Manitou MVT 665 T COMFORT LINE Series E2 Operator Manual - PDF DOWNLOAD

INTRODUCTION

MANITOU NORTH AMERICA, INC. 6401 IMPERIAL DRIVE Waco, TX 76712--6803

For Parts Orders contact your Manitou North America Dealer or call: Manitou North America, Parts Dept. 800--425--3727 or (254) 799--0232 Parts Dept. Fax: (254) 867--6504

Website: www.manitou--na.com

MVT 665 T

COMFORT LINE Series E2 S/N: 750607 & ABOVE, INCLUDING S/N: 410334

OPERATOR/SERVICE MANUAL

THIS OPERATOR’S MANUAL MUST BE KEPT IN THE LIFT TRUCK. IT MUST BE READ AND UNDERSTOOD BY THE LIFT TRUCK OPERATOR.

CATALOG 648342AS R11-10

INTRODUCTION

INTRODUCTION

- INTRODUCTION TO SAFETY -

- ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS - - - - - - - - - - - I - SAFETY MESSAGES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VII - SAFETY DECALS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - VIII

- TABLE OF CONTENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3

INTRODUCTION

INTRODUCTION

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS

I

INTRODUCTION ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS STUDY THE OPERATOR/SERVICE MANUALS The information in this manual provides general instructions for the safe operation and maintenance of your forklift truck. This information is vital and must be clearly understood by the operator and serviceman. Study this manual and the Rough Terrain Forklift Safety Manual (part no. 422494) thoroughly and carefully before operating or servicing your forklift. Contact your dealer or Manitou North America, Inc. if you have any questions concerning your forklift, its operation, service or parts. Keep both manuals in the literature box on the forklift available for reference. If either manual becomes illegible or is missing, contact your dealer for replacements immediately. This manual cannot cover every situation that might result in an accident. It is the responsibility of the operator to always remain alert for potential hazards and be prepared to avoid them!

ADDITIONAL RECOMMENDED LITERATURE: ANSI / ITSDF B56.6 is the national consensus standard for rough terrain forklift trucks. It contains rules about forklift safety, maintenance, safe operation, training, and supervision. Forklift owners should learn this standard and make it available for their operators, service personnel, and supervisors. These standards can be obtained, free of charge, from the Industrial Truck Standards Development Foundation (ITSDF) on their website at www.itsdf.org. The following references are examples from the standard, addressing forklift operators:

A.) OPERATOR TRAINING QUALIFICATIONS 1.) The user shall ensure that operators understand that safe operation is the operator’s responsibility. The user shall ensure that operators are knowledgeable of, and observe, all safety rules and practices.

2.) Create an effective operator training program centered around user company’s policies, operating conditions, and rough terrain forklift trucks. The program should be presented completely to all new operators and not be condensed for those claiming previous experience.

3.) Information on operator training is available from several sources, including rough terrain forklift truck manufacturers, users, government agencies, etc.

4.) An operator training program should consist of the following: a.) careful selection of the operator, considering physical qualifications, job attitude, and aptitude; b.) emphasis on safety of stock, equipment, operator, and other personnel; c.) citing of rules and why they were formulated; d.) basic fundamentals of rough terrain forklift truck and component design as related to safety, e.g., in.-lb (N-m) loading, mechanical limitations, center of gravity, stability, etc.; e.) introduction to equipment, control locations, and functions. Explain how they work when used properly and problems when used improperly. f.) supervise practice on operating course remote from normal activity and designed to simulate actual operations, e.g., lumber stacking, elevating shingles to the roof, etc.; g.) oral, written, and operational performance tests and evaluations during and at completion of the course; h.) refresher courses, which may be condensed versions of the primary course, and periodic “on job” operator evaluation; i.) understanding of nameplate data and operator instructions and warning information appearing on the rough terrain forklift truck.

B.) GENERAL SAFETY PRACTICES 1.) Rough terrain forklift trucks can cause injury if improperly used or maintained.

2.) Only authorized operators trained to adhere strictly to all operating instructions shall be permitted to operate rough terrain forklift trucks. Unusual operating conditions may require additional safety precautions, training, and special operating instructions.

3.) Modifications and additions which affect capacity or safe operation shall not be preformed without the manufacturer’s prior written approval. Where such authorization is granted, capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly.

4.) If the rough terrain forklift truck is equipped with front end attachment(s) or optional forks, the user shall see that the truck is marked to identify the forks or attachment(s), show the approximate weight of the truck and fork or attachment combination, and show the capacity of the truck with forks or attachment(s) at maximum elevation with load laterally centered.

5.) The user shall see that all nameplates and caution and instruction markings are in place and legible.

6.) The user shall consider that changes in load dimension may affect rough terrain forklift truck capacity.

II

INTRODUCTION

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

B.) GENERAL SAFETY PRACTICES (cont.)

7.) Where steering can be accomplished with either hand and the steering mechanism is of a type that prevents road reactions from causing the handwheel to spin (power steering or equivalent), steering knobs may be used. When used, steering knobs shall be of a type that can be engaged by the operator’s hand from the top and shall be within the periphery of the steering handwheel.

8.) Experience has shown that rough terrain forklift trucks which comply with stability requirements are stable when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the requirements.

9.) Users shall give consideration to special operating conditions. The amount of forward and rearward tilt to be used is governed by the application. Although the use of maximum rearward tilt is allowable under certain conditions, such as traveling with the load lowered, the stability of a rough terrain forklift truck as determined by standardized tests does not encompass consideration for excessive tilt at high elevations or the operation of trucks with excessive off-center loads.

10.) Some of the conditions which may affect stability are ground and floor conditions, grade, speed, loading (rough terrain forklift trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment), dynamic and static forces, improper tire inflation, and the judgement exercised by the operator.

C.) OPERATING SAFETY RULES AND PRACTICES 1.) Safe operation is the responsibility of the operator.

2.) This equipment can be dangerous if not used properly. The operator shall develop safe working habits and also be aware of hazardous conditions in order to protect himself, other personnel, the rough terrain forklift truck, and other material.

3.) The operator shall be familiar with the operation and function of all controls and instruments before undertaking to operate the rough terrain forklift truck.

4.) Before operating any rough terrain forklift truck, truck operators shall have read and be familiar with the operator’s manual for the particular truck being operated.

5.) Before starting to operate the rough terrain forklift truck: a.) be in operating position and fasten seat belt; b.) place directional controls in neutral; c.) apply brakes; d.) start engine.

6.) Do not start or operate the rough terrain forklift truck, any of its functions, or attachments from any place other than the designated operator’s position.

7.) Keep hands and feet inside the operator’s designated area or compartment. Do not put any part of the body outside the operator compartment of the rough terrain forklift truck.

8.) Never put any part of the body into the mast structure or between the mast and the rough terrain forklift truck.

9.) Never put any part of the body within the reach mechanism of the rough terrain forklift truck or other attachments.

10.) Understand rough terrain forklift limitations and operate the truck in a safe manner so as not to cause injury to personnel.

11.) Do not allow anyone to stand or pass under the elevated portion of any rough terrain forklift truck, whether empty or loaded.

12.) Do not permit passengers to ride on rough terrain forklift trucks.

13.) Check clearance carefully before driving under electrical lines, bridges, etc.

14.) A rough terrain forklift truck is attended when the operator is less than 25 ft (7.6m) from the truck, which remains in his view.

15.) A rough terrain forklift truck is unattended when the operator is 25ft (7.6m) or more from the truck, which remains in his view, or whenever the operator leaves the truck and it is not in his view.

16.) Before leaving the operator’s position: a.) bring rough terrain forklift truck to a complete stop; b.) place directional controls in neutral; c.) apply the parking brake; d.) lower load-engaging means fully, unless supporting an occupied elevated platform; e.) stop the engine; f.) if the rough terrain forklift truck must be left on an incline, block the wheels; g.) fully lower the load-engaging means.

17.) Maintain a safe distance from the edge of ramps, platforms, and other similar working surfaces.

18.) Do no move railroad cars or trailer with a rough terrain forklift truck.

III

INTRODUCTION

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

C.) OPERATING SAFETY RULES AND PRACTICES (cont.)

19.) Do not use a rough terrain forklift truck for opening or closing railroad car doors.

20.) In areas classified as hazardous, use only rough terrain forklift trucks approved for use in those areas.

21.) Report all accidents involving personnel, building structures, and equipment to the supervisor or as directed.

22.) Do not add to, or modify, the rough terrain forklift truck.

23.) Do not block access to fire aisles, stairways, and fire equipment.

24.) For rough terrain forklift trucks equipped with a differential lock, the lock should not be engaged when driving on the road or at high speeds or when turning. If the lock is engaged when turning, there could be loss of steering control.

25.) Observe all traffic regulations including authorized speed limits. Under normal traffic conditions, keep to the right, maintain a safe distance, based on speed of travel, from the truck ahead; and keep the truck under control at all times.

26.) Yield the right-of-way to pedestrians and emergency vehicles such as ambulances and fire trucks.

27.) Do not pass another truck traveling in the same direction at intersections, blind spots, or at other dangerous locations.

28.) Slow down and sound the audible warning device(s) at cross-aisles and other locations where vision is obstructed.

29.) Cross railroad tracks at an angle wherever possible. Do not park closer than 6 ft (1.8m) to the nearest rail of a railroad track.

30.) Keep a clear view of the path of travel and observe other traffic, personnel, and safe clearances.

31.) If the load being carried obstructs forward view, travel with the load trailing.

32.) Ascend or descend grades slowly and with caution. a.) When ascending or descending grades in excess of 5%, loaded rough terrain forklift trucks should be driven with the load upgrade. b.) Unloaded rough terrain forklift trucks should be operated on all grades with the load-engaging means downgrade. c.) On all grades, the load and load-engaging means shall be tilted back, if applicable, and raised only as far as necessary to clear the road surface. d.) Avoid turning, if possible, and use extreme caution on grades, ramps, or inclines; normally travel straight up or down.

33.) Under all travel conditions, operate the rough terrain forklift truck at a speed that will permit it to be brought to a stop in a safe manner.

34.) Travel with load-engaging means or load low and, where possible, tilted back. Do not elevate the load except during stacking.

35.) Make starts, stops, turns, or direction reversals in a smooth manner so as not to shift load and/or overturn the rough terrain forklift truck.

36.) Do not indulge in stunt driving or horseplay.

37.) Slow down for wet and slippery surfaces.

38.) Before driving over a dockboard or bridge plate, be sure that it is properly secured. Drive carefully and slowly across the dockboard or bridge plate, and never exceed its rated capacity.

39.) Do not drive rough terrain forklift trucks onto any elevator unless specifically authorized to do so.

Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize the controls, shut off engine, and set brakes. It is advisable that all other personnel leave the elevator before truck is allowed to enter or leave.

40.) Avoid running over loose objects on the roadway surface.

41.) When negotiating turns, reduce speed to a safe level, and turn steering handwheel in a smooth sweeping motion. Except when maneuvering at a very low speed, turn the steering handwheel at a moderate, even rate.

42.) Use special care when traveling without load, as the risk of lateral overturning is greater.

43.) Improper use of stabilizer controls (if so equipped) could cause rough terrain forklift truck upset. Always lower the carriage before operating stabilizer controls.

44.) For rough terrain forklift trucks equipped with lateral leveling: a.) Always level the frame before raising the boom or mast, with or without a load. b.) Lateral leveling should not be used to position an elevated load; instead, lower the load and reposition the rough terrain forklift truck.

45.) Handle only stable or safely arranged loads. a.) When handling off-center loads which cannot be centered, operate with extra caution. b.) Handle only loads within the capacity of the rough terrain forklift truck. c.) Handle loads exceeding the dimensions used to establish rough terrain forklift truck capacity with extra caution. Stability and maneuverability may be adversely affected.

IV

INTRODUCTION 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 transporting 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 dynamic 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 operator 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 protection of the personnel must be taken (see ITSDF B56.6, chapter 5.15 Elevating Personnel).

V

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

D.) SUSPENDED LOADS A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level. Transporting suspended loads must ALWAYS be done slowly and cautiously, with the boom and load as low as possible. Use taglines to restrict loads from swinging, to avoid overturn.

The handling of suspended loads by means of a truss boom or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards. Grades and sudden starts, stops and turns can cause the load to swing and create a hazard.

Guidelines for “Free Rigging / Suspended Loads” 1.

DO NOT exceed the rated capacity of the telescopic handler as equipped for handling suspended loads. The weight of the rigging must be included as part of the load.

2.

During transport, DO NOT raise the load more than 12 inches (305 mm) above the ground, or raise the boom more than 45 degrees.

3.

Only lift the load vertically – NEVER drag it horizontally.

4.

Use multiple pickup points on the load when possible. Use taglines to restrain the load from swinging and rotating.

5.

Start, travel, turn and stop SLOWLY to prevent the load from swinging. DO NOT exceed walking speed.

6.

Inspect rigging before use. Rigging must be in good condition and in the U.S. comply with OSHA regulation §1910.184, “Slings,” or §1926.251, “Rigging equipment for material handling.”

7.

Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft. The load center must not exceed 24 inches (610 mm).

8.

