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3 - Hawkins Equipment

1. MC RFS M VSLR ce a 3bar_ COLETTORE 1 Rd IN ES COLETTORE 2 COLETTORE 3 A re eps FR o V M M 10 MICRONS 5 OPTIONAL ACCESSORIES ENVISAGED MHT 10210 L 5 INTRODUCTION The manufacturer makes available with warranty a vast range of accessories perfectly suited to your lift truck he accessories are supplied complete with a load diagram relating to your truck The user manual and the load diagram must be kept on the truck The use of the possible accessories is subject to the instructions in this manual Some specific uses require adaptation of the accessory not included in the optionals in the catalogue Other solutions are possible contact your agent or dealer for further information Only accessories approved and CE certificates by the manufacturer can be used on our lift trucks The manufacturer will have no liability in case of modifications or use of accessories without his knowledge Manitou assures oneself about the employement s capacity of this machine in normal conditions of working foreseen in the user s manual with a static test coefficient of 1 33 and a dynamic test coefficient of 1 foreseen in the harmonized rules EN 1459 for the truck with variable capacity and EN 1726 1 for
2. vespere ee pcm EA TEN E ud lt 62 0 a 5 i qoo oe om HS 1 X E i3 t la dk ore ES 1 29 COLLET D S D SX E F S FDAR FDAV I D M C P F PH G RFS S V D VCLR VSLR 30 MHT 10210 MSeries KEY TO BRAKE STEERING SYSTEM DIAGRAM Manifol
3. Before changing the cooling liquid check the seals and condi tions of the cab cooling and heating system Drain the cooling liquid Before draining the liquid cover the cables piping etc present under the drainage screw Place a container under the drainage screw large enough to hold the quantity of liquid to be collected Gradually open the cap on the tank 1 Fig F4 1 discharge the excess pressure then remove the cap Turn the temperature regulator knob 2 Fig F4 2 present in the cabin completely FIG F4 2 Insert tube recommended length 1m on drainage screw 3 Fig F4 3 present on the engine Unscrew drainage screw 3 Fig F4 3 1 2 turns and let the cooling liquid flow out from the engine block FIG F4 3 29 3 MHT 10210 L MSexes Place a container large enough for the quantity of liquid to be col lected under the radiator drainage screw 4 Fig F4 4 Unscrew the radiator drainage screw 4 fig F4 4 in the lower part of the radiator and drain out the cooling liquid Clear the drainage opening of obstruction if present Tighten the cooling liquid drainage screws present on engine 3 Fig F4 3 and on radiator 4 Fig F4 4 FIG F4 4 Filling the cooling system Before filling the cooling system prepare the liquid to be filled according to the water and cooling liquid percentages indicated in the Table F4 5 TABL
4. Check that all the correct grades of oils and greases that are required are available see chapter SERVICING SCHEDULE in paragraph 3 MAINTENANCE and top up if necessary For operation under average climatic conditions i e between 15 C and 35 C cor rect levels of lubricants in all the circuits are checked in production For operation under more severe climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures It is the same for the cooling liquid Contact your dealer for infor mation if necessary Dry air filter Ensure that the air filter is undamaged and not blocked Tighten the fastening devices if necessary Never run the 1 C engine with the air filter removed or damaged Cooling circuit Always check the cooling liquid level before starting up the lift truck Hydraulic circuit Visually check for oil leakage or sweating on the couplings hose pipes pipes and unions Tighten or check the defective connections if necessary Also check the oil level in the tank MHT 10210 MSeries Braking system Check by a visual examination that there are no leaks or oil oozing in the hoses con nections and unions If necessary tighten or repair the defective connections Also check the oil level in the tank Use only the recommended brand of
5. GENERAL GREASING Grease HD NLGI 2 TELESCOPIC BOOM GREASING Grease HD NLGI 2 MANITOU ANTIFREEZE 25 COOLING CIRCUIT sooounsorcut MANITOU ANTIFREEZE 30 FEATURES OF FUEL Use good quality fuel to obtain the best performance out of the engine FEATURES OF THE RECOMMENDED FUEL DERV in accordance with 590 BS2869 Class A2 ASTM 0975 91 Class 2D 75 K2204 1992 Degrees 1 2 3 and Special Degree 3 N B HYDROSTATIC TRANSMISSION FILTER HYDRAULIC FILTER AND ENGINE OIL AND FILTER MUST BE CHANGED AFTER THE FIRST 50 WORKING HOURS TO GUARANTEE SAFETY 3 A EVERY DAY EVERY 10 WORKING HOURS 4 CHECK THE ENGINE OIL LEVEL Before checking the oil level make sure that the engine is stopped and that the truck is on a flat horizontal surface To obtain accurate information wait for a few minutes after the engine stops so that the oil flows into the engine sump Remove the dipstick 1 fig A1 clean it and check the oil level Top up if necessary by removing the filler cap 2 fig A1 A2 CHECK THE COOLING LIQUID LEVEL This is done on the cooling liquid tank in the engine compart ment There are two notches on the tank to indicate a minimum and a maximum check to make sure the liquid level is always between these values ATTENTION Open the cap to top up the cooling system only if the temperature of the liquid is less than 90 C 194 F In any case it is obligatory
6. Depress the switch a second time to deactivate 15 2 LIGHT HORN AND DIRECTION INDICATOR CONTROL LEVER The lever controls the lights and horn Lights off direction indicator lights not working Direction indicator lights signalling right Direction indicator lights signalling left Side lights on Dipped headlights and side lights on Full beam headlights and side lights on Lights flashing Press the tip of the lever to sound the horn gt N B Position D E G can be activated without the ignition contact made Y IGNITION SWITCH The switch has four positions Internal combustion engine Electrical contact Warming up Start up and return to position has been released after the key BEFORE THE START UP POSITION WAIT AT LEAST 5 SECOND CASING GIVING ACCESS TO BRAKE FLUID AND WINDSCREEN WASHING LIQUID Undo the screw H and remove the casing for access to the brake fluid and screen washing liquid tanks BRAKE FLUID TANK 16 MHT 10210 L MHT 10210 L 2 10 WINDSCREEN WASHING LIQUID TANK On the operator s left Remove the cap A make sure that the tank is always full Liquid to be used water window cleaning detergent use an anti freeze in winter 11 ACCELERATOR PEDAL SERVICE BRAKE AND INCHING PEDAL Pedal B can
7. Forks or attachment facing downhill Moving with load Forks or attachment facing uphill Ensure that scaffolding loading platform or pile are capable of bearing the weight Ensure the stability and solidity of the ground before depositing a load D Handling Always consider safety and only transport balanced and correctly secured loads to avoid any risk of tipping Fully engage forks under the load and move it in the transport position The forks 300 mm from the ground the jib retracted to the maximum and the carriage sloping backwards For obvious reasons regarding the lift truck s stability and clear visibility of the surroun ding environment only move the lift truck when the jib is in the transport position Do not manoeuvre the lift truck with the jib in the raised position unless under excep tional circumstances and then with extreme caution at very low speed and using gen tle braking Ensure that visibility is adequate and get another person to guide you along if necessary Never shift the position of the load while the lift truck is in motion Never drive too fast or brake abruptly when carrying a load During handling drive at low speed Check the load particularly when turning corners and especially if it is very bulky Secure unstable loads Handle loads with caution at slow speed without sudden jerks when moving them at significant heights and jib extention In the event of high
8. MANITOU MANITOU NORTH AMERICA INC 6401 Imperial Drive Waco TX 76712 6803 For Parts Orders contact your Manitou North America Dealer or call Manitou North America Parts Dept 800 425 3727 or 254 799 0232 Parts Dept Fax 254 867 6504 Website www manitou com www mnadealers com 10210 L E3 M SERIES OPERATOR SERVICE MANUAL THIS OPERATOR S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS CATALOG 648412 R10 10 MHT 10210 L MHT 10210 L M Tarba MHT 10210 L INDEX TABLE OF CONTENTS 1 INSTRUCTIONS ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS DRIVER S OPERATING INSTRUCTIONS Warning General instructions Operating instructions Handling instructions Load handling MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK BEFORE STARTING UP A NEW LIFT TRUCK 2 DESCRIPTION CHARACTERISTICS DIMENSIONS AND LOAD CHARTS INSTRUMENTS AND CONTROLS MAINTENANCE FILTERS CARTRIDGES AND BELTS LUBRIFICANTS SERVICING SCHEDULE A Daily or every 10 hours service B Every 50 hours service C Every 250 hours service D Every 500 hours service E Every 1000 hours service F Every 1500 hours service G Occasional maintenance 4 SYSTEMS ELECTRICAL SYSTEM Electrical system key Electrical system tables HYDRAULIC LAYOUT Movements hydraulic system Steerin
9. A General Check conformity of the accessories to the vehicle safety system calibration Ensure the correct functioning of your lift truck s attachments Do not carry out operations which exceed the capacity of the lift truck or the accessory is prohibited to increase thecounterweight value in any way t is strictly prohibited to carry or to lift up persons using the lift truck unless the vehicle is specially equipped for this purpose and has the corresponding certificate of confor mance for lifting people Avoid travelling for a long distance in reverse When lifting or lowering the boom ensure the control lever is moved slowly and smoothly whether operating with or without a load B Attachments Ensure that the attachment is correctly fitted and locked to its frame Conform to the limits on the load chart for the attachment Position the forks perpendicular to the load to be lifted taking account of the load s centre of gravity Never lift a load with a single fork Never lift a sling load with a single fork or with the carriage Optional solutions exist consult your dealer f not utilise place the attachment in horizontal on the ground For unstable attach ments ensure they are secured using wedges Place the attachments in the closed position flat on level ground for unstable attac ments secure using wedges Ensure that rapid hydraulic connections on the attachment system are cle
10. R9a d 5 m Q N MG BEEN Yao lt T 586 233 p 0 Q 5 T N E R N les I N Y 1 1 87 G G AG1 5 124 aH mm in 6 gt c S5 57 72725 7 0LCOL MANITOU 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA TABLE Denominazione ANTI RIBALTAMENTO E TERGI 9 Name ANTI OVERTURNING WINDSCREEN L _ _ 2 5 5 4 5 6 7 88 m9 9 9 mt Hg 11 0 M1 5nr18 19 0 00 N 19 E ac F27a _ ZI 3 z OF Oo 17 0 O 4 lt z Bnr20 He w O 4 PEE a oBnr10 N SRNW4B O RNnr48 w gt AVAILABLE ONLY FOR MHT 10120 134 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA F en MA N TOU Denominazione MANIP LIVELLAMENTO E LAMPADA ROTANTE 40 AND WORKING LAMP 91 10 9 10 9 RN nr 49 Fl4a 2 10A RNnr14 RNnr14 9 6 2 C RNnr14 GN 9 7 VN gt 16 36 e HR 7 9 MANITOU HN 138 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 Denominazione Name M16
11. RN nr 49 REDISPOSITION ONLY OR MHT 7140 L SB RN nr 49 RN 100 Q O re c 2 a MO RN nr 100 100 ES CO L12 lt RN nr 100 EA E O amp nr 100 T gt 5 c 126 TAVOLA CHECK E INDICATORI OTTICI CHECK AND WARNING LIGHTS 11 72725 7 0LCOL 2 1 E _ 1 5 1 165 11 9 E MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA y MANITUU gt TABLE Name 1 2 INSTRUMENTATION 72725 7 0LCOL EA 7 __ 5 1 81 A EA A 1 7 O A AA 8L A 11 9 ie M16 RNnr 49 13 9 u BGH1 5 SSS SSS SS SS 2 128 gt LL 2 2 TS e O O I F Y C5 129 X lt es ee ee ee 222 11 gt lt I M M10 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA F MANITUU gt CONDIZIONATORE CABINA TABLE Name CONDITIONER 72725 7 0LCOL 6L e R25 R25 c 13 9 M16 D cg I LO 5 F30a 7 5A e p m GZ 5 N O 3E R30 EV 0 0 01 LN eM 10 vcc is C EU Su es GH MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 99
12. m gt o 2 o 332 8 7 x 55 c o gt 70 F 20 m 36 38 35 28 N nr 2 18 0 R nr 3 B nr 3 18 0 18 0 N 18 0 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TA VOLA A Denominazione 4 POS E 2a 3a USCITA BRACCIO Name MANIPULATOR AND 2ND 3RD BOOM S EXIT 17 72725 7 0LCOL 9 A 1 2 1 c _ dq 5 58 1 7 1 85 1 8 15 9 RN nr 49 RN nr 49 19 0 I 17 9 4 RN nr 41 17 9 17 9 RN nr 27 S C 17 9 S 5 AH 00 bd O O CO amp AK Ee 0 MX n o Cl pe gt lt gt lt lt lt m i 2 gt 2 O O x gt 9 3 23000709 1 m E mc m v Beg gm m 5 m o 2 2 o 5 a 2 113 2 2 15 Q 70 79 C gt 5 RUE 2 L19 C 1 0 BS 36 38 35 2 28 z 17 9 R nr 3 17 9 N nr 2 17 9 B nr 3 E BS S12 X 813 N E 17 9 i MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA y MANITUU gt NUBE SUME EE INE TABLE Name HYDRAULIC MOVEMENT SET RESET el o p T __ 2 2 27 S p 94 __ A 20 0 RN nr 49 RN nr 49 21 0 10 9 M1 5nr18 E E FLA1 Se lt gt
13. this might cause an explosion or a fire Place a container under the drainage cap 1 Fig E5 2 and unscrew it Remove the cap 1 Fig E5 1 Allow all the fuel to drain out and rinse with 10 litres of clean fuel poured into the filler orifice Replace and tighten the drainage cap 1 Fig E5 2 Start the thermic motor and let it run to the minimum for a few minutes before using the truck at maximum speed FIG E5 2 2 CHECK THE WEAR OF THE PADS For this oparations consult your agent or dealer 25 3 MHT 10210 L MSexes r EVERY 1500 WORKING HOURS 1 CLEAN THE FUEL PREFILTER CARTRIDGE Open the tank cap to discharge the excess pressure inside the system Clean the outside of the fuel prefilter after taking care to cover the ducts hoses and cables which may be present under the prefilter Unscrew the threaded cap 1 fig F1 and remove it from the filter casing together with filter cartridge 2 Fig F1 Clean the threaded cap 1 Fig F1 and filter cartridge 2 Fig F1 Replace the filter cartridge if it is excessively dirty or damaged Check sealing ring 3 Fig F1 for the threaded cap and replace it if necessary Grease sealing ring 3 slightly Fig F1 Insert the filter cartridge in the threaded cap and screw the lat ter in the filter casing Tightening torque 25 Nm 26 MHT 10210 L 3 22 REPLACE THE FU
14. 1 fig E2 1 Remove the cap and allow the oil to fluid to flow out To speed up the emptying process allow air to enter by remov ing the filler cap 1 fig E2 2 Filling the tank Replace and tighten the drain cap 1 fig E2 1 Fill the tank with oil see table OILS GREASES FLUIDS FUEL FILTERS through the filler hole 71 fig E2 2 until the oil level reaches the mark on the gauge 1 fig E2 3 Check for any leaks from the drainage hole Fit the cap to close the tank 1 fig E2 2 Use only filtered uncontaminated oil 7711122 fig MILL A m T Th LS UN PAL A n j 1 Ls LE Ad h 1 i in 9 d 1 Fer RM It may sometimes be necessary to bleed the pump intake circuit if an al bubble has formed on drainage In this case consult your agent or dealer T FIG E2 3 23 3 23 CHANGING OIL IN FRONT AND REAR WHEEL FINAL DRIVES Place the truck on a horizontal surface with the engine stopped and the final drive oil still hot Empty each front wheel final drive Place the cap 1 fig E3 in horizontal position place a con tainer under the drainage screws 2 fig and unscrew them Take off the cap 1 fig E3 and allow all the oil to flow out Tighten the screws 2 fig E3 with a torque wrench of 130 Nm using loctite 270 for the thread and downcorning silicone type 7091 for the
15. 100 The hours are shown on the dial up to multiples of one thousand electronic Q FUEL LEVEL GAUGE The red zone indicates that the fuel level is low and the truck can only be used for a limited time R MAX WATER TEMPERATURE INDICATOR N B When each red light switches on a buzzer also starts to sound except the light When the ignition key is turned to the first catch with the engine off a check is performed All the lights illuminated and a buzzer starts to operation everything returns to normal once the engine starts 12 MHT 10210 L 2 4 LOAD STATUS CONTROL AND SAFETY DEVICE The load status control and safety device allows the user to check the condition of the fork lift truck in relation to the maximum permitted load at any moment OPERATION When the truck electrical contact is made an automatic check is carried out Correct operation All LEDs and the buzzer operate continuously for 2 seconds Faulty operation All LEDs and the buzzer operate in intermittent mode Switch off the truck and contact your agent or dealer never make repairs yourself A LED VISUAL ALARM Fig 1 1 Fig 1 2 1 4 green LEDs _ The fork lift truck is operating in complete safety 2 2 yellow LEDs The fork lift truck is approaching the maximum permitted load 1 red LED The fork lift truck has reached the maximum permitted load limit The buzzer is activated simultaneously in slow inte
