Manitou MT 1440 A 100D ST5 S1 Operator's Manual
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Manitou MT 1440 A 100D ST5 S1 Operator's Manual

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647784
EN (05/11/2020)
MT 1440 A 100D ST5 S1
MT 1840 A 100D ST5 S1
OPERATOR'S MANUAL
(ORIGINAL MANUAL)

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Summary of Contents for Manitou MT 1440 A 100D ST5 S1

  • Page 1 647784 EN (05/11/2020) MT 1440 A 100D ST5 S1 MT 1840 A 100D ST5 S1 OPERATOR'S MANUAL (ORIGINAL MANUAL)
  • Page 2 - Descriptions and figures are nonbinding. - 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 available to answer all your questions.
  • Page 3 MANITOU BF. Any violation of the above is subject to civil and criminal penalties. The logos and visual identity of the company are property of MANITOU BF and may not be used without express formal authorization.
  • Page 4 1 - OPERATING AND SAFETY INSTRUCTIONS 2 - DESCRIPTION 3 - MAINTENANCE 4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE 5 - OPTIONAL ADAPTABLE PLATFORMS FOR 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 - SUITABILITY OF THE LIFT TRUCK FOR THE JOB ........... . . 1-6 B - ADAPTATION OF THE LIFT TRUCK TO STANDARD ENVIRONMENTAL CONDITIONS .
  • Page 9 LIFT TRUCK MAINTENANCE INSTRUCTIONS 1-30 GENERAL INSTRUCTIONS 1-30 PLACING THE BOOM SAFETY WEDGE 1-30 FITTING THE WEDGE ..............1-30 REMOVING THE WEDGE .

  • Page 10: Instructions To The Company Manager

    A - SUITABILITY OF THE LIFT TRUCK 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 1.25 and a DYNAMIC TEST COEFFICIENT OF 1, as specified in harmonised standard EN 1459 for mast trucks.

  • Page 11: C - Modification Of The Lift Truck

    Inflate the tires in accordance with recommendations. • The seat is an essential way of reducing the vibrations transmitted to the operator. In the event of seat replacement, please contact MANITOU. • Ensure that the operators adapt their operating speed to suit the conditions on site.

  • Page 12: Instructions

    INSTRUCTIONS - The operator's manual must always be in good condition and kept in the place provided on the lift truck and in the language used by the operator. - The operator's manual and any plates or stickers which are no longer legible or are damaged, must be replaced immediately. MAINTENANCE - Maintenance or repairs other than those detailed in Part: 3 - MAINTENANCE must be carried out by qualified personnel (consult your dealer) and in the necessary safety conditions to preserve the health of the operator and any third party.
  • Page 13 1 - 9...

  • Page 14: Instructions For The Operator

    - At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself when you use it. IMPORTANT In order to reduce or prevent any danger with a MANITOU-approved attachment, follow the instructions in Paragraph: 4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE: INTRODUCTION. GENERAL INSTRUCTIONS A - OPERATOR'S MANUAL...

  • Page 15: E - Modification Of The Lift Truck

    Right-hand column • With a PLATFORM-fitted lift truck, people can only be lifted using platforms designed by MANITOU for the purpose. - MANITOU sells equipment specifically designed for lifting people (OPTION PLATFORM lift truck, contact your dealer). 1 - 11...

  • Page 16: 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 object may hinder the operation of the lift truck.

  • Page 17: D - Visibility

    - Take into account the lift truck’s dimensions and its load before trying to negotiate a narrow or low passageway. - Never move onto a loading platform without having first checked: • That it is suitably positioned and made fast. •...

  • Page 18: E - Starting The Lift Truck

    E - STARTING THE LIFT TRUCK SAFETY INSTRUCTIONS IMPORTANT The lift truck must only be started up or manoeuvred when the operator is sitting in the driver’s cab, with his seat belt adjusted and fastened. - Never try to start the lift truck by pushing or hauling it. Such an operation may cause severe damage to the transmission. If necessary, towing requires the transmission to be put in neutral (  3 - MAINTENANCE).

  • Page 19: G - Stopping The Lift Truck

    - Use the rear-view mirrors frequently. - Drive round obstacles. - Never drive on the edge of a ditch or steep slope. - It is dangerous to use two lift trucks simultaneously to handle heavy or bulky loads, since this operation requires particular precautions to be taken.

  • Page 20: H - Driving The Lift Truck On The Public Highway

    H - DRIVING THE LIFT TRUCK ON THE PUBLIC HIGHWAY (or see current legislation in other countries) FRENCH ROAD TRAFFIC RULES - The driving of non EC type-approved tractors on the public 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 Equipment Order of 20 November 1969 that determines the procedures applicable to special machines.
  • Page 21 1 - 17...

  • Page 22: 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 suitable for the work to be done (  4 - OPTIONAL ADAPTABLE ATTACHMENTS FOR THE RANGE).

  • Page 23: D - Transverse Attitude Of The Lift Truck

    D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK Depending on the model of lift truck The transverse attitude is the transverse slope of the chassis with respect to the horizontal. Raising the boom reduces the lift truck's lateral stability. The transverse attitude must be set with the boom in down position as follows: 1 - ...

  • Page 24: F -  Picking Up And Putting Down A High Load On Tires

    F -  PICKING UP AND PUTTING DOWN A HIGH LOAD ON TIRES IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:...
  • Page 25 PUTTING DOWN A HIGH LOAD ON TIRES - Approach the load in the transport position in front of the stack (fig. F6). - Apply the parking brake and place the forward/reverse selector in neutral. - Raise and extend the boom (1) (2) until the load is above the stack, while monitoring the longitudinal stability limiter and warning device (  INSTRUCTIONS FOR HANDLING A LOAD: C - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE).

  • Page 26: G -  Picking Up And Putting Down A High Load On Stabilisers

    G -  PICKING UP AND PUTTING DOWN A HIGH LOAD ON STABILISERS Depending on the model of lift truck IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:...
  • Page 27 TAKING UP A HIGH LOAD ON STABILISERS - Ensure that the forks will easily pass under the load. - Check the position of the lift truck with respect to the load and make a test run, if necessary, without taking the load. - Raise and extend the boom (1) (2) until the forks are at the level of the load (fig. G5).

  • Page 28: H - Picking Up And Putting Down A Suspended Load

    H - PICKING UP AND PUTTING DOWN A SUSPENDED LOAD IMPORTANT Failure to follow the above instructions may lead the lift truck to loose stability and overturn. MUST be used with a lift truck equipped with an operational hydraulic movement cut-out device. CONDITIONS OF USE - The length of the sling or the chain shall be as short as possible to limit swinging of the load.

  • Page 29: Instructions For Use As A Loader

    INSTRUCTIONS FOR USE AS A LOADER For agricultural-type lift trucks (MLT range) A - LOADING IMPORTANT In no circumstances should you raise the boom if you have not checked the transverse attitude of the lift truck  INSTRUCTIONS FOR HANDLING A LOAD: D - TRANSVERSE ATTITUDE OF THE LIFT TRUCK). REMINDER: Make sure that the following operations can be performed with good visibility (  OPERATING INSTRUCTIONS UNLADEN AND LADEN:...

  • Page 30: Platform Operating Instructions

    - MANITOU has ensured that this platform is suitable for use under the normal operating conditions provided in this operator's manual, with a STATIC test coefficient of 1.25 and a DYNAMIC test coefficient of 1.1 as specified in harmonised European standard EN 280:2013+A1 for "mobile elevating work platforms".

  • Page 31: E - Environment

    E - ENVIRONMENT IMPORTANT It is forbidden to use the platform close to electricity cables. Maintain the specified safe distances. RATED VOLTAGE SAFETY DISTANCE (METRES) 50 < U < 1,000 2,30 M 1,000 < U < 30,000 2,50 M 30000 < U < 45000 2,60 M 45000 <...

