Operators Manual 81 Xe Manitou

BP 249 249 Z. I. 44158 ANCENIS CEDEX - FRANCE TEL : 33 (0)2 (0)2 40 09 10 10 11 YOUR DEALER

547367 EN (23 / 06 / 2006)

ACCESS ACCESS PLATF PLATFO ORM 81 XE OPERATOR’S MANUAL

THIS INSTRUCTION LEA FLET MUST BE KEPT PERMANENTLY PERMANENTLY ON THE ACCESS PLATFORM AND BE READ AND UNDERSTOOD UNDERSTOOD BY THE OPERATORS.

1s t DATE OF ISSUE DATE OF ISSUE

03 / 06 / 02 OB SERVATION

03 / 06 / 2002

First edition

26 / 02 / 2004

Corrections pages 1-11 / 2-8 / 2-9 / 2-10 / 2-11 / 2-12 / 2-13

09 / 11 / 2004

Change of title page following the change of MANITOU logo Corrections Chapter 3 : MAINTENANCE

23 / 06 / 2006

Modification of Chapters 2 and 3 following addition of the machine overload system : 510474 / 510475 / 510476 / 510477.

TABLE O F CON TENTS

1 - I N STRUCTIONS

1- 1

– ORIGINA L REPL AC EMENT PARTS

1- 3

– DRIVER’ S IN STRUCTIONS FOR USE - General instructions - Driving instructions - Handling instructions

1- 4 1-4 1-6 1-8

– INSTRUCTIONS ON PL ATFORM’ S MA INTENANCE

1- 9

– PL ATFORM IDENTIFI CATION

1 - 11

– B EFORE STA RTING THE PLATFORM FOR THE FIRST TI ME

1 - 12

2 - DESCRIPTION

2- 1

– CHARACTERISTICS

2- 4

– DIMENSI ONS

2- 6

– A CCESS PL AT FORM FUNCT ION

2- 8

– MONITORING AND CONTROL INSTRUMENTA TION

2 - 12

– USING THE MOB IL E PL ATFORM

2 - 21

– RESCUE PROCEDURE

2 - 22

AI NTE NAN CE 3 - M

3- 1

– FI LT ER ELE MENT

3- 3

– L UBRICA NTS

3- 3

– MA INTENA NCE SCHEDULE A : Every day or every 5 hours of operation B : Every 50 hours of operation C : Every 100 hours of operation D : Occasional maintenance

3- 5 3-6 3-9 3 - 10 3 - 11

AI NTE NAN CE 4 - M

HAN DBO OK

4- 1

1 - INSTRUCTIONS

1-1

ORIGINAL REPLACEMENT PARTS OUR MOBILE PLATFORMS MUST ONLY BE MAINTAINED WITH ORIGINAL REPLACEMENT PARTS.

BY AUTHORISING THE USE OF NON-ORIGINAL REPLACEMENT PARTS,, YOU RISK

- Legally, being liable in the event of an accident. - Technically, causing operating faults or shortening the equipment’s operating life.

The use of counterfeit parts or components not approved by the manufacturer may invalidate the terms of the contractual guarantee and lead the manufacturer to withdraw his declaration of conformity. BY USING ORIGINAL PARTS IN YOUR MAINTENANCE WORK, YOU PROTECT

- Any user obtaining suppliers from elsewhere does so at his own risk.

YOURSELF LEGALLY

- Any user who modifies his platform or has it altered by a service provider must take into account that a new item of equipment is being thereby introduced on the market and must therefore assume responsibility for it. - Any user who copies original parts or has them copied exposes himself to legal risks. - The declaration of conformity is only binding on the manufacturer for the selected parts or those developed under his control. - The manufacturer lays down the practical maintenance conditions. The fact that the user does not observe these creates no liability on the manufacturer.

YOU HAVE

THE PROVIDES THE USER WITH,

THE BENEFIT OF KNOW-HOW

- His know-how and expertise. - A guarantee of the work performed. - Original replacement parts. - Assistance in preventive maintenance. - Efficient diagnostic assistance. - Improvements based on experience. - Training for the operators. - Only the manufacturer knows the design of the mobile platform in detail and therefore has the best technical capabilities to ensure its maintenance.

ORIGINAL REPLACEMENT PARTS ARE ONLY DISTRIBUTED BY MANITOU AND ITS CONCESSIONAIRES. Telephone the Parts Department to obtain a list of the network of dealers: TEL: 02.40.09.10.21 1-3

DRIVER’S INSTRUCTIONS FOR USE

WHEN YOU SEE THIS SYMBOL, IT MEANS:

WARNING! TAKE CARE! YOUR SAFETY OR THE PLATFORM’S SAFETY IS IN JEOPARDY

G E NERAL

INSTRUCTIONS

A – INSTRUCTIONS MANUAL - Carefully read and fully understand the instructions manual. - The instructions manual must always be kept in the mobile platform, in the location provided and in the driver’s usual language. - All operations or manœuvres not described in the operator's manual are prohibited. - Observe the safety instructions and the instructions written on the platform. - Any plates or stickers that become illegible or damaged must be replaced.

