Manitou MC 18-2 D K ST5 S1 Operator's Manual
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Manitou MC 18-2 D K ST5 S1 Operator's Manual

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647837
EN-USM1 A052020
MC 18-2 D K ST5 S1
MC 18-4 D K ST5 S1
OPERATOR'S MANUAL
(ORIGINAL INSTRUCTIONS)

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  • Page 1 647837 EN-USM1 A052020 MC 18-2 D K ST5 S1 MC 18-4 D K ST5 S1 OPERATOR'S MANUAL (ORIGINAL INSTRUCTIONS)
  • Page 2 - Descriptions and figures are non binding. - MANITOU reserves the right to change its models and their equipment without being required to update this manual. - The MANITOU network, consisting exclusively of qualified professionals, is at your disposal to answer all your questions.
  • Page 3 MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be...
  • Page 4 1 - OPERATING AND SAFETY INSTRUCTIONS 2 - DESCRIPTION 3 - MAINTENANCE 4 - OPTIONAL ATTACHMENTS FOR USE WITH THE RANGE...
  • Page 5 1 - OPERATING AND SAFETY INSTRUCTIONS 1 - 1...
  • Page 6 1 - 2...
  • Page 7 1 - 3...

  • Page 8: Table Of Contents

    1 - OPERATING AND SAFETY INSTRUCTIONS INSTRUCTIONS TO THE COMPANY MANAGER THE SITE THE OPERATOR THE LIFT TRUCK A - THE TRUCK'S SUITABILITY FOR THE JOB ............1-6 B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS .
  • Page 9 IF THE LIFT TRUCK IS NOT TO BE USED FOR A LONG TIME 1-18 INTRODUCTION 1-18 PREPARING THE LIFT TRUCK 1-18 DEF (Diesel Exhaust Fluid) TANK 1-18 PROTECTING THE ENGINE 1-18 PROTECTING THE LIFT TRUCK 1-18 BRINGING THE LIFT TRUCK BACK INTO SERVICE 1-19 LIFT TRUCK DISPOSAL 1-20...

  • Page 10: Instructions To The Company Manager

    A - THE TRUCK'S SUITABILITY FOR THE JOB - MANITOU has ensured that this lift truck is suitable for use under the standard operating conditions defined in this operator's manual, with a STATIC TEST COEFFICIENT OF 1.33 and a DYNAMIC TEST COEFFICIENT OF 1, as specified in harmonised standard ISO 3691-1 for mast trucks.

  • Page 11: C - Modification Of The Lift Truck

    - Our lift trucks comply with Directive 2004/108/EC concerning electromagnetic compatibility (EMC), and with the corresponding harmonised standard EN 12895. Their correct operation is no longer guaranteed if they are used within areas in which the electromagnetic fields exceed the limit specified by this standard (10 V/m). - Directive 2002/44/EC requires company managers to not expose their employees to excessive vibration doses.

  • Page 12: Instructions To The Operator

    Failure to respect the safety and operating instructions, or instructions for repairing or servicing your lift truck, may lead to serious, even fatal accident. In order to reduce or avoid any danger with a MANITOU-approved attachment, follow the instructions of paragraph: 4 - ADAPTABLE ATTACHMENTS AVAILABLE ON THE RANGE: INTRODUCTION.

  • Page 13: Operating Instructions Unladen And Laden

    OPERATING INSTRUCTIONS UNLADEN AND LADEN A - BEFORE STARTING THE LIFT TRUCK - Perform the daily maintenance operations (  3 - MAINTENANCE). - Make sure that the driver's cab is clean, particularly the floor and floor mat. Check that no movable objects can hinder operation of the lift truck.

  • Page 14: D - Visibility

    - Never stack loads on uneven ground, they may tip over. - The load or the attachment must not be left just above a structure for long periods at a time because of the descending mast. In such a case, a constant watch must be kept and the height of the forks or the attachment readjusted if necessary. - When working near aerial lines, ensure that the safety distance is sufficient between the working area of the lift truck and the aerial line.

  • Page 15: F - Driving The Lift Truck

    F - DRIVING THE LIFT TRUCK SAFETY INSTRUCTIONS IMPORTANT The operators' attention is drawn to the risks involved in using the lift truck, in particular: - Risk of losing control. - Risk of losing lateral and frontal stability of the lift truck. The operator must remain in control of the lift truck.

  • Page 16: G - Stopping The Lift Truck

    G - STOPPING THE LIFT TRUCK SAFETY INSTRUCTIONS - Never leave the ignition key in the lift truck during the operator's absence. - When the lift truck is stationary, or if the operator has to leave his cab (even for a moment), place the forks or attachment on the ground, apply the parking brake and place the forward/reverse selector in neutral.