  • Page 32: Instructions For Using The Radio-Control

    INSTRUCTIONS FOR USING THE RADIO-CONTROL For lift trucks with RC radio control HOW TO USE THE RADIO-CONTROL SAFETY INSTRUCTIONS - This radio-control consists of electronic and mechanical safety elements. It cannot receive commands from another transmitter because the internal encoding is unique to each radio-control. IMPORTANT If it is used improperly or incorrectly, there is a risk of danger to: - The physical and mental health of the user or others.
  • Page 33 1 - 29...
  • Page 34 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. - Stop the engine and remove the ignition key, when an intervention is necessary.
  • Page 35 LUBRICANT AND FUEL LEVELS - Use the recommended lubricants (never use contaminated lubricants). - Do not fill the fuel tank when the engine is running. - Only fill up the fuel tank in areas specified for this purpose. - Do not fill the fuel tank to the maximum level. - Do not smoke or approach the lift truck with a flame, when the fuel tank is open or is being filled.
  • Page 36 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 37 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. - Drain and clean the fuel tank (  3 - MAINTENANCE).
  • Page 38 • 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 39 2 - DESCRIPTION 2 - 1...
  • Page 40 2 - 2...
  • Page 41 2 - DESCRIPTION CE DECLARATION OF CONFORMITY SAFETY PLATES AND STICKERS IDENTIFICATION OF THE LIFT TRUCK 2-10 SPECIFICATIONS 2-14 MT 1440 A 100D ST5 S1 SPECIFICATIONS 2-18 MT 1840 A 100D ST5 S1 TIRES 2-22 DIMENSIONS 2-24 MT 1440 A 100D ST5 S1 (FLOATING FORK CARRIAGE) DIMENSIONS 2-26 MT 1440 A 100D ST5 S1 (EXTENDIBLE PLATFORM 2M25/4M 1000KG) DIMENSIONS...
  • Page 42 CE DECLARATION OF CONFORMITY DÉCLARATION «CE» DE CONFORMITÉ (originale) «EC» DECLARATION OF CONFORMITY (original) : MANITOU BF Constructeur, Manufacturer Adresse, :  430, RUE DE L’AUBINIÈRE - B.P 10249 Address 44158 - ANCENIS - CEDEX - FRANCE Titulaire de dossier technique, MANITOU BF Holder of the technical file Adresse, : ...
  • Page 43 2 - 5...
  • Page 44 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 ITEM PART NO.
  • Page 45 STICKERS AND PLATES UNDER THE ENGINE COVER ITEM PART NO. DESCRIPTION 52501046 -Anti-freeze 52656411 -Water/diesel separator 52708618 -Engine fuse 52656429 -Battery troubleshooting 52656416 -Electrical hazard 233088 -Preheat rod (OPTION) N°52501046 52708618 220-240V ; 4.5 A ; 50-60Hz N233088 FUEL / WATER SEPARATOR FUEL 52656411...
  • Page 46 MANITOU BF 44158 ANCENIS CEDEX FRANCE ROPS - ISO3471 : 2008 FOPS - ISO3449 : 2008 LEVEL 2 YEAR : MT1435-MT1440-MT1840 MODEL : 14000 kg MAX MASS : N°52521701 239596 STANDARD MODE N°52553499 ≤5° 2 Sec WAIT 40-50 min N°52655274...
  • Page 47 PLATES AND STICKERS IN THE CAB ITEM PART NO. DESCRIPTION 52521701 -Cabin compliance 261476 -Gear selection 239596 -Sound power level 106dB 184276 -Steering selection control 290183 -Bucket instruction on telescope 268491 -Brake fluid instruction 52652268 -Fuses 52553499 -Operating mode management instruction 52651762 -Hydraulic controls activation 52655274...
  • Page 48 "Rated capacity" Rated capacity "Max vertical force (on trailer hook)" Maximum vertical force (on trailer hook) "Drag strain" Pulling force ENGINE "MODEL" Model "CODE" Code "E1" Identification "SERNO" Serial number "SPEC" Specification GEARBOX Type Serial number MANITOU Part No. 2 - 10...
  • Page 49 FRONT AXLE Type Serial number MANITOU Part No. REAR AXLE Type Serial number MANITOU Part No. CABIN "Constructeur" Manufacturer "Type Cabine" Cabin type "N° de série" Serial number BOOM MANITOU Part No. Date of manufacture and manufacturer CHASSIS Serial number / Product Identification Number...
  • Page 50 ATTACHMENT MANUFACTURER'S PLATE "MODELE" Model "N° série" Serial number "Année Fabrication" Year of manufacture "Masse à vide" Unladen weight "Centre de gravité" Center of gravity "Capacité Nominale" Rated capacity "Pression service" Working pressure 2 - 12...
  • Page 51 2 - 13...
  • Page 52 SPECIFICATIONS MT 1440 A 100D ST5 S1 ENGINE Type DEUTZ TCD3,6L4/2501-3540 Fuel Diesel Number of cylinders 4 in line Suction Supercharged cooled Injection system Direct Ignition sequence 1.3.4.2 Displacement 3621 Bore and stroke 98 x 120 Compression ratio 17:2 Nominal speed laden 2200 Min.
  • Page 53 HYDRAULIC CIRCUIT Hydraulic pump - Type Gears with flow divider on 2nd housing 1st housing 2nd housing - Displacement - Max. rating capacity unladen ℓ/min - Flow at 1600 rpm ℓ/min Filtration - Return µm - Suction µm Maximum working pressure - Telescoping circuit 190 / 265 - Lift circuit...
  • Page 54 FLOATING FORK CARRIAGE SPECIFICATIONS AND WEIGHTS Speed of movement for lift truck in standard configuration on flat ground - Front unladen km/h km/h km/h 15,1 km/h - Rear unladen km/h km/h km/h 15,1 km/h Standard attachment TFF 45 MT 1040 - Weight of attachment (without forks) - Weight of forks (each) Rated capacity with standard attachment 4000...
  • Page 55 EXTENDIBLE PLATFORM 2M25/4M 1000KG SPECIFICATIONS AND WEIGHTS Speed of movement for lift truck in standard configuration on flat ground - Front unladen km/h km/h km/h 15,1 km/h - Rear unladen km/h km/h km/h 15,1 km/h Standard attachment EXTENDIBLE PLATFORM 2M25/4M 1000KG - Attachment mass 1030 Rated capacity with standard attachment 1000 (including 3 people)
  • Page 56 SPECIFICATIONS MT 1840 A 100D ST5 S1 ENGINE Type DEUTZ TCD3,6L4/2501-3540 Fuel Diesel Number of cylinders 4 in line Suction Supercharged cooled Injection system Direct Ignition sequence 1.3.4.2 Displacement 3621 Bore and stroke 98 x 120 Compression ratio 17:2 Nominal speed laden 2200 Min.
