Manitou MC 18-2 D K ST5 S1 to MSI 35 D K ST5 S1 Service Manual 647869EN-USM134

[Hyundai]

Download this document, you need 4400 Gallons

Manitou MC 18-2 D K ST5 S1 to MSI 35 D K ST5 S1 Service Manual 647869EN-USM134
Size: 31.95 MB
Format: PDF
Language: English
Brand: Manitou
Type of Machine: Forklift
Type of Manual: Service Manual, Electric and Hydraulic Diagram
Model: Manitou
MC 18-2 D K ST5 S1
MC 18-4 D K ST5 S1
MC 25-2 D K ST5 S1
MC 25-4 D K ST5 S1
MC 30-2 D K ST5 S1
MC 30-4 D K ST5 S1
MSI 25 D K ST5 S1
MSI 30 D K ST5 S1
MSI 35 D K ST5 S1
Part Number: 647869EN-USM134
Publication Date: 2021
Number of Pages: 328 Pages

Contents:
Legal disclaimer
Foreword
Intervention during the warranty period
Supplier Documentation List
Safety

Servicing Rules​

Machine Service Operations

Servicing position​

Preparation and safety instructions​

Characteristics and specifications

Technical datasheet MC 18-2 ST5​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MC 18-4 ST5​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MC 25-2 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MC 25-4 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MC 30-2 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MC 30-4 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MSI 25 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MSI 30 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Technical datasheet MSI 35 D K ST5 S1​

