Manitou MSI25 36KW to MH25-4 T BUGGIE 4ST3B Repair Manual 647473EN

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Manitou MSI25 36KW to MH25-4 T BUGGIE 4ST3B Repair Manual 647473EN

Type Of Manual: Repair Manual
Manual ID: 647473EN
Format: PDF
Size: 42.8MB
Number of Pages: 312

Category: Manitou Repair Manual PDF

Description

Model List:
- MSI25 36KW
- MSI30 36KW
- MSI35 36KW
- MSI25 T 4ST3A
- MSI30 T 4ST3A
- MSI35 T 4ST3A
- MH25-4 36KW BUGGIE 4ST3A
- MH25-4 T BUGGIE 4ST3A
- MSI20 T 4ST3B
- MSI25 T 4ST3B
- MSI30 T 4ST3B
- MSI35 T 4ST3B
- MH20-4 T BUGGIE 4ST3B
- MH25-4 T BUGGIE 4ST3B

2. GENERAL, CHARACTERISTICS
2.1. MSI 20 / 25 / 30 / 35 T BUGGIE
2.1.1. CHARACTERISTICS AND FLUIDS
2.1.2. DIMENSIONS
2.1.3. MH 204 / 254 T BUGGIE
2.1.4. CHARACTERISTICS AND FLUIDS
2.1.5. DIMENSIONS
2.2. LOCATION OF NAME AND IDENTIFICATION PLATE
2.3. STANDARD TIGHTENING TORQUES
3. ENGINE
3.1. ENGINE ELEMENTS
3.1.1. V2403ME3 (36KW 4ST3A)
3.1.2. V2403CR TE4 (t 4ST3b)
3.2. PREPARATION AND SAFETY INSTRUCTIONS
3.2.1. AIR INTAKE REMOVAL
3.2.1.1. W T 4ST3A
3.2.2. ALTERNATOR BELT REMOVAL / REFIT
3.2.3. ALTERNATOR REMOVAL
3.2.4. EXHAUST FILTER REMOVAL / REFIT
3.2.4.1. W T 4ST3A
3.2.5. FAN REMOVAL
3.2.6. RADIATOR REMOVAL
3.2.7. TURBO REMOVAL
3.2.7.1. T 4ST3A
3.2.7.2. T 4ST3B
3.2.8. STARTER REMOVAL
3.2.8.1. W T 4ST3A
3.2.9. ENGINE ECU REMOVAL
3.2.10. ENGINE REMOVAL
3.2.10.1. PREPARATION AND SAFETY INSTRUCTIONS
3.2.10.2. REAR CAB PANEL REMOVAL
3.2.10.3. ELECTRICITY 36KW T 4ST3A
3.2.10.4. ELECTRICITY 4ST3B
3.2.10.5. HOSES 36KW T 4ST3A
3.2.10.6. Place a container under the machine.
3.2.10.7. HOSES 4ST3B
3.2.10.8. ENVIRONMENT 36KW T 4ST3A
3.2.10.9. ENGINE WITHOUT HYDROSTATIC PUMP REMOVAL
3.2.10.10. ENGINE WITH HYDROSTATIC PUMP REMOVAL
3.3. ENGINE REFIT
3.3.1. PREPARATION AND SAFETY INSTRUCTIONS
3.3.2. REFITTING
3.3.3. LEVELS VERIFICATION TESTING
3.4. ELECTRONIC TENSION METER
4. TRANSMISSION
4.1. VF SERVICE BRAKE (OR BRAKE TH7) EV PARKING BRAKE
4.1.1. SERVICE BRAKE
4.1.2. PARKING BRAKE
4.2. INCHING VALVE VIN (MH)
4.3. FLOW DIVIDER DDb (MH)
4.3.1. IN FORWARD GEAR
4.3.2. IN REVERSE GEAR
4.4. DISENGAGEMENT VALVE VDE OPTION (MH)
4.5. MSI 20 / 25 / 30 / 35 T BUGGIE
4.5.1. FORWARD GEAR CIRCUIT
4.5.1.1. TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
4.5.1.1.1. REVERSE GEAR CIRCUIT
4.5.1.1.2. TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
4.5.1.2. MH 20 / 25 T BUGGIE
4.5.1.2.1. FORWARD GEAR CIRCUIT
4.5.1.2.2. TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
4.5.1.2.3. REVERSE GEAR CIRCUIT
4.5.1.2.4. TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
4.5.1.3. DISENGAGEMENT OPTION MH 254 BUGGIE 36KW 4ST3A
4.5.1.3.1. FORWARD GEAR CIRCUIT 4 WHEEL DRIVE