  • Page 17: Instructions For Handling A Load

    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 (  4 - ADAPTABLE ATTACHMENTS AVAILABLE ON THE RANGE).

  • Page 18: D - Picking Up A Load On The Ground

    D - PICKING UP A LOAD ON THE GROUND - Approach the lift truck perpendicular to the load, with the forks in a horizontal position (fig. D1). - Adjust the fork spread and centring in connection with the load (fig. D2) (optional solutions exist, consult your dealer).
  • Page 19 - Slightly raise the load (1) and tilt the carriage (2) backwards to stabilise the load (fig. F3). - Tilt the load sufficiently backwards to ensure its stability. - Reverse the lift truck (1) very carefully and gently to free the load. Lower the mast (2) to bring the load into transport position (fig.

  • Page 20: Lift Truck Maintenance Instructions

    LIFT TRUCK MAINTENANCE INSTRUCTIONS GENERAL INSTRUCTIONS - Ensure the area is sufficiently ventilated before starting the lift truck. - Wear clothes suitable for the maintenance of the lift truck, avoid wearing jewellery and loose clothes. Tie back and protect your hair, if necessary. - Before carrying out any work on the lift truck: •...

  • Page 21: Welding

    WELDING - Disconnect the battery before any welding operations on the lift truck. - When carrying out electric welding work on the lift truck, connect the negative cable from the equipment directly to the part being welded, so as to avoid high tension current passing through the alternator. - Never carry out welding or work which gives off heat on an assembled tire.
  • Page 22 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 service for an extended period. IMPORTANT Procedures to follow if the lift truck is not to be used for a long time and for starting it up again afterwards must be performed by your dealership. This period of long-term stoppage must not exceed 12 months.
  • Page 23 BRINGING THE LIFT TRUCK BACK INTO SERVICE - Remove the waterproof adhesive tape from all the holes. - Refit and reconnect the battery. - Remove the protection from the cylinder rods. - Perform the daily maintenance operations ( 3 - MAINTENANCE). - Put the handbrake on and remove the axle stands.
  • Page 24 • Glass items can be removed and collected for processing by glaziers. ENVIRONMENTAL PROTECTION By entrusting the maintenance of your lift truck to the MANITOU network, the risk of pollution is limited and the contribution to environmental protection contribution is made.
  • Page 25 2 - DESCRIPTION...
  • Page 27 2 - DESCRIPTION DECLARATION CE OF CONFORMITY SAFETY PLATES AND STICKERS IDENTIFICATION OF THE LIFT TRUCK SPECIFICATIONS MC 18-2... SPECIFICATIONS MC 18-4... MAST CHARACTERISTICS AND LOAD CHARTS TYRES INSTRUMENTS AND CONTROLS SLINGING AND SECURING PIN...
  • Page 28 430, rue de l’Aubinière - BP 10249 - 44158 - ANCENIS CEDEX - FRANCE NCENIS CEDEX Dossier technique, Technical file MANITOU BF - 430, rue de l’Aubinière e l’Aubinière BP 10249 - 44158 - ANCENIS CEDEX - FRANCE EDEX - FRAN Constructeur de la machine décrite ci-après,...
  • Page 29 bg : 1) удостоверение за « СЕ » съответствие (oригинална), 2) Фирмата, 3) Адрес, 4) Техническо досие, 5) Фабрикант на описаната по-долу машина, 6) Обявява, че тази машина, 7) Отговаря на следните директиви и на тяхното съответствие национално право, 8) За машините към допълнение IV, 9)Номер на удостоверението, 10) Наименувана фирма, 15) хармонизирани...
  • Page 30 SAFETY PLATES AND STICKERS IMPORTANT Clean all stickers and safety plates so that they are legible. Any safety plates and stickers which are illegible or damaged must be replaced. Check that stickers and safety plates are present after replacing any spare parts. EXTERNAL PLATES AND STICKERS REF.
  • Page 31 EFFEKTIVE KAPAZITÄT EFFEKTIVE KAPAZITÄT CAPACIDAD EFECTIVA CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA CAPACITÀ EFFETTIVA N° 52563320 N° 52563320 N°234802 N° 234798 N°52515083 MANITOU BF 44158 ANCENIS CEDEX FRANCE MODELE MODELLO SERIE SERIE MODEL MODELO SERIES SERIE Année de fabrication Anno di fabbricazione Année modèle...