Designation​

Weight​

Running carriage​

Dimensions​

Performance parameters​

Engines​

Miscellaneous​

Dimensional diagram​

Lubricants & Fuels​

Engine​

Mast​

Hydraulics​

Overhead guard​

Rear Axle (MC in 2W / MSI)​

Rear Axle (MC in 4W)​

Oil​

Grease​

Liquid​

Location

Location of name and identification plate​

Location of name and identification plates​

Reference Information

Explanation of symbols​

List of Abbreviations​

Standard tightening torques​

Metric - imperial unit conversion​

List of reference service manuals - Engine
Characteristics and specifications

Specifications D1803-CR-E5 - 26 kW​

Specifications D1803-CR-TE5 - 36 kW​

Location

engine component location 26 kW​

Location of engine elements 26 kW​

engine component location 36 kW​

Location of engine elements 36 kW​

air intake location 26 kW​

Engine 26 kW​

air intake location 36 kW​

Engine 36 kW​

exhaust location 26 kW​

Engine 26 kW​

exhaust location 36 kW​

Engine 36 kW​

Water circuit Engine location 26 kW​

Engine 26 kW​

Water circuit Engine location 36 kW​

Engine 36 kW​

Fuel circuit Location 26 kW​

Engine 26 kW​

Fuel circuit Location 36 kW​

Engine 36 kW​

Control and adjustment

cooling check - 26 kW​

Fan control – 26 kW​

cooling check - 36 kW​

Fan control – 36 kW​

Engine suspension adjustment​

Tightening torque​

Installation drawing​

alternator belt tension adjustment​

Alternator belt tension adjustment​

Removal

DPF removal (26 kW)​

Exhaust outlet tube​

Outlet tube​

DPF attachment​

Exhaust outlet tube​

Connection on the DPF​

Pressure sensor​

Counterweight cross member​

Removal of the DPF​

Removal DPF (36 kW)​

Outlet pipe clamp​

FAP pipe attachment​

Sensor​

Manifold outlet pipe​

Reinforcement lug​

Exhaust pipe support​

FAP removal​

Remove the alternator belt (26Kw)​

Alternator pivot screw​

Alternator tension screw​

Belt routing​

Remove the alternator belt (36kW)​

Turbo hose​

Alternator tension screw​

Alternator pivot screw​

Belt routing​

Engine removal (26 kW)​

Cooling hose​

Changing the oil​

Upper cooling hose​

Cooler openings​

Cooler fasteners​

Disengage the cooler​

Cooler removal​

Diesel filters​

ECU connectors​

Cooling reservoir hose​

Filter support fasteners​

Diesel fuel filter support assembly​

Fuse box lid​

captive nut​

Fuse box​

Diagnostics plug​

Engine ECU​

Air filter​

Engine ECU ground​

Engine ECU and air filter assembly​

Injector​

Preheat​

Connector XC1​

Alternator​

Starter​

Diesel fuel hose​

Windshield washer reservoir​

Hydraulic pump​

Cab shock mount​

Strap on the hydraulic pump​

Engine shock mount​

Sling on the engine​

Hydraulic coupling​

Disconnect the pump from the engine​

Engine ground​

Engine removed​

Remove the motor (36 kW)​

Radiator lower plate​

Lower hose​

Drain hose​

Drip plate​

Cooling and water return hose​

Air hose​

ECU harness and clamp​

Cooling reservoir hose​

Diesel fuel filters​

Expansion tank support bracket​

Expansion tank support bracket​

SPU computer​

Fuse box cover​

Fuse box​

Diagnostics plug​

Air filter clogging​

ECU and air filter support bracket​

ECU and air filter support bracket assembly​

Cooler fastener​

cooler disengaged​

Cooler on the ground​

Manifold outlet​

Engine sensors​

FAP support​

Alternator​

Engine connector​

Preheat​

Diesel pump​

Engine ground​

Windshield washer reservoir​

Hydraulic pump​

Cabin shock mounts​

Hydraulic pump strapped​

Diesel fuel hose​

Engine mountings​

Hydraulic pipe​

Engine slinging​

Engine removal​

Troubleshooting

Engine Diagnostic Codes (Refer to Section 120)​

Engine Troubleshooting Details​

Specific tools

Electronic belt tensiometer​

Electronic belt tensiometer​

List of reference service manuals - Engine
Characteristics and specifications

HYDROSTATIC PUMP A4VG CHARACTERISTICS​

HYDROSTATIC PUMP A4VG 40 DA1D7/32R - 52556872​

View of the pump​

Technical file​

Hydraulic diagram of the pump​

Location of pump components​

HYDROSTATIC PUMP A4VG 71 DA1D7 - 52596962​

View of the pump​

Technical file​

Hydraulic diagram of the pump​

Location of pump components​

HYDRAULIC WHEEL MOTOR - MS05 - 52600979​

