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101.200

17

Q

3

Fork lift truck “MANITOU”

Part No 41

Cut out pattern 4 . Centre punch and drill the holes. Finally cut out

the slots with a Junior hacksaw. Clean up all edges of the slots

with a needle file

Part Nr:40

Cut out the sides according to patterns No 2 and 3 and drill the 3mm holes

Fold using a vice with soft jaws

View from underneath

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Summary of Contents for MANITOU 101.200

Page 1: ...g children They are teaching aids for young people learning the skills of Craft Design and Technology These projects should only be underta ken and tested with the guidance of a fully qualified adult...

Page 2: ...led strip 5x15 x 105mm 7 holes 1 Fork coupling 21 Steel holed strip 1x45 3holes 2 Forks 22 Steel holed strip 1x15x250mm 1 Fork drive 23 Plastic double gear 30 10 Red brown 1 Motor R20 24 Metal 1 Motor...

Page 3: ...es Nuts M3 Plastic washer Metal axles 3 x 70 mm Distance pieces Join to gear part 4 Double gears 50 10 White grey Loose fit Parts No 6 17 The exploded diagram shows the construction of right hand moto...

Page 4: ...ith a file Mark out and drill the 2 diameter in the holed metal strip Hold the holed metal strip up to the bottom line in a vice See diagram And twist the top half Upper line with a pair of pliers fir...

Page 5: ...ts Part Nr 31 and contra tighten them so that the holders swivel Part Nr 5 To fit the two small wheels as shown Insert the machine screw M3 x25 Part Nr 29 and washer Part Nr 30 from the inside through...

Page 6: ...ly between the two rear axle holders Join both welding rods together in a connector block lightly tighten Hook the eye at the end of rod through the 2mm dia hole in the axle holder Tighten the loop af...

Page 7: ...r 6 Mount the one motor and gearbox and wheel assembly with 2 machine screws Part No 28 and nuts Part No 31 in the 10th row of holes and 3 holes from the edge 2 Carry out the same Procedure with the s...

Page 8: ...101 200 7 Fork lift truck MANITOU Finished chassis with wheels and gearboxes...

Page 9: ...2 Cut the fork assembly to length Use the machine screws M4x 8 Part Nr 23 M4 nuts and domed nuts Part Nr 34 and 35 join them to part 20 See sheet 9 Part Nr 21 Cut off a piece 45mm long from a remainin...

Page 10: ...1 200 9 Fork lift truck MANITOU Assembling the fork Machine screw M4 x 8 Part Nr 33 Machine screw M4 x 8 Part Nr 33 Nuts M4 Part Nr 34 Nuts M4 Part Nr 34 Domed nut Part Nr 35 Front view View from behi...

Page 11: ...saw Part Nr 18 In drive direction Mount the right hand fork guide Part Nr 18 in the first row of holes in the 3rd or fourth hole in from left Fix with two nuts M4 Part Nr 34 as shown in diagram Z Moun...

Page 12: ...side Part 19 Mount the fork drive Part 19 in the middle between the two fork guides From underneath place a washer Part 30 and lock with two M3 nuts Part 31 Part Nr 23 Finally from above place a wash...

Page 13: ...on the motor shaft Part Nr 25 Mount the motor and gear so that the worm gear engages lightly with the Fork drive gear Fix the motor in position with the metal loop holder Part Nr 25 and two machi ne s...

Page 14: ...ITOU Part Nr 35 Part Nr 32 Part Nr 20 22 Mount the completed fork assembly Turn the worm by hand so that the fork assembly lowers by about a centimetre Finally add a domed nut to the tops of the guide...

Page 15: ...hold them in position with tape or glue Cut out the shapes with metal snips along the thicker lines In patterns 1 and 4 along with the contour lines other inner cuts must be made Along the thickened l...

Page 16: ...200 15 1 2 7 3 4 6 5 8 10 9 Fork lift truck MANITOU Use folding bars or a vice for accuracy View from underneath Part 39 After cutting out pattern 1 Motor cover fold the metal sheet along the broken l...

Page 17: ...e edges as shown using vice or folding bars The small short folds can be folded with pliers Part Nr 43 Cut out the pattern 5 from the metal sheet Bend using a vice Use soft jaws at an angle of 80 degr...

Page 18: ...ntre punch and drill the holes Finally cut out the slots with a Junior hacksaw Clean up all edges of the slots with a needle file Part Nr 40 Cut out the sides according to patterns No 2 and 3 and dril...

Page 19: ...r 39 and 41 To fit the bodywork you will need to loosen the nuts on the fork guides where they join the chassis Holed metal sheet Now mount the bodywork Slide one part under the loosened nuts and adju...

Page 20: ...x nuts and dome nuts on the 4 pillars Part Nr 44 Now hold the roof and pillars in position on the bodywork and mark the four holes Centre punch an drill the four 4 mm holes Add another set of M4 Part...

Page 21: ...101 200 20 Fork lift truck MANITOU Part Nr 37 Finally fix the seat using double sided tape Part Nr 37 Use the second pad to fix the battery Use double sided tape...

Page 22: ...for the switches 7 5mmdia and file out the long shaped hole Pattern A page 22 Finally bend the U shaped form Use a hot air gun or strip heater Attention N B be careful of burns Glue the switches with...

Page 23: ...101 200 22 1 2 3 4 5 6 7 8 Fork lift truck MANITOU drill 7 5 mm Pattern A The broken lines denotes folds The thick lines represent the outer shape of the pattern Vergr erung des Verdrahtungsplans...

Page 24: ...24 D101200 1...

Page 25: ...101 200 23 Q3 Q3 Fork lift truck MANITOU The broken lines denotes folds The thick lines represent the outer shape of the pattern Pattern 2 Pattern 3 Pattern 1...

Page 26: ......

Page 27: ...101 200 24 Q 4 R 3 Fork lift truck MANITOU Pattern 6 Pattern 4 Pattern 5 The broken lines denote folds The thicker lines represent the outer shape of the pattern...

Page 28: ......

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