Manitou Systems 160 ATJ, 180 ATJ Operator's Manual

ACCESS PLATFORM

160 ATJ & 180 ATJ

547370 EN (22 / 11 / 2006)

BP 249 Z. I.

44158 ANCENIS CEDEX - FRANCE

TEL : 33 (0)2 40 09 10 11

YOUR DEALER

OPERATOR’S MANUAL

THIS INSTRUCTION LEAFLET MUST BE KEPT PERMANENTLY ON THE ACCESS PLATFORM AND BE READ AND

UNDERSTOOD BY THE OPERATORS.

1st DATE OF ISSUE 28 / 06 / 04

DATE OF ISSUE OBSERVATIONS

28 / 06 / 2004 First edition

09 / 11 / 2004 Change of title page following the change of MANITOU

logo

15 / 11 / 2004 Update

16 / 09 / 2005 Update: ch.2 following program developments

ch.3 following production of the MAINTENANCE SCHEDULE.

05 / 07 / 2006 Corrections: Ch.2 - 4 add backup pump power fuse.

Ch.3 corrections to MAINTENANCE SCHEDULE. Ch.5 ajout de l’option : Roues 20” + Panier large sur 180 ATJ.

22 / 11 / 2006 Corrections: Ch.2 - 20, 2 - 22, 2 - 23, 2 - 27 and 3 - 5

following replacement of the diesel gauge with a proportional gauge. From machine N°511335 - 180 ATJ From machine N° 511231 - 160 ATJ.

1 - INSTRUCTIONS

– GENUINE SPARE PARTS

– INSTRUCTIONS TO THE COMPANY MANAGER

– INSTRUCTIONS FOR THE OPERATOR

– MAINTENANCE INSTRUCTIONS OF THE ACCESS PLATFORM

– IF THE PLATFORM IS NOT TO BE USED FOR A LONG TIME

– IDENTIFICATION OF THE ACCESS PLATFORM

– BEFORE STARTING UP A PLATFORM FOR THE 1ST TIME

2 - DESCRIPTION

– CHARACTERISTICS

– DIMENSIONS

– REMINDER

– INSTRUMENTS AND CONTROLS

– USE OF THE ACCESS PLATFORM

– RESCUE PROCEDURE

3 - MAINTENANCE

– FILTERS CARTRIDGES AND BELTS

– LUBRICANTS

– MAINTENANCE SCHEDULE

A : Every day or every 10 hours of operation B : Every 50 hours of operation C : Every 250 hours of operation D : Every 500 hours of operation E : Every 1000 hours of operation F : Every 3000 hours of operation

G : Occasional maintenance

4 - ELECTRICITY

5 - O

PTIONAL ACCESSORIES FOR THE RANGE

6 - MAINTENANCE HANDBOOK

TABLE OF CONTENTS

1 - 1

1 - 3

1 - 4

1 - 14

1 - 16

1 - 18

1 - 20

2 - 1

2 - 4

2 - 8

2 - 12

2 - 14

2 - 40

2 - 43

3 - 1

3 - 3

3 - 5

3 - 6

3 - 8 3 - 10 3 - 12 3 - 18 3 - 24 3 - 28 3 - 29

4 - 1

5 - 1

6 - 1

1 - 1

1 - OPERATING

AND SAFETY

INSTRUCTIONS

1 - OPERATING

AND SAFETY

INSTRUCTIONS

1 - 3

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 access platform's 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 machine's certificate of compliance.

BY USING ORIGINAL PARTS DURING MAINTENANCE OPERATIONS,

YOU ARE LEGALLY

- Any user who procures parts from another quarter does so at his own risk.

COVERING YOURSELF

- Any user who modifies his access platform or has it modified by a service company, must consider that a new item of equipment has been brought onto the market 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 binds the maker for parts chosen or produced under the maker's control.

- The practicalities of maintenance terms are set out by the maker. The maker is in no way liable in the event of the user not complying with such terms.

YOU GET THE THE MANUFACTURER BRINGS TO THE USER, BENEFIT OF THE MANUFACTURER'S - His know-how and skill. KNOW-HOW

- 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 the details of the access platform design and therefore has the best technological capability to carry out maintenance.