  • Page 57 HYDRAULIC CIRCUIT Hydraulic pump - Type Gears housingflow divider on 2nd housing 1st casing 2nd housing - Displacement - Max. rating capacity unladen ℓ/min - Flow at 1600 rpm ℓ/min Filtration - Return µm - Suction µm Maximum working pressure - Telescoping circuit 210 / 265 - Lifting circuit 210 / 265...
  • Page 58 FLOATING FORK CARRIAGE SPECIFICATIONS AND WEIGHTS Speed of movement for lift truck in standard configuration on flat ground - Front unladen km/h km/h km/h 15,1 km/h - Rear unladen km/h km/h km/h 15,1 km/h Standard attachment TFF 45 MT 1040 - Weight of attachment (without forks) - Weight of forks (each) Rated capacity with standard attachment 4000...
  • Page 59 EXTENDIBLE PLATFORM 2M25/4M 1000KG SPECIFICATIONS AND WEIGHTS Speed of movement for lift truck in standard configuration on flat ground - Front unladen km/h km/h km/h 15,1 km/h - Rear unladen km/h km/h km/h 15,1 km/h Standard attachment EXTENDIBLE PLATFORM 2M25/4M 1000KG - Attachment mass 1030 Rated capacity with standard attachment 1000 (including 3 people)
  • Page 60 TIRES LOAD PER TIRE (kg) MT 1440 A 100D ST5 S1 PRESSURE FLOATING FORK CARRIAGE (bar) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN ALLIANCE 400/80-24 A325 162A8 TOUGH TRAC 400/80-24 162A8 IND TL PCL 2650 6350 2800 1100 MICHELIN 440/80-24 168A8 IND TL PCL LOAD PER TIRE (kg) MT 1440 A 100D ST5 S1 PRESSURE...
  • Page 61 LOAD PER TIRE (kg) MT 1840 A 100D ST5 S1 PRESSURE FLOATING FORK CARRIAGE (bar) FRONT UNLADEN FRONT LADEN REAR UNLADEN REAR LADEN 400/80-24 A325 162A8 TOUGH TRAC ALLIANCE 440/80-24 A325 168A8 ATG 400/80-24 162A8 IND TL PCL 2750 6450 3100 1400 440/80-24 168A8 IND TL PCL MICHELIN 440/80 R24 161A8/161B IND TL BIBLOAD HARD SURFACE...
  • Page 62 DIMENSIONS MT 1440 A 100D ST5 S1 (FLOATING FORK CARRIAGE) 2 - 24...
  • Page 63 ℓ1 7335 ℓ3 6135 ℓ5 MACHINE LENGTH 1160 ℓ10 4859 ℓ11 6020 2364 1040 MACHINE WIDTH 3793 1960 1960 2422 1855 MACHINE HEIGHT 2452 2640 1134 DISTANCE 1790 1905 Ast2 AISLE WIDTH 4310 ℓ 1200 ATTACHMENT 3940 5410 TURNING RADIUS 3738 1100 GROUND CLEARANCE...
  • Page 64 DIMENSIONS MT 1440 A 100D ST5 S1 (EXTENDIBLE PLATFORM 2M25/4M 1000KG) 2 - 26...
  • Page 65 ℓ1 7749 ℓ5 1160 MACHINE LENGTH ℓ10 4859 ℓ11 6020 2364 3793 MACHINE WIDTH 1960 1960 2422 1855 MACHINE HEIGHT 2452 2640 1134 DISTANCE 1790 3519 Ast2 AISLE WIDTH 6162 ℓp 1200 2250-4000 PLATFORM 1312 3940 7262 TURNING RADIUS 3738 1100 GROUND CLEARANCE °...
  • Page 66 DIMENSIONS MT 1840 A 100D ST5 S1 (FLOATING FORK CARRIAGE) 2 - 28...
  • Page 67 ℓ1 7474 ℓ3 6274 ℓ5 MACHINE LENGTH 1160 ℓ10 4859 ℓ11 6159 2364 1040 MACHINE WIDTH 3793 1960 1960 2422 1855 MACHINE HEIGHT 2452 2640 1134 DISTANCE 1929 2044 Ast2 AISLE WIDTH 4360 ℓ 1200 ATTACHMENT 3940 5460 TURNING RADIUS 3738 1100 GROUND CLEARANCE...
  • Page 68 DIMENSIONS MT 1840 A 100D ST5 S1 (EXTENDIBLE PLATFORM 2M25/4M 1000KG) 2 - 30...
  • Page 69 ℓ1 8281 ℓ5 1160 MACHINE LENGTH ℓ10 4859 ℓ11 6159 2364 3793 MACHINE WIDTH 1960 1960 2422 1855 MACHINE HEIGHT 2452 2640 1134 DISTANCE 1929 4051 Ast2 AISLE WIDTH 6212 ℓp 1200 2250-4000 PLATFORM 1312 3940 7312 TURNING RADIUS 3738 1100 GROUND CLEARANCE °...
  • Page 70 LOAD CHARTS MT 1440 A 100D ST5 S1 (EXCEPT FOR AUSTRALIA) STANDARD EXTENDIBLE PLATFORM 2M25/4M 1000KG EN 280 15.40m 13.40m kg + =1000kg 72° 70° kg + =700kg 60° 50° kg + =365kg 40° 5 / 4 30° 2 . 2 kg + =250kg 6.18m 20°...
  • Page 71 LOAD CHARTS MT 1440 A 100D ST5 S1 (FOR AUSTRALIA) STANDARD 2 - 33...
  • Page 72 LOAD CHARTS MT 1840 A 100D ST5 S1 (EXCEPT FOR AUSTRALIA) STANDARD EXTENDIBLE PLATFORM 2M25/4M 1000KG EN 280 kg + =700kg kg + =365kg 19.25m kg + =150kg 17.25m kg + =1000kg 74° 70° 60° 50° 40° 30° 2 . 2 6.50m 20° 10° MT1840A 1000kg 0°...
  • Page 73 LOAD CHARTS MT 1840 A 100D ST5 S1 (FOR AUSTRALIA) STANDARD 2 - 35...
  • Page 74 VISIBILITY MT 1440 A 100D ST5 S1 We use European standard EN15830 relating to operator visibility. - Adhere to the instructions for optimizing operator visibility in the immediate vicinity (  1 - OPERATING AND SAFETY INSTRUCTIONS: OPERATOR INSTRUCTIONS: OPERATING INSTRUCTIONS WITH AND WITHOUT LOAD: D - VISIBILITY). DESCRIPTION AND ADJUSTMENT OF REAR-VIEW MIRRORS 1 - LEFT REAR-VIEW MIRROR 2 - MAIN RIGHT REAR-VIEW MIRROR...
  • Page 75 DIRECT AND/OR INDIRECT VISIBILITY BLIND SPOT ZONES The two diagrams below indicate the blind spots in the visibility test circle (12m radius) and the rectangular zone 1m from the lift truck’s perimeter according to tests conducted in compliance with standard EN15830. SUSPENDED LOAD HANDLING (Test conducted in compliance with point 6.3.3 of standard EN 15830) 9,5 m...
  • Page 76 VISIBILITY MT 1840 A 100D ST5 S1 We use European standard EN15830 relating to operator visibility. - Adhere to the instructions for optimizing operator visibility in the immediate vicinity (  1 - OPERATING AND SAFETY INSTRUCTIONS: OPERATOR INSTRUCTIONS: OPERATING INSTRUCTIONS WITH AND WITHOUT LOAD: D - VISIBILITY). DESCRIPTION AND ADJUSTMENT OF REAR-VIEW MIRRORS 1 - LEFT REAR-VIEW MIRROR 2 - MAIN RIGHT REAR-VIEW MIRROR...
  • Page 77 DIRECT AND/OR INDIRECT VISIBILITY BLIND SPOT ZONES The two diagrams below indicate the blind spots in the visibility test circle (12m radius) and the rectangular zone 1m from the lift truck’s perimeter according to tests conducted in compliance with standard EN15830. SUSPENDED LOAD HANDLING (Test conducted in compliance with point 6.3.3 of standard EN 15830) 9,5 m...
  • Page 78 INSTRUMENTS AND CONTROLS DESCRIPTION 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. 1 - DRIVER'S CAB ACCESS ..................... . . 2-42 2 - DRIVER'S SEAT .
  • Page 79 52 51 10 11 2 - 41...

