Manitou Forklift MI MI-X 50 60 70 80 100 D LD LG G ST3B / ST3A / ST4 Serie 2 service manual

Description Manitou Forklift MI MI-X 50 60 70 80 100 D LD LG G ST3B / ST3A / ST4 Serie 2 service manual

Manitou Forklift MI MI-X 50, 60, 70, 80, 100 D / LD / LG / G ST3B / ST3A / ST4 Series 2 pdf service & repair manual

Models covered:
MI 50 LD ST3B S2
MI 60 D ST3B S2
MI 70 D ST3B S2
MI 80 D ST4 S2
MI 100 D ST4 S2
MI-X 50 LD C ST3A S2
MI-X 60 D C ST3A S2
MI-X 70 D C ST3A S2
MI 50 LG S2
MI 60 G S2
MI 70 G S2
MI 50 LD ST3B S2 US
MI 60 D ST3B S2 US
MI 70 D ST3B S2 US
MI 80 D ST4 S2 US
MI 100 D ST4 S2 US
MI-X 80 D C ST3A S2
MI-X 100 D C ST3A S2
MI 50 LG S2 US
MI 60 G S2 US
MI 70 G S2 US

MANUAL CONTENT:
CHARACTERISTICS AND SPECIFICATIONS
ENGINE VIEWS
ENGINE SPECIFICATION
POWER CONFIGURATION
ENGINE CONTROLS AND ADJUSTMENTS
AIR CIRCUIT
EXHAUST CIRCUIT
REMOVAL - REFITTING OF ENGINE COMPONENTS MI 70 D
REMOVE THE MUFFLER
REMOVE THE AIR FILTER
REMOVE THE RADIATOR
REMOVE THE GEARBOX MOTOR ASSEMBLY
ELECTRICAL HARNESS AND HYDRAULICS HOSE DISCONNECTION
REMOVE THE HYDRAULIC PUMP
REMOVAL - REFITTING OF ENGINE COMPONENTS MI 100 D
REMOVE THE MUFFLER
REMOVE THE AIR FILTER
REMOVE THE CATALYTIC CONVERTER
REMOVE THE EXHAUST LINE
REMOVE THE DEF TANK DIPSTICK
ACCESS TO THE ADEBLUE PUMP
REMOVE THE ALTERNATOR
REMOVE THE STARTER
REMOVE THE RADIATOR
REMOVE THE MOTOR - GEARBOX ASSEMBLY
SPECIFIC TOOLING
DEF INSINUE KIT

CHARACTERISTICS AND SPECIFICATIONS
HYDRODYNAMIC TRANSMISSION GEARBOX (MI-X & MI G)
PRESENTATION
MAIN TECHNICAL DATA
OPERATING PRINCIPLE
TRANSMISSION PRINCIPLE
OIL CIRCUIT
STRUCTURAL PRESENTATION
HYDRODYNAMIC TRANSMISSION GEARBOX
INSTALLATION AND DISASSEMBLY PROCEDURE
HYDRODYNAMIC CONVERTER
OIL PUMP ASSEMBLY
MAIN CONTROL VALVE AND OVERFLOW VALVE ASSEMBLY
CONTROL VALVE ASSEMBLY
CLUTCH
STRUCTURAL PRESENTATION
INSTALLATION AND DISASSEMBLY PROCEDURE
PRECAUTIONS FOR INSTALLATION AND USE
REMOVE THE GEARBOX MI 50L - 60 - 70 D
REMOVE THE HYDRAULIC PUMP
RELEASE THE GEARBOX
TROUBLESHOOTING
(MI-X & MI G)

