS ensuring that it is properly seated in the grooves of each pulley and tighten the belt using the automatic tensioner 3 NOTE Take advantage of belt removal to check the correct operation of the pulleys and bearings noise rubbing play etc Reassemble the guard 2 3 2 1 649100 EN US AU 20 05 2019 MLT 961 145 V...

Page 151: ...sonsystemcomponentsslowly Covertheareathatyouaredisconnectingwithacloth Wearsuitableprotectivegloves protectiveclothingandsafetygoggles Ifthe DEF getsintothecoolantcircuit evenminuteamounts thermostatsandtemperaturesensorswillbedamaged Alwayskeepthe DEF completelyseparatefromotherserviceproducts Donotusethesamecontainersandfluidcollectingpansforthe DEF andotherserviceproducts Donotcontinuetouseser...

Page 152: ...g 6 and rotate the pipe 7 to direct the water to all the inside points of the tank 1 and make sure that water is leaking from the other openings 6a Repeat the operation for at least 30 seconds Repeat the same operation with hot water pipe 8 and rotate the pipe to direct the water to all the inside points of the tank make sure that water is leaking from the other openings Repeat the operation for a...

Page 153: ... filter 10 to visually check for the presence of larger or smaller particles Repeat the procedure when detecting the presence of foreign particles Clean the filter before the next check rinse and blow Aspirate 11 the residual water inside the DEF tank 1 Visually inspect the point 12 inside DEF tank 1 cleaning no water and contamination If the tank is not visually clean repeat the cleaning procedur...

Page 154: ...rovided for the mechanical and manual release of the braking units then move the nuts backward by approximately 8 mm 0 3 in b Tighten screws 3 to fasten them onto the pressure plate c Using a wrench tighten the screws 3 in an alternate sequence by 1 4 turn at a time so as to compress the belleville washers and disengage the braking disks tIMPORTANT t Tightenmaximumbyoneturn Adjust the negative bra...

Page 155: ...ESSING Telehandler Take into account the position of the telehandler center of gravity for lifting A 1632mm 64 2in B 1248mm 49 1in Place the hooks in the fastening points 1 provided for this purpose B A 1 1 1 1 ...

Page 156: ...tationoftheturbo shaft withoutlubricationwhentheconvoymoves LOAD THE LIFT TRUCK Block the wheels of the platform Fix the loading ramps so that you obtain an angle as little as possible to lift the lift truck Load the lift truck parallel to the platform Shut down the lift truck e1 OPERATING AND SAFETY INSTRUCTIONS DRIVING INSTRUCTIONS UNLADEN AND LADEN SECURING THE LIFT TRUCK Fix the chocks to the ...

Page 157: ...4 OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE 4 1 ...

Page 158: ...4 2 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 159: ...SUMMARY 4 OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE INTRODUCTION 5 ATTACHMENTCONNECTIONMANOEUVRES 6 ATTACHMENTCHARACTERISTICS 8 4 3 ...

Page 160: ...4 4 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 161: ...ained in this manual dIMPORTANT d Themaximumloadsaredefinedbythecapacityofthetelehandlertakingintoaccounttheweightandthecentreofgravityoftheattachment Ifthecapacityoftheattachmentisbelowthecapacityofthetelehandler neverexceedthislimit Some specific uses require the attachment to be adapted as it may not be included in the optional catalogue Other solutions are available for more information please...

Page 162: ...onnection pipe of the attachment slightly raise the boom and tilt the carriage back in order to position the attachment Fig C Raise the attachment off the ground for easier engagement MANUAL LOCKING Take the locking pin from the support Fig A and lock the attachment in place Fig D Do not forget to fit on the split pin MANUAL RELEASE Follow the MANUAL LOCKING procedure in reverse order taking care ...

Page 163: ...PORTANT d Checkthequickcouplingsforcleanlinessandprotecttheunusedorificeswiththecapsprovided Take the locking pin from the support Fig A and lock the attachment in place Fig D Do not forget to fit on the split pin Turn off the I C engine and keep the telehandler ignition on Press the button for two seconds to release the attachment circuit hydraulic pressure screens and will be alternately display...

Page 164: ...K HOLDER TFF75MT 1430 REFERENCE 504280 Nominal capacity 8000kg Width 1545mm Weight 565kg FLOATING FORK REFERENCE 528083 578154 Section 200x60x1200mm 200x60x1500mm Weight 188kg 217kg 8 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 165: ...al capacity 8000kg 8000kg 8000kg Width 1260mm 1750mm 2000mm Weight 370kg 460kg 590kg FEM FORK HOLDER PFB75MT 1750 TDL PFB75MT 2000 TDL REFERENCE 504365 566531 Nominal capacity 7500kg 7500kg Width 1800mm 2000mm Weight 740kg 840kg FEM FORK REFERENCE 513110 Section 200x60x1200mm Weight 195kg 9 ...

Page 166: ...al capacity 3200l 4000l Width 2500mm 2500mm Weight 1110kg 1050kg GRIPPING BUCKET CBG2480 2600MS CBG2480 2200DIB REFERENCE 790658 790657 Nominal capacity 2600l 2200l Width 2480mm 2480mm Jaw Weight 1350kg 1300kg PLOUGH WITH BRUSH BRB2200 BRB2500 REFERENCE 790315 790316 Nominal capacity 530l Width 2600mm Weight 925kg 10 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 167: ...ht 262kg GRIPPER FOR BALES P2BG2X4 REFERENCE 790518 Nominal capacity 1500kg Width 1090mm Jaw 2x4 Weight 275kg GRIPPER FOR BALES MBC2X3 REFERENCE 790506 Nominal capacity 800kg Width 1196mm Weight 290kg GRIPPER FOR BALES PBE REFERENCE 757613 Nominal capacity 1000kg Width 1600mm Weight 242kg 11 ...

Page 168: ...EFERENCE 790534 Nominal capacity 2000kg Width 2435mm Tips 12 Jaw 5 Weight 686 FORKS FOR BALES FB1900 1700 REFERENCE 790699 Nominal capacity 1700kg Width 1878mm Tips 4 Weight 215kg 12 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 169: ...eusedwithatelehandlerfittedwithhydraulicmovementcut offinservice PCRBGM REFERENCE 673697 Nominal capacity 4000kg Weight 230kg BOOM WITH HOOK ItMUSTbeusedwithatelehandlerfittedwithhydraulicmovementcut offinservice PC60 REFERENCE 939050 Nominal capacity 6000kg Weight 130kg BIG BAG HANDLER HBB1500 2400 REFERENCE 931627 Nominal capacity 2400kg Width 1450mm Weight 186kg 13 ...

Page 170: ...14 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 171: ...5 LOAD CHARTS FOR INTERCHANGEABLE EQUIPMENT ...

Page 172: ...PREAMBLE dIMPORTANT d Thecapacitychartsareapplicableonlywhenthesafetysystemisproperlyinserted 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 173: ...MLT 961 145 V PLUS L JD ST4 S1 ...

Page 174: ...649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 175: ...5 5 MLT 961 104JD ST4 S1 ...

Page 176: ...5 6 IT MLT 961 104JD ST4 S1 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 177: ...5 7 MLT 961 104JD ST4 S1 ...

Page 178: ...5 8 IT MLT 961 104JD ST4 S1 649100 EN US AU 20 05 2019 MLT 961 145 V PLUS L JD ST4 S1 ...

Page 179: ...5 9 MLT 961 104JD ST4 S1 ...

Page 180: ...5 10 IT MLT 961 104JD ST4 S1 ...

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