DO NOT lift the load with anyone on the load, rigging or lift equipment, and NEVER lift the load over personnel.

9.

Beware of the wind, which can cause suspended loads to swing, even with taglines.

10.

DO NOT attempt to use frame-leveling to compensate for load swing.

WARNING U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in Construction) include requirements for employers that use powered industrial trucks ("forklifts") configured to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a hook (with or without a winch), or a hook assembly attached to the forks. [Note: This regulation is in addition to the OSHA regulation that requires specific forklift operator training: §1910.178(l).]

When a forklift / telescopic handler is configured and used for hoisting, the employer must ensure that: 1.

Forklift, lift equipment and rigging have been inspected (each shift, month and year) and are in good, safe condition and properly installed.

2.

An operator's manual and applicable load charts are on the forklift.

3.

Work zone ground conditions can support the equipment and load. Any hazardous conditions in the work area have been identified, and the operator notified.

4.

Equipment is being used within its rated capacity and in accordance with the manufacturer's instructions.

VI

5.

Operator and crew members have been trained in the safe use and operation of the equipment, including how to avoid electrocution.

6.

During use, no part of the equipment, load line or load will be within the minimum clearance distance specified by OSHA [10 feet (3.0 m), and more for lines rated over 50 kV] of any energized power line, and any taglines used are non-conductive.

7.

In addition, for lift equipment with a rated capacity greater than 2000 lbs. (907 kg), the employer must ensure that: a.) An accessible fire extinguisher is on the forklift; b.) Monthly and annual inspections are performed and documented, and records retained (three months for monthly, one year for annual); c.) Before November 10, 2014, operators must have had the additional training and qualification / certification required by OSHA regulations §1926.1427 and §1926.1430.

Note: Refer to the full text of the OSHA crane regulation (29 CFR Part 1926, Subpart CC) for a detailed description

VII

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

CONCLUSION: 1.) ATTEND OPERATOR TRAINING CLASSES The forklift operator must clearly understand all instructions concerning the safe operation of the forklift and all safety rules and regulations of the work site. They must have successfully completed a training coarse in accordance with the Powered Industrial Truck Standard (29 CFR 1910.178) as described by the Occupational Safety and Health Administration (OSHA). They must be qualified as to their visual, hearing, physical, and mental ability to operate the equipment safely. NEVER use drugs or alcohol while operating a forklift! NEVER operate or allow anyone to operate a forklift when mental alertness or coordination is impaired! An operator on prescription or over-the-counter drugs must consult a medical professional regarding any side effects of the medication that may impair their ability to safely operate the forklift.

2.) CREATE A MAINTENANCE PROGRAM OSHA recommends a maintenance log, listing repairs requested and completed, for each forklift. Also, “lock out tag procedures” should be utilized. If the forklift malfunctions; park it safely, remove the key, tag “Do Not Use”, and report the problem to the proper authority or authorized service personnel immediately.

ROUGH TERRAIN FORKLIFT TRUCK GENERAL SAFETY STANDARDS (cont.)

2.) CREATE A MAINTENANCE PROGRAM (cont.)

For the best forklift performance and operation, a maintenance program is required. Use the hour meter on the instrument panel to keep maintenance properly scheduled (see SECTION TWO - “Servicing Schedule”).

For repairs on major components (engine, transmission, etc.), contact your nearest dealer for a Repair Manual.

Do not operate a forklift that is damaged or does not function properly. Only authorized personnel may make repairs or adjustments to the lift truck. After repairs, the lift truck must be tested for safe operation before returning to service.

3.) FORKLIFT KNOWLEDGE Forklift trucks can cause serious injury if improperly used or maintained. Study all of the manuals provided for your forklift model. Learn the locations and meanings of all safety decals. If any decals are illegible or missing, have them replaced immediately. Make sure all safety features provided by the original manufacturer are in place and function properly. Do not operate a forklift with damaged, missing or unsafe components. Have it repaired by authorized service personnel. Learn the functions of all controls, gauges, indicator lights, etc. on the forklift. Know the speed/gear ranges, braking and steering capabilities, load ratings and clearances. When referring to the location of forklift components, the terms “left”, “right”, “front”, and “rear” are related to the operator seated normally, facing forward in the operator’s seat. If you have any questions about the forklift, consult your supervisor. Failure to fully understand or obey safety warnings can result in serious injury or death!

4.) WORK SITE KNOWLEDGE Before operating on a work site, learn the rules for movement of people, forklifts and all other traffic. Check the size, weight, and condition of the loads you will be expected to handle. Verify that they are properly secured and safe to transport. Learn where the loads are to be placed, planning your route for a safe approach, watching for hazardous conditions. Will a signal man be required to help place the load? Remove any debris which may cause tire damage or rupture. Plan your route around problem areas or have them corrected. Inform the supervisor of any unsafe conditions observed at the site. Examples of hazards: power lines, cables, low clearance structures, garage doors, telephone pole guide lines, fencing, loose lumber, building materials, drop-offs, trenches, rough/soft spots, oil spills, deep mud, steep inclines, railroad tracks, curbs, etc.. NEVER approach power lines, gas lines or other utilities with the forklift! Always verify that local, state/provincial and federal regulations have been met. Report any accidents involving personnel, building structures, and equipment to the supervisor immediately. Always remain alert - conditions are constantly changing at the work site!

TECHNICAL SUPPORT All data provided in this manual is subject to production changes, addition of new models, and improved product designs. If a question arises regarding your forklift, please consult your dealer or K-D Manitou, Inc. for the latest information. When ordering service parts or requesting technical information, be prepared to quote the applicable Model/Serial Numbers.

VIII

SAFETY MESSAGES NOTE THE SAFETY ALERT SYMBOL (SHOWN BELOW). IT IDENTIFIES POTENTIAL HAZARDS WHICH, IF NOT AVOIDED MAY RESULT IN INJURY OR DEATH! Also, observe the safety messages places throughout this manual; providing special instructions, telling you when to take precautions and to identify potential hazards. The safety messages are highlighted and outlined in a box similar to those shown in the examples below.

SAFETY ALERT SYMBOL

NOTE or NOTICE Provides information, special instructions or references about the lift truck.

IMPORTANT Precautions which must be taken to avoid damage to the lift truck.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. May also alert unsafe practices.

WARNING Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury!

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

CALIFORNIA PROPOSITION 65 WARNING Diesel Engine Exhaust and some of its constituents are known to the State of California to cause cancer, birth defects or other reproductive harm.

WARNING: Battery posts, terminals and related accesories and related accessories contain lead and lead compounds. Wash hands after handling.

IX

INTRODUCTION SAFETY DECALS The purpose of this chapter is to introduce you to the safety messages, decals, and nameplates found on your forklift truck. The decals are identified by name, part number, location, and a brief description. (The forklift model logos, and other misc. decals not shown, can be found in your forklift parts manual.) The decals illustrated may not be exactly the same as those installed on your forklift; installation of the decals varies depending on the forklift model, series, decal updates, etc.. The size and location of some decals limit the amount of information that can be placed upon it. For this reason, additional detailed information not found on the decals is provided through-out this manual.

Every decal placed on the lift truck is important; they are constant reminders of safety and instructions that should never be taken for granted. Even experienced operators can be seriously injured or killed by ignoring, refusing to enforce, or forgetting to follow safe operating procedures! Do not assume you know all safety issues concerning the decals. Before operating the lift truck; learn the meaning(s) of the decals as described in this manual. If any decal becomes illegible or missing, have it replaced immediately! Always replace decals using the same decal part no., unless otherwise specified by the manufacturer. For replacement decals not found in your parts manual, contact your nearest dealer. If you have any questions, contact your supervisor or nearest dealer for advice before operating your forklift!

801011 Before Starting - 801011 (Boom equipped models). Location: on the brake fluid cover panel (to the left and below the dash panel).

Safety Instructions - 420792 (Mast equipped models). Location: on or near the operator manual storage case, and/or on the dash panel.

Instructions for the forklift operator; before operating the forklift.

Use of Seat Belt - 801012 (Boom equipped models). Location: to the right of the operator, near the hydraulic control lever.

Instructs the operator to always wear the seat belt during operations, and never jump from an over-turning forklift.

X

INTRODUCTION SAFETY DECALS

Emergency and Parking Brake - 801010 Location: near the park brake lever.

Identifies the Emergency/Parking Brake Lever.

Alarm Must Sound - 496162 Location: on the dash, in direct view of the operator.

The backup alarm must sound when the forklift is placed in reverse gear.

No Riders - 420732 Location: on the cab entrance(s), and on or near wheel fenders and engine cover.

Informs: riders are not allowed on the forklift.

Clear of Raised Boom - 801006 (Boom equipped models). Location: on both sides of the boom nose.

Keep away from unsupported boom.

Clear of Power Lines - 801007 (Boom equipped models). Location: on both sides of the boom nose.

Keep away from power lines.

XI

INTRODUCTION SAFETY DECALS Use of Frame Leveling - 801013 (Boom equipped models). Location: to the right of the operator near the hydraulic control lever.

Frame leveling notice; load must be lowered.

Attachment and Boom Safety - 801009 (Boom equipped models). Location: on both sides of the boom nose.

Important reminders of attachment and boom safety.

Hydraulic Coupling - 234805 Location: near the quick-disconnect adapters.

Stop the engine and release hydraulic pressure before changing attachments.

Rotating Fan and Belt(s) - 801008 Location: on the radiator near the fan, and on any fan belt/pulley cover(s).

Keep hands and clothing away from rotating fan and belts.

XII

INTRODUCTION SAFETY DECALS

Gear Shift Pattern - 33460 (4-speed transmission models). Location: near the gear shift lever.

Identifies the gear shift pattern of the forklift transmission.

Steering Mode - 184276 (4 wheel steer equipped models). Location: near the steering mode selection lever.

Identifies the steering mode selection.

221322

Mineral Oil (Brake Reservoir) - 221322 or 234800 has been replaced by 164091.

Location: near the brake fluid reservoir where applicable.

Refer to the Operator/Service Manual for the correct brake fluid (mineral oil) to be used in the brake system.

234800

XIII

INTRODUCTION SAFETY DECALS Hydraulic Oil - 234798 or 76573 Location: on the hydraulic tank or filler cap.

Identifies the hydraulic reservoir (tank) or filler cap.

Hydraulic Oil - 61024 Location: on the hydraulic tank.

Identifies the hydraulic reservoir (tank).

Anti-Freeze - 234799 Location: on the radiator, near the radiator filler cap.

Indicates required minimum to maximum anti-freeze protection (-220F to -400F).

Diesel Fuel - 161101 Location: on the fuel tank, near the filler cap.

Identifies the fuel tank, and use of diesel fuel.

No Step - 496735 Location: varies, depending on the forklift model.

Instructs personnel not to use the designated area as a step.

Do Not Tow - 494918 (Hydrostatic equipped models). Location: on the dash, in view of the operator.

Towing the forklift will damage the transmission; refer to the operator’s manual.

XIV

INTRODUCTION 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

INTRODUCTION SAFETY DECALS

Acid in Battery - 801014 Location: in or near the battery storage compartment.

Addresses battery hazards.

Jump Start Battery - 801015 Location: in or near the battery storage compartment.

Jump start instructions.

Attachment Plate - 425995 Location: on the optional removeable forklift attachment.

Important manufacturer information about the attachment. Record this information for use when contacting the maufacturer for parts and service.

Overhead Guard Data Plate - B6109 Location: attached to the overhead guard.

Overhead guard conformity.

496550

Forklift Data Plate - 496550 (Boom equipped models)

Forklift Data Plate - 496538 (Mast equipped models) Location: within the operator’s compartment.

Important forklift truck identification. Record this information for use when contacting the manufacturer for parts and service.

XVI

496538

INTRODUCTION OPERATOR MANUAL

MVT 665 T

TABLE OF CONTENTS CHAPTER OPERATOR MANUAL

PAGES 3 to 73

- INSTRUCTIONS FOR THE LIFT TRUCK DRIVER

4

- SPECIFICATIONS

7

- DIMENSIONS

10

- LOAD CHARGE

11

- INSTRUMENTS AND CONTROLS

12

- OPERATING ADVICE TO DRIVERS

27

- ADVICE FOR THE USE OF THE TRUCK

28

- BEFORE STARTING UP A NEW TRUCK

29

- DRIVING THE TRUCK

30

- OILS-GREASES-LIQUIDS-FUEL

31

- FILTERS ,CARTRIDGES AND BELT

32

- SERVICING SCHEDULE

34

A - DAILY OR EVERY 10 HOURS SERVICE B - EVERY 50 HOURS SERVICE

36 40

C - EVERY 250 HOURS SERVICE D - EVERY 500 HOURS SERVICE OR ONE TIME FOR YEAR

45 48

E - EVERY 1000 HOURS SERVICE OR ONE TIME FOR YEAR F - EVERY 2000 HOURS SERVICE OR ONE TIME FOR YEAR

51 55

ELECTRICAL SYSTEM

56

HYDRAULIC SYSTEM

68

SPARE PARTS CATALOGUE Page

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

INSTRUCTIONS FOR THE LIFT TRUCK DRIVER

REMEMBER THAT THIS SYMBOL MEANS:

ATTENTION : BE CAREFUL !