  • Page 80: Driver's Cab Access

    1 - DRIVER'S CAB ACCESS - Face the driver's cab access to get in and out, and always use the three support points provided for this purpose. 1 - Left handle. 2 - Right handle. 3 - Step. 2 - DRIVER'S SEAT DRIVER’S SEAT (STANDARD) DESIGNED FOR MAXIMUM COMFORT, THIS SEAT CAN BE ADJUSTED AS FOLLOWS.
  • Page 81 LUMBAR ADJUSTMENT (FIG. F) This increases the comfort of the seat and the driver’s freedom of movement. - Turn the handle either left or right to adjust the height and depth of the lumbar support. BACKREST ANGLE ADJUSTMENT (FIG. G) IMPORTANT If you do not support the backrest when making adjustments, it swings completely forwards.

  • Page 82: Seat Belt

    3 - SEAT BELT IMPORTANT Under no circumstances must the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the seat belt. - Sit correctly on the seat. - Check that seat belt is not twisted. - Place the seat belt at hip level.
  • Page 83 1 - INSTRUMENTS AND INDICATORS A - TACHOMETER B - ENGINE WATER TEMPERATURE If the indicator lamp comes on when the lift truck is running, this means that the coolant temperature is high. Stop the engine immediately and look for the cause of the cooling circuit malfunction. C - FUEL LEVEL Indicator lamp , indicates that you are in reserve and that your running time is limited.
  • Page 84 ENGINE PREHEAT INDICATOR LAMP Preheat is necessary. When the lift truck is switched on, the indicator lamp comes on for 2 seconds and goes off as soon as preheat is ended. Start the lift truck’s engine. GEARBOX OIL PRESSURE WARNING INDICATOR LAMP This light comes on when there is an abnormal drop in gearbox pressure.
  • Page 85 2 -  INFORMATION SCREEN BOOM ANGLE MAINTENANCE REQUIRED MAINTENANCE REQUIRED + ERROR CODE NUMBER HYDRAULIC MOVEMENT NEUTRALIZATION DISABLING “AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF STABILIZER POSITION INDICATORS GEAR RATIO WHEEL STEERING INDICATOR CLOCK DRIVING WORK (OPTION) EXTERNAL TEMPERATURE HOUR METER SPEEDOMETER HYDRAULIC FLOW RATE ADJUSTMENT (OPTION) POP UP - Blue POP UP: information message.

  • Page 86: Longitudinal Stability Limiter And Warning Device

    8 - LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE IMPORTANT The operator must respect the lift truck's load chart, and the operating mode according to the attachment. This device warns the operator of the forklift truck’s longitudinal stability limits. However, lateral stability can reduce the load chart in the upper part, and this reduction is not detected by the device.
  • Page 87 A - VISUAL ALARMS • A1 - A2 - A3: There is a significant reserve of longitudinal stability. • A4 - A5: The lift truck is nearing the limit of longitudinal stability. Maneuver with care. • A6: The lift truck is close to the longitudinal stability limit. Maneuver with care. •...

  • Page 88: Information Screen Control Buttons

    9 - INFORMATION SCREEN CONTROL BUTTONS INFORMATION MENU - Press the button to display the “INFORMATION” menu - Press the button to select from the menus and sub-menus. - Press knob  to confirm. > FAULT TROUBLESHOOTING > MAINTENANCE RESET MAINTENANCE GENERAL >...

  • Page 89: Push Button Panel

    10 - PUSH BUTTON PANEL BUTTON FUNCTIONS - Red button: Safety. - Orange button: Transmission/Engine. - Blue button: Hydraulics. - Black button: Other. BUTTON DIAGNOSTICS - If all buttons are unlit, there is a power supply problem. Contact your dealer. - If the buttons blink simultaneously, power problem, contact your dealer.

  • Page 90: Switches

    TILT CIRCUIT LOCKING - Press the button to shut off the tilt circuit hydraulic movements. The indicator lamp indicates it is in use. ATTACHMENT CIRCUIT LOCKING - Press the button to shut off the attachment circuit hydraulic movements. The indicator lamp indicates it is in use. FORCED OPERATION OF ATTACHMENT CIRCUIT (OPTION)  DESCRIPTION AND USE OF THE OPTIONS FAN REVERSAL (OPTION)

  • Page 91: Hazard Warning Lights

    12 - HAZARD WARNING LIGHTS 13 - USB RECHARGING SOCKET 14 - LIGHTING, HORN AND INDICATOR SWITCH The switch controls the visual and sound alarms. • A - All lights are off, the turn signals work. • B - The right hand indicator lights flash. •...

  • Page 92: Fuses And Relays In The Cab

    17 - FUSES AND RELAYS IN THE CAB A sticker on the inside of the access panel provides a quick indication of the use of the fuse plate's components described below. - Remove access panel 1 to gain access to the fuses and relays. Replace a blown fuse with a new fuse of the same quality and rating.
  • Page 93 F58 20 A Lighting, horn and indicator switch. F59 15 A Relay (K31). Unused. F61 7.5 A Left-hand indicator light. F62 7.5 A Right-hand indicator light. F63 15 A Dipped beam headlights. F64 15 A Main beam headlights. F65 7,5 A Left sidelights. F66 7,5 A Right sidelights.

  • Page 94: Fuses And Relays Under The Engine Cover

    18 - FUSES AND RELAYS UNDER THE ENGINE COVER - Open the engine bonnet, remove cover 1 to gain access to the fuses and relays. Replace a blown fuse with a new fuse of the same quality and rating. Never use a repaired fuse.

  • Page 95: Forward/Neutral/Reverse Gear Selection

    19 - FORWARD/NEUTRAL/REVERSE GEAR SELECTION When changing the direction of travel, the lift truck should be traveling at slow speed and not accelerating. • FORWARD: Push the switch forward (position A). • REVERSE: Push the switch backward (position B). Reversing lights and a backup alarm indicate that the lift truck is traveling in reverse.

  • Page 96: Steering Selection

    21 - STEERING SELECTION IMPORTANT Before selecting one of the three steering possibilities, align the 4 wheels in relation to the lift truck axis. Never change the steering mode whilst driving. The green indicator lights on the information screen come on to indicate the alignment of the wheels relative to the lift truck.

  • Page 97: Hydraulic Boom Controls

    25 - HYDRAULIC BOOM CONTROLS IMPORTANT Do not try to modify the hydraulic pressure of the system. If it malfunctions contact your dealer. ANY MODIFICATION INVALIDATES THE WARRANTY AND YOU WILL BE CRIMINALLY LIABLE IN THE EVENT OF AN ACCIDENT. Use the hydraulic controls gently without jerking, to avoid incidents caused by shaking the lift truck.

  • Page 98: Hydraulic Frame Leveling Controls

    27 - HYDRAULIC FRAME LEVELING CONTROLS FRAME LEVELLING ON LEFT FRAME LEVELLING ON RIGHT NOTE: The tilt correction may only be performed if the lifting angle for the boom is less than 34°. 28 - LEVEL INDICATOR EXCEPT FOR AUSTRALIA A - SPIRIT LEVEL (EXCEPT FOR AUSTRALIA) Confirms if the lift truck is horizontal.

  • Page 99: Air Conditioning Controls (Air Conditioning Option)

    30 - AIR CONDITIONING CONTROLS (AIR CONDITIONING OPTION) IMPORTANT The air conditioning only works if the lift truck has been started. When using your air conditioning, it is essential to work with the cab closed. In winter: So as to ensure that the air conditioning unit is correctly operated and completely efficient, start up the compressor once a week, even for a short period of time, in order to lubricate the internal seals.

  • Page 100: Door Opening Handle

    33 - DOOR OPENING HANDLE Two keys are provided with the lift truck to enable the cab to be locked. - Pull on the handle to open the door. 34 - DOOR OPEN LEVER 35 - DOOR CLOSE HANDLE 36 - WINDOW WINDER SWITCH 37 - SIDE STORAGE SPACE 38 - HANDLE FOR REAR WINDOW OPENING EMERGENCY EXIT...

