Manitou MSI 40, Operator'S Manual

Page 1: ...MSI 40 MSI 50 BP 249 Z I 44 158 ANCENIS CEDEX FRANCE TEL 02 40 09 10 11 YOUR DEALER OPERATOR S MANUAL REF 47974 EN 06 07 2000...

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Page 3: ...1993 12 1993 05 1994 19 09 1997 06 07 2000 1st ISSUE ADDING REPAIRS NOTICE UP DATING LIFTING CAB UP DATING UP DATING LIFTING CAB UP DATING REVISION OF THE OPERATOR S MANUAL UP DATING 03 1993 THE TEXT...

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Page 5: ...HARACTERISTICS MAST CHARACTERISTICS DIMENSIONS AND LOAD CHART INSTRUMENTS AND CONTROLS Up to machine n 117 315 From machine n 117 316 DESCRIPTION AND OPERATION OF ELECTRIC AND HYDRAULIC OPTIONS 3 MAIN...

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Page 7: ...1 1 1 OPERATING AND SAFETY INSTRUCTIONS 1 OPERATING AND SAFETY INSTRUCTIONS...

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Page 9: ...the legal viewpoint The certificate of compliance only binds the maker for parts chosen or produced under the maker s control The practicalities of maintenance terms are set out by the maker The make...

Page 10: ...traffic conditions particularly Risk of loss of control on a poor quality track Increased stopping distance The user must remain in full control of his lift truck and should Adapt his speed to each si...

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Page 12: ...keep the lift truck properly cleaned if this is among his responsibilities Carry out daily maintenance See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAINTENANCE Ensure tyres are adapted...

Page 13: ...ic conditions before starting up it is necessa ry to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures It is the sam...

Page 14: ...yres and the tyre pressures See chapter CHARACTERISTICS in paragraph 2 DESCRIPTION Before starting the lift truck check the different levels Engine oil Hydraulic reservoir oil Cooling liquid Braking o...

Page 15: ...ensitive to movement of the steering wheel so turn it gently and not jerkily Never leave the engine on when the lift truck is unattended Look in the direction you are travelling and always keep clear...

Page 16: ...heck the level of antifreeze close the rear windows lock the cab doors and ensure that the hood is properly secured INSTRUCTIONS Park the lift truck on flat ground or on an incline lower than 15 Relea...

Page 17: ...braking equipment for the trailer on the lift truck Do not forget to connect the lift truck s braking equipment to that of the trailer The maximum vertical pull on the trailer hook must not exceed 15...

Page 18: ...hment in the closed position flat on the ground For unstable attachments ensure they are secured using wedges Switch off the I C engine Remove pressure from the attachment hydraulic system using the h...

Page 19: ...s and jib extention In the event of high winds or storms do not carry out handling work that jeopardizes the stability of the lift truck and its load particularly if the load catches the wind badly Do...

Page 20: ...to limit these variations as far as possible B TAKING UP A LOAD ON THE GROUND Approach the lift truck perpendicular to the load with the forks in a horizontal position Fig C Adjust the fork spread and...

Page 21: ...ter HANDLING INSTRUCTIONS for visibility of the road Bring the forks to stop in front of the load Fig H Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1...

Page 22: ...checking the correct positioning of the load Fig M To drive very gently and carefully Free the forks by reversing the lift truck 3 Fig M See paragraph E VISIBILITY in the chapter HANDLING INSTRUCTIONS...

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Page 24: ...truck with a flame when the fuel tank is open or is being filled Take care not to burn yourself Exhaust radiator I C engine etc Disconnect the negative cable terminal from the top of the battery befor...

Page 25: ...articulations and electrical components and connections If necessary protect against penetration of water steam or cleaning agents components susceptible of being dama ged particularly electrical comp...

Page 26: ...ng lubricants properly suited to the relevant ambient temperatures It is the same for the cooling liquid Contact your dealer for information if necessary DRY AIR FILTER Ensure that the air filter is u...