  • Page 32 "Modèle" Model "N° de série" Serial number "N° de moteur thermique" Engine number HYDROSTATIC PUMP "Référence" MANITOU Part no. "Type de codification" Type of codification "N° série" Serial number "N° de fabrication" Manufacturing number "Année de fabrication" Year of manufacture...
  • Page 33 "N° de moteur" Engine number "N° de fabrication" Manufacturing number "Année de fabrication" Year of manufacture OVERHEAD GUARD / CAB "Constructeur" Manufacturer "Type Cabine" Cabin type "Numéro de série" Serial number MASTS WITH ROLLERS Part No. MANITOU FRAME Serial number/Product identification number...
  • Page 34 NOTE: The specifications given are not binding on the manufacturer and can be modified without prior notification. 1.1 Manufacturer MANITOU 1.2 Model type / Serial no. MC 18-2 D K ST5 S1 1.3 Propulsion: battery, diesel, petrol, LPG, mains Diesel 1.4 Type of operation: manual, pedestrian, standing, seated Seated 1.5 Rated capacity/load on forks...
  • Page 35 5.1 Speed of travel laden km/h 5.1.1 Speed of travel unladen (2RM / 4RM) km/h 23.5 / - 5.2 Speed of rise laden 0.44 5.2.1 Speed of rise unladen 0.44 5.3 Speed of lowering laden 5.3.1 Speed of lowering unladen 5.5 Nominal towing power laden 1020 5.5.1 Nominal towing power unladen...
  • Page 36 MC 18-4... NOTE: The specifications given are not binding on the manufacturer and can be modified without prior notification. 1.1 Manufacturer MANITOU 1.2 Model type / Serial no. MC 18-4 D K ST5 S1 1.3 Propulsion: battery, diesel, petrol, LPG, mains Diesel 1.4 Type of operation: manual, pedestrian, standing, seated...
  • Page 37 5.1 Speed of travel laden km/h 5.1.1 Speed of travel unladen (2RM / 4RM) km/h 23.5 / 13 5.2 Speed of rise laden 0.44 5.2.1 Speed of rise unladen 0.44 5.3 Speed of lowering laden 5.3.1 Speed of lowering unladen 5.5 Nominal towing power laden 1860 5.5.1 Nominal towing power unladen...
  • Page 38 MAST CHARACTERISTICS AND LOAD CHARTS LIFTING MAST FREE LIFT HEIGHT OF MAST TILTING MC 18-2 D K ST5 S1 MC 18-4 D K ST5 S1 h1 (mm) h4 (mm) FRONT MISCELLANEOUS h3 (mm) h2 (mm) lowered extended α (°) β (°)
  • Page 39 VALUES ON FORKS VALUES WITH INTEGRATED SIDESHIFT ATTACHMENT Height at max. capacity Capacity at max. height Height at max. capacity Capacity at max. height (mm) CoG at 500 mm (kg) (mm) CoG at 500 mm (kg) 3300 1800 3300 1800 3300 1800 3300...
  • Page 40 TYRES FRONT PRESSURE (bar) MC 18-2 D MC 18-4 D LOAD PER TYRE (kg) PRESSURE SOLIDEAL/ 12,5/80-18/12 SL R4 Front unladen CAMSO Front laden 2250 2250 PRESSURE CONTINENTAL 275/80R20 14PR Front unladen Front laden 2250 2250 PRESSURE ALIANCE 300/75 R18 A580 Front unladen Front laden 2250...
  • Page 41 GROUND CONTACT PRESSURE GROUND CONTACT AREA (kg/cm2) (cm2) PRESSURE LOAD (bar) (kg) HARD GROUND SOFT GROUND HARD GROUND SOFT GROUND 12,5/80-18/12 SL R4 2250 SOLIDEAL/CAMSO 7.00-12/12 ED PLUS 27x10-12 14PR SKS ALIANCE 300/75 R18 A580 2250 15.5/55 R18 DUNLOP 2250 MPT SPPG7 14PR 12.5/80-18 TL12 2250...
  • Page 42 INSTRUMENTS AND CONTROLS NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are as seen by an observer occupying the driver's seat and looking straight ahead. DESCRIPTION (standard) 1 - DRIVER'S CAB ACCESS................2-20 2 - DRIVER'S SEAT .
  • Page 43 2-19...

  • Page 44: Description (Standard)

    DESCRIPTION (standard) 1 - DRIVER'S CAB ACCESS - Getting into and out of the driver's cab. - Use the three support points provided. 1 - Left handle. 2 - Steering wheel. 3 - Driver's cab floor. 2 - DRIVER'S SEAT ADJUSTING WEIGHT (FIG.

  • Page 45: Steering Wheel Adjustment Lever

    4 - STEERING WHEEL ADJUSTMENT LEVER - Pull the handle (1) to adjust the steering wheel. - Push in the handle (1) to lock the steering wheel in the desired position. 5 - DASHBOARD HANDSET SIGNAL LIGHTS IMPORTANT With the engine running, a permanently lit or flashing warning lamp is the sign of an operating fault. If any of the warning lamps comes on while the lift truck is in motion, stop the lift truck under the safest possible conditions.
  • Page 46 HYDRAULIC RETURN OIL FILTER CLOGGING LAMP If the indicator lamp comes on, switch off the engine and replace the filter cartridge (  3 - MAINTENANCE). NOTE: This lamp may come on when starting the forklift truck, and it should go off when the hydraulic oil reaches its operating temperature.