  • Page 101: Front Headlights

    40 - FRONT HEADLIGHTS • A -  Front left-hand indicator light. • B -  Front left-hand dipped headlight. • C -  Front left-hand headlight. • D -  Front left-hand sidelight. • E -  Front right-hand indicator light. • F -  Front right-hand low beam headlight. • G -  Front right-hand high beam headlight. •...

  • Page 102: Inside Rear-View Mirror (Option)

    46 - INSIDE REAR-VIEW MIRROR (OPTION) 47 - STEERING WHEEL ADJUSTMENT LEVER (OPTION) This handle enables the angle and height of the steering wheel to be adjusted. - Pull the knob backwards. - Adjust the steering wheel to the desired position. - Push the knob back to lock the steering wheel in position.

  • Page 103: Truck/Platform Selector Switch

    51 - TRUCK/PLATFORM SELECTOR SWITCH Handling or platform mode operation from driver's cab controls. Platform operation mode from control console. Radio control (OPTION). - Operation via the radio-control controls. 52 - RESCUE SWITCH  OPERATION OF THE PLATFORM 53 - DEAD-MAN BUTTON IN RESCUE MODE  OPERATION OF THE PLATFORM 54 - CONTROL CONSOLE IMPORTANT...

  • Page 104: Radio-Control (Option)

    55 - RADIO-CONTROL (OPTION) A - RADIO CONTROL TRANSMITTER (OPTION) B - RADIO CONTROL RECEIVER (OPTION) IMPORTANT The transmitter and the receiver must not be used without an antenna at the risk of damaging them. When the radio-control transmitter is not in use, always disconnect it, switch it off and remove the key switch. Store the radio-control transmitter in the space provided behind the driver's seat.

  • Page 105: Fuel Tank

    The diesel exhaust fluid quality can be measured using a refractometer. The diesel exhaust fluid must comply with standard ISO 22241-1 with a urea concentration of 32.5%. Refractometer (MANITOU part number: 959709) STORAGE "DEF" (Diesel Exhaust Fluid) Up to 4 months without using the lift truck, check the quality of the diesel exhaust fluid with a refractometer.
  • Page 106 OPERATION OF THE PLATFORM 1 - ATTACHING THE PLATFORM TO THE LIFT TRUCK ................2-68 2 - HYDRAULIC CONNECTION OF THE PLATFORM TO THE LIFT TRUCK .

  • Page 107: Hydraulic Connection Of The Platform To The Lift Truck

    2 - HYDRAULIC CONNECTION OF THE PLATFORM TO THE LIFT TRUCK IMPORTANT Make sure that the rapid connectors are clean and protect the holes which are not used, with the caps provided. - Stop the engine and keep the ignition on the lift truck. - Release the pressure from the hydraulic platform slewing circuit.

  • Page 108: Deploying The Extendible Platform

    4 - DEPLOYING THE EXTENDIBLE PLATFORM UNFOLDING IMPORTANT To avoid the flooring pieces 1 falling, check that they are properly secured by the locking bolts 2. - Remove the pin 3 and withdraw the locking pin 4 (2 pins on each side of the platform). - Fold out the mobile sides and lock them with the pins and clips 5 (6 pins and clips on each side of the platform).

  • Page 109: Using The Control Panel

    5 - USING THE CONTROL PANEL IMPORTANT A supervisor MUST be present on the ground while the platform is in use - Set the TRUCK/PLATFORM 1 selector switch to , which will shut down the engine. - Take the control console from the cab and mount it on the platform. - Pass the cable through the rings 2.
  • Page 110 DESCRIPTION OF THE CONTROL CONSOLE ENGINE START-UP ENGINE SHUT-DOWN HORN Operates the lift truck's horn when needed. A - HYDRAULIC MOVEMENT SELECTOR Press the trigger lever 1 to increase the engine speed before performing the hydraulic movement. BOOM MOVEMENTS • Lever backward to lift. •...
  • Page 111 LIFT TRUCK OVERLOAD The continuously lit red indicator lamp and the pictogram of the warning device and the longitudinal stability limiter indicate that the lift truck is at the limit of its maximum permitted load. All “AGGRAVATING” movements are neutralised: •...

  • Page 112: Removing The Platform

    6 - REMOVING THE PLATFORM IMPORTANT Be sure to store the platform in a place where it will not obstruct the work of others. Perform the previous operations (A - B - C - D - E) in reverse order, in accordance with the following instructions: - Return the control console or remote-control to the lift truck cab. - Place the safety cable in its housing.

  • Page 113: Manual Repair Procedure

    8 - MANUAL REPAIR PROCEDURE IN THE EVENT OF A BREAKDOWN OR FAULT THAT PREVENTS RESTARTING HYDRAULIC MOVEMENTS FROM THE LIFT TRUCK CONTROLS, THE PLATFORM CAN BE LOWERED TO THE GROUND MANUALLY AS FOLLOWS: FOLLOW THE INSTRUCTIONS BELOW: - Switch on lift truck ignition. - Remove the protective casing 1.
  • Page 114 USING THE RADIO-CONTROL FOR HANDLING (OPTION) IMPORTANT THE RADIO CONTROL CANNOT BE USED WITH THE PLATFORM. Place the lift truck in its working area, in accordance with the operating and safety instructions given in the lift truck operator's manual. - Set the forward/reverse selector to neutral. - Leave the engine running idle.
  • Page 115 DESCRIPTION OF THE RADIO-CONTROL A - KEY BUTTON B - GREEN LAMP A flashing green lamp indicates that the radio-control is operating correctly. A very rapidly flashing green lamp indicates one of the following: • that the link between the transmitter and receiver has been interrupted (the engine stops automatically), •...
  • Page 116 TOWING DEVICE IMPORTANT Do not tow a trailer or an attachment that is not in perfect working condition. Using a trailer in poor condition may affect the lift truck's steering and braking, and hence the safety of the assembly. If a third party helps in coupling or uncoupling the trailer, this person must be permanently visible to the driver and wait until the lift truck has stopped, the handbrake is on and the I.C.
  • Page 117 4 - REAR ELECTRIC SOCKET (OPTION) - Connect the male plug to the female socket 1 on the lift truck and make sure the lights of the trailer or the light bar are working properly. 2 - 79...
  • Page 118 DESCRIPTION AND USE OF THE OPTIONS 1 - WINDSCREEN GRILL ......................2-81 2 - WATERPROOF DOCUMENT HOLDER .

  • Page 119: Windscreen Grill

    1 - WINDSCREEN GRILL DESCRIPTION The windscreen grill provides additional protection for the operator from any external elements spattered on the windscreen. This grill must be removable from inside the cab to enable an emergency exit. EMERGENCY EXIT - After breaking the windscreen with the emergency hammer, push (with force) on the windscreen grill at A to remove it.

  • Page 120: License Plate Light

    6 - LICENSE PLATE LIGHT 7 - FUEL PREHEATER The paraffin particles found naturally in diesel crystallise at low temperatures. The fuel preheater limits their accumulation in the filter. 8 - PREHEAT ROD Enables the engine to be kept warm during prolonged periods of stoppage and thus improves engine starting.

  • Page 121: Keypad "Easymanager

    10 - KEYPAD "EasyMANAGER" A code must be created for the operator via the "EasyMANAGER" portal. For more information, contact your dealer. OPERATION BY ID CODE - Switch on lift truck ignition, LED 1 comes on. - Enter your ID code and confirm by pressing the "V"key. - LED 2 comes on to confirm the operator’s identification.

  • Page 122: Fan Reversal

    12 - FAN REVERSAL Cleans the radiator core and the grille of the engine cover by reversing the air flow. IMPORTANT The self-cleaning fan is operational from an engine coolant temperature of 40 °C. When in use, beware of the risk of projection into the eyes. AUTOMATIC FAN REVERSAL - The indicator lamp is on, the fan operates in self-cleaning mode for a few seconds once every 3 minutes.

