Manitou MI 20 D K ST5 S1 Operator's Manual
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Manitou MI 20 D K ST5 S1 Operator's Manual

Manitou MI 20 D K ST5 S1 Operator's Manual

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647852EN-USM1(B-12/2021)
(EUROPEAN UNION)
OPERATORS MANUAL
(NOTICE ORIGINALE)
MI 20 D K ST5 S1
MI 25 D K ST5 S1
MI 30 D K ST5 S1
MI 35 D K ST5 S1

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Mohamed Osama
January 20, 2025

NEED OPERATION MANUAL @SPEER PARTS BOOK

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Summary of Contents for Manitou MI 20 D K ST5 S1

  • Page 1 647852EN-USM1(B-12/2021) (EUROPEAN UNION) OPERATORS MANUAL (NOTICE ORIGINALE) MI 20 D K ST5 S1 MI 25 D K ST5 S1 MI 30 D K ST5 S1 MI 35 D K ST5 S1...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY 1.1. REDUCE RISKS ..........................9 1.2. INSTRUCTIONS TO THE COMPANY MANAGER ..............10 1.2.1 The Site ..............................10 1.2.2 The Operator............................10 1.2.3 The Lift Truck ............................10 1.2.4 Instructions ............................11 1.2.5 Maintenance ............................11 1.3. INSTRUCTIONS FOR THE OPERATOR..................12 1.3.1 Foreword ............................12 1.3.2 General Instructions..........................12 1.3.3 Operating Instructions Unladen and Laden ....................13...
  • Page 3 2.2. MACHINE MANUFACTURER PLATE ..................23 2.3. ATTACHMENT MANUFACTURER PLATE................24 2.4. MACHINE SPECIFICATIONS....................... 24 2.4.1 Technical datasheet MI 20 D K ST5 S1 ....................24 2.4.2 Technical datasheet MI 25 D K ST5 S1 ....................27 2.4.3 Technical datasheet MI 30 D K ST5 S1 ....................30 2.4.4 Technical datasheet MI 35 D K ST5 S1 ....................33...
  • Page 4 4.3.1 Original Manitou Spare Parts and Equipment ..................66 4.3.2 By Allowing the Use of Non-Original Manitou Parts, You Risk ..............66 4.3.3 By Using Original Manitou Parts for Maintenance Operations, You Benefit from Our Know-How ....66 4.4. FORKLIFT TRUCK MAINTENANCE ..................67 4.4.1 Daily and Weekly Maintenance ......................67...
  • Page 5 TABLE OF CONTENTS 4.7. 10 HOURS OF SERVICE OR DAILY MAINTENANCE ............72 4.7.1 Check engine oil level ..........................72 4.7.2 Check cooling liquid level ........................72 4.7.3 Check fuel level ...........................72 4.7.4 Check hydraulic fluid Level ........................73 4.7.5 Check brake fluid level .........................74 4.8.
  • Page 6 TABLE OF CONTENTS 4.12. OCASSIONAL MAINTENANCE ....................88 4.12.1 Replace wheel ...........................88 5. REFERENCES & ATTACHMENTS 5.1. REFERENCES ..........................90 5.1.1 Lubricants & fuel - MI 20→35 D K ST5 S1....................90 5.1.2 Filter elements & belts — MI 20→35 D K ST5 S1 ...................91 5.1.3 Fuses &...
  • Page 7 Manitou. In the event that Manitou authorizes a Manitou machine user to access all or part of this database, Manitou, as producer of this database, cedes to the user only a right to personal, non-exclusive, nontransferable use of the database, and only by access to an information technology platform hosted by a server owned or controlled by Manitou.
  • Page 8 EXPLANATION OF SYMBOLS 00. EXPLANATION OF SYMBOLS DANGER Indicates an imminent hazardous situation which, if not avoided will result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor injury or damage to property.

  • Page 9: Safety

    SAFETY 1. SAFETY 1.1. REDUCE RISKS Figure 1: Reduce risks program 647852EN-USM1(B-12/2021)

  • Page 10: Instructions To The Company Manager

    1.2.3 THE LIFT TRUCK 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...

  • Page 11: Instructions

    SAFETY • The driving of non-approved lift trucks on the public WARNING highway is subject to the provisions of the highway code relating to special machines, defined in article R311-1 of the highway code, in category B of the Your lift truck is designed for outdoor use under normal Equipment Order of 20 November 1969 that atmospheric conditions and indoor use in suitably aerated determines the procedures applicable to special...