16. 1830 330 Kg F FLOTT L2000 350 Kg F FLOTT L2400 2 X 8000 Kg 80 2400 400 Kg DESCRIPTION CAPACITY WEIGHT 10 MHT 10210 L 5 LOAD CAPACITY CHART m m mu mu m _ 744531 J 5 ARM WITH HOOK FEATURES MHT 10210 L TT LL FEATURES APACITY DIMENSIONS ACCESSORY HOOK DISTANCE DESCRIPTION fain ain WEIGHT PF P2 P D 4 160 16000 Kg 10000 Kg 7500 Kg 850 555 2290 300 300 550 mm 700 1350 2000 650 Kg 12 MHT 10210 L 5 ARM WITH HOOK FEATURES FEATURES DIMENSIONS ACCESSORY HOOK DISTANCE DESCRIPTION CAPACITY mm mm WEIGHT EF 21 21000 850 555 945 300 300 340 mm 700 430 13 5 MHT 10210 L MSexes LOAD CAPACITY CHART oun 10240 21000 TN 2200022 744582 E MHT 10210 L ARM WINCH 7 TON FEATURES DESCRIPTION PT 7000 CAPACITY 7000 Kg FEATURES DIMENSIONS 850 1200 1750 HOOK DISTANCE mm WEIGHT 15 5 MHT 10210 L MSexes WiNCH 16 TON FEATURES LUBRICATION DESCRIPTION RECOMMENDED PRODUCT QUANTITY FREQUENCY ROPE GREASE SHELL RETINAX HDX 2 30 HOURS BLOCK GREASE SHELL ALVANIA GREASE
17. F Flow divider ECL Levelling control solenoid valve EVS Anti tipping solenoid valve F A ntake filter FS Parking brake control cylinder I D P P connection of power steering unit I D LS LS connection of power steering unit M Control lever MC Brake pump M V Fan Motor Pump Optional attachment connection of hydrostatic pump R Hydraulic fluid tank RFS Parking brake control lever V C Compensation cylinder VCLR Slow fast control cylinder Tilting cylinder V L Lifting cylinder V L 1 First levelling cylinder V L 2 Second levelling cylinder V T Boom extension cylinder VM Solenoid and relief valve VSLR Slow fast selector valve 28 MHT 10210 MSeres MOVEMENT HYDRAULIC SYSTEM DIAGRAM VT 110x85x4253 el E NE EX pt M a SR E jJ rm le 2 e E MP 48 53 ier E a En T e EE E ia 1 _ a 200 bar Lo Eu E E e 02 0 E jd gt gt TILTING A 350 bar MER amp
18. UNIT Lubrification of telescope s Lubrification of all pivot pins Wear pads adjustment tightness SAFETY SYSTEM MANISCOPIC Check operation and adjustment ACCESSORIES OPTIONS Check operation CAB Check control panel and all instruments check and control heating and air conditioning ELECTRIC CIRCUIT Battery level checking Lighting operation WHEELS Wheel nut tightness Tyre pressures GENERAL LUBRICATION OF MACHINE TEST OF MACHINE Hydraulic test with nominal load Driving test steering and breaking MHT 10210 L FREQUENCY OF OPERATIONS MAINTENANCE AND LUBRICATION TABLE FREQUENCY COMPONENTS OPERATION N Daily and A1 Engine oil level every 10 2 Cooling liquid level hours Fuel level service 4 Tyre pressure and wheel nut tightness Telescopic boom slide rails XX xx CHECK crease x CLEAN Every 50 84 Air filter cartridge hours 82 Hydraulic oil level service 311 Pins of the base plate and of the rod of the snap coupling cylinder 814 Pins of the base plate and of the rod of the lifting coupling cylinder 813 Pins of the base plate and of the rod of the compensation coupling cylinder 914 Cab door 315 Front and rear wheel pivot pins 816 Steering pins of the front and rear axle 817 Front and rear axle shaft cross journals 819 Pins of the base p
19. be used to vary the speed of the fork lift truck by adjusting the engine rpm Pedal C acts on the front brakes and can be used to slow down and stop the truck During the first 20 mm of its stroke the brake pedal acts as an inching pedal allowing precise slow movements in the rest of its stroke it produces the braking effect 42 DIRECTION REVERSER LEVER The truck s travel direction must be reversed at low speed and without accelerating FORWARD TRAVEL Raise the lever slightly and push it forward Position A REVERSE Raise the lever slightly and pull it back Position B NEUTRAL When the truck is started the lever must be in neutral Position C N B The reverse travel lights indicate that the truck is travelling in reverse There is also a reverse warning beeper If the gear does not engage forwards or backwards see point 5B on page 14 These instructions must be complied with to allow the transmission to operate correctly 17 2 113 PARKING BRAKE LEVER To prevent any accidental release the lever has a safety locking system To engage the parking brake pull the lever back Position A To disengage the parking brake release the lever and push it forward Position B Con il freno di stazionamento attivato leva in posizione A insieme all accensione della spia sul cruscotto viene anche inibito il comando della traslazione del carrello elevatore 14 a HEATING CONTROLS C Fan
20. check that the cartridge has been correctly installed 03 REPLACING THE BREATHER FILTER Unscrew the filter 1 fig D3 in the back of the cab and replace it with a new one of the same characteristics see table FILTER ELEMENTS AND BELTS Fit the new filter tightening it by hand 16 MHT 10210 L MHT 10210 L 3 04 CHANGE THE OIL IN THE FRONT AND REAR AXLE DIFFERENTIAL Place the truck on a horizontal surface with the engine stopped and the differential oil still hot Drain the oil from the front axle differential Place a container under the drainage cap 1 fig E4 1 and allow the oil to flow out Remove the filler cap 2 fig E4 1 to ensure complete drainage Replace and tighten the cap 1 fig E4 1 Fill up with oil see table OILS GREASES FLUIDS FUEL FIL TERS through the filler inlet 2 fig E4 1 The level is correct when the oil is just up to the level indicator cap 2 fig E4 1 Check for any leaks from the drainage cap Replace and tighten the filler cap 2 Fig E4 1 Carry out the same operation for the rear axle differential using the drainage cap 3 fig E4 2 and the filler inlet 4 fig E4 2 DS REPLACE THE AIR FILTER CARTRIDGE The air taken in by the engine is filtered by a dry air filter the truck must not be used without the air filter or with a damaged filter Slacken nut 1 fig D5 1 a
21. down on the pile by lowering and retracting the jib 1 2 in order to position the load correctly Fig N Free the forks by alternately retracting and lifting the jib 3 Fig N or if possible by reversing the lift truck 3 See paragraph E VISIBILITY in the chapter HANDLING INSTRUCTIONS for visibility of the road Then bring the jib into the transport position E Taking up a load without pallet Tilt the carriage 1 forwards and extend the jib 2 while simultaneously crowding the carriage backwards to slip the forks under the load Fig O If necessary wedge the load F Load status indicator Always watch the load status indicator while handling a load If the load status indicator alarm is actived do not carry out A Extend the jib B Lower jib f the load status indicator alarm is actived carry out in all security movements in the following order Fig P 1 Fully retract the jib 2 its necessary lift the jib 3 Lower the jib in order to lay the load The device reading may be false if the steering is turned to the maximum or if the rear axle is swung to the maximum Before lifting a load always make sure the steering is not turned all the way and that the rear axle is not swung completely 15 MHT 10210 MSeries Lift truck with level corrector Correct the slope using the hydraulic control and check the horizontal position on the level before lift
22. from the lift truck portmanteau etc f the control components are fitted with a forced operation lever lock device it is for bidden to leave the cab without first putting these controls in neutral Never allow a passenger to travel on the lift truck in the driver s cab B Before starting the lift truck f the lift truck is new refer to chapter BEFORE STARTING UP A NEW LIFT TRUCK in paragraph 1 OPERATING AND SAFETY INSTRUCTIONS Check the condition of the tyres and the tyre pressures See chapter CHARACTERI STICS in paragraph 2 DESCRIPTION Before starting the lift truck check the different levels Engine oil Hydraulic reservoir oil Transmission oil Cooling liquid Brakes fluid Also check for possible leakage of oil fuel or liquid from the lift truck Check the closing and locking of the hood Whatever his experience as a truck driver is the operator is advised to familiarize him self with the position and operation of all the controls and instruments before operating the lift truck C Starting the lift truck Safety notice The lift truck must only be started up or manoeuvred when the operator is sitting in the driver s cab with his seat belt adjusted and fastened Never try to start the lift truck by pushing or towing it Such operation may cause severe damage to the transmission If necessary to tow the lift truck in an emergency the gear box must be
23. of the carriage in order to keep the load completely stable Slowly move the life truck forward 1 and stop with the forks in front of the load Fig E if necessary slightly lift the jib 2 while taking up the load Apply the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 tilt the carriage backwards 2 in the transport position Fig F Inclinare sufficientemente il carico all indietro per assicurarne la stabilit perdita del carico durante la frenata facendo pero attenzione a non modificarne l equilibrio 13 1 MHT 10210 L MSezxee C Taking up a high load A load MUST NOT be picked up unless the lift truck is on a level surface See para graph G LIFT TRUCK HORIZONTALITY in the Chapter HANDLING A LOAD X x Ensure that the forks will easily pass under the load Position the lift truck perpendicular to the load with the forks in a horizontal position Fig G manoeuvring gently and carefully See paragraph E VISIBILITY in the chap ter HANDLING INSTRUCTIONS for visibility of the road Always think about keeping the distance necessary to fit the forks under the load between the pile and the lift truck Fig G and use the shortest possible length of jib yx Stop with the forks in front of the load Fig H Action the parking brake and place the forward reverse lever in neutral Slightly lift the load 1 and incline the fork
24. ropes at the front of the lift truck on the fastening point 2 Fig G5 3 and at the front of the lift truck on the fastening point 3 Fig G5 3 Tighten the ropes FIG G5 1 FIG G5 2 35 3 MHT 10210 L MSexes G6 ADJUST THE FRONT HEADLAMPS Recommended setting As per standard ECE 76 756 76 761 ECE20 Set to 2 of the dipped beam in relation to the horizontal line of the headlamp Adjusting procedure Place the lift truck unloaded and in the transport position and perpendicular to a white wall on flat level ground Fig G6 Check the tyre pressures See chapter A4 CHECK THE TYRE PRESSURES AND THE WHEEL NUTS TORQUE in paragraph 3 MAINTENANCE Put the gear reverser lever in neutral and action the parking brake Calculating the height of the dipped beam h2 FIG G6 h1 Height of the dipped beam in relation to the ground h2 Height of the adjusted beam Distance between the dipped beam and the white wall h2 h1 I x 2 100 G7 AIR CONDITION Change the gas if the air is not as cold as desired use 134 FREON 1 Kg in case of failure or part s substitution change the oil using 60 gr of specific oil for Air Condition compressor 36 4j o SYSTEMS MHT 10210 MSeres 4 ELECTRICAL SYSTEM Starter motor The starter motor is installed on the left of the engine and no maintenance is required except cleaning and tightening of the terminals If the starter mot
25. the ENGAGING THE ACCESSORY procedure taking care to place it in a safe position on firm flat ground 5 MHT 10210 L MSexes TECHNICAL FEATURES OF ACCESSORIES Index DESCRIPTION PART PAGE PF FLOTT L 2000 Floating fork holder 3 FLOTT L 1800 Floating forks 200x100x1800 TDL FL L 2250 Side shifting fork positioner TDL 550 2250 TDL FL L 2200 Side shifting fork positioner TDL 600 2200 PC 160 Arm with hook 21 T Arm with hook PT 7000 Arm Winch WINCH 16 T MHT 10210 L 5 FLOATING FORK HOLDER FEATURES FEATURES DIMENSIONS ACCESSORY DESCRIPTION CAPACITY mm WEIGHT TIENES AA PF FLOTT L 2000 21000 Kg 2090 1450 770 800 795 Kg FORKS FEATURES DIMENSIONS DESCRIPTION CAPACITY mm WEIGHT F FLOTT L1800 2 X 10500 Kg 200 100 1800 390 Kg 5 MHT 10210 L MSexes SIDE SHIFT FORK POSITIONER FEATURES Ut MAI I di j FEATURES DIMENSIONS DESCRIPTION CAPACITY mn WEIGHT TDL FL 550 2250 8000 Kg 2600 1200 2250 1310 Kg TDL FL 600 2200 10000Kg 2600 1200 470 200 550 2250 1310 Kg FORKS FEATURES DIMENSIONS mm F FLOTT 11500 2X8000Kg 200 80 1500 270 Kg F FLOTT L1830 2X8000Kg 200 80
26. the belt tightener device and the pulleys are in per fect condition for example that there are no damaged bearings on the belt tightener device the belt tightener roller and the return rollers and that the pulley profile is not worn replace the components if necessary Apply the ribbed V belt new on all the pulleys except on the belt tighte ner roller observe Fig D7 which shows the route of the ribbed V belt Rise the belt tightener roller by means of a lever apply the ribbed V belt and then bring the belt tightener roller backwards Remove the release lever and check to ensure the ribbed V belt is lodged correctly on the pulleys Route of the ribbed V belt Fig 07 3 Alternator 4 Belt tightener roller 5 Cooling liquid pump 6 Engine shaft 3 e 5 lt ue 02 i T Hi 5 5 ON 4 AM Wi P gt 18 MHT 10210 L 08 CHECKING ADJUSTING THE VALVE CLEARANCE Operation to be performed the first time on reaching 500 hours of service periodically every 1500 hours of service Adjust the valve clearance with the engine cold Disassembling assembling the cover of the head end 1 Fig 08 If the head covers are excessively smeared wipe and then remove them Disassembly Remove the engine vent tube 6 fig D8 1 from the cover of the cylinders head 2 Fig D8 1 Unscrew and remove the hollow hex head screw 3 fi
27. the circuit using the joystick Always check these pipe unions to ensure they are clean MHT 10210 MSeries GENERAL INSTRUCTIONS A Driver s operating instructions Read the operator s manual carefully making sure you understand it The operator s manual must always be kept in the lift truck in the place provided and in the language understood by the operator Respect the safety notices and instructions given on the lift truck is compulsory to replace all plates or stickers which are no longer legible or which have become worn or damaged B Authorisation to operate Or refer to the legislation for each particular country Only qualified personnel may use the lift truck Its use is subject to authorisation to operate being given by the appropriate manager in the user establishment The user should always carry this authorisation to operate with him while he is using the lift truck The driver is not competent to authorise the driving of the lift truck by another person In addition the vehicle should be used in accordance with good practice for the profes sion C Maintenance The user must immediately advise his superior if his lift truck is not in good working order or does not comply with the safety notice he operator is prohibited from carrying out any repairs or adjustments himself unless he has been trained for this purpose He must keep the lift truck properly cleaned if this is a
28. the forklift Do not use interchangeable accessories not originally included in the machine supply For subsequent requests for implementation of machine functions using other accessories before starting up the machine the user must request inspection for suitability for use by an authorized MANITOU technician who will check the correct working and updating of the documentation necessary for using the new accessory It is only after this inspection that a new CE conformity certificate will be issued for the machine indicating only the new accessories installed 5 MHT 10210 L MSexes GENERAL RECOMMENDATIONS FOR USE OF A LIFT TRUCK WHEN YOU SEE THIS SYMBOL CAUTION TAKE CARE YOUR SAFETY OR THAT OF THE TRUCK IS AT STAKE Follow the data provided in the load diagram Never attempt to raise loads greater than those permitted in the load diagrams supplied with the machine Transport the load in low position with the telescopic boom fully retracted Drive the truck at a speed suitable to the conditions and the state of the ground When the truck is empty travel with the telescopic boom lowered and fully retracted Never go too fast or brake sharply with a load When the load is lifted check that no one can get in the way of the operation and take care not to carry out incorrect procedures Never attempt operations which exceed the lift truck s capacity care over electrical cables Never leave th
29. to be corrected 4 to the right and to the left 4 IMPORTANT HOW TO USE THIS DEVICE Use the bubble gauge to level the machine before lifting and telescoping the boom out The levelling operation cannot be carried out when the boom has been raised more than 30 from the ground If the machine is not on level lower the boom again and repeat the leveling operation 4 mox ____ BEFORE ANY HANDLING WORK CHECK THAT THE LIFT TRUCK IS COMPLETELY HORIZONTAL Never move the vehicle with the boom raised with or without load as it can overturn place the load from a height with the machine stopped MHT 10210 MSeries OPERATING INSTRUCTIONS A Driver s operating instructions Wear clothes suited for driving the lift truck avoid loose clothes Never operate the vehicle when hands or feet are wet or soiled with greasy substan ces For increased comfort adjust the driver s seat to your requirements and adopt the cor rect position in the driver s cab The operator must always be in his normal position in the driver s cab It is prohibited to have arms or legs or generally any part of the body protruding from the driver s cab of the lift truck Always remember to fasten your seat belt and adjust it to your requirements The control units must never in any event be used for any other than their intended purposes e g climbing onto or down