Page 27: ...evel and the density of the electrolyte in the battery See chapter B EVERY 50 HOURS SERVICE in paragraph 3 MAINTENANCE Check the components of the electrical system the connections and fastening devic...

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Page 29: ...2 1 2 DESCRIPTION 2 DESCRIPTION...

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Page 31: ...2 3...

Page 32: ...rmation always specify NOTE For the owner s convenience it is recommended that a note of these numbers is made in the spaces provided at the time of the delivery of the lift truck PLATE MANUFACTURER O...

Page 33: ...CHMENT FIG H Model Serial Nr Year of manufacture E F G MANITOU BF 44158 ANCENIS CEDEX FRANCE TELEX 710 521 FAX 40 83 36 88 MODELE N dans la s rie Ann e fabrication Masse vide C d G Tablier A vide En c...

Page 34: ...ic by valve TH7 56 cm3 0 cm3 141 68 L min ENGINE Type Number of cylinders Number of strokes Injection system Ignition sequence Clearance of rocker valve Cold Inlet Exhaust Capacity Bore Stroke Volumet...

Page 35: ...ot pedal Hydraulic brake acting on front wheels Mechanical hand lever applied on the front wheels Working pressure Up to pump N 3890010 From pump N 3890011 Boost pump Cubic capacity MAX flow rate Boos...

Page 36: ...valve TH7 56 cm3 0 cm3 141 68 L mn 380 Bar ENGINE Type Number of cylinders Number of strokes Injection system Ignition sequence Rocker arm clearance Hot Inlet Exhaust Capacity Bore Stroke Volumetric...

Page 37: ...ke immersed in oil Foot pedal Hydraulic brake acting on front wheels Mechanical hand lever applied on the front wheels Boost pump Cubic capacity MAX flow rate Boost pressure MAX r p m HYDROSTATIC MOTO...

Page 38: ...N THE CONTACT SURFACE AERA OF THE CONTACT SURFACE UNLADEN LOADED UNLADEN LOADED UNLADEN LOADED 225 75 R15 XZM 149 A5 5 Bar 1850 Kg 650 Kg 5 4 Kg cm2 3 1 Kg cm2 345 cm2 210 cm2 MICHELIN DIMENSIONS PRES...

Page 39: ...ing direction Flow rate at full speed Pressure Filtration Return Suction Up to machine N 115 593 Hydraulic shock absorber Capacities Pressure HYDRAULIC CIRCUIT FROM MACHINE N 130 518 Type of pump Capa...

Page 40: ...dard mast Unladen lifting Rated load lifting Unladen lowering Rated load lowering Weight of lift truck with standard mast Unladen Rated load Weight per axle with standard mast Transport position Front...

Page 41: ...ON THE CONTACT SURFACE AERA OF THE CONTACT SURFACE UNLADEN LOADED UNLADEN LOADED UNLADEN LOADED 225 75 R15 XZM 149 A5 6 Bar 2300 Kg 800 Kg 6 3 Kg cm2 3 8 Kg cm2 370 cm2 210 cm2 MICHELIN DIMENSIONS PRE...

Page 42: ...ing direction Flow rate at full speed Pressure Filtration Return Suction From machine N 115 593 Hydraulic shock absorber Capacities Pressure HYDRAULIC CIRCUIT FROM MACHINE N 130 518 Type of pump Capac...

Page 43: ...dard mast Unladen lifting Rated load lifting Unladen lowering Rated load lowering Weight of lift truck with standard mast Unladen Rated load Weight per axle with standard mast Transport position Front...

Page 44: ...10 12 1463 2375 5272 44 4m50 4550 10 12 1533 2450 5467 19 4560 10 12 1538 2450 5472 19 4m70 4750 10 12 1593 2510 5667 39 4760 10 12 1598 2510 5672 39 5m00 5050 10 12 1708 2625 5967 14 5060 10 12 1713...