YOUR SAFETY AND THAT OF YOUR TRUCK ARE AT STAKE

-

Become familiar with the telescopic lift truck on the terrain where it will be used.

Carry the load in a low position with the telescopic arms fully retracted.

Set the fork arms perpendicular to the load.

Drive the truck at a speed suited to the ground conditions in question.

Never drive too fast or sharply brake with a load.

When picking up a load, check that the ground is as even as possible.

When the load is lifted, check that no one will be able to hamper the operation and avoid incorrect manoeuvres.

Never attempt operations that are beyond the capacity of the lift truck.

Never lift a load that is heavier than the truck capacity and never increase the size of the counterweight.

Drive around obstructions.

Be careful when there are electric cables, ditches, freshly dug soil or recently filled excavations.

Never leave the engine running when the truck is unattended.

Use the brake when depositing a difficult load or when the ground is sloping.

Never ever leave the truck parked with a raised load.

Never authorize anyone to come near or walk under a load.

Always bear safety in mind and only carry well balanced loads.

Never lift a load by one single fork arm.

Drive carefully and with prompt reflexes.

When the lift truck is not used, lower the fork arms to the ground and engage the hand brake.

Never ever leave the starting keys in the truck whilst the driver is absent.

Never leave the truck loaded with the hand brake engaged on slopes exceeding a 15% gradient.

Comply with the values given in the load curves.

Never ever transport passengers on the lift truck.

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

INTRODUCTION Our telescopic handler has been designed to incorporate simplicity of operation for the driver and ease of accessibility for routine servicing for the mechanic.

However, before operating the truck attention should be given to the various chapters in this manual which have been prepared to provide all of the information required for proper servicing and operating technique. Be sure that these instructions are followed and the truck is operated within its capacity at all times.

The terms "LEFT" and "RIGHT", "FRONT" and "REAR" used in this manual refer to the position as if the driver was seated normally in the driver's seat.

When ordering spare parts or requesting technical information, always quote: MANUFACTURER'S DATA PLATE (Fig A)

(fig.A)

- Model _____________________________ - Series _____________________________ - Serial N° ___________________________ - Chassis N° _________________________ - Year of manufacture __________________

ON THE THERMICAL ENGINE (fig.A)

(fig.B)

- the thermical engine number ___________

ON HYDROSTATIC DRIVE (fig.B)

(fig.D)

- MANITOU reference N° _______________ - Serial N° ___________________________

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

ON FRONT AND REAR AXLE (Fig. D) - Axle type and model __________________ - Serial N° of front axle _________________ - Serial N° of rear axle __________________ Fig. D

2

1 3

ON CAB (Fig. E)

1

Axle type and model

2

Serial N°

3

Lubricant

Fig. E

Cab N° ______________________________

☞

Write all these numbers in the empty spaces. Since the MANITOU policy is to constantly improve our products, our range of telescopic lift trucks may be subject to modifications without our being obliged to give advance warning to our customers.

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

SPECIFICATIONS

Engine - Type - Cylinders number - Cycles number - Injection system - Firing order - Valve clearance - Intake - Exhaust - Displacement - Bore - Stroke - Compression ratio - Nominal speed - Idle speed - Power ISO/TR 14396 - Maximum torque at 1400 rpm

PERKINS 1104C.44T 4 4 direct 1.3.4.2.

8/1000 inches (with engine cold) 18/1000 inches (with engine cold) 4400 cm3 105 mm 127 mm 17.5 : 1 2200 rpm 800 rpm 101 CV-74,5 KW at 2200 rpm 412 Nm - 42 Kgm

Cooling system - Type - Fan - number of blades - diameter - Complete open

Water cooled 7 500 mm 82° +/- 3°C

Electrical circuit - Ground - Battery - Alternator - Voltage regulator - Starting

Negative 12 V 120 Ah 12 V 72 Ah incorporated in the alternator 12 V

Brake - Type - Service brake - Parking brake

Disc brakes in oil bath Foot pedal actuated on both axles Hydraulic actuated on front axle negative type

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

Transmission

Hydrostatic REXROTH

- Type - Gear box - N° of forward speeds - N° of reverse speeds

Pump and motor with variable displacement hydraulically operated 2 2

- Reverser

Electrohydraulic

Hydraulic circuit - Lifting, tilting of telescopic boom and device - Type of pump - Flow rate - Pressure

Gear type 140 l/min 275 bar

Spécifications - Maximum travel speed - Forward : unloaded : loaded - Reverse : unloaded : loaded

20 km/h 9 km/h 20 km/h 9 km/h

- Tire sizes - Front - Rear

158 - 22,5 T35 16 PR TL 158 - 22,5 T35 16 PR TL

- Tire pressures - Rear - Front

5 bar 5 bar

- Std lifting height

5800 mm

- Lifting speed (telescopic boom retracted) unloaded

28,8 m/min

- Lowering speed (telescopic boom retracted) unloaded

40 m/min

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

Telescopic boom speed - unloaded extension - unloaded retract Fork dimensions (lenght x width x thickness) External fork spread

18 m/min 28,8 m/min 1200x200x60 mm 1750 mm

Spread by center

600 mm

Rated capacity with std equipment

6500 Kg

Truck weight with std carriage and forks - unloaded - loaded

11000 kg 17500 kg

Axle ground weights with std equipment - front unloaded - rear unloaled

3800 kg 7200 kg

Drawbar pull - unload - loaded

7800 kg 10100 kg

Page

9

INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

DIMENSIONS

MVT 665 T D1 C1

G 26° G1 26°

G2 28°

M Y L Z

C

N

I

B D

A E

J

V1

F W

T

R

V2 V

K

U

A B C C1 D D1 E F G G1 G2 I J K L M N O R S T U V V1 V2 W Y Z

A B C C D D E F G G G I J K L M N O R S T U V V1 V2 W Y Z

47.24 98.43 39.76 34.25 183.86 178.35 231.10 78.35 15.75 19.29 15.75 45.67 34.06 56.30 2.36 60 72.83 74.41 7.87 131.50 276.57 155.51 98.82 175.20 37.40 140.35 96.06 11° 124°

in

O

mm

1200 2500 1010 870 4670 4530 5870 1990 400 490 400 1160 865 1430 60 1850 1890 200 3340 7025 3950 2510 4450 950 3565 2440 11° 124°

S

Page

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INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

LOAD CHARGE

MVT 665 T

Page

11

INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

INSTRUMENT AND CONTROLS

15 5 10

6 2 4

3

14

1

22 11

25

17

12 9 16

13

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12

INTRODUCTION O P E R AT O R M A N U A L

MVT 665 T

DESCRIPTION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

- Driver's seat - Switch console - Starting key - Steering wheel adjustment lock lever - Instrument panel (dashboard) - Light switch, horn and indicator switch - Accelerator pedal - Service brake pedal - Gear lever (slow- fast) - Forward / Reverse lever - Hydraulic parking brake lever - Proportional electro-hydraulic servo control - Red emergency button - Distributor control lever for steering mode - Admittance cover to braking oil tank and fuses - Braking oil tank - Windscreen washer tank - Air vents - Roof light - Cab heater control - Door closing - Handle for rear window opening - Locking handle for upper half-door in open position - Space for documents - Load capacity charts manual - Front lights for road circulation - Rear lights for road circulation - Rotating beacon - Towing hook

RECOMMENDATIONS The operator is advised to familiarize himself with the position and operation of all of the controls and instruments before operating the truck.

It is recommended that all instruments be checked for correct function immediately after starting the engine, when the engine has warmed up, and at frequent intervals while the truck is in use.

The engine should be stopped and any malfunction investigated and rectified with the last possible delay.

WARNING : Operating the truck without due regard of these recommendations could be dangerous.

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INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

1) DRIVER'S SEAT (Fig. 1) ADJUSTING THE SEAT ACCORDING TO THE DRIVER'S WEIGHT The seat suspensions can be adjusted according to the driver’s weight.

Use knob “A” and select the required value with reference to the graduated scale on the knob itself.

FORWARD-BACK SEAT ADJUSTMENT Pull lever “B” up.

Position the seat as desired.

Release the lever and check that it returns to the locked position.

SEAT BACK TILT ADJUSTMENT Pull lever “C” upwards.

Position the seat in the desired way.

Release the lever and check that it returns to the locked position.

SAFETY BELT Before starting to work with the truck, adjust the safety belt using the side “D”.

Fig. 1

➟

➟

A D

➟

C

➟

➟

B

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INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

2) SWITCHES CONSOLE (Fig. 2) A B C D E F G H I J

-

HEATER SWITCH EMERGENCY LIGHTS SWITCH FRONT WIPER BLADE AND WINDOW WASHER SWITCH REAR WIPER BLADE SWITCH ROTATING LAMP SWITCH OPTIONAL OPTIONAL EXCLUSION SWITCH OPTIONAL GREEN LIGHTS A C BLUE LIGHTS

Fig. 2

E

G

I

I

A - HEATER SWITCH The two-position switch turns the heater on and off.

B

D

F

H J J

B - EMERGENCY LIGHTS SWITCH Pressing this switch turns on all the turn signal indicators. To turn them off just press the switch again.

C - FRONT WIPER BLADE AND WINDOW WASHER SWITCH Three-position switch: for wiper blade (1); for window washer (2). To turn off the window washer just release the switch.

D - REAR WIPER BLADE SWITCH Two-position switch for front wiper blade.

E - ROTATING LAMP SWITCH Two positions switch for rotating lamp.

G - OPTIONAL EXCLUSION SWITCH (accessories hydraulic block) The two position switch is used for activating or deactivating the optional.

With the switch pressed (read indicator light ON) the Optional/accessories hydraulic block function is activated.

With the switch pressed (read indicator light OFF) the Optional/accessories hydraulic block function is deactivated.

I - GREEN LIGHTS The green lights indicate enabling of the control lever for load lifting movements and telescopic arm extension.

J- BLUE LIGHTS The blue lights indicate enabling of the control lever for fork tilting movements and for the optional control.

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INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

3) STARTING KEY (Fig. 3)

Fig. 3

This key switch has four positions : 0 : internal combustion engine I : electrical contact II : warming-up III : start-up and return to position I after the key has been released.

III

I II

4) STEERING WHEEL ADJUSTMENT LOCK LEVER (Fig. 5) This lever is used to adjust the steering wheel to match the driver’s position: - turn the lever counterclockwise to loosen the grip of the steering wheel lock, - adjust the height "A" (Fig. 4), - perform the telescopic adjustment "B" (Fig. 4), - turning the lever clockwise locks the steering wheel.

Note: If lever cannot be moved far enough to loosen or tighten it completely, pull the lever as "C", returning the lever to the original position and repeat the operation.

Fig. 5

Fig. 4

➟

➟

➟

B

➟

A

C

➟

B

A

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INTRODUCTION MVT 665 T

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5) INSTRUMENT PANEL A - RED LAMP FOR COMBUSTION ENGINE OIL PRESSURE B - RED LAMP FOR WATER TEMPERATURE INDICATOR C - RED LAMP FOR FUEL RESERVE D - RED LAMP FOR AIR FILTER FOULING INDICATOR E - RED LAMP FOR ALTERNATOR EXCITATION F - RED LAMP FOR PARKING BRAKE G - GREEN LAMP FOR DIRECTION INDICATORS H - BLUE LAMP FOR HIGH BEAMS I - RED LAMP FOR LOW BRAKE CIRCUIT PRESSURE INDICATOR L - FUEL LEVEL INDICATOR M - HOUR METER

L

M

A

B

C

D

E

F

G

H

I

A - RED LAMP FOR COMBUSTION ENGINE OIL PRESSURE THIS LAMP TURNS ON WHEN THE ELECTRIC CONTACT IS ACTIVATED ON THE FORK-LIFT TRUCK AND SHOULD TURN OFF AFTER THE COMBUSTION ENGINE HAS STARTED OPERATING. IF THE LAMP TURNS ON WHILE OPERATING THE FORK-LIFT TRUCK, IMMEDIATELY TURN OFF THE COMBUSTION ENGINE AND TROUBLESHOOT THE CAUSE (CHECK THE LEVEL OF THE OIL IN THE ENGINE PAN).

B - RED LAMP FOR WATER TEMPERATURE INDICATOR WHEN THE FORK-LIFT TRUCK IS OPERATING UNDER NORMAL CONDITIONS, THE INDICATOR LAMP REMAINS OFF. IF THE TEMPERATURE REACHES 95° C, THE LAMP TURNS ON. IMMEDIATELY TURN OFF THE COMBUSTION ENGINE AND TROUBLESHOOT THE CAUSE IN THE COOLING CIRCUIT.

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INTRODUCTION O P E R AT O R M A N U A L

MVT 665 T

C - RED LAMP FOR FUEL RESERVE THIS LAMP IS USED TO INDICATE THE FUEL RESERVE.

D - RED LAMP FOR AIR FILTER FOULING INDICATOR THIS LAMP IS USED TO INDICATE THE CONDITION OF THE FILTER CARTRIDGE: IF IT IS FOULED OR DAMAGED, THE LAMP TURNS ON (TO REPLACE THE CARTRIDGE, REFER TO THE CHAPTER “OILS - GREASES - LIQUIDS FUELS - FILTERS”).