  • Page 47: Switches

    MULTIFUNCTION SCREEN FORWARD/NEUTRAL/REVERSE INDICATOR FORWARD/NEUTRAL/REVERSE GEAR SELECTION INDICATOR LIGHTS AND WARNING INDICATORS LIGHTING, INDICATOR AND HORN SWITCH SWITCHES MAIN BEAM INDICATOR SWITCHES GENERAL FAULT INDICATOR The indicator lamp is accompanied by an error code on the display. Contact your dealer. 500H MAINTENANCE INDICATOR The indicator lamp is accompanied by the time remaining or the time elapsed on the display.
  • Page 48 C - REV COUNTER 10-level LED display from 0 to 3,500 rpm IMPORTANT The red zone from 3,000 to 3,500 rpm must be avoided at the risk of damaging the engine. D - MULTIFUNCTION SCREEN NAVIGATION MENU SCROLL BUTTON NOTE: By default, when the lift truck is started, the screen displays the last selection made by the operator. •...
  • Page 49 6 - SWITCHES NOTE:  The location of the switches may vary depending on the options. A - PARKING BRAKE The parking brake has 3 functions (brake on/automatic/released): - Press the top of the switch to apply the brake . The red indicator lamp on the top of the switch will come on together with the dashboard indicator lamp.

  • Page 50: Horn

    D - SWITCHING BETWEEN 4WD (low speed) <-> 2WD (high speed) Only for MC . . -4 D When starting the lift truck, low speed (14 km/h - 4RM) is automatically selected. - Press the top of the switch for 2 seconds to activate fast speed (24 km/h - 2RM) .

  • Page 51: Emergency Stop

    9 - EMERGENCY STOP - Press the button (1) to stop the lift truck. - Turn the button to unlock the emergency stop. 10 - ACCELERATOR PEDAL 11 - BRAKE AND "INCHING" TRANSMISSION CUT-OFF PEDAL This pedal operates in two steps: •...

  • Page 52: Forward/Neutral/Reverse Gear Selection

    13 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION When changing the direction of travel, the lift truck should be travelling at slow speed and not accelerating. To start the lift truck, the switch must be in neutral. A - FORWARD GEAR - Press the front of the switch. B - REVERSE GEAR - Press the back of the switch.

  • Page 53: Battery Cut-Off

    17 - BATTERY CUT-OFF Enables the battery to be rapidly cut off from the electric circuit in the event of a short circuit or a fire. 18 - 12V SOCKET NOTE: As an option there is a reading light for a 12 V socket. 19 - DOCUMENT CLIP 20 - DOCUMENT STORAGE NET Make sure that the operator’s manual is in the right place, i.e.

  • Page 54: Fuses And Relays

    23 - FUSES AND RELAYS - Open the engine cover (  INSTRUMENTS AND CONTROLS). - Remove the air filter cover (1) and the cartridge. - Loosen the screws and remove the cover (2) from the fuse and relay box. Fuses IMPORTANT Replace the faulty fuse with a new fuse with the same rating.
  • Page 55 Engine ECU (power) F39 20A Air flow meter sensor Fuel pump. F40 10A 12V permanent (option 2) F50 50A Engine preheat Free F52 50A 12V permanent Free Relay Starter Flashing unit (option) +BAT Engine preheat General power supply Intermittent windscreen wiper (option) Engine ECU Air intake management Fuel pump...

  • Page 56: Description (Option)

    DESCRIPTION (option) 24 - DRIVER'S SEAT DRIVER'S SEAT "CLASSIC“ DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS. WEIGHT ADJUSTMENT (FIG. A) It is advised that the weight be adjusted when the driver is not sitting in the cab. - Refer to the graduation (1) of the seat.
  • Page 57 EXTENDING THE HEAD-REST (FIG. E) - The height of the head-rest can be adjusted by pulling it upwards (the notches will click) up to the stop. - The head-rest can be removed by applying sufficient pressure to pull it off the stop. LUMBAR ADJUSTMENT (FIG.
  • Page 58 “PREMIUM” DRIVER'S PNEUMATIC SEAT DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS. WEIGHT ADJUSTMENT (FIG. A) Adjust the weight when the driver is sitting on the seat. - Pull the weight adjustment lever (1) fully out. - Move the weight adjustment lever (1) upwards to increase the weight or downwards to reduce it.
  • Page 59 “ÉLITE” DRIVER'S PNEUMATIC SEAT NOTE: Do not operate the pneumatic compressor for more than 1 minute. WEIGHT ADJUSTMENT (FIG. A) - Sit on the seat. - Switch on lift truck ignition. - Pull or push the thumb wheel (1) until the green area appears in the indicator lamp (2). SEAT HEIGHT ADJUSTMENT (FIG.
  • Page 60 LUMBAR ADJUSTMENT (FIG. F) - Turn the handle either left or right to adjust the height and depth to the desired position. ADJUSTMENT OF THE ANGLE OF THE BACKREST (FIG. G) - Support the backrest, pull the lever and tilt the backrest to find the desired position. HORIZONTAL SHOCK ABSORBER (FIG.