  • Page 123: Attachment Circuit Manual Override

    15 - ATTACHMENT CIRCUIT MANUAL OVERRIDE IMPORTANT This OPTION should only be used with an attachment that requires a continuous hydraulic movement such as: sweeper, feed wagon, mixer, sprayer, etc. It is strictly prohibited in handling and for all other attachments (winch, crane, crane jib with winch, hook, etc.). USING AND STORING MANUAL OVERRIDE - Press the button to select the work mode...

  • Page 124: Attachment Easy Hydraulic Connection

    17 - ATTACHMENT EASY HYDRAULIC CONNECTION For easy connection and disconnection of hydraulic attachments. PUSH BUTTON OPERATION - Switch on lift truck ignition. - Press for two seconds on pushbutton 1 to release the attachment circuit hydraulic pressure. - Connect or disconnect the quick couplers of the hydraulic attachment  4 - ADAPTABLE ATTACHMENTS AS AN OPTION ON THE RANGE: PICKING UP THE ATTACHMENTS).

  • Page 125: Boom Head Solenoid Valve

    19 - BOOM HEAD SOLENOID VALVE Enables use of two hydraulic functions on the attachment circuit. ATTACHMENT LINE L1 CONTROL - Push switch 1 forward or backward. ATTACHMENT LINE L2 CONTROL - Hold down button 2 and operate button 1 forwards or backwards. 20 - BOOM HEAD SOLENOID VALVE + ATTACHMENT HYDRAULIC LOCKING The addition of these two options on the attachment line allows two hydraulic functions to be used and locks the attachment onto the carriage.

  • Page 126: Lifting Ring On Single Carriage

    21 - LIFTING RING ON SINGLE CARRIAGE CONDITIONS OF USE IMPORTANT Follow the instructions given in the instruction manual (  1 - OPERATING AND SAFETY INSTRUCTIONS: INSTRUCTIONS FOR HANDLING LOADS). - The lifting ring must be used WITHOUT FORKS AND ATTACHMENTS, but the angle of inclination of the carriage must be same as when the forks are used in the horizontal position.
  • Page 127 3 - MAINTENANCE 3 - 1...
  • Page 128 3 - MAINTENANCE ORIGINAL MANITOU SPARE PARTS AND EQUIPMENT FORKLIFT TRUCK MAINTENANCE DAILY AND WEEKLY MAINTENANCE MANDATORY FIRST 500 HOURS OR 6 MONTHS OF SERVICE PERIODIC MAINTENANCE OCCASIONAL MAINTENANCE AND OPERATION FILTER CARTRIDGES AND BELTS LUBRICANTS AND FUEL 3-10 Ü  10H - DAILY MAINTENANCE OR EVERY 10 HOURS OF SERVICE 3-14 Ü...
  • Page 129 • 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 130 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 131 MANDATORY FIRST 500 HOURS OR 6 MONTHS OF 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 ÜŒ service and periodic 500 H service (  ...
  • Page 132 PERIODIC MAINTENANCE MAINTENANCE SCHEDULE Þ Þ 500 H 1000 H Ü 250 H 750 H SCHEDULE FIRST 6 MONTHS FIRST 500 HOURS or 1 YEAR or 2 YEARS MANDATORY SERVICE Ü Œ Œ  Œ Œ   PERIODIC MAINTENANCE MANDATORY SERVICE ...
  • Page 133 Ü  500H - PERIODIC MAINTENANCE - EVERY 500 HOURS OF SERVICE OR 1 YEAR - CHECK Countdown before “stationary lift truck” exhaust regeneration........3-24 - CHECK Alternator belt tension .
  • Page 134 Ü  2000H - PERIODIC MAINTENANCE - EVERY 2000 HOURS OF SERVICE OR EVERY 4 YEARS ALSO PERFORM THE 500-HOUR AND 1000-HOUR PERIODIC MAINTENANCE PROCEDURES. - CHECK Wheel nut tightening torque ............... . 3-36 - CLEAN Air conditioning (OPTION) * .
  • Page 135 FILTER CARTRIDGES AND BELTS Ü  500H - PERIODIC MAINTENANCE - EVERY 500 HOURS OF SERVICE OR 1 YEAR ENGINE OIL FILTER EXTERIOR CAB VENTILATION FILTER Part No.: 943326 Part No.: 261971 HYDRAULIC RETURN OIL FILTER CARTRIDGE INTERIOR CAB VENTILATION FILTER Part No.: 311821 Part No.: 958671 Ü  1000H - PERIODIC MAINTENANCE - EVERY 1,000 HOURS OF SERVICE OR EVERY 2 YEARS ALSO ADD THE FILTER CARTRIDGES FROM THE PERIODIC MAINTENANCE FOR 500 HOURS OF SERVICE.
  • Page 136 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 137 REAR AXLE DESCRIPTION CAPACITY RECOMMENDATION 7,2 ℓ SPECIAL MANITOU OIL FOR IMMERSED BRAKES REAR AXLE DIFFERENTIAL -40 °C +50 °C 2 x 0,75 ℓ MANITOU SAE80W90 MECHANICAL TRANSMISSION OIL REAR WHEEL REDUCING GEAR -40 °C +50 °C REAR WHEEL REDUCING GEAR PIVOTS MANITOU BLACK MULTI-PURPOSE LUBRICANT -40 °C...
  • Page 138 2 ℓ 5 ℓ 20 ℓ 55 ℓ 209 ℓ - MANITOU EVOLOGY OIL 10W40 API CJ4 895837 895838 895839 895840 - MANITOU DX IIIG AUTOMATIC TRANSMISSION OIL 958186 947972 947973 947974 947975 - MANITOU ISO VG 46 HYDRAULIC FLUID 545500 582297 546108...
  • Page 139 3 - 13...

  • Page 140: Daily Maintenance Or Every 10 Hours Of Service

    Ü  10H - DAILY MAINTENANCE OR EVERY 10 HOURS OF SERVICE CHECK Lift truck environment Carry out a general inspection around the lift truck: - Fluid leaks or stains on the ground. - Additional objects on the lift truck and in the cabin. - Mounting and locking of the attachment.

  • Page 141: Check Fuel Pre-Filter

    CHECK Fuel pre-filter IMPORTANT Carefully clean the outside of the pre-filter and its holder, to prevent dust from getting into the system. - Open the engine cover. - Disconnect electrical wiring harness 1 from the fuel pre-filter. - Place a hose on the drain plug 2 and the other end in a container. - Unscrew the drain plug 2 by two turns.

  • Page 142: Weekly Maintenance Or Every 50 Hours Of Service

    Ü  50H - WEEKLY MAINTENANCE OR EVERY 50 HOURS OF SERVICE CHECK Gear box oil level Park the lift truck on level ground with the boom raised and the engine stopped. IMPORTANT Raise the boom and place the boom safety wedge on the rod of the lifting cylinder (  1 - INSTRUCTIONS AND SAFETY RECOMMENDATIONS: LIFT TRUCK MAINTENANCE INSTRUCTIONS).

  • Page 143: Check Brake Fluid Level

    - Telescope the boom several times in order to spread the lubricant evenly. - Remove the surplus lubricant. IMPORTANT If the lift truck is used in an abrasive environment (dust, sand, coal) use lubricating varnish (MANITOU Part No.: 483536). Consult your dealer. 3 - 17...

  • Page 144: Check Hydraulic Fluid Level

    CHECK Hydraulic fluid 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. - Check dipstick 1, the correct level must be at the level of the red dot.

  • Page 145: Clean

    - Cleaning is completed when there is no more dust on the cartridge. - Clean the cartridge seal surface with a damp, clean lint-free cloth and grease with a silicone lubricant (MANITOU part no.: 479292).