30. 0 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA eN TOU SISTEMA RAFFREDDAMENTO OLIO OIL COOLING SYSTEM 14 A 0c L0 _ 1 2 4 5 6 7 8 9 A M16 16 0 S1 5NR 1 DS 222271 S1 5NR 1 s O gt 4 OPTION AL NEM B 16 0 pa MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TA VOLA 3 ZA TABLE Denominazione STERZATE E ALLINEAMENTO PONTI N Name STEERING CYRCUIT 15 LE gt 72725 7 0LCOL X17 06 40304 duoydua4 IND 0900 UME OV MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA MANITUU CENTRALINA MERCEDES TABLE Name MERCEDES ELECTRONIC DEVICE M16 16 20 0 F10b F8b 9 5 SN nee O GL 18 0 fen m 9 4 ac AS 9 1 RN 27 RN nr 27 18 0 RN nr 41 RN nr 41 18 0 N owe N L c c c 2 2 2 B gt OOOO 0 cq Cl 2 6 5 55 gt m mc Y D 2 T
31. 2 2 18 9 2 RNnr49 M 1 5nr18 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA v MEAE ANTIFURTO AUTORADIO E FARI DI LAVORO p 19 ANTI THIEFT RADIO WORKING LIGHTS 72725 7 0LCOL M16 mre 21 0 N lt 2 c gt amp z 16 5 a RN1 5nr62 LAO N O I N Bc R nr 58 E T AS X36 T R O 199 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA y x e TOU Denominazione ANTIFURTO AUTORADIO 20 Name ANTI THIEFT RADIO 9c L 0 _ 1 j 2 15 4 5 6 7 8 9 19 9 RN nr 49 Al 20 9 RNnr 49 RN2 5 4 9 MBnr 2 51 E E 20 9 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA F MANITUU cero CESTELLO BENNA MIX TABLE Name BASKET MIXING BUCKET 1 X61 A oc nnm I 72725 7 01201 HYDRAULIC SYSTEM MHT 10210 MSeries KEY TO MOVEMENT HYDRAULIC SYSTEM DIAGRAM A Pressure booster COLLET Manifold CPD Locking and balancing valve CSD Double piloted relief valve CSP Piloted relief valve D Directional control valve D
32. 2 OPTIONAL CONTROL ORANGE LED IF EQUIPPED H1 3 OPTIONAL CONTROL GREEN LED IF EQUIPPED WINDSCREEN WIPER WASHER SWITCH L REAR WINDOW WIPER SWITCH M FLASHING LIGHT SWITCH N STEERING SELECTION O EMERGENCY WARNING LIGHTS SWITCH A RESET TRANSMISION In normal operating conditions the button is For more detailed information on use see point B RUNNING SELECTOR SLOW FAST The machine has two speeds Slow work site speed Fast for road travel To change the speed follow the instructions given below stop vehicle movement completely MHT 10210 L AB illuminated keep the I C engine running at minimum speed set the reverse gear in idle see point 12 on page 17 push the brake pedal down all the way and switches on press the fast slow B button till the respective light C or D If the forward or reverse speed is not engaged follow the instructions given below set the reversal lever in the required position Forwards Backwards discharge pressure from the brake pedal press the RESET TRANSMISSION button A to engage in the required direction If the vehicle does not move accelerate the engine slowly and gradually till the truck starts moving These instructions must be followed for proper work
33. 725 7 0LCOL 7 0 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA DEVIO LUCI EMERGENZA ED INTERMITTENZA LIGHT S SELECTOR HAZARD 6 MANITOU 2 CV 2 1 SA 1 7 4 R25 R25 19 19 Roa C 81 5 et CG1 5 186 30 6 3 CV1 5 186 30 Fan LEA N 85 N 85 87 87 O To Te gt B1 5 5 9 54 5 9 LN L 6 9 b 3 63 6 9 6 9 6 9 0 2 O 4 FPDX 7 turn light high beam ition high beam P3 tu position C9 C9 09 amp 09 Q C9 low beam positio low beam turn light turn light 8 0 ET MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA cero FANALERIA TABLE Name LIGHTS I 72725 7 0LCOL L 2148 72725 7 0LCOL 3 LR nr 4 z R16b x RL 9 0 MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TA VOLA Denominazione DEVIO MARCE UR Name FOWARD AND REVERSE GEAR 2 1 _ _ 1 Y p 3 4 A M16 M16 8 9 10 0 I RN nr 49 RN nr 49 6 9 10 9 A 20 7 5 RNnr20 14 S E N S N gt cc E o gt
34. 9 7 40 2 mm if necessary screw the nut 1 until the piston reach that depht unscrew the caps 4 take off the spring 7 with a key of 19 mm and external diameter not higher than 26 mm unscrew the counter nut 9 and screw the nut 1 till the piston is at a maximum depht of 39 7 40 2 mm dimension The nut is 1 has a pitch of 1 75 mm so it s pos sible to calculate how screw the nut for example if the dimension A is of 36 2 mm it s necessary to screw it of 2 turns 3 5 mm Check again the mesure as described and if not right again repeat the operations till now described Screw the counter nut 9 untill the nut 1 mount again the spring 7 and the caps 4 and 5 Note exceeding the mesure of 40 2 mm the complete unlock of the brake it s not possible so the brake could overheat and damage it self quickly A bad regulation could cause big damages to the brakes and also a quickly destruction If the nut 1 is unscrewed too far the machine doesn t brake Dangerous to your life Pay attention to the dimension B if it s lower than 24 5 mm you must change the brake disk FOR THESE OPERATION CONSULT YOUR AGENT OR DEALER caca LR Fa NARA wn M M 4 A FAA rar IE ee 224 ifs mm Fig G3 33 3 MHT 10210 L MSexes G4 SLING THE LIFT TRUCK
35. A2 5 B1 4 DIAG1 17 DIAG2 18 DL 6 DM 8 F1b 21 F2a 21 F4a 8 F4b 9 F5a 8 F5b 5 F6a 7 F6b 15 T F7b 8 F8a 7 F8b 17 F9a 7 F9b 17 F10a 5 F10b 17 F11a 6 F11b 20 F12a 6 F12b 10 F13a 5 F13b 5 F14a 11 F14b 21 F15a 16 F15b 20 F16a 13 F16b 8 F17a 13 F17b 8 F18a 13 Function Reverse engaged buzzer Horn 12 V battery Diagnostics connector 1 Diagnostics connector 2 Lights switch Run switch Basket fuse 15 Air heater fuse Gear reset fuse Slow fast movement fuse Forward reverse movement fuse Differential block fuse Position lights fuse Steering power supply fuse Position lights fuse Fuse for start up from motor Low beam lights fuse Rexroth outputs fuse High beam lights fuse Manoeuvre manipulator fuse Brake lights fuse Rexroth control unit fuse Emergency 15 fuse Antitheft 15 fuse Emergency 30 fuse Levelling fuse Horn fuse Military lights selector fuse Optical indicators fuse Mixer bucker emergency pump fuse Diagnostics power supply fuse Radio 15 fuse 1st rear fan speed diode Forward gear engaged diode 2nd rear fan speed diode Reverse gear engaged diode 3rd rear fan speed diode F18b F19a F19b F20a F20b F21a F21b F22a F22b F23a F23b F24a F24b F25a F26a F26b F27a F28a F28b F29a F29b F30a F30b F31a F31b F32a F32b F33a F33b F34a F34b F35a F35b F36a F36b FADX FASX FG I lt lt Y 09 Y Reverse relay diode 1200 rpm s
36. E F4 5 FREEZING POINT DEPENDING ON THE 9 6 VOLUME OF ANTIFREEZE AND WATER Antifreeze Water Temperature SHELL ANTIFREEZE distilled recommended freezing 25 75 12 35 65 21 C filling by Manufacturer 40 60 26 50 50 38 Pour the cooling liquid through the opening in tank 5 Fig F4 6 up to the MAX mark Refit cap 5 to close the tank Fig F4 6 Start up the engine and run it for about one minute changing the speed to release air bubble from the cab cooling and hea ting system Switch the engine off and top up with cooling liquid to the MAX level in the tank FIG F4 6 30 MHT 10210 L OCCASIONAL MAINTENANCE 1 CHANGE A WHEEL In the event of a wheel being changed on the public highway make sure of the following points Stop the lift truck if possible on even and hard ground pass on stop of lift truck See chapter DRIVING INSTRUCTIONS in paragraph 1 OPERATING AND SAFETY INSTRUCTIONS Action the parking brake Put the warning lights on Immobilise the lift truck in both directions on the axle opposite to the wheel to be changed Unlock the nuts of the wheel to be changed Place the jack under the flared axle tube F R as near as possible to the wheel and adjust the jack Fig G1 Lift the wheel until it comes off the ground and put in place the safety support under the axle Fig G1 For this operation we advi
37. EL PREFILTER CARTRIDGE WITH WATER SEPARATOR Turn knob 1 Fig F2 1 clockwise to close the fuel flow dur ing cartridge replacement Open drainage valve 2 Fig F2 2 and bleed screw 3 Fig F2 1 and collect the water fuel mixture flowing out of the filter element in a container Unscrew and remove filter cartridge 4 Fig F2 2 Unscrew and remove the separator container 5 fig F2 2 from the filter cartridge and clean or replace it as required Reassemble by following the procedure described in reverse order tightening elements 4 and 5 fig F2 2 manually on the filter body 3 In the assembly phase use new lubricated sealing rings X FIG F2 1 Close drainage valve 2 Fig F2 2 Turn knob 1 Fig F2 1 anticlockwise to open the fuel flow Press the small hand pump 6 Fig F2 1 F2 2 repeatedly until the fuel flows out through the vent hole 3 Fig F2 1 Then close venting screw 3 Fig F2 1 Start up the engine and keep it running at minimum for about one minute to let out the air bubbles automatically from the sup ply system Check for fuel leaks from the prefilter 27 3 MHT 10210 L MSerces FS REPLACE THE FUEL FILTER CARTRIDGE Open the tank cap to prevent overpressure from building up insi de J 4 a Unscrew threaded cap 1 Fig F3 of the fuel filter using a pipe wrench Remove threaded cap 1 Fig F3
38. EP2 LF 30 HOURS WINCH RED OIL SHELL SPIRAX HD 80W 90 1 51 150 HOURS 1000 HOURS HOOK ROTATION OIL AT 40 30 HOURS FEATURES ACCESSORY DESCRIPTION CAPACITY ROPE HOOK LIMIT STOP mm WEIGHT SPEED 16000 4000 16 WINCH 16 T WITH 4 DIRECT 25100 daN 22T m min HYDRAULIC 1205 2340 1000 250 1185 Kg ROPES TYPE x60m 16 MHT 10210 L 5 LOAD CAPACITY CHART 74533
39. Ensure that the service brakes and the sound alarm are working properly Drive according to and at an appropriate speed for the conditions and state of the ter rain Slow down before executing a turn n all circumstances make sure you are in control of your speed On damp slippery or uneven terrain drive slowly Brake gently never abruptly Only use the lift truck s forward reverse lever from a stationary position and never do so abruptly Always remember that hydraulic type steering is extremely sensitive 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 visibility of the road Use the left and right rear view mirrors frequently and ensure that they are kept in good condition are clean and correctly adjusted Never use the truck in places poorly lighted When working at night ensure that your lift truck is fitted with full beam lights There are optional solutions consult your agent or dealer Drive round obstacles Never move onto a loading platform without having first checked That it is suitably positioned and madefast That the unit to which it is connected Wagon lorry etc will not shift That this platform is prescribed for the total weight of the lift truck to be loaded That this platform is prescribed for the width of the lift tru
40. ILTER WITH WATER SEPARATOR if necessary Position the truck on a level surface with the engine switched off Open the engine hood Check for liquid in the tank B7 1 and top up if necessary Place a container under the drain plug B7 2 and unscrew it Let the gas oil flow out until it is free of impurities Screw the plug back on while the gas oil is flowing out 1 4 No Ue A MHT 10210 L 3 GREASE POINTS To be carried out weekly if the lift truck has been operated for less than 50 hours during the week In the event of prolonged use in an extremely dusty or oxidising atmosphere reduce this interval to 10 working hours or every day 59 Grease the articulation pin of the telescopic boom 1 fig B8 89 Grease the telescopic boom upper shoes 1 fig B9 840 Grease the articulation pin of the snap coupling 1 fig B10 814 Grease the pins of the base plate 1 fig B11 1 and of the rod 2 fig B11 2 of the snap coupling cylinder 842 Grease the pins of the base plate 1 fig B12 1 and of the rod 2 fig B12 2 of the lifting cylinder 843 Grease the pins of the base plate 3 fig B13 1 and of the rod 4 fig B13 2 of the compensation cylinder 844 Grease the cab door 1 fig B14 315 Grease the pivots of the front and rear wheels 1 fig B15 1 B15 2 316 Grease the ste
41. ION R15 25 SEGNALE ROSSO sez 1 5 mm DIRETTO A PAG 2 COLONNA 5 RED SIGNAL sect 1 5 mm LEADING TO PAGE 2 COLUMN 5 7 0 SEGNALE ROSSO sez 1 5 mm PROVENIENTE DA PAG 1 COLONNA 7 RED SIGNAL sect 1 5 mm COMING FROM PAGE 1 COLUMN 7 Colori Colors Bianco White R Roso R MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA TABLE Denominazione LEGENDA COLORI 3 72725 7 0LCOL MANITOU Name COLORS NOTE FG R25 XI A pee 6 0 150A e BR N 12 4 21 0 es 16 8 P X19 R25 O M16 ED MBnr 1 21 8 ES 14 0 30 Cn N Pss YY 15 54 B N 40004 09006 T O __ __ __ i 16 2 x 83 5 0 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA Denominazione QUADRO AVVIAMENTO STARTING ENGINE 4 A OL ARA ee 4 9 M16 Mae 2 1 5 T RN nr 49 11 5 ZN 6 0 RV 1 5 8 0 30 RN nr 49 O 87 870 21 7 4 B5 8 6 2 21 8 E E El AVAILABLE ONLY TT TR 299 7140 L N MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA Denominazione SELETTORE LUCI MILITARE LUCI SCRUPOLARE 5 72725 7 0LCOL Name WAR LIGHT S SELECTOR 72
42. NOTE LEGENDA COLORI COLOUR NOTE QUADRO AVVIAMENTO STARTING ENGINE SELETTORE LUCI MILITARE LUCI OSCURATE WAR LIGHT S SELECTOR DEVIO LUCI EMERGENZA ED INTERMITTENZA LIGHT S SELECTOR HAZARD FANALERIA LIGHTS DEVIO MARCE FORWARD AND REVERSE GEAR ANTI RIBALTAMENTO E TERGI ANTI OVERTURNING WINDSCREEN MANIP LIVELLAMENTO E LAMPADA ROTANTE LEVELLING AND WORKING LAMP CHECK E INDICATORI OTTICI CHECK AND WORNING LIGHTS STRUMENTAZIONE INSTRUMENTATION CONDIZIONATORE CABINA CONDITIONER SISTEMA RAFFREDDAMENTO OLIO OIL COOLING SYSTEM STERZATE E ALLINEAMENTO PONTI STEERING CYRCUIT CENTRALINA MERCEDES MERCEDES ELECTRONIC DEVICE MANIPOLATORE 4 POS E 2a 3a USCITA BRACCIO MANIPULATOR AND 2nd 3rd BOOM S EXIT SET RESET MANOVRE IDRAULICHE HYDRAULIC MOVEMENT SET RESET FARI LAVORO WORKING LIGHTS ANTIFURTO AUTORADIO ANTI THIEFT RADIO 21 CESTELLO BENNA MIX BASKET MIXING BUCKET 72725 7 0LCOL e oco NO lt gt N O E EUN N MHT 990 7140 10160 M SERIES DISTRIBUTORE REXROTH 09 2003 MHT 990 7140 10160 M SERIES DISTRIBUTOR REXROTH 09 2003 TAVOLA F gt LEGENDA FOLGLI TABLE Name TABLE NOTE I AE __ __ OA 1 27 A A LEGENDA DESCRIPT
43. Ps ATEN DUM sir KMS 58 gt ER x e om i 9 o gt LL 4 A u 4 1 1 4 gt 9 ee oal 1 IS ee lt 100 4 n 300 2 83 i E 1 1 M TELESKOP A ME 5 E P 1 a3 DON ba ANE E Mc LS dij m E 5 8 4 1 1 pes 1 HE FD x ES m B2 280 par i 5 i 5 P 2 A A 7 NE _ a N 2s pol 1L DN gt 6 ra PSl 2 5 LIFTING A1 A 280 bar 5 E 1 3 7 O EEN EE em 5 epee iH ux 20 8 1 5 5 55 Hr 4 W 22 0 1 P em SI Y j 53 ts A NP 4 9 01 6 s 6 4 4 gt 5 gt 8 1 8 E E T 350 bar a lis 20 8 5 208 La UT ig si gt gt E EUN 0 LS 30 15L min 860 eee Ore mo Zu LH T S SX i 5 1 F L
44. RISK EXTEND THE TELESCOPIC SYSTEM FAR ENOUGH TO ELIMINATE THE INTERFERENCE THE DISTANCE WILL DEPEND ON THE TRUCK AND THE ACCESSORY The maximum loads are defined by the lift truck s capacity bearing in mind the weight and centre of gravity of the accessory If the capacity of the accessory is below that of the lift truck never exceed this limit Before putting any type of accessory into operation on the fork lift truck check the machine s compatibility and the calibration of the safety system with regard to the accessory used MHT 10210 L ACCESSORY WITHOUT HYDRAULIC SYSTEM AND MANUAL LOCKING ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly positioned take the necessary precautions to move it in the conditions of maximum safety Check that the locking pin is engaged in the support provided on the frame Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement MANUAL LOCKING Take the locking pin on the support and fix the accessory Fig C Do not forget to fit the split pin MANUAL RELEASE Proceed in revers
45. Take into account the position of the lift truck gravity center for lifting Fig G4 1 Place the hooks in the fastening points provided Fig G4 2 and G4 3 FIG 64 2 FIG 643 2450 mm 1200 mm 3900 mm D 2500 mm G Position of the center of gravity Fig G4 1 34 MHT 10210 L 3 G5 TRANSPORT THE LIFT TRUCK ON A PLATFORM To carry the machine respect the circulation laws Ensure that the safety instructions connected to the platform are respected before the loading of the lift truck and that the driver of the means of transport is informed about the dimensions and the weight of the lift truck See chapter CHARACTERISTICS in paragraph 2 DESCRIPTION Ensure that the platform has got dimensions and a load capacity sufficient for transporting the lift truck Check also the pressure on the contact surface allowable for the platform in connection with the lift truck 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 Stop the lift truck See chapter DRIVING INSTRUCTIONS in paragraph 1 OPERATING AND SAFETY INSTRUCTIONS Sling the lift truck Fix the chocks to the platform at the front and at the back of each tyre 1 Fig G5 1 and Fig G5 2 Stow the lift truck on the platform with enough resisting
46. V ud COLLET 3 31 4 COLLETTORE D DF F A ER I D M MC R Rd RFS V l VM VSLR 32 Manifold Directional control valve Flow divider Intake filter Drain filter Power steering unit Control lever Brake pump Hydrostatic motor Engine Fan Motor Hydrostatic pump G connection of hydrostatic pump Hydraulic fluid tank Oil radiator Parking brake control lever Inching valve Solenoid and relief valve Slow fast selector valve MHT 10210 MSeries KEY TO TRANSMISSION HYDRAULIC SYSTEM DIAGRAM TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 72725 7 0LCOL PS EV D i i i b UJ NU y 512 bar A Ue