E - RED LAMP FOR ALTERNATOR EXCITATION THIS LAMP TURNS ON WHEN THE ELECTRIC CONTACT IS ACTIVATED ON THE FORK-LIFT TRUCK AND SHOULD TURN OFF AFTER THE COMBUSTION ENGINE HAS STARTED OPERATING. IF THE LAMP TURNS ON WHILE OPERATING THE FORK-LIFT TRUCK, IMMEDIATELY TURN OFF THE COMBUSTION ENGINE AND CHECK THE ELECTRIC CIRCUIT AND THE ALTERNATOR BELT

F - RED LAMP FOR PARKING BRAKE WHEN ON, THE LAMP INDICATES THAT THE PRAKING BRAKE IS LOCKED.

G - GREEN LAMP FOR DIRECTION INDICATORS THIS LAMP TURNS ON SIMULTANEOUSLY WITH THE DIRECTION INDICATORS AND INDICATES THAT THEY ARE OPERATING CORRECTLY.

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INTRODUCTION O P E R AT O R M A N U A L

MVT 665 T

H - BLUE LAMP FOR HIGH BEAMS THIS LAMP TURNS ON WHEN THE HIGH BEAMS ARE TURNED ON.

I - RED LAMP FOR OIL BRAKE LEVEL IF THE LAMP TURNS ON WHILE OPERATING THE FORK-LIFT TRUCK, IMMEDIATELY TURN OFF THE COMBUSTION ENGINE, PULL THE HANDBRAKE AND CONTACT YOUR AGENT OR DEALER.

L - FUEL LEVEL INDICATOR

M - HOUR METER THIS INDICATES THE NUMBER OF HOURS THE FORK-LIFT TRUCK HAS BEEN USED. THE HOURS APPEAR ON THE DIAL UP TO MULTIPLES OF ONE THOUSAND.

N. B. : - A BUZZER IS ACTIVATED EACH TIME A RED LAMP TURNS ON. - WHEN THE IGNITION KEY IS TURNED TO THE FIRST POSITION (WITH THE ENGINE OFF) A “CHECK” IS PERFORMED, ALL THE LAMPS TURN ON AND A BUZZER IS ACTIVATED. EVERYTHING RETURNS TO NORMAL ONLY AFTER THE “DIESEL” HAS BEEN TURNED ON.

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INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

6) LIGHT SWITCH, HORN AND INDICATOR SWITCH (Fig. 6) The switch commands the lights and horn. Turn the knob one position to switch on the front and rear parking lights. Turn the knob to the second position to switch on the traffic beams. Pull the lever upwards to switch on the driving beams and the blue switch on the instrument panel will turn on.

To operate the turn signals, just push lever “1” to position “A” or “B” according to the desired direction.

Push towards “A” to turn left, or towards “B” to turn right. Depress the end of the knob “C” to operate the horn.

Fig. 6

A

➠

C

1 B

7) ACCELERATOR PEDAL (Fig. 7) This pedal “A” is used to vary the truck speed by modifying the engine rpm rate.

8) SERVICE BRAKE PEDAL (Fig. 7) The pedal “B” acts on the front and rear wheels, thus slowing and halting the lift truck. In the first 20 mm of its travel, the brake pedal acts as an Inching pedal, allowing accurate and slow movements. It produces the braking effect in the remaining part of its stroke.

Fig. 7

A B

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O P E R AT O R M A N U A L

9) GEAR LEVER (SLOW-FAST) (FIG. 8) The truck has two speeds : - to drive on job site - to drive on road.

To insert the first pull the lever to the position "B" , to insert the second push it to the position "A".

Fig. 8 A

B

WARNING : -Truck must be stopped completely -Always put the forward and reverse lever in neutral position when you change speed, changing without this precaution can damage the gear box

10) REVERSING LEVER (Fig. 9) Fig. 9

The lift truck must be reversed at low speed and without accelerating: - Forward running: push the lever forwards (pos. A at end of travel*) - Reverse running: pull the lever back (pos. B at end of travel*) - Neutral: the lever must be in the neutral position (pos.

C) when the truck is started.

A C B

* Always comply with these instructions in order to ensure that the transmission unit operates correctly.

11) HYDRAULIK PARKING BRAKE LEVER (fig. 10)

Fig. 10

The parking brake acts on the front axle.

- Pull the lever back to position “A” to engage the brake.

- Push the lever forwards to disengage the brake “B”.

A B

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O P E R AT O R M A N U A L

12) PROPORTIONAL ELECTRO-HYDRAULIC SERVO CONTROL (Fig. 11) The truck is equipped with a proportional electro-hydraulic servo control on the operator's right.

Fig. 11 Servo control “A”: can operate various double-acting elements simultaneously.

C Button “C” selects the type of circuit enabled: with the A green lights illuminated the load can be lifted and the forks tilted; with the blue B lights illuminated, the telescopic arm can be extended and the optional control used.

- To lift the load, pull the control lever back (green lights on).

- To lower the load, push the control lever forward (green lights on).

- To extend the telescopic arm push the control lever to the right (green lights on).

- To retract the telescopic arm push the control lever to the left (green lights on).

- To tilt the fork press the control lever forward (blue lights on).

- To raise the fork back into position pull the control lever back (blue lights on).

- To operate the optional function, push the control lever to the right and left (blue lights on) (push button “G” pressed and red indicator light ON, see page 15).

CAUTION When the button is pressed with the control lever in the neutral position, the other related function is enabled automatically.

WARNING : Do not attempt to alter the hydraulic system pressure.

In case of suspected malfunction, consult your dealer or agent.

Any alteration may render the warranty null and void.

12/A) Optional circuit decompression This operation must be carried out each time it is necessary to connect or disconnect a supplemental accessory to the fork-lift truck.

1) Turn off the engine and place the ignition key “3” in position “I”.

2) With the blue lights on, push the control lever to the right and left (push button “G” pressed and red indicator light ON, see page 15).

When the operation has been completed, the optional circuit has been depressurised; therefore, it will be easier to connect and disconnect the rapid fittings on the top of the arm.

N. B. The operation should be performed immediately after turning off the engine, and for no more than 3 seconds for each button.

13) RED EMERGENCY BUTTON (Fig. 11) N. B. : IT’S NECESSARY TO KEEP THE EMERGENCY BUTTON “B” PUSHED DURING THE ROAD MOTION. Page

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O P E R AT O R M A N U A L

14) DISTRIBUTOR CONTROL LEVER FOR STEERING MODE (Fig. 12)

Fig. 12

Three steering modes.

To select one of this modes use lever "A" in this way: - Round ( Front and rear wheels steering in the opposite direction) Put the lever to the position "1".

1

2

3 A

- Front wheel steering Put the lever in the position “2”.

- Crabwise steering Put the lever in the position “3”.

Before selecting one of the three possible steering positions, bring the four wheels into alignment, in the straight ahead position.

15) ADMITTANCE COVER TO BRAKING OIL TANK AND FUSES (Fig. 13) For the admittance to the brake oil tank and to the fuses box is necessary to disassemble the cover on the dashboard turning of 90° the two screws “A” and lifting it .

Fig. 13

16) BRAKING OIL TANK A

17) WINDSCREEN WASHER TANK (Fig. 14)

A

Located to the operator's left. Check the level in the windscreen washer tank, removing the cap “A”. Make sure that the tank is always full.

Liquid to use: water + glass washer (in winter use anti-freeze liquid).

Fig. 15

Fig. 14

18) AIR VENTS (Fig. 15)

☞

They are used to direct the ventilation inside the cab; they are located on the upper part of the cab.

A

☞ ☞

☞

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O P E R AT O R M A N U A L

19) ROOF LIGHT (Fig. 16)

Fig. 16

This switch is on the roof light.

It has two positions : I - Switched on ( continuous light ) II - Switched off 20) CAB HEATER LEVER (Fig. 17) This lever is on the operator's right and allows the temperature to be adjusted by the heater tap.

To make the temperature hotter, turn the lever to the left.

Fig. 17

21) DOOR CLOSING External lock: To open the door, grab the handle and pull towards the external of the cab.

Two keys are supplied with the truck to lock the doors.

Fig. 18

Interior lock: To open the door, grab the handle and pull towards the interior of the cab.

22) HANDLE FOR REAR WINDOW OPENING (Fig. 18)

A

To open the rear window turn the handle “A” to the right and push the window.

Fig. 19

23) LOCKING HANDLE FOR UPPER HALF-DOOR IN OPEN POSITION

2

➟

Closing position : to open, press the button “1” (Fig. 19) down.

To close, pull the lever “2” (Fig. 19) towards the interior.

Open position : Push the door towards the cab to lock it in the latch “3” (Fig. 20).

To release push the button “4” (Fig. 21).

1

Fig. 21 Fig. 20

➟

4

☞

3

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INTRODUCTION MVT 665 T

O P E R AT O R M A N U A L

24) SPACE FOR DOCUMENTS (Fig. 22)

Fig. 22

Make sure that the use and maintenance manual is in the right place under the operator’s seat.

☞ 25) LOAD CAPACITY CHARTS MANUAL (Fig. 23) Fig. 23 This charts’ manual shows the load capacity charts of the accessories used with the truck, commands symbology and warnings.

26) FRONT LIGHTS FOR ROAD CIRCULATION A - Front left direction light (Fig. 24) B - Front left parking light (Fig. 24) C - Front left low beams and high beams (Fig. 24) D - Front right low beams and high beams (Fig. 25) E - Front right parking light (Fig. 25) F - Front right direction light (Fig. 25) Fig. 24

Fig. 25

F

E

B

D

C

A

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INTRODUCTION MVT 665 T

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27) REAR LIGHTS FOR ROAD CIRCULATION Fig. 26 A - Rear left direction light (Fig. 26) B - Rear left stop light (Fig. 26) C - Rear left parking light (Fig. 26) D - Rear right parking light (Fig. 27) E - Rear right stop light (Fig. 27) F - Rear right direction light (Fig. 27)

C

A

B

Abb. 27

28) ROTATING BEACON (Fig. 28) D

It’s possible to remove the rotating beacon to reduce the truck height and to avoid the theft.

- Unscrew the nut “1” and remove the rotating beacon “2”.

E

F

- Protect the support “3” with the cover “4”.

Abb. 28

2

☞

4 3

1

Fig. 29 29) TOWING HOOK (Fig. 29) Located at the back of the truck, this pin makes possible to pull loads ( see "DRAWBAR PULL" in the paragraph "SPECIFICATIONS").

During the towing the speed of the truck has to be reduced.

WARNING : Make sure, during the towing operation, that the pin is locked to the right split-pin.

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INTRODUCTION OPERATOR MANUAL

MVT 665 T

OPERATING ADVICE TO DRIVERS - Familiarize yourself with the truck and the ground on which it is to be operated.

- Transport the load in low position and with telescopic arm retracted to a maximum.

- Place the fork perpendicular to the load which has to be lifted.

- Drive the truck at a speed appropriate to the ground conditions.

- Do not accelerate or brake sharply with a load on the forks.

- When transporting a load , select a path that is smooth as possible.

- Do not attempt to carry out operations in excess of the capacity of the truck.

- Do not lift a load in excess of the truck rating by adding to counterweight.

- Drive around obstacles.

- Keep a look out for overhead cables, trenches, back-filled land etc...

- Do not leave the truck unattented with load in an elevated position.

- Apply the parking brake when lifting or depositing a load.

- Do not stop the truck and leave it with load in an elevated position.

- Do not allow personnel to stand or pass beneath an elevated position.

- Think always to the safety and transport loads well balanced - Do not lift a load with one fork only.

- Drive smoothly and progressively at all times.

- Lower the forks to the ground and apply the parking brake when the truck is not used.

- Do not leave the key in the switch when the truck is out of use.

- Do not leave the truck loaded with the parking brake with a ground inclination higher then 15 %.

- When a load is lifted, pay attention that nobody hamper the movement and do not make wrong movements - Pay attention to the load diagrams - Do not transport another person on the truck WARNING To avoid damage to the quick release coupling when attachments are being changed: - It is necessary to release the pressure in the attachment circuit by operating the valve in this way : - Keep couplings clean

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INTRODUCTION MVT 665 T

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ADVICE FOR THE USE OF THE TRUCK DO - Daily maintenance.

- Use the recommended oils and greases. Make sure to use fresh lubricants (never use a contaminated oil or grease).

- Change the filter cartridges (see servicing schedule).

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

- Wait until the engine is cold before taking off the radiator cap.

- Stop the engine when a repair is necessary.

- Disconnect the negative cable terminal from the top of the battery before working on the electrical circuit or on the truck ( ex.: welding).

- When carrying out electric welding work on the 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.

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

- Ensure oil pressure is normal in the circuits of lifting, telescoping, tilting, attachments and steering.

DO NOT - Run the engine without air filter, or with leaks of oil, water or fuel.

- Start the truck without having checked the different levels : engine oil Hydraulic oil tank fuel cooling liquid brakes oil

: dipstick : dipstick : level gauge : radiator cap : visible

- Let the engine turn idle for a too long period of time.

