Manitou MSI 40 T S3 ST3B, MSI 50 T S3 ST3B Repair Manual 647180EN

Description

• Model List:
  • MSI 40 T S3 ST3B
  • MSI 50 T S3 ST3B

• 1. MR_647180EN_10_2021
• 1.1. Front page
• 1.2. GR00 GENERAL, CHARACTERISITCS AND SAFETY
• 1.2.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 1.2.1.1. INTRODUCTION
• 1.2.1.2. SERVICING POSITION
• 1.2.1.3. SERVICING RULES
• 1.2.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 1.2.2.1. CHARACTERISTICS
• 1.2.2.2. DIMENSIONS
• 1.2.3. GENERAL LOCATION
• 1.2.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 1.2.4. GENERAL CONTROL AND ADJUSTMENT
• 1.2.4.1. STANDARD TIGHTENING TORQUES
• 1.2.4.2. LUBRICANTS AND FUEL
• 1.3. GR10 ENGINE
• 1.3.1. ENGINE GENERAL CHARACTERISTICS ANDSPECIFICATIONS
• 1.3.1.1. ENGINE CHARACTERISTICS
• 1.3.1.2. PERKINS ENGINE OVERVIEW
• 1.3.1.3. AFTERTREATMENT SYSTEM OVERVIEW
• 1.3.1.4. REGENERATION
• 1.3.1.5. OVERVIEW OF THE VARIOUS TYPES OF REGENERATION
• 1.3.1.6. MAIN ELECTRICAL SCHEMATIC DIAGRAM OF PERKINS 854 ENGINE.
• 1.3.2. ENGINE COMPONENTS LOCATION
• 1.3.2.1. ENGINE COMPONENTS
• 1.3.2.2. WATER COOLING SYSTEM
• 1.3.2.3. DIESEL FUEL CIRCUIT
• 1.3.2.4. EXHAUST PIPE
• 1.3.2.5. AIR INLET
• 1.3.3. ENGINE CONTROL AND ADJUSTMENT
• 1.3.3.1. COMPONENT REMOVAL/ REFIT
• 1.3.3.2. TIGHTENING TORQUES
• 1.3.4. ENGINE REMOVAL
• 1.3.4.1. PREPARATION AND SAFETY INSTRUCTIONS
• 1.3.4.2. A RADIATOR REMOVAL
• 1.3.4.3. B ENGINE REMOVAL
• 1.3.5. ENGINE REFIT
• 1.3.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 1.3.5.2. A ENGINE REFIT
• 1.3.5.3. B RADIATOR REFIT
• 1.4. GR20 TRANSMISSION
• 1.4.1. TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS
• 1.4.1.1. HYDROSTATIC TRANSMISSION
• 1.4.1.2. A4VG 4056/DA PUMP
• 1.4.1.3. A6VM / DA SERIES 63 MOTOR
• 1.4.2. TRANSMISSION SCHEMATIC DIAGRAMS
• 1.4.2.1. TRANSMISSION DRIVE CHAIN
• 1.4.2.2. HYDROSTATIC TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
• 1.4.2.3. FORWARD GEAR FLUID FLOW DISPLAY
• 1.4.2.4. HYDROSTATIC TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
• 1.4.2.5. REVERSE GEAR FLUID FLOW DISPLAY
• 1.4.3. TRANSMISSION COMPONENTS LOCATION
• 1.4.3.1. HYDROSTATIC TRANSMISSION COMPONENT POSITIONS
• 1.4.4. TRANSMISSION CONTROL AND ADJUSTMENT
• 1.4.4.1. PRESSURE CONNECTORS
• 1.4.4.2. TRANSMISSION CONTROL AND ADJUSTMENT
• 1.4.4.3. TIGHTENING TORQUES
• 1.4.4.4. TRANSMISSION CUTOFF
• 1.4.5. TRANSMISSION REMOVAL
• 1.4.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 1.4.5.2. A HYDROSTATIC PUMP REMOVAL
• 1.4.5.3. B HYDROSTATIC MOTOR REMOVAL
• 1.4.5.4. TRANSMISSION REFIT
• 1.4.6. SPECIFIC TRANSMISSION TOOLING
• 1.4.6.1. BASIC MANOMETER SET
• 1.4.6.2. DIGITAL MANOMETER SET
• 1.4.6.3. HYDROMATIK KIT (Replacement A 4 VG DA pump/A 6 VM DA motor)
• 1.4.6.4. TH7 VALVE HOSE AND CONNECTOR
• 1.5. GR30 AXLE
• 1.5.1. AXLE CONTROL AND ADJUSTMENT
• 1.5.1.1. FRONT AXLE TIGHTENING TORQUE
• 1.5.1.2. REAR AXLE TIGHTENING TORQUE
• 1.5.1.3. REAR AXLE WHEEL NUT TIGHTENING TORQUE AND SETTING
• 1.6. GR40 BRAKE
• 1.6.1. BRAKE CHARACTERISTICS AND SPECIFICATIONS
• 1.6.1.1. BRAKING CIRCUIT CHARACTERISTICS
• 1.6.2. BRAKE COMPONENTS LOCATION
• 1.6.2.1. BRAKE COMPONENT POSITIONS
• 1.6.3. BRAKE CONTROL AND ADJUSTMENT
• 1.6.3.1. PARKING BRAKE CONTROL AND ADJUSTMENT
• 1.6.3.2. PEDAL CONTROL AND ADJUSTMENT