  • Page 12: Instructions For The Operator

    The fitting of foam inflated tyres is prohibited and is not guaranteed by the manufacturer, excepting prior WARNING authorization. In order to reduce or prevent any danger with a MANITOU- • The operator must ensure tyres are adapted to the approved attachment, follow the instructions in the section - nature of the ground.

  • Page 13: Operating Instructions Unladen And Laden

    SAFETY addition of counterweight, unapproved attachments, • Never operate the lift truck when hands or feet are alarm systems, etc.) yourself. In this event, the wet or soiled with greasy substances. manufacturer cannot be held responsible. • For increased comfort, adjust the seat to your requirements and adopt the correct position in the Lifting People driver's cab.
  • Page 14 SAFETY • That the unit to which it is connected (wagon, making sure to keep this person clearly in view lorry, etc.) will not shift. always, • That this platform is prescribed for the total weight • in any case, do not reverse over long distances. of the lift truck to be loaded.
  • Page 15 SAFETY very low speed and using gentle braking. Ensure parking brake and place the forward/reverse that visibility is adequate. selector in neutral. • Take bends slowly. • Make sure that the lift truck is not stopped in any position that will interfere with the traffic flow and at •...

  • Page 16: Lift Truck Maintenance Instructions

    SAFETY The driving of non-approved lift trucks on the public • The vertical force on the towing hook must not highway is subject to the provisions of the highway exceed the maximum authorised by the code relating to special machines, defined in article manufacturer (consult the manufacturer’s plate on R311-1 of the highway code, in category B of the your lift truck).

  • Page 17: Lubricant And Fuel Levels

    SAFETY numbers of any lift truck components that are replaced equipment directly to the part being welded to avoid are indicated. high tension current passing through the alternator. • Never carry out welding or any work which gives off 1.4.3 LUBRICANT AND FUEL heat on an assembled tyre.

  • Page 18: Preparing The Lift Truck

    SAFETY 1.5.2 PREPARING THE LIFT TRUCK 1.5.5 BRINGING THE LIFT TRUCK BACK INTO SERVICE • Clean the lift truck thoroughly. • Check and repair any fuel, oil, water or air leaks. WARNING • Replace or repair any worn or damaged parts. •...

  • Page 19: Environmental Protection

    Rubber processing of used oil. • Tyres and seals can be ground for use in cement • By handing over your waste oil to MANITOU, the manufacture or to obtain reusable granules. risk of pollution is limited. Glass Used Batteries •...

  • Page 20: Decals

    SAFETY 1.7. DECALS 1.7.1 DECALS LOCATION — MI 20→35 D K ST5 S1 Figure 2: Decals location Table 1. List of decals Marker Reference Description Option 24653 Slinging point 828054 Crushing hazard 52521805 Slinging warning 52719360 Safety instructions for mast trucks 240078 Acoustic plate 107 dB 647852EN-USM1(B-12/2021)
  • Page 21 SAFETY Marker Reference Description Option 52521857 Diesel ULSD 300681 Safety instructions 52722738 Parked DPF regeneration 52549319 DPF inside 289101 Tie-down point 647852EN-USM1(B-12/2021)

  • Page 22: Specifications & Description

    2. SPECIFICATIONS & DESCRIPTION 2.1. “EC” DECLARATION OF CONFORMITY — MI 20→35 D K ST5 S1 MI 20 D K ST5 S1 MI 25 D K ST5 S1 MI 30 D K ST5 S1 MI 35 D K ST5 S1...

  • Page 23: Machine Manufacturer Plate

    SPECIFICATIONS & DESCRIPTION Figure 4: “EC” declaration of conformity — MI 20→35 D K ST5 S1 (specimen) page 2/2 2.2. MACHINE MANUFACTURER PLATE “Designation” Designation “Series” Series “Power” Power “Year of manufacture” Year of manufacture “Model year” Model year “Max vertical force (on trailer hook)” Max vertical force (on trailer hook) “Serial number / Product identification number”...

