Manitou MI 20 D K ST5 S1 to MI 35 G G ST5 S1 Service Manual 647893EN-USM1

Description

• Model List:
  • MI 20 D K ST5 S1
  • MI 25 D K ST5 S1
  • MI 30 D K ST5 S1
  • MI 35 D K ST5 S1
  • MI 15 G G ST5 S1
  • MI 18 G G ST5 S1
  • MI 20 G G ST5 S1
  • MI 25 G G ST5 S1
  • MI 30 G G ST5 S1
  • MI 35 G G ST5 S1

• 1. Legal disclaimer
• 2. Foreword
• 3. Intervention during the warranty period
• 4. Supplier Documentation List
• 5. Safety
• 5.1. Servicing position
• 5.2. Servicing Rules
• 6. Reference Information
• 6.1. Explanation of symbols
• 6.2. Metric imperial unit conversion
• 6.3. List of Abbreviations
• 6.4. Standard tightening torques
• 7. Characteristics and Specifications
• 7.1. Technical Datasheet MI 20 D K ST5 S1
• 7.2. Technical Datasheet MI 25 D K ST5 S1
• 7.3. Technical Datasheet MI 30 D K ST5 S1
• 7.4. Technical Datasheet MI 35 D K ST5 S1
• 7.5. Technical Datasheet MI 15 G G ST5 S1
• 7.6. Technical Datasheet MI 18 G G ST5 S1
• 7.7. Technical Datasheet MI 20 G G ST5 S1
• 7.8. Technical Datasheet MI 25 G G ST5 S1
• 7.9. Technical Datasheet MI 30 G G ST5 S1
• 7.10. Technical Datasheet MI 35 G G ST5 S1
• 8. Supplier Documentation
• 9. Characteristics and Specifications
• 9.1. Power system
• 9.2. Petrol engine GK21 and GK25 LPG operation
• 9.3. Engine Characteristics And Specifications
• 9.4. GCT (NISSAN) GK21/GK25 Gasoline
• 9.5. GK21/GK25 Maintenance
• 9.6. V2607CrE5b Specifications
• 9.7. Air Inlet System
• 9.8. Exhaust system MI G
• 9.9. Exhaust system MI D
• 9.10. Cooling system
• 10. Location
• 10.1. Engine mount
• 10.2. Engine Components MI G
• 10.3. Engine Components MI D
• 11. Removal
• 11.1. Removal Of The DPF
• 11.2. Removal Of The Exhaust Line
• 11.3. Removal Of The Coolant Expansion Tank
• 11.4. Removal Of The Air Filter Box
• 11.5. Removal Of The Alternator
• 11.6. Removal Of The Starter
• 11.7. Removal Of The Radiator
• 11.8. Removal Of The Engine
• 11.9. Removal Of The Fan Belt
• 12. Troubleshooting
• 12.1. Gas Engine GK21 GK25
• 12.2. Engine Diagnostic Codes (Refer to Section 120)
• 13. Specific Tools
• 13.1. Electronic belt tensiometer
• 13.2. Elastic belt specific tools
• 14. Supplier Documentation
• 15. Characteristics and Specifications
• 15.1. Overview/Summary
• 15.2. GearBox Hoisting Diagram
• 15.3. Working Principle
• 15.4. Hydraulic Transmission Box Structure
• 16. Removal
• 16.1. General Information
• 16.2. Preparation And Safety Instructions
• 16.3. Disassembly Procedures
• 16.4. Assembling Procedures
• 16.5. Gearbox Removal
• 17. Troubleshooting
• 17.1. Troubleshoot
• 18. Driving axle
• 18.1. Data
• 18.2. Trouble Diagnoses And Corrections
• 18.3. Driving Axle Assemble Removal And Installation
• 18.4. Axle Shaft And Wheel Hub
• 18.5. Removal
• 18.6. Inspection
• 18.7. Installation
• 18.8. Bearing Adjustment
• 19. Steering Axle
• 19.1. Trouble Diagnoses Corrections
• 19.2. Structure, Disassembly And Installation
• 19.3. Steering Axle
• 19.4. Kingpin And Steering Spindle
• 19.5. Inspection
• 19.6. Installation
• 19.7. Wheel Bearing Adjustment
• 19.8. Steering Cylinder
• 19.9. Disassemble
• 19.10. Installation
• 20. Steering system
• 20.1. Summarize
• 20.2. Data
• 20.3. Full Hydrostatic Power Steering Gear Assemble
• 20.4. Full Hydrostatic Power Steering Gear
• 20.5. Steering Cylinder
• 20.6. Steering System Installation
• 20.7. Trouble Diagnoses
• 21. Characteristics and Specifications
• 21.1. Summary
• 21.2. Master Cylinder