- Drive with the foot on the brake pedal or with the parking brake applied.

- Operate a new engine with full load or at maximum rpm (this would cause premature wear).

- Smoke or work near a flame when the fuel tank is open or being filled.

- Fill the fuel tank when the engine is running.

- Reverse the direction of travel of the truck when the truck is moving.

- Tow or push the truck to start the engine.

- Attempt to tow the vehicle trasmission damage will occur.

- Attempt to tighten unions or hoses with the hydraulic system under pressure.

WHEN IN DOUBT, CONSULT YOUR DEALER.

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INTRODUCTION OPERATOR MANUAL

MVT 665 T

BEFORE STARTING UP A NEW TRUCK Familiarise yourself with the operation and function of all the control instruments.

DO NOT START A NEW TRUCK BEFORE THE FOLLOWING CHECKS HAVE BEEN CARRIED OUT: LUBRICATION Check that all the correct grades of oils and greases that are required are available;refer to "SERVICING SCHEDULE" and top up if necessary.

IMPORTANT : For operation under average climatic conditions, i.e. : between - 15°C (5 F°) and +35°C ( 95 F°), 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, than ensure correct levels of lubricants using lubricants properly suited to the relevant ambient temperatures (Contact your regular supplier for information).

AIR FILTER Ensure that the air filter is undamaged and that all the connections are secured.

NEVER RUN THE ENGINE WITH THE AIR FILTER REMOVED OR DAMAGED. If the truck operates in a heavily dust laden atmosphere (brickyard, cement work, etc...)refer to the chapter "FILTER CARTRIDGES AND BELT".

COOLING SYSTEM Do not start the engine until the radiator coolant level has been checked and topped up as necessary or if the fan belt is damaged or disassembled.

HYDRAULIC SYSTEM Check that all hoses, connections and unions are secured. Also check that the tank oil level is correct.

BRAKING SYSTEM Check that connections are secured, also check the level in the tank.

WARNING: Ensure that the recommended oil is used, so as to avoid serious damage to the braking system.

WHEELS AND TYRES Make sure that the wheel nuts are correctly tightened and that the tyre pressure is correct. ( See chapter "CHARACTERISTICS" paragraph "SPECIFICATIONS").

FUEL SYSTEM Check that all fuel lines are secured. If necessary drain the fuel filter and bleed the fuel system of air.

ELECTRICAL CIRCUIT Check the level and the density of the electrolyte in the battery. Check the components of the electrical system, the connections and fastening devices.

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29

INTRODUCTION MVT 665 T

OPERATOR MANUAL

DRIVING THE TRUCK BEFORE STARTING THE TRUCK Check the following levels: - Engine oil - Hydraulic oil - Braking oil - Cooling system

: dipstick : dipstick : level gauge : radiator cover

If the truck is new, refer to the preceding pages and carry out the operations indicated in detail.

STARTING THE TRUCK Make sure that the forward / reverse lever is in neutral.

Turn the ignition key to the position I to activate the electrical system.

Check the level on the fuel level gauge.

Turn the ignition key to the position II to preheat for 15 seconds.

ATTENTION: Do not engage the starting motor for more then 30 seconds. Wait 2 minutes between unsuccessful attempts.

Depress the accelerator pedal at half-travel and turn the ignition key fully: the engine should then start.

Release the ignition key and let the engine run at idle.

ATTENTION: Never try to start the truck by pushing or towing the truck. Such operation may cause severe damage to the transmission.

DRIVING THE TRUCK Check the transmission oil level.

Lift the forks or attachment.

Engage the gear required.

Shift the forward / reverse lever to the selected direction of travel.

Select the steering mode.

Untighten the parking brake and accelerate gradually until the truck moves off.

Change the direction of travel only when the truck is at low speed or stationary.

Always remember that the steering is hydrostatic; therefore steer progressively and not abruptly.

STOPPING THE TRUCK Make sure that the truck is not stopped on an incline, or in any position that will interfere with the traffic flow.

Release the accelerator pedal and stop the truck.

Place the forward / reverse lever in neutral.

Tighten the parking brake.

Place the gear lever in neutral.

Lower the forks or attachment to rest on the ground.

Let the engine run at idle for about two minutes, especially after it has run at full load and capacity at high rpm . This action allows the cooling oil and liquid to lower the temperature of the engine and transmission.

Do not forget this precaution , in the event of frequent stops of the 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.

Turn off the ignition switch and remove the key.

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

OILS-GREASES-LIQUIDS-FUEL

SUGGESTED LUBRICANT Oil Shell: Rotella 15w40 SHELL RIMULA X OIL 15W/40 Citgo: C-600 15w40 Oil

Shell: Spirax DH80w90 SHELL DONAX TD Citgo: Premium Gear MP 80w90

Oil

Shell: Donax TD DONAX TDHyd Citgo:SHELL Transgard Tractor Fluid Shell: Tellus T46Oil TELLUS T 46 Citgo: SHELL Transgard THF Lo-Temp

CAPACITY

8.68,1 QTS L

- Engine crankcase

8,2 L x 2 1.3 QTS 8,2 EA. L x 2

- Front wheel reduction gear - Rear wheel reduction gear

10 - 11 L

- Front axle differential gear - Reduction gear - Rear axle differential gear

L 29110 GAL

- Hydraulic and transmission oil tank

11 QTS L 2.62,5 QTS 10 11 11 QTS L

Oil

Shell: Donax TG Dexron III LHM S.8214.B Citgo:SHELL Transgard ATF Dexron III

LUBRICATED PART

- Braking system 0.85 0,8QTS L

Grease

Shell: Rentinax Am SHELL EP2 Citgo: Lithoplex CM-2

- General greasing

Grease

Shell: Rentinax Am SHELL SUPER GREASE G2 Citgo: Lithoplex CM-2

- Telescopic boom lubrication

Water with a low quantity of Tulco 50/50 Premix Anti-freeze limestone + Antifreeze in winter

4.0 15GAL L

- Cooling system

Diesel fuel Grade 1-D Diesel

120GAL L 31.7

- Fuel tank

Page

31

INTRODUCTION MVT 665 T

OPERATOR MANUAL

FILTERS CARTRIDGES AND BELT

2

5

1 3 4

6

8

7

9

50 ÷ 100 H (WITHIN 3 MONTHS) REPLACEMENT (COUPON) SCHEDULE

DESCRIPTION

MANITOU REFERENCE

1 Engine oil filter

476 954

REPLACE

500 H

2 Air filter cartridge

504 507

CLEAN

500 H

3 Transmission oil filter

485 695

REPLACE

500 H

4 Fuel filter cartridge

605 013

REPLACE

500 H

5 Hydraulic oil filter cartridge (exhaust)

545 267

REPLACE

500 H

6 Sfiato serbatoio olio idraulico

448 269

7 Hydraulic oil filter cartridge (intake)

513 752

CHECK

1000 H

8 Air filter safety cartridge

514 161

CHECK

1000 H

9 Engine belt

503 965

CHECK

1000 H

500 H

In heavily dutsy atmosphere.

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32

INTRODUCTION MVT 665 T

OPERATOR MANUAL

ADDITIONAL AIR FILTERS FOR HEAVILY DUSTY CONDITIONS (OPTION).

If the truck is used in a very dusty place, contact your dealer regarding additional air filters.

Automatic vacuum-cleaning pre-filter (Ref.160946 fig.B) This pre-filter can be fitted without any modification: - Loosen the fastener" Jubilee clip" of the external cap fig.A - Remove it and replace with the pre-filter fig.B. The pre-filter needs no maintenance, as it is automatically cleaned.

fig.A

☞

fig.B

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33

INTRODUCTION MVT 665 T

OPERATOR MANUAL

A Daily or every 10 hors service

A1 A2 A3 A4 A5 A6 A7

- Engine oil level - Cooling fluid level - Fuel level - Cleaning of fuel pre-filter - Cooling liquid (if necessary) - Tyre pressure and wheel nut torque - Telescopic boom wear pads

B Every 50 hors service

B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14

- Air filter cartridge ▲ - Hydraulic and transmission oil level - Radiator grille - Brake oil level - Telescopic boom wear pads ■ - Grease articulation pin telescopic boom ◆ - Grease articulation pin quick connection ◆ - Grease iclination cylinder pad and head pins ◆ - Grease lifting cylinder pad and head pins ◆ - Grease compensation cylinder pad and head pins ◆ - Grease cab door ◆ - Grease front and rear wheel pivot pins ◆ - Grease rear axle float bushes ◆ - Grease drive shaft universal coupling and cross journals ◆

C Every 250 hors service

C1 C2 C3 C4 C5

- Crankshaft/alternator belt tension - Oil level in front and rear axle differential - Oil level in front and rear wheel final drives - Slewing gear oi 2 speeds on front axle - Battery

D Every 500 hors service or once a year

D1 D2 D3 D4 D5 D6 D7

- Themic engine oil - Thermic engine filter oil - Air filter cartridge ▲ - Fuel filter cartridge - Transmission oil filter - Hydraulic oil filter cartridge (exhaust) - Transmission and hydraulic oil vent

X X X X X X X

DRAIN

ADJUST

REPLACE

GREASE

CLEAN

COMPONENTS CHECK

FREQUENCY

OPERATION N°

CHAPTER

SERVICING SCHEDULE

X

X X X X X X X X X X X X X X

X X X X X X X X X X

X X X X X X X X X X X X

X

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

E Every 1000 hors service or once a year

F Every 2000 hors service or once a year

E1 E2 E3 E4 E5 E6 E7 E8 E9

- Air filter safety cartridge ▲ - Transmission and hydraulic oil - Hydraulic oil filter cartridge (“strainer” intake) - Front and rear axle differential oil - Oil in front and rear wheel final drives - Oil in 2-speed reduction gear on axle - Combustible reservoi - Alternator belt/throw shaft - Wear of the jib pads *

X

F1 F2 F3 F4

- Engine valve clearance * - Injectors * - Alternator and starter motor * - Turbo compressor *

X X X X

X X X X X X

DRAIN

ADJUST

REPLACE

GREASE

CLEAN

COMPONENTS CHECK

FREQUENCY

OPERATION N°

CHAPTER

SERVICING SCHEDULE

X X X

X X

N.B. : To be done once a year if the truck has not reached recommended hours as shown.

■ :

Every 50 hours during the first 250 hours; then regularly every 1000 working hours.

▲ :

In very dusty atmospheres, reduce the interval and replace earlier.

◆ : In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval

to 10 working hours or every day.

* :

Consult your agent or dealer for these operations.

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

A1/1 A -DAILY OR EVERY 10 HOURS SERVICE A1 - CHECK THE ENGINE OIL LEVEL

With the engine stopped and the truck standing on level ground, wait a few minutes after the engine has stopped to allow the oil to drain into the sump and then check the oil level as follows: - Remove the dipstick 1 (fig. A1/1).

- Clean the dipstick 1 and check the oil level.

- If necessary add oil (see chapter : SERVICING SCHEDULE) through the filler cap neck 2 (fig.A1/2).

A2 - CHECK THE COOLING LIQUID LEVEL

☞

1

A1/2

Place the truck on level ground , stop the engine. This check is to be carried out on the cooling liquid tank in the engine compartment.

On the tank there are two marks that indicate the minimum and the maximum level; check that the liquid level always remains between them.

If necessary add liquid as follows: - Slowly turn the cap 1 (Fig.A2) until it reaches the safety stop.

- Let the vapor pressure escape.

- Press down and release the cap fully.

If necessary add water with anti-freeze until the mark.

Occasionally smear some grease on the radiator cap lugs 2 (Fig.A2) to facilitate removal of the cap 1.

A2

☞

1

2

☞

WARNING : If the cooling liquid is very hot ,do not add cold water but only hot liquid (80°C; 194 F°).

2

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INTRODUCTION MVT 665 T

OPERATOR MANUAL A3 - CHECK THE FUEL LEVEL

A3

Keep the fuel tank full to reduce as much as possible any condensation due to the atmospheric conditions.

- Remove cap 1 (fig. A3).

- Fill the fuel tank with clean fuel, filtered through a strainer or a clean, lint free cloth, through filler port.

WARNING : Never smoke or approach with a flame during filling operations or when the tank is open.

A4 - DRAIN THE FUEL PRE-FILTER

☞

1

A4

- Unscrew drain plug 1 (Fig. A5) of two or three turns.

- Let the fuel flow until it becomes free from impurities and water.

- Retighten the drain plug while the fuel flows out.

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

A5- DRAIN AND REPLACE COOLING LIQUID

A5/1

This series of operations is to be carried out whenever required or once a year at the approach of winter.

- Loosen radiator drain plug 1 (Fig.A5/1) .

- Loosen cylinder block drain plug 2 (Fig.A5/2) .

- Remove radiator filler cap 3 (Fig.A5/3).

- Allow the cooling liquid to drain completely, making sure the drain holes do not become obstructed.Check the state of the hoses and their mountings and change the hoses if necessary.

- Clean the system with clean water and use a cleaning product if necessary.

- Retighten drain plugs 1(Fig.A5/1) and 2 (Fig.A5/2).

