PDF Operator’s Manual Manitou MT 523 MLT 523 Telehandler - 6 MB
Learn to operate your Manitou MT 523 or MLT 523 series telehandler safely and efficiently with this official operator's manual.
It covers all the controls, safety features, and daily inspection points.
This guide is a crucial tool for any operator to maximize productivity and ensure a safe working environment.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
INTRODUCTION TO SAFETY
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, Inc. Parts Dept. (800) 425-3727 or (254) 799-0232
Parts Dept. Fax (254) 867-6504 Website: www.manitou-na.com
MT 523 Series B-E2
MLT 523 Turbo MONO-ULTRA
Series B-E2
S/N: 204734 and ABOVE
OPERATOR'S MANUAL
THIS OPERATOR'S MANUAL MUST BE KEPT IN THE LIFT TRUCK AND MUST BE READ AND UNDERSTOOD BY OPERATORS.
547896AS
R11/10
--- Page 3 ---
ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)
C.) OPERATING SAFETY RULES AND PRACTICES (cont.)
46.) When attachments are used, extra care shall be taken in securing, manipulating, positioning, and trans-
porting the load. Operate rough terrain forklift trucks equipped with attachments as partially loaded trucks
when not handling a load.
47.) Completely engage the load with the load-engaging means. Fork length should be at least two-thirds of
load length. Where tilt is provided, carefully tilt the load backward to stabilize the load. Caution should be used
in tilting backward with high or segmented loads.
48.) Use extreme care when tilting load forward or backward, particularly when high tiering. Do not tilt forward
with load-engaging means elevated except to pick up or deposit a load over a rack or stack. When stacking
or tiering, use only enough backward tilt to stabilize the load.
49.) The handling of suspended loads by means of a crane arm (boom) or other device can introduce dynam-
ic forces affecting the stability of a rough terrain forklift truck. Grades and sudden starts, stops, and turns can
cause the load to swing and create a hazard if not externally stabilized. When handling suspended loads:
a.) do not exceed the truck manufacturer’s capacity of the rough terrain forklift truck as equipped
for handling suspended loads.
b.) only lift the load vertically and never drag it horizontally;
c.) transport the load with the bottom of the load and the mast as low as possible;
d.) with load elevated, maneuver the rough terrain forklift truck slowly and cautiously, and only to
the extent necessary to permit lowering to the transport position;
e.) use tag lines to restrain load swing whenever possible.
50.) At the beginning of each shift and before operating the rough terrain forklift truck, check its condition,
giving special attention to:
a.) tires and their inflation pressure
b.) warning devices
c.) lights
d.) lift and tilt systems, load-engaging means, chains, cables, and limit switches
e.) brakes
f.) steering mechanism
g.) fuel system(s)
51.) If the rough terrain forklift truck is found to be in need of repair or in any way unsafe, or if it contributes to
an unsafe condition, the matter shall be reported immediately to the user’s designated authority, and the truck
shall not be operated until it has been restored to safe operating condition.
52.) If during operation the rough terrain forklift truck becomes unsafe in any way, the matter shall be reported
immediately to the user’s designated authority, and the truck shall not be operated until it has been restored to
safe operating condition.
53.) Do not make repairs or adjustments unless specifically authorized to do so.
54.) When refueling, smoking in the area shall not be permitted, the engine shall be stopped, and the opera-
tor shall not be on the rough terrain forklift
truck.
55.) Spillage of oil or fuel shall be carefully and completely absorbed or evaporated and fuel tank cap replaced
before restarting engine.
56.) Do not use open flames when checking electrolyte level in storage batteries, liquid level in fuel tanks, or
the condition of LPG fuel lines and connectors.
57.) Do not lift personnel with the forklift. If the forklift must be used to lift people, precautions for the protec-
tion of the personnel must be taken (see ITSDF B56.6, chapter 5.15 Elevating Personnel).
V
--- Page 4 ---
SAFETY DECALS
Attachment Warning - 421016
(Boom equipped models). Location: on the boom coupler,
near where the retaining shaft is installed.
Reminder to operator; install attachment retaining shaft and
safety pin before operations.
Hook Here - 24653
Location: at points provided on the forklift, where straps or chains may be attached to
secure the forklift to a trailer during transport.
Fork Safety - 426641
(Mast equipped models). Location: on the front and back side of the mast’s outer rails,
at eye level (4 required).
Instructs personnel not to travel beneath or upon the lift truck forks.
Pinch Point, Large, 2.5 x 4.5 in. - 426643
Pinch Point, Small, 1.5 x 2.75 in. - 426642
(Mast equipped models). Location: on the front and rear sides
of the mast cross bracing.
Keep fingers away from the mast
crossbracing.
HAND THROTTLE DANGER - 804784
(Boom equipped models, option). Location: Near the hand throttle mechanism.