  • Page 24: Attachment Manufacturer Plate

    Designation Unit Value Manufacturer MANITOU Type of model MI 20 D K ST5 S1 Drive : battery, diesel, gasoline, LPG, mains Diesel Driving position : manual, walking alongside, standing, seated Seated Nominal load / Load on forks (basic capacity) Q (t)
  • Page 25 SPECIFICATIONS & DESCRIPTION Tires Table 4. Tires Designation Unit Value Tire equipment : bandage (V), superelastic (SE), pneumatic (L) Size of front wheels " / mm 7.00-12 12PR Size of rear wheels " / mm 6.00-9 10PR Number of front wheels (x = drive wheels) 3.4.1 Number of rear wheels (x = drive wheels) Front wheel gauge (middle of wheels) b10 (mm) 965...
  • Page 26 SPECIFICATIONS & DESCRIPTION Performances Table 6. Performances Designation Unit Value Travelling speed laden km/h 5.1.1 Travelling speed unladen 2WD / 4WD km/h 18.5 Lifting speed laden 5.2.1 Lifting speed unladen 0.65 Lowering speed laden 0.48 5.3.1 Lowering speed unladen 0.55 Nominal towing power laden 18000 5.4.1 Nominal towing power unladen...

  • Page 27: Technical Datasheet Mi 25 D K St5 S1

    Specifications Table 9. Specifications Designation Unit Value Manufacturer MANITOU Type of model MI 25 D K ST5 S1 Drive : battery, diesel, gasoline, LPG, mains Diesel Driving position : manual, walking alongside, standing, seated Seated Nominal load / Load on forks (basic capacity)
  • Page 28 SPECIFICATIONS & DESCRIPTION Weights Table 10. Weights Designation Unit Value Weight of truck in working order 4000 Front axle load on loaded truck 5735 2.2.1 Rear axle load on loaded truck Front axle load on unloaded truck 1710 2.3.1 Rear axle load on unloaded truck 2290 Tires Table 11.
  • Page 29 SPECIFICATIONS & DESCRIPTION Designation Unit Value 4.16 Ground clearance at centre of wheelbase m2 (mm) 4.17 Width of aisle for pallet 1000x1200 crossways Ast (mm) 3930 4.18 Width of aisle for pallet 800x1200 lengthways Ast (mm) 4130 4.19 Turning radius (position down/up) Wa (mm) 2265 4.20.

  • Page 30: Technical Datasheet Mi 30 D K St5 S1

    Specifications Table 16. Specifications Designation Unit Value Manufacturer MANITOU Type of model MI 30 D K ST5 S1 Diesel Drive : battery, diesel, gasoline, LPG, mains Driving position : manual, walking alongside, standing, seated Seated Nominal load / Load on forks (basic capacity)
  • Page 31 SPECIFICATIONS & DESCRIPTION Designation Unit Value Distance from the load-bearing surface to centre of front axle x (mm) Wheelbase y (mm) 1700 Weights Table 17. Weights Designation Unit Value Weight of truck in working order 4610 Front axle load on loaded truck 6650 2.2.1 Rear axle load on loaded truck Front axle load on unloaded truck...
  • Page 32 SPECIFICATIONS & DESCRIPTION Designation Unit Value 4.12.1 Width of fork arms e (mm) 4.12.2 Fork arms length l (mm) 1150 4.13 Fork carriage to DIN 15173 A/B FEM3A 4.14 Fork carriage width b3 (mm) 1100 4.15 Ground clearance of mast m1 (mm) 4.16 Ground clearance at centre of wheelbase...

  • Page 33: Technical Datasheet Mi 35 D K St5 S1

    SPECIFICATIONS & DESCRIPTION Miscellaneous Table 22. Miscellaneous Designation Unit Value Hydraulic pressure for attachments Oil volume for attachments L/min Sound level at driver's ear according to DIN 12053 (overhead dB (A) guard / cab) Towing coupling design / DIN type Average weighted acceleration on driver's body (according to m/s²...
  • Page 34 SPECIFICATIONS & DESCRIPTION Specifications Table 23. Specifications Designation Unit Value Manufacturer MANITOU Type of model MI 35 D K ST5 S1 Drive : battery, diesel, gasoline, LPG, mains Diesel Driving position : manual, walking alongside, standing, seated Seated Nominal load / Load on forks (basic capacity)
  • Page 35 SPECIFICATIONS & DESCRIPTION Designation Unit Value Height mast extended h4 (mm) 4445 Height of standard overhead guard or cab or cab with air h6 (mm) 2130 conditioning Seat height h7 (mm) 1215 Height of towing bar h10 (mm) 360 Overall length l1 (mm) 3935 4.10.
  • Page 36 SPECIFICATIONS & DESCRIPTION Designation Unit Value No. Of cylinders / displacement 4/2615 Fuel consumption acc. To VDI cycle 4.55 Miscellaneous Table 29. Miscellaneous Designation Unit Value Hydraulic pressure for attachments Oil volume for attachments L/min Sound level at driver's ear according to DIN 12053 (overhead dB (A) guard / cab) Towing coupling design / DIN type...

