Manitou MC 18-2 D K ST3A S1 to MSI 35 D K ST3A S5 Repair Manual 647659EN

Description

• Model List:
  • MC 18-2 D K ST3A S1
  • MC 18-4 D K ST3A S1
  • MC 25-2 D K ST3A S1
  • MC 25-4 D K ST3A S1
  • MC 30-2 D K ST3A S1
  • MC 30-4 D K ST3A S1
  • MSI 25 D K ST3A S5
  • MSI 30 D K ST3A S5
  • MSI 35 D K ST3A S5

• 1. Page de garde / Front page
• 2. Sommaire général General table of content
• 4. GENERAL, CHARACTERISTICS AND SAFETY
• 4.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 4.1.1. FOREWORD
• 4.1.2. SERVICING POSITION
• 4.1.3. EXPLANATION OF SYMBOLS
• 4.1.4. SERVICING RULES
• 4.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 4.2.1. CHARACTERISTICS (MC)
• 4.2.2. CHARACTERISTICS (Msi)
• 4.2.3. LUBRICANTS AND FUEL
• 4.2.4. DIMENSIONS (MC 182 / MC 184)
• 4.2.5. DIMENSIONS (MC 252 _ MC 302/ MC 254 _ MC 304)
• 4.2.6. DIMENSIONS (Msi 20 MSI 25 MSI 30)
• 4.3. GENERAL LOCATION
• 4.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 4.4. GENERAL CONTROL AND ADJUSTMENT
• 4.4.1. STANDARD TIGHTENING TORQUES
• 4.4.2. METRIC IMPERIAL UNIT CONVERSION
• 6. ENGINE SPECIFICATION
• 6.1. ENGINE GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 6.1.1. CHARACTERISTICS
• 6.2. ENGINE location
• 6.2.1. ENGINE COMPONENTS
• 6.2.2. WATER COOLING SYSTEM
• 6.2.3. FUEL SYSTEM
• 6.3. ENGINE CONTROLS AND ADJUSTMENTS
• 6.3.1. Engine SUSPENSION
• 6.3.2. EXHAUST SYSTEM
• 6.3.3. Cooling system
• 6.3.4. Adjusting belt tension
• 6.4. kW ENGINE REMOVAL REFITTING (MC 18)
• 6.4.1. Removing the alternator
• 6.4.2. Removing the coolant radiator
• 6.4.3. Removing the starter motor
• 6.4.4. Removing the radiator
• 6.4.5. Removing the engine
• 6.4.6. Removing the fuel tank
• 6.5. kW ENGINE REMOVAL REFITTING (MSI / MC 2530)
• 6.5.1. Air filter removal
• 6.5.2. Exhaust pipe removal
• 6.5.3. Radiator removal
• 6.5.4. Alternator removal
• 6.5.5. Starter motor removal
• 6.5.6. Hydrostatic transmission engine removal
• 6.6. ENGINE SPECIFIC TOOLING
• 6.6.1. SPECIAL ENGINE TOOLING
• 6.6.2. ELECTRONIC TENSION METER
• 8. TRANSMISSION
• 8.1. Transmission characteristics and specifications
• 8.1.1. HYDROSTATIC PUMP
• 8.1.2. HYDROSTATIC pump A4VG 40 DA1D7/32R
• 8.1.3. HYDROSTATIC pump A4VG 71 DA1D7
• 8.1.4. HYDRAULIC WHEEL MOTOR MS05
• 8.1.5. HYDRAULIC WHEEL MOTOR MSE05
• 8.1.6. Rear HYDRAULIC WHEEL MOTOR MG02 / MGE02
• 8.1.7. WHEEL DRIVE HYDROSTATIC TRANSMISSION BLOCK
• 8.1.8. WHEEL DRIVE HYDROSTATIC TRANSMISSION BLOCK
• 8.2. HYDROSTATIC TRANSMISSION SCHEMATIC DIAGRAM
• 8.2.1. FORWARD OPERATION fluid direction MC 18 25 30 in 4 wheel drive
• 8.2.2. FORWARD OPERATION fluid direction Msi 253035
• 8.3. Transmission components location
• 8.3.1. Hydrostatic circuit MC182
• 8.3.2. Hydrostatic circuit MC184
• 8.3.3. Hydrostatic circuit MC25/302
• 8.3.4. Hydrostatic circuit MC25/304
• 8.3.5. Hydrostatic circuit MSI
• 8.4. Transmission controls and adjustments
• 8.4.1. Tightening torque
• 8.4.2. PUMP A4VG 56 DA
• 8.4.3. TRANSMISSION CUTOFF
• 8.4.4. DISENGAGEMENT
• 8.5. TRANSMISSION REMOVAL
• 8.5.1. Removing the front wheel motor
• 8.5.2. Removing the rear wheel motor
• 8.5.3. Remove the hydrostatic pump
• 8.6. Specific transmission tooling
• 8.6.1. HYDROMATIK KIT (Replacement A4VGDA pump / A6VM motor)
• 8.6.2. TH7 VALVE HOSE AND CONNECTOR