B - AUTHORISATION TO DRIVE (LEGISLATION IN FORCE IN FRANCE) (or please refer to the appropriate legislation for the respective country) - Only qualified, duly trained personnel may operate the platform. This training is the employer’s responsibility. - When using the platform, as a safety precaution, another operator must be present on the ground. - Familiarise yourself with the platform on the site where it will be operating. - The driver is not empowered to authorise someone else to drive the platform. - The platform must be used in a professional manner. - Do not use the equipment if it is windy. This access platform (for indoor use) must not be subjected to wind. The access platform basket must not be subjected to a lateral force of more than 40 kg. - Hard hats must be worn. - It is strongly recommended to wear a safety harness when using the platform. - Equip the platform with its own fire extinguisher when it is operating in an area with no means of extinction. Other optional solutions exist; please contact your agent or dealer.

1-4

C – MAINTENANCE - Any user who notices that his platform is not in good operating condition or that it does not comply with the safety instructions must immediately notify his supervisor. - It is forbidden for the driver to attempt to carry out any repairs or adjustments. He must keep his platform in a perfectly clean condition if he is charged with this task. - The safety devices must not be disconnected or bypassed. - Perform daily servicing (See chapter : A - EVERY DAY OR EVERY 5 HOURS OF OPERATION in part 3 MAINTENANCE). - For your safety and that of others, do not alter the structure or the settings of the different components of your platform yourself. . Hydraulic pressure . Limit switch ratings . Addition of extra equipment The manufacturer is released from any liability in such cases. - So that you can keep your mobile platform in a condition of conformity, we recommend that you have it checked regularly by your agent or concessionaire, given that regular checking is a legally envisaged (please refer to the upcoming legislation). - Do not replace the batteries with lighter ones (this would compromise stability). - Do not work on the hydraulic circuit without depressurising it first. - Always wear safety goggles when charging the batteries. - Do not charge batteries in an explosive environment.

IF NECESSARY, CONSULT YOUR AGENT OR DEALER.

1-5

D R IVING

INSTRUCTIONS

A – BEHAVIOUR WHEN DRIVING - Wear suitable clothing for driving the platform; avoid loose-hanging clothing. - Never drive with wet or greasy hands or shoes. - Always keep your feet, and in general every part of your body, inside the platform. - A safety helmet must be worn. - It is strongly recommended to wear a safety harness when using the platform. - Never attach the safety harness to an adjacent structure when in the basket. - Ensure that the barrier is firmly closed before operating the platform from the basket. - It is forbidden in all cases to exceed the platform's standard capacity. Please refer to the Chapter "Characteristics" in Section 2: "Description". - Evenly distribute the load in the basket.

B – BEFORE STARTING UP THE PLATFORM - If the platform is new, see Chapter: BEFORE STARTING THE PLATFORM FOR THE FIRST TIME, Section: 1 – SAFETY INSTRUCTIONS AND ADVICE. - Check that the tyres are in good condition. - Before starting the platform, check the hydraulic oil level and the battery’s charge. - Whatever his level of experience, the user must familiarise himself with the location and use of all the monitoring and control instrumentation before operating the platform. - The platform must be set to transport position (basket in the low position) before embarking. - The platform may only be used on a flat surface. An asphalted surface is normally required. - It is forbidden to use the platform if the guardrails are not in place.

1-6

C – DRIVING THE PLATFORM SAFETY INSTRUCTIONS - Do not use the platform if the battery is discharged to the point that movement is slowed down; in certain cases, the control can cease to function. - Do not use the platform unless it is in perfect working order or if it has not been checked. - Wear suitable clothing for driving the platform; avoid loose-hanging clothing. - When working in areas of through traffic, avoid any risk of something becoming caught. - Keep your eyes in the direction of travel and always retain good visibility of your route. - In all circumstances, keep your speed under control. - Drive slowly on wet, slippery or uneven surfaces. - Drive around obstacles. - You are recommended to use a winch when loading the platform onto or unloading it from a flatbed or truck.

Beware of trenches, scaffolding and recently excavated or back-filled terrain

1-7

H A NDLING

INSTRUCTIONS

- The platform may only be manoeuvred from the ground: ensure access is forbidden. - The platforms cannot be used as cranes or lifts for the constant transport of materials or people, nor as jacks or supports. - When raising the platform, ensure that nothing or no one is impeding its travel and do not perform any false manoeuvres. - When working near to overhead electrical cables, ensure that there is adequate safety distance between the cables and the platform’s working area. Check the prevailing legislation.

You should seek advice from your local electricity provider.

You could be electrocuted or seriously hurt if you work or park the platform too close to electrical cables. You are strongly advised to ensure that the safety rules on the site conform to the prevailing local regulations regarding all types of work near to electrical cables. - Do not attempt to accomplish operations beyond the platform’s capabilities. - Working over the heads of other people is forbidden. - Ensure that the material loaded onto the platform (pipes, cables, containers, etc.) cannot escape and fall. Do not heap such material up to the point that they must be stepped over. - Do not use ladders or improvised constructions inside the platform to reach higher.

IF NECESSARY, CONSULT YOUR AGENT OR DEALER.

1-8

INSTRUCTIONS FOR THE PLATFORM’S MAINTENANCE M AINTENANCE I NSTRUCTIONS A - GENERAL

Do not work on the machine with the scissors extended without first blocking their descent using the maintenance locks. - Carefully read the instructions manual. - Clean the platform, or at least the area concerned, before performing any work. - Wear suitable clothing for maintaining the platform: avoid wearing jewellery and loose-hanging clothing. Tie up and cover your hair if necessary

Ensure that consumable materials and replaced parts are disposed of in complete safety and in an ecological manner. - Carry out any necessary repairs immediately, even minor repairs. - Repair any leaks immediately, even minor ones. - Do not attempt to loosen the connections, the hoses or a hydraulic component while the circuit is still pressurised.

