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

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