Reminder to operator; set parking brake before operating hand throttle.
Disengage hand throttle before leaving the forklift.
XV
--- Page 5 ---
C - ENVIRONMENT
- Comply with site safety regulations.
- If you have to use the lift truck in a dark area or at night, make sure it is equipped with working lights.
- During handling operations, make sure that no one is in the way of the lift truck and its load.
- 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 transverse slope, before lifting the boom, follow the instructions given in the paragraph : INS-
TRUCTIONS FOR HANDLING A LOAD : D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK.
- Travelling on a longitudinal slope :
• Drive and brake gently.
• Moving without load : Forks or attachment facing downhill.
• Moving with load : Forks or attachment facing uphill.
- Take into account the lift truck’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, truck, 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 size of the lift truck.
- 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.
- Be careful in the area of loading bays, trenches, scaffolding, soft land and manholes.
- Make sure the ground is stable and firm under the wheels and/or stabilizers before lifting or removing the load. If necessary, add
sufficient wedging under the stabilizers.
- Make sure that the scaffolding, loading platform, pilings or ground is capable of bearing the load.
- Never stack loads on uneven ground, they may tip over.
If the loadmust
If the load or the attachment or theremain
attachment
above must remainfor
a structure above a structure
a long forisathe
time, there period
riskofthat
time, there
it will restis on
thethe
riskstructure
that it will settle of
because
the boom descending upon the to
owing structure asthe
the oil in thecylinders
hydrauliccooling
oil in the cylinders cools.
down.
WARNING
To To: eliminate this risk :
eliminate this risk
- Regularly check the - Regularly
distance check
betweenthethedistance
load orbetween the load and
the attachment or the
theattachment
structure andandreadjust
the structure
this if and readjust as necessary.
necessary.
- If possible use the- lift
If possible
truck atuse thetemperature
an oil lift truck at as
an close
oil temperature
as possibleastoclose as possible
ambient to ambient temperature.
temperature.
- In 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
You local
mustelectrical agency.
consult your local You could agency.
electrical be electrocuted or be
You could seriously injuredorif seriously
electrocuted you operate or park
injured theoperate
if you lift truck
or too
parkclose
the
DANGER
to power cables. lift truck too close to power lines.
In the event of high winds, do not carry out handling work that jeopardizes the stability of the lift truck and its load, particularly if the load
DANGER
catches During high winds do not attempt moving loads that may catch the wind or cause the fork lift to be unstable.
the wind badly.
D - VISIBILITY
- Maintain permanently good visibility throughout the route. In reverse, either look directly behind you or use the panoramic rear-
view mirrors. In any case, avoid reversing over long distances.
- Visibility may be reduced on the right-hand side when the boom is raised, so before lifting the boom make sure that the move-
ment can be made in complete safety.
- If the visibility in forward motion is not sufficient because of the bulkiness of the load, drive in reverse motion. This maneuver
must remain exceptional and for short distances.
- Ensure you have good visibility (clean windows, adequate lighting, correctly adjusted rear view mirrors, etc.).
- If visibility of your road is inadequate, ask someone to help, standing outside the area in which the truck will be moving, and
make sure you always have a good view of this person.
1-9
--- Page 6 ---
WELDING
- Disconnect the battery before any welding operations on the lift truck.
- 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 current passing through the alternator.
- Never carry out welding or work which gives off heat on an assembled tire. The heat would increase the pressure which could
cause the tire to explode.
- If the lift truck is equipped with an electronic control unit, disconnect this before starting to weld, to avoid the risk of causing irre-
parable damage to electronic components.
WASHING THE LIFT TRUCK
- Clean the lift truck or at least the area concerned before any intervention.
- Remember to close and lock all accesses to the lift truck (doors, windows, cowls…).
- During washing, avoid the articulations and electrical components and connections.
- If necessary, protect against penetration of water, steam or cleaning agents, components susceptible of being damaged, parti-
cularly 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.
1 - 19
--- Page 7 ---
FRONT AXLE
- Type DANA
- Hub reducers Epicyclical
REAR AXLE
- Type DANA
- Hub reducers Epicyclical
BRAKE
- Service brake Foot pedal. Hydraulic brake, applied on the front wheels.
. Type Multidisc brake immersed in oil.
- Parking brake Mechanical hand lever applied on the front wheels.
. Type Multidisc brake immersed in oil.
ELECTRIC CIRCUIT
- Earth Negative
- Battery 12 V - 110 Ah - 750 A EN
- Alternator 12 V - 75 A
. Type Denso A115i
. Tension regulator Incorporated into the alternator
- Starter 12 V - 3,0 kW
. Type Denso E95RL
2-7
--- Page 9 ---
SEAT DEPTH ADJUSTMENT (FIG. D) D
The depth of the seat may be adjusted to suit the individual.