4.5.1.3.2. TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
4.5.1.3.3. REVERSE GEAR CIRCUIT 4 WHEEL DRIVE
4.5.1.3.4. TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
4.5.1.3.5. FORWARD GEAR CIRCUIT 2 WHEEL DRIVE
4.5.1.3.6. TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
4.5.1.3.7. REVERSE GEAR CIRCUIT 2 WHEEL DRIVE
4.5.1.3.8. TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
4.6. HYDROSTATIC PUMP
4.7. FRONT HYDROSTATIC MOTOR(S)
4.8. REAR HYDROSTATIC MOTOR(S) (MH)
4.9. FRONT HYDROSTATIC MOTOR (MSIMH)
4.10. PEDALS
4.10.1. MSI 20 / 25 / 30 / 35 T BUGGIE
4.10.2. MH 20 / 25 T BUGGIE
4.11. TRANSMISSION CUTOFF
4.11.1. OPERATING PRINCIPLE
4.11.2. TRANSMISSION CUTOFF MODULE
4.12. DISENGAGEMENT MODULE OPTION
4.13. TIGHTENING TORQUES
4.14. HYDROSTATIC TRANSMISSION REMOVAL
4.14.1. PREPARATION AND SAFETY INSTRUCTIONS
4.14.2. HYDROSTATIC PUMP 4ST3A REMOVAL
4.14.3. HYDROSTATIC PUMP 4ST3B REMOVAL
4.14.4. FRONT HYDROSTATIC MOTOR REMOVAL
4.15. REMOVAL OF DISENGAGEMENT VALVE VDE OPTION MH 254 4ST3A
4.15.1. PREPARATION AND SAFETY INSTRUCTIONS
4.15.2. VALVE REMOVAL
4.16. HYDROSTATIC TRANSMISSION REFIT
4.16.1. HYDROSTATIC PUMP REFIT
4.16.1.1. HYDROSTATIC MOTOR REFIT
4.16.1.2. REFITTING DISENGAGEMENT VALVE VDE OPTION MH 254 4ST3A
4.16.1.3. LEVELS VERIFICATION TESTING
4.17. HYDROSTATIC PUMP
4.18. GENERAL INFORMATION
4.18.1. PILOT CIRCUIT
4.18.2. CROSSSECTIONAL VIEWS OF THE CYLINDER SWASHPLATE Angle 18.
4.18.3. DA CONTROL CARTRIDGE
4.18.4. DR VALVE
4.19. FRONT HYDROSTATIC MOTOR(S)
4.20. VA (OR ACCELERATION TH7)
5. AXLE
5.1. FRONT WHEEL REDUCING GEAR
5.1.1. PRELIMINARY REMARKS
5.1.2. CLEANING AND GENERAL CONDITION OF COMPONENTS
5.1.3. TABLES
5.1.4. ASSEMBLY OF THE REDUCER MODEL CWD2050/M
5.1.5. READING FOR THE BEARINGS ADJUSTMENT
5.1.6. SEALING TESTS
5.1.7. DISASSEMBLING THE WHEEL REDUCER
5.1.8. CROSSSECTIONAL VIEW, EXPLODED VIEW AND LIST OF COMPONENTS OF THE WHEEL REDUCER UNIT
6. BRAKE
6.1. SERVICE BRAKE / PARKING BRAKE MSI
6.2. SERVICE BRAKE / PARKING BRAKE MH
7. MAST
7.1. VIEW OF MAST ASSEMBLY
7.1.1. NOMENCLATURE
7.2. CHECKING AND ADJUSTING MAST CHAIN TENSION AND ALIGNMENT
7.2.1. REPLACING A CHAIN
7.2.2. REFIT A CHAIN
7.3. CARRIAGE ROLLER REMOVAL
7.3.1. GUIDE ROLLER REMOVAL
7.3.2. REASSEMBLY
7.3.3. BEARING ROLLER REMOVAL
7.4. MAST ADJUSTMENT
7.4.1. MAST LIFT ROLLER ADJUSTMENT
7.4.2. FORK CARRIAGE ROLLER ADJUSTMENT
7.4.3. MAST STRIP ADJUSTMENT
7.5. MAST ROLLER REMOVAL/REFIT
7.6. LIFTING CYLINDER REMOVAL/REFITTING
7.7. LIFTING CYLINDER ROD SHIM ADJUSTMENT (PREVENTING UNEQUAL LIFTING)
7.8. MAST REMOVAL
7.8.1. PREPARATION AND SAFETY INSTRUCTIONS
7.8.2. REMOVAL
7.9. MAST REFIT
7.9.1. PREPARATION AND SAFETY INSTRUCTIONS
7.9.2. REFITTING
7.9.3. LEVELS VERIFICATION TESTING
8. HYDRAULICS