  • Page 37: Mast Technical Datasheet Mi 20/25 D K St5 S1

    SPECIFICATIONS & DESCRIPTION 2.4.5 MAST TECHNICAL DATASHEET MI 20/25 D K ST5 S1 Mast specifications MI 20/25 D K ST5 S1 Table 30. Mast specifications MI 20/25 D K ST5 S1 Height - Height mast Height - mast Mast fork extented Tilt range - Tilt range -...
  • Page 38 SPECIFICATIONS & DESCRIPTION Capacity with integrated TDL MI 20/25 D K ST5 S1 Table 32. Capacity with integrated TDL MI 20/25 D K ST5 S1 Height at max capacity (mm) Load capacity at 500mm (KG) 2.5 T 2.5 T 3300 3300 2000 2500...

  • Page 39: Mast Technical Datasheet Mi 30/35 D K St5 S1

    SPECIFICATIONS & DESCRIPTION 2.4.6 MAST TECHNICAL DATASHEET MI 30/35 D K ST5 S1 Mast specifications MI 30/35 D K ST5 S1 Table 34. Mast specifications MI 30/35 D K ST5 S1 Mast Height mast Tilt Tilt Height - mast fork Height - mast extented range -...

  • Page 40: Tires - Mi 20/25 D K St5 S1

    3150kg - 4000kg 1200 1400 2.4.7 TIRES – MI 20/25 D K ST5 S1 Table 38. Front tires Load per tire (Kg) Pressure MI 20 D K ST5 S1 MI 25 D K ST5 S1 (bar) Unladen Laden Unladen Laden PPS 7.00-12/5.00...

  • Page 41: Tires - Mi 30/35 D K St5 S1

    SPECIFICATIONS & DESCRIPTION Load per tire (Kg) Pressure MI 20 D K ST5 S1 MI 25 D K ST5 S1 (bar) Unladen Laden Unladen Laden JUM 7.00-12-12PR 7.00-12/5.00 SC20 M+S CONTINENTAL 7.00-12 16PR 7.00-12/ 5.00 Table 39. Rear tires Load per tire (Kg)

  • Page 42: Ground Contact Pressure - Mi 20→35 D K St5 S1

    SPECIFICATIONS & DESCRIPTION 2.4.9 GROUND CONTACT PRESSURE - MI 20→35 D K ST5 S1 Table 42. ADVANCE tires Ground contact pressure Ground contact area (cm Pressure (Kg/cm Load (Kg) (bar) Hard ground Soft ground Hard ground Soft ground PPS 7.00-12/5.00 2500 2850 PPS JUM 7.00-12/5.00 -...
  • Page 43 SPECIFICATIONS & DESCRIPTION Ground contact pressure Ground contact area (cm Pressure (Kg/cm Load (Kg) (bar) Hard ground Soft ground Hard ground Soft ground 3300 3700 6.50-10-10PR 1350 1500 Table 44. CONTINENTAL tires Ground contact pressure Ground contact area (cm Pressure (Kg/cm Load (Kg) (bar)

  • Page 44: Load Chart

    SPECIFICATIONS & DESCRIPTION Ground contact pressure Ground contact area (cm Pressure (Kg/cm Load (Kg) (bar) Hard ground Soft ground Hard ground Soft ground 6.50-10 14PR 1350 1500 PPS NM 6.50-10/5.00 1350 1500 2.4.10 LOAD CHART SUIVANT NORME EN 1726-1 (ISO 1074) Figure 13: Load chart informations Marker Description...

  • Page 45: Machine Components

    SPECIFICATIONS & DESCRIPTION 2.5. MACHINE COMPONENTS 2.5.1 COMPONENTS LOCATION — MI 20→35 D K ST5 S1 10 11 Figure 14: Components location — MI 20→35 D K ST5 S1 Table 45. List of components — MI 20→35 D K ST5 S1 Marker Description Option...