- Press the right-hand button while raising or lowering the seat to find the desired position.
EXTENDING THE HEAD-REST (FIG. E)
- The height of the back-rest can be adjusted by pulling it upwards (the notches will click)
up to the stop.
- The head-rest can be removed by applying sufficient pressure to pull it off the stop.
LUMBAR ADJUSTMENT (FIG. F)
This increases the comfort of the seat and the driver’s freedom of movement.
- Turn the handle either left or right to adjust the height or depth of the lumbar support.
ADJUSTMENT OF THE ANGLE OF THE BACK-REST (FIG. G)
- Support the back-rest, pull the lever and position the back-rest to find the desired posi-
tion. E
Dothe
If you do not support notback-rest
operate the
whenlift making
truck with a defectiveitseat
adjustments, beltcompletely
swings (fixing, locking, cuts,
forwards.
CAUTION tears, etc.). Repair or replace the seat belt immediately.
LONGITUDINAL ADJUSTMENT (FIG. H)
- Adjust the locking lever until you reach the position required. This then locks and the seat
will not shift into another position.
MAINTENANCE (FIG. I)
Dirt may adversely affect the correct functioning of the seat. For this reason, make sure
your seat is always clean.
- To clean or change the cushions, simply remove them from the seat frame.
CAUTION A rocking head-rest increases the risk of an accident!
A rocking head-rest increases the risk of an accident ! F
Avoid wetting the cushion fabric when cleaning. Check the resistance of the fabric on a
small hidden area before using any fabric or plastic cleaner.
G
H I
2 - 17
--- Page 10 ---
21 - AIR CONDITIONING CONTROLS (OPTION AIR CONDITIONING)
MLT 523 Turbo MONO-ULTRA Series B-E2
The air conditioning only comes on when the forklift truckIMPORTANT
has been started up. When using your air conditioning, you must work with the
doors and windows closed.
The air conditioning operates only while the lift truck engine is running. During use, keep the doors and windows closed.
In winter : So as to ensure correct operation and complete efficiency of the air conditioning unit, start up the compressor once a
In the winter : To ensure correct operation and efficiency of the air conditioning unit, run the compressor once a week, for a few
week, if only for a short spell, so as to lubricate the internal seals.
minutes, to lubricate the internal seals.
In cold weather : Warm the I.C. engine before switching on the compressor, so as to allow the coolant that has collected in the
In cold weather : Warm the I.C. engine before switching on the compressor, this will allow the coolant that has collected in the
liquid state at the lowest point of the compressor circuit to turn into gas under the effect of the heat given off by the I.C. engine, as the
liquid state at the lowest point of the compressor circuit to turn into gas by the heat given off by the I.C. engine (otherwise the compressor is
compressor is liable to be damaged by coolant in the liquid state.
liable to be damaged by pumping coolant in the liquid state when operated).
If your air conditioning does not seem to be working properly, have it examined by your dealer (see : 3 - MAINTENAN-
IfWARNING
your air conditioning
CE :does not seem
H - EVERY TWOtoYEARS
be working regularly,
"OPTION have it examinedThe
AIR CONDITIONING"). by air
yourconditioning
dealer (seesystem
: 3 - MAINTENANCE
is under high :pressure,
H - EVERY TWO
YEARS "OPTION AIRrepairs
CONDITIONING").
must be made Never
by atryprofessional
to repair anyairconditioning
anomalies yourself.
repairman.
B
DESCRIPTION OF THE AIR CONDITIONING CONTROLS
A - Control with signal light indicating start-up and cutout of
the air conditioning system, if control "C" is in position
1, 2 or 3. C A
B - Heating air temperature control.
C - Air flow setting and fan speed control. In position "0" the air conditioning system no longer functions.
NOTE : Possible losses of water under the forklift truck are due to condensate discharges caused by the drying effect of the ins-
tallation, especially with high outside temperatures and high relative humidity.
For the air conditioning to perform properly, the air intakes must not be blocked by frost, snow or leaves.
When the facility is running, at least one of the cab air grilles must be open so as to avoid any risk of freezing to the
evaporator.
HEATING MODE B
The controls must be adjusted in the following way :
A - Control with signal light off.
B - At the required temperature.
C - At the required temperature 1, 2 or 3. C A
CONDITIONED AIR MODE B
The controls must be adjusted in the following way :
A - Control with signal light on.
B - At the required temperature.
C - At the required temperature 1, 2 or 3. C A
DEMISTING (DEFROST) MODE B
The controls must be adjusted in the following way :
A - Control with signal light on.
B - At the required temperature.
C - At the required temperature 1, 2 or 3. C A
22 - CAB FILTER VENTILATORS
MLT 523 Turbo MONO-ULTRA Series B-E2
See : 3 - MAINTENANCE : D - EVERY 500 HOURS SERVICE.