Hydraulic wheel motor MS05​

Hydraulic diagram — Hydraulic wheel motor MS05​

HYDRAULIC WHEEL MOTOR - MSE05 - 52577970​

HYDRAULIC WHEEL MOTOR MSE05​

Hydraulic diagram — Hydraulic wheel motor MSE05​

HYDRAULIC WHEEL MOTOR - MG02 / MGE02 - 52536697​

Hydraulic wheel motor MG02 / MGE02​

Hydraulic diagram — Hydraulic wheel motor MG02 / MGE02​

2 WHEEL DRIVE HYDROSTATIC TRANSMISSION BLOCK - 52600350​

2-wheel drive hydrostatic transmission block​

General characteristics — 2-wheel drive hydrostatic transmission block​

Hydraulic diagram — 2-wheel drive hydrostatic transmission block​

Input/Output detail — 2-wheel drive hydrostatic transmission block​

4 WHEEL DRIVE HYDROSTATIC TRANSMISSION BLOCK - 52541454​

4-wheel drive hydrostatic transmission block​

Hydraulic diagram— 4-wheel drive hydrostatic transmission block​

Schematics

FORWARD OPERATION FLUID DIRECTION - MC 18-25-30-4WD​

Direction of fluids in forward operation - MC 18 -25-30-4​

FORWARD OPERATION FLUID DIRECTION - MSI 25-30-35​

Direction of fluids in forward operation - MSI 25-30-35​

Location

TRANSMISSION COMPONENTS LOCATION MC -2​

HYDROSTATIC SYSTEM MC18-2​

TRANSMISSION COMPONENTS LOCATION MC -4​

HYDROSTATIC SYSTEM MC18-4​

TRANSMISSION COMPONENTS LOCATION MSI​

MSI hydrostatic system​

Control and adjustment

TIGHTENING TORQUE​

Front wheel motor​

Rear wheel motor​

Engine / transmission flange​

Engine / transmission flange​

Measuring, checking and adjusting pump A4VG 56 DA​

Pump A4VG 56 DA​

Pump calibration​

HP relief valve check​

HP relief valve calibration​

Removal

REMOVING THE FRONT WHEEL MOTOR​

Wheel removal​

Removal of hoses​

Speed sensor​

Fasteners​

Wheel motor removal​

REMOVING THE REAR WHEEL MOTOR​

Removal of the rear wheel motor​

REMOVING THE HYDROSTATIC PUMP​

Slinging the hydrostatic pump​

Hydrostatic pump fasteners​

Refit

Hydrostatic pump REFIT​

Hydrostatic pump refit​

Front wheel engine REFIT​

Wheel motor fasteners​

Wheel nuts​

Rear wheel engine REFIT​

Rear wheel motor refit​

Specific tools

Basic manometer kit​

Basic manometer box — overview​

Digital manometer kit​

Digital manometer box​

HYDROMATIK KIT (REPLACEMENT - A4VG-DA PUMP / A6VM MOTOR)​

Hydromatik kit​

Kit composition​

TH7 VALVE HOSE AND CONNECTOR​

Hose (TH7 by-pass valve)​

Coupling (TH7 valve hose union fitting)​

TH7 valve by-pass, consisting of:​

Control and adjustment

Adjusting the stops on the rear axle (4WD)​

Rear axle central hoses​

Rear axle left motor stop screw​

Measurement of dimension on rear axle cylinder rod​

Min. clearance between the hoses and the rear axle cylinder rod​

Rear axle left locknut and stop screw​

Measurement of dimension on rear axle cylinder rod​

Min. clearance between the hoses and the rear axle cylinder rod​

TIGHTENING TORQUE 2WD​

2-wheel drive rear axle​

TIGHTENING TORQUE 4WD​

Rear axle tightening torque, 4-wheel drive​

PRE STRESSING THE SPINDLE BEARINGS: 2 WHEEL DRIVE​

Direction of the force on the spindle bearing​

TURNING RADII: 2 WHEEL DRIVE​

2-wheel drive turning radii​

TURNING RADII: 4 WHEEL DRIVE​

4-wheel drive turning radii​

Refit

SECURE THE CONNECTING RODS​

CASE No. 1: THE SPINDLE OR THE WHEEL MOTOR ENTERS BETWEEN THE 2 CONNECTING RODS​

Shimming of connecting rods, case 1​

CASE No. 2: THE WHEEL MOTOR HITS THE LOWER CONNECTING ROD​

Shimming of connecting rods, case 2​

CASE No. 3: THE WHEEL MOTOR HITS THE UPPER CONNECTING ROD​

Shimming of connecting rods, case 3​

Section Not Applicable
Characteristics and specifications

Table - Double mast specifications​

Table - Triple mast specifications​

Schematics

DVT masts​

View of mast assembly - New Mast DVT 3T​

TLL masts​

View of mast assembly - New Mast TLL 3T​

TSLL masts​

View of mast assembly - New Mast TSLL 3T​

Control and adjustment

Adjust lifting cylinder - New mast 3T​

Adjustment of lifting cylinder clearance​

Tightening torques for mast chain - New Mast 3T​

3 T mast chain tightening torque​

Adjust mast lift rollers - New Mast 3T​

Positioning of the roller to adjust its radial clearance​

Positioning of the roller to adjust its axial clearance​

Addition of shims on an inner mast roller​

DVT masts​

