AEG COMPETENCE 5003 F- Manuals

1-6 INSTRUCTIONS FOR THE OPERATOR PREAMBLE WHENEVER YOU SEE THIS SYMBOL IT MEANS: WARNING ! BE CAREFUL ! YOUR SAFETY OR THE SAFETY OF THE LIFT TRUCK IS AT RISK. The risk of accident while using, servicing or repairing your lift truck can be restricted if you follow the safety instructions and safety...

1-8 OPERATING INSTRUCTIONS UNLADEN AND LADEN A - BEFORE STARTING THE LIFT TRUCK - Carr y out daily maintenance (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE).- Make sure the lights, indicators and windscreen wipers are working properly.- Make sure the rear view mirrors are in good condi...

1-14 500 mm B1 B2 1 2 3 C INSTRUCTIONS FOR HANDLING A LOAD A - CHOICE OF ATTACHMENTS - Only attachments approved by MANITOU can be used on its lift trucks.- Make sure the attachment is appropriate for the work to be done (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE).- If the lift truck is ...

1-21 PLATFORM OPERATING INSTRUCTIONS For PLATFORM-fitted lift trucks Installation of the platform on the lift truck is only possible if the shields “operating the platform” of the lift truck and the platform are identical (see: 2- DESCRIPTION: OPERATING THE PLATFORM). A - AUTHORISATION FOR USE - Ope...

1-23 INSTRUCTIONS FOR USING THE RADIO-CONTROL For lift trucks with RC radio control HOW TO USE THE RADIO-CONTROL SAFETY INSTRUCTIONS- This radio-control consists of electronic and mechanical safety elements. It cannot receive commands from another transmitter because the internal encoding is unique ...

1-24 MAINTENANCE INSTRUCTIONS OF THE LIFT TRUCK GENERAL INSTRUCTIONS - Ensure the area is suf ficiently ventilated before star ting the lift truck.- Wear clothes suitable for the maintenance of the lift truck, avoid wearing jeweller y and loose clothes. Tie and protect your hair, if necessar y. - St...

1-25 WELDING - Disconnect the batter y before any welding operations on the lift truck.- When carr ying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the par t being welded, so as to avoid high tension current passing through the alternator. -...

1-26 IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME INTRODUCTION The following recommendations are intended to prevent the lift truck from being damaged when it is withdrawn from ser vice for an extended period.For these operations, we recommend the use of a MANITOU protective product, referenc...

1-27 BRINGING THE LIFT TRUCK BACK INTO SERVICE - Remove the waterproof adhesive tape from all the holes.- Refit the intake hose.- Refit and reconnect the batter y.- Remove the protection from the cylinder rods.- Per form the daily ser vice (see: 3 - MAINTENANCE: A - DAILY OR EVERY 10 HOURS SERVICE)....

2-4 «EC» DECLARATION OF CONFORMITY 1) DÉCLARATION «CE» DE CONFORMITÉ (originale) «EC» DECLARATION OF CONFORMITY (original) 2) La société, The company : MANITOU BF 3) Adresse, Address : 430, rue de l’Aubinière - BP 10249 - 44158 - ANCENIS CEDEX - FRANCE 4) Dossier technique, Technical file : MANITOU ...

2-6 IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement of our products, our range of telescopic lift trucks may undergo cer tain modifications, without obligation for us to advise our customers. When you order par ts, or when you require any technical information, al...

2-8 CHARACTERISTICS MT 1440 E3 I.C. ENGINE Type PERKINS 1104D-44TA RP52117 Fuel Diesel Number of cylinders 4 in line Suction Supercharged Injection system Direct Ignition sequence 1.3.4.2 Capacity cm3 4400 Bore and stroke mm 105 x 127 Compression ratio 18,2/1 Nominal rating loaded rpm 2200 Rating sl...

2-12 FRONT AND REAR TIRES MT 1440 E3 PRESSURE (bar) TYRE LOAD (kg) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN DUNLOP 440/80-24 T37 158B TUBELESS 4,5 2700 6300 2900 1250 GALAXY 15.5-25 16PR GIRAFFE L2 5,2 MICHELIN 400/80-24 162A8 TUBELESS 5 MITAS 15.5-25 12PR EM-20 TUBELESS 4,6 PRESSION (bar) ...