ALL MAINTENANCE ON OUR ACCESS PLATFORM MUST BE CARRIED OUT USING ORIGINAL PARTS.

ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU

AND ITS DEALER NETWORK.

You can obtain the list of dealers by phoning the spare parts department

on 02 40 09 10 21

GENUINE SPARE PARTS

1 - 4

INSTRUCTIONS TO THE COMPANY MANAGER

PREAMBLE

THE OPERATOR

- Only qualified, authorized personnel can use the platform. This authorization is given in writing by the appropriate person in the establishment with respect to the use of platform and must be carried permanently by the operator.

On the basis of experience, there are a number of possible situations in which operating the platform 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 platform.

- Behaviour resulting from application of the "principle of least action" when performing a task.

- For certain machines, the foreseeable behaviour of such persons as : apprentices, teenagers, handicapped persons, trainees tempted to drive a platform, operator tempted to operate a truck to win a bet, in competition or for their own personal experience.

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.

OBTAIN INFORMATION ON :

- How to behave when there is a fire.

- The location of the nearest first aid kit and fire extinguisher.

- The emergency telephone numbers for calling (the doctors, ambulance, hospital and fire brigade).

THE PLATFORM

A - THE PLATFORM'S SUITABILITY FOR USE

- MANITOU has ensured that this platform is suitable for use under the standard operating conditions defined in this operator's manual, with an overload test coefficient of 1,25 and an operational test coefficient of 1,1, as stipulated in standardised norm EN 280 for MPLP (Mobile Personnel Lifting Platforms).

- Before commissioning, the company manager must make sure that the platform is appropriate for the work to be done, and perform certain tests (in accordance with current legislation).

B - ADAPTATING THE PLATFORM TO THE USUAL ENVIRONMENTAL CONDITIONS

- In addition to series equipment mounted on your platform, many options are available, such as : flashing light, working headlight, etc. Contact your dealer.

- Take into account climatic and atmospheric conditions of the site of utilisation.

. Protection against frost (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL). . Adaptation of lubricants (ask your dealer for information). . I.C. engine filtration (see : 3 - MAINTENANCE : FILTERS CARTRIDGES AND BELTS).

WHENEVER YOU SEE THIS SYMBOL IT MEANS :

WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE

PLATFORM IS AT RISK.

1 - 5

For operation under average climatic conditions, i.e. : between -15 °C and + 35 °C, correct 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.

- A platform operating in an area without fire extinguishing equipment must be equipped with an individual extinguisher. There are solutions, consult your dealer.

Your platform is designed for outdoor use under normal atmospheric conditions and indoor use in suitably aerated and ventilated

premises. It is prohibited to use the platform in areas where there is a risk of fire or which are potentially explosive (e.g. Refineries,

fuel or gas depots, stores of inflammable products…). For use in these areas, specific equipment is available (ask your dealer for

information).

C - MODIFYING THE PLATFORM

- For your safety and that of others, you must not change the structure and settings of the various components used in your platform (hydraulic pressure, calibrating limiters, I.C. engine speed, addition of extra equipment, addition of counterweight, unapproved attachments, alarm systems, etc.) yourself. In this event, the manufacturer cannot be held responsible.

THE INSTRUCTIONS

- The operator's manual must always be in good condition and kept in the place provided on the platform and in the language used by the operator.

- You must necessarily replace the instructions manual, as well as any plates or stickers, if they are no longer legible or are missing or damaged.

THE MAINTENANCE

- Maintenance or repairs other than those detailed in part: 3 - MAINTENANCE must be carried out by qualified personnel (consult your dealer) and under the necessary safety conditions to maintain the health of the operator and any third party.

Your patform must be inspected periodically to ensure that it remains in compliance. The frequency of this inspection is

defined by current legislation in the country in which the platform is used.

1 - 6

INSTRUCTIONS FOR THE OPERATOR

REAMBLE

The risk of accident while using, servicing or repairing your platform can be restricted if you follow the safety instructions and safety

measures detailed in these instruction.