• 21.3. Brake
• 22. Control and Adjustment
• 22.1. Adjusting The Inching and Brake Pedal
• 22.2. Hand Brake Device
• 22.3. Replace Brake Shoe
• 23. Removal
• 23.1. Dissasembling The Front Wheel Brake
• 24. Refit
• 24.1. Refitting the front wheel brake
• 25. Troubleshooting
• 25.1. Trouble Diagnoses And Corrections
• 26. Characteristics and Specifications
• 26.1. Assemble Debugging Data
• 26.2. Trouble Diagnoses And Corrections
• 26.3. Summary
• 26.4. Double High Visibility Mast
• 26.5. Double Full Free Lift Mast (Including Container Mast)
• 26.6. Triple Full Free Lift Mast
• 27. Control and Adjustment
• 27.1. Removal And Adjustment
• 27.2. Removal Of Forks And Mast Assembly
• 27.3. Disassembly
• 27.4. Removal Of The Lifting Jack
• 27.5. Removal Of The Inner Mast
• 27.6. Inspection
• 27.7. Assembly And Adjustment
• 27.8. Lift Roller
• 27.9. Left And Right Cylinder Height Initial Adjustment
• 27.10. Lifting Chain Adjustment
• 27.11. Clearance of fork arm CARA
• 27.12. Removal Of The Roller
• 28. Removal
• 28.1. Disassembly and installation of lifting jack
• 28.2. Disassembly and installation of tilting cylinder
• 28.3. Noticing Proceeding Of Debugging
• 29. Characteristics and Specifications
• 29.1. Main pump
• 29.2. Multiway valve
• 30. Schematics
• 30.1. Hydraulic Piping or Schematics
• 31. Removal
• 31.1. Removal Of The Hydraulic Pump
• 31.2. Removal Of The Hydraulic Dispenser
• 31.3. Removal Of The Tilt Cylinders
• 32. Troubleshooting
• 32.1. Trouble Diagnoses And Corrections
• 33. Specific Tools
• 33.1. Digital manometer kit
• 33.2. Basic manometer kit
• 34. Characteristics and Specifications
• 34.1. Fuse Location
• 34.2. Electronic Control Unit
• 34.3. Lighting System
• 34.4. Key (start) switch
• 34.5. Reverse Buzzer
• 34.6. Brake Lamps Switch
• 34.7. PreHeat And Start Switch
• 34.8. Combination Switch Assembly
• 34.9. Water Temperature Sensor
• 34.10. Fuel Gauge Sensor
• 34.11. Fuel Pressure Warner
• 34.12. Backup Buzzer/Reverse Warner
• 34.13. HandBrake Switch Assembly
• 34.14. Reversing Solenoid Valve
• 35. Schematics
• 35.1. Position per diagram MI 1535 G ST5
• 35.2. MI 1535 G ST5 Electrical Schematic
• 35.3. Position per diagram MI 2035 D ST5
• 35.4. MI 2035 D ST5 Electrical Schematic
• 36. Location
• 36.1. Location of electrical system components
• 37. Removal
• 37.1. Removal Of The Battery
• 37.2. Removal of the Engine Calculator
• 37.3. Removal of the Hydraulic Distributor Computer
• 38. Specific Tools
• 38.1. Breakout boxes
• 39. Interactive Instrument
• 39.1. Interactive Instrument
• 39.2. Engine fault information display page
• 39.3. Forklift operation parameters
• 39.4. Settings Page
• 39.5. Disassembly and installation
• 40. Removal
• 40.1. Cabin Components
• 40.2. Removal Of Lpg Cylinder
• 40.3. Removal Of Cabin
• 40.4. Disassembly Procedure
• 40.5. Removal Of The Drivers Seat Cover
• 40.6. Drop The Floor Of The Workstation
• 40.7. Open The Drivers Seat Hood
• 41. Removal
• 41.1. Counter Weight Removal
• 41.2. Removal Of The Counterweight
• 42. Optional mini levers
• 42.1. Characteristics and Specifications
• 42.2. Hydraulics
• 42.3. Electrical Diagram
• 42.4. Location
• 42.5. Control and Adjustments
• 42.6. Troubleshooting
• 43. Engine diagnostics
• 44. DTC engine ECU diagnosis (V2607 ST5)
• 45. DTC engine ECU diagnosis (GK21/25)
• 46. Diagnostics tools Kubota DIAGMASTER (DSTi)
• 46.1. KUBOTA engine diagnostics tool Diagmaster