  • Page 46: Driver's Cab Components Location - Mi 20→35 D K St5 S1

    SPECIFICATIONS & DESCRIPTION Marker Description Option Leftside step Front headlights ● Front windscreen wiper Exhaust pipe Rear lights Rear working light Rotating beacon light ● Rear windscreen wiper Rightside step 2.5.2 DRIVER'S CAB COMPONENTS LOCATION — MI 20→35 D K ST5 S1 Figure 15: Driver's cab components location —...

  • Page 47: Display & Controls

    SPECIFICATIONS & DESCRIPTION Table 46. List of driver's cab components — MI 20→35 D K ST5 S1 Marker Description Option Steering wheel Horn Lighting and indicator switch Lifting hydraulic control lever Tilting hydraulic control lever Fork carriage side-shift hydraulic control or Attachment hydraulic control Forward/Neutral/Reverse gear selector Ignition switch Cup holder...

  • Page 48: Mini-Levers Controls

    SPECIFICATIONS & DESCRIPTION 2.6.2 MINI-LEVERS CONTROLS Figure 16: Mini-levers controls Table 48. List of mini-levers controls Marker Description Option ● Fork lifting hydraulic ● Mast tilting hydraulic ● Fork carriage side-shift hydraulic ● Hydraulic attachment ● Forward/Neutral/Reverse gear selector ● Horn ●...

  • Page 49: Work Page - Mi 20→35 D Kst5 S1

    SPECIFICATIONS & DESCRIPTION Table 49. List of display screen's components Marker Description Display screen Access to engine fault information display page Access to language switch (Chinese/English) Access to engine information display page Access to setting page /Return to main page 2.6.4 WORK PAGE –...
  • Page 50 SPECIFICATIONS & DESCRIPTION Marker Pictogram Description Service brake Engine fault Air filter Operator Presence System Exhaust regeneration information • Flashing : Passive exhaust regeneration will begin shortly. • Steady : Passive exhaust regeneration in progress. • Flashing & engine fault lamp ON : Parked regeneration required. Exhaust regeneration warning Exhaust regeneration limited and impossible Exhaust regeneration status...

  • Page 51: Machine Operation

    MACHINE OPERATION 3. MACHINE OPERATION 3.1. INSTALLATION AT THE DRIVER'S CAB 3.1.1 GETTING ON/OFF THE MACHINE CAUTION Risk of injury Do not jump out of the lift truck. NOTICE Risk of machine damage Do not use the steering wheel as point of support. Figure 19: Driver’s seat weight adjustment 2.

  • Page 52: Adjusting The Steering Wheel

    MACHINE OPERATION Figure 20: Driver’s seat longitudinal adjustment Figure 22: Driver’s seat angle adjustment of the back-rest Lumbar adjustment 3.1.3 ADJUSTING THE STEERING WHEEL • Turn knob to 1 to adjust the height and depth of the lumbar support of the upper part of the back-rest. 1.

  • Page 53: Fastening The Seat Belt

    MACHINE OPERATION 3.1.5 FASTENING THE SEAT BELT 1. Turn the ignition switch to the preheating position (2) for a few seconds until the lamp goes out. DANGER In no event should the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.).

  • Page 54: Operating The Horn On The Mini-Levers

    MACHINE OPERATION • Press the red button on the driving seat access handle. In both cases, the horn will sound. 3.2.5 OPERATING THE HORN ON THE MINI-LEVERS • Press on the button on the side of the mini-lever armrest. The horn will sound. 3.2.6 OPERATING THE ROTATING BEACON •...

  • Page 55: Handling A Load

    7. Operate the gear selector to move forwards or backwards Choice of Attachments • Only attachments approved by MANITOU can be 3.2.8.4 Operating the lights and indicators used on its lift trucks. Positions (2) and (3) can be used without •...
  • Page 56 MACHINE OPERATION • Comply with the load chart limits for the lift truck for Raising the mast reduces the lift truck's lateral stability. the attachment used. The transverse attitude must be set with the mast in down position as follows: •...
  • Page 57 MACHINE OPERATION FOR A NON-PALLETISED LOAD 1. Tilt the carriage (1) forwards and move the lift truck slowly forwards (2), to insert the fork under the load (block the load if necessary). 2. Continue to move the lift truck forwards (2) tilting the carriage (3) backwards to position the load on the 3.
  • Page 58 MACHINE OPERATION 5. Tilt the load sufficiently backwards to ensure its stability. 6. Reverse the lift truck (1) very carefully and gently to free the load. Lower the mast (2) to bring the load into transport position. 3. Place the load in a horizontal position by tilting the mast forwards (1) and lay it down on the pile (2) while checking the correct positioning of the load .
  • Page 59 MACHINE OPERATION 3.2.9.2 Using the hydraulic controls Additional accessory • Move the lever (4) forwards or backwards WARNING 3.2.1 Operating the machine with the operator presence system, page 53 Machine shaking 3.2.9.3 Using the hydraulic controls on the Risk of accident mini-levers Use the hydraulic controls without jerking WARNING...