- Only the operations and manœuvres described in these operator's manual must be performed. The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions given in the operator's manual and on the platform itself are not exhaustive.

- At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the platform itself when you use it.

Failure to respect the safety and operating instructions, or the instructions for repairing or servicing your platform may lead to serious,

even fatal accident.

GENERAL INSTRUCTIONS

A - OPERATOR’S MANUAL

- Carefully read and understand the operator's manual.

- The operator’s manual must always be kept in the place provided for it on the platform and be written in the language used by the operator.

- Any operations or manoeuvres not described in the operator’s manual must necessarily be forbidden right from the start.

- Follow the safety advice and the instructions on the platform.

- Ypu must necessarily replace the operator’s manual, as well as any plates or stickers, if they are no longer legible or are damaged.

- A second operator must necessaily be present on the ground as a safety measure when using the platform.

- Familiarise yourself with the platform on the terrain it has to travel over.

- The machine must also be used in accordance with good engineering practice.

- Do not use the platform if the wind speed is over 45 km/h. The platform’s arms must not be subjected to a lateral force of more than 40 kg (platforms for indoor use must not be used outside the building).

B - AUTHORIZATION FOR USE IN FRANCE

(or see current legislation in other countries)

- Only qualified, authorized personnel may use the platform. This authorization is given in writing by the appropriate person in the company, in charge of using the platform, and must be permanently carried by the operator.

- The operator is not competent to authorise the driving of the platform by another person.

WHENEVER YOU SEE THIS SYMBOL IT MEANS :

WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE

PLATFORM IS AT RISK.

1 - 7

C - MAINTENANCE

- The operator must immediately advise his superior if his platform is not in good working order or does not comply with the safety notice.

- The operator is prohibited from carrying out any repairs or adjustments himself, unless he has been trained for this purpose. He must keep the platform properly cleaned if this is among his responsibilities.

- The operator must carry out daily maintenance (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).

- The operator must ensure tyres are adapted to the nature of the ground (see area of the contact surface of the tyres in the chapter : 2 - DESCRIPTION : CHARACTERISTICS). There are optional solutions, consult your dealer.

Do not use the platform if the tyres are damaged or excessively worn, because this could put your own safety or that of

others at risk, or cause damage to the platformk itself.

- In the case of electric platforms, the operator must ensure that:

• The batteries are not replaced with lighter ones (compromising stability).

• Safety goggles are always worn when charging the batteries.

• The batteries are not charged in an explosive environment.

• There is no smoking and no naked flame directed towards the batteries whe they are being handled (during removal, re-installation and checking the levels) .

D - MODIFYING THE PLATFORM

- For your safety and that of others, you must not change the structure and settings of the various components used in your platform yourself:

• hydraulic pressure,

• calibrating limiters,

• I.C. engine speed,

• addition of extra equipment,

• addition of counterweight,,

• unapproved attachments,

• alarm systems, etc...

In this event, the manufacturer cannot be held responsible.

E - PLATFORM AXLES

- Standard axles:

The chassis is rigid, so the platform can have a ground reach on only three wheels.

- Oscillating axle (if the option is available):

An oscillating axle enables the platform, when in transport position, to have a ground reach on four wheels.

When moving in working position over uneven terrain, the oscillating axle is locked (the chassis is rigid) so the platform

can have a ground reach on only three wheels.

1 - 8

DRIVING INSTRUCTIONS

A - BEFORE STARTING THE PLATFORM

- Ensure that the intermediate rail is fully in the locked position before operating the platform from the basket.

- If the platform is new, see the Chapter : BEFORE STARTING THE PLATFORM FOR THE FIRST TIME in Section : 1 - SAFETY ADVICE AND INSTRUCTIONS.

- Carry out daily maintenance (see : 3 - MAINTENANCE : A - DAILY OR EVERY 10 HOURS SERVICE).

- Before starting the platform, check the levels :

• IC PLATFORMS : I • ELECTRIC PLATFORMS :

• IC engine oil I • Hydraulic reservoir oil.