Adjust fork carriage support rollers - New Mast DVT 3T​

Removal

Remove the central lifting cylinder​

Slinging of the fork carriage​

Hose guide block​

Guide rollers​

Cylinder head nut​

Free lift cylinder​

Rigid tubular support​

Free lift cylinder hydraulic coupling​

Retaining lug​

Lower mounting screw​

Cylinder removal​

Tilt the mast to the ground​

Tilt of the mast​

Slinging the mast​

Hydraulic couplings​

Tilting cylinder pin​

Tilting cylinder pin​

Mast inclined to the floor​

Remove the free lift mast​

Slinging the mast​

Disconnection of the hydraulic couplings from the mast​

Unscrewing the tilting cylinder head pins​

Disengagement of the tilting cylinder head pins​

Removal of the mast’s lower half-clamps​

Raising the mast​

Mast resting on the ground​

Remove the lateral lifting cylinder​

Cylinder head fastener​

Tube retaining tie​

Cylinder upper fastener​

Lower hydraulic coupling​

Lower retaining nut​

Cylinder head to be disengaged​

Cylinder removal​

Remove the inner jamb​

Connection of hoses​

Hose retaining lug​

Interior upright removed​

Hydraulic pipe​

Lifting chains​

Free lift hydraulic pipe​

Lower stop​

Upper guide rollers​

Lower guide rollers​

Pulley support​

Chain rollers​

Disengagement of the interior upright​

DLL masts​

Tilt the mast to the ground​

Remove the free lift cylinder​

Refit

Mast chain assembly (New Mast) - 3T​

Orientation of the chain fastener pins​

Opening angle of chain fastener pins​

Bending back of chain fastener pins​

Axial clearance of the chain plates​

Assembly of the chain tensioners to the mast​

Characteristics and specifications

List of Data Sheets for Hydraulic Components​

SDM100 hydraulic valve block​

SDM100 hydraulic valve bank​

General characteristics — SDM100 hydraulic valve bank​

Details of inlets/outlets — SDM100 hydraulic valve bank​

Wiring diagram — SDM100 hydraulic valve bank​

Electrical values — SDM100 hydraulic valve bank​

2D views — SDM100 hydraulic valve bank​

Details of elements — SDM100 hydraulic valve bank​

Hydraulic diagram — SDM100 hydraulic valve bank​

SDM100 hydraulic valve block - JSM​

SDM100 hydraulic valve bank - JSM​

General characteristics — SDM100 hydraulic valve bank - JSM​

Details of inlets/outlets — SDM100 hydraulic valve bank - JSM​

2D views — SDM100 hydraulic valve bank - JSM​

Details of elements — SDM100 hydraulic valve bank - JSM​

Hydraulic diagram — SDM100 hydraulic valve bank - JSM​

Steering pump/Steering unit ospc 160 ls​

3D diagram of steering pump/steering block​

Hydraulic diagram of steering pump/steering block​

Color key for steering pump operating principle diagrams​

Steering pump schematic diagram – left turn​

Schematic diagram of steering pump – resistance on a wheel​

Schematic diagram of steering pump – full lock​

PARKER 13 cm3 hydraulic pump​

Hydraulic pump 13 cm3​

Hydraulic diagram — Hydraulic pump 13 cm3​

Input/Output detail — 13 cm3 hydraulic pump​

General characteristics — Hydraulic pump 13 cm3​

Working pressures — Hydraulic pump 13 cm3​

HYDRAULIC PUMP 21 cm3​

21 cm3 gear-driven hydraulic pump​

Hydraulic diagram — 21 cm3 gear-driven hydraulic pump​

Input/Output detail — 21 cm3 gear-driven hydraulic pump​

General characteristics — 21 cm3 gear-driven hydraulic pump​

Working pressures — 21 cm3 gear-driven hydraulic pump​

Operation of the ECS option​

Easy Connect system option​

Hydraulic diagram — ECS Option​

Schematics

Hydraulic Schematic MC18-2​

Hydraulic diagram MC18–2​

Hydraulic Schematic MC18-4​

Hydraulic diagram MC18–4​

Hydraulic Schematic MC25-30-2​

Hydraulic diagram MC25–30–2​

Hydraulic Schematic MC25-30-4​

Hydraulic diagram MC25–30–4​

Hydraulic Schematic MSI25-30-35​

Hydraulic diagram MSI25–30–35​

Location

Hydraulic local MC 18-25-30-2WD​

Hydraulic location MC 18-25-30-2​

Hydraulic local MC 18-25-30-4WD​

Hydraulic location MC 18-25-30-4​

Hydraulic local MSI 25-30-35​

Hydraulics location MSI 25-30-35​

Specific tools

Digital manometer kit​

Digital manometer box​

Basic manometer kit​

Basic manometer box — overview​

Characteristics and specifications

Fusibles et Relais​

Fuses and Relays​