  • Page 146: Lubricate General Lubrication

    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 10 hours of service or every day. Clean, then lubricate the following points with grease (  LUBRICANTS AND FUEL) and remove the surplus.
  • Page 147 3 - 21...
  • Page 148 ÜŒ  250H - PERIODIC MAINTENANCE - EVERY 250 HOURS OF SERVICE CHECK Tension of boom outer chains MT 1840 … Set the lift truck on its stabilizers, with the boom horizontal. IMPORTANT These checks are important for the proper operation of the boom. If there is a fault, consult your dealer.
  • Page 149 3 - 23...
  • Page 150 Ü  500H - PERIODIC MAINTENANCE - EVERY 500 HOURS OF SERVICE OR 1 YEAR CHECK Countdown before “stationary lift truck” exhaust regeneration Depending on the countdown before the next regeneration, you can evaluate and, if necessary, perform a regeneration during the periodic 500-hour service (  3 - MAINTENANCE: OCCASIONAL MAINTENANCE).
  • Page 151 CHECK Hydraulic fluid MANITOU offers a hydraulic fluid analysis kit which might make it possible to delay the recommended deadline in the periodic maintenance schedule (2,000 hours). In this case we recommend an analysis of the hydraulic fluid every 500 hours of service.
  • Page 152 REPLACEMENT OF THE FILTER - Unscrew and discard the engine oil filter 5, together with its seal. - Clean the filter bracket with a clean, lint-free cloth. - Lightly oil the seal before refitting the new oil filter (  FILTER CARTRIDGES AND BELTS) on its bracket (tightening torque 15 - 17 N.m).
  • Page 153 REPLACE Hydraulic return oil filter cartridge Stop the engine and release the pressure from the systems by operating the hydraulic controls. IMPORTANT Thoroughly clean the outside of the filter and its surroundings before any operation to prevent any risk of polluting the hydraulic system.
  • Page 154 CHAIN ELONGATION We recommend that you perform this operation using the chain checking gauge (MANITOU Part No.: 161583). - Set the lift truck on its stabilizers, with the boom horizontal. - Fully extend the telescopes and continue operating the control for a few moments to properly tension the chains.
  • Page 155 CHECK Seat belt IMPORTANT Under no circumstances must the lift truck be used if the seat belt is defective (fixing, locking, cuts, tears, etc.). Immediately repair or replace the seat belt. SEAT BELT WITH TWO ANCHORING POINTS - Check the following points: •...
  • Page 156 REPLACE Coolant These operations are to be carried out as necessary or every 2 years at the beginning of winter. Place the lift truck on level ground with the engine stopped and cold. IMPORTANT The engine does not contain any anti-corrosion elements and must be filled throughout the year with a mixture containing 25% ethylene glycol-based antifreeze.
  • Page 157 REPLACE Dry air filter cartridge Prefiltration elements are available for use in very dusty conditions (  FILTER CARTRIDGES AND BELTS). Also, the checking and cleaning periodicity of the cartridge must be reduced (up to 250 hours in a very dusty atmosphere and with pre-filtration). IMPORTANT Change the cartridge in a clean location, with the engine stopped.
  • Page 158 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 and wear personal protective equipment (gloves and goggles). Carefully clean the outside of the fuel filter, to prevent dust from getting into the system. - Switch off the lift truck's ignition and wait for the pump to stop.
  • Page 159 REPLACE Alternator belt IMPORTANT Check the belt tension again after the first 20 hours of operation. - Open the engine cover. - Remove the protective casing 1. - Loosen the screws 2 and 3 by two to three thread turns. - Loosen the screw 4 to swivel the alternator assembly so as to free the belt 5. - Remove the belt and replace with a new one (  FILTER CARTRIDGES AND BELTS).
  • Page 160 REPLACE Front wheel reducer oil REPLACE Rear wheel reducer oil Place the lift truck on level ground with the engine stopped and the reducers’ oil still warm. IMPORTANT Dispose of the used oil in an ecological manner. - Drain and change the oil of each wheel reduction gear. - Place drain plug 1 in position A.
  • Page 161 3 - 35...
  • Page 162 Ü  2000H - PERIODIC MAINTENANCE - EVERY 2000 HOURS OF SERVICE OR EVERY 4 YEARS ALSO PERFORM THE 500-HOUR AND 1000-HOUR PERIODIC MAINTENANCE PROCEDURES. 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 163 REPLACE Hydraulic fluid REPLACE Breather for the hydraulic fluid tank CLEAN Hydraulic fluid tank suction strainer REPLACE Brake accumulator unit filter REPLACE Distributor control head filter REPLACE Fan reversal filter (OPTION) Place the lift truck on level ground with the engine shut down and the boom retracted and lowered as far as possible.
  • Page 164 REPLACING THE DISTRIBUTOR CONTROL HEAD FILTER IMPORTANT Be careful to mount the filter 9 in the same direction as the arrow. - Undo the two connections 8 and replace the filter 9 (  FILTER CARTRIDGES AND BELTS). REPLACING THE FAN REVERSAL FILTER (OPTION) IMPORTANT Be careful to mount the filter 10 in the same direction as the arrow.
  • Page 165 CHECK Radiator * CHECK Water pump and thermostat * CHECK Alternator and starter * CHECK Turbocharger * CHECK Transmission pressures * CHECK Steering * CHECK Steering swivel joints * CHECK Brake pad and brake disk wear * CHECK Condition of boom assembly * CHECK Bearings and bushings of the boom * CHECK...
  • Page 166 Ü  4000H - PERIODIC MAINTENANCE - EVERY 4000 HOURS OF SERVICE OR EVERY 8 YEARS CHECK Boom inner chain wear MT 1840 … IMPORTANT Checking of the boom's inner chains requires the telescopes to be disassembled (contact your dealer). 3 - 40...
  • Page 167 3 - 41...
  • Page 168 700 hours (700h => 0h). REPLACE Wheels For this operation, we advise you to use the hydraulic jack (MANITOU part no.:  505507) and the safety support prop (MANITOU part no.: 554772). IMPORTANT In the event of a wheel being changed on the public highway, secure the lift truck vicinity: - Stop the lift truck, if possible on firm, level ground.
  • Page 169 REPLACE Battery IMPORTANT Operate the battery cut-off for a minimum of 30 seconds after having switched off the ignition with the ignition key. Handling and servicing a battery can be dangerous, take the following precautions: - Wear protective goggles. – - Keep the battery horizontal.
  • Page 170 RESET Longitudinal stability limiter and warning device According to the use of the lift truck, the device may need to be periodically reset. This operation can be easily performed by means of the following procedure. - Provide a fork carrier or a bucket and a load corresponding to at least half the lift truck's rated capacity. - Preferably perform the reset when the lift truck is still cold (before it is used) or ensure that the temperature of the rear axle is not more than 50 °C.
