Manitou MI 80 D ST4 S2 Operator's Manual
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Manitou MI 80 D ST4 S2 Operator's Manual

Manitou MI 80 D ST4 S2 Operator's Manual

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647651
EN (01/12/2017)
MI 80 D ST4 S2
MI 100 D ST4 S2
OPERATOR'S MANUAL
(ORIGINAL INSTRUCTIONS)

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  • Page 1 647651 EN (01/12/2017) MI 80 D ST4 S2 MI 100 D ST4 S2 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 EN 1726-1 for mast trucks.

  • Page 11: C - Modification Of The Lift Truck

    - Our trucks comply with Directive 2004/108/EC concerning electromagnetic compatibility (EMC), and with the corresponding harmonised standard EN 12895. Their proper operation is no longer guaranteed if they are used within areas in which the electromagnetic fields exceed the limit specified by that 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 IN OPTION ON THE RANGE: INTRODUCTION.

  • Page 13: Operating Instructions Unladen And Laden

    OPERATING INSTRUCTIONS UNLADEN AND LADEN A - BEFORE STARTING THE LIFT TRUCK - Carry out daily maintenance ( 3 - MAINTENANCE: 10H - DAILY MAINTENANCE). - Make sure that the driver's cab is clean, particularly the floor and floor mat. Check that no movable object may hinder the 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 Operators' attention is drawn to the risks involved in using the forklift truck, in particular: - Risk of losing control. - Risk of losing lateral and frontal stability of the forklift 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 and protect your hair, if necessary. - Stop the engine and remove the ignition key, when an intervention is necessary.

  • 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 long-term storage period 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. - Carry out daily maintenance ( 3 - MAINTENANCE: 10H - DAILY 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 «CE» DECLARATION OF CONFORMITY SAFETY PLATES AND STICKERS IDENTIFICATION OF THE LIFT TRUCK CHARACTERISTICS 2-10 CHARACTERISTICS OF MASTS WITH ROLLERS AND LOAD CHARTS 2-12 FRONT AND REAR TYRES 2-14 INSTRUMENTS AND CONTROLS 2-16...
  • Page 28 430, rue de l’Aubinière - BP 10249 - 44158 - ANCENIS CEDEX - FRANCE NCENIS CEDE ANCE Dossier technique, Technical file MANITOU BF - 430, rue de l’Aubinière l’Aubini BP 10249 - 44158 - ANCENIS CEDEX - FRANCE S CEDEX - 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...
  • Page 30 SAFETY PLATES AND STICKERS IMPORTANT Clean all of the stickers and safety plates to make them legible. It is essential to replace stickers and safety plates which are illegible or damaged. Check the presence of stickers and safety plates after replacing any spare parts. EXTERNAL PLATES AND STICKERS REF.
  • Page 31 EQUIPEMENT - ATTACHMENT ZUBEHOR - EQUIPO - ATTREZZATURA SUIVANT NORME EN 1726-1 EFFECTIVE ACTUAL EFFEKTIVE EFFECTIVA EFFETTIVA HAUTEURS EFFECTIVES CAPACITES EFFECTIVES CAPACITES EFFECTIVES ACTUAL HEIGHT ACTUAL CAPACITIES ACTUAL CAPACITIES EFFEKTIVE HOME EFFEKTIVE KAPAZITAT EFFEKTIVE KAPAZITAT ALTURA EFECTIVA CAPACIDAD EFECTIVA CAPACIDAD EFECTIVA ALTEZZA EFFETTIVA CAPACITA EFFETTIVA CAPACITA EFFETTIVA...
  • Page 32 IDENTIFICATION OF THE LIFT TRUCK As our policy is to promote a constant improvement in our products, our range of lift trucks may undergo certain modifications, without any obligation for us to advise our customers. When you order parts, or when you require any technical information, always specify: NOTE: For the owner's convenience, it is recommended that a note of these numbers is made in the spaces provided, at the time of the delivery of the lift truck.
  • Page 33 Serial no. - Month/Year FRAME Serial number / Product identification number MAST Mast identification no. ATTACHMENT MANUFACTURER'S PLATE "MODÈLE" MODEL MANITOU BF 44158 ANCENIS CEDEX "N° dans la série" Serial No. FRANCE MODELE "Année fabrication" Year of manufacture N dans la série "Masse à...
  • Page 34 CHARACTERISTICS NOTE: The specifications given are not binding on the manufacturer and can be modified without prior notification. Manufacturer MANITOU Model type MI 80 D MI 100 D Propulsion: battery, diesel, petrol, LPG, mains Diesel Type of operation: manual, pedestrian, standing, seated...
  • Page 35 Speed of travel laden (1st/2nd/3rd) 6 / 12 / 25 6 / 12 / 24 km/h Speed of travel unladen (1st/2nd/3rd) 6 / 12 / 25.5 6 / 12 / 24.5 5.1.1 km/h Speed of rise laden 0.37 0.31 Speed of rise unladen 0.39 0.33 5.2.1...
  • Page 36 CHARACTERISTICS OF MASTS WITH ROLLERS AND LOAD CHARTS NOTE: The specifications given are not binding on the manufacturer and can be modified without prior notification. 2-12...
  • Page 37 CAPACITE NOMINALE RATED CAPACITY RATED CAPACITY NENNKAPAZITÄT CAPACIDAD NOMINAL CAPACITÀ NOMINALE ACTUAL CAPACITIES CAPACITES EFFECTIVES ACTUAL CAPACITIES EFFEKTIVE KAPAZITÄT SUIVANT NORME ISO 3691-1 ISO 22915-2 CAPACIDAD EFECTIVA CAPACITÀ EFFETTIVA (according to standard EN Jusqu'à hauteur de levée 1726-1) Up to height of Bis zur hubhöhe Hasta altura de elevación Sino ad altezza di sollevamento...
  • Page 38 FRONT AND REAR TYRES PRESSURE (bar) FRONT MI 80 D ST4 S2 MI 100 D ST4 S2 TYRE LOAD (kg) PRESSURE 8.25-15-14PR unladen laden PRESSURE 8.25-15-14PR unladen laden PRESSURE SOLID SOLID 9.00-20-14PR unladen 2,590 3,395 laden 9,170 10,945 PRESSURE 9.00-20-14PR...
  • Page 39 PRESSION DE CONTACT AU SOL GROUND CONTACT AREA PRESSURE LOAD (kg/cm2) (cm2) (bar) (kg) HARD GROUND SOFT GROUND HARD GROUND SOFT GROUND 2,590 9.00-20-14PR 3,395 SOLID 9,170 10,945 2,590 9.00-20-14PR 3,395 9,170 10,945 1,100 9.00-20-14PR 1,230 SOLID 3,680 3,775 1,100 1,230 9.00-20-14PR 3,680...
  • Page 40 INSTRUMENTS AND CONTROLS DESCRIPTION NOTE: All the terms such as: RIGHT, LEFT, FRONT, REAR are as seen by an observer seated on driver's seat and looking straight ahead. 1 - DRIVER'S SEAT ..................2-18 2 - SEAT BELT .
  • Page 41 2-17...