47. afe position on firm flat ground MHT 10210 L ACCESSORY WITH HYDRAULIC SYSTEM AND MANUAL LOCKING OPTIONAL ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly positioned take the necessary precautions to move it in the conditions of maximum safety Check that the locking pin is engaged in the support provided on the frame Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement MANUAL LOCKING AND CONNECTION OF THE ACCESSORY Take the locking pin on the support and fix the accessory Fig C Do not forget to fit the split pin Switch off the engine Eliminate the accessory hydraulic circuit pressure using the optional control refer to the controls pages of the use and maintenance manual Connect the snap couplings following the description of the hydraulic movements of the accessory Keep the snap couplings clean and protect the unused orifices with the caps provided REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking ca
48. an and pro tected Carry out the following procedure before changing hydraulic attachments to prevent damage to the quick release couplings Switch off the engine turn key to position release pressure from the circuit using the joystick 10 MHT 10210 MSeres C Environment Verify that the lighting in suitable Ensure that no person or objet is in the vicinity before raising the load Don t make any incorrect manoeuvres n the case of work near aerial lines ensure that the safety distance is sufficient between the working area of the lift truck and the aerial line You must consult your local electrical agency You could be electrocuted or seriously injured if you operate or park the lift truck too close to power cables You are strongly advised to ensure that the safety rules on the site conform to the local regulations in force regarding all types of work carried out close to power cables Do not allow anybody to come near the working area of the lift truck or pass beneath an elevated load When using the lift truck on a slope before raising the jib ensure that the ground is horizontal However fork lift trucks provided with level correctors and or stabilizers can operate on transverse slopes provided this slope is corrected See paragraph G LIFT TRUCK HORIZONTALITY in the Chapter HANDLING A LOAD Travelling on a longitudinal slope Drive and brake gently Moving without load
49. ation in order to be maintain his own safety that of others and of his equipment Always be aware of his stopping distance On the basis of experience there are a number of possible situations in which operating the lift truck is contra indicated Such foreseeable abnormal uses the main ones being listed below are strictly forbidden The foreseeable abnormal behaviour resulting from ordinary neglect but does not result from any wish to put the machinery to any improper use The reflex reactions of a person in the event of a malfunction incident fault etc during operation of the lift truck Behaviour resulting from application of the principle of least action when performing a task For certain machines the foreseeablebehaviour of such persons as apprentices tee nagers handicapped persons and trainees tempted to drive a lift truck Truck drivers tempted to operate a truck to win a bet in competition or for their own per sonal experience MHT 10210 MScxucee 1 The person in charge of the equipment must take these criteria into account when assessing whether or not a person will make a suitable driver Get to know the telescopic fork lift truck on the terrain where it is to be used Transport the load with the boom lowered and fully retracted Position the forks at right angles to theload to be lifted Drive the truck at a speed appropriate to conditions and the state of the ground Neve
50. ck Never move onto a foot bridge floor or freight lift without being certain that they are prescribed for the weight and size of the lift truck to be loaded and without having checked that they are in sound working order Take extreme care with loading platforms trenches scaffolding recently dug and or backfilled ground The loaded lift truck must not travel at speeds in excess of 10 km h 1 MHT 10210 L MSezxee Movement instructions Check the transmission oil level Raise the forks or attachment to the transport position approximately 300 mm from the ground Engage the gear selected See chapter CONTROL AND COMMAND INSTRUMENTS in part 2 DESCRIPTION Select the required steering mode Shift the forward reverse lever to the selected direction of travel Release the parking brake and accelerate gradually until the lift truck moves off E Stopping the lift truck Safety notice Before stopping the lift truck after a long working period leave the engine idling for a few moments to allow the coolant liquid and oil to lower the temperature of the engine and transmission Ensure you comply wiyh this safety notice as stopping the engine without allowing it to cool could cause damage to components damaging such parts Never leave the ignition key in the lift truck when the lift truck is unattended When the lift truck is stationary place the forks or attachment on the gr
51. ck the level of the electrolyte in each battery cell 1 fig B6 1 If necessary add only distilled water to restore the level Never add sulphuric acid If frequent topping up with distilled water becomes necessary or if the battery is subject to getting discharged check the regulator voltage which must be between 13 V and 14 7 V with the engine running at maximum speed Once in a while check the connecting terminals to make sure they are not rusted If the vehicle is to remain unused for a long time disconnect the battery FIG B6 1 When the ambient temperature is high the level should be checked more frequently than once every 50 hours Maintenance Check connections 2 fig B6 2 Check eleclrolyte levels regularly 3 fig B6 2 Add distilled or demineralised water if necessary Never add acid Battery needs to be recharged if voltage drops below 12 3 V specific gravity of 1 21 f vehicle is not being used for a long period disconnect the battery F Charging off the vehicle Remove vents 3 fig B6 2 Only use direct current DC Connecl with with gt Charge at recommended bench rate i e 10 of battery capacity The battery is fully charged when specific gravity has reached 1 28 1 23 under tropical climate When charge has completed Switch off charger then disconnect Check electrolyte level 87 CLEAN THE FUEL PRE F
52. d S connection of directional control valve SX connection of directional control valve Solenoid valve Parking brake control cylinder Rear axle disk brake Front axle disk brake Power steering unit Brake pump Brake pedal G connection of hydrostatic pump Parking brake control lever Brake oil tank Steering Cylinder Slow fast control cylinder Slow fast selector valve MHT 10210 MSeres BRAKE STEERING SYSTEM DIAGRAM 4 LN MEN RFS BA XT TAS TP VSLR COLLET 2 COLLET 3 PH G FDAR FDAV D S D SX VEER FS 2 4 V D E e FS FDAR 4 FDA
53. d at once and put right without delay the instrument is not giving a correct reading stop the engine and take the necessary measures to restore correct operation immediately Using the fork lift truck without following these recommendations may have dangerous consequences 2 MHT 10210 L MSexes 1 DRIVER S SEAT STANDARD FOR ENHANCED COMFORT THIS SEAT ALLOWS VARIOUS ADJUSTMENTS WEIGHT ADJUSTMENT The seat should be adjusted to the driver s weight with no one sitting on it Take the seat notch 1 as reference Turn the knob 2 as appropriate to the driver s weight N B To avoid health problems the weight setting should be checked and adjusted before the truck is put into operation ADJUSTING THE SEAT HEIGHT Bring the seat to the desired position until the catch is heard to engage If the seat is raised above the last catch it will return to the lowest position ADJUSTING THE SEAT ANGLE The seat angle can be regulated individually Press the button on the left and at the same time push or release the seat to obtain the position desired ADJUSTING THE SEAT POSITION The seat position can be regulated individually Press the button on the right and move the seat forward or back to obtain the position desired SEAT BACK EXTENSION The height of the seat back extension can be adjusted the catches can be heard until the stop is reached The seat back extension can be removed by pulling until it mo
54. d equipment Truck weights with std carriage and forks Axle ground weights with std equipment Front unloaded Rear unloaded Drawbar pull Forks dimensions lenght x width x thickness external fork spread Distance from center of gravity Tank capacities Hydraulic oil Fuel Vibrations Acceleration of upper limbs Acceleration of body feet or seated part Noise The noise level guaranteed 25 Km h 10 Km h 25 Km h 10 km h 80 38 9700 mm 21000 Kg 28350 kg 9320 kg 19030 kg 15000 daN 1800 x 200 x 100 mm 2000 mm 900 mm 200 1 200 2 5 m s 0 5 m s LwA 108 dB in accordance with Directive EN 2000 14CE modified by Directive 2005 88 CE N c c cc Homxozmr x ooommocoou lt 1800 3650 1350 6860 8660 2000 510 470 510 1860 2000 100 2325 200 5750 12030 5040 2960 7280 3160 6050 2500 12 105 PF 4 E Ens ima mma vids pm OR 1 T MHT 10210 L MHT 10210 L 2 LOAD CAPACITY CHART MIT 10210 21000 2 Y ee 1 d CN 788835 P 2 MHT 10210 L MSexes MHT 10210 L MSeries 2 DESCRIPTION 1 Driver s seat 2 Seat belt 3 Moni
55. e stopped Check the level on the final drive of each front wheel Set the level cap 1 fig C2 horizontal Remove the cap the oil must be up to the surface of the hole Top up with oil if necessary see OILS GREASES FLUIDS FUEL FILTERS table Carry out the same operation on the final drive of each rear wheel G3 CHECK THE OIL OF FRONT REDUCTION GEAR ON AXLE Place the truck on a horizontal surface with the engine stopped Remove the level cap 1 Fig C3 the oil must come up to the orifice f necessary top up with oil through the same orifice See OILS GREASES FLUIDS FUEL FILTERS table Replace and re tighten the level cap 1 Fig C3 14 MHT 10210 L 3 CHECKING THE POLY V RIBBED BELT TENSION Open the engine hood and remove crank case 1 C4 1 Check for the presence of damage on ribbed belt 2 C4 2 moving one section at a time to carry out this check Make a mark with chalk on the ribbed belt Make the engine run in bursts or move the ribbed belt by means of a rotation device up to the chalk mark Replace ribbed belt 2 C4 2 if one of the following types of damage mentioned are present C4 3 The damage FIG C4 1 1 New belt comparison ribbing 2 Wear on the sides wedge shaped ribbing 3 Frame visible at the bottom of the ribbing 4 Ribbing broken 5 Transverse cracks in different ribs 6 Rubber nodu
56. e direction to the MANUAL LOCKING procedure taking care to replace the locking pin in the support on the frame REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking care to place it in a safe position on firm flat ground MHT 10210 L 5 ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly positioned take the necessary precautions to move it in the conditions of maximum safety Check that the rods of the locking cylinder are retracted Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connection pipe raise the boom slightly and tilt the connection back to position the accessory Fig B Raise the accessory off the ground for easier engagement HYDRAULIC LOCKING AND RELEASE OPTIONAL The accessory if any is locked and released using the optional con trol which may be operated by a push button or using the control lever itself depending on the type of truck For further information refer to the use and maintenance manual provided with the truck REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to the ENGAGING THE ACCESSORY procedure taking care to place it in a s
57. e truck parked with a raised load Never authorise anyone to approach or pass under the load Always think of safety and only transport well balanced loads Never leave the truck loaded with the parking brake engaged on gradients exceeding 15 With the winch or equipment with a load hanging from the hook always adopt the following precautions Position the winch perpendicular to the load to be lifted The empty hook must be lowered slowly gently since if it is operated too quickly the cable wound round the drum may become slack causing serious problems for the cable the limit stop device etc If the cable tends to become twisted around the block release the fixed end hook pull the cable in the opposite direction until the twisting is eliminated then re connect the end unit Operate the control lever gently to prevent jerking of the load and possible problems in the winding of the cable onto the drum Raise the load vertically avoiding swaying and slanting lifting Check the cable daily if it is worn or damaged or has even one broken strand see ISO 4309 replace it immediately contact your dealer Check that the hydraulic hook raising and lowering limit stop is in good working order and that the brake holds with load applied Oil the revolving part of the hook periodically Check periodically that the cable is winding onto the drum correctly The following accessories are not intended for systems for lifting or
58. en the air filter cartridge is fouled Switch off the truck and make the necessary repairs see frequency of cleaning and replacement procedures E RED MERCEDES ENGINE ALARM LIGHT The light idicates the failure of the Mercedes engine contact your agent or dealer F RED ENGINE OIL LEVEL LIGHT If the light is activated during operation of the fork lift truck stop the engine immediately and check the engine oil level If the level is relatively low fill with the proper oil o o E RED BRAKE FLUID LEVEL LIGHT If the light and buzzer are activated during operation of the fork lift truck stop the engine immediately and check the brake fluid level If the level is relatively low contact your agent or dealer H RED LIGHT PARKING BRAKE The light indicates that the parking brake has been pulled on GREEN DIRECTION INDICATOR LIGHT This light comes on at the same time as the direction indicators and shows that they are operating correctly L GREEN LIGHT SIDE LIGHTS This light illuminates when the side lights are in operation M GREEN DIPPED HEADLIGHT LIGHT This light illuminates when the dipped headlights are switched on e 11 2 MHT 10210 L MSexes N BLUE FULL BEAM HEADLIGHT LIGHT This light illuminates when the full beam headlights are in operation O RPM COUNTER HOUR COUNTER Indicates the number of hours the truck has worked RPM x
59. eplace the seat belt immediately 2 MHT 10210 L MSe e 3 MONITORING INSTRUMENT AND INDICATOR LIGHT PANEL Red alternator excitation light Redengine oil pressure light Red engine water temperature light filter fouling indicator light Red Mercedes engine alarm light Redengine oil level light Red brake fluid level light Red parking brake light Green direction indicator light Green dipped headlight light Green side light light Blue full beam headlight light Rpm counter Hour counter Fuel level gauge Engine water temperature AO VTOZSET IO0TMUOOUO gt 7 20 10 9 25 N30 electronic A RED ALTERNATOR EXCITATION LIGHT If lights A B C D F G and the buzzer are activated during operation of the fork lift truck stop the engine immediately and check the electrical system and the fan belt B RED ENGINE OIL PRESSURE LIGHT If the light and buzzer are activated during operation of the fork lift truck stop the engine immediately and look for the origin of the fault See oil level in engine pump RED WATER TEMPERATURE INDICATOR LIGHT If the light and buzzer are activated during operation of the fork lift truck stop the engine immediately and look for the origin of the fault in the cooling circuit 10 MHT 10210 L D RED AIR FILTER FOULING LIGHT The light and buzzer are activated wh
60. ering pins the front and rear axle 1 fig B16 317 Grease the front and rear axle shaft cross journals 1 fig B17 FIG B15 2 FIG B16 11 DIA DIA cya A 21 9 OIA N T L LL DI 019 91 MHT 10210 L 3 318 Grease the pins of the rod 1 fig B18 and of the base plate 2 fig B18 of the levelling cou pling cylinder 319 Grease tilting bushes of front axle 1 2 Fig B19 1 Grease tilting bushes of rear axle 3 4 Fig B19 2 820 Grease the axle drive shaft and cross journals on the rear side 1 fig B20 1 and front side 1 fig B20 2 fig B20 3 n 4 13 3 MHT 10210 L MSexes EVERY 250 WORKING HOURS 4 CHECK THE OIL LEVEL OF THE FRONT AND REAR AXLE DIFFERENTIAL Place the truck on a horizontal surface with the engine stopped Check the oil level of the front axle differential Remove the cap 1 fig C1 1 The level is correct when the oil is just up to the level indicator cap 1 fig C1 1 If necessary top up with oil through the filler inlet 1 fig C1 1 see OILS GREASES FLUIDS FUEL FILTERS table Repeat this operation for the rear axle differential using the filler inlet 1 fig C1 2 2 CHECK THE OIL LEVEL OF THE FRONT AND REAR WHEEL FINAL DRIVES Place the truck on a horizontal surface with the engin
61. g D8 1 from the cover of the cylinders head together with sealing ring 4 Fig D8 1 Remove the head cover 2 Fig D8 1 Assembly Clean the sealing surfaces of the cylinder heads and relative cover 2 Fig 08 1 Always replace gasket 5 fig 08 1 between the cover of the cylinder head and the head Fit the cylinders head cover 2 Fig D8 1 Insert the hollow hex head screw 3 Fig D8 1 with new sealing rings 4 Fig D8 1 and tighten tightening torque 30 Nm e 1 Tm 2 e e s 9 FIG D8 1 19 3 MHT 10210 L MSexes Layout of cylinders and valves Fig D8 2 suction valve q discharge valve X handwheel side Checking adjusting the clearance of the valves Measure the valve clearance between the rocker arm and the valve stem discharge valve or the valves bridge suction valve using a thickness gauge arrow The thickness gauge must be able to pass through with slight resistance Valve clearance 0 40 mm 0 60 mm suction valve discharge valve To adjust the valve clearance slacken lock nut 1 fig D8 3 Adjust the valve clearance by turning adjuster screw 2 Fig 08 3 FIG D8 3 Retighten the lock nut Tightening torque 25 Nm Check the valve clearance again and correct it if necessary 20 MHT 10210 L 3 09 CHANGE THE OIL AND THE ENGINE FILTER Change the oil only with t