Any manipulation or removal of the equalising valves that may be fitted to the jacks on your platform can prove dangerous. An equalising valve should only be removed when the jack concerned is at rest and the hydraulic circuit under residual pressure. This operation should only be performed by approved personnel

- Disconnect the negative terminal (-) from the top of the battery before working on the electrical circuit or the platform itself (e.g. welding). - Do not lay metal items on the battery. - The electric box may only be opened by authorised personnel. - The periodic checks prescribed by the approved control departments are essential. - Do not work on the hydraulic circuit without depressurising it first. - Always wear safety goggles when charging the batteries. - Do not charge batteries in an explosive environment.

1-9

B – MAINTENANCE - Clean away any trace of oil or grease from the platform. - Clean the platform, or at least the area concerned, before performing any work. - Do not clean with high-pressure equipment near to the electrical components.

If necessary, protect components liable to damage from penetration by water, steam or cleaning products and protect the electrical components and connections in particular - The platform must compulsorily be maintained and kept in a condition of conformity. - Perform daily servicing (See chapter : A - EVERY DAY OR EVERY 5 HOURS OF OPERATION in part 3 MAINTENANCE).

1 - 10

PLATFORM IDENTIFICATION

Since it is our policy constantly to improve our products, certain modifications may be introduced to our platform range without our being required to notify our esteemed customers. On any orders for replacement parts or any request for technical information, please always specify: NB: So that you can provide all these numbers easily, you are recommended to write them down in the places provided for this purposes when you take delivery of the platform.

M ANUFACTURER ’ S

PLATE ON THE PLATFORM ( FIG . A )

- Type - Serial No. - Year of manufacture

1 - 11

A

BEFORE STARTING THE PL ATFORM FOR THE FI RST TIME I NTRODUCTION - Our platforms have been designed with the aim of providing the driver with great ease of manoeuvring and maximum ease of maintenance. - However, before starting the platform for the first time, the user must carefully read and fully understand the different chapters in this instructions manual, which has been designed to cover any driving or maintenance problems. By following these instructions, the user will be able to take fullest advantage of all the platform’s capabilities. -The user must inform himself of the position and function of the various monitoring and control instruments before using his platform.

Never use a new platform without carrying out the following checks:

L UBRICATION - Check the different grease nipples and different levels. see chapter : SERVICE ENGINE SCHEDULE in part 3 MAINTENANCE and complete if necessary.

The machine is filled with lubricant at the factory to suit average climatic conditions, i.e. -15°C to +35°C. For more severe use, before starting up the machine must be drained and refilled with lubricants suitable for the ambient temperatures. (if necessary, contact your agent or dealer for advice).

H YDRAULIC C IRCUIT - Visually check that there are no leaks or sweating of oil on the connections, hoses, pipes and fittings. If necessary, retighten or check the defective connections. - Also check the oil level in the reservoir.

T YRES - Make sure the wheelnuts are properly tightened (See chapter : B - EVERY 50 HOURS OF OPERATION in part 3 MAINTENANCE).

E LECTRICAL C IRCUIT - Check the level and the density of the electrolyte in the battery. - Check the various components in the electrical circuit and their fixings and connections. IF NECESSARY, CONSULT YOUR AGENT OR DEALER.

1 - 12

2 2 -- DESCRIPTION DESCRIPTION

2-1

2-2

2-3

CHARACTERISTICS L ECTRIC E LECTRIC

PUMP

- Supply - Output - Cubic capacity - Pressure

L ECTRICAL E LECTRICAL

24 V 3.2 KW 4,8 cm3 200 bar +/- 10 bar

CIRCUIT

- Battery - Charger - Variator (Type)

R ONT / F RONT /

4 elements, each of 6V-220 Ah C 20 24 V - 25 Ah Curtis

REAR TYRES

DIMENSIONS

TY P E

LOAD PER TYRE UNLOADED

UNDER MAX. LOAD ON 1 WHEEL

16-5-11.1/4

Rubber ty tyre

425 kg

1130 kg

- Wheel nut tightening torque - Front wheels - Rear wheels H EAL W HEAL

AREA OF GROUND CONTACT FOR 1 WHEEL

94.5 cm2

7 DaNm 7 DaNm

GEARED MOTORS

- Motor

2-4

STAMPING

12 daN/cm2

81 XE P ECIFICATIONS S PECIFICATIONS

- Use:

Indoors

- Capacity: - Standard platform: - Extension extended:

340 Kg including 2 people 120 Kg including 1 people

- Control system:

Electro-hydraulic

- Lifting system:

Single scissors

- Platform movement speed: - In operating position (Floor height > 2000 mm): - High speed: - High torquee:

0.7 km/h 4 km/h 2.1 Km/h

- Time to raise/lower scissors

29 s / 33 s

- Operating height - Floor height: - Height with guard rails folded

809 3 m m 6093 mm 1917 mm

- Overall basket size: - Extension retracted: - Extension extended:

2 29 8 x 79 0 m m 3290 x 790 mm

- Floor area: - Extension retracted - Extension extended:

2 28 4 x 58 0 m m 3235 x 580 mm

- Platform weight, empty:

1700 Kg

- No. of gears

2

- Handleadle gradient

25%

- Inclinaison, alarm activation

3,5% ou 2°

- Maximum authorized wind speed

0 km/h

V IBRATION I BRATION

LEVEL

- Vibrations perceived by the hands-arms and body overall : -Mean quadratic values for the upper limbs : -Mean quadratic values for the body :

2-5

< 2.5 m/s2 < 0.5 m/s2

DIMENSIONS 81 XE

B

A

2-6

81 XE

A

6106

B

990

C

92

D

2280

E

100

F

2315

G

810

H

98

I

1056

J

2146

K

rails 1918 guard folded

L

1839

M

2468

N

373

C

D

E F

J

K

H

I

G

N

L M

2-7

PLATFORM OPERATION D ESCRIPTION - This machine is a mobile platform for lifting people. It consists of a working platform on a scissor lifting structure. - MANITOU lifting platforms are solely for use for bringing people, and their tools and supplies (within the authorised weight limit, please refer to the paragraph “SPECIFICATIONS”), to a desired working height. - The lifting platform is equipped with a control station in the basket. From this, the operator can drive or move the machine forwards or backwards. The operator can raise or lower the scissors and turn the platform right or left. - The lifting platform is also equipped with a ground backup and maintenance station which can control all lifting functions except travelling The base controls are only to be used in an emergency to bring the operator back to ground level if he is incapable of doing this himself. - The ground backup and maintenance station and the basket control station must be checked by the operator every day to ensure that they work properly. - The lifting platform’s movements are powered by a hydraulic pump, operated by a battery-powered electric motor. The hydraulic components are controlled by electro-valves actuated by contactors and the manipulator. - The base or basket console’s controls are via changeover contactors and are either in “Run” or “Stop” mode. - The lifting platform is a two-wheel drive machine driven by an electric motor on each wheel. The drive wheels have spring-operated, hydraulically released brakes. These brakes tighten automatically as soon as the travelling manipulator is returned to the neutral position. - The lifting platform can lift up to the limit of its capacities (seer “SPECIFICATIONS” in this Chapter). Having a maximum capacity load or less in the basket will still enable you to move in any position, provided that the machine on ground with a slope of no more than 2°.

G ENERAL - In the following pages, you will find all the information required for using the machine, including the platform’s operating, driving, parking, loading and transport instructions.

2-8

O PERATION

Do not raise the basket's platform if the machine is not on a flat, stable surface. When starting up, set the battery cutout to the "ON" position (battery compartment). Remember to set the selector switch to "Basket" before climbing into the basket.

D RIVING

AND STEERING

NB: To move the machine, set the console's selector switch to "Movement". Engaging the authorisation lever authorises the movement and steering functions. The direction wheels do not return to the neutral position by themselves: they must be reset via the directional rocker switch. To move forwards, lower the lever and raise the lever to reverse. The movement speed is proportional to the movement of the lever. Once released, the regulator handle returns to the Neutral position.

B RAKING

WARNING Activating the Emergency Stop button on the basket platform immediately engages the brakes, which risks causing unexpected movement of the platform when the machine stops abruptly. When the machine is operating, hold on tight- ly and tie down any objects on the basket platform. NB: For parking, the brake locks automatically when the console's control lever is in the central position (Neutral).

R AISING THE

BASKET

USING THE BASKET CONTROLS To raise the basket, set the mode selector to the "Raise" position. Pushing the authorisation trigger down and moving the regulator handle upwards causes the basket to rise. The lifting speed is proportional to the movement of the regulator handle. USING THE BASE CONTROLS Set the selector to the "Base" position and push and hold down the commutator switch (Raise/Lower) on the base console in the "Raise" position until the desired height is reached or the basket attains its maximum height.

LOWERING THE BASKET USING THE BASKET CONTROLS To lower the basket, set the mode selector to the "Raise" position. Push down the authorisation trigger and move the regulator handle downwards to lower the basket. The speed of descent is fixed. The basket's platform stops at a height of around 2m. After a 3 second pause, the basket will continue its complete descent. USING THE BASE CONTROLS Set the selector to the "Base" position and push and hold down the commutator switch in the "Lower" position until the desired basket height is reached or the basket reaches the low position. The basket's platform stops at a height of around 2m. After a 3 second pause, the basket will continue its complete descent. 2-9

E XTENDING

THE BASKET

Use the handle at the back of the extension to lift the spring pin from its locked position. With the handle pulled out, push the extension to the desired length and release the handle to lock the spring pin in position. Length can be increased at 25 cm intervals along the length of the extension.

WARNING Before lowering the platform, check that there is nothing under the extension.

L OWERING

THE PLATFORM ’ S GUARDRAILS

Lift and fold back the front guard rail on the extension floor. Lift the extension guard rails and fold them back. Lift and swivel the rear guard rails. Finshing by folding back the main guard rails. Return to normal machine operating mode, carefully reinstalling the guardrails. Reposition the basket console.

S TOP

PROCEDURE

When an operating period is finished, set the mobile platform to Transport position (basket lowered, extension retracted). Park the machine on a level surface. Stop the motor by engaging the Emergency Stop. Carefully, get of the platform. Cut off the circuit, using the battery cutout on the base console. NB: The batteries will drain if the battery cutout is left in the "ON" position for a prolonged period. Always set the selector switch to the "OFF" position when the machine is parked at the end of the working day.