2-14 DIMENSIONS AND LOAD CHART MT 1440 E3 A mm 1200 B mm 3070 C mm 1905 C1 mm 1790 D mm 6135 D1 mm 6020 D2 mm 4872 E mm 7335 F mm 1960 F1 mm 1960 G mm 384 G1 mm 367 G2 mm 380 G3 mm 355 H ° 9 H1 ° 9 I mm 1160 J mm 892 K mm 1040 L mm 50 N mm 1855 O mm 125 P2 ° 34 P3 ° 33 R mm 3779 S mm 8615 T mm 4183 ...

2-18 INSTRUMENTS AND CONTROLS 5 8 31 10 36 9 13 11 8 12 2 35 32 33 35 26 26 41 1 2 3 4 6 7 14 15 17 17 17 17 18 19 20 23 24 24 24 24 24 25 25 25 27 28 29 30 34 16 21 22 37

2-19 DESCRIPTION 1 - DRIVER’S SEAT2 - SAFETY BELT3 - IGNITION SWITCH4 - EMERGENCY STOP BUTTON5 - BATTERY CUT-OFF6 - MAN-MACHINE INTERFACE (MMI) 6A - DRIVER PRESENCE6B - INSTRUMENT CONTROL PANEL6C - PANEL FOR BUTTONS AND KEYBOARD6D - SCREEN DISPLAY 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVIC...

2-24 2 - SAFETY BELT - Sit correctly on the seat.- Check that the seat belt is not twisted.- Place the seat belt at hip level.- Attach the seat belt and check that it locks.- Adjust the seat belt to your body shape without squeezing your hip and without over-slack. In no event should the lift truck ...

2-25 6 - MAN-MACHINE INTERFACE (MMI) 6A - DRIVER PRESENCE6B - INSTRUMENT CONTROL PANEL6C - PANEL FOR BUTTONS AND KEYBOARD6D - SCREEN DISPLAY UPDATED: In order to gain maximum advantage from the Man-Machine Inter face of your lift truck, contact your dealer to receive the most recent available versio...

2-27 GEAR BOX OIL TEMPERATURE LAMP This lamp comes on when the temperature of the gear box oil is abnormally high. In this case, place the for ward/reverse selector in neutral and let the I.C. engine running at idle for a few minutes. If the lamp remains on, stop the lift truck and contact your deal...

2-30 LOCKING HYDRAULIC CONTROLS HYDRAULIC CONTROLS AVAILABLE (by default) TILT CONTROL LOCKED HYDRAULIC CONTROLS LOCKED When driving on the road, it is strongly recommended that you lock all hydraulic movements. - Press the button to display the other available mode(s), the first screen displayed is...

2-31 HOUR METER SCREEN Operator present in the cab. The screen displays the total number of hours worked [888888h], the number of hours for that working day [888.88h] and the number of hours before the next major maintenance [888h]. RESETTING THE DAILY WORKING HOURS COUNTER BACK TO ZERO- Authorizati...

2-36 7 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE This device warns the operator of the lift truck’s longitudinal stability limits. However, lateral stability can reduce the load char t in the upper par t, and this reduction is not detected by the device.According to the type of work requir...

2-38 8 - SWITCHES A - OPTION WORKING TAIL LIGHTS B - OPTION WORKING LIGHTS ON JIB C - OPTION FOR ROOF WINDSCREEN WIPER AND WINDSCREEN WIPER This switch, when set in the “high” position, allows the windscreen wiper to be worked and with the “down” position pressed, the windscreen-washer to be operate...

2-39 F11 - Cigar lighter (10A).F12 - Front windscreen wiper and windscreen washer (15A).F13 - Rear windscreen wiper and windscreen washer (10A).F14 - OPTION.F15 - OPTION.F16 - OPTION Working lights on jib (15A).F17 - OPTION Working tail light (15A).F18 - OPTION Rear window de-icing (15A).F19 - OPTIO...

2-40 11 - DOOR PRESENCE SENSORS See: 2 - DESCRIPTION: 6 - MAN-MACHINE INTERFACE (MMI) 12 - LIGHTER 13 - HANDLE FOR OPENING ENGINE HOOD 14 - SWITCH FOR LIGHTING, HORN AND INDICATORS The switch controls the visual and sound alarms. A - All lights are of f, the direction indicators do not flash.B - The...

2-41 17 - HYDRAULIC CONTROLS Authorisation for using the hydraulic controls is given by the validation of the driver’s presence (see: 2 - DESCRIPTION: 6 - MAN-MACHINE INTERFACE (MMI)) and if the conditions for using the hydraulic control are followed. Do not attempt to alter the hydraulic system pre...