62. g and brakes hydraulic system Hydrostatic transmission system 5 OPTIONAL ACCESSORIES ENVISAGED INTRODUCTION General recommendations for use of a lift truck Accessory without hydraulic system and manual locking Accessory without hydraulic system and hydraulic locking optional Accessory with hydraulic system and manual locking optional Accessory with hydraulic system and hydraulic locking optional Technical features of accessories MHT 10210 L INTRODUCTION Our telescopic lift trucks have been designed to ensure simple manoeuvres and easy maintenance Before operating the truck for the first time the driver should read and become fully familiar with the various chapters in this manual These instructions have been prepared to provide all the information required for proper servicing and truck operation By complying with these instructions the truck driver will be able to get the best performances from his vehicle The terms right and left front and rear used in this manual refer to positions viewed by the driver seated normally in the driving seat Always state the following information when ordering spare parts or requesting technical information Manufacturer s data plate FIG A Model L MANITOU Series MANITOU BF 44158 ANCENIS CEDEX FRANCE 4 H o Serial N Year of manufacture o Chassis Nr Chassis N A Unladen weight Ma
63. he engine at operating temperatu re Engine oil filter Unscrew the threaded oil filter cap using a 36mm pipe wren ch Drain the oil out of the filter casing Remove threaded cap 1 fig D9 1 together with oil filter cartridge 3 Fig D9 1 and release cartridge 3 Fig D9 1 by pressing on the sides of the lower edge Make sure no foreign bodies enter the filter casing The filter casing must not be wiped with cloth or anything similar Change sealing ring 2 Fig D9 1 present on threaded 1 Fig D9 1 Grease sealing ring 2 slightly Fig D9 1 Introduce the new cartidge 3 fig D9 1 in threaded cap 1 Fig D9 1 and press to fit it in place Screw the threaded cap on the oil filter casing and lock it tight Tightening torque 40 Nm FIG D9 1 Drain the engine oil Place a suitable container under the oil drainage screw 4 fig D9 2 present on the lower part of the oil cup Unscrew the drainage screw carefully and allow the oil to flow out The engine oil and the filter must be disposed off in compli ance with the legal prescriptions applicable in the place where the engine is used Refit the drainage screw with a new sealing ring and tighten it Tightening torque M20 x 1 5 60 Nm M26 x 1 5 85 Nm 21 3 MHT 10210 L MSexes Change the engine oil Pour fresh oil into the engine through filler plug 5 fig D9 3 until the level reaches the ma
64. head of the screw Fill up with oil see table OILS GREASES FLUIDS FUEL FILTERS through the filler hole 1 fig F3 The level is correct when the oil is just up to the hole 1 fig E3 Replace the cap 1 fig E3 and tighten it Repeat this operation for each rear wheel final drive 24 CHANGE THE OIL IN THE FRONT AXLE REDUCTION GEAR the truck on a horizontal surface with the engine off and the oil in the reduction gear still hot Place a receptacle under drain plug 1 fig E4 Remove plug 1 and allow the oil to drain out Remowve fill and level plug 2 fig E4 to ensure that all oil has drained out Refit and tighten plug 1 fig E4 Fill with oil see LUBRICANT chart through fill and level plug 2 fig E4 The level is correct when flush with the top of the hole Refit and tighten the fill and level plug 2 fig E4 Check for any leaks from the drain plug 24 MHT 10210 L MHT 10210 L 3 25 EMPTYING AND CLEANING THE FUEL TANK During this operation do not smoke and do not approach with naked lights Place the truck on a horizontal surface the engine must be stopped Make a visual and manual check on the parts on the fuel circuit and in the tank which may leak n case of leaks contact your agent or dealer FIG E5 1 Never attempt to make a weld or perform any other operation on your own
65. hird party MHT 10210 MSeres D Environment A lift truck operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher There are optional solutions consult your agent or dea ler Take into account climatic and atmospheric conditions of the site of utilisation For operation under average climatic conditions i e between 15 and 35 C cor rect levels of lubricants in all the circuits are checked in production For operation under more severe climatic conditions before starting up it is necessary to drain all the circuits then ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures It is the same for the cooling liquid Protection against frost See chapter LUBRICANTS AND FUEL in paragraph 3 MAINTENANCE Adaptation of lubricants Ask your dealer for information Engine filtration Lighting Working headlight Optional solutions exist consult your dealer Use of a lift truck is prohibited in protected areas e g refinery explosive atmosphere For use in these areas specific equipment is available as an option Consult your dealer If necessary consult your dealer RECOMMENDATIONS FOR USING THE TRUCK LEVELLING DEVICE The machine MHT 10210 L have a device to level the chassis in relation to the ground to raise the boom in safety conditions This device allows the level
66. ic oil filter cartridge intake Air filter safety cartridge A 11 Air filter cartridge for cab 12 Engine belt3k 709 666 723 755 485 695 709 664 709 667 709 663 724 670 448 269 513 752 723 754 225 052 739 731 CLEAN REPLACE CLEAN CHECK REPLACE CLEAN CHECK CHECK CLEAN CHECK Reduce the periodicity and advance the replacement in a dusty atmosphere Parts that can be supplied only if the engine serial number is indicated Every 500 H Every 500 H Every 500 H Every 1500 H Every 1500 H Every 500 H Every 500 H Every 1000 H Every 1000 H Every 500 H Every 500 H 3 MHT 10210 L MSexes FIRST COUPON OBLIGATORY 50 100 H WITHIN 3 MONTHS LISTS OF THE OPERATION TO BE CARRIED OUT FOR THE FIRST COUPON ENGINE Check fuel filter Clean air filter Tightness check injection power supply Check cooling circuit Check belt s tension HYDROSTATIC TRANSMISSION Change suction filter Clean Return filter as for assembly Check oil level Check transmission inching control adjustment AXLES TRANSFER BOX Change differential brake housing Change oil of reduction gears Lubrification of pivots hinges and controls Oscilation lubrification Change transfer box oil HYDRAULIC CIRCUIT Change return filter s Check oil level Check tightness BREAKING CIRCUIT Check service brake operation Check brake fluid level as for assembly BOOM
67. icient for certain applications or night time road use Optional accessories are available If necessary consult your dealer 12 MHT 10210 MSerxes 1 LOAD HANDLING A Weight of load and centre of gravity Carrying a load greater than the rated capacity for the lift truck or for the attachment is prohibited Before taking up a load you must know its weight and its centre of gravity The load chart relating to your lift truck is valid for a weight with its centre of gravity 1200 mm from the heel of the forks Fig A For a load with a higher centre of gra vity consult your agent or dealer For irregular loads determine the centre of gravity in the transverse direction before handling Fig B For loads with a moving centre of gravity e g liquids take account of the variations in the centre of gravity in order to determine the load to be handled Consult your agent or dealer and be vigilant and take extra care to limit these variations as far as possible B Taking up a load on the ground Position the lift truck perpendicular to the load with the jib retracted and the forks in a horizontal position Fig C Adjust the fork spread and centering in connection with the load Fig D Optional solutions exist consult your dealer Beware of the risks of trapping or squashing limbs when manually adjusting the forks Always maintain an equal distance between the forks and the centre
68. if equipped press button C and use roller B to carry out the required movements Fig 16 2 N B button C activates the two optional outputs at the top of the boom alternately Button D selects the main optional Never attempt to modify the hydraulic pressure of the system In case of malfunction contract your agent or dealer ANY MODIFICATION WILL CASE THE WARRANTY TO BECOME NULL AND VOID OPTIONAL CIRCUIT DECOMPRESSION This operation must be carried out each time it is necessary to connect or disconnect a supplemental accessory to the fork lift truck 1 Turn off the engine and place the ignition key 7 in position d 2 Rotate roller B forwards and backwards pushbutton 17 pressed and red LED On see page 20 and press button C to activate the 2 3 optional at the top of the boom and act on roller When the operation has been completed the optional circuit has been depressurised therefore it will be easier to connect and disconnect the rapid fittings on the top of the arm N B The operation should be performed immediately after turning off the engine and for no more than 3 seconds for each button j ty Fig 16 1 y 4 gt mw 19 2 MHT 10210 L MSexes 417 OPTIONAL EXCLUSION SWITCH accessories hydraulic block The switch A has two differents posit
69. ing of the transmission C SLOW SPEED GREEN LIGHT When the green light is ON it indicates selection of slow speed D FAST SPEED GREEN LIGHT When the green light is ON it indicates selection of fast speed CENTRAL DIFFERENTIAL BLOCK PUSHBUTTON Differential block pushbutton is used when the machine does not have optimum road grip On selecting the button the central differential of the truck is blocked and torque is transmitted to both the front and rear axles To block the central differential carry out the stop carriage movement completely following operations keep the I C engine running at minimum speed push the brake pedal all the way and press keeping the differential block pushbutton E pressed gradually accelerate the engine to obtain the required movement 14 the differential block pushbutton E MHT 10210 L 2 TELESCOPE FAULT RED LIGHT When the light is on the telescope has a fault please check the signal into the electri cal box XX and consult your agent or dealer G OPTIONAL FAULT RED LIGHT When the light flashes the optional has a fault or is manually disanabled through the optional exclusion switch red light off See point 17 page 20 If the light flashes also if the optional switch is pressed red light on See point 17 page 20 please check the signal into the electrical box XX and consult your agent o
70. ing the boom See chapter INSTRUMENTS AND CONTROLS in paragraph 2 DESCRIPTION Apart from the transverse slope of the ground several parameters can upset the horizontal position of the lift truck The tyre pressures The stability of the ground The balance of the load Strong wind or stormy conditions Before any handling work check the points above and ensure that the lift truck is com pletely horizontal See bubble level 16 MHT 10210 MSerxes 1 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK A General Read the operator s manual carefully and ensure you understand it Stop the engine when an intervention is necessary Wear clothes suitable for the maintenance of the lift truck avoid wearing jewellery and loose clothes Tie and protect your hair if necessary Ensure the area is sufficiently ventilated before starting the lift truck Make sure that the disposal of process materials and of spare parts is carried out in total safetyand in a ecological way Carry out all repairs immediately even if the repairs concerned are minor Repair all leaks immediately even if the leak concerned is minor Do not attempt to loosen unions hoses or any hydraulic component with the circuit under pressure The handling and removal of the balancing valves or safety valves which may be fitted to the cy
71. ion optical indi cator Boom top 3 outlet optical indica tor Normal steering optical indicator Starter motor Hydraulic oil cooling fan Hydraulic oil cooling fan Hydraulic oil cooling fan Hydraulic oil cooling fan Front wiper motor PPP R1a R1b R2b R3a R4a RAb R5a R5b R6a R6b R7a R7b R8a R8b R9a R9b R10a R10b R11b R12a R12b R13 R14a R16b R33 R34 R35 O gt N 17 Front windscreen washer pump Rear wiper motor Rear aeration solenoid valve Air conditioner compressor Cab aeration fan motor Pneumatic seat Top wiper motor Identification plate light Cab light Provision for front axle alignment proximity switch Provision for rear axle alignment proximity switch Start up enable relay Work lights power supply relay Forward movement relay Reverse relay Machine locked with key power supply relay Machine locked with key power supply relay Low beam lights relay Oil cooling fan relay High beam lights relay Oil cooling fan relay Parking optical indicator relay Oil cooling fan relay 1200 rpm solenoid valve relay Levelling relay Anti tilting relay Differential block relay Relay intermittence relay Horn relay Buzzer and reversal lights relay Brake lights relay Oil cooling relay Intermittence Air heater relay Starter motor relay Slow fast bistatic relay Optional double relay Boom top outputs set reset relay X61 14 4i
72. ions enabled or disabled the optional command With the switch pressed B red indicator light ON the Optional accessories hydraulic block function is activated With the switch pressed C red indicator light OFF the Optional accessories hydraulic block function is inhibited 118 RED EMERGENCY BUTTON It deactivates all the movements for the charge lifting IT 15 COMPULSORY TO INHIBIT HYDRAULIC MOVEMENTS USING EMERGENCY PUSHBUTTON D WHILE TRAVELLING ON ROADS To deactivate the movements press the red pushbutton To restore movements turn the red pushbutton D clockwise 19 BUBBLE LEVEL It is on the upper part of the cab in front of the operator It is used to control the horizontality of t he machine in case of need use the levelling device see point 20 Levelling device 20 LEVELLING DEVICE The lever E has two positions controls lift truck levelling towards the right or left pushing F the truck inclinates to the left pushing G the truck inclinates to the right To ensure the truck is level check the bubble level N B The levelling operation cannot be carried out when the telescopic boom has been raised more than about 30 from the ground 20 MHT 10210 L 24 CEILING LIGHT The switch A is incorporated in the light unit It has two positions constant lighting and off 22 DOOR LOCK Outside lock B To open the door
73. ist of dealers by phoning the spare parts department on TEL 0033240091011 1 MHT 10210 MSeries DRIVER S OPERATING INSTRUCTION Caution Whenever you see this symbol it means ve Warning Be careful Your safety or the safety of the lift truck is at risk Most accidents connected with the use maintenance and repair of the lift truck are due to non application of the basic safety instructions By being aware of the risks to which you are exposed and by taking the necessary preventive measures you should be able to avoid accidents occurring Any operation or manoeuvre not described in the instructions is prohibited however any person who does use another method must first ensure that he is not putting him self another person or the lift truck in danger The manufacturer is not able to anticipate all possible risk situations Therefore the safety instructions and notices given in the user manual and on the lift truck are not exhaustive Any bending of the rules in safety notices or the user maintenance or repair instruc tions for your lift truck may result in serious or even fatal accidents We would remind users of the risks in driving at excessive speed with regard to 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 situ
74. knob This 3 speed knob allows distribution of warm or cold air from the outlets D Temperature regulator knob This knob allows regulation of the temperature inside the cab Valve closed fan delivering cold air Valve completely open fan delivering warm air The intermediate positions allow regulation of the temperature 15 VENTILATION OUTLETS These allow direction of the ventilation jets inside the cab they are placed in the top of the cab E and near the driver s feet F MHT 10210 L 18 MHT 10210 L 116 HYDRAULIC MOVEMENT CONTROLS The truck is equipped with a one lever manipulator with proportional electro hydraulic servo control placed on the operator s right and composed of two proportional button A and B Fig 16 To lift the load pull the control lever back Fig 16 1 To lower the load pull the control lever forward Fig 16 1 To tilt the forks down pull the control lever to the right Fig 16 1 To raise the fork back into position pull the control lever to the left Fig 16 1 To extend the telescopic arm pull the A proportional button up Fig 16 2 To retract the telescopic arm pull the A proportional button down Fig 16 2 To operate the optional function pull the B proportional but ton up or down Fig 16 2 to activate the 2 or 3 optional at the top of the boom or the movements of an accessory