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Page 46: ...2 18 DIMENSIONS AND LOAD CHART MSI 40 MSI 50...

Page 47: ...5 mm H 2575 mm 2575 mm H1 4677 mm 4672 mm H1 4277 mm 4272 mm I 545 mm 545 mm J 1300 mm 1300 mm K 1670 mm 1670 mm L 50 mm 60 mm N 1710 to 1775 mm 1710 to 1775 mm O 150 mm 150 mm P1 30 58 30 58 P2 27 51...

Page 48: ...2 20 INSTRUMENTS AND CONTROLS UP TO MACHINE N 117 315 1 2 3 4 5 6 7 8 9 10 11 12 13 13 13 14 15 19 20 20 21 21 22 22 17 23 23 24 24 25 16 18 28 26 27 30...

Page 49: ...R 15 ENGINE SLUDGE DOOR LIFTING CAB 16 UNLOCKING HANDLE FOR CAB 17 LIFTING CAB SWITCH OPTION 18 SAFETY SHORE FOR LIFTING CAB 19 CAB HEATER CONTROL 20 HEATING VENTILATORS 21 DOOR LOCKS 22 CLOSING HANDL...

Page 50: ...USPENSION ADJUSTMENT Pull and lift up the locking lever 2 so as to place it into one of these five positions Position A Light weight driver 50 kg Position B Intermediate Position C Middle weight drive...

Page 51: ...f this lamp stays on when the engine is running stop the fork lift truck immediately and look for the cause see oil level in engine crankcase F RED ALTERNATOR CHARGE LAMP This lamp is illuminated when...

Page 52: ...her B OPTION heater fan switch C R ear windscreen washer switch E OPTION warning light switch D Brake oil level lamp F OPTION working head light switch or OPTION left working head light switch G OPTIO...

Page 53: ...I The engine starts return to position I as soon as the key is released 7 FUSES BOX Remove the cover to replace a fuse which is to be used as per the following numbers 1 OPTION Working tail lights 10A...

Page 54: ...VER The parking brake acts on the two front wheels To tighten the parking brake pull the lever backwards Position A To untighten the parking brake push the lever forwards Position B 13 HYDRAULIC CONTR...

Page 55: ...nitial position position B Engage the safety shore 18 Fig D in its clip vertically under the cab LOWERING OF THE CAB Re position the safety shore 18 Fig D To decrease the necessary effort to tilt the...

Page 56: ...the bottom of the switch 17 Fig E to lower the cab in its initial position and be sure of the locking Re close the R H door Check that nothing or nobody can impede the lowering of the cabin 19 CAB HEA...

Page 57: ...sible Total Moveable Weight P T M W the drawbar pull and the maximum vertical drawbar pull on the towing pin This information is indicated on the manufacturer s plate on each lift truck See chapter ID...

Page 58: ...2 30 INSTRUMENTS AND CONTROLS FROM MACHINE N 117 316 1 2 3 4 7 9 10 12 14 15 19 20 22 24 26 30 1 5 6 7 8 9 10 11 13 14 17 19 20 21 22 24 25 26 28 16 18 23 27 32 1...

Page 59: ...5 BRAKING OIL TANK SLUDGE DOOR LIFTING CAB 16 UNLOCKING HANDLE FOR CAB 17 LIFTING CAB SWITCH 18 SAFETY SHORE FOR LIFTING CAB 19 CAB HEATER CONTROL 20 HEATING VENTILATORS 21 DOOR LOCKS 22 CLOSING HANDL...

Page 60: ...ENSION ADJUSTMENT Pull and lift up the locking lever 2 so as to place it into one of these five positions Position A Light weight driver 50 kg Position B Intermediate Position C Middle weight driver P...

Page 61: ...f this lamp stays on when the engine is running stop the fork lift truck immediately and look for the cause see oil level in engine crankcase F RED ALTERNATOR CHARGE LAMP This lamp is illuminated when...