• 1.6.4. SPECIFIC BRAKE TOOLING
• 1.6.4.1. HYDRAULIC BRAKE BLEED VALVE
• 1.7. GR60 MAST
• 1.7.1. MAST CHARACTERISTICS AND SPECIFICATIONS
• 1.7.1.1. DOUBLE MAST WITH ALLROUND VISION (D VT)
• 1.7.1.2. DOUBLE MAST WITH FREEACTING LIFT (D LL)
• 1.7.1.3. TRIPLE MAST WITH FREEACTING LIFT (T LL)
• 1.7.2. MAST CONTROL AND ADJUSTMENT
• 1.7.2.1. VIEW OF MAST ASSEMBLY
• 1.7.2.2. CHECKING AND ADJUSTING MAST CHAIN TENSION AND ALIGNMENT
• 1.7.2.3. CARRIAGE ROLLER REMOVAL
• 1.7.2.4. MAST ADJUSTMENT
• 1.7.2.5. MAST ROLLER REMOVAL/REFIT
• 1.7.2.6. LIFTING CYLINDER REMOVAL/REFITTING
• 1.7.2.7. LIFTING CYLINDER ROD SHIM ADJUSTMENT(PREVENTING UNEQUAL LIFTING)
• 1.8. GR70 HYDRAULICS
• 1.8.1. HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
• 1.8.1.1. STEERING PUMP/STEERING UNIT OSPR 200 LS
• 1.8.1.2. CROSS DISTRIBUTOR SDM 140 WITH MOVEMENT CUTOFF
• 1.8.1.3. SDM 140 JSMX DISTRIBUTOR WITH MOVEMENT CUTOFF
• 1.8.1.4. CASAPPA KP30 HYDRAULIC PUMP
• 1.8.2. HYDRAULIC SCHEMATIC DIAGRAMS
• 1.8.2.2. HYDRAULIC DIAGRAM
• 1.8.3. HYDRAULIC COMPONENTS LOCATION
• 1.8.3.2. HYDRAULIC COMPONENT POSITIONS (STANDARD)
• 1.8.3.3. HYDRAULIC COMPONENT POSITIONS (JSM OPTION)
• 1.8.3.4. CAB LIFTING COMPONENT POSITIONS
• 1.8.4. HYDRAULIC CONTROL AND ADJUSTMENT
• 1.8.4.1. FORK CARRIAGE DAMPING FLEXIBILITY ADJUSTMENT
• 1.8.4.2. TIGHTENING TORQUES
• 1.8.4.3. PRESSURE CONNECTOR
• 1.8.5. HYDRAULIC COMPONENTS REMOVAL
• 1.8.5.1. PREPARATION AND SAFETY INSTRUCTIONS
• 1.8.5.2. A HYDRAULIC PUMP REMOVAL
• 1.8.5.3. B 4ELEMENT DISTRIBUTOR REMOVAL(JSM OPTION)
• 1.8.5.4. HYDRAULIC COMPONENTS REFIT
• 1.8.6. HYDRAULIC SPECIFIC TOOLING
• 1.8.6.1. BASIC MANOMETER SET
• 1.8.6.2. DIGITAL MANOMETER SET
• 1.8.6.3. INFLATION KIT
• 1.9. GR80 ELECTRICITY
• 1.9.1. ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
• 1.9.1.1. WIRING
• 1.9.1.2. OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM
• 1.9.1.3. INPUTS/OUTPUTS
• 1.9.1.4. DATA SHEETS FOR ELECTRICAL COMPONENTS
• 1.9.2. ELECTRICAL SCHEMATIC DIAGRAMS
• 1.9.2.1. ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
• 1.9.2.2. CABLE IDENTIFICATION ON A WIRING HARNESS
• 1.9.2.3. POSITION OF CONNECTORS ON DIAGRAMS
• 1.9.2.4. ELECTRICAL DIAGRAMS
• 1.9.3. ELECTRICAL COMPONENTS LOCATION
• 1.9.3.1. KEYS
• 1.9.3.2. LOCATION
• 1.9.3.3. LOCATION
• 1.9.4. ELECTRICAL CONTROL AND ADJUSTMENT
• 1.9.4.1. ENGINE ECU
• 1.9.5. ELECTRICAL TROUBLESHOOTING
• 1.9.5.1. READING ERROR CODES
• 1.9.5.2. ENGINE ECU ERROR CODES LIST (DTC)
• 1.9.6. ELECTRICAL SPECIFIC TOOLING
• 1.9.6.1. DIAGNOSTIC TOOLS
• 1.9.6.2. BREAKOUT BOXES
• 1.9.6.3. ELECTROVALVE ADAPTER
• 1.10. GR85 DRIVERS CAB
• 1.10.1. DRIVERS CAB CONTROL AND ADJUSTMENT
• 1.10.1.1. CAB LIFTING
• 1.10.1.2. RAISING THE CAB IN CASE OF HYDRAULIC SYSTEM FAILURE
• 1.11. GR110 OPTIONS ATTACHMENTS
• 1.11.1. OPTIONS ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS
• 1.11.1.1. AIR CONDITIONING
• 1.11.2. OPTIONS ATTACHMENTS COMPONENTS LOCATION
• 1.11.2.1. AIR CONDITIONING
• 1.11.3. OPTIONS ATTACHMENTS CONTROL AND ADJUSTMENT
• 1.11.3.1. ASSEMBLY INSTRUCTIONS FOR AIRCONDITIONING CIRCUIT
• 1.11.3.2. SAFETY MEASURES FOR HANDLING R134a
• 1.11.3.3. REFRIGERANT FLUID LOAD FOR THE AIRCONDITIONING CIRCUIT
• 1.11.3.4. CHARGING METHOD
• 1.11.3.5. FUNCTIONAL CHECKS
• 1.11.3.6. AIRCONDITIONING INSPECTION FORM