75. l see OILS GREASES FLUIDS FUEL FILTERS table through the filler hole 1 fig B2 2 The oil must always be kept topped up to the maximum level since cool ing improves as the oil passes through the tank B3 CLEAN THE OIL WATER RADIATOR GRILLE To prevent the radiator from clogging water radiator fig B3 1 oil radiator T fig B3 2 it must be cleaned with a jet of compressed air from the inside towards the outside This is the only way to clean off the debris MHT 10210 L MSerces 3 B4 CLEAN AND GREASE THE TELESCOPIC BOOM SHOES Every 10 hours up to the first 50 hours and periodically every 250 hours service Completely extend the telescopic boom Use a brush to apply a layer of grease see OILS GREASES FLUIDS FUEL FILTERS table to the 4 sides of the telescopic boom fig B4 Operate the telescopic boom several times to distribute the grease evenly Remove the excess grease 89 CHECK THE BRAKE CIRCUIT FLUID LEVEL Place the truck on a flat surface with the engine off Remove the casing giving access to the braking fluid tank The fluid must be at the tank 10 mm under the maximum level f necessary add oil through the filler orifice 1 Fig B5 see OILS GREASES FLUIDS FUEL FILTERS table In case of an abnormal drop in the level consult your agent or dealer 3 MHT 10210 L MSexes 36 CHECK THE LEVEL OF THE BATTERY ELECTROLYTE Che
76. l to maintain lift truck exhaust brake G Driving the lift truck with trailer on roads To use a trailer observe the regulations applicable in the country of use maximum permitted speed braking system maximum trailer weight etc Remember to connect the electrical system of the lift truck to that of the trailer Do not use a trailer if the unit weight of the load is greater than that specified by Highway Code Do not use a braked trailer if the lift truck does not have a trailer braking system Remember to connect the lift truck braking system to that of the trailer The total permitted weight for transport must not exceed the maximum permitted by the manufacturer See the lift truck manufacturer sidentification plate H Operating the lift truck with a front end attachment on a public highway For driving with an attachment check the regulations currently applicable in your country The attachment must not exceed the overall width of the lift truck Do not mask the lighting range of the front headlamps Set the attachments shields in place f necessary fit the block spacer on the lifting and slewing cylinder Front dimensions of equipment indicated on all three sides with 10 cm wide alternate white and red reflecting stripes slanting 45 Follow the specific instructions for each type of equipment If necessary consult your dealer MHT 10210 MSeries HANDLING INSTRUCTIONS
77. late and of the rod of the levelling coupling cylinder 819 Grease the tilting bushes of the front and rear axle 820 Front and rear axle drive shaft and cross journals X X X X X X X X X X X X X X X X X X X X X X X X X X lt 2 lt lt Every 250 1 Front and rear axle differential oil level hours Front and rear wheel final drive oil level service Oil of front reduction gear on axle V belt tension XXX lt X Every 500 04 Transmission oil filter Engine oil 2 Hydraulic oil exhaust filter cartridge hours 3 Breather filter service or 4 Front and rear wheel final drive oil once a year D5 J Air filter cartridge A if the lift 6 Cab ventilation filter truck has not reached Valves clearance 3k the 500 9 Engine oil and filter hours service X in the year gt CHAPTER QJ MHT 10210 L COMPONENTS OPERATION FREQUENCY Every 1000 21 Air filter safety cartridge A hours service 82 Hydraulic oil and hydraulic oil exhaust filter cartridge oroncea 23 Front and rear axle differential oil year if the 24 Transmission reduction gear box oil lift truck 29 Fuel tank has not Wear of the jib pads reached the 1000 hours service in the year Every 1500 4 Fuel
78. les at the bottom of the belt 7 Dirt or rubble deposits 8 Ribbing detached from the bottom of the belt 9 Wires of the frame torn on the sides 10 Outer wires of the frame frayed 11 Transverse cracks on the back 12 Transverse cracks in different ribs For assembling and disassembling the ribbed belt see point D7 3 D EVERY 500 WORKING HOURS DI CHANGING THE TRANSMISSION OIL FILTER Use a collar wrench to remove the transmission oil filter 1 fig D1 1 and throw it away together with the gasket Clean the filter support with a clean cloth which does not leave threads Fit the new filter of the same characteristics see table FILTER ELEMENTS AND BELTS using your hands only taking care that the gasket lubricated before fitting is properly positioned Start the truck and check that there are no leaks To check the efficency of the filter see the indicator 2 fig D1 2 If the indicator reach the red zone before 500 working hours change immediately the filter D2 CHANGING THE HYDRAULIC OIL EXHAUST FILTER CARTRIDGE Slacken the 4 screws that fix the cover of filter 1 fig D2 remove the old cartridge Fit the new filter of the same characteristics see table FILTER ELEMENTS AND BELTS taking care that the gasket lubricat ed before fitting is properly positioned Start the truck and check that there are no leaks Before fitting the cover of filter 1 Fig D2
79. light B Front left side light C Front left dipped headlight and full beam headlight D Front right side light E Front right dipped headlight and full beam headlight F Front right direction indicator light 27 REAR LIGHTS Rear left direction indicator light Rear left brake light Rear left side light Rear left reversing light Rear right reversing light Rear right side light Rear right brake light Rear right direction indicator light TOTMOOU gt 22 MHT 10210 L 28 REVOLVING FLASHING LIGHT The revolving flashing light can be removed for example to reduce the dimensions of the truck or to prevent its theft Unscrew the nut A and remove the revolving flashing light Protect the support B with the cover C 29 STEERING WHEEL ADJUSTER LEVER This lever allows adjustment of the height and angle of the steering wheel Turn the lever D anti clockwise E to loosen and adjust the steering wheel 3 Turn the lever D clockwise F to lock the steering wheel in the chosen posi tion 30 KEY TO SWITCH OFF THE SAFETY DEVICE There are two key positions 0 1 With normal conditions of work the safety device is always activated position 1 To disengage the safety device keep the key is position 0 and a red light H on the dashboard lights on It s possible to disable the safety system turning the key on
80. linders of your lift truck can be dangerous A balancing valve must only be removed when the cylinder concerned is at rest and the hydraulic circuit is depressuri sed This operation can only be carried out by authorised staff Do not smoke or approach the lift truck with a flame when the fuel tank is open or is being filled Take care not to burn yourself Exhaust radiator engine etc Disconnect the negative cable terminal from the top of the battery before working on the electrical circuit or on the lift truck e g Welding Do not drop metallic items on the battery When carrying out electric welding work on the lift truck connect the negative cable from the equipment directly to the part being welded so as to avoid high tension cur rent passing through the alternator B Maintenance The maintenance and the keeping in compliance of the lift truck are compulsory Carry out daily maintenance See chapter A DAILY OR EVERY 10 HOURS SERVI CE in paragraph 3 MAINTENANCE Do not run the engine without air filter or with oil water or fuel leaks Wait for the 1 C engine to cool before removing the radiator cap Change the filter cartridges See servicing schedules in chapter FILTERS CAR TRIDGES AND BELTS in paragraph 3 MAINTENANCE MHT 10210 L MSeries C Levels Use the recommended lubricants Never use contaminated lubricants Do not fill the fuel
81. ly working conditions with bucket ATTENTION With the safety system nothing prevents overloading and or tipping of the vehicle 23 2 MHT 10210 L 31 AIR CONDITIONING OPTIONAL A COMPRESSOR SWITCH This switch has two positions AO Off indicator light Off A1 On compressor switched on indicator light On N B The indicator light On indicates the compressor is switched on ATTENTION The compressor switches on only with the fan knob turned to C1 C2 C3 If the fan knob is on CO the compressor is not switched on B Knob Regulates the air flow in the supplementary inlets located behind the operator seat BO Off B1 1 speed B2 2 speed B3 3 speed Adjust the direction of the inlets located behind the operator seat C Front fan knob CO Off C1 1 speed C2 2 speed 3 speed 24 e MAINTENANCE MHT 10210 L ROUTINE MAINTENANCE FILTERING ELEMENTS AND BELTS XX KA RU ORO ARRA MANNA RA E NO UM Z 27 1 5 Ly 22 DESCRIPTION MANITOU 50 100 H WITHIN 3 MONTHS REPLACEMENT REFERENCE COUPON SCHEDULE Engine oil filter3k Air filter cartridge A Transmission oil filter Fuel filter cartridge 3k Fuel prefilter cartridge3k Fuel prefilter cartridge with water separator Hydraulic oil filter cartridge exhaust Breather filter Hydraul
82. mong his responsibilities Carry out daily maintenance See chapter A DAILY OR EVERY 10 HOURS SERVI CE in paragraph 3 MAINTENANCE Ensure tyres are adapted to the nature of the ground See area of the contact surface of the tyres in the chapter CHARACTERISTICS in paragraph 2 DESCRIPTION THERE ARE SAND tyres LAND tyres Snow chains There are optional solutions consult your agent or dealer Do not use a worn or damaged tyre The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer excepting prior authorisation For your own and other people s safety it is forbidden to modify the structure and set tings of the various components of your lift truck yourself Hydraulic pressure relief valve calibration engine running speed addition of extra equipment etc The same holds with regard to any suppression or modification of the safety systems in which case the maker would no longer be liable Regular inspection of your lift truck is mandatory if it is to be kept in conforming condi tion The frequency of such checks are defined by the current legislation of the country in which the lift truck is being operated Maintenance or repairs other than those detailed in part 3 MAINTENANCE must be carried out by qualified personnel Consult your agent or dealer and under the neces sary safety conditions to maintain the health of the operator and any t
83. moving people Before putting the winch or any other equipment in which the load hangs from a hook into service report it to the relative authority ISPEL in your zone for checking for Italy only Every year remember to request your local health authority USL for a visit of inspection Italy only It is forbidden to lift hanging loads using fork accessories or other supports not meant for this func tion Contact your agent or dealer see crane accessories list MHT 10210 L 5 Using the machine outfitted with hoist When all the green yellow and red LEDs Fig A Ref 1 on the truck stabilization control instrument light up the hydraulic commands are automatically blocked Only the boom retraction fork inclination and hoist rope descent commands are authorized Do not turn key 30 page 23 paragraph 2 for excluding auto matic blocking of movements as this must be done only for operation with shovel Before putting the winch into operation on the lift truck check that the machine is compatible and that its safety system is set appropriately for the type of winch required CAUTION Incorrect setting of the safety system may put your safety at serious risk if in doubt do not hesitate to contact your dealer immediately In view of their size when the boom is lowered and retracted some accessories may interfere with the front tyres and damage them if the board is tilted downward TO ELIMINATE THIS
84. nd remove cover 2 Fig D5 1 Then unscrew nut 3 Fig D5 2 which fixes filter cartridge 4 Fig D5 2 and remove it Wipe the inside of the filter with a clean damp cloth that does not leave residue Never wash an air filter cartridge Fit a new cartridge having the same features FILTER ELEMENTS AND BELTS TABLE in place of the one removed fix it by means of butterfly nut 3 Fig D5 2 Refit cover 2 Fig D5 1 with the valve facing downwards and lock it by means of nut 1 Fig D5 1 06 CLEAN THE VENTILATION FILTER FIG 05 2 Lift up protective casing 1 Fig D6 Lift out cabin ventilation filter 2 Fig D6 Clean the filter with a compressed air jet Check its condition and change if necessary with another of the same char acteristics see table FILTER ELEMENTS AND BELTS Refit the filter and protective casing 3 MHT 10210 L 07 REPLACE THE POLY V RIBBED BELT Replace the ribbed V belt if one of the following types of damage illu strated is present C4 3 Take great care while disassembling and assembling the ribbed V belt keeping the fingers well out of the area between the pulley and the belt Insert release lever 2 fig D7 using a 17 mm wrench on the hex head screw of the tightener roller 1 Fig D7 Tip the belt tightener roller upwards and remove the ribbed V belt Reposition the belt tightener device Check to make sure
85. nection while the engine is running If electric arc welding is carried out on the truck directly connect the welder negative wire to the piece to be welded to ensure that the high voltage current cannot pass through the alternator and then disconnect the battery MHT 10210 MSeries FUSE AND RELAY BOX The electric circuit is protected by fuses mounted in the fuse box To change a fuse remove it and replace it with a new one with the same quality and calibration values check all the fuses and verify if a short circuit has occurred DO NOT TRY TO REPAIR A BURNED FUSE If a power failure occurs MHT 10210 MSerxes LIGHTING A blown bulb must be changed immediately Do not handle a new bulb with bare or dirty fingers Any traces of grease oil or sweat will evaporate when the bulb is hot and stain the reflector Never touch or attempt to polish the reflector Just open the headlamp to change the bulb BATTERY Battery efficiency becomes progressively lower as the ambient temperature drops until it practically ceases to function at 40 C Never attempt to use the starter motor if the battery has been exposed to temperatures of around 29 C In these cases heat the battery by immersing it in lukewarm water to 5 cm below the cell caps If the temperatures are very low remove the battery from the truck and store it in a warm place until it is requi red MHT ELECTRIC SYSTEM USERS LEGEND Code Page A1 5
86. no steering or braking assistance Operate the steering and pedal slowly avoiding sudden jerky movements Reactivating negative brake Brake cylinder regulation fig G2 2 unscrew the caps 4 and 5 take off the spring 7 with a key of 19 mm and external diameter not higher than 26 mm screw the nut 1 till the piston is at a maximum depht of 39 7 40 2 mm dimension The nut is 1 has a pitch of 1 75 mm so it s possible to calculate how screw the nut for example if the dimension A is of 36 2 mm it s necessary to screw it of 2 turns 3 5 mm Check again the mesure as described and if not right again repeat the operations till now described screw the counter nut 9 untill the nut 1 mount again the spring 7 and the caps 4 and 5 Note exceeding the mesure of 40 2 mm the complete unlock of the brake it s not possible so the brake could overheat and damage it self quickly A bad regulation could cause big damages to the brakes and also a quickly destruction If the nut 1 is unscrewed too far the machine doesn t brake Dangerous to your life Pay attention to the dimension B if it s lower than 24 5 mm you must change the brake disk FOR THESE OPERATION CONSULT YOUR AGENT OR DEALER Fig G2 2 MHT 10210 L 3 G3 CHECK THE BRAKE CYLINDER Brake cylinder fig G3 unscrew the caps 5 check that the dimension A is 3
87. nputs and 4 outputs circuit 20 1200 rpm solenoid valve 8 Forward movement solenoid valve 8 Reverse solenoid valve 10 LH levelling solenoid valve 9 Anti tilting solenoid valve 10 RH levelling solenoid valve 9 Fast movement solenoid valve 9 Slow movement solenoid valve 5 Differential block solenoid valve 17 Boom extension solenoid valve 17 Boom retract solenoid valve 18 Optional 1 solenoid valve 18 Optional 2 solenoid valve 15 Crab steering solenoid valve 15 Concentric steering solenoid 17 Optional double solenoid valve 21 Mixer bucket solenoid valve 17 Optional triple solenoid valve 12 Hour meter and rev counter 12 Water temperature instrument 12 Fuel level instrument 9 Anti tilting control unit 9 Load cell 9 Load cell 9 Anti tilting control unit 19 Float 21 Thermo starter 16 Mercedes adm control unit 16 Diagnostics connector 17 RC2 2 20 Rexroth 1 control unit 18 RC2 2 20 Rexroth 2 control unit 16 Mercedes motor control unit 16 Accelerator pedal connector 20 Antitheft connector 20 Car radio connector 21 Basket connector 72725 7 0LCOL SCHEMA ELETTRICU 55 0 caro 555 02 vs 710086 MHI SERIE 990 7140 10160 10210 DISTRIBUTORE REXROTH TAVOLA MANITUD gt TT TABLE Name TITLE 1 72725 7 01201 LISTA FOGLI INDEX Tavola Descrizione Tavola Descrizione Table Description Table Description 1 TITOLO TITLE LEGENDA FOGLI TABLE