  • Page 42: Driver's Seat

    1 - DRIVER'S 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. - Switch on lift truck ignition. - Move the switch 1 up to increase the weight or down to reduce it. - The driver's weight is correctly adjusted when the marker is in the centre of indicator 2.

  • Page 43: Steering Wheel Tilting Knob

    3 - STEERING WHEEL TILTING KNOB - Push knob 1 forwards. - Tilt the steering wheel to the desired position. - Pull the knob back to lock the steering wheel in position. 4 - IGNITION SWITCH This switch has 3 positions: •...
  • Page 44 ENGINE FAULT If the indicator lamp comes on when the lift truck is running, stop the engine then: - Seek the cause (possible leak, etc.). - Consult your dealer if necessary. DIESEL ENGINE PREHEAT The engine needs to be preheated. - Turn on the ignition, the light comes on for a few seconds, then start the engine.
  • Page 45 5B - INDICATOR LAMPS AND CONTROL INSTRUMENTS L - YELLOW INDICATOR LAMP This lamp indicates a fault with "SCR" regeneration. - Perform a "stationary lift truck" exhaust regeneration ( 3 - LIFT TRUCK MAINTENANCE). M - RED INDICATOR LAMP This lamp indicates immediate engine shutdown following a "SCR" regeneration fault. Switch off the engine immediately.

  • Page 46: Switches

    R - LIFT TRUCK SETTINGS DISPLAY "SCR" CONDITION • 1 - Diesel Exhaust Fluid "DEF"level • 2 - Soot percentage • 3 - Exhaust gas inlet temperature • 4 - Exhaust gas outlet temperature ENGINE/GEARBOX CONDITION • 1 - Engine performance •...