23 - WINDSCREEN DEMIST VENTS
MLT 523 Turbo MONO-ULTRA Series B-E2
For optimum effectiveness, close the heating ventilators.
2 - 27
--- Page 12 ---
A = AJUST N = CLEAN After Day 1 year 1 year
C = CHECK P = BLEED the first or 50 250 or or 2000 4000
D = DESCALE R = CHANGE 50 10 hours hours 500 1000 hours hours
G = GREASE V = DRAIN/CHANGE hours hours hours hours
BRAKE
Brake oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C/A
Parking brake lever mechanism . . . . . . . . . . . . . . . . . . . . G
Brake oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V**
Brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P**
Brake circuit pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A**
STEERING
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Steering swivel joints . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
CAB
Windscreen washer liquid level . . . . . . . . . . . . . . . . . . . . C
Cab door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G
Cab ventilation filter (OPTION Air conditioning) . . . . . . . . . N R
Cab ventilation filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . N
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Condition of the rear view mirrors . . . . . . . . . . . . . . . . . . C**
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
OPTION Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICITY
Battery electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . C
Battery electrolyte density . . . . . . . . . . . . . . . . . . . . . . . . C
Condition of wiring harness and cables . . . . . . . . . . . . . . C**
Lights and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Adjust the front headlamps . . . . . . . . . . . . . . . . . . . . . . .
FRONT AXLE
Front wheels reducers pivots . . . . . . . . . . . . . . . . . . . . . . G G/C**
Transfer box oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Front axle differential oil level . . . . . . . . . . . . . . . . . . . . . C
Front wheels reducers oil level . . . . . . . . . . . . . . . . . . . . C
Transfer box oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V V
Front axle differential oil . . . . . . . . . . . . . . . . . . . . . . . . . V V
Front wheels reducers oil . . . . . . . . . . . . . . . . . . . . . . . . V V
Wearing of front axle brake discs . . . . . . . . . . . . . . . . . . C**
Front wheels reducers universal joint . . . . . . . . . . . . . . . . C**
Front wheels reducers clearance . . . . . . . . . . . . . . . . . . . C**
Bearings clearance of the transfer box . . . . . . . . . . . . . . C**
REAR AXLE
Rear wheels reducers pivots . . . . . . . . . . . . . . . . . . . . . . G G/C**
Rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . G G/C**
Rear axle differential oil level . . . . . . . . . . . . . . . . . . . . . C
Rear wheels reducers oil level . . . . . . . . . . . . . . . . . . . . . C
Rear axle differential oil . . . . . . . . . . . . . . . . . . . . . . . . . V V
Rear wheels reducers oil . . . . . . . . . . . . . . . . . . . . . . . . V V
Rear wheels reducers clearance . . . . . . . . . . . . . . . . . . . C**
CHASSIS
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Bearings and articulation rings . . . . . . . . . . . . . . . . . . . . C**
ATTACHMENTS
Forks wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Attachment carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . C**
Condition of attachments . . . . . . . . . . . . . . . . . . . . . . . . C**
LIFT TRUCK
Tow the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sling the lift truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transport the lift truck on a platform . . . . . . . . . . . . . . . .
(*) : Every 10 hours during the first 50 hours, then once
at 250 hours.
(**) : Consult your dealer.
3 - 11
--- Page 13 ---
C3 - LEVEL OF THE TRANSFER BOX OIL C3/1
CHECK
Park the lift truck on level ground with the engine stopped.
- Remove access panel 1 (fig. C3/1).
- Remove level plug 2 (fig. C3/2). The oil should be flush with the edge of the filler port.
- If necessary, add oil (see : 3 - MAINTENANCE : LUBRICANTS AND FUEL) by the same filler 1
port.
- Set back and tighten the level plug 3 (fig. C3/2) (tightening torque 31 ft/lb).
C3/2
2
C4/1
C4 - PARKING BRAKE 7
CHECK - ADJUST
A
Park the lift truck on a slope less than 15 % with the rated load in the transport position.
- Check the tightening adjustment by locking the parking brake in position A (fig. C4/1).
- The adjustment is correct when the lift truck is held stationary on a slope.
- Carry out adjustments if necessary. B
Adjustment of the parking brake cable on the front axle
- Press and release the brake pedal, then release the parking brake, putting it in position
B (fig. C4/1).
- Remove the cover plate 1 (fig. C4/2).
- Unscrew nut 2 and screws 3 (fig. C4/3).
- Adjust the cable by loosening the screw 4 (fig. C4/3), until a clearance of 0.06 in. bet-
ween cams 5 (fig. C4/4) and stops 6 (fig. C4/4) is obtained. C4/2
The adjustment of The adjustment
the stops of thebystops
performed performed bymust
the manufacturer the manufacturer must
not be modified not any