88. oil to avoid risk of damage to the brakes circuit see Chapter LUBRICANTS in part 3 MAINTENANCE Tyres Make sure that the wheel nuts are correctly tightened See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAINTENANCE and that the tyre pressures are correct See chapter CHARACTERISTICS in paragraph 2 DESCRIPTION Fuel system Check that all fuel lines are secured f necessary drain the fuel filter and bleed the fuel system of air Electrical circuit Check the level 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 devices If necessary consult your dealer 20 2 DESCRIPTION MHT 10210 L 2 SPECIFICATIONS Engine E3 Type Cylinders number Number of strokes Injection system Firing order Displacement Bore Stroke Volumetric ratio Nominal rpm Idling rpm Power Maximum torque Cooling system Type Intake fan Number of blades Diameter Thermostat Complete open Electrical circuit Ground Battery Alternator Voltage regulator Starting Brake Type Service brake Parking brake MERCEDES BENZ OM 904 LA 4 4 direct 1 3 4 2 4250 cm 102 mm 130 mm 18 1 2200 rpm 800 rpm 175 CV 129 Kw 675 Nm f
89. olenoid valve fuse 30 antitheft fuse Anti tilting fuse Hydraulic oil fan fuse Intermittence fuse Hydraulic oil fan Front wiper fuse 30 car radio fuse Rear wiper fuse Hydraulic oil fan fuse Cab front work lights fuse Hydraulic oil fan fuse Cab rear work lights fuse Boom work lights fuse Mercedes adm control unit fuse Rotary light fuse Conditioner auxiliary unit fan power supply fuse Basket power supply fuse Heating fuse Air conditioner fuse Timer fuse Pneumatic seat fuse Diagnostics connector fuse 15 basket fuse Mercedes mr control unit power supply fuse Provision for load cell e Adm control unit direct power sup ply fuse Manoeuvre manipulator fuse Cab aeration fan third speed diode Differential block fuse Cab aeration fan second speed diode Differential block by brake diode Cab aeration fan first speed diode Reverse relay diode RH front headlight LH front headlight Main Fuse gt uh Front work lights Front work lights Boom top work light Boom top work light Rear work lights Rear work lights Provision for military lights Provision for military lights RH rear headlight LH rear headlight Provision for military lights Provision for military lights Alternator Rotary light Start up panel Emergency switch Differential block pushbutton Steering selector Slow fast switch Gear reset switch Anti tilting exclusion key Rotary lamp switch Rear wiper switch F
90. or does not work properly consult your agent or dealer Alternator The alternator is installed on the left of the motor The alternator and regulator are designed to operate in a system polarised in one direction only so the following precautions must be taken when working on the battery charging circuit otherwise serious damage may be caused to the electrical equipment Never operate the alternator with the circuit open ensure that all terminals are firmly tightened It is important not to remove the terminals on the back of the alternator while the engine is running as this may damage the alternator itself When fitting a battery check that the connections are correctly polarised It is essential for the cable marked to be connected to the positive terminal of the battery and the cable marked to be connected to the negative terminal on the battery and that there is a ground connection If a second battery is used to start the engine always connect terminals of the same polarity Fig A Fit a battery with the same voltage as that installed on the truck If an external charger is used always connect the wire of the charger to the terminal of the battery and the wire of the charger to the terminal of the battery and ground connection Never short circuit the alternator terminals or connect them to ground Never reverse the alternator connection on the battery Never remove or replace an electrical con
91. orm to the provisions of the Highway Code If necessary optio nal solutions exist consult your dealer Transport of loads on the public highway is forbidden and attachments mounted on the lift truck must be fitted with equipment in accordance with regulations or else dismoun ted Instructions for driving on roads Ensure that the flashing light is installed and is in perfect working order Dipped headlights working also during hours and on roads where it is not obligatory to use visual and lighting indicator devices Check the headlights turn indicators and windscreen wipers to ensure they are clean and in perfect working condi tion Check the position of the rear view mirrors Check wheel alignment and press the steering selector in the operating position with only front wheel steering Position the rear axle steering mechanical block Ensure that the fuel level is sufficient Ensure that the truck is fitted with all the accessories required for traveling on roads depending on the model and country Keep the boom retracted and the attachment about 300 mm above ground level Level the machine with the chassis parallel to the ground using the inclination correc tor Cut out the operating system control by means of the red button The vehicle can only circulate without load The vehicle must not be used for transporting the company personnel While on the road do not put the reverse gear in neutra
92. ound place the gear lever in neutral apply the parking brake and put the forward reverse lever in neutral f the driver has to leave his cab even for a moment it is essential to place the gear lever in neutral apply the parking brake and put the forward reverse lever in neutral Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at less than one metre from the track of a railway In the event of prolonged parking on a site protect the lift truck from bad weather par ticularly from frost Check the level of antifreeze close the rear window lock the cab door and ensure that the hood is properly secured Stop instructions Park the lift truck on flat ground or on an incline lower than 15 Place the forward reverse lever in neutral Apply the parking brake Completely retract the boom Lower the forks or attachment to rest on the ground Stop the engine Remove the ignition key Check the closing and locking of door rear window and hood Before leaving your driver s cabin ensure that you have carried out all operations for stopping the lift truck for your safety and the safety of others MHT 10210 MSeres F Driving the lift truck on the public highway Safety instructions Lift truck drivers driving on the public highway must abide by the general provisions relative to highway traffic The lift truck must conf
93. placed in the neutral position See chapter G2 OCCASIONAL MAINTENANCE in paragraph 3 MAINTENANCE MHT 10210 MSeres 1 Instructions Make sure that the forward reverse lever is in neutral Turn the ignition key to the position to activate the electrical system Check the level on the fuel level gauge Turn the ignition key to position 11 to preheat for 15 seconds If the environmental conditions require it Do not engage the starter motor for more than 15 seconds and carry out the preheating for 10 seconds between unsuccessful attempts Press the accelerator pedal and turn the ignition key fully the 1 engine should then start Release the ignition key and let the I C engine run at idle Before operating in very cold environment wait for the engine and hydraulic systems to heat up adequately Check all control instruments immediately after starting up when the I C engine is warm and at regular intervals during use so as to quickly detect any faults and to be able to correct them without any delay If an instrument does not show the correct display stop the engine and immediately carry out the necessary operations D Driving the lift truck Safety notice Always drive the lift truck with the forks or attachment at approximately 300 mm from the ground i e In the transport position Familiarise yourself with the lift truck on the terrain where it will be used
94. prefilter cartridge hours service P2 Fuel prefilter cartridge with water separator 28 Fuel filter cartridge F4 Cooling liquid of cooling system CHAPTER Occasional 64 Change a wheel maintenance 94 Tow the lift truck Check the brake cylinder 64 Sling the lift truck Transport the lift truck on a platform Adjust the front headlamps Air condition XXxx REPLACE To be carried out annually if the truck has not reached these operating times In a very dusty atmosphere reduce the interval and replace earlier B Every 10 hours up to the first 50 hours and periodically every 250 hours service In the event of prolonged use in an extremely dusty or oxidising atmosphere reduce this interval to 10 working hours or every day Operation to be carried out the first time after 500 hours of service periodically every 1500 hours of ser vice Consult your dealer MHT 10210 L OILS GREASES PLUIDS gt PUBL FILTERS COMPONENTS FOR LUBRICATION CAPACITY RECOMMENDED PRODUCT MANITOU 500 Engine oil C ENGINE FILTER 15 0 8L API CH4 FRONT WHEEL FINAL DRIVE Special MANITOU oil REAR WHEEL FINAL DRIVE for immersed brakes FRONT AXLE DIFFERENTIAL Special MANITOU oil GEARBOX REAR AXLE DIFFERENTIAL Drakes HYDRAULIC FLUID TANK 200 Oil MANITOU ISO 46 Oil BRAKING CIRCUIT SHELL LHM S
95. r dealer Fig XX H 2 OPTIONAL CONTROL ORANGE LED IF EQUIPPED The orange LED lights up to indicate that the 2 optional con trol has been selected See point 16 page 19 H1 3 OPTIONAL CONTROL GREEN LED IF EQUIPPED The green LED lights up to indicate that the 3 optional con trol has been selected See point 16 page 19 WINDSCREEN WIPER WASHER SWITCH owitch with 3 positions for wiper 2 and for washer 3 To stop the washer simply release the switch L REAR WINDOW WIPER SWITCH On off switch for rear window wiper M FLASHING LIGHT SWITCH On off switch for the rotating flashing light N STEERING SELECTION Before selecting one of the three steering options align the 4 wheels with the axis of the truck 1 Front and rear wheel steering in opposite directions short or concentric steering 2 Front wheel steering use on public highways 3 Front and rear wheel steering in the same direction sideways or crab movement N1 GREEN LIGHT SHORT STEERING The green light on indicates the short steering selection N2 GREEN LIGHT USED ON PUBLIC HIGHWAYS The green light on indicates the steering selection for use on public highways N3 GREEN LIGHT SIDEWAYS OR CRAB MOVEMENT The green light on indicates the steering selection for sideways or crab movement O EMERGENCY WARNING LIGHTS SWITCH Press this switch to activate all turn signals at the same time
96. r go too fast or brake sharply with a load When picking up a load check that the ground is as even as possible Never attempt to carry out operations which exceed the lift truck s capabilities Never raise a load in excess of the lift truck s capacity and never increase the size of the ballast Drive around obstacles Take care over electrical wires trenches and recently excavated or filled ground Never leave the engine running unattended Use the parking brake when depositing difficult loads or on sloping ground Never leave the truck parked with a raised load Never authorise anyone to approach or pass below a load Always think of safety and only transportwell balanced loads Never lift a load using one fork only Drive with care and with reflexes alert When the lift truck is not in use lower the forks to the ground and engage the parking brake Never leave the ignition key in the truck unattended Never leave the truck loaded on a gradient of over 1596 even with the parking brake engaged When lifting a load take care that nothing and no one interferes with the movement and adopt proper handling procedures only Comply with the data provided in the load diagrams Never transport another person on the lift truck Whenever an implement is changed to prevent damage to the hydraulic unions always proceed as follows Stop the engine turn key to position release pressure from
97. re to place it in a safe position on firm flat ground MHT 10210 L ACCESSORY WITH HYDRAULIC SYSTEM AND HYDRAULIC LOCKING OPTIONAL ENGAGING THE ACCESSORY Check that the accessory is in a position which simplifies connection of the snap coupling If it is badly positioned take the necessary pre cautions to move it in the conditions of maximum safety Check that the rods of the locking cylinder are retracted Position the lift truck with the boom lowered squarely in front of and parallel to the accessory and tilt the snap coupling forward Fig A Bring the snap coupling into position below the accessory s connec tion pipe raise the boom slightly and tilt the connection back to posi tion the accessory Fig B Raise the accessory off the ground for easier engagement HYDRAULIC LOCKING AND RELEASE OPTIONAL The accessory if any is locked and released using the optional con trol which may be operated by a push button or using the control lever itself depending on the type of truck For further information refer to the use and maintenance manual provided with the truck Remember to decompress the optional circuit whenever an extra accessory is to be connected to or disconnected from the lift truck this will simplify the engagement and disengagement of the snap couplings on the end of the boom REMOVING AND PUTTING DOWN THE ACCESSORY Proceed in reverse direction to
98. rmitted mode A4 2 red LED The fork lift truck is overloaded The buzzer is activated simultaneously in rapid intermit tent mode Carry out the hydraulic movements needed to reduce the loadin the following order boom retraction and then boom lowering When A4 2 red LED is switched on the hydraulic controls are automatically blocked Only boom retraction and inclination of the forks are authorized DO NOT turn key 30 Page 23 for exclusion of automatic blocking of movements to be used only when operating with shovel BUZZER SWITCH Fig 1 1 Fig 1 2 Enables or disables use of the alarm buzzer If not in use the red light B1 indicates that the buzzer is disabled and only the warning lights are operational C TEST INDICATOR Fig 1 1 Press the switch to check that the load status indicator device is operating correctly at any moment Correct operation All LEDs and the buzzer operate continuously Faulty operation All LEDs and the buzzer operate in intermittent mode Switch off the truck and contact your agent or dealer never make repairs yourself m B p O O e O e gt SNNT FIG 1 1 BS 13 2 5 a SWITCH CONSOLE A RESET TRANSMISION B RUNNING SELECTOR SLOW FAST C SLOW SPEED GREEN LIGHT D FAST SPEED GREEN LIGHT E CENTRAL DIFFERENTIAL BLOCK PUSH BUTTON F TELESCOPE FAULT RED LIGHT G OPTIONAL FAULT RED LIGHT
99. rom 1200 to 1600 rpm Water cooled 1750 rpm T 550 mm 95 Negative 12 v 120 Ah 14 v 90 150A incorporated in the alternator 12 v Disc brakes in oil bath Foot pedal actuated on front and rear axles Lever actuated on front and rear axle negative type 2 MHT 10210 L MSexes Transmission Hydrostatic Pump and motor with variable displacement Gear box hydraulically operated of forward speeds 2 of reverse speeds 2 Reverser Electrohydraulic Hydraulic circuit Lifting tilting of telescopic boom and device Type of pump Piston type load sensing Delivery 165 l min Pressure 350 bar Steering circuit Type of pump Load sensing Delivery 165 l min Pressure 205 bar Leveling circuit Type of pump Gear pump Delivery 25 l min Pressure 205 bar Cooling circuits Water and intercooler by hydraulic motor Type of pump Gear pump Delivery 25 l min Pressure 175 bar Hydraulic oil Electrical fan Number 4 Front and rear tyre Type e dimension 23 5 R25 XLB Inflating pressure bars MHT 10210 L Specifications Maximum speed Forward unloaded Loaded Reverse unloaded Loaded The maximum speed may be reduced depending on the laws which regulate road travel in different countries Gradeability best slip condition Unloaded Loaded Standard lifting height Max rated capacity with st
100. ront wiper switch Military lights provision connector Mixer bucket switch Optional exclusion switch Air conditioner switch Front work lights switch Rear work lights switch Boom top work lights switch Front aeration selector Rear aeration selector Stop pressure switch Gear microswitch Parking brake pressure switch Emergency stop pushbutton Boom below 2m Proximity switch Brakes oil level gauge Air conditioner pressure switch Air conditioner thermostat Air conditioner thermostat 72725 7 0LCOL L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L20b L21 Stop pressure switch Back up lights switch Emergency pump switch Manoeuvres manipulator Levelling switch Air filter pressure switch Ceiling light switch Battery optical indicator Turn indicators optical indicator Position lights optical indicator High beam lights optical indicator Low beam lights optical indicator Air filter clogged optical indicator Oil pressure optical indicator Oil level optical indicator Water temperature optical indica tor Control unit fault optical indicator Parking brake optical indicator Brakes oil level optical indicator Slow speed optical indicator Fast speed optical indicator Crab steering optical indicator Concentric steering optical indica tor Boom top second outlet optical indicator Control unit fault indicator Control unit fault indicator Anti tilting exclusion optical indi cator Anti tilting exclus