  • Page 47: Light And Indicator Switch

    7 - LIGHT AND INDICATOR SWITCH The switch controls the visual signals. • A - OFF, Indicators and lights switched off. • B - Right indicator lights. • C - Left indicator lights. • D - Sidelights and rear lights. •...

  • Page 48: Forward/Neutral/Reverse Gear Selection

    12 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION When changing the direction of travel, the lift truck should be travelling at slow speed (less than 2 km/h) and not accelerating. In the neutral position, a mechanical lock prevents an accidental shifting movement. The selected mode is displayed on the dashboard screen and linked to the gear selection. NEUTRAL •...

  • Page 49: Parking Brake Lever

    14 - PARKING BRAKE LEVER To prevent accidental loosening or release, the lever is fitted with safety locking. - To apply the parking brake, depress the service brake pedal and pull the lever backwards (position A). - To loosen the parking brake, press button 1 and push the lever forwards (position B). - Before moving, depress the brake pedal for a few seconds.

  • Page 50: Inside Rear-View Mirror

    19 - INSIDE REAR-VIEW MIRROR 20 - ROOF LIGHT 21 - CAB VENTILATION AIR VENTS (OPTION) 22 - DRIVER'S CAB ACCESS HANDLES 23 - DOOR OPENING HANDLES (OPTION) 24 - DOOR HANDLES (OPTION) 25 - CAB DOOR SLIDING WINDOWS (OPTION) 26 - REAR WINDOW OPENING (OPTION) 27 - WINDSCREEN WASHER TANK ACCESS PANEL 28 - ENGINE COVER OPENING...

  • Page 51: Fuses And Relays Under The Engine Bonnet

    29 - FUSES AND RELAYS UNDER THE ENGINE BONNET - Open the engine cover ( INSTRUMENTS AND CONTROLS). - Remove the cover 1 to access fuses and relays. - Use the pliers 2 to replace a faulty fuse. FUSES F3 - Engine preheat (10A). F4 - Starter (30A).

  • Page 52: Front Headlights

    - Remove the cover 3 to access fuses and relays. FUSES F1 - Front windscreen wiper (15A). F2 - Rear windscreen wiper (15A). F3 - Free (10A). F4 - Free (10A). F5 - Free (15A). F6 - Free (10A). 30 - FRONT HEADLIGHTS •...

  • Page 53: Front Windscreen Wiper (Option)

    DIESEL EXHAUST FLUID "DEF"QUALITY • The diesel exhaust fluid must comply with standard ISO 22241-1 with a urea concentration of 32.5%. • The diesel exhaust fluid "DEF"quality can be measured using a refractometer (MANITOU part no. 959709). DIESEL EXHAUST FLUID "DEF"STORAGE •...
  • Page 54 2-30...
  • Page 55 3 - MAINTENANCE 3 - 1...
  • Page 56 3 - MAINTENANCE ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FORKLIFT TRUCK MAINTENANCE DAILY AND WEEKLY MAINTENANCE MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE PERIODIC MAINTENANCE OCCASIONAL MAINTENANCE AND OPERATION FILTER CARTRIDGES AND BELTS LUBRICANTS AND FUEL 3-10 10H - DAILY SERVICING OR EVERY 10 HOURS OF SERVICE...
  • Page 57 • 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 ONLY BY MANITOU AND THE DEALER NETWORK.
  • Page 58 This schedule enables the operator to keep up with the periodic maintenance 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 59 MANDATORY FIRST 500 HOURS OR 6 MONTHS SERVICE FIRST 500 HOURS BEFORE THE FIRST 6 MONTHS - If the lift truck completes its first 500 hours of service before the first 6 months are up, carry out the mandatory service and the 500 hour periodic maintenance ( 500 HOURS - PERIODIC MAINTENANCE).
  • Page 60 PERIODIC MAINTENANCE MAINTENANCE SCHEDULE 500 H 1,000 H 1,500 H 2,000 H WHEN DUE FIRST 6 MONTHS FIRST 500 HOURS or 1 YEAR or 2 YEARS or 3 YEARS OR 4 YEARS MANDATORY SERVICE PERIODIC MAINTENANCE MANDATORY SERVICE MACHINE COUNTER DATE OF SERVICING 2,500 H 3,000 H...
  • Page 61 - CHECK Engine speeds * ............... . . 3-27 - CHECK Engine valve clearances *.
  • Page 62 OCCASIONAL MAINTENANCE AND OPERATION OCCASIONAL MAINTENANCE - REPLACE Wheels ................. 3-32 - REPLACE Battery.
  • Page 63 FILTER CARTRIDGES AND BELTS 500H - PERIODIC MAINTENANCE - EVERY 500 HOURS OF SERVICE ENGINE OIL FILTER FAN BELT Part number: 943326 Part number: 944380 FUEL FILTER ALTERNATOR BELT Part number: 942117 Part number: 944377 COMPRESSOR BELT FUEL PRE-FILTER (air-conditioning option) Part number: N50302445 Part number: HYDRAULIC RETURN OIL FILTER...