8.1.1. HYDRAULIC DIAGRAM
8.1.2. MSI25/30/35 T 4ST3A4ST3B
8.1.3. MSI25/30/35 36KW 4ST3A
8.1.4. MH204 T BUGGIE 4ST3A4ST3B
8.1.5. MH254 36KW BUGGIE 4ST3A
8.1.6. MASTS TABLE
8.2. HYDRAULIC PUMP MSI T/MH T BUGGIE 4ST3A4ST3B
8.2.1. D VIEW
8.2.2. TIGHTENING TORQUE AND HYDRAULIC DIAGRAM
8.2.3. EXPLODED VIEW
8.2.4. HYDRAULIC CIRCUIT TIGHTENING TORQUE
8.2.5. DISTRIBUTOR INLET PRESSURE SOCKET LOCATION (Pp1)
8.2.6. HYDRAULIC PUMP MSI 36KW/MH 36KW BUGGIE 4ST3A
8.2.7. D VIEW
8.2.8. TIGHTENING TORQUE AND HYDRAULIC DIAGRAM
8.2.9. EXPLODED VIEW
8.2.10. HYDRAULIC CIRCUIT TIGHTENING TORQUE
8.2.11. DISTRIBUTOR INLET PRESSURE SOCKET LOCATION (Pp1)
9. ELECTRICITY
9.1. CONNECTORS
9.2. OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM
9.2.1. OPERATION
9.2.2. OVERVIEW
9.3. DISENGAGEMENT VALVE OPTION OVERVIEW
9.3.1. OPERATION
9.3.2. OVERVIEW
9.4. TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
9.4.1. X130 HORN (B1)
9.4.2. X113 SAFETY MODULE (MTC)
9.4.3. X1X2 STARTER IGNITION SWITCH (S1)
9.4.4. X67 FNR JOYSTICK (S11)
9.4.5. X16 PARKING BRAKE ELECTROVALVE (Y6)
9.5. ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
9.6. CABLE IDENTIFICATION ON AN ELECTRICAL WIRING HARNESS
9.7. MSI 25 / 30 / 35 T MH 254 T BUGGIE 36KW 4ST3A
9.7.1. ELECTRICAL DIAGRAM KEY
9.7.2. WIRING DIAGRAM
9.7.3. WIRING DIAGRAM OPTION (air conditioning JSM)
9.8. MSI 25 / 30 / 35 T MH 254 T BUGGIE 4ST3B
9.8.1. POSITION OF CONNECTORS ON DIAGRAMS
9.8.2. ELECTRICAL DIAGRAMS
9.8.3. STARTING
9.8.4. CAN / ECU
9.8.5. TRANSMISSION
9.8.6. HYDRAULIC MOVEMENTS
9.8.7. SENSORS
9.8.8. LIGHTING/SIGNALLING
9.8.9. VENTILATION / AIR CONDITIONING / WIPERS
9.8.10. OPTIONS
9.9. MSI 25 / 30 / 35 T MH 254 T BUGGIE 36KW 4ST3A
9.9.1.1. CONNECTORS
9.9.1.2. COMPONENTS
9.9.1.3. FUSES AND RELAYS
9.9.1.4. DIODES AND SPLICES
9.9.2. LOCATION
9.9.2.1. MAIN HARNESS
9.9.2.2. FLOW DIVIDER CONTROL HARNESS
9.9.2.3. DISENGAGEMENT OPTION HARNESS
9.9.3. LOCATION
9.9.3.1. CONNECTORS ON FRAME
9.10. MSI 25 / 30 / 35 T MH 254 T BUGGIE 4ST3B
9.10.1.1. CONNECTORS
9.10.1.2. DIODES AND SPLICES
9.10.2. LOCATION
9.10.2.1. HARNESS ASSEMBLY
9.10.2.2. MAIN HARNESS
9.10.3. LOCATION
9.10.3.1. CONNECTORS IN CAB
9.10.3.2. CONNECTORS ON FRAME / ENGINE
9.10.3.3. ENGINE HARNESS CONNECTION
9.11. READING ERROR CODES
9.11.1. DASHBOARD ERROR CODE DISPLAY PRINCIPLE
9.11.2. Engine ECU (A13)
9.12. DIAGNOSTIC TOOLS
9.12.1. VERSION 1
9.12.2. VERSION 2
9.13. BREAKOUT BOXES
9.14. ELECTROVALVE ADAPTER
10. FRAMEBODYWORK
10.1. FRAME BODY REMOVAL
10.1.1. COUNTERWEIGHT REMOVAL/ REFIT
10.1.1.1. PREPARATION AND SAFETY INSTRUCTIONS
10.1.1.2. REMOVAL
10.1.1.3. REFITTING

Manitou MSI25 36KW to MH25-4 T BUGGIE 4ST3B Repair Manual 647473EN

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