  • Page 61: Hydraulic Controls For Additional Attachments

    25 - HYDRAULIC CONTROLS FOR ADDITIONAL ATTACHMENTS IMPORTANT In the event of a malfunction, consult your dealer. For your own safety, do not attempt to alter the hydraulic pressure in the system. ANY MODIFICATION WILL INVALIDATE THE WARRANTY. The hydraulic controls must be used carefully without jerking, to avoid accidents caused by shaking the lift truck.

  • Page 62: Hydraulic Control Joystick

    TILTABLE CARRIAGE AND HYDRAULIC ATTACHMENT LOCKING option IMPORTANT If the attachment's hydraulic locking equipment is used, make sure that the attachment is properly locked onto the tiltable carriage before use. WITHOUT ADDITIONAL HYDRAULIC ATTACHMENT B1 - OPTIONAL 3RD HYDRAULIC LINE (TILTABLE CARRIAGE) B2 - OPTIONAL 3RD HYDRAULIC LINE (TILTABLE CARRIAGE) WITH MORE THAN ONE HYDRAULIC ATTACHMENT - Press button C on lever B to select the attachment AUX.1 or AUX.2:...
  • Page 63 HYDRAULIC CONTROLS WITH MORE THAN ONE HYDRAULIC ATTACHMENT C1 - OPTIONAL 3RD HYDRAULIC LINE (AUX.1) C2 - OPTIONAL 3RD HYDRAULIC LINE (AUX.1) D1 - OPTIONAL 4TH HYDRAULIC LINE (AUX.2) D2 - OPTIONAL 4TH HYDRAULIC LINE (AUX.2) TILTABLE CARRIAGE option C1 - OPTIONAL 3RD HYDRAULIC LINE (AUX.1 - TILTABLE CARRIAGE) C2 - OPTIONAL 3RD HYDRAULIC LINE (AUX.1 - TILTABLE CARRIAGE) D1 - OPTIONAL 4TH HYDRAULIC LINE (AUX.2) D2 - OPTIONAL 4TH HYDRAULIC LINE (AUX.2) E + D1 - ...
  • Page 64 FORWARD/NEUTRAL/REVERSE GEAR SELECTION When changing the direction of travel, the lift truck should be travelling at slow speed and not accelerating. To start the lift truck, the switch must be in neutral. A - FORWARD - Push the switch forwards. B - REVERSE - Pull the switch backwards.

  • Page 65: Load Suspension

    27 - LOAD SUSPENSION The purpose of this option is to damp lifting and lowering of the load. 28 - DECOMPRESSION OF THE HYDRAULIC ATTACHMENT CIRCUIT (CS) The purpose of this option is to easily connect a hydraulic attachment: 1 - Sit in the seat. 2 - Switch off the engine.

  • Page 66: Lighting, Horn And Indicator Light Control

    30 - LIGHTING, HORN AND INDICATOR LIGHT CONTROL ROAD LIGHTS The road lights can be used without the ignition key. • A - Off. • B - Front and rear side lights. • C - Dipped beam headlights. • D - Main beam headlights. •...

  • Page 67: Front Worklights

    32 - FRONT WORKLIGHTS NOTE: As an option there is a guard for the front worklights. 33 - REAR WORKLIGHTS NOTE: As an option there is a guard for the rear worklights. 34 - REVERSING LIGHT 35 - ROTATING BEACON LIGHT OR LED FLASHING LIGHT The magnetic rotating beacon light can be fitted by disconnecting plug A.

  • Page 68: Cab Option

    37 - CAB OPTION DOOR OPENING HANDLES - Insert the ignition key into lock A to lock or unlock the cab. - Pull on the handle B or C to open the door. NOTE: The door must be: • Either closed. •...

  • Page 69: Heating Vents

    38 - HEATING VENTS 39 - HEATER CONTROL • A - Temperature adjustment. • B - Ventilation speed adjustment. 40 - CAR RADIO 41 - ENGINE IMMOBILISER SYSTEM 42 - WATERPROOF DOCUMENT HOLDER 2-45...