- Prepare the cooling liquid (see Fig.A5/4).

- Slowly fill the cooling system (see chapter "Oils- Greases Liquids - Fuel - Filters") through the filling neck.

- Check for possible leaks. Allow the engine to run at idle and add liquid up to the higher mark (“Oils - Greases - Liquids Fuel - Filters).

- Refit filler cap 3 (Fig.A5/3) .

☞

1

A5/2

2

WARNING : The engine has no corrosion resistor and must be filled with a minimum mixture of 25 % ethylene-glycol base antifreeze all year round.

SCHEDULE A5/4 Freezing point in function of the anti-freeze %

ANTI-FREEZE UK 5110 25% 33% 40% 50%

TEMPERATURE -12°C -19°C -26°C -38°C

A5/3

☞

3

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INTRODUCTION MVT 665 T

OPERATOR MANUAL A6 - CHECK THE TYRE PRESSURE AND THE WHEEL NUT TORQUE

A6 - Check and adjust the tyre pressure if necessary (see chapter : “SPECIFICATIONS”).

- At the same time check the condition of the tyres, to detect cuts, wear, etc...

- Check the torque of the wheel nuts (see fig. A6).

Non compliance with this instruction can cause damage and rupture of the wheel bolts and distortion to the wheels.

WHEEL NUT TORQUE LOADING FRONT WHEEL

65 kgm 470 ft/lb

REAR WHEEL

65 kgm 470 ft/lb

A7 - CHECK GREASING OF TELESCOPIC BOOM SLIDING BLOCKS Extract telescopic boom completely and check to make sure the telescopic boom sliding blocks are greased properly (if they are to be greased, see point B5).

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INTRODUCTION MVT 665 T

OPERATOR MANUAL

B1

B - EVERY 50 HOURS SERVICE B1 - CLEAN THE DRY AIR FILTER CARTRIDGE

In case of use in heavily dusty environment, reduce this periodicity and see chapter: “FILTERS CARTRIDGES AND BELT” in paragraph “ADDITIONAL AIR FILTER FOR HEAVILY DUST LADEN ATMOSPHERE”.

- Unscrew nut 1 (fig. B1), and remove cover 2 (fig. B1) - Unscrew nut 3 (fig. B1/2) and take the filter cartridge 4 (fig.

B1/2).

- Leave the safety cartridge in place. (OPTIONAL) - Clean the filter cartridge using a low pressure air blow directed from the inside to the outside surface of the cartridge only.

- Clean the inside of the casing with a clean, damp lint-free cloth.

- Check the condition of the filter cartridge, replace the cartridge if necessary.

- Refit the cartridge and the cover.

2

☞

1

B1/2

WARNING: Do not clean the dry air filter cartridge by washing it in liquid and do not clean by any means the safety cartridge located inside the filter cartridge.

☞ 3

4

B2 - CHECK THE HYDRAULIC AND TRANSMISSION OIL LEVEL

This operation is to be carried out when the truck is standing B2 on level ground , with engine stopped , telescopic booms retracted and completely lifted.

To check this level, refer to the gauge 1 (see Fig.B2) the oil level is correct when it is at the half of the gauge. If necessary add oil until level is correct (see chapter “OILS GREASES - LIQUIDS - FUEL - FILTERS).

Always maintain the oil level at maximum as cooling depends on the oil flowing through the tank when the truck is operating.

1

Page

40

INTRODUCTION MVT 665 T

OPERATOR MANUAL B3 - CLEAN THE RADIATOR

B3

➠

To prevent the radiator from clogging, it must be cleaned with a jet of compressed air from the front towards the back (fig. B3).

This is the only way to clean off the debris.

B4 - CHECK THE BRAKE OIL LEVEL

Place the truck on level ground.

- Remove filler cap 1 (fig. B4).

- The level is correct when it is at the maximum level.

- If necessary , add oil (see chapter : SERVICING SCHEDULE) by the filler port.

B4

WARNING: If the brake oil level is abnormally low, consult your dealer.

1 B5 - GREASING LININGS OF THE BOOM This operation is to be carried out every 50 hours during the first 250 hours; then regularly every 1000 working hours.

- Extend completely the telescopic booms.

- Grease with a brush (see chapter : SERVICING SCHEDULE) the four sides of the boom (see Fig. B5).

B5 - Extend and retract several times to spread the coat of grease evenly.

- Remove the surplus of grease.

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INTRODUCTION MVT 665 T

OPERATOR MANUAL LUBRICATORS OF TELESCOPIC BOOM

To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week.

In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to 10 working hours or every day..

Clean and lubricate at the following points with grease (see chapter : SERVICING SCHEDULE) and remove the surplus.

B6 - Grease articulation pin telescopic boom 1 (fig.B6).

B7 - Grease articulation pin quick connection 1 (fig. B7).

B8 - Grease inclination cylinder pad (fig. B8/1) and head 1 (Fig. B8/2) pins.

B9 - Grease lifting cylinder pad 1 (fig. B9/1) and head pins 1 (fig. B9/2).

B10 - Grease compensation cylinder pad 1 (fig. B10/1) and head pins 1 (fig. B10/2).

B11 - Grease cab door 1 (fig. B11).

B12 - Grease front “1” (fig. B12/1) and rear “1” (fig. B12/2) wheel pivot pins.

B11

☞

1

B12/1

B12/2

1

2

1

2

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42

INTRODUCTION MVT 665 T

OPERATOR MANUAL

B6

B7

1

1

☞ B8/1

☞

☞

1

B8/2

☞

1

1

☞ B9/1

B9/2

☞

1

1

☞

B10/1

☞

B10/2

1

☞

1

1

1

☞ ☞

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43

INTRODUCTION MVT 665 T

OPERATOR MANUAL

B13 - Grease rear axle float bushes 1 et 2 (fig. B13).

☞

☞

B13

B14 - Grease drive shaft universal coupling and cross journals front axle side 1 (fig. B14/1); rear axle side 1 and 2 (fig. B14/2).

B14/1

☞

2 1

☞

☞

1

B14/2

Page

44

INTRODUCTION MVT 665 T

OPERATOR MANUAL

C - EVERY 250 HOURS SERVICE C1- CHECK AND ADJUST THE ALTERNATOR / FAN / CRANKSHAFT BELT TENSION

- Check the belt tension between the pulley of the crankshaft and the pulleys of the alternator.

- Under a normal pressure exerted with the thumb , the tension should be approximately 10 mm (0.4") (see fig. C1/1).

- Carry out adjustments if necessary.

- Untighten screws 1 and 2 (fig. C1/2) by two to three thread turns.

- Swivel the alternator assembly so as to obtain the belt tension required.

- Retighten screws 1 and 2(fig. C1/2).

- Check the belt for wear and cracks and change it if necessary.

C1/2

C1/1

C2 - CHECK THE FRONT AND REAR AXLE DIFFERENTIAL OIL LEVEL

Place the truck on level ground with the engine stopped.

- Check the front axle differential oil level.

- Remove level and filler plug 1 (fig. C2).

C2 The oil should be flush with the edge of the hole.

- If necessary , add oil (see chapter : SERVICING SCHEDULE) by the same hole.

- Repeat this operation for the rear axle differential.

1

1

OIL LEVEL PLUG

Page

45

INTRODUCTION MVT 665 T

OPERATOR MANUAL C3 - CHECK THE FRONT AND REAR WHEEL REDUCER OIL LEVEL

C3

1

☞

Place the truck on level ground with the engine stopped.

- Check the level on each front wheel reducer.

- Place level plug 1 (fig C3) in the horizontal position.

- Remove the level plug ; the oil should be flush with the edge of the hole.

- If necessary , add oil (see chapter : SERVICING SCHEDULE) by the same hole.

- Repeat the same operation on each rear wheel reducer.

OIL LEVEL PLUG

C4 C4 - CHECKING THE OIL IN THE 2 SPEED REDUCTION GEAR ON THE FRONT AXLE

Place the truck on a horizontal surface with the engine off and the oil in the reduction gear still hot.

Remove the level and filler plug 1 (fig. C4): the oil should appear at the surface of the hole.

Add oil if necessary (see “SUPPLY TABLE”) Replace and tighten the level and filling plug 1 (fig.C4).

☞

2

Page

46

INTRODUCTION MVT 665 T

OPERATOR MANUAL C5 - CHECK THE BATTERY ELECTROLYTE LEVEL

C5/1 Check the electrolyte level in each cell of the battery. If the truck is working in a high temperature environment, check the level more frequently then every 50 hours service.

- Remove cap 1 (fig. C5/1) from each cell of the battery.

- The level is correct when it is 1/2 inche above the top of the plates in the battery.

- If necessary, top up the cells with clean distilled water.

- Clean and dry caps 1 (fig. C5/1) and refit in place.

- Check the terminal connections and lightly smear them with petroleum jelly to prevent the formation of oxidation.

☞

1

CHECK THE BATTERY ELECTROLYTE DENSITY

The electrolyte density varies depending on the temperature concerned, but a minimum of 1260 at 16°C (60,8 F°) must be maintained.

In the shaded area (fig. C5/2), the battery is in a normal charge condition.

Reading above this zone indicate that the battery needs to be recharged.

The density should not vary more than 0,025 units between cells.

Check the electrolyte density in each battery cell using a hydrometer.

Do not carry out this check immediately after topping up with distilled water.

Recharge the battery for at least an hour before checking the battery electrolyte,density.

C5/2

Page

47

INTRODUCTION MVT 665 T

OPERATOR MANUAL

D - EVERY 500 HOURS SERVICE OR ONCE A YEAR D1 - DRAIN AND REPLACE THE ENGINE OIL

D1/1 D2 - REPLACE THE ENGINE OIL FILTER

Place the truck on level ground, let the engine run at idle for a few minutes, then stop the engine.

Draining the oil

1

☞

- Place a container under drain plug 1 (fig. D1/1) and unscrew the plug.

- Remove filler cap 2 (fig. D1/2) in order to ensure that the oil is drained properly.

Replacement of the filter - Remove engine oil filter 3 (fig. D1/3) ; discard the filter and the filter seal.

- Clean the filter bracket with a clean, lint-free cloth.

- Lightly lubricate the seal of the new filter.

- Install.

D1/2

ATTENTION: Tighten the oil filter by hand only and lock the filter in place by a quarter turn.

2

Filling up the oil

4

- Refit and tighten drain plug 1 (fig. D1/1).

- Fill up with oil (see chapter : SERVICING SCHEDULE) by filler port 4 (fig. D1/2).

- Wait a few minutes to allow the oil to flow into the sump.

- Start the engine and let it run for a few minutes.

- Check for possible leaks at the drain plug and the oil filter.

- Stop the engine , wait a few minutes and check the level using dipstick 5 (fig. D1/4).

- Top up the level if necessary.

5

☞

☞

3

D1/4

D1/3 Page

48

INTRODUCTION MVT 665 T

OPERATOR MANUAL

D3 - REPLACE THE DRY AIR FILTER CARTRIDGE

The air used to burn the fuel is purified by a dry air filter . It is therefore very important that the truck should never be used with the cartridge removed or damaged.

- Unscrew nut 1 (fig. D3/1) and remove cover 2 (fig. D3/1).

- Unscrew nut 3 (fig. D3/2), remove and discard filter cartridge 4 (fig. D3/2).

- Leave the safety cartridge in place.

- Clean the inside of the casing with a clean , damp lint free cloth.

- Refit the new cartridge and the cover.

In the event of the truck being used in a heavily dust laden atmosphere, see chapter : “FILTERS CARTRIDGES AND BELT” in paragraph : “ADDITIONAL AIR FILTER FOR HEAVILY DUST LADEN ATMOSPHERE”.

D4 - REPLACE THE FUEL FILTER CARTRIDGE

D3/1

2

☞

1

D3/2

Carefully clean the exterior of the filter and this bracket to prevent the dust from entering the system.

- Unscrew locking screw 1 (Fig. D4). Remove cover 2 (Fig. D4) and discard cartridge 3 (fig. D4) as well as the seals of the cartridge.

☞ 3

- Clean the inside of the filter head , using a brush immersed in a clean diesel oil.

- Refit the assembly with a new cartridge and new seals.

4

- Turn the ignition key to the first notch for electric ignition.

- Idle the engine for at least two minutes immediately after venting the air from the fuel system.

D4

3

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49

INTRODUCTION MVT 665 T

OPERATOR MANUAL

D5

D5- REPLACE THE TRANSMISSION OIL FILTER

- Cleanthe external surface of the filter.

- Remove and discard the transmission oil filter 1 (fig.D5).

- Carefully clean the filter head with a clean, lint-free cloth.

- Slighty lubricate the new seal and fit the seal on the filter.

- Fill up the new transmission oil filter with extremely clean oil (see chapter: SERVICING SCHEDULE).

- Refit the filter, making sure that the seal is correctly positioned and tighten.

- Priming the transmission pump: start the engine, allow it turn 1 or 2 seconds and stop it, repeat this operation one more time and start normally.

1

WARNING : Tighten the transmission oil filter by hand only and lock the filter in place by a quarter turn.

D6 D6 - REPLACE THE HYDRAULIC RETURN OIL FILTER CARTRIDGE

- Unscrew the four locking screws of the cover 1 (fig.D6).