2 - 10

S AFETY 12

SLOPE 11

When the access platform has reached the maximum authorised inclination (see chapter : CHARACTERISTICS), the LED 11* on the basket console flashes regularly. Furthermore, the beeper 15* in the basket also sounds intermittently. The "AGGRAVATING" basket elevation movement is prohibited for safety reasons.

To restore these functions, only perform "disaggravating" movements : - return to safety position by lowering the basket, then reposition the basket to more horizontal ground to start a lifting movement.

OVERLOAD

15

When the platform has reached its authorized weight limit (see chapter : CHARACTERISTICS) in the basket, a default code is displayed on the can 5* (F 10) display. The overload LED at the basket console 12* flash regularly. The beeper 15* in the basket sounds constantly. All movements are prohibited for safety reasons.

To restore these functions : - Lighten the basket by removing the item(s) causing the overload, OR, - Ask someone at ground level to lower the basket under manual control (see “RESCUE PROCEDURE”).

* : the above references are the same as those used in the description of these components in the following pages.

2 - 11

5

MONITORING AND C ONTROL I NSTRUMENTATION A - B A SE

T O

CONSOLE

MACHINE N O.

506128

F ROM

MACHINE N O.

506129

3 4

2

1

6

5

8

7

9

8

2 - 12

A - B A SE

CONSOLE

1. R AISE / LOWER

CONTROL

This governs the raising and lowering of the basket from the base console when selector switch 2 is in the "BASE" position.

B 2

2. B ASE /S TOP /B A SKET

1

SELECTOR SWITCH

Select "BASE" (position A) to control the raising of the basket using the controls on the base. Select "BASKET" to control the machine's operation using the basket console. NB: A key is provided to lock the commutator. NOTE: The button must be held in low position (position A) to be able to move the basket.

3. E MERGENCY S TOP

A

BUTTON 3

This switch cuts off all the machine's movements in the event of danger or anomalies. - Press the knob to cut off all movements. - Turn the knob a quarter turn to the right to release (the switch will automatically return to its initial position)

This command has priority at all times, even when movements are made from the basket.

4. H OUR

T O

METER AND LOAD INDICATOR

MACHINE N O.

506128

A - BATTERY CHARGE LEVEL INDICATOR · BATTERY CHARGED - The display shows 100%. · BATTERY DISCHARGED - The display shows 0%.

B

B - HOUR METER INDICATOR It shows the number of hours completed by the access platform. The hour meter is displayed only when the machine is switched on; to display it, press and release the emergency stop button (to switch the machine off and on).

5. C AN

F R OM

DISPLAY

MACHINE N O.

506129

2 - 13

5

A

P 52

LIFT P014

Tacc 1,3s P

P

LIFT P015

F2

Parametering for raising at Paramètrage acceleration time

53

Parametering for raising at Paramètrage time deceleration

Tdec 0,6s

F2

54 Menu principal des paramètres Main menu for factory settings usine.

FACTORY SETTINGS P

55

F2 TO CONFIRM:

PRESS ' - ' (5s) -

F2 5 sec

RECYCLE POWER

56

F2

Request for access code for the

Demande du code pour accéder various machine parameters aux différents paramètres machine

18

KEY ? XXXX

+

The first 2 numbers - les 2 premiers chiffres

P

+

The last 2 numbers - les 2 derniers chiffres

P

(Manufacturer’s code) (code constructeur)

P

2 - 16

Confirmation for resetting factory Confirmation pour settings. remettre les paramètres usine.

Cut off the general power supply while still Couper l'alimentation générale tout en restant in this display. The factory settings are redans cet affichage. Les paramètres usine seront installed during initialisation. réinsérés lors de l'initialisation.

6. " BATTERY

CHARGE LEVEL" INDICATOR 6

The LED changes colour according to the battery charge level : LED is red : - The charger is in the initial charging phase. LED is yellow : - The battery is 80% charged. LED is green : - The battery is 100% charged.

7 - S O UND

ALARM HORN

This sound alarm horn is activated by pressing button 14 (in the basket).

8 - O VERLOAD

SENSORS

- These sensors are used to control overload in the basket.When the access platform has reached the maximum authorised weight (see chapter : CHARACTERISTICS) in the basket. The overload LED at the basket console 12 flash regularly. The beeper 15 in the basket sounds constantly. All movements are prohibited for safety reasons.

9 - S LOPE

7

8

8

SENSOR

- This sensor checks the platform’s inclination When the platform has reached its max. authorized slope (See chapter : CHARACTERISTICS), the buzzer ref. 33 is triggered intermittently and any "AGGRAVATING" scissor elevation movement is blocked. The LED 11 on the platform is lit.

If the buzzer does not sound and the LED does not light, immobilise the platform and make the necessary repairs.

2 - 17

9

MONITORING AND C ONTROL I NSTRUMENTATION B - B A SKET

CONSOLE

17 16

18

12 19 11

13

10

14

15

2 - 18

B - B A SKET

CONSOLE

10.R AISE / M OVE

COMMUTATOR SWITCH

10

B

A - COMMUTATOR IN POSITION A - The control lever (10) moves the machine in translation mode

A

B - COMMUTATOR IN POSITION B - The control lever (10) raises or lowers the scissors.

11. T ILT

INDICATOR LIGHT

This lights when the machine is inclined more the 2 degrees.

12

11

12. AVERTISSEUR

DE SURCHARGE

If the basket is overloaded, the LED flashes intermittently (See : ACCESS PLATFORM OPERATION– SAFETY INSTRUCTIONS ).

