Description
-
Model List:
- MI-X 40 45 50 D E3 S1
- MI 40 45 50 D ST3B S1
- MI 40 45 50 D ST3B S1 US
- MI 40 45 50 G S1
- MI 40 45 50 G S1 US
- 1. MIX 40 45 50 D E3 S1, MI 40 45 50 D ST3B S1, MI 40 45 50 D ST3B S1 US, MI 40 45 50 G S1, MI 40 45 50 G S1 US, 647510EN (11/05/2018), REPAIR MANUAL
- 2. HOW TO USE THIS REPAIR MANUAL
- 3. GLOSSARY
- 4. SUMMARY
- 5. GR00 GENERAL, CHARACTERISTICS AND SAFETY
- 5.1. GENERAL INSTRUCTIONS AND SAFETY NOTICE
- 5.1.1. PREAMBLE
- 5.1.2. MAINTENANCE POSITION
- 5.1.3. RULES FOR MAINTENANCE
- 5.2. GENERAL CHARACTERISTICS AND SPECIFICATIONS
- 5.2.1. MIX 404550 D St3A
- 5.2.1.1. CHARACTERISTICS
- 5.2.2. MI 404550 G
- 5.2.2.1. CHARACTERISTICS
- 5.2.3. MI 404550 D St3B
- 5.2.3.1. CHARACTERISTICS
- 5.2.4. MI 404550 D US
- 5.2.4.1. CHARACTERISTICS
- 5.2.5. MI 404550 G US
- 5.2.5.1. CHARACTERISTICS
- 5.3. GENERAL LOCATION
- 5.3.1. LOCATION OF NAME AND IDENTIFICATION PLATE
- 5.4. GENERAL CONTROL AND ADJUSTMENT
- 5.4.1. STANDARD TIGHTENING TORQUES
- 5.4.2. METRIC IMPERIAL UNIT CONVERSION
- 6. GR10 ENGINE
- 6.1. ENGINE CONTROL AND ADJUSTMENT
- 6.1.1. PREPARATION AND SAFETY INSTRUCTIONS
- 6.1.2. LIFT TRUCKS MI 404550 G/US.
- 6.1.2.1. GAS KIT REMOVAL.
- 6.1.2.2. REMOVAL OF THE STARTER PSI 4.3 L PSI 4X ENGINE.
- 6.1.2.3. REMOVAL OF THE ALTERNATOR PSI 4.3 L PS 4X ENGINE.
- 6.1.2.4. REMOVAL OF THE RADIATOR PSI 4.3 L PSI 4X ENGINE.
- 6.1.3. LIFT TRUCKS MI 404550 G/US. REMOVAL AND ADJUSTMENT OF ENGINE COMPONENTS.
- 6.1.3.1. OIL CAP
- 6.1.3.2. FREE PULLEY
- 6.1.3.3. TENSIONER
- 6.1.3.4. WATER PUMP FAN/PULLEY
- 6.1.3.5. CRANKSHAFT PULLEY
- 6.1.3.6. BELT POSITIONING
- 6.1.3.7. ORING
- 6.1.3.8. MIXER
- 6.1.3.9. REGULATOR
- 6.1.3.10. INLET AIR SENSOR
- 6.1.3.11. ALTERNATOR
- 6.1.3.12. OIL PRESSURE SENSOR
- 6.1.4. LIFT TRUCKS MIX 404550 D STAGE 3A.
- 6.1.4.1. REMOVAL OF THE STARTER EURO 3 DIESEL ENGINE.
- 6.1.4.2. REMOVAL OF THE ALTERNATOR EURO 3 DIESEL ENGINE.
- 6.1.4.3. REMOVAL OF THE RADIATOR EURO 3 DIESEL ENGINE.
- 6.1.5. REMOVAL OF THE AIRCONDITIONING COMPRESSOR.
- 6.2. ENGINE REMOVAL
- 6.2.1. PREPARATION AND SAFETY INSTRUCTIONS
- 6.2.2. PROCEDURE FOR REMOVING THE PSI 4.3 L PSI 4X ENGINE ON LIFT TRUCKS MI 404550 G.