FRONT AXLE CHARACTERISTICS AND SPECIFICATIONS
MAIN TECHNICAL DATA
STRUCTURE OF THE FRONT AXLE
STRUCTURAL DIAGRAM OF THE MAIN GEAR REDUCER
LUBRICATION
STEERING AXLE CHARACTERISTICS AND SPECIFICATIONS
FRONT AXLE INSPECTION AND ADJUSTMENT
GEARS AND ADJUSTMENT METHODS OF DRIVEN HELICAL SATELLITE GEARS
DISASSEMBLY AND INSTALLATION OF THE WHEEL SIDE GEAR REDUCER
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND INSTALLATION OF THE CENTRAL GEAR REDUCER
REMOVING THE DIFFERENTIAL HOUSING
DISASSEMBLING THE HELICAL DRIVE GEAR
ASSEMBLING THE HELICAL DRIVE GEAR
FITTING THE DIFFERENTIAL HOUSING
FITTING THE REDUCER HOUSING
STEERING AXLE INSPECTION AND ADJUSTMENT
REMOVING THE WHEELS
REMOVING THE SPINDLE
REMOVING THE CROSS BEAM AND THE STEERING PIVOT
REMOVING THE HUB
REMOVING THE SPINDLE
STEERING CYLINDER REMOVAL
FITTING THE SPINDLE
STEERING CYLINDER ASSEMBLY
INSPECTING THE STEERING KNUCKLES
CHECKING FOR SPINDLE LOOSENING
CHECKING THE GAP BETWEEN THE SPINDLES AND PADS
CHECKING AND ADJUSTING THE GAP BETWEEN THE STEERING KNUCKLES AND THE STEERING AXLE
ADJUSTING THE PRE-TIGHTENING LOAD OF THE HUB BEARING
FRONT AXLE REMOVAL - REFITTING
FRONT AXLE REMOVAL MI 50L - 60 - 70 D
REMOVE THE WHEELS
REMOVE THE FRONT AXLE
FRONT AXLE REMOVAL MI 80 - 100 D
REMOVE THE WHEELS
REMOVE THE FRONT AXLE
STEERING AXLE REMOVAL - REFITTING
REMOVING THE AXLE
SPECIFIC TOOLING
SQUARE SOCKET

CHARACTERISTICS AND SPECIFICATIONS
SPECIFICATIONS
BRAKE MASTER CYLINDER
ACCUMULATOR
OIL-IMMERSED DISC BRAKE SYSTEM (5T - 7T)
OIL-IMMERSED DISC BRAKE SYSTEM (8T - 10T) - DIAGRAM
CONTROL AND ADJUSTMENTS
TRANSMISSION CUT-OFF BRAKE PEDAL
SERVICE BRAKE PEDAL
PARKING BRAKE LEVER
CHECKING AND REPLACING THE OIL-IMMERSED DISC BRAKES
LUBRICATION OIL
BRAKE SYSTEM TEMPERATURE
OIL SEAL
CHANGING THE SPLINED BUSHING
CHANGING THE FRICTION DISCS
ELIMINATION OF AIR IN THE HYDRAULIC BRAKE SYSTEM
HYDRAULIC BRAKING TROUBLESHOOTING

CHARACTERISTICS AND SPECIFICATIONS
OVERVIEW
ASSEMBLY AND ADJUSTMENT PARAMETERS
MAST COMPONENTS LOCATION
DUPLEX MAST WITH TOTAL FREE-ACTING LIFT
TRIPLEX MAST WITH TOTAL FREE-ACTING LIFT
CHECKING AND ADJUSTMENT OF MASTS
MAST DISASSEMBLY
LIFTING CYLINDER DISASSEMBLY
ROLLER DISASSEMBLY
OUTER MAST REMOVAL
CHECKING
MAST ASSEMBLY AND ADJUSTMENT
ROLLER ASSEMBLY
ADJUSTING THE ROLLERS AND THE SPACE BETWEEN THE MAST UPRIGHTS
SPACE BETWEEN THE SLIDES AND THE MAST UPRIGHTS
ASSEMBLING AND ADJUSTING THE LEFT LIFTING CYLINDERS
LIFTING CHAIN ADJUSTMENT
ADJUSTING THE CLEARANCE OF THE ROLLERS ON 5 TO 6 TONNE TRUCKS
ADJUSTING THE CLEARANCE OF THE CARRIAGE ROLLERS ON 7 TONNE TRUCKS
ADJUSTING THE CLEARANCE OF THE ROLLERS ON 8 TO 10 TONNE TRUCKS
BACK-REST DISASSEMBLY AND INSTALLATION
CYLINDER PART DISASSEMBLY
INSTALLING AND REPLACING THE FAULTY PARTS
TILTING CYLINDER REMOVAL AND INSTALLATION
DISASSEMBLY
REMOVAL OF PARTS
REASSEMBLY AFTER SEALING RING REPLACEMENT
ADJUSTMENTS AFTER TRUCK REASSEMBLY
REMOVAL - REFITTING ON MAST 50L - 60 - 70 D
REMOVE THE FORKS
MAST REMOVAL
REMOVAL - REFITTING ON MAST 80 - 100 D
REMOVE THE MAST

