mht 10120 hydrostatic transmission ......a6vm 107 motor pressure control points hp socket note: the...

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20TRANSMISSION COMPONENTS LOCATION

page

MHT 10120 HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION 4

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20

2 TRANSMISSION COMPONENTS LOCATION

20

(20/02/2012) 20-03-M184EN

3TRANSMISSION COMPONENTS LOCATIONMHT 10120 HYDROSTATIC TRANSMISSION

Radiator

Hydrostatic

pump

Rear axle

Gearbox

Front axle

Shaft

Hydrostatic

motor

2

0

(20/02/2012)20-03-M184EN

4 TRANSMISSION COMPONENTS LOCATION

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION

Radiator

Hydrostatic

pump

Rear axle

Gearbox

Front axle

Shaft

Hydrostatic

motor

(24/02/2012) 20-04-M184EN

20TRANSMISSION CONTROL AND ADJUSTMENT

page

CHECKING THE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PRESSURE CONTROL POINTS ON A4VG 71 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

– CONTROL AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

– HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

– BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

– CASING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

A6VM 107 MOTOR PRESSURE CONTROL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

– HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

– SWITCHING PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHECKING AND ADJUSTING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

TRANSMISSION ADJUSTMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

– A4VG PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

– A6VM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER

A REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

– STARTING UP: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CHECKING AND ADJUSTING THE BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ADJUSTING THE PUMP MECHANICAL “0”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

– CHECKING THE ADJUSTMENT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CHECKING AND ADJUSTING THE START OF REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . .9

– BEGINNING OF THE REGULATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CHECKING AND ADJUSTING THE END OF REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

– CHECK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

– END OF THE REGULATION:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CHECKING AND ADJUSTING THE HP LIMITERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

– ADJUSTING THE HP LIMITERS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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20


ADJUSTING THE A6VM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

– A. CHECK MINIMUM DISPLACEMENT (MAX SPEED): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

– B. CHECKING THE BEGINNING OF THE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

– C. MAX DISPLACEMENT: (MAX. TRACTION FORCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REGULATING THE HYDROSTATIC TRANSMISSION PRESSURES . . . . . . . . . . . . . . . . . . . . . .13

– GENERAL PRESSURE REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

– ADJUSTING THE BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

– REGULATING THE VEHICLE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

– CHECKING