13. S PEED

OF MOVEMENT SELECTOR SWITCH

This selector switch determines the speed of movement in transport mode.

13

- "Tortoise" position: the speed does not exceed 2.1 km/h - "Hare" position: the speed does not exceed 4 km/h

14

NB: In the "Hare" position, the drive torque is lower than in the "Tortoise" position.

14. S O UND

ALARM HORN

Press the button to sound the horn.

15. A LARM

BUZZER

- This buzzer so unds when the mach ine is in either of t he critical situations below: - Case 1 ; INTERMITTENCE : (See : ACCESS PLATFORM OPERATION - SAFETY INSTRUCTIONS).

- Case 2 ; CONTINUOUS : (See : ACCESS PLATFORM OPERATION - SAFETY INSTRUCTIONS). 2 - 19

15

16. E MERGENCY

STOP 16

This switch cuts off all the machine’s movements in the event of danger or an anomaly. - Press the knob to cut off all movements. - Turn the knob a quarter turn to the right to release (the switch will automatically return to its initial position)

This control has priority in all cases, even when movements are being made from the platform.

17. D IRECTION

COMMUTATOR 17

Press this rocker switch during movement to steer the platform.

18. F ORWARDS /R EVERSE ” AN D “R A ISE /L OWER ” CONTROLS 18

- MODE SELECTOR IN THE “RAISE” POSITION.” The trigger is pushed in :

19

- Push the handle (A : white arrow) to lower the basket at a speed which is proportional to the movement of the handle. - Pull the handle (B : black arrow) to raise the basket at a fixed speed. - MODE SELECTOR IN THE “MOVEMENT” POSITION. Controls the forwards and reverse movement of the machine at a speed proportional to the movement of the handle.

19. AUTHORISATION

TRIGGER

Press the trigger to activate the drive, direction and raising functions..

2 - 20

A B

USING THE PLATFORM LIMITED

TRANSPORT / OPERATING MODE

Transfer from transport to operating mode takes place when the basket is 2 metres above the ground / floor.

WORKING MODE

The access platform has two modes of displacements: the transport mode and the working mode. - Transport mode (below 2 m) : the scissors are folded. The access platform arms are in low position. This mode is used to move at high speed and go beyond the slope of the machine (See chapter : CHARACTERISTICS). - Working mode (below 2 m) : the scissors are folded. One or many arms of the access platform are lifted or the telescope is gone out. In this mode, the travelling are made with a small speed, the safeties for the slope and the overload are activated..

NSTALLATION AND RAISING

The platform has been designed to work on an even, horizontal surface. It is important to clear the area in which the platform will be operating.

2m - Bring the platform to the work site. - If necessary, load the material to be carried (arrange it so that it does not inconvenience the operator and to avoid it falling). . - Climb into the basket.

TRANSPORT MODE

Safety helmets must be worn.

When manoeuvring the platform (raising, rotating, etc.), look all around and above you. Pay particular attention to any electric cables and other objects that may be within the platform's operating area.

T RANSPORTING

Fork emplacements THE PLATFORM

The platform has been designed to be able to be transported on a forklift truck.

2 - 21

RESCUE PROCEDURE I F

A

THE OPERATOR BECOMES ILL

Should the operator be taken ill or become incapable of manoeuvring the platform, the person present on the ground can regain control of the platform. 1

Follow the instructions below:

2

- Switch the key contactor 1 (Fig. A) to position A to regain control of the platform's movements. A

- Proceed to lower the platform with commutator 2.

Take care regarding any constructions or objects that may be under the platform.

E MERGENCY

B

LOWERING PROCEDURE

The emergency lowering system is used to lower the platform in the event of a power failure or a valve breaking down. This system is located on the rear righthand side of the machine and can be accessed via the window in the chassis.

3

Follow the procedure below to lower the platform: 1 Unscrew the knurled knob 3 (fig B) on the lifting cylinder electrovalve to lock the valve open. 2 Pull tappet 7 (fig C) on the main distributor to lower the platform to the desired height. 3 Tighten knurled knob 3 (fig B) on the lifting cylinder electrovalve to return to normal function. The valve will lock automatically.

P R O CE D U R E

C

TO R E L E AS E T H E B R A K E A N D G O I N TO

FREE WHEEL POSITION 7

In the event of a power cut, the machine can be moved, using a winch or not, over short distances at a speed not exceeding 8.0 km/h. 5

Releasing the brakes / towing the machine

4

Your machine is equipped with a brake release. Release the brakes as follows : • Unscrew the knurled rod on main distributor 5 (fig C). D

• Push in tappet 4 (fig C) on the main distributor. • Pump until the brakes are released, using the hand pump at the back of frame 6 (fig D). • The machine is now ready to be towed. • To reset the brakes, tighten knurled rod 5 (fig C) and the circuit will be under pressure again when the hydraulic circuit is switched on.

6

When the brakes are released and the machine is in free-wheel mode, there is nothing to stop the movement of the machine. Use chocks to prevent the machine from moving. 2-22

3 3 -- MAINTENANCE MAINTENANCE

3-1

3-2

FILTER ELEMENT

1

DESIGNATION

1 - Hydraulic oil filter cartridge

REFERENCE

REPLACE AFTER

599004

100h

LUBRICANTS COMPONENTS TO LUBRICATE

HYDRAULIC OIL RESERVOIR

CAPACITY

13 Litres

RECOMMENDATION

MANITOU hydraulic oil ISO 46

STEERING PIVOTS

SHELL Retinax HD grease

SCISSOR SYSTEM SLIDE RAILS

Dry lubricant

3-3

PACK

REFERENCE

20 L. 55 L. 209 L.

582297 546108 546109

Cartridge 400 Gr.