CHARACTERISTICS AND SPECIFICATIONS
STEERING SYSTEM
ING SYSTEM
WARNING CONCERNING ASSEMBLY AND USE
OIL PUMP
SPECIFICATIONS
STEERING CYLINDER
LIFTING CYLINDER
TILTING CYLINDER
ONE-WAY FLOW CONTROL VALVE
HYDRAULIC FILTER
FILTER DIAGRAM
SPECIFICATIONS
HYDRAULIC CONTROL VALVE
STRUCTURE AND PRINCIPLE
3 TO 5-WAY VALVE BANK
DIAGRAM FOR MI-X & G S2
SPECIFICATIONS
DIAGRAM FOR MI 50L TO 100 D ST3B S2 - ST4 S2 & US DEUTZ ENGINE
SPECIFICATIONS
HYDRAULIC SCHEMATIC DIAGRAM
MI 50L-60-70-80-100 D E3 S2 (CUMMINS ENGINE)
MI 50L-60-70 D ST3B S2 & US (DEUTZ ENGINE)
MI 80-100 D ST4 S2 & US (DEUTZ ENGINE)
CONTROL AND ADJUSTMENT
VALVE BANK MAIN PRESSURE RELIEF VALVE
HYDRAULIC FILTER ASSEMBLY
INTERNAL HYDRAULIC FILTER REPLACEMENT
METHOD FOR BLEEDING THE HYDRAULIC SYSTEM
TROUBLESHOOTING
TROUBLESHOOTING (MAIN HYDRAULICS)
TROUBLESHOOTING (CONTROL VALVE)
STEERING SYSTEM

CHARACTERISTICS AND SPECIFICATIONS
ECU INPUTS/OUTPUTS
ENGINE ECU (PLUG 1)
ELECTRICAL BOX
CONTROL UNIT FUSE BOARD
SCHEMATIC DIAGRAM OF THE CONTROL UNIT
IGNITION SWITCH
MULTIFUNCTION LIGHT LEVER
CONNECTION
INDICATOR LIGHTS CONTROL
CHECKING THE LIGHT SWITCH
HEADLIGHTS AND TAIL LIGHTS
ELECTRICAL SCHEMATIC DIAGRAMS
MI 50L-60-70 D ST3B S2 & US
MI 80-100 D ST4 S2 & US
MI-X 50L-60-70 D C ST3A S2
MI-X 80-100 D C ST3A S2
MI 50L-60-70 G_DUALFUEL
MI 50L-60-70 G_SINGLEFUEL
ELECTRICAL LOCATION
HARNESS PLAN
MI 50L 60 70 D ST3B S2 & US
MI 80-100 D ST4 S2 & US
ELECTRICAL COMPONENT REMOVAL MI 100 D
REMOVE THE BATTERIES
REMOVE THE ECUS
REMOVE THE HEADLAMPS
TAIL LIGHT CLUSTER
TROUBLESHOOTING
STARTER MAINTENANCE
ALTERNATOR MAINTENANCE
DEUTZ ENGINE FAULT CODES (DTC)
CUMMINS ENGINE FAULT DETECTION
CUMMINS ENGINE FAULT CODES (DTC)
PSI 4.3 L ENGINE FAULT CODES (DTC)

DRIVERS CAB REMOVAL - REFIT MI 70 D
REMOVING THE CAB
REMOVING THE FLOOR PANEL
DASHBOARD PANEL REMOVAL
REMOVE THE ELECTRICAL HARNESS
DISCONNECT THE HYDRAULIC CIRCUITS
DRIVERS CAB REMOVAL - REFIT MI 100 D
REMOVE THE DRIVERS SEAT
REMOVING THE CAB

REMOVAL - REFITTING MI 70 D
REMOVE THE COUNTERWEIGHT
REMOVE THE DRIVERS SEAT COVER