  • Page 60: Management Of The Pollution Control System

    MACHINE OPERATION 3.3. MANAGEMENT OF THE • Move the mini-lever (3) forwards to move sideways to the left POLLUTION CONTROL SYSTEM Attachment • Move the mini-lever (3) forwards or backwards 3.3.1 DEACTIVATING THE EXHAUST REGENERATION Additional accessory • Move the mini-lever (4) forwards or backwards NOTICE 3.2.1 Operating the machine with the operator presence system, page 53...

  • Page 61: Parking And Storing The Machine

    MACHINE OPERATION The parked regeneration and engine default indicator 6. Turn off the engine and remove the key. lamp are lit on the work page 3.4.2 STORING THE MACHINE FOR A SHORT DURATION 1. Wait for the machine to cool down. 2.

  • Page 62: Tying Down The Machine

    MACHINE OPERATION 2. Also fix the chocks to the platform on the inside of WARNING each tyre. Ensure that the platform is of sufficient size and load capacity for transporting the machine. Check also the allowable ground contact pressure of the platform relative to the machine.

  • Page 63: Lifting The Machine - Mi 20→35 D K St5 S1

    Machine A (mm) B (mm) MI 20 D K ST5 S1 MI 25 D K ST5 S1 MI 30 D K ST5 S1 MI 35 D K ST5 S1 2. Place the hooks in the fastening points provided and around the uprights of the guard.

  • Page 64: Maintenance

    MAINTENANCE 4. MAINTENANCE 4.1. MAINTENANCE COMPONENTS LOCATION - MI 20→35 D K ST5 S1 Figure 33: Maintenance components location - MI 20→35 D K ST5 S1 Table 51. Maintenance components location - MI 20→35 D K ST5 S1 Marker Description Floor mat Floor engine cover Engine cover key and button...
  • Page 65 MAINTENANCE Figure 34: Maintenance components location under the engine cover - MI 20→35 D K ST5 S1 Table 52. Maintenance components location under the engine cover - MI 20→35 D K ST5 S1 Marker Description Radiator cap Radiator Engine cap Battery Engine oil gauge Dry air filter...

  • Page 66: Opening The Engine Cover

    4.3.1 ORIGINAL MANITOU SPARE retract the armrest. PARTS AND EQUIPMENT • Lifting the engine cover Our lift trucks must be serviced using original Manitou 1. Turn counterclockwise the key (1). parts. 4.3.2 BY ALLOWING THE USE OF NON-ORIGINAL MANITOU PARTS,...

  • Page 67: Forklift Truck Maintenance

    (whichever occurs first). 4.4.3 PERIODIC SERVICE The periodic maintenance must be carried out by a professional approved by the Manitou network. Maintenance Schedule This schedule lets the operator to keep up with the periodic maintenance of the lift truck by notifying the...

  • Page 68: Servicing Program

    MAINTENANCE 10 hours or 50 hours or 1,000 hours First 6 First 500 500 hours SCHEDULE daily weekly or 1 year months hours or 6 months See: Weekly See: Daily mainte- maintenance Mandatory nance Mandatory PERIODIC MAINTENANCE or every 10 every service service +...

  • Page 69: First Mandatory Servicing

    MAINTENANCE Table 54. 50 hours of service or weekly maintenance Operation Description Note Check Transmission oil level Check Differential oil level Clean Radiator core Clean Dry air filter cartridge Check Wheel nut torque Adjust Tension and alignment of the mast lifting chains Mast Grease...

  • Page 70: Periodic Servicing

    Differential oil 4.6.3 PERIODIC SERVICING The periodic maintenance must be carried out by a professional approved by the Manitou network. 500 hours of service or 1 year Carry out the daily and weekly maintenance. Table 56. 500 hours of service or 1 year...
  • Page 71 MAINTENANCE Operation Description Note Check Lights and signals Consult your dealer Check Warning indicators Consult your dealer Check Condition of the rear view mirrors Consult your dealer Check Cab structure Consult your dealer Check Frame structure Consult your dealer 2000 hours of service or 4 years Carry out the 500 and 1000 hours service.