• Hydraulic reservoir oil. I • Battery charge level.

• Fuel. I

• Coolant. I

- Whatever his experience, the operator is advised to familiarize himself with the position and operation of all the controls and instruments before operating the platform.

- The platform must be in transport position (arms fully folded or scissors in the low position) before you climb onto the platform.

- Make sure the horn works.

B - DRIVER’S OPERATING INSTRUCTIONS

- Wear suitable clothing for driving the platform, do not wear baggy clothes.

- Make sure you have the appropriate protective equipment for the job to be done.

- Prolonged exposure to high noise levels may cause hearing problems. It is recommended to wear ear muffs to protect against excessive noise.

- Always pay attention when using the platform. Do not listen to the radio or music using headphones or earphones

- For increased comfort, adopt the correct position in the driver’s cab.

- The operator must always be in his normal position in the driver’s seat : extending arms or legs (or, in general, any part of the body), outside the basket is forbidden.

- Safety helmets must be worn.

- MANITOU recommends a safety harness in the operator’s size be provided when the platform is in use (for the harness

attachement in the basket , see 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).

- The control units must never in any event be used for any other than their intended purposes (e.g. climbing onto or down from the platform, portmanteau, etc.).

- In the case of scissors-type platforms, it is forbidden to use the platform without the guardrails in place.

- Suspending a load under the basket or on any part of the lifting apparatus is strictly forbidden.

- The operator must not climb into or get down from the basket unless it is at ground level (with the lifting system folded).

- The platform must not be fitted with any accessory increasing the machine’s wind profile.

- Do not use a ladder or any improvised constructions in the basket to reach greater heights.

- Do not climb on the sides of the basket to reach greater heights.

C - ENVIRONMENT

- Comply with site safety regulations.

- The platform can be manoeuvred from the ground: ensure that you forbid access.

- If you have to use the platform in a dark area or at night, make sure it is equipped with working lights.

- The platforms may not be used as cranes or elevators for the permanent transport of people or materials, nor as jacks or supports.

- When operating, ensure that there is no one or anything impeding the platform’s progress ans operation.

- When raising the platform, ensure that no one or anything inpedes the platform’s operation and do not perform any inappropriate manœuvres.

1 - 9

- Do not allow anybody to come near the working area of the platform or pass beneath an elevated load. To do this, mark your operating area with warning signs.

- Travelling on a longitudinal slope :

• Ensure that you adapt the platform’s travelling speed by controlling the speed with the travelling manipulator.

- Take into account the platform’s dimensions and its load before trying to negotiate a narrow or low passageway.

- Never move onto a loading platform without having first checked :

• That it is suitably positioned and made fast.

• That the unit to which it is connected (wagon, lorry, etc.) will not shift.

• That this platform is prescribed for the size and the total weight of the platform.

• That the slope is not greater than the platform’s maximum authorised slope.

- Never move onto a foot bridge, floor or freight lift, without being certain that they are prescribed for the weight and size of the platform to be loaded and without having checked that they are in sound working order.

- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.

- Ensure that the ground or floor under the wheels and/or the stabilizers is stable and firm before raising the basket. If necessary, add sufficient wedging under the stabilizers.

- Do not attempt any operations outside the plarform’s capabilities.

- Ensure that the materials on the platform (pipes, cables, containers, etc ...) cannot slip off and fall. Do not heap up these materials to the pint where you have to step over them.

If the basket must remain stationary over a structure for a long period, there is a risk that the basket will rest on this

structure because of the oil cooling in the cylinders or a minor leak in the cylinder locking system.

To eliminate this risk :

- Regularly check the distance between the basket and the structure and re-adjust if necessary.

- If possible use the platform at an oil temperature as close as possible to ambient temperature.

- In the case of work near aerial lines, ensure that the safety distance is sufficient between the working area of the platform and the aerial line.

You must consult your local electrical agency. You could be electrocuted or seriously injured if you operate or park the platform too

close to power cables.

If the platform comes into contact with electric wires, press the Emergency Stop button.

If you can, jump from the basket without simultaneously being in contact with the basket and the ground.