  • Page 70: Reversing Buzzer Alarm

    43 - REVERSING BUZZER ALARM 44 - ROOF SUNSHADE 45 - LOCKABLE CAP 46 - ENGINE BLOCK HEATER Enables the engine block to be kept warm during prolonged periods of stoppage and thus improves engine starting. SUPPLY CHARACTERISTICS OF PREHEATING SYSTEM: •...
  • Page 71 2-47...
  • Page 72 SLINGING AND SECURING PIN IMPORTANT This lift truck is not intended for use with a trailer. This device is used only for slinging and lashing the lift truck (  3 - MAINTENANCE - OCCASIONAL OPERATION). IF NECESSARY, CONSULT YOUR DEALER. 2-48...
  • Page 73 3 - MAINTENANCE 3 - 1...
  • Page 74 3 - MAINTENANCE ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FORKLIFT TRUCK MAINTENANCE DAILY AND WEEKLY MAINTENANCE MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE PERIODIC SERVICE OCCASIONAL MAINTENANCE AND OPERATION FILTER CARTRIDGES AND BELTS LUBRICANTS AND FUEL 3-10  10H - DAILY SERVICE OR EVERY 10 HOURS OF SERVICE 3-12  50H - ...
  • Page 75 • Efficient help with diagnosis. • Improvements due to experience feedback. • Operator training. • Only the MANITOU network has detailed knowledge of the design of the lift truck and therefore the best technical ability to provide maintenance. IMPORTANT ORIGINAL REPLACEMENT PARTS ARE DISTRIBUTED EXCLUSIVELY BY MANITOU AND ITS DEALER NETWORK.
  • Page 76 This schedule enables the operator to keep up with the periodic service of the lift truck by notifying the total number of hours of operation and the date of the service performed by the professional approved by the MANITOU network.
  • Page 77 MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE FIRST 500 HOURS BEFORE THE FIRST 6 MONTHS - If the lift truck has reached the first 500 hours of service before the first 6 months have expired, perform both the mandatory service and routine 500 H service  ...
  • Page 78 PERIODIC SERVICE MAINTENANCE SCHEDULE 500 H 1000 H 1500 H 2000 H WHEN DUE FIRST 6 MONTHS FIRST 500 HOURS or 1 YEAR or 2 YEARS or 3 YEARS or 4 YEARS MANDATORY SERVICE PERIODIC SERVICE MANDATORY SERVICE MACHINE COUNTER DATE OF SERVICING 2500 H 3000 H 3500 H...
  • Page 79  1000H -PERIODIC SERVICE - EVERY 1,000 HOURS OF SERVICE OR 2 YEARS ALSO CARRY OUT THE PERIODIC MAINTENANCE FOR 500 HOURS OF SERVICE. - CHECK Seat belt................... . 3-26 - CLEAN Fuel tank .
  • Page 80 OCCASIONAL MAINTENANCE AND OPERATION OCCASIONAL MAINTENANCE - CLEAN "Stationary lift truck" particle filter (Regeneration)........... . 3-34 - CLEAN Driver's cab .
  • Page 81 FILTER CARTRIDGES AND BELTS  500H - PERIODIC SERVICE - EVERY 500 HOURS OF SERVICE OR 1 YEAR ENGINE OIL FILTER HYDRAULIC RETURN OIL FILTER CARTRIDGE Part no.: 272192 Part no.: 52555157 FUEL FILTER CARTRIDGE CAB INTERIOR VENTILATION FILTER (OPTION) Part no.: 52561068 Part no.: 52577675 FUEL PRE-FILTER CARTRIDGE CAB EXTERIOR VENTILATION FILTER (OPTION) Part no.: 52502539 Part no.: 52640879...
  • Page 82 USE THE RECOMMENDED LUBRICANTS AND FUEL: - For topping up, oils may not be miscible. - For oil changes, MANITOU oils are perfectly appropriate. DIAGNOSTIC ANALYSIS OF OILS If a service or maintenance contract has been set up with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use.
  • Page 83 +50 °C WHEEL REDUCTION GEAR PIVOTS MANITOU BLUE MULTI-PURPOSE LUBRICANT PACKAGING PACKAGING / PART NO. PRODUCT 20 L 55 L 209 L - MANITOU EVOLOGY OIL 10W40 API CJ4 895837 895838 895839 895840 - MANITOU ISO VG 46 HYDRAULIC OIL 545500 582297 546108...

  • Page 84: Lift Truck Environment

     10H - DAILY SERVICE OR EVERY 10 HOURS OF SERVICE CHECK Lift truck environment IMPORTANT Follow the operator instructions (  1 - OPERATING AND SAFETY INSTRUCTIONS: OPERATOR INSTRUCTIONS). - Carry out a general inspection of the lift truck: • Fluid leaks or stains on the ground. •...