101. s carriage 2 backwards to stabilize the load Fig Tilt the load sufficiently backwards to ensure its stability loss of load on braking without upsetting the balance of the load in so doing f possible Fig J lower the load without shifting the lift truck Lift the jib 1 to release the load retract 2 and lower the jib 3 to bring the load into the transport position Fig J f this is not possible back the lift truck up Fig Manoeuvring very gently and care fully See paragraph E VISIBILITY in the chapter HANDLING INSTRUCTIONS for visibility of the road back up the lift truck 1 to release the load retract 2 and lower the jib 3 to bring the load into the transport position Fig K 14 MHT 10210 L MSeres 1 D Laying a high load Under no circumstances should you lay down a load if the lift truck is not a horizontal position See paragraph G HORIZONTAL POSITION OF THE LIFT TRUCK in the chapter LOAD HANDLING Approach the load in the transportposition in front of the pile Fig L Lift and extend the jib 1 2 until the load is above the pile if necessary move the lift truck forward 3 Fig M manoeuvring very gently and carefully See paragraph E VISIBILITY in the chapter HANDLING INSTRUCTIONS for visibility of the road Apply the parking brake and place the forward reverse lever in neutral Place the load in a horizontal position and lay it
102. se you to use the hydraulic jack and the safety support 5 Completely unscrew the wheel 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 Tighten the wheel nuts with a torque wrench See chapter A DAILY OR EVERY 10 HOURS SERVICE in paragraph 3 MAINTENANCE for tightening torque Remove the safety support and lower the lift truck with the jack 31 3 MHT 10210 L MSexes G2 TOW THE LIFT TRUCK The lift truck can be towed through a rigid bar hooked to the frame ears front or rear and for short distance with slow speed Block all four wheels to prevent accidental movement of the lift truck Shut down engine Put the forward reverse lever in neutral position Release the parking brake Put the emergency lights put the gear selector in neutral position a Disconnect and close the hydraulic X Fig G2 1 of the cylinder of the gear selector b Put the rod Y Fig G2 1 in neutral position this is on half stroke between two d tente C Deactivate the negative brake fig G2 2 unscrew the caps 4 and 5 take off the spring 7 with a key of 19 mm and external diameter not higher than 26 mm unscrew the counter nut 9 unscrew the nut 1 untill at the position The brake is deactivated Note If the engine is not running there will be
103. service life Using counterfeit parts or components not approved by the manufacturer may put an end to contract warranty terms and lead the maker to withdraw the lift truck s certificate of compliance By using original parts during maintenance operations you are legally cove ring yourself Any user who procures parts from another quarter does so at his own risk Any user who modifies his lift truck or has it modified by a service company must con sider that a new item of equipment has been brought onto themarket and therefore takes liability for it Any user who copies original parts or has them copied is taking a risk from the legal viewpoint The certificate of compliance only bindsthe maker for parts chosen or produced under the maker s control The practicalities of maintenance terms are set out by the maker The maker is in no way liable in the event of the user not complying with such terms The manufacturer brings to the user His know how and skill Guaranteed quality work Original replacement parts Help with preventive maintenance Effective help with diagnosing faults Enhancements gained from feedback Training for operating staff Only the manufacturer knows thedetails of the lift truck design and therefore has the best technological capability to carry out maintenance Original replacement parts are distributed exclusively by MANITOU and its dealer network You can obtain the l
104. take hold of the handle and pull it outward Two keys for locking the cab are supplied with the truck Inside lock C To open the door take hold of the handle and pull it inward 23 REAR WINDOW OPENING LEVER To open the rear window pull the lever D clockwise to the right and push on the window 24 UPPER HALF DOOR LOCK Closed position To open push the lock A down To close simply pull the handle B inward Open position Push the door towards the cab to engage in the bolt C To release press the knob D or use the lever 21 2 MHT 10210 L MSexes 25 TOWBAR On rear of the truck the towbar allows towing of a trailer For each truck the towing capacity is limited by the total authorised weight for travel on the public highway the traction force and the maximum vertical stress on the tow ing pin These data are shown on the manufacturer s data plate applied to each truck N B Other optional solutions are available for towing trailers for further information contact your agent or dealer Only trucks registered as agricultural tractors are allowed to tow trailers on the public highway Check the trailer s braking and light systems and connect them to the truck Reduce the speed of the truck Follow your country s highway code Make sure that the split pin is properly positioned on the towbar 29 FRONT LIGHTS A Front left direction indicator
105. tank when the engine is running Only fill up the fuel tank in areas specified for this purpose D Washing Clean the lift truck or at least the area concerned before any intervention Remember to close the door and the rear window of the cab During washing avoid the articulations and electrical components and connections If necessary protect against penetration of water steam or cleaning agents compo nents susceptible of being damaged particularly electrical components and connections and the injection pump Clean the lift truck of any fuel oil or grease trace For any intervention other than regular maintenance consult your dealer 18 BEFORE STARTING UP A NEW LIFT TRUCK Introduction MHT 10210 MSerxes Our lift trucks have been designed for easy handling by the operator and maximum ease of maintenance for the mechanic However before commencing to operate the lift truck the user should carefully read and understand the various chapters of this manual which has been provided to solve driving and maintenance problems By following these instructions the user will be able to take full advantage of the versatility of this lift truck The operator must familiarize himself with the positions and functions of all the controls and instruments before operating the lift truck Do not attempt to start a new lift truck before the following checks have been carried out Lubrication
106. to use protective gloves and clothing as well as safety goggles If topping up is required operate carefully as follows Turn cap 1 fig A2 anticlockwise gradually to the safety stop position Release the pressure and the steam Press the cap and remove it by rotating it If necessary add water and antifreeze liquid Occasionally grease the radiator cap 1 fig A2 to facilitate its removal ATTENTION Before topping up wait for the cooling liquid tem perature to drop below 50 122 F MHT 10210 L MHT 10210 L MSeries 3 CHECK THE FUEL LEVEL Place the truck on a horizontal surface with the engine stopped To minimise the condensation due to weather conditions the fuel tank should be kept full as far as possible Remove the cap 1 Fig A3 Through the filler intake fill the tank with clean Diesel fuel fil tered by a rose pipe or a clean cloth which does not leave residues Replace the cap 1 Fig Never smoke or approach with naked lights during filling or when the tank is open Never fill up with the engine running A4 TYRE PRESSURE AND WHEEL NUT TIGHTNESS Check the tyre pressure and adjust if necessary see Characteristics section WHEEL NUT TORQUE LOADING Check the tyres for any cuts bulges signs of wear etc Check the tightness of the wheel nuts see Fig A4 FRONT WHEEL REAR WHEEL Failure to follow these instr
107. together with cartridge 3 Fig of the filter from filter casing 5 Fig Drain out the fuel Remove the threaded cap 1 Fig F3 with filter cartridge 3 Fig F3 Release filter cartridge 3 Fig F3 from the retainer by pressing on the sides of the lower edge Remove the cup containing the impurities 4 fig F3 from filter casing 5 fig holding it by the tabs The filter casing must never contain water or impurities Clean the threaded cap 1 Fig F3 and cup for collecting impu rities 4 Fig F3 Replace sealing ring 2 Fig Fit the new filter cartridge 3 Fig F3 back in place in threaded cap 1 Fig Grease sealing ring 2 Fig F3 and the filter cartridge gaskets slightly Insert the cup containing the impurities 4 fig F3 in filter casing 3 5 Fig F3 ensuring it is fitted in the correct position Screw and tighten the threaded cap with the filter cartridge Tightening torque 25 Nm Start up the engine and run it for about one minute to bleed the supply system With the engine switched on check the fuel filter seal 28 MHT 10210 L 3 CHANGE THE COOLING LIQUID IN THE COOLING SYSTEM ATTENTION Open the cap for filling the cooling system only if the temperature of the liquid is less than 90 C 194 F In any case it is obligatory to use protective gloves and clothing as well as safety goggles
108. toring instrument and indicator light panel 4 Load status control and safety device Switch console 6 Light horn and direction indicator lever 7 Key switch Casing giving access to brake fluid tank and windscreen washing liquid 9 Brake fluid tank 10 Windscreen washing liquid tank 11 Accelerator pedal service brake and inching pedal 12 Direction reverser lever 13 Parking brake lever 14 Heating controls 15 Ventilation outlets 16 Hydraulic movement controls 17 Optional exclusion switch 18 Red emergency button 19 Bubble level 20 Levelling device 21 Ceiling light 22 Door lock 23 Rear window opening lever 24 Upper half door lock 25 Towbar 26 Front lights 27 Rear lights 28 Revolving flashing light 29 Steering wheel adjuster lever 30 Key to switch off the safety device 31 Air conditioning optional USEFUL ADVICE Regardless of the operator s experience in this sector he must learn the position and function of all instruments and controls on board before putting the fork lift truck into operation When the ignition key is turned without starting the engine a test is automatically performed on the instrumen tation all the lights come on and a beeper sounds All this stops once the engine has started A check must be made on all the truck s instruments immediately after start up once the engine has warmed up and at regular intervals during use so that any malfunctions can be note
109. uctions may cause damage and breakage of the wheel fixing nuts leading to accidents AS CHECK THE TELESCOPIC BOOM SLIDE RAILS Extend the telescopic boom completely Check to ensure the telescopic boom slide rails are greased prop erly If necessary clean and grease the telescopic boom slide rails see B4 3 MHT 10210 L MSexes EVERY 50 WORKING HOURS 84 CLEANING THE AIR FILTER CARTRIDGE Slacken nut 1 Fig B1 1 and remove cover 2 Fig B1 1 Slacken nut 3 Fig B1 2 which fixes cartridge 4 Fig B1 2 Clean the filter cartridge using a jet of compressed air directed from insi de outwards Clean the inside of the filter housing using a clean damp cloth that does not leave residue protecting the inlet tube to the I C engine Check the condition of the cartridge Cartridges that are no longer efficient must be replaced immediately Refit cartridge 4 Fig B1 2 inside the filter and fix it by means of nut 3 Fig B1 2 Refit cover 2 Fig B1 1 with the valve facing downwards and lock it by means of nut 1 Fig B1 1 Never wash an air filter cartridge mu FIG B1 2 B2 CHECK THE HYDRAULIC OIL LEVEL Place the truck on a flat surface with the engine off and the telescopic boom retracted and as low as possible Refer to the gauge 1 fig B2 1 The oil level is correct when it is 10 mm under the maximum the upper and lower marks If necessary top up with oi
110. ves beyond the last stop BACK SUPPORT This allows adjustment of both the seat conform level and the driver s freedom of movement Turn the knob to the right or left to adjust the height and depth of the back support MHT 10210 L ADJUSTING THE SEAT BACK ANGLE Lean against the back pull the lever and move the seat back into the position desired If the back is not held in place when adjusted it will tip completely forward LONGITUDINAL ADJUSTMENT Engage the locking lever in the position desired Once locked in place the seat cannot be adjusted further CLEANING Dirt may prevent the seat from functioning correctly it must therefore always be kept clean To clean or replace the cushions simply extract them from the frame of the seat Risk of accident are increased when the seat tips up Take care not to wet the cushions fabric when cleaning them First check the fabric s resistance to the normal detergents for fabrics and plastics on a con cealed surface 2 SEAT BELTS Sit on the seat correctly Check that the seat belt is not twisted Place the belt over your pelvis not over your stomach Fasten the seat belt and check that it is firmly engaged Adjust the belt to your physique so that it does not apply excess pressure to your pelvic region The fork lift truck may never be used if the seat belt is faulty mounts fasten ing seams tears etc Repair or r
111. winds or storms do not carry out handling work that jeopardizes the stability of the lift truck and its load Do not change direction sharply and at high speed 11 MHT 10210 MSeries In the event of the lift truck overturning do not try to leave the cab DO NOT TRY TO JUMP CLEAR STAY IN THE CAB WITH YOUR SEAT BELT FASTENED Apply the parking brake when lifting or depositing a difficult load or when on an incline Do not stop the lift truck with the load in an elevated position Do not leave a laden lift truck with the parking brake applied on an incline which exceeds 15 95 E Visibility Constantly keep clear visibility of the road either direct view looking backwards when reversing or indirect view using the panoramic rear view mirrors to check for people animals holes obstacles change of slope etc Since visibility can be reduced on the right side when the jib is raised ensure clear visibility of the road before raising the jib and before undertaking any manoeuvres f the visibility in forward motion is not sufficient because of the bulkiness of the load drive in reverse motion This manoeuvre must remain exceptional and for short distan ces Ensure you have good visibility Clean windows adequate lighting correctly adjusted rear view mirror etc Signalling and lighting on the lift truck must take account of the conditions of use The standard lighting system may not be suff
112. x notch on level rod 6 Fig D9 3 Start up the engine at minimum speed and observe the oil low pressure indi cator Keep the engine running at minimum speed until the low pressure indicator switches off owitch off the engine immediately if the low pressure indicator does not switch off after about 10 seconds and check for the cause of the oil pressure failure in the engine Check the oil filter seal and the discharge screw seal About 5 minutes after switching off the engine check the oil level and if nec essary top up with oil up to the max notch on level rod 6 Fig D9 3 y gt ba 22 MHT 10210 L 3 2 EVERY 1000 WORKING HOURS 24 REPLACING THE AIR FILTER SAFETY CARTRIDGE Dismantle the air filter cartridge see Chapter D5 Remove the air filter safety cartridge 1 Fig E1 and replace it with a new one Then unscrew nut 1 Fig E1 which fixes filter cartridge 2 Fig E1 and remove it Fit a new cartridge having the same features FILTER ELE MENTS AND BELTS TABLE in place of the one removed fix it by means of butterfly nut 1 Fig E1 Refit the air filter cartridge see Chapter D5 22 CHANGING THE HYDRAULIC OIL AND HYDRAULIC OIL EXHAUST FILTER CARTRIDGE Before carrying out these procedures make sure that the truck is on a horizontal surface the engine is off and the boom raised Place a container under the drain cap
113. x train weight Power ISO TR14396 Tractive effort Year of manufacture pressures Bar Vertical max effort Front ear on trailer hook MANUFACTURED BY MANITOU COSTRUZIONI INDUSTRIALI s r VIA C COLOMBO 2 Loc Cavazzona 41013 Castelfranco E MO ITALY Tel 059 959811 Fax 059 959850 n 726139 FIG B On internal combustion engine FIG B Engine No MHT 10210 L On hydrostatic drive FIG C MANITOU referenceN Serial N On front and rear axle FIG D Axle type and model Serial N of front axle Serial N of rear axle 1 Axle type and model 2 Serial N On cab FIG E Cab Write all these numbers in the empty spaces Since the MANITOU policy is to constantly improve our products our range of telescopic lift trucks may be subject to modifications without our being obliged to give advance warning to our customers FIG C a A BF 212 262 75 REF MANITOU MFG Tm DANA FIG E J INSTRUCTIONS MHT 10210 MSeres ORIGINAL REPLACEMENT PARTS AND ATTACHMENTS maintenance on our lift trucks must be carried out using original parts By allowing non original parts to be used you run the risk Legally of being liable in the event of an accident Technically of causing breakdowns to occur or of reducing your lift truck s

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