2-42 20 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION When operating this control, the lift truck should be travelling at slow speed and not accelerating. FORWARD: Push the switch for ward (position A).REVERSE: Push the switch backward (position B). Reversing lights and an acoustic reversing alarm indica...

2-46 TOWING PIN AND HOOK Located at the rear of the lift truck, this device is used to attach a trailer. Its capacity is limited for each lift truck by the authorized gross vehicle weight, tractive ef for t and maximum ver tical force on the coupling point. This information is given on the manufactu...

2-48 DESCRIPTION AND USE OF THE OPTIONS 1 - NUMBER PLATE LIGHTING2 - PREHEATING ELEMENT3 - FINTRONIC ANTI-START SYSTEM4 - MODCLE ANTI-START SYSTEM5 - ELECTRICAL PROVISION ON JIB6 - QUICK-RELEASE COUPLER ON ATTACHMENT CIRCUIT7 - ANGULAR SECTOR ON JIB8 - EXTERIOR DRAIN-BACK9 - HYDRAULIC ATTACHMENT LOC...

2-49 3 - FINTRONIC ANTI-START SYSTEM OPERATION - Switch on the lift truck and set the black key A next to the antenna B (maximum 80 mm). - Wait a few seconds for red LED C to go out before star ting the lift truck. NOTE: You can restar t the lift truck within 20 seconds of stopping it: after this ti...

2-50 8 - EXTERIOR DRAIN-BACK Enables connection of an attachment for which drain-back is required. MT 1440 E3 A - Fixed position, drain back not connected.B - Movable position, drain back connected. 9 - HYDRAULIC ATTACHMENT LOCKING Enables the attachment to be locked onto the carriage and a hydrauli...

2-51 11 - JIB HEAD ELECTROVALVE + HYDRAULIC ATTACHMENT LOCKING The addition of these two options on the attachment line allows two hydraulic functions to be used and locks the attachment onto the carriage. ATTACHMENT LINE L1 CONTROL - Set valve 1 to position A.- Push button 2 for ward or backward. A...

2-52 3 2 3 2 L1 L1 L2 L2 B A 1 L2 L2 L1 L1 2 WITH JIB HEAD ELECTROVALVE TSDL LINE L1 CONTROL - Push button 2 for ward to move sideways to the right, and backward to move sideways to the left. ATTACHMENT LINE L2 CONTROL - Hold down button 3 and push button 2 for wards or backwards. WITH JIB HEAD ELEC...

2-53 14 - LIFTING RING ON SINGLE CARRIAGE CONDITIONS OF USE Follow the instructions given in your lift truck’s instruction manual (see:1 - OPERATING AND SAFETY INSTRUCTIONS ON HANDLING LOADS), inaddition to those given below. - The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS, but the ang...

3-4 MANITOU ORIGINAL SPARE PARTS AND EQUIPMENT OUR LIFT TRUCKS MUST BE SERVICED USING ORIGINAL MANITOU PARTS. IF YOU USE PARTS WHICH ARE NOT ORIGINAL MANITOU PARTS, YOU RISK - Legally - to be held responsible in the event of an accident. - Technically - to generate operating failure or shor ten the ...

3-6 I.C. ENGINE I.C. ENGINE OIL FILTERPar t number: 476954Change: 500 H ALTERNATOR BELTPar t number: 702974 DRY AIR FILTER CARTRIDGEPar t number: 563416Clean: 50 H*Change: 500 H* ALTERNATOR BELT(OPTION AIR CONDITIONING)Par t number: 286931 SAFETY DRY AIR FILTER CARTRIDGEPar t number: 563415Change: 1...

3-8 I.C. ENGINE ORGANS TO BE LUBRICATED CAPACITY RECOMMENDATION PACKAGING PART NUMBER I.C. ENGINE 10,9 Liters MANITOU OilAPI CH4 5 l 20 l55 l 209 l 1000 l 661706582357582358582359490205 COOLING CIRCUIT 20 Liters Cooling liquid(protection - 25°) 2 l5 l 20 l 210 l 788245788246788247788248 Cooling liqu...

3-10 SERVICING SCHEDULE (1): MANDATORY 500 HOUR OR 6 MONTH SERVICE This service must be carried out after approximately the first 500 hours of operation or within the 6 months following the star t-up of the machine(whichever occurs first). A = ADJUST, C = CHECK, G = GREASE, N = CLEAN, P = BLEED, R =...