161589

Aerosol

719741

3-4

MAINTENANCE SCHEDULE A = ADJUST C = CHECK Ch = LOAD D = DESCALE G = GREASE

After

N = CLEAN

the first

P = PURGE

50

R = REPLACE

Day or 5 hours

hours

V = EMPTY

50 hours or 6 months*

100 hours or 1 year*

200 hours or 2 years*

PAGE

TRANSMISSION

Rear wheel reducer oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . TYRES C

Tightening wheelnuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condition of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic return oil filter cartridge . . . . . . . . . . . . . . . . . . . . Auxiliary hydraulic oil filter cartridge . . . . . . . . . . . . . . . . . . Hydraulic oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic circuit strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . Backup pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turret motor brake reducer . . . . . . . . . . . . . . . . . . . . . . . .

3-9 C**

HYDRAULICS

R

3-10

V/R N

3-7 3-10 3-10

C

ELECTRICITY

Battery charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Density of battery electrolyte . . . . . . . . . . . . . . . . . . . . . . . Battery electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening electric power cables . . . . . . . . . . . . . . . . . . . . Replace the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C Ch C C

3-6 3-6 3-8 3-8 3-9 3-12

C

FRAME

Access platform slew ring . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening screws on the turret slew ring . . . . . . . . . . . . . . Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering pivots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scissor system slide rails . . . . . . . . . . . . . . . . . . . . . . . . . .

G

3-9

N

3-7

LIFTING FRAME

Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locking the telescope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basket overload and rotation . . . . . . . . . . . . . . . . . . . . . . . Tightening turret rotation motor bolts . . . . . . . . . . . . . . . . . SAFETY COMPONENTS

Arm position sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slope sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overload sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCESS PLATFORM

Change a wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attach a sling to the platform . . . . . . . . . . . . . . . . . . . . . . . Transport the platform on a skid . . . . . . . . . . . . . . . . . . . . . *: At the first period reached **: Consult your dealer

3-5

C** C** C**

3-11 3-11

A - EVERY DAY OR EVERY 5 HOURS OF OPERATION A1 - B ATTERY

CHARGE CHECK

A1/1

- When the display shows 100%, it means that the batteries are 100% charged. - When using the access platform, the percentage indicates the level of charge of the batteries. - When the batteries are discharged, the display shows 0% on model (Fig. A1/1) and 20% on model (Fig. A1/2); be sure to recharge the batteries before reaching this percentage, to avoid damaging the batteries.

A2 - B ATTERIES LOAD

- The platform is fitted with an electric charger 3 (Fig. A2/3) located in the battery compartment.

A1/2

USING THE CHARGER.

Recharge the batteries in a well-ventilated place where smoking is forbidden to eliminate the risk of explosion. - Open the battery compartment and leave it open throughout the charging operation. - Cut of the power supply to the platform using the battery cutout 2 (Fig. A2/2). - Do not lay any metal items on the batteries (risk of short-circuit).

A2/1

- Do not remove the caps. - Do not recharge the batteries if the electrolyte’s temperature exceeds 40°C; leave it to cool down first.

1

- Extract the extension lead 1 (Fig. A2/1). When the batteries are charged: - Disconnect the extension lead 1 (Fig. A2/1) and return it to its storage place. - Close the battery compartment. - Restore power supply to the platform via battery cut-off 2 (Fig. A2/2).

NOTA

: The charger has been adjusted in the factory to the cable with which it is fitted. If the cable must be replaced, ensure that a cable with the same cross-section and of the same length is fitted.

A2/2

A2/3

3

2

3-6

A3 - S C IS SO R

S YS TE M S LI DE R AI LS

A3/1 CLEAN

- Use a compressed air jet to remove impurities (metal turnings, wood shavings…) from the slide rails 1 (Fib. A3/1 and A3/2). - Grease the slide rails if necessary (see chapter on "lubricants").

1

A3/2

1 1

A4/1

A4 - H Y DRAULIC

OIL LEVEL CHECK

- Check the hydraulic oil level; it must be above the red spot on gauge 1 (Fig. A4/1) - Add oil if required (see Chapter: "Lubricants") via the filling cap 2 located on the top of the reservoir (Fig A4/2).

1

A4/2

1

3-7

A5 - D E NSITY

OF BATTERY ELECTROLYTE A5

CHECK

The electrolyte’s density varies according to the temperature but a minimum density of 1270 at 16°C must be maintained.

1.240 1.250 1.260

In the hatched area (Fig. A5), the batteries are normally charged. Below the hatched area, the batteries require to be recharged.

1.270

The density must not vary by 0.025 units from one battery element to another.

1.290

1.280

1.300

- Check the density of the electrolyte in each battery element using an acid densimeter.

°C -18 -10 °F

0

14

0

10

20

30

32

50

68

86 104

- Never check after adding distilled water. - Recharge the batteries and wait 1 hour before checking the density of the electrolyte.

