Manitou MSI 40 D D ST5 S1, MSI 50 D D ST5 S1 Repair Manual 647960EN

Description

• Model List:
  • MSI 40 D D ST5 S1
  • MSI 50 D D ST5 S1

• 1. Page de garde / Front page
• 2. Sommaire général General table of content
• 4. GENERAL, CHARACTERISTICS AND SAFETY
• 4.1. Work during the Warranty Period
• 4.2. GENERAL INSTRUCTIONS AND SAFETY NOTICE
• 4.2.1. FOREWORD
• 4.2.2. SERVICING POSITION
• 4.2.3. EXPLANATION OF SYMBOLS
• 4.2.4. SERVICING RULES
• 4.3. GENERAL CHARACTERISTICS AND SPECIFICATIONS
• 4.3.1. LIFT TRUCK SPECIFICATIONS
• 4.3.2. MAST SPECIFICATIONS MSI 40 D D ST5 S1
• 4.3.3. MAST SPECIFICATIONS MSI 50 D D ST5 S1
• 4.4. GENERAL LOCATION
• 4.4.1. LOCATION OF NAME AND IDENTIFICATION PLATE
• 4.5. GENERAL CONTROL AND ADJUSTMENT
• 4.5.1. STANDARD TIGHTENING TORQUES
• 4.5.2. METRIC IMPERIAL UNIT CONVERSION
• 4.5.3. LUBRICANTS AND FUEL
• 6. ENGINE SPECIFICATION
• 6.1. CHARACTERISTICS AND SPECIFICATIONS
• 6.1.1. SPECIFICATIONS
• 6.2. Engine Schematic Diagrams
• 6.2.1. Lubrication system
• 6.2.2. Cooling circuit
• 6.2.3. Fuel system
• 6.2.4. exhaust gas recirculation
• 6.3. Location
• 6.3.1. Engine
• 6.3.2. Cooling circuit
• 6.3.3. Diesel fuel circuit
• 6.4. Control and adjustment
• 6.4.1. Exhaust system tightening torques
• 6.4.2. Diesel fuel circuit tightening torques
• 6.4.3. Cooling circuit tightening torques
• 6.4.4. Engine suspension tightening torques
• 6.5. removal refit
• 6.5.1. Remove the alternator belt
• 6.5.2. Remove the alternator
• 6.5.3. Remove the air filter
• 6.5.4. Remove the starter
• 6.5.5. Remove the DPF
• 6.5.6. Remove the radiator
• 6.5.7. Remove the gearbox motor assembly
• 6.6. TROUBLESHOOTING
• 6.6.1. ENGINE ERROR CODES
• 6.6.2. IGNITION SWITCHING TEST
• 6.6.3. STARTUP CONDITIONS
• 6.6.4. LACK OF POWER
• 6.6.5. Error table
• 6.7. SPECIFIC TOOLING
• 6.7.1. Special engine tooling
• 6.7.2. ELECTRONIC TENSION METER
• 8. TRANSMISSION
• 8.1. CHARACTERISTICS AND SPECIFICATIONS
• 8.1.1. HYDROMATIK TRANSMISSION SYSTEM
• 8.1.2. OPERATION OF A4VG 4056 / DA PUMP
• 8.1.3. CONTROL CARTRIDGE OPERATION
• 8.1.4. DR VALVE OPERATION
• 8.2. FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS
• 8.2.1. TRANSMISSION DRIVE CHAIN
• 8.2.2. HYDROSTATIC TRANSMISSION FORWARD GEAR SCHEMATIC DIAGRAM
• 8.2.3. HYDROSTATIC TRANSMISSION REVERSE GEAR SCHEMATIC DIAGRAM
• 8.3. TRANSMISSION COMPONENTS LOCATION
• 8.4. Control and adjustment
• 8.4.1. PRESSURE MEASURING POINTS
• 8.4.2. ADJUSTMENT POINTS
• 8.4.3. BOOST PRESSURE CONTROL AND ADJUSTMENT
• 8.4.4. PUMP MECHANICAL 0 ADJUSTMENT
• 8.4.5. CHECKING AND SETTING HP RELIEF VALVES
• 8.4.6. SETTING A6VM ENGINE CONTROL
• 8.4.7. PREOPERATION OR POSTREPAIR CHECKS
• 8.4.8. Hydrostatic assembly TIGHTENING TORQUES
• 8.4.9. TRANSMISSION CUTOFF
• 8.5. Removal refit
• 8.5.1. HYDROSTATIC PUMP REMOVAL
• 8.5.2. HYDROSTATIC MOTOR REMOVAL
• 8.6. SPECIFIC TOOLING
• 8.6.1. BASIC MANOMETER BOX
• 8.6.2. DIGITAL MANOMETER BOX
• 8.6.3. HYDROMATIK KIT (Replacement A 4 VG DA pump/A 6 VM DA engine)
• 10. AXLE
• 10.1. FLOW DIAGRAMS AND SCHEMATIC DIAGRAMS
• 10.1.1. TRANSMISSION DRIVE CHAIN
• 10.2. CONTROL AND ADJUSTMENT
• 10.2.1. TIGHTENING TORQUES
• 10.2.2. REAR AXLE WHEEL NUT ADJUSTMENT
• 12. BRAKE