3-12 A - DAILY OR EVERY 10 HOURS SERVICE A1 - I.C. ENGINE OIL LEVEL CHECK Place the lift truck on level ground with the I.C. engine stopped, and let the oil drain into the sump. - Open the I.C. engine bonnet.- Remove the dipstick 1 (fig. A1).- Clean the dipstick and check the correct level between t...

3-13 A5 - CYCLONIC PRE-FILTER CLEAN The cleaning inter val is given as a guide, however the prefilter must be emptied as soon as impurities reach the MAXI level on the tank. - Loosen nut 1 (fig. A5), remove cover 2 (fig. A5) and empty the tank.- Clean the prefilter unit with a clean dr y cloth and r...

3-14 A9 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE CHECK - These tests are essential for checking the correct operation and adjustment of the dif ferent components of the device.- Place the lift truck on flat, level ground with the wheels straight. In case of doubt during the test procedure...

3-16 B - EVERY 50 HOURS SERVICE Carry out the operations described previously as well as the following operations. B1 - DRY AIR FILTER CARTRIDGE CLEAN In case of use in a heavily dust laden atmosphere, there are pre-filtration car tridges (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS). Also, t...

3-17 B4 - HYDRAULIC OIL LEVEL CHECK Place the lift truck on level ground with the I.C. engine stopped, and the jib retracted and lowered as far as possible. - Check dipstick 1 (fig. B4/1). The correct level must stand at the level of the red point.- If necessar y, add oil (see: 3 - MAINTENANCE: LUBR...

3-18 B7 - CAB VENTILATION FILTER CLEAN EXTERNAL CAB VENTILATION FILTER - Lift out cabin ventilation filter 1 (fig. B7/1).- Clean the filter with a compressed air jet.- Check its condition and change if necessar y (see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS). - Put the filter back into place....

3-20 C - EVERY 250 HOURS SERVICE Carry out the operations described previously as well as the following operations. C1 - ALTERNATOR BELT TENSION CHECK - ADJUST - Open the I.C. engine bonnet.- Unscrew the fastening screws 1 (fig. C1/1).- Lay down the protective guard 2 (fig. C1/1).- Check the belt fo...

3-21 C4 - OUTER JIB CHAINS CLEAN - GREASE - CHECK MT 1840 E3 CLEAN AND GREASE - Set the lift truck on its stabilizers, with the jib horizontal.- Fully extend the telescopes.- Protect the underside of the telescopes.- Wipe the chains on the outside of the jib 1 (fig. C4/1) with a clean, lint-free clo...

3-22 C5 - CAB VENTILATION FILTERS CHANGE EXTERNAL CAB VENTILATION FILTER- Remove protective casing 1 (fig. C5/1) using the switch key. - Lift out cab ventilation filter 2 (fig. C5/2) and replace it with a new one (see: 3 - MAINTENANCE: FILTERS AND BELTS). - Refit the protective casing. INTERNAL CAB ...

3-24 D - EVERY 500 HOURS SERVICE Carry out the operations described previously as well as the following operations. D1 - I.C. ENGINE OIL DRAIN D2 - I.C. ENGINE OIL FILTER CHANGE Place the lift truck on level ground, let the I.C. engine run at idle for a few minutes, then stop the I.C. engine. DRAINI...

3-25 D3 - DRY AIR FILTER CARTRIDGE CHANGE In case of use in a heavily dust laden atmosphere, there are pre-filtration car tridges, see: 3 - MAINTENANCE: FILTERS CARTRIDGES AND BELTS. Also, the checking and cleaning periodicity of the car tridge must be reduced (up to 250 hours in a heavily laden dus...

3-26 D6/1 1 D6/2 2 3 D6/3 4 D6/4 5 6 D6/5 7 D5 - FUEL FILTER CARTRIDGE CHANGE Make sure the electrical contact on the lift truck is cut, otherwise fuel will be released if the lift pumpis on. - Open the engine hood.- Carefully clean the outside of the filter and its holder, to prevent dust from gett...

3-27 D7 - FRONT AND REAR AXLE DIFFERENTIAL OIL DRAIN Place the lift truck on level ground with the I.C. engine stopped and the dif ferential oil still warm. Dispose of the drain oil in an ecological manner. - Place a container under drain plugs 1 (fig. D7) and unscrew the plugs.- Remove level plug 2...

3-28 E - EVERY 1000 HOURS SERVICE Carry out the operations described previously as well as the following operations. E1 - FUEL TANK CLEAN E2 - FUEL TANK BREATHER CHANGE While carrying out these operations, do not smoke or work near a flame. Place the lift truck on level ground with the I.C. engine s...