- Remove the cartridge hydraulic return oil filter and fit new replacement cartridge.

- Make sure that the cartridge is correctly positioned and refit the cover 1 (fig.D6).

1

D7 D7 - REPLACE THE HYDRAULIC AND TRANSMISSION OIL VENT

Unscrew vent 1 (fig. D7) on the oil tank and replace it with a new one see ("SCHEDULE MAINTENNCE").

Screw on the new vent by hand.

1

Page

50

INTRODUCTION MVT 665 T

OPERATOR MANUAL

E1/1

E - EVERY 1000 HOURS SERVICE OR ONCE A YEAR E1 - CHANGE THE AIR FILTER SAFETY CARTRIDGE

Remove the air filter cartridge (see chapter D3).

Remove the air filter safety cartridge 1 (Fig. E1/1) and replace it with a new one.

Reassemble the kit (see chapter D3).

1

E2 - DRAIN AND REPLACE THE HYDRAULIC OIL

Place the truck on level ground with engine stopped and the telescopic booms completely retracted.

Draining the oil - Place a container under drain plug 1 (fig. E2/1) and unscrew the plug.

- Remove the filler cap 2 (fig. E2/2) in order to ensure that the oil is drained properly.

E2/1

E3 - CLEAN THE HYDRAULIC SUCTION OIL FILTER CARTRIDGE

- Disassemble the hydraulic oil filter 3 (Fig. E2/2) removing the four screws.

- Disassemble and remove the suction cartridge located on the bottom of the tank and clean it.

- Refit the cartridge.

1

☞

Filling up the oil - Refit and tighten drain plug 1 (fig. E2/1) - Fill up with the oil (see chapter : SERVICING SCHEDULE) by filler port 2 (fig. E2/2) until the oil level reaches the red mark on the level gauge 4 (fig. E3).

ATTENTION : It may be necessary to bleed the system at the inlet of pumps, if any air bubbles have formed during the draining; if so, consult your dealer.

E2/2 E3

2

4 2

3

Page

51

INTRODUCTION MVT 665 T

OPERATOR MANUAL

E4 - DRAIN AND REPLACE THE FRONT AND REAR AXLE DIFFERENTIAL OIL Place the truck on level ground with the engine stopped and the differential oil still warm.

E4

- Place a container under drain plug 1 (fig.

2 E4) and unscrew the plug.

1 1 - Remove level and filler plug 2 (fig. E4) in order to ensure that the oil is drained properly.

- Refit and tighten drain plug 1 (fig. E4).

- Fill up with oil (see chapter : SERVICING SCHEDULE) by filler port 3 (fig. E4).

- The level is correct when the oil level is flush with the edge of the hole.

- Check for any possible leaks at the drain plug.

- Refit and tighten level and filler plug 2 (fig. E4).

3 2 1

E5 - DRAIN AND REPLACE THE FRONT AND REAR WHEEL REDUCERS OIL

Place the truck on level ground with the engine stopped and the reducer oil still warm.

- Drain each front wheel reducer.

- Place drain plug 1 (fig. E5/1) in position A. - Place a container under the drain plug and unscrew the plug.

- Let the oil drain fully.

- Place drain plug in position B. - Fill up with oil (see chapter : SERVICING SCHEDULE) by filler port 1 (fig. E5/2).

- The oil level is correct when is flush with the edge of the hole.

- Refit and tighten the plug.

- Repeat this operation on each rear wheel reducer.

E5/1

E5/2

1

2

B

A

Page

52

INTRODUCTION MVT 665 T

OPERATOR MANUAL E6 - DRAIN AND REPLACE THE TRANSFER BOX OIL

E6

Place the truck on level ground with the engine stopped and differential and tranfer box oil still warm.

☞

2

1

☞

- Place a container under drain plug 1 (fig. E6) and unscrew the plug.

- Remove level and filler plug 2 (fig. E6) in order to ensure that oil is drained properly.

- Refit and tighten drain plug 1 (fig. E6).

- Fill up with oil (see chapter : SERVICING SCHEDULE) by filler port 2 (fig. E6).

- The level is correct when the oil level is flush with the edge of the hole.

- Check for any possible leaks at the drain plug.

- Refit and tighten level and filler plug 2 (fig. E6).

E7 - DRAIN AND CLEAN THE FUEL TANK

E7/1

WARNING : While carrying out these operations do not smoke or work near a flame.

Place the truck on level ground with the engine stopped.

- Place a container under the drain plug 1 (fig. E7/1) and unscrew the plug.

- Let the fuel flow and clean with ten litres of clean fuel by filler port 2 (fig. E7/2).

- Refit and tighten the drain plug 1 (fig. E7/1) .

- Fill the fuel tank with clean fuel filtered through a strainer or a clean, lint-free cloth and refit the filler plug.

- Make sure that there is a sufficient amount of fuel in the tank, turn the ignition key to the first notch for electric ignition.

- Idle the engine for at least two minutes immediately after venting the air from the fuel system.

☞

1

E7/2

2

Page

53

INTRODUCTION MVT 665 T

OPERATOR MANUAL E8 - CHANGING THE ALTERNATOR BELT/CRANKSHAFT

Place the truck on a flat surface with the engine off.

Loosen the connection screw of alternator 1 and the set screw of the belt tensioner lever 2 (Fig. E8) by 2 or 3 thread turns and rotate the position of the alternator to loosen the tension of the belt so that it can be removed from the pulleys.

Replace the belt with another one with similar features (see “FILTERING ELEMENT AND BELT TABLE”) and rotate the position of the alternator to apply the correct tension on the belt.

Tighten the set screw of the belt tensioner 2 (Fig. F8) and the alternator connection screws 1(Fig. E8).

Check the belt tension again to make sure it is still correct.

It is recommended to check the belt tension again after 20 hours of service from when the belt was replaced (see operation no. C1).

E8

E9 - CHECK THE WEAR OF THE JIB PADS

Consult your agent or dealer for these operations.

Page

54

INTRODUCTION OPERATOR MANUAL

MVT 665 T

F - EVERY 2000 HOURS SERVICE

F1 - CHECK THE VALVE CREARANCE F2 - CHECK THE INJECTORS F3 - CHECK THE ALTERNATOR AND THE STARTER MOTOR F4 - CHECK THE TURBOCOMPRESSOR

Consult your dealer for these operations.

Page

55

INTRODUCTION MVT 665 T

OPERATOR MANUAL

ELECTRICAL SYSTEM STARTER

The starter is mounted on the left side of the engine, and no maintenance is required other than to ensure that the terminals are kept clean and secure. Should the starter not function correctly , contact your dealer.

ALTERNATOR

The alternator is mounted on the left side of the engine . The alternator and integral regulator are designed to operate in a system which is polarized in one direction only, therefore it is necessary to take the folllowing precautions when working on the battery charging circuit, otherwise serious damage may be caused to the electrical equipment.

- Do not operate the alternator with an open circuit, always ensure the connections are secure.

- It is important that the cable terminals at the rear of the alternator are tight when the engine is running otherwise damage will be caused to the alternator.

- When installing a battery , ensure that the connections are correclty polarized. It is essential that the cable marked (+) is connected to the positive (+) terminal of the battery, and that the cable marked (-) is connected to the negative (-) terminal on the battery and to earth.

- When using a second battery to assist engine starting, always connect terminals of similar polarity (voir fig.A). Any battery used in this way must be of the same voltage as that fitted to the truck.

- When using an external battery charger, always connect the charger positive (+) lead to the positive (+) terminal of the battery, and the negative lead (-) to the negative (-) terminal, and disconnect the battery earth lead.

- Never short circuit or connect the alternator terminals to earth.

- Never reverse the connections to the alternator terminals.

- Do not remove or replace any electrical system connections while engine is running.

- When carrying out electrical welding operations on the truck, connect the negative lead from the welding equipment to the part being welded so that high tension current does not pass through the alternator , and disconnect the battery.

fig.A

Page

56

INTRODUCTION MVT 665 T

OPERATOR MANUAL

FUSES AND RELAY BOX The electric circuit is protected by fuses located in the fuses box under the dashboard cover “1” (Fig. B).

To change a fuse removbe it and replace it with a new one that has the same quality and rating.

If no power is present, check all fuses and verify if a short-circuit has been generated.

Do not try to repair a fuse that has burned.

Fig. B

☞

1

➠ 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

E1

E2

E3

E4

E5 E11

E7

E8

E9

E10

➩

E6

➩ Page

57

INTRODUCTION MVT 665 T

OPERATOR MANUAL

DESCRIPTION OF THE FUSES FUNCTION IN THE BOX SITUATED UNDER THE COVER OF THE DASHBOARD REF.

AMPERE

DESCRIPTION

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19

7,5 5 3 7,5 5 15 10 7,5 10 10 7,5 10 10 Diodo 10 7,5 10 10 10

F20 F21 F22 F23 F24 F25 F26 F27 F28

5 5 10 10 15 25 10 15 7,5

Horn Instrument, indicator lights check Power supply with key-switch, unused Brake lights Direction indicator lights Electric ventilation fan Front windscreen wiper Rear and top windscreen wipers Available for additional front working lights Anti-tipping solenoid valve Rotating flashing light Available for additional rear axle lock Available for additional rear working lights Unused Power supply with key-switch, unused Engine cut-out Gear lever and respective solenoid valves Available for additional levelling solenoid valves Boom extension and optional operation solenoid valves + respective control buttons Front rh and rear lh side-lights Front lh and rear rh side lights Dipped headlights Full-beam headlights Conditioner Direct power supply, unused Emergency lights + ceiling light Available for extra basket Cooling fan speed solenoid valve

DESCRIPTION OF THE RELE FUNCTION IN THE BOX SITUATED UNDER THE COVER OF THE DASHBOARD REF.

CHARACTERISTICS

DESCRIPTION

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10

20/30 Ampere 20/30 Ampere 20/30 Ampere 20/30 Ampere 20/30 Ampere 20/30 Ampere 20/30 Ampere 20/30 Ampere 20/30 Ampere 12 Volt 42/46 Watt

Ignition enabling Forward travel Reverse travel unused unused unused unused Cooling fan speed Parking brake indicator light Direction indicator/emergency light intermittence unit

Page

58

INTRODUCTION OPERATOR MANUAL

MVT 665 T

LIGHTING

Ablown bulb must be changed immediately .

Do not handle a new bulb with bare or dirty fingers, because any traces of grease , oil or sweat, evaporate when the bulb is hot and then stain the reflector.

Never touch or attempt to polish the reflector. Only open the headlamp when changing the bulb.

BATTERY

The efficiency of the battery is progressively reduced as the ambient temperature falls and ceases to function as of - 40° C (-40° F).

Do not attempt to use the starter if the battery has been exposed to temperatures in the order of - 29° C (-20° F) the battery should be warmed before attempting this by immersing it in warm water up to 5 cm below the cell caps.

If the temperature is very low , remove the battery from the truck and store in a warm environment until the battery is required for use.

Page

59

. . . . .

F10 .

F11 .

F12 .

Horn (tab.2) Reverse travel warning beeper (tab.3) 12 volt battery (tab.1) Lights and horn control lever (tab.2) Gear lever (tab.3) 4 amp diode (tab.7) Ignition enabling relay Forward travel relay Reverse travel relay Relay: unused Relay: unused Relay: unused Relay: unused Cooling fan speed relay Parking brake indicator light relay Direction indicator/emergency light intermittence unit (tab.3) Conditioner relay Step-by-step operation switching relay Fuse 7.5A : Horn (tab.2) Fuse 5A : Instrumentation + indicator light check (tab.1) Fuse 3A : Power supply with key-switch, unused (tab.2) Fuse 7.5A : Brake lights (tab.1) Fuse 5A : Direction indicator lights (tab.2) Fuse 15A : Electric ventilation fan (tab.4) Fuse 10A : Front windscreen wiper(tab.4) Fuse 7.5A : Rear and top windscreen wipers (tab.4) Fuse 10A : Available for additional front working lights (tab.6) Fuse 10A :Anti-tipping solenoid valve (tab.4) Fuse 7.5A : Rotating flashing light (tab.5) Fuse 10A :Available for additional rear axle lock (tab.6)

F13 . Fuse 10A :Available for additional rear working lights (tab.6) F14 . Diode 1A :Unused (tab.6) F15 . Fuse 10A :Power supply with key-switch, unused (tab.2) F16 . Fuse 7.5A :Engine cut-out (tab.6) F17 . Fuse 10A :Gear lever and respective solenoid valves (tab.3) F18 . Fuse 10A :Available for additional levelling solenoid valves (tab.5) F19 . Fuse 10A :Boom extension and optional operation solenoid valves + respective control buttons (tab.6) F20 . Fuse 5A :Front rh and rear lh side-lights (tab.2) F21 . Fuse 5A :Front lh and rear rh side lights (tab.2) F22 . Fuse 10A :Dipped headlights (tab.2) F23 . Fuse 10A :Full-beam headlights (tab.2) F24 . Fuse 15A :Conditioner (tab.7) F25 . Fuse 25A :Direct power supply, unused (tab.2) F26 . Fuse 10A :Emergency lights + ceiling light (tab.2) F27 . Fuse 15A :Available for extra basket (tab.6) F28 . Fuse 7.5A :Cooling fan speed solenoid valve (tab.6) F29 . Fuse 80A :Master power supply (tab.1) F30 . Fuse 30A :Conditioner (tab.7) G1 . Alternator (tab.1) H1 . Hour-counter instrument (tab.1) KEY. Ignition switch (tab.1) I1 . Brake light pressure switch (tab.1) I2 . Emergency light switch (tab.2) I3 . Parking brake microswitch (tab.3) I4 . Anti-tipping microswitch (tab.4) I5 . Anti-tipping system reset switch (tab.4) I6 . Electric ventilation fan switch (tab.4) I7 . Front windscreen wiper switch (tab.4) I8 . Rear and upper windscreen-wiper switch(tab.4) . . . . . . . . . . . . . . . .