  • Page 72: Hours Of Service Or Daily Maintenance

    MAINTENANCE 4.7. 10 HOURS OF SERVICE OR 2. The fluid must be at the MAX level on the expansion tank (1). DAILY MAINTENANCE 4.7.1 CHECK ENGINE OIL LEVEL Place the lift truck on level ground with the engine stopped, and let the oil settle in the sump.

  • Page 73: Check Hydraulic Fluid Level

    MAINTENANCE 2. Remove cap (1). NOTICE The fuel tank is degassed via the filler plug. When changing it, always use an original part, with degassing hole. The fuel level is shown by a fuel gauge. As far as possible, keep the fuel tank well filled in order to minimize condensation due to the atmospheric conditions.

  • Page 74: Check Brake Fluid Level

    MAINTENANCE 6. Add fluid through filler port (3). 4. If necessary, add fluid through filler port (2). Use a clean funnel and clean the underside of the oil drum before filling. 7. Put back the cap (1). 8. Visually check that there is no leakage in the tank and pipes.

  • Page 75: Check Differential Oil Level

    MAINTENANCE 4. Remove dipstick (3). 1. Remove level plug (1). The oil should be flush with the edge of the hole. 5. Wipe the dipstick and check the correct level 2. If necessary, add oil through the same hole. between the MINI and MAXI marks. 3.

  • Page 76: Clean Dry Air Filter Cartridge

    5. Clean the cartridge seal surfaces with a damp, clean lint-free cloth and grease with a silicone CARTRIDGE lubricant (MANITOU reference: 479292). 6. Check visually the outer condition of the air filter NOTICE and its mounts. Verify the condition of the hoses and their mounts also.

  • Page 77: Grease Mast

    MAINTENANCE 5. Loosen the lock nut (2) of the chain tension 1.2.Lubricators of the tilt cylinder head axles (4 adjuster. lubricators). 6. Adjust the tension by tightening or loosening the nut 3 while checking the alignment of the lifting chains. 7.

  • Page 78: Check Windscreen Washer Liquid Level (Option)

    MAINTENANCE 4.8.8 CHECK WINDSCREEN 4.8.9 GREASE CAB DOOR (OPTION) WASHER LIQUID LEVEL (OPTION) 1. Clean and lubricate the points (1) (4 lubricators) with grease and remove the surplus of grease. 1. Remove the storage tray (1). 4.8.10 GREASE REAR AXLE 2.

  • Page 79: 500 Hours Of Service Or 6 Months

    MAINTENANCE reduced (to 250 hours in a heavily laden dust 1.2.Steering rod lubricators (4 lubricators). atmosphere and with pre-filtration). 1. Raise the engine cover. 2. Release the bolts (1) and remove cover (2). 1.3.Rear axle oscillation pin lubricators (2 3. Gently remove the cartridge (3), taking care to avoid lubricators).

  • Page 80: Drain Fuel Water Trap

    MAINTENANCE 1. Draining the oil 3.4.Start the engine and let it run for a few minutes. 3.5.Check for possible leaks at the drain plug and the 1.1.Raise the engine cover. oil filter. 1.2.Place a container under drain plug (1) and 3.6.Stop the engine, wait a few minutes and check unscrew the plug.

  • Page 81: Grease Mast Lifting Chains

    MAINTENANCE 5. Undo screws (1) by two to three thread turns. 3. Rinse the chains by means of a paint brush impregnated with clean diesel fuel and dry them with a compressed air jet. 4. Moderately lubricate the chains. 4.10. 1000 HOURS OF SERVICE OR 1 YEAR 4.10.1 REPLACE FUEL FILTER 1.

  • Page 82: Replace Safety Dry Air Cartridge

    MAINTENANCE 4. Discard the fuel filter cartridge and its seals. 3. Undo the screws (1) to remove the floor (2). 5. Clean the inside of the filter head using a brush immersed in clean diesel oil. 6. Refit the assembly with a new cartridge and new seals.