  • Page 85: Coolant Level

    CHECK Coolant level Place the lift truck on level ground with the engine stopped, and allow the engine to cool. IMPORTANT To avoid any risk of spraying or scalding, wait until the engine has cooled down before removing the cooling system filler plug.

  • Page 86: Alternator Belt Tension

     50H -  WEEKLY SERVICE OR EVERY 50 HOURS OF SERVICE CHECK Alternator belt tension IMPORTANT If the compressor belt has to be changed, check the tension again after the first 20 hours of operation. - Remove the access panel 1. - Check the belt for signs of wear and cracks and change if necessary (  FILTER CARTRIDGES AND BELTS).

  • Page 87: Tension And Alignment Of Mast Lifting Chains

    CHECK Tension and alignment of mast lifting chains Place the lift truck on level ground with the mast in a vertical position and the forks raised approximately 200 mm. IMPORTANT These checks are important to ensure correct mast operation. In case of technical faults, consult your dealer. - Check the alignment of the mast lifting chains between the carriage chain fasteners and the chain rollers.

  • Page 88: Dry Air Filter Cartridge

    - Use a damp, clean, lint-free cloth to clean the surface of the cartridge seal. - Lubricate the surface of the seal with a silicone lubricant (Part No. MANITOU: 479292). - Check visually the outer condition of the air filter and its attachments.
  • Page 89 LUBRICATE General lubrication To be carried out weekly, if the lift truck has been operated for less than 50 hours during the week. IMPORTANT In the event of prolonged use in an extremely dusty or oxidising atmosphere, reduce this interval to every 10 hours of service or every day. - Clean, then lubricate the following points with grease (  LUBRICANTS AND FUEL) and remove the surplus.

  • Page 90: Engine Oil

    REPLACE Engine oil ** REPLACE Engine oil filter ** ** Only for the first 50 hours of service, and then every 500 hours of service or 1 year. NOTE: When the lift truck is first put into service, the maintenance key is lit up. The oil and oil filter must be replaced after the first 50 hours of service to abide by the guarantee.
  • Page 91 3 - 19...
  • Page 92 CHECK Hydraulic oil MANITOU offers a hydraulic oil analysis kit which makes it possible to extend the recommended interval for routine servicing (2,000 hours). In this case, we recommend an analysis of the hydraulic oil every 500 hours of service.
  • Page 93 REPLACE Engine oil REPLACE Engine oil filter Place the lift truck on level ground, let the engine run at idle for a few minutes, then stop the engine. IMPORTANT Dispose of the drain oil in an ecological manner. - Open the engine cover (  2 - DESCRIPTION - INSTRUMENTS AND CONTROLS).
  • Page 94 REPLACE Fuel pre-filter - Switch off the lift truck's ignition. - Open the engine cover (  2 - DESCRIPTION - INSTRUMENTS AND CONTROLS). - Carefully clean the outside of the pre-filter and its holder, to prevent dust from getting into the system. - Disconnect the wiring harness 1. - Place a receptacle under the plug (2).
  • Page 95 REPLACE Alternator belt IMPORTANT Check the belt tension again after the first 20 hours of operation. - Remove the access panel 1. - Loosen screws 2 by two to three thread turns. - Swivel the alternator assembly so as to free the belt 3. NOTE: Take the opportunity provided by the removal of the belt to check that the pulleys and bearings are working correctly (noise, friction, play, etc.).
  • Page 96 REPLACE Cab fan filters (OPTION) INTERIOR CAB VENTILATION FILTER - Remove the protective grid 1. - Remove the cab ventilation filter (2) and replace it with a new one (   FILTER CARTRIDGES AND BELTS). - Refit the protective grid. EXTERIOR CAB VENTILATION FILTER - Remove the floor mat.
  • Page 97 3 - 25...
  • Page 98  1000H -PERIODIC SERVICE - EVERY 1,000 HOURS OF SERVICE OR 2 YEARS ALSO CARRY OUT THE PERIODIC MAINTENANCE FOR 500 HOURS OF SERVICE. CHECK Seat belt IMPORTANT It is forbidden to use the lift truck if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the seat belt.
  • Page 99 REPLACE Engine crankcase ventilation filter - Open the engine cover (  2 - DESCRIPTION - INSTRUMENTS AND CONTROLS). - Remove the air filter 1 and its holder. - Carefully clean the outside of the filter 2 and its holder to prevent dust from getting into the system.
  • Page 100 REPLACE Coolant These operations are to be carried out as necessary or every two years at the beginning of winter. IMPORTANT The engine does not contain any anti-corrosion element and must be filled with a mixture containing 25% of ethylene glycol-based antifreeze all year round. - Place the lift truck on level ground with the engine stopped and cold.
  • Page 101 CHECK Silentblocks ** CHECK Valve lash ** CHECK Injectors ** CHECK Exhaust gas recirculation cooler "EGR" ** CHECK Condition of wiring harnesses and cables * CHECK Lights and signals * CHECK Warning indicators * CHECK Condition of the rear-view mirrors * CHECK Structure of the overhead guard or the cab * CHECK...
  • Page 102  2000H -PERIODIC SERVICE - EVERY 2,000 HOURS OF SERVICE OR 4 YEARS ALSO PERFORM THE 500 HOUR AND 1000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Wheel nut tightening torque - Check the condition of the tyres to detect cuts, blisters, wear, etc. - Check the tightening torque of the wheel nuts with a torque wrench. •...
  • Page 103 FILLING WITH OIL - Clean and refit the drain plug 1 (tightening torque 73 - 97 N.m). - Fill up with oil (  LUBRICANTS AND FUEL) through filler hole 3. - Check the oil level on the dipstick 4, the oil level should be level with the red point. - Check for any possible leaks at the drain plug.
  • Page 104  3000H - PERIODIC SERVICE - EVERY 3,000 HOURS OF SERVICE OR 6 YEARS ALSO PERFORM THE 500 HOUR AND 1,000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Exhaust gas recirculation system "EGR" ** CLEAN Exhaust particle filter "DPF" ** ** Engine service, consult your dealer. 3 - 32...
  • Page 105 3 - 33...