If not, call for help, wam people not to touch the basket and to switch off the power supply to the wires or have it

switched off.

If the wind is in excess of 45Km/h, do not make any movements putting the platform’s stability at risk.

D - VISIBILITY

- Maintain permanently good visibility throughout the route. To increase your visibility, you can move forwards with the pendular arm slightly raised (pay attention to the risk of falls in the basket from knocking into a low doorway, overhead electric wires, travelling cranes, highway bridges, tracks or any obstacle in the area in front of the platform). In reverse, look directly behind you. In any case, avoid reversing over long distances.

- If visibility of your road is inadequate, ask someone to help, standing outside the area in which the platform will be moving, and make sure you always have a good view of this person.

1 - 10

E - STARTING THE PLATFORM

PLATFORMS WITH IC ENGINES

SAFETY NOTICE

- Never try to start the platform by pushing or towing it. Such operation may cause severe damage to the transmission. In case of necessity, towing requires the platform to be set for free-wheeling (see : 3 - MAINTENANCE).

- If using an emergency battery for start-up, use a battery with the same characteristics and respect battery polarity when connecting it. Connect at first the positive terminals before the negative terminals.

Failure to respect polarity between batteries can cause serious damage to the electrical circuit. The electrolyte in the battery may

produce an explosive gas. Avoid flames and generation of sparks close to the batteries.

Never disconnect a battery while it is charging.

INSTRUCTIONS

- Check the closing and locking of the hood(s).

- Turn the ignition key to notch I to switch on the electrical power, which automatically starts the pre-heating system (all the bars must be displayed), the message “OK” is displayed.

- Check that everything is operating correctly by ensuring that no fault pages are displayed on the screen and no warning about the fuel level (a pump icon is present on the screen) (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).

- Turn the ignition key to notch II to start.

- Release the ignition key and let the engine run at tick-over speed.

NB : In very cold weather (see: 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).

- Do not engage the starter motor for more than 15 seconds and carry out the preheating for 10 seconds between unsuccessful attempts.

- Check all control instruments 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 any faults are displayed on the screen, stop the engine and immediately take the necessary measures.

ELECTRIC PLATFORMS

SAFETY NOTICE

- Do not use the platform if the battery is discharged to the point that movements are slowed down. In certain cases, the platform may stop (see : 3 - MAINTENANCE : EVERY DAY OR EVERY 5 HOURS FOR OPERATION, for the minimum permissible charge level).

INSTRUCTIONS

- Set the battery cut-out to the ON position.

- Check the closing and locking of the hood(s).

- Turn the ignition key to the basket position.

- Check that everything is operating correctly by ensuring that no error messages are displayed on the screen and that the machine maintenance light is not flashing (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).

NB: For machines not fitted with a display or a maintenance warning light, faults can be identified from the light directly

on the variable speed drive unit (to access: open the cowl on the control size, remove the casing from the variable speed drive and see whether the light is flashing).

1 - 11

- If any error messages are constantly displayed or the machine maintenance light is flashing, return the key to the neutral position.

- Set the battery cut-off to the OFFposition.

- Immediately take the necessary measures.

F - DRIVING THE PLATFORM

SAFETY NOTICE

Operators should be aware of the risks connected with using the platform, notably:

- Risk of losing control.

- Risk of losing lateral and frontal stability of the platform.

The operator must remain in control of the platform.

- Do not carry out operations which exceed the capacities of your platform.

- Familiarise yourself with the platform on the terrain where it will be used.

- Ensure that the brakes work efficiently when stopping a travelling movement, taking into account the braking distances.

- Drive smoothly at an appropriate speed for the operating conditions (land configuration, load in the basket).

- take extreme care if manoeuvring the platform with the basket in the high position. Ensure you have adequate visibility.

- Take bends slowly.

- In all circumstances make sure you are in control of your speed.

- Travel slowly on damp, slippery or uneven terrain or on truck ramps.

- Always remember that the hydraulic form of steering is very sensitive to movements.

- Never leave the I.C. engine on when the platform is unattended.