- 6.2.2.1. REMOVING THE EXHAUST AND THE COUNTERWEIGHT
- 6.2.2.2. ENGINE COVER REMOVAL
- 6.2.2.3. RADIATOR REMOVAL
- 6.2.2.4. EXHAUST REMOVAL
- 6.2.2.5. HYDRAULIC PUMP REMOVAL
- 6.2.2.6. GAS HOSE DISCONNECTION
- 6.2.2.7. AIR FILTER REMOVAL
- 6.2.2.8. DISCONNECT THE REMAINING PERIPHERAL CONNECTIONS.
- 6.2.3. PROCEDURE FOR REMOVING THE PERKINS 1104D ENGINE ON LIFT TRUCKS MIX 404550 D Stage 3A.
- 6.2.3.1. REMOVING THE EXHAUST AND THE COUNTERWEIGHT
- 6.2.3.2. CAB TAILGATE REMOVAL
- 6.2.3.3. Remove the rear windscreen wiper.
- 6.2.3.4. PEDAL UNIT DISCONNECTION.
- 6.2.3.5. ENGINE COVER REMOVAL
- 6.2.3.6. RADIATOR REMOVAL
- 6.2.3.7. EXHAUST REMOVAL
- 6.2.3.8. HYDRAULIC PUMP REMOVAL
- 6.2.3.9. AIR FILTER REMOVAL
- 6.2.3.10. DISCONNECT THE REMAINING PERIPHERAL CONNECTIONS.
- 7. GR20 TRANSMISSION
- 7.1. TRANSMISSION CHARACTERISTICS ANDSPECIFICATIONS
- 7.1.1. TRANSMISSION SYSTEM
- 7.1.1.1. GENERAL INFORMATION
- 7.1.1.2. AXLE PARAMETERS AND STRUCTURE
- 7.1.1.3. HYDRAULIC GEARBOX
- 7.1.1.4. MAIN PARAMETERS
- 7.2. TRANSMISSION CONTROL AND ADJUSTMENT
- 7.2.1. DRIVE SHAFT
- 7.2.2. HYDRAULIC GEARBOX
- 7.2.2.1. OPERATING PRINCIPLE (DIRECTION OF FLUIDS)
- 7.2.2.2. PRINCIPLE OF THE HYDRAULIC GEARBOX SYSTEM
- 7.2.2.3. LIFTING THE GEARBOX
- 7.3. TRANSMISSION TROUBLESHOOTING
- 7.3.1. GEARBOX INSPECTION AND MAINTENANCE
- 8. GR30 AXLE
- 8.1. AXLE CONTROL AND ADJUSTMENT
- 8.1.1. FRONT TRANSMISSION AXLE
- 8.1.1.1. PARAMETERS AND STRUCTURE
- 8.1.1.2. AXLE STRUCTURE
- 8.1.1.3. STRUCTURE OF THE MAIN REDUCTION GEAR
- 8.1.1.4. OPERATING PRINCIPLE
- 8.1.1.5. GEAR REPLACEMENT
- 8.1.1.6. HANDLING AND STORAGE
- 8.1.1.7. CONTACT STATE AND ADJUSTMENT OF SLAVE BEVEL GEAR
- 8.1.1.8. DISASSEMBLY AND ASSEMBLY OF THE TRANSMISSION AXLE
- 8.1.1.9. DISASSEMBLY AND ASSEMBLY OF THE MAIN REDUCTION GEAR
- 8.1.1.10. REFITTING THE MAIN REDUCTION GEAR
- 8.1.2. REAR STEERING AXLE
- 8.1.2.1. STEERING AXLE ASSEMBLY
- 8.1.2.2. TECHNICAL PARAMETERS
- 8.1.2.3. DISMANTLING AND ASSEMBLY
- 8.2. AXLE REMOVAL
- 8.2.1. PREPARATION AND SAFETY INSTRUCTIONS
- 8.2.2. REMOVING THE REAR AXLE.
- 8.2.3. REMOVING A REAR AXLE HUB.
- 8.2.4. REMOVING THE FRONT AXLE.
- 8.3. AXLE TROUBLESHOOTING
- 8.3.1. INSPECTION AND MAINTENANCE
- 8.3.1.1. FRONT AXLE
- 8.3.1.2. REAR STEERING AXLE
- 9. GR40 BRAKE
- 9.1. BRAKE CONTROL AND ADJUSTMENT
- 9.1.1. BRAKING SYSTEM
- 9.1.1.1. GENERAL INFORMATION
- 9.1.1.2. PARAMETERS
- 9.1.1.3. MICROPEDAL ADJUSTMENT
- 9.1.1.4. PARKING BRAKE ADJUSTMENT
- 9.1.1.5. DRUM BRAKE
- 9.1.1.6. WET DISC BRAKE (OPTION)
- 9.1.1.7. BRAKE SERVO ASSEMBLY
- 9.1.1.8. DISMANTLING THE HYDRAULIC BRAKE ASSISTANCE UNIT
- 9.2. BRAKE REMOVAL
- 9.2.1. PREPARATION AND SAFETY INSTRUCTIONS
- 9.2.2. FRONT BRAKE DRUM REMOVAL.