  • Page 106: Occasional Maintenance

    OCCASIONAL MAINTENANCE CLEAN "Stationary lift truck" particle filter (Regeneration) IMPORTANT If the indicator lamp comes on, contact your dealer. If you are performing regeneration of the particle filter during the 500-hour routine servicing, replace the engine oil after regeneration. Regeneration of the particle filter is an automated procedure activated by the operator when the following indicator lamps are displayed: MINI •...

  • Page 107: Clean

    CLEAN Driver's cab NOTE: The frequency of cleaning is given as an example. IMPORTANT Do not use a high pressure cleaner or water jet. Take precautions with electrical and electronic components. - Clean the inside of the overhead guard or the cab using a small brush, vacuum cleaner and a cloth. CLEAN Engine compartment CLEAN...

  • Page 108: Replace Wheels

    - Unlock the nuts of the wheel to be changed. REAR WHEEL For this operation, we advise you to use the hydraulic jack (MANITOU Part no.: 505507). - Place the jack under the counterweight. It must be situated in the middle and under the flat part of the counterweight.

  • Page 109: Battery

    REPLACE Battery IMPORTANT Handling and servicing a battery can be dangerous, take the following precautions: - Wear protective goggles. - Keep the battery horizontal. - Never smoke or work near a naked flame. - Work in a well-ventilated area. - In the event of electrolyte being spilled onto the skin or splashed in the eyes, rinse thoroughly with cold water for 15 minutes and call a doctor.

  • Page 110: Occasional Operation

    OCCASIONAL OPERATION Lift truck If the lift truck is on a slope, with parking brake applied, chock it so that it does not descend the slope. IMPORTANT The lift truck must be towed very slowly (less than 5 km/h) and for as short a distance as possible (less than 100 m). Use a rigid drawbar, as the lift truck is disconnected from its brake system.

  • Page 111: Sling

    SLING Lift truck - Take into account the position of the lift truck centre of gravity for lifting. A = 1030 mm B = 870 mm MC 18-2 A = 1020 mm B = 880 mm MC 18-4 - Position the hooks: • At the front, at the head of the mast, on the anchorage points 1. •...
  • Page 112 3 - 40...
  • Page 113 4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE...
  • Page 115 4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE INTRODUCTION TECHNICAL SPECIFICATIONS OF ATTACHMENTS ATTACHMENT GUARDS...
  • Page 117 A wide range of attachments is available, guaranteed by MANITOU and designed to fit your lift truck perfectly. IMPORTANT Only attachments approved by MANITOU can be used with their lift trucks (see: 4 ADAPTABLE ATTACHMENTS AVAILABLE ON THE RANGE: TECHNICAL SPECIFICATIONS OF ATTACHMENTS).
  • Page 118 TECHNICAL SPECIFICATIONS OF ATTACHMENTS Double mast with all-round vision (DVT) Double mast with free-acting lift (DLL) ***: Triple mast with free-acting lift (TLL) STANDARDISED SIDESHIFT CARRIAGE TDL 25N / L1260 PART NO. 229814 Rated capacity Sideshift - mm Width Weight STANDARDISED FORK PART NO.
  • Page 119 ATTACHMENT GUARDS FORK GUARD PART NO. 227801...

This manual is also suitable for:

Mc 18-4 d k st5 s1

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