3-29 E4 - GEAR BOX OIL DRAIN E5 - GEAR BOX OIL FILTER CHANGE Place the lift truck on level ground with the I.C. engine stopped, the gear box oil still warm. DRAINING THE OIL - Remove clutch housing cover 1(fig. E4/1).- Place a container under drain plug 2 (fig. E4/2) and unscrew it.- Remove dipstick...

3-30 E6 - JIB OUTER CHAIN WEAR CHECK MT 1840 E3 Chain wear occurs at a number of locations. On the ar ticulations, which leads to elongation of the chain. On the edge of link plates through contact with the pulleys. On the face of the plates and the extended pins through contact with the pulley flan...

3-31 E7 - HYDRAULIC OIL DRAIN E8 - HYDRAULIC OIL TANK BREATHER CHANGE E9 - SUCTION STRAINER FOR HYDRAULIC OIL TANK CLEAN E10 - BRAKE ACCUMULATOR UNIT FILTER CHANGE Place the lift truck on level ground with the I.C. engine stopped and telescope jib retracted and lowered as far as possible. Before any...

3-32 E11 - SEAT BELT CHECK SEAT BELT WITH TWO ANCHORING POINTS- Check the following points: • Fixing of the anchoring points on the seat.• Cleanness of the strap and the locking mechanism.• Triggering of the locking mechanism.• Condition of the strap (cuts, curled edges). REELED SEAT BELT WITH TWO A...

3-34 F - EVERY 2000 HOURS OF SERVICE Carry out the operations described previously as well as the following operations. F1 - COOLING LIQUID DRAIN These operations are to be carried out if necessar y or ever y two years at the beginning of winter. Place the lift truck on level ground with the I.C. en...

3-36 G - EVERY 4000 HOURS OF SERVICE Carry out the operations described previously as well as the following operations. G1 - JIB INNER CHAIN WEAR CHECK MT 1840 E3 THE CHECKING OF THE JIB INNER CHAINS REQUIRES THE TELESCOPES TO BE DISASSEMBLED (CONTACT YOUR DEALER). Chain wear occurs at a number of l...

3-38 H - OCCASIONAL MAINTENANCE H1 - FUEL SYSTEM BLEED These operations are to be carried out only in the following cases: • A component of the fuel system replaced.• A drained tank.• Running out of fuel. Ensure that the level of fuel in the tank is suf ficient and bleed in the following order: - Op...

3-39 H3 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE RESET According to the use of the lift truck, the device may require to be periodically reset.This operation can be easily per formed by means of the following procedure.- Provide a fork carrier or a bucket and a load corresponding to at le...

3-40 H4 - FRONT HEADLAMPS ADJUST RECOMMENDED SETTING (as per standard ECE-76/756 76/761 ECE20) Set to - 2 % of the dipped beam in relation to the horizontal line of the headlamp. ADJUSTING PROCEDURE - Place the lift truck unloaded and in the transpor t position and perpendicular to a white wall on f...

3-42 H8 - LIFT TRUCK ON A PLATFORM TRANSPORT Ensure that the safety instructions connected to the platform are respected before the loading of the lifttruck and that the driver of the means of transpor t is informed about the dimensions and the weight ofthe lift truck (see: 2 - DESCRIPTION: CHARACTE...

4-6 PICKING UP THE ATTACHMENTS A - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE TAKING UP AN ATTACHMENT - Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessar y precautions in order to move it safely. - Chec...

4-7 B - HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE TAKING UP AN ATTACHMENT - Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessar y precautions in order to move it safely. - Check that the locking pin and the cli...

4-8 TECHNICAL SPECIFICATIONS OF ATTACHMENTS FLOATING FORK CARRIAGE TFF 45 MT-1040 TFF 45 MT-1300 PART NUMBER 653344 653345 Rated capacity 4500 kg 4500 kg Width 1040 mm 1300 mm Weight 370 kg 400 kg FLOATING FORK SIDE-SHIFT CARRIAGE Use is prohibited with the optional single side-shift carriage (TSDL)...

4-14 FORK PROTECTOR PART NUMBER 227801 ATTACHMENT SHIELDS BUCKET PROTECTOR NOTE: Always ensure that the width of the protector you choose is less than or equal to the width of the bucket. PART NUMBER 206734 206732 206730 Width 1375 mm 1500 mm 1650 mm PART NUMBER 235854 206728 206726 Width 1850 mm 19...