  • Page 64: Diesel Exhaust Fluid "Def"Tank

    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 organised with the dealer, a diagnostic analysis of engine, transmission and axle oils may be requested depending on the rate of use.
  • Page 65 WINDSCREEN WASHER LIQUID PACKAGING PACKAGING / PART NO. PRODUCT 1 LITRE 2 LITRES 5 LITRES 20 LITRES 55 LITRES 209 LITRES - MANITOU EVOLOGY OIL 10W40 API CJ4 895837 895838 895839 895840 - MANITOU ISO VG 32 HYDRAULIC OIL 744638 744637 744636...

  • Page 66: Lift Truck Environment

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

  • Page 67: 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 burning, wait until the engine has cooled down before removing the cooling circuit filler plug.

  • Page 68: Belt Tension

    50H - WEEKLY MAINTENANCE OR EVERY 50 HOURS OF SERVICE CHECK Belt tension IMPORTANT If the compressor belt has to be changed, check the tension again after the first 20 hours of operation. - Unscrew the thumbscrews 1 and open the cover 2. - Check the belts for signs of wear and cracking and change if necessary ( FILTER CARTRIDGES AND BELTS).

  • Page 69: Gear Box Seal

    CHECK Gear box seal Place the lift truck on level ground with the engine stopped. - Open the engine cover ( INSTRUMENTS AND CONTROLS). - Visually check for seepage and leaks. - If there are any, check the level. - Pull out and clean the dipstick 1. - Reinsert the dipstick and remove it again.

  • Page 70: Hydraulic Oil Level

    CHECK Hydraulic oil level Place the lift truck on level ground with the engine stopped, and the boom retracted and lowered as far as possible. IMPORTANT Use a clean funnel and clean the underside of the oil drum before filling. - Open the engine cover ( INSTRUMENTS AND CONTROLS).

  • Page 71: Dry Air Filter Cartridge

    Never clean the air filter security cartridge; replace it with a new one if it is dirty or damaged. - Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU part no.: 479292).

  • Page 72: Condenser Core (Option)

    CLEAN Condenser core (option) IMPORTANT In a polluting atmosphere, clean the radiator core every day. Do not use a water jet or high-pressure steam as this could damage the radiator fins. - Visually check whether the condenser is clean and clean it if necessary. - Clean the condenser using a compressed air jet aimed in the same direction as the air flow.