Page 62: ...her B OPTION heater fan switch C Rear windscreen washer switch E OPTION warning light switch D Brake oil level lamp F OPTION working head light switch or OPTION left working head light switch G OPTION...

Page 63: ...ions P Ignition off parking position O Ignition switched off and engine stopped I Ignition on II Heating III The engine starts return to position I as soon as the key is released 7 KEY OPERATED BATTER...

Page 64: ...truck should always be driven in a straight line and at low speed 12 FORWARD REVERSE LEVER The lift truck must be stationary when operating the forward reverse lever FORWARD 1st ASSEMBLY Push the lev...

Page 65: ...regulating valve In the event of suspected malfunction contact your dealer ANY ALTERATION MAY RENDER THE WARRANTY NULL AND VOID 15 BRAKING OIL TANK SLUDGE DOOR LIFTING CAB Be sure that the mast is ti...

Page 66: ...he temperature inside the cab to be adjusted A With the valve closed the blower delivers fresh air B With the valve opened completely the blower delivers warm air The intermediate positions allow the...

Page 67: ...W the drawbar pull and the maximum vertical drawbar pull on the towing pin This information is indicated on the manufacturer s plate on each lift truck See chapter IDENTIFICATION OF THE LIFT TRUCK in...

Page 68: ...the seat belt at hip level and not across the stomach Attach the seat belt and check that it locks Adjust the seat belt to your body shape without squeezing your hip In no event should the lift truck...

Page 69: ...ACTING DISTRIBUTOR ELEMENT LEVER A Intended for controlling a single or double acting additional equipment LEVER B Intended for controlling a single or double acting additional equipment 4 HYDRAULIC M...

Page 70: ...REVERSER The lift truck must be stationary when operating the forward reverse lever FORWARD Press the pedal 1 on the right REVERSE Press the pedal 2 on the left NEUTRAL To start the lift truck do not...

Page 71: ...3 1 3 MAINTENANCE 3 MAINTENANCE...

Page 72: ...3 2...

Page 73: ...5 800 H 6 Hydrostatic transmission oil filter cartridge 46 028 800 H 7 Hydraulic return oil filter cartridge 221 174 400H 8 Oil tank breather 457 509 400 H 9 Fuel filter cartridge 49 660 400 H 10 Fan...

Page 74: ...winter fuels may be available for use in the engine at temperatures below 0 C These fuels have a lower viscosity and thus reduce the formation of paraffin in the fuel at low temperatures The formation...

Page 75: ...3 5 DIAGNOSTIC ANALYSIS OF OIL In the event of a maintenance or service contract with the dealer you may be requested to provide a sample of a selected component s oil for diagnostic analysis...

Page 76: ...aden atmosphere reduce this servicing schedule B2 Check the hydraulic oil level B3 Check the braking oil level B4 Check the level of the windscreen washer liquid B5 Check the battery electrolyte level...

Page 77: ...ge the oil of the front axle differential E6 Drain and change the oil of the front wheel reducers E7 Drain and change the cooling liquid E8 Drain and clean the fuel tank E9 Change the safety dry air f...

Page 78: ...eck the steering axle G3 Check the clearance of the front wheel reducers G4 Check the bearings clearance of the transfer box G5 Check the alternator and the starter motor Consult your dealer H OCCASIO...

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Page 80: ...cool down Lift up the cabin See chapter INSTRUMENTS AND CONTROLS in paragraph 2 DESCRIPTION The liquid must be at the MAXIMUM level on the expansion pan 1 Fig A2 1 If necessary add cooling liquid thro...

Page 81: ...ee thread turns Allow oil to flow void of all impurities and water Tighten the drain plug while the oil flows A5 CHECK THE TYRE PRESSURES AND THE WHEEL NUTS TORQUE Check the condition of the tyres to...

Page 82: ...ng it in liquid Do not clean by any means the safety cartridge located inside the filter cartridge change it for a new one if it is dirty or damaged FROM MACHINE N 142 127 Loosen the nuts and remove c...