- Look where you are going and always make sure you have good visibility along the route.

- Drive round obstacles.

- Never drive on the edge of a ditch or steep slope.

- Whatever your travelling speed, you must reduce the speed as much as possible before stopping.

INSTRUCTIONS

- When moving the platform a long distance, always travel with the arms folded or the scissors in the low position.

- Engage the appropriate gear (see : 2 - DESCRIPTION : INSTRUMENTS AND CONTROLS).

1 - 12

G - STOPPING THE PLATFORM

SAFETY NOTICE

- Never leave the ignition key in the platform during the operator's absence.

- Make sure that the platform is not stopped in any position that will interfere with the traffic flow and at less than one

meter from the track of a railway.

- In the event of prolonged parking on a site, protect the platform from bad weather, particularly from frost (check the level of antifreeze), close and lock all the platform accesses (cowls…).

INSTRUCTIONS

PLATFORMS WITH IC ENGINES

- Before stopping the platform after a long working period, leave the I.C. engine idling for a few moments, to allow the coolant liquid and oil to lower the temperature of the I.C. engine and transmission

Do not forget this precaution, in the event of frequent stops or warm stalling of the I.C. engine,

or else the temperature of certain parts will rise significantly due to the stopping of the cooling system, with the risk of

badly damaging such parts.

- Stop the I.C. engine with the ignition switch.

- Remove the ignition key.

- Check that all the accesses on the platform are closed and locked (cowls…).

ELECTRIC PLATFORMS

- Remove the ground/platform control selection key.

- Check that all the accesses on the platform are closed and locked (cowls…).

- Set the battery cut-out to the OFF position (ELECTRIC PLATFORM).

1 - 13

INSTRUCTIONS FOR WELDING AND BLOW TORCH WORK ON THE EXTERNAL STRUCTURE

Ensure that there are no hydraulic or electrolyte leaks on the platform.

When welding, work in the opposite direction

from the control console to avoid sparks damaging it .

Any welding and cutting (blow torch) work from the basket on a building’s metallic structures requires the following precautions to be taken:

A - WITH ELECTRIC WELDING EQUIPMENT

- It is essential that the machine has a discharge braid connecting the platform’s chassis to the ground.

- It is also essential that the external structure to be welded is connected to the earth. If the above conditions are observed, the platform can, in this case, be in contact with the structure or the elements to be welded without damaging the electronic components.

- The power supply to the welding equipment must be via an earthed socked and any extension required just also be earthed.

- In all cases, ensure that there are no electrical arcs in the basket or on the platform (contact between the brazing rod or the torch and the welding equipment’s earth). To ensure this, at any time the welding equipment’s earth must not be positioned on the platform’s basket but instead only as close as possible to the element to be welded.

- Switch off the welding equipment before disconnecting the earth clamp from the element or elements to be welded.

B - WITH A BLOW TORCH

- Attach the blow torch’s bottles to the basket’s handrails.

- instructions for welding and blow torch work on the external structure

- Do not set the blow torch down on the lip of the basket while it is still operating or point it towards the control console or its power cables.

1 - 14

GENERAL INSTRUCTIONS

- Ensure the area is sufficiently ventilated before starting the platform.

- Wear clothes suitable for the maintenance of the platform, avoid wearing jewellery and loose clothes. Tie and protect your hair, if necessary.

- Stop the engine before conducting any work on the platform, remove the ignition key and disconnect the “Minus” battery terminal.

- Set the battery cut-out to the OFF position (ELECTRIC PLATFORM).

- Read the operator's manual carefully.

- Carry out all repairs immediately, even if the repairs concerned are minor.

- Repair all leaks immediately, even if the leak concerned is minor.

- Make sure that the disposal of process materials and of spare parts is carried out in total safety and in a ecological way.

- Be careful of the risk of burning and splashing (exhaust, radiator, I.C. engine, etc.).

MAINTENANCE

- Perform the periodic service (see : 3 - MAINTENANCE) to keep your platform in good working conditions. Failure to perform the periodic service may cancel the contractual guarantee.