• 12.1. BRAKING CIRCUIT CHARACTERISTICS
• 12.1.1. SERVICE BRAKE
• 12.1.2. Parking brake
• 12.2. CONTROL AND ADJUSTMENT
• 12.2.1. PARKING BRAKE
• 12.2.2. PEDAL CONTROL AND ADJUSTMENT
• 12.2.3. TH7 VALVE ADJUSTMENT
• 12.3. SPECIFIC TOOLING
• 12.3.1. BRAKE FLUID BLEEDER
• 14. MAST
• 14.1. CHARACTERISTICS AND SPECIFICATIONS
• 14.1.1. Flow rate pressure on STANDARD MASTS
• 14.1.2. mast weight
• 14.2. LOCATION
• 14.2.1. OVERVIEW OF THE DOUBLE MAST ASSEMBLY
• 14.3. CONTROL AND ADJUSTMENT
• 14.3.1. CHECKING AND ADJUSTING MAST CHAIN TENSION AND ALIGNMENT
• 14.3.2. CHECKING AND ADJUSTING DVT MAST LIFTING ROLLERS
• 14.3.3. CHECKING AND ADJUSTING THE FORK CARRIAGE ROLLERS
• 14.3.4. CHECKING AND ADJUSTING THE SPACING OF THE DVT MAST WEAR PLATE
• 14.4. Removal
• 14.4.1. REMOVING THE FORK CARRIAGE
• 14.4.2. REMOVING THE FORK CARRIAGE GUIDE ROLLERS
• 14.4.3. REMOVING THE FORK CARRIAGE BEARING ROLLERS
• 14.4.4. REMOVING THE DVT MAST ROLLERS
• 14.4.5. REMOVING THE MAST CHAINS
• 16. HYDRAULICS
• 16.1. CHARACTERISTICS AND SPECIFICATIONS
• 16.1.1. HYDRAULIC COMPONENT SHEETS
• 16.2. SCHEMATIC DIAGRAMS
• 16.2.2. Diagram
• 16.3. Hydraulic components location
• 16.3.1. Location
• 16.4. CONTROL AND ADJUSTMENT
• 16.4.1. FORK CARRIAGE DAMPING FLEXIBILITY ADJUSTMENT
• 16.4.2. PRESSURE CONNECTOR
• 16.4.3. Tightening torque
• 16.4.4. Mounting direction
• 16.5. HYDRAULIC COMPONENT REMOVAL
• 16.5.1. REMOVING THE HYDRAULIC PUMP
• 16.5.2. ELEMENT DISTRIBUTOR REMOVAL (JSM OPTION)
• 16.6. SPECIFIC TOOLING
• 16.6.1. BASIC MANOMETER BOX
• 16.6.2. DIGITAL MANOMETER BOX
• 16.6.3. INFLATION KIT BOX
• 18. ELECTRICITY
• 18.1. ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
• 18.1.1. FUSES AND RELAYS
• 18.1.2. OVERVIEW OF ELECTRICAL AND ELECTRONIC SYSTEM
• 18.1.3. ECU INPUTS/OUTPUTS
• 18.1.4. XA,B,C,E,F,N OVERLOAD CONTROLLER ECU (A1)
• 18.1.5. TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
• 18.2. ELECTRICAL SCHEMATIC DIAGRAMS
• 18.3. ELECTRICAL DIAGRAM CODIFICATION EXAMPLE
• 18.3.1. Electrical diagram msi 4050 DD ST5 S1
• 18.4. ELECTRICAL LOCATION
• 18.4.1. Location
• 18.4.2. location JSM version
• 18.4.3. harness location
• 18.5. Troubleshooting
• 18.5.1. MULTIFUNCTION SCREEN NAVIGATION
• 18.5.2. LIST OF ENGINE ECU ERROR CODES
• 18.5.3. Display ERROR CODES LIST
• 18.6. Specific tooling
• 18.6.1. DIAGNOSTICS CASE
• 18.6.2. OBD PLUG DEUTZ PLUG CABLE
• 18.6.3. BREAKOUT BOXES
• 18.6.4. ELECTROVALVE ADAPTER
• 20. DRIVERS CAB
• 20.1. DRIVERS CAB CONTROL AND ADJUSTMENT
• 20.1.1. CAB LIFTING
• 20.1.2. RAISING THE CAB IN CASE OF HYDRAULIC SYSTEM FAILURE
• 20.2. CONTROL AND ADJUSTMENT
• 20.2.1. Cab suspension tightening torques
• 20.2.2. Cab lock tightening torques
• 20.2.3. Cab seat tightening torques
• 22. CHASSIS BODYWORK
• 22.1. CONTROL AND ADJUSTMENT
• 22.1.1. COUNTERWEIGHT TIGHTENING TORQUES
• 24. OPTIONS ATTACHMENTS
• 25. AIR CONDITIONING OPTION
• 25.1. Air conditioning characteristics and specifications
• 25.1.1. Description of operation
• 25.1.2. OPERATING PRINCIPLE
• 25.1.3. SCHEMATIC DIAGRAM
• 25.2. Location
• 25.3. AIR CONDITIONING CONTROL AND ADJUSTMENT
• 25.3.1. ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT
• 25.3.2. CHARGING METHOD
• 25.3.3. FUNCTIONAL CHECKS