  • Page 83: Replace Hydraulic Oil

    MAINTENANCE 4.2.Remove filler plug (4) in order to ensure that the 6.3.Wait a few minutes to allow the oil to flow into the oil is drained properly. sump. 6.4.Start the engine and let it run for a few minutes. 6.5.Check for any possible leaks from the oil filter drain plug.
  • Page 84 MAINTENANCE 1.1.Place a container under drain plug (1) and 2.1.Remove the filler plug cover (3) by twisting unscrew the plug. through a quarter turn. 1.2.Remove filler plug (2) in order to ensure that the 2.2.Remove and clean the filter (4) . oil is drained properly.

  • Page 85: Grease Brake Pedal Axles

    MAINTENANCE 4.10.6 GREASE BRAKE PEDAL 4.1.Unscrew the hydraulic return oil filter (10) and replace with a new one. AXLES WARNING In the event of prolonged use in an extremely dusty or oxidizing atmosphere, reduce this interval to 500 hours of service or every year.

  • Page 86: Check Seat Belt

    MAINTENANCE 4.10.7 CHECK SEAT BELT 1.3.Undo engine block drain plug. 1.4.Remove expansion tank filling plug (2) and empty DANGER the tank. 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 87: Clean Fuel Tank

    MAINTENANCE 2.9.Refit expansion tank filler plug (2). 4. Remove filling plug (2) in order to ensure that the oil is drained properly. 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 88: Check Wheel Nuts Tightening

    6. Replace rear wheel For this operation, we advise you to use the hydraulic jack (MANITOU Part number 505507). 6.1.Place the jack under the counterweight. It must be situated in the middle and under the flat part of the counterweight.
  • Page 89 MAINTENANCE 6.6.Refit the nuts by hand, if necessary grease them. 7.9.Remove the wedges under the axle and lower the lift truck. 6.7.Remove the security wedges and lower the lift 7.10.Tighten the wheel nuts with a torque wrench. truck with the jack. 6.8.Tighten the wheel nuts with a torque wrench.

  • Page 90: References & Attachments

    Recommended lubricants and fluids NOTICE Use the recommanded 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...

  • Page 91: Filter Elements & Belts - Mi 20→35 D K St5 S1

    REFERENCES & ATTACHMENTS Table 63. Hydraulics Description Capacity Temperature range Recommendation MANITOU Oil 40 Litres Hydraulic oil tank -25 °C / +20 °C Hydraulic ISO VG 32 50 Litres Table 64. Transmission Temperature range Description Capacity Recommendation MANITOU Oil Transmission 4 Litres -25 °C / +50 °C...

  • Page 92: Fuses & Relays - Mi 20→35 D K St5 S1

    REFERENCES & ATTACHMENTS 5.1.3 FUSES & RELAYS - MI 20→35 D K ST5 S1 To access fuses and relays,4.2. Opening the engine cover, page Figure 37: Fuses and relays placement Table 69. List of fuses - MI 20→35 D K ST5 S1 Table 70.

  • Page 93: Optional Adaptable Attachments For The Range

    4. Do a check if the fastening pieces become flexible. 5. Do a check if each connector of hydraulic return line Manitou will choose attachment that is in accordance loosens or the tube damages. Never use before with International standard ISO2328 (Forklift pothook repairing the damage.

  • Page 94: Attachment Specifications

    MANITOU. NOTICE Only attachments approved by MANITOU are to be used on our lift trucks The manufacturer’s liability will be denied in case of modification or of attachment adaptation carried out without his knowing it.
  • Page 95 REFERENCES & ATTACHMENTS HC 20/25 * HC 20/25 ** HC 20/25 *** Side-shift 2 x 100 mm 2 x 100 mm 2 x 100 mm Width 988 mm 988 mm 988 mm Weight 44 kg 44 kg 44 kg Standardized side-shift carriage for MI 30/ 35 D K ST5 S1 Table 72.
  • Page 96 REFERENCES & ATTACHMENTS Standardized fork for MI 20/25 D K ST5 S1 Table 75. Standardized fork for MI 20/25 D K ST5 S1 Part Number 916183 Section 122x40x1150 Weight 58 kg Standardized fork for MI 30 D K ST5 S1 Table 76.
  • Page 97 REFERENCES & ATTACHMENTS Fork protector for MI 20→35 D K ST5 S1 Table 79. Fork protector for MI 20→35 D K ST5 S1 Part Number 227801 647852EN-USM1(B-12/2021)
  • Page 98 Manitou Group...

This manual is also suitable for:

Mi 25 d k st5 s1Mi 30 d k st5 s1Mi 35 d k st5 s1

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