LUBRICANT AND FUEL LEVELS

- Use the recommended lubricants (never use contaminated lubricants).

- Do not fill the fuel tank when the I.C. engine is running.

- Only fill up the fuel tank in areas specified for this purpose.

- Do not fill the fuel tank to the maximum level.

- Do not smoke or approach the platform with a flame, when the fuel tank is open or is being filled.

LEVEL OF ELECTROLYTE IN THE BATTERY

- Check the level of the battery or batteries.

When doing this, ensure you take all the safety precautions (See: 3 - MAINTENANCE).

HYDRAULIC

- Make any repairs and fix any leaks, including minor ones, immediately.

- Do not attempt to loosen unions, hoses or any hydraulic component with the circuit under pressure.

BALANCING VALVE : It is dangerous to change the setting and remove the balancing valves or safety valves which

may be fitted to your platform cylinders. These operations must only be performed by

approved personnel (consult your dealer).

PLATFORM MAINTENANCE INSTRUCTIONS

1 - 15

Ensure that all consumables and replacement parts are disposed of safety, in an

environmentally friendly manner.

ELECTRICITY

- Do not drop metallic items on the battery (between the “Plus” and “Minus terminals”).

- Disconnect the battery or batteries before working on the electrical circuit.

- The electrical box must only be opened by authorized personnel.

WELDING ON THE ACCESS PLATFORM

- Disconnect the battery or batteries before welding on the platform.

- When carrying out electric welding work on the platform, connect the negative cable from the equipment directly to the part being welded, so as to avoid high tension current passing through the alternator or the live ring.

- If the platform is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing irreparable damage to electronic components.

WASHING THE PLATFORM

- Clean the platform or at least the area concerned before any intervention.

- Remember to close and lock all accesses to the platform (cowls…).

- When cleaning with a pressure washer, avoid the articulation joints, and the electrical components and connections.

- If necessary, protect components likely to be damaged, and in particular the electrical components (variable speed drive, charger) and connections and the injection pump from penetration by water, steam or cleaning products.

- Dry the electrical components.

- Clean the platform of any fuel, oil or grease trace.

- Grease the shafts.

FOR ANY INTERVENTION OTHER THAN REGULAR MAINTENANCE, CONSULT YOUR DEALER.

1 - 16

INTRODUCTION

The following recommendations are intended to prevent the platform from being damaged when it is withdrawn from service for an extended period. For these operations, we recommend the use of a MANITOU protective product, reference 603726. Instructions for using the product are given on the packaging.

Procedures to follow if the platform is not to be used for a long time and for starting it up again afterwards must be

performed by your dealership.

PREPARING THE PLATFORM

- Clean the platform thoroughly.

- Check and repair any leakage of fuel, oil, water or air.

- Replace or repair any worn or damaged parts.

- Wash the painted surfaces of the platform in clear and cold water and wipe them.

- Touch up the paintwork if necessary.

- Shut down the platform (see : OPERATING INSTRUCTIONS UNLADEN AND LADEN).

- Make sure the cylinder rods are all in retracted position.

- Release the pressure in the hydraulic circuits.

PROTECTING THE I.C. ENGINE

- Fill the tank with fuel (see : 3 - MAINTENANCE).

- Empty and replace the cooling liquid (see : 3 - MAINTENANCE).

- Leave the I.C. engine running at idling speed for a few minutes, then switch off.

- Replace the I.C. engine oil and oil filter (see : 3 - MAINTENANCE).

- Add the protective product to the engine oil.

- Run the I.C. engine for a short time so that the oil and cooling liquid circulate inside.

- Disconnect the battery and store it in a safe place away from the cold, after charging it to a maximum.

- Remove the injectors and spray the protective product into each cylinder for two seconds with the piston in low neutral position.

- Turn the crankshaft once slowly and refit the injectors (see I.C. engine REPAIR MANUAL).

- Remove the intake hose from the manifold or turbocharger and spray the protective product into the manifold or turbocharger.

- Cap the intake manifold hole with waterproof adhesive tape.

- Remove the exhaust pipe and spray the protective product into the exhaust manifold.