Entrées/Sorties Calculateurs​

Main controller input/output SPU 40-26​

Dashboard Module Bauser (MSI MC ST5)​

Fiches techniques des composants électriques​

electrical table TDS​

Ignition switch​

Air filter clogging​

Front horn​

FUEL LEVEL GAGE​

JSM​

BMEP​

EMERGENCY STOP​

Schematics

Functional Organization (MSI MC ST5)​

Key​

Schematic diagram of operation (MSI MC ST5)​

Position by Schematics - MSI MC ST5 Version PC​

Schematics electrical MSI MC ST5 - Version PC​

Diagram 1 - Starting​

Diagram 1 - Starting​

Diagram 2 - CAN Networks​

Diagram 2 - CAN Networks​

Diagram 3 - Transmission​

Diagram 3 - Transmission​

Diagram 4 - Hydraulic movements​

Diagram 4 - Hydraulic movements​

Diagram 5 - Sensors​

Diagram 5 - Sensors​

Diagram 6 - Ventilation and wipers​

Diagram 6 - Ventilation and wipers​

Diagram 7 - Options​

Diagram 8 - Lights and signals​

Diagram 8 - Lights and signals​

Position by Schematic - MSI MC ST5 Version CAB​

Schematics electrical MSI MC ST5 - Version CAB​

Diagram 1 - Starting​

Diagram 1 - Starting​

Diagram 2 - CAN Networks​

Diagram 2 - CAN Networks​

Diagram 3 - Transmission​

Diagram 3 - Transmission​

Diagram 4 - Hydraulic movements​

Diagram 4 - Hydraulic movements​

Diagram 5 - Sensors​

Diagram 5 - Sensors​

Diagram 6 - Ventilation, air conditioning and wipers​

Diagram 6 - Ventilation, air conditioning and wipers​

Diagram 7 - Options​

Diagram 7 - Options​

Diagram 8 - Lights and signals​

Diagram 8 - Lights and signals​

Position by Schematic - MSI MC ST5 Version JSM​

Schematics electrical MSI MC ST5 - Version JSM​

Diagram 1 - Starting​

Diagram 1 - Starting​

Diagram 2 - CAN Networks​

Diagram 2 - CAN Networks​

Diagram 3 - Transmission​

Diagram 3 - Transmission​

Diagram 4 - Hydraulic movements​

Diagram 4 - Hydraulic movements​

Diagram 5 - Sensors​

Diagram 5 - Sensors​

Diagram 6 - Ventilation, air conditioning and wipers​

Diagram 6 - Ventilation, air conditioning and wipers​

Diagram 7 - Options​

Diagram 7 - Options​

Diagram 8 - Lights and signals​

Diagram 8 - Lights and signals​

Location

Localization harness​

PC location​

JSM location​

CAB location​

PC location​

JSM location​

CAB location​

Control and adjustment

Resetting the oil maintenance counter​

Display reset button​

Flow chart of oil counter reset​

Removal

Calculator removal​

Battery cut-off​

Rear transversal fastener​

ECU connectors​

Front fastener of the ECU​

ECU removal​

Troubleshooting

Diagnostic Codes (Refer to Section 120)​

Specific tools

Solenoid adapter​

Electrovalve adapter​

Breakout boxes​

Breakout boxes​

Control and adjustment

Calibrate the pedals​

Dashboard​

General menu​

CAL1 menu: accelerator calibration​

Removal

Lifting the operator station​

Sling loading/lifting rings​

Slinging the guard on the mast​

Guard shock mounts​

Driver's seat switches​

Valve bank lever cover​

Tilting lever with pressure on the seat​

Raising the cabin​

Sling loading/lifting rings​

Cab slinging​

Cabin shock mounts​

Valve bank cover​

Tilt of the mast​

Removal

Removal of counterweight grille​

Counterweight cowling​

Rear spotlight connection​

Removal air inlet on counterweight (26 kW)​

Air intake hose clamps​

Air intake hose​

Counterweight removal (26 kW)​

Exhaust and filter support fasteners​

Sling loading/lifting rings​

Wheel flaps​

Counterweight lower attachment​

Rear attachment​

Counterweight slinging​

Lifting the counterweight​

Remove the counterweight (36 kW)​

Rain cap​

Rain cap support​

Air filter hose​

Outlet hose​

filter support cross member​

3-point slinging​

Counterweight fasteners​

Counterweight rear attachments​

Counterweight removal​

Section Not Applicable
Default Management on the Bauser Screen

Fault display format​

Reporting of a fault on the display​

Display error counter​

1st fault code display​

1st fault code display​

Machine Error Codes
Diagnostics Codes (Kubota 1803-CR-E5B)
Diagnostics Codes After Treatment (Kubota 1803-CR-E5B)
Diagnostics component

Component diagnostics box​

Example of connection to the component​

Diagnostics case

Diagnostics case​

Example of connection to the machine​

Accessories​