. . . . .

M1 M2 M3 M4 M5 M6 M7 P1 P2 P3 P4 P5

. . . . . . . . . . . .

L12 .

L9 .

L10 .

L11 .

I14 I15 I16 I17 I18 I19 I20 I21 L1 L2 L3 L4 L5 L6 L7 L8

I9 I10 I11 I12 I13

Rotating flashing light switch (tab.5) Fuel level switch (tab.5) Air filter pressure switch (tab.5) Engine oil pressure switch (tab.5) Max. engine water temperature thermal contact (tab.5) Brake fluid level switch (tab.5) Engine water thermo-contact (tab.6) Hydraulic fluid thermal contact (tab.6) Operation switch button (tab.6) Hydraulic movement disabling button (tab.4) Dehydrator filter pressure switch (tab.7) Thermostat thermal contact (tab.7) Conditioner switch (tab.7) Battery charge warning light (tab.1) Full-beam headlights indicator lights (tab.2) Direction indicator light pilot light (tab.3) Parking brake indicator light (tab.3) Low fuel level indicator light (tab.5) Air filter fouling indicator light (tab.5) Low engine oil pressure warning light (tab.5) Engine water maximum temperature warning light (tab.5) Low brake fluid level warning light (tab.5) Red neutral indicator light, unused (tab.5) Dark blue neutral light for lifting and swivel operations (tab.6) Green neutral light for optional and boom extension operations (tab.6) Starter motor (tab.1) Ventilation fan motor (tab.4) Windscreen-washer motor (tab.4) Front windscreen wiper motor (tab.4) Rear windscreen wiper motor (tab.4) Upper windscreen-wiper motor (tab.4) Conditioner compressor (tab.7) Rear lh stop light (tab.1) Rear rh stop light (tab.1) Rh front side-light (tab.2) Lh rear side-light (tab.2) Lh front side-light (tab.2)

OPERATOR MANUAL

F9 .

F4 F5 F6 F7 F8

F3 .

E11 .

E12 .

F1 .

F2 .

A1 .

A2 .

B1 .

D1 .

D2 .

D3 .

E1 .

E2 .

E3 .

E4 .

E5 .

E6 .

E7 .

E8 .

E9 .

E10 .

KEY TO ELECTRIC SYSTEM USERS MVT665/675 MANITOU vers. 10/1998 ( reference to drawing n.1255 )

INTRODUCTION MVT 665 T

Page

60

C : orange L : dark blue R : red Z : purple

Examples : AB0.5 = light blue/white gauge 0.5 mm2 AB = light blue/white gauge 1 mm2

B : white H : grey N : black V : green

OPERATOR MANUAL

A : light blue G : yellow M : brown S : pink

KEY TO COLOURS

P6 . Rh rear side-light (tab.2) P7 . Lh dipped head-light (tab.2) P8 . Rh dipped head-light (tab.2) P9 . Lh full-beam head-light (tab.2) P10 . Rh full-beam head-light (tab.2) P11 . Cab ceiling light (tab.2) P12 . Front lh direction indicator light (tab.2) P13 . Rear lh direction indicator light (tab.2) P14 . Front rh direction indicator light (tab.2) P15 . Rear rh direction indicator light (tab.2) P16 . Cab rotating flashing light (tab.5) P17 . Rh front clearance light (tab.2) P18 . Lh rear clearance light (tab.2) P19 . Lh front clearance light (tab.2) P20 . Rh rear clearance light (tab.2) S1 . Forward travel solenoid valve (tab.3) S2 . Reverse travel solenoid valve (tab.3) S3 . Anti-tipping solenoid valve (tab.4) S4 . Cooling fan speed solenoid valve (tab.6) S5 . Engine cut-out solenoid valve (tab.6) S6 . Optional switching solenoid valve (tab.6) S7 . Telescopic boom switching solenoid valve (tab.6) ST1 . Anti-tipping alarm instrument (tab.4) ST2 . Fuel level instrument (tab.5) T1 . Fuel level transmitter (tab.5) TR . Thermal starter (tab.1)

INTRODUCTION MVT 665 T

Page

61

2

1

Nota Bene

B1

XX

G

CHECK LAMP

CHECK LAMP

CHECK LAMP

H1

N0.5

h

HR0.5

= Connessioni con impianto cestello

M 10

H4.0

Mÿ2.5

Mÿ2.5

3/7

E1

H4.0

HR0.5nr.1

L1

24

23

50

M 10 30

7

RNnr.2

M

M1

Vÿ2.5

Vÿ2.5

19

18

P 0 1 2 3

GZ

24

58

30

M4.0

B0.5

23

R6

M2.5 15/54

B0.5

27

19

17

N0.5

21

50

LN2.5

H4.0

KEY

N0.5

22

TR

LN2.5

F2

P1 N

R

P2

F4

17

CHECK LAMP

12

CHECK LAMP

06

11

33

8

HR

10

F29

CHECK LAMP

G1

3

62

4

Page

5

CHECK LAMP 12

CHECK LAMP

28

6

N

R

R

I1

RNnr.4

N3 M2.5

N

N

Gnd

N0

N4

N2

M4.0

RNnr.2

N1

19

R4.0

OPERATOR MANUAL

13

CHECK LAMP

M 10

15

TABLE 1

INTRODUCTION MVT 665 T

18

16

14 9

1

N0

N

2

2

N

G

3

Nota Bene

P3

F20

1

XX

P4

3

63

P17

G

N

= Connessioni con impianto cestello

N

P18

HN1.5

B

G

56b

57/58

4

Page

5

0

N

G

P5

F21

VN1.5

56a

6

30

N

GN

P6

54/S

7

LN

L

N

A1

P19

54/D

GN

L

SG

8

31

N

GN

N

Z

Z

49

Z

D1

P20

RNnr.1

F3

9

F1

N

GN

13

P7

F22

F15

10

M2.5

N

HN

P8

F25

11

N3

N

HN

P9

F23

RB

F26

12

M4.0

N

VN

P11

0

P10

1

13

LN

N

VN

N

P12 N

LN

N

L

SG

B

B

VN0.5nr.1

02

L2

RN

08

GR

RB

F5

CHECK LAMP 14

CHECK LAMP

N2

15

R4.0

P13

I2

16

N1

N

LN

P14

17

N

L

P15

N2 M4.0

N0

N6 SG

N

N5 GR

L

N1

19

R4.0

OPERATOR MANUAL

18

TABLE 2

INTRODUCTION MVT 665 T

1

N0

SG

N6

C

SG

+

GR

N

2

Nota Bene

L0.5

XX

1 0 2

E10

3/11

M0.5

F17

E2

BV

= Connessioni con impianto cestello

N

L3

L0.5nr.1

03

N

31

CHECK LAMP

09

L0.5

R

FLASHER LIGHT

GR

CHECK LAMP

3

64

4

Page

5

N5

D2

6

RNnr.2

1/6

7

M4.0

E1

AB0.5

AB 09

3/13

E3

SM0.5

02 01

10

N2

LR

LR

I3 SB

N

GH

N

HV

S2

3/9

3/5

16

E3

12

E2

S1

BV

13

N4

9

N

HV

A2 3/18

SB

E9

N

C0.5

25

N

3/16

E9

C0.5

L4

N0

N4

RNnr.2

RNnr.2

N2

19

M4.0

OPERATOR MANUAL

16

CHECK LAMP 17

TABLE 3

INTRODUCTION MVT 665 T

18

15

14

11 8

1

N0

N

BN

XX

06

S3

CN1.5

I18

Nota Bene

AG1.5

2

0

N

ALLARM

BN

CN

ST1

RNnr.2

AG1.5

= Connessioni con impianto cestello

05

1

RN1.5

N

CN

I5

M2

2 1 0

7

I4

4

65

5

Page

3

RN1.5

N

M

SN

SN

8

RN1.5

MN

MN

RNnr.6

B

B

RNnr.6

9

F6

N

B

I6 2

1

M3

11

10

6

F10

0

N

M

BG

12

RNnr.2

M4

V

N

M

AG

13

N4

N

V

I7

F7

RNnr.7

14

M4.0

1

0

2

M5

RNnr.8

VB

GM

N

M

F8

16

M6

HL

N

M

CB

N

VB

I8

N

N0

N35 G

N2 N4

19

RNnr.2

M4.0

OPERATOR MANUAL

17

N2

18

TABLE 4

INTRODUCTION MVT 665 T

15

66

1

RNnr.2

N

N0

XX

F18

Nota Bene

M4.0

2

N2

3

Page

P16

0

N

AB

AB

N

I9

AB0.5

= Connessioni con impianto cestello

1

RNnr.11

CHECK LAMP GH0.5

GH0.5

L10

CHECK LAMP S0.5

26

N

S

S

9

29

7

I10

L5

RNnr.2

N

T1

MB

CHECK LAMP H0.5

32

11

RNnr.2

10

N0.5

N

H

H

I11

L6

RNnr.2

12

MB

CHECK LAMP BR0.5

30

13

L

I12

BR

BR

L7

RNnr.2

GV0.5

31

t

ST2

14

CHECK LAMP 15

RNnr.2

I13

GV

GV

L8

RNnr.2

16

F11

4

CHECK LAMP GL0.5

35

N0.5

I14

GL0.5

GL0.5

L9

RNnr.2

N

M4.0

N0

N2

OPERATOR MANUAL

5

N4

17

TABLE 5

INTRODUCTION MVT 665 T

19

18 8

6

1

F28

Nota Bene

N

N0

2

M4.0

6/7

XX

3

67

t

t

= Connessioni con impianto cestello

N

I15

N

ZV

I16

6

ZV

Rÿ2.5 12

N

CR

6/3

S4

E8

04

9

7

03

N

M

S5

6/16

F12

6/13

HB

E12

I19

RN

11

F9

F13

N

LB

L11

6/11

E12

RN

N

HZ

L12

1

S7

RG1.5nr.1

0

6/18

1

N

5

E7

6/11

E12

RN

9

10

I28

17

F14

10

F19

13

F27

F16

15

E8

4

Page

5

N2

16

N

S6

RG1.5

RG1.5

N

6/16

E7

RN

N

M4.0

N0

N2

OPERATOR MANUAL

18 8

TABLE 6

INTRODUCTION MVT 665 T

19

14

12

INTRODUCTION MVT 665 T

HYDRAULIC MANOEUVERING SYSTEM

OPERATOR MANUAL

Page

68

INTRODUCTION OPERATOR MANUAL

MVT 665 T

KEY TO HYDRAULIC MANOEUVERING SYSTEM A CSD CSP D FA FR M P PA R VC VI VL VT SM EVS CPD PI MC LS

= = = = = = = = = = = = = = = = = = = =

Accumulator Lock double valve Lock valve Directional control valve Suction filter Exhaust filter Manipulator Pump Optional connection Oil tank Compensation cylinder Tilting cylinder Lifting cylinder Extension cylinder Valve for telescope and option control Movements cut solenoid valve Locking and balancing valve Hydrostatic pump Brake pump Load sensig signal

Page

69

INTRODUCTION MVT 665 T

HYDRAULIC STEERING - BRAKE SYSTEM

OPERATOR MANUAL

Page

70

INTRODUCTION OPERATOR MANUAL

MVT 665 T

KEY TO HYDRAULIC STEERING - BRAKE SYSTEM CS CFS D D3 FA FDAV FDAR FR P PD PF RFS PI (G) S R

= = = = = = = = = = = = = = =

Steering cylinder Parking brake cylinder Directional control valve Steering control valve Suction filter Front axle disc brake Rear axle disc brake Exhaust filter Boom movements pump Steering pump Brake pump Parking brake lever Hydrostatic pump Brake oil tank Oil tank

Page

71

INTRODUCTION MVT 665 T

HYDRAULIC TRANSMISSION AND FAN SYSTEM

OPERATOR MANUAL

Page

72

INTRODUCTION OPERATOR MANUAL

MVT 665 T

KEY TO HYDRAULIC TRANSMISSION AND FAN SYSTEM M R FA FR PI MI MV PV SC VI RFS PF

= = = = = = = = = = = =

Perkins engine Oil tank Suction filter Exhaust filter Variable displacement hydrostatic pump Variable displacement hydrostatic motor Fan engine Fan pump Radiator Inching valve Parking brake lever Brake pump

Page

73

INTRODUCTION