- Refit the exhaust pipe and block the outlet with waterproof adhesive tape..

NOTE : The spray time is noted on the product packaging.

- Open the filler plug, spray the protective product around the rocker arm shaft and refit the filler plug.

- Cap the fuel tank using waterproof adhesive tape.

- Remove the drive belts and store them in a safe place.

- Disconnect the engine cut-off solenoid on the injection pump and carefully insulate the connection.

IF THE PLATFORM IS NOT TO BE USED FOR A LONG TIME

1 - 17

CHARGING THE BATTERIES

- In the case of electric platforms, in order to preserve the batteries’life and their capacity, check them periodically and keep the charge level constant (see : 3 - MAINTENANCE).

PROTECTING THE PLATFORM

- Protect cylinder rods which will not be retracted, from corrosion.

- Wrap the tyres.

NOTE : If the platform is to be stored outdoors, cover it with a waterproof tarpaulin.

BRINGING THE PLATFORM BACK INTO SERVICE

- Remove the waterproof adhesive tape from all the holes.

- Refit the intake hose.

- Reconnect the engine cut-off solenoid.

- Refit and reconnect the battery.

- Remove the protection from the cylinder rods.

- Perform the daily service (see : 3 - MAINTENANCE

- Empty and replace the fuel and replace the fuel filter (see : 3 - MAINTENANCE).

- Refit and set the tension in the drive belts (see : 3 - MAINTENANCE).

- Turn the I.C. engine using the starter, to allow the oil pressure to rise.

- Lubricate the platform completely (see : 3 - MAINTENANCE : TABLEAU D'ENTRETIEN).

Make sure the area is adequately ventilated before starting up the platform.

- Start up the platform, following the safety instructions and regulations (see : OPERATING INSTRUCTIONS).

- Carry out all the lifting system’s hydraulic movements right up to the limit switches for each cilinder.

1 - 18

As our policy is to promote a constant improvement of our products, our range of access platforms may undergo certain modifications, without obligation for us to advise our customers.

When you order parts, or when you require any technical information, always specify :

NOTE : For the owner's convenience, it is recommended that a note of these

numbers is made in the spaces provided, at the time of the delivery of the access platform.

PLATE MANUFACTURER OF THE ACCESS PLATFORM (FIG

. A)

- Model

- Serial Nr

- Year of manufacture

I.C. ENGINE (FIG. B)

- Engine Nr

HYDROSTATIC PUMP (FIG. C)

- Pump Nr

- Codification type

- Manufacturer’s Nr

- Year of manufacture

RONT AXLE ASSEMBLY (FIG. D)

- Axle type

- Serial Nr

- Maker's N°

IDENTIFICATION OF THE ACCESS PLATFORM

1 - 19

REAR AXLE ASSEMBLY (FIG. E)

- Axle type

- Serial Nr

- Maker's N°

1 - 20

INTRODUCTION

- Our access platforms have been designed for easy handling by the operator and maximum maintenance easiness for the mechanic.

- However, before commencing to operate the access platform, 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 access platform.

- The operator must familiarize himself with the positions and functions of all the controls and instruments before operating the access platform.

Do not attempt to start a new access platform before the following checks have been carried out :

LUBRICATION

- Check that all the correct grades of oils and greases that are required are available (See chapter : SERVICING SCHEDULE) and top up if necessary.

For operation under average climatic conditions, i.e. : between - 15°C and + 35°C, correct levels of lubricants in all the

circuits are ensured in works. 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 information, if necessary.)

AIR FILTER

- Ensure that the air filter is undamaged and not choked.

- Tighten the fastening devices if necessary.

Never use the platform with no air filter or with a damaged air filter.

OOLING SYSTEM

- Never start up the platform without first checking the level of the cooling liquid or when the fan belt is damaged or broken.

HYDRAULIC SYSTEM

- Check by a visual examination that there are no leaks or oil oozing in the hoses, connections and unions. If necessary, tighten or control the defective connections.

- Also check that the tank oil level is correct.

BEFORE STARTING UP A PLATFORM FOR THE 1ST TIME