  • Page 73: Tension And Alignment Of The Mast Lifting Chains

    REAR AXLE • 5 - Swivel pins (4 lubricators). • 6 - Steering connecting rods (2 lubricators). • 7 - Rear axle oscillation (2 lubricators). CAB DOORS (OPTION) • 8 - Cab door articulation axles (8 lubricators). ADJUST Tension and alignment of the mast lifting chains Place the lift truck on level ground with the mast in a vertical position and the forks lifted at approximately 200 mm.
  • Page 74 500H - PERIODIC MAINTENANCE - EVERY 500 HOURS OF SERVICE GREASE Mast lifting chains - Wipe the mast lifting chains with a clean, lint-free cloth. - Vigorously brush the chains to get rid of any foreign matter, with a hard nylon brush and clean diesel fuel.
  • Page 75 CHECK Speeds of hydraulic movements * CHECK Condition of hoses and flexible pipes * CHECK Condition of cylinders (leakage, rods) * CHECK Fork wear * * Consult your dealer. 3 - 21...
  • Page 76 1000H - PERIODIC MAINTENANCE - EVERY 1,000 HOURS OF SERVICE OR 2 YEARS ALSO PERFORM THE 500 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Safety belt IMPORTANT If the seat belt is defective (fixing, locking, cuts, tears, etc.), the lift truck must not be used. Repair or replace the seat belt immediately.
  • Page 77 REPLACE Fuel pre-filter After replacing the fuel filter, replace the fuel pre-filter. - Carefully clean the outside of the filter and its holder, to prevent dust from getting into the system. - Disconnect the wiring harness 1. - Open bleed screw 2 to ensure proper emptying. - Place a receptacle under the drain plug 3 and unscrew by two to three turns.
  • Page 78 REPLACE "DEF" (Diesel Exhaust Fluid) supply pump filter Place the lift truck on level ground with the engine stopped. IMPORTANT Diesel exhaust fluid is corrosive: - Protect the bodywork - Wear personal protective equipment (gloves and goggles). Carefully clean the outside of the pump to prevent dust from entering the system. - Switch off the lift truck's ignition and wait for the pump to stop.
  • Page 79 REPLACE Gear box oil REPLACE Gear box oil filter CLEAN Metal gear box oil filter Place the lift truck on level ground with the engine stopped and the gear box oil still warm. IMPORTANT Dispose of the drain oil in an ecological manner. - Open the engine cover ( INSTRUMENTS AND CONTROLS).
  • Page 80 REPLACE Hydraulic oil REPLACE Hydraulic return oil filter CLEAN Hydraulic oil tank filter cap CLEAN Hydraulic oil tank suction strainers Place the lift truck on level ground with the engine stopped, the mast tilted backward and lowered as far as possible. - Open the engine cover ( INSTRUMENTS AND CONTROLS).
  • Page 81 CHECK Engine speeds * CHECK Engine valve clearances * CHECK Engine silent blocks * CHECK Gear box silent blocks * CHECK Condition of wheels and tyres * CHECK Brake * CHECK Condition of wiring harnesses and cables * CHECK Lights and signals * CHECK Warning indicators * CHECK...
  • Page 82 2000H - PERIODIC MAINTENANCE - EVERY 2,000 HOURS OF SERVICE OR 4 YEARS ALSO PERFORM THE 500 HOUR AND 1,000 HOUR PERIODIC MAINTENANCE OPERATIONS. CHECK Wheel nut tightening torques - 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 83 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 corrosion resistor and must be filled during the whole year with a mixture containing 25 % of ethylene glycol-based antifreeze.
  • Page 84 CHECK Radiator * CHECK Water pump and thermostat * CHECK Alternator and starter * CHECK Turbocharger * CHECK Injection pump * CHECK Injectors * CHECK Swivel pins * CHECK Steering connecting rods * CHECK Rear axle oscillation * CHECK Steering * CHECK Rear axle * CHECK...
  • Page 85 3 - 31...

  • Page 86: Occasional Maintenance

    - 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 87: Battery

    REPLACE Battery 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 88: Occasional Operation

    - Take into account the position of the lift truck centre of gravity for lifting. A = 1,467 mm B = 1,033 mm MI 80 D ST4 S2 A = 1,526 mm B = 1,074 mm MI 100 D ST4 S2 - Place the hooks in the fastening points 1 provided.

  • Page 89: Transport

    TRANSPORT Lift truck IMPORTANT Ensure that the platform safety instructions are correctly applied before the loading of the lift truck and that the driver of the means of transport is informed about the dimensions and the weight of the lift truck ( CHARACTERISTICS). Ensure that the platform is of sufficient size and load capacity for transporting the lift truck.
  • Page 90 3 - 36...
  • Page 91 4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE...
  • Page 93 4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE INTRODUCTION TECHNICAL SPECIFICATIONS OF ATTACHMENTS ATTACHMENT SHIELDS...
  • Page 95 INTRODUCTION Your lift truck must be used with interchangeable equipment. These items are called: ATTACHMENTS. A wide range of attachments is available, guaranteed by MANITOU and designed to fit your lift truck perfectly. IMPORTANT Only attachments approved by MANITOU are to be used on our lift trucks (see: 4 - ADAPTABLE ATTACHMENTS IN OPTION ON THE RANGE: TECHNICAL SPECIFICATIONS OF ATTACHMENTS).
  • Page 96 TECHNICAL SPECIFICATIONS OF ATTACHMENTS STANDARDIZED FORK MI 80 D ST4 S2 PART NO. 52522267 52522271 52522272 Section 160 x 75 x 1520 mm 160 x 75 x 2000 mm 160 x 75 x 2440 mm Weight STANDARDIZED FORK MI 100 D ST4 S2 PART NO.
  • Page 97 ATTACHMENT SHIELDS FORK PROTECTOR PART NO. 227801...

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Mi 100 d st4 s2

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