Page 83: ...ENANCE by the filler port 2 Fig B2 Use a clean funnel and clean the underside of the oil drum before filling Always maintain the oil level at maximum as cooling depends on the oil flowing through the...

Page 84: ...an distilled water that has been stored in a glass container Clean and dry caps 1 Fig B5 and refit in place Check the terminal connections and lightly smear them with petroleum jelly to prevent the fo...

Page 85: ...g chains Then block the lock nut 1 Fig B7 and the nut 2 Fig B7 These checks are important for the good working operation of the mast In case of technical faults consult your dealer B8 LUBRICATE THE MA...

Page 86: ...e following points with grease See chapter LUBRICANTS AND FUEL in paragraph 3 MAINTENANCE and remove the surplus of grease 1 Lubricators of cabin door 1 Fig B10 1 4 lubricators Up to machine N 116 222...

Page 87: ...head axles 8 Fig B10 9 of the steering cylinder 2 lubricators 8 Lubricators of steering rod pins 9 fig B10 9 2 lubricator 9 Lubricators of the swivel pins 10 Fig B10 9 6 lubricators 10 Lubricators of...

Page 88: ...tween the fan and alternator pulleys Under a normal pressure exerted with the thumb the tension should be approximately 10 mm Carry out adjustments if necessary Untighten screws 1 Fig C2 by two to thr...

Page 89: ...the level plug 1 Fig C5 Tightening torque 34 to 49 N m C6 CLEAN AND LUBRICATE THE MAST UPRIGHTS OPERATION TO BE DONE BEFORE OPERATING A NEW LIFT TRUCK AND ONCE AT 200 HOURS SERVICE Clean and remove t...

Page 90: ...an the filter bracket with a clean lint free cloth Lightly lubricate the new seal Refit the oil filter on the filter bracket Tighten the oil filter by hand pressure only and lock the filter in place b...

Page 91: ...Leave the safety cartridge in place Clean the inside of the casing with a clean damp lint free cloth Also clean the cartridge seal surfaces on the filter and cover Then fit a new cartridge making sure...

Page 92: ...air breather tighten by hand pressure only D7 CHECK THE DENSITY OF THE BATTERY ELECTROLYTE The electrolyte density varies depending on the temperature concerned but a minimum of 1260 at 16 C must be...

Page 93: ...e the fuel lift pump D9 CHECK CLEAN AND LUBRICATE THE MAST LIFTING CHAINS Wipe the mast lifting chains 1 Fig D9 with a clean lint free cloth then examine them closely so as to detect any signs of wear...

Page 94: ...ydrostatic transmission oil filter 5 Fig E1 3 Unscrew the four screws 6 Fig E1 3 and remove the complete filter 5 Fig E1 3 Unscrew the suction strainer at the bottom of the tank clean it with the help...

Page 95: ...ed for 1 minute then activate the steering system and the service brakes This operation makes a pollution abatement of the circuit possible through the hydraulic return oil filter E4 DRAIN AND CHANGE...

Page 96: ...possible leaks at the drain plugs Refit and tighten the filler plug 2 Fig E5 2 and the level plug 3 Fig E5 2 Tightening torque 34 to 49 N m E6 DRAIN AND CHANGE THE FRONT WHEEL REDUCER OIL Place the l...

Page 97: ...he 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 product if necessary LIQUID FILLING Close the tap 1 f...

Page 98: ...t 3 Fig E8 2 Refit and tighten drain plug 1 Fig E8 1 Tightening torque 29 to 39 N m Fill the fuel tank with clean fuel See chapter LUBRICANTS AND FUEL in paragraph 3 MAINTENANCE filtered through a str...

Page 99: ...CARTRIDGE in paragraph 3 MAINTENANCE E10 CLEAN THE HEATING SUCTION FILTER Lift up the cabin See chapter INSTRUMENTS AND CONTROLS in paragraph 2 DESCRIPTION Loosen the knurled nuts 1 Fig E10 1 and rem...