A6

1

A6 - B ATTERY

ELECTROLYTE LEVEL

1

CHECK

Check the electrolyte level in each battery element. If the ambient operating temperature is high, check the level more frequently than every 50 hours of operation. - Open the battery covers. - Remove cap 1 (Fig. A6) don each battery element. - The level should be 1cm above the battery plates. - If necessary, top up with clean distilled water, kept in a glass container. - Clean and dry the caps 1 (Fig. A6) and replace them. - Check the terminals and apply Vaseline to avoid oxidation.

Handling and servicing a battery can be dangerous, take the following precautions - Wear protective goggles - Handle batteries horizontally - Never smoke or work near a naked flame - Work in a well-ventilated area - In the event of electrolyte being spilled onto the skin or splashed in the eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.

3-8

1

40

B - EVERY 50 HOURS OF OPERATION B1 - T I GHTENING

WHEELNUTS CHECK

- Check the tightness of the wheel nuts. See chapter 2 : Page 2-5 Non-observance of this instruction can result in damage to or breakage of the wheel pins and deformation of the wheels.

B2 - S TEERING

PIVOT GREASE

B2

Clean and grease the grease nipples 1 (Fig. B2) on the two wheel pivots using grease (see "lubricants" chapter) and wipe off the surplus.

B3 - T IGHTENING

1

ELECTRIC POWER CABLES CHECK

B3/1

Check the tightness of connectors and various power harness components (Fig. B3/1, B2/2 and B3/3).

+

B3/2

B3/3

-

B-

A1

MB+

3-9

D1

C - EVERY 100 HOURS OF OPERATION C1 - H YDRAULIC

OIL C1/1

EMPTY

C2 - H YDRAULIC

CIRCUIT STRAINER 2

CLEAN

C3 - H YDRAULIC

RETURN OIL FILTER CARTRIDGE REPLACE

- Position the platform on horizontal ground in transport position, with the wheels in line. OIL CHANGE

- Set a container under the oil tank - Set a container under drain plug 1 (fig C1/1) and unscrew it. - Remove drain plug 2 (fig C1/1) for easier drainage.

1

C2/1 CLEANING THE STRAINER

- Unscrew strainer 3 (fig C2/1) in the container, clean it using a jet of compressed air. - Replace the strainer in the container.

OIL FILLING

- Refit and tighten drain plug 1 (fig C1/1). - Fill up with hydraulic oil (See chapter "LUBRICANTS") via the filler hole. - The oil level should reach the middle of signal light 4 (fig C2/2).

3

C2/2

Dispose of the drained oil ecologically. Use a very clean container and fun- nel and clean the top of the oil can before filling.

REPLACING THE HYDRAULIC OIL FILTER CARTRIDGE

- Unscrew the three mounting screws from lid 5 (fig C3/1). - Remove filter cartridge 6 (fig C3/1) and replace it with a new one. (See chapter "FILTER CARTRIDGE"). NB

4

: Be careful to fit it the right way round.

- Refit lid 7 (fig C3/1) to the filter holder.

C3/1

7

6

5

1

3 - 10

C4 - S L OPE

SENSOR CHECK

For this operation, the platform moves in transport position. - Place the platform at an angle of tilt higher than is authorised (see : 2 DESCRIPTION: SPECIFICATIONS). - A buzzer sounds.

In the event of dysfunction, do not allow the platform to be used. Contact your dealer.

C5 - O V ERLOAD

SENSOR CHECK

For this operation, fold the arms into transport position. - Place a heavier weight than that indicated in the basket (see : 2 DESCRIPTION : SPECIFICATIONS). - Telescope extension and arm raising movements must be blocked (the overload signal light is on in the basket, the buzzer sounds constantly in the basket).

In the event of dysfunction, do not allow the platform to be used. Contact your dealer.

3 - 11

D - OCCASIONAL MAINTENANCE D1 - BATTERIES REPLACE

When the batteries must be replaced, it is essential that batteries of the same capacity and weight be used to ensure the machine’s stability. PRECAUTIONS : - Keep the battery very straight while it is lifted. - Take care to distance the slings to avoid any short-circuit. - Take care to position the battery correctly on the platform. When installing new batteries, recharge them after 3 to 4 hours of use. Repeat 3 to 5 times.

3 - 12

4 4 -- MAINTENANCE MAINTENANCE HANDBOOK HANDBOOK

4-1

MAINTENANCE HANDBOOK

- The maintenance handbook is provided by MANITOU’s dealer when the machine is put into service. - It accompanies the machine throughout the guarantee period and subsequently enables regular monitoring of the maintenance conducted on the machine in accordance with MANITOU’s recommendations. - Maintaining the equipment ensures that it is available for use and its profitability. - The MANITOU dealer can also propose maintenance programmes specially adapted to a variety of needs, ensuring (through his own expertise and the use of MANITOU original replacement parts the equipment’s maximum efficiency. - We recommend that the maintenance handbook be carefully kept throughout the machine operating life and, in particular, that it be handed over to the future owner it the machine is sold.

DATE

ACTUAL HOURS

ENGINEER’S SIGNATURE

50 HOURS DEALER’S STAMP REMARKS:

DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



4-3

DATE

ACTUAL HOURS



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4-4

DATE

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DATE

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4-5

DATE

ACTUAL HOURS



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4-6

DATE

ACTUAL HOURS


HOURS DEALER’S STAMP REMARKS:

DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



4-7

DATE

ACTUAL HOURS



DATE

ACTUAL HOURS



DATE

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4-8

DATE

ACTUAL HOURS



DATE

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4-9

Operators Manual 81 Xe Manitou

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