- 9.2.3. REMOVAL OF THE BRAKE with the wet discs.
- 9.2.4. BRAKE MASTER CYLINDER REMOVAL.
- 9.3. BRAKE TROUBLESHOOTING
- 9.3.1. ANALYZE AND REPAIR BRAKE SYSTEM FAULTS
- 10. GR60 MAST CONTROL AND ADJUSTMENT
- 10.1. LIFTING SYSTEM
- 10.1.1. GENERAL POINTS
- 10.1.2. ASSEMBLY AND ADJUSTMENT PARAMETERS
- 10.1.3. MAST DISASSEMBLY, INSTALLATION AND ADJUSTMENT
- 10.1.4. REMOVING AND DISASSEMBLING THE LIFTING CYLINDER
- 10.1.5. INSTALLING AND DISASSEMBLING THE TILTING CYLINDER
- 10.1.6. POINTS TO WATCH FOR ADJUSTMENT AND TESTING
- 10.2. MAST REMOVAL
- 10.2.1. MAST REMOVAL.
- 10.3. MAST TROUBLESHOOTING
- 10.3.1. ANALYSIS AND REPAIR
- 11. GR70 HYDRAULICS
- 11.1. HYDRAULIC SCHEMATIC DIAGRAMS
- 11.1.1. MAIN HYDRAULIC DIAGRAM
- 11.2. HYDRAULIC CONTROL AND ADJUSTMENT
- 11.2.1. HYDRAULIC SYSTEM
- 11.2.1.1. MAIN PUMP
- 11.2.1.2. HYDRAULIC DISTRIBUTOR
- 11.2.2. STEERING SYSTEM
- 11.2.2.1. STRUCTURE
- 11.2.2.2. HYDRAULIC STEERING BLOCK
- 11.2.2.3. STEERING CYLINDER
- 11.3. HYDRAULIC COMPONENTS REMOVAL
- 11.3.1. PREPARATION AND SAFETY INSTRUCTIONS
- 11.3.2. HYDRAULIC PUMP REMOVAL ON MI G.
- 11.3.3. HYDRAULIC PUMP REMOVAL ON MI D.
- 11.3.4. HYDRAULIC DISTRIBUTOR REMOVAL.
- 11.3.5. TILT CYLINDER REMOVAL.
- 11.4. HYDRAULIC TROUBLESHOOTING
- 11.4.1. DIAGNOSIS AND CORRECTION OF GEAR PUMP FAULTS
- 11.4.2. DISTRIBUTOR FAULTS AND REPAIR
- 11.4.3. STEERING SYSTEM FAULTS
- 11.4.4. HYDRAULIC STEERING FAULTS
- 12. GR80 ELECTRICITY
- 12.1. ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
- 12.1.1. ELECTRICAL SYSTEMS
- 12.1.1.1. FUSE BOX
- 12.1.1.2. INSTRUMENT ASSEMBLY
- 12.1.1.3. REVERSER AND LIGHT COMMUTATOR SWITCH
- 12.1.1.4. LIGHTING SYSTEM
- 12.1.1.5. KEY SWITCH, REVERSING BUZZER, WARNING SIGNAL
- 12.1.1.6. ELECTRICAL CONNECTOR COMPONENTS
- 12.2. ELECTRICAL SCHEMATIC DIAGRAMS
- 12.2.1. ELECTRICAL DIAGRAMS
- 12.2.1.1. LIFT TRUCK MIX 404550 D STAGE 3 A
- 12.2.1.2. TRUCK MI 404550 G
- 12.2.1.3. TRUCK MI 404550 D STAGE 3 B
- 12.3. ELECTRICAL TROUBLESHOOTING
- 12.3.1. Engine fault inspection
- 12.3.2. FAULT DETECTION ON THE CUMMINS ST3B ENGINE
- 12.3.3. FAULT DETECTION ON THE ENGINE, PSI 4.3L PSI 4X