• 8.6.3. BASIC MANOMETER BOX
• 8.6.4. DIGITAL MANOMETER BOX
• 10. AXLE
• 10.1. Axle control and adjustment
• 10.1.1. Tightening torque
• 10.1.2. Rear axle mounting instructions
• 10.1.3. Adjust the rear axle stops (4wheel drive versions)
• 10.1.4. Post installation inspection
• 10.2. Axle removal
• 10.2.1. Removing the rear axle
• 12. BRAKE
• 12.1. Brake characteristics and specifications
• 12.2. Brake diagrams
• 12.3. Brake control and adjustment
• 12.3.1. Inchingbrake pedal adjustment
• 12.3.2. Adjusting the brake contactor
• 12.3.3. Calibrating the pedal potentiometer
• 14. MAST
• 14.1. Mast characteristics and specifications
• 14.1.1. Weight of double masts
• 14.1.2. Weight of triple masts
• 14.2. Mast checks and adjustments
• 14.2.1. ROLLER INSTALLATION MAST/MAST ONLY
• 14.2.2. ROLLER INSTALLATION CARRIAGE/INNER UPRIGHT ONLY
• 14.2.3. USE OF OVERSIZE ROLLERS
• 14.2.4. WEAR PLATE INSTALLATION
• 14.2.5. INSTALLATION OF CYLINDER SUPPORTS
• 14.2.6. mast stop shock absorber adjustment (fv mast only)
• 14.2.7. CHAIN ASSEMBLY
• 14.2.8. INSTALLATION OF LIFTING CHAINS
• 14.3. Mast removal (mc 18)
• 14.3.1. Placing the mast on the ground
• 14.3.2. Removing the mast
• 14.4. Mast removal (msi)
• 14.4.1. Tilting the mast to the ground
• 16. HYDRAULICS
• 16.1. Hydraulic characteristics and specifications
• 16.1.1. SDM100 hydraulic valve block
• 16.1.2. SDM100 hydraulic valve block with JSM
• 16.1.3. W HYDRAULIC PUMP (MC18)
• 16.1.4. W HYDRAULIC PUMP (MC 2530)
• 16.1.5. DOUBLE HYDRAULIC PUMP (MSI)
• 16.2. Hydraulic diagrams
• 16.2.2. Diagrams
• 16.3. Hydraulic components location
• 16.3.1. MC 18/25/3024 D K ST3A S1
• 16.3.2. MSI 25/30/35 D K ST3A S5
• 16.4. HYDRAULIC component removal
• 16.4.1. Removing the hydraulic pump
• 16.4.2. Removing the hydraulic tank
• 16.4.3. Replace the hydraulic pump seals
• 18. ELECTRICITY
• 18.1. Electricity characteristics and specifications
• 18.1.1. BF1 FUSES AND RELAYS
• 18.1.2. Electrical data sheets
• 18.1.3. Electrical component inputs and outputs
• 18.2. Wiring diagrams
• 18.2.1. ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
• 18.2.2. CABLE IDENTIFICATION ON AN ELECTRICAL WIRING HARNESS
• 18.2.3. MC 182/4 D K St3A S1 (up to serial No. 1002405)
• 18.2.4. Cab installation with JSM
• 18.2.5. Cab installation without JSM
• 18.2.6. Overhead guard installation with JSM
• 18.2.7. Overhead guard installation without JSM
• 18.3. Electrical location
• 18.3.1. MC 182/4 D K St3A S1 (up to serial No. _ _ _ _ __)
• 18.3.2. MSIMC HarnessES (MC 182/4 D K St3A S1 (up to serial No. __)
• 18.3.3. MSIMC HarnessES (MC 182/4 D K St3A S1 (up to serial No. __)
• 18.4. Electrical component removal
• 18.4.1. ECU removal
• 20. DRIVERS CAB
• 20.1. DRIVERS CAB CONTROL AND ADJUSTMENT
• 20.1.1. Installing CAB suspensions
• 20.1.2. Seat fasteners
• 20.2. DRIVERS CAB REMOVAL (MC18)
• 20.2.1. Raise the cab
• 20.2.2. Raise the cab fully
• 20.3. DRIVERS CAB REMOVAL (MSI)
• 20.3.1. Raising the cab
• 20.3.2. heating block removal
• 20.4. Specific drivers cab tooling
• 20.4.1. Safety strut
• 22. FRAME BODYWORK
• 22.1. Characteristics and specifications
• 22.1.1. Tightening torque
• 22.2. REMOVAL REFITTING FRAME BODYWORK
• 22.2.1. Remove the counterweight (MC18)
• 22.2.2. Removing the counterweight (MSI)