  • Page 171 3 - 45...
  • Page 172 Ü OCCASIONAL OPERATION TOW OR WINCH Lift truck IMPORTANT Do not tow the lift truck at a speed exceeding 6 km/h. over a miximum distance of 5 km. This is a dangerous maneuver. Carefully chock the lift truck before towing, as the parking brake system is inoperative. - Place the forward/reverse selection lever and gear lever in neutral.
  • Page 173 TRANSPORT Lift truck IMPORTANT Ensure that the safety instructions associated with the flatbed are complied with before loading the lift truck and that the driver of the carrier vehicle is informed of the dimensions and the weight of the lift truck (  2 - DESCRIPTION: SPECIFICATIONS).
  • Page 174 3 - 48...
  • Page 175 4 - ATTACHMENTS THAT CAN BE ADAPTED TO THE RANGE 4 - 1...
  • Page 176 4 - ATTACHMENTS THAT CAN BE ADAPTED TO THE RANGE INTRODUCTION PICKING UP THE ATTACHMENTS TECHNICAL SPECIFICATIONS OF ATTACHMENTS ATTACHMENT GUARDS 4-12 4 - 2...
  • Page 177 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 can be used on its lift trucks ( TECHNICAL CHARACTERISTICS OF ATTACHMENTS).
  • Page 178 PICKING UP THE ATTACHMENTS 1 - ATTACHMENT WITHOUT HYDRAULICS AND HAND LOCKING DEVICE FITTING AN ATTACHMENT - Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessary precautions in order to move it safely. - Check that the locking pin is in position in the bracket (Fig.
  • Page 179 2 - HYDRAULIC ATTACHMENT AND MANUAL LOCKING DEVICE FITTING AN ATTACHMENT - Ensure that the attachment is in a position facilitating the locking to the carriage. If it is not correctly oriented, take the necessary precautions in order to move it safely. - Check that the locking pin is in position in the bracket (Fig.
  • Page 180 TECHNICAL SPECIFICATIONS OF ATTACHMENTS FLOATING FORK CARRIAGE TFF 45 MT-1040 TFF 45 MT-1300 PART NO. 653344 653345 Rated capacity 4500 kg 4500 kg Width 1040 mm 1300 mm Weight 370 kg 400 kg FLOATING FORK PART NO. 211922 Section 125x50x1200 mm Weight 71 kg 4 - 6...
  • Page 181 STANDARDISED TILTING FORK CARRIAGE PFB 45 N MT-1260 S2 PFB 45 N MT-1670 S2 PFB 45 N MT-2000 S2 PART NO. 654407 653747 653748 Rated capacity 4500 kg 4500 kg 4500 kg Width 1260 mm 1670 mm 2000 mm Weight 200 kg 255 kg 300 kg STANDARDISED FORK PART NO.
  • Page 182 BUILDING BUCKET CBC 800 L2250 S3 CBC 900 L2450 S3 PART NO. 654471 654470 Rated capacity 814 ℓ 893 ℓ Width 2250 mm 2450 mm Weight 385 kg 410 kg LOADING BUCKET CBR 900 L2250 S2 CBR 1000 L2450 S2 PART NO. 653749 654716 Rated capacity 904 ℓ...
  • Page 183 CONCRETE BUCKET (ADAPTABLE ON FORKS) BB 500 S4 BBH 500 S4 PART NO. 654409 751462 Rated capacity 500 ℓ/1300 kg 500 ℓ/1300 kg Width 1100 mm 1100 mm Weight 205 kg 220 kg CONCRETE BUCKET WITH SPOUT (ADAPTABLE ON FORKS) MT 1440 … BBG 500 S4 BBHG 500 S4 PART NO.
  • Page 184 CRANE P 600 MT S3 PART NO. 653228 Rated capacity 600 kg Weight 170 kg CRANE P 4000 MT S2 PART NO. 653226 Rated capacity 4000 kg/1200 kg Weight 210 kg CRANE JIB WITH WINCH PT 600 MT S6 PART NO. 708538 Rated capacity 600 kg Weight 288 kg...
  • Page 185 CRANE JE 6000/600 PART NO. 939995 Rated capacity 600 kg Weight 182 kg BOOM CRANE WITH BIG BAG HBB 1500/2400 PART NO. 931627 Rated capacity 2400 kg Weight 186 kg POSITIONING THE EDGE PART NO. 790523 Rated capacity 1500 kg Weight 450 kg 4 - 11...
  • Page 186 ATTACHMENT GUARDS FORK GUARD PART NO. 227801 FORK BLOCK FOR FLOATING FORK CARRIAGE PART NO. 261210 BUCKET PROTECTOR Always ensure that the width of the protector you choose is less than or equal to the width of the bucket. PART NO. 206734 206732 206730...
  • Page 187 5 -  OPTIONAL ADAPTABLE PLATFORMS FOR THE RANGE 5 - 1...
  • Page 188 5 - 2...
  • Page 189 The manufacturer cannot be held responsible for any modifications or adaptations made to platforms without its knowledge. - A wide range of platforms are available, guaranteed by MANITOU and designed to fit your lift truck perfectly. - The platforms are delivered with a load chart concerning your lift truck. The operator's manual and the load chart should be kept in the places provided in the lift truck.
  • Page 190 TECHNICAL CHARACTERISTICS OF FIXED PLATFORMS FIXED PLATFORM 2M PART NO. 788782 Rated capacity 365 kg including 3 persons 2000 mm 1210 mm 1292 mm Weight 410 kg EN 280 15.40m 13.40m 72° kg + =365kg 70° 60° 50° 40° 30° 6.18m 20°...
  • Page 191 MINE PLATFORM 1200KG 914730 939701 PART NO. Wire floor Solid floor Rated capacity 1,200 kg including 3 people 1,200 kg including 3 people 2216 mm 2216 mm 1608 mm 1608 mm 1215 mm 1215 mm Weight 1010 kg 1096 kg 5 - 5...
  • Page 192 TECHNICAL CHARACTERISTICS OF SWIVEL PLATFORMS SWIVELLING PLATFORM 5M00 PART NO. 52526534 Rated capacity 365 kg including 3 persons 5000 mm 1200 mm 1250 mm 887 mm 90 ° Weight 770 kg 5 - 6...
  • Page 193 EXTENDIBLE AND SWIVELLING PLATFORM 2M25/4M00 PART NO. 788783 Rated capacity 365 kg including 3 persons 2250 mm 4000 mm 1210 mm 1320 mm 980 mm 90 ° Weight 700 kg EN 280 EN 280 kg + =150kg 19.30m 17.30m 15.40m 13.40m kg + =365kg kg +...
  • Page 194 EXTENDIBLE AND SWIVELLING PLATFORM 2M25/4M00 700KG PART NO. 788787 Rated capacity 700 kg including 3 persons 2250 mm 4000 mm 1200 mm 1300 mm 887 mm 90 ° Weight 1030 kg CSA 354.1-04 CSA 354. 1 -04 = 250 kg kg + = 150 kg kg + 551 lbs...
  • Page 195 EXTENDIBLE AND SWIVELLING PLATFORM 2M25/4M00 1000KG PART NO. 788785 Rated capacity 1,000 kg including 3 people 2250 mm 4000 mm 1200 mm 1300 mm 887 mm 90 ° Weight 1030 kg EN 280 EN 280 kg + =700kg kg + =365kg 19.25m kg + =150kg 15.40m...
  • Page 196 TECHNICAL CHARACTERISTICS OF ROOFER'S PLATFORMS ROOFER PLATFORM NC 365KG PART NO. 788789 Rated capacity 365 kg including 3 persons 2420 mm 1305 mm 1600 mm 1200 mm 90 ° Weight 1745 kg (1110 + 635 kg) - Pod only 1110 kg - Platform orientation 635 kg kg + =150kg...
  • Page 197 ROOFER PLATFORM NC 1000KG PART NO. 788791 Rated capacity 1,000 kg including 3 people 2420 mm 1305 mm 1600 mm 887 mm 90 ° Weight 1655 kg (1020 + 635 kg) - Pod only 1020 kg - Platform orientation 635 kg kg + =700kg kg + =700kg...
  • Page 198 TECHNICAL SPECIFICATIONS OF PLATFORMS "PSE" PLATFORM PSE 4400/365 D PART NO. 939021 Rated capacity 365 kg including 3 persons 2212 mm 4328 mm 1280 mm 1300 mm 887 mm 90° Weight 670 kg 150kg 365kg 4 . 4 2 . 2 MT1840A 365kg N°52532178 PLATFORM PSE 4400/365 DD...
  • Page 199 PLATFORM PSE 4400/700 D PART NO. 939023 Rated capacity 700 kg including 3 persons 2212 mm 4348 mm 1300 mm 1312 mm 887 mm 90° Weight 1030 kg 4 . 4 2 . 2 MT1840A 700kg N°52532180 PLATFORM PSE 4400/1000 D PART NO. 939022 Rated capacity 1,000 kg including 3 people...
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