Page 100: ...the feed pump is in the maximum raised position turn the crankshaft by one turn Tighten the bleed screw while the diesel fuel is flowing out BLEEDING THE HEATER PLUG Loosen connection 3 Fig H1 3 on t...

Page 101: ...s flowing out Tightening torque 22 N m The engine is then ready to be started up Turn the IC engine over slowly for 5 minutes immediately after bleeding the fuel feed circuit in order to ensure that t...

Page 102: ...ents and roll it on the side Slip the new wheel on the wheel hub Screw the nuts by hand if necessary grease them Remove the safety wedging and lower the lift truck with the jack Tighten the wheel nuts...

Page 103: ...UNLOCKING OF HIGH PRESSURE VALVES Check the X dimension Fig H3 2 on the two HP valves Unlock the counter nut 3 Fig H3 2 Tighten the screw 4 Fig H3 2 until flusching the counter nut 3 Fig H3 2 After to...

Page 104: ...SLING THE LIFT TRUCK Take into account the position of the lift truck gravity center for lifting Fig H4 1 Place the hooks in the fastening points provided Fig H4 2 and H4 3 A 1056 mm B 1019 mm MSI 40...

Page 105: ...truck LOAD THE LIFT TRUCK Block the wheels of the semitrailer 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 semitra...

Page 106: ...attery disconnecting device Disassemble the panel 2 Fig H 6 3 to access to the connections of the battery disconnecting device Connect the negative cable onto the battery and take a good earth on the...

Page 107: ...belt of the mobile column Fig H 7 2 and fasten the sling ends onto the welded rings 2 Fig H 7 3 at the back of the roof Start the I C engine Carefully lift the mast so as to stretch the sling Slowly...

Page 108: ...l of motor 1 Fig H8 1 Unlock the cabin with the lever 2 Fig H 8 2 in position A Disassemble the cowling 3 Fig H 8 3 and the rear plate 4 Fig H8 4 By means of a tool for example screwdriver push the lo...

Page 109: ...4 1 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE 4 ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE...

Page 110: ...4 2...

Page 111: ...dealer It is COMPULSORY for all ATTACHMENTS WITH SUSPENDED LOAD Hoist crane jib crane jib with winch hook etc to be used with a fork lift fitted with AUTOMATIC HYDRAULIC MOVEMENT CUT OFF Only attachme...

Page 112: ...acity 2500 Kg Lenght 2500 mm Section 200 x 75 mm Weight 70 Kg FORKS EXTENSION Reference 572 788 4T 5T Width 1670 mm Weight Kg Reference 572 790 4T 5T Width 2000 mm Weight Kg LOAD BACK REST Reference 4...

Page 113: ...00 Reference For double mast 572 304 For triple mast 572 071 Nominal load capacity 3600 Kg Side shift 2 x 100 mm Width 2000 mm Weight 380 Kg TDLA 50N 1670 Reference For double mast 572 305 For triple...

Page 114: ...ference 556 305 Nominal load capacity 1000 L 1800 Kg Width 2200 mm Weight 715 Kg SP 1000 50N AD Reference 556 309 Nominal load capacity 1000 L 1800 Kg Width 2200 mm Weight 690 Kg EARTHMOVING BUCKET BC...

Page 115: ...77 Kg GL 1000 S2 Reference 174 247 Nominal load capacity 1000 L 2200 Kg Weight 325 Kg GL 800 S2 Reference 174 246 Nominal load capacity 800 L 1760 Kg Weight 308 Kg GL 1500 S2 Reference 174 248 Nominal...

Page 116: ...2 Width 1500 mm Reference 206728 Width 1950 mm Reference 206724 Width 2150 mm BUCKET PROTECTOR NOTE Always ensure that the width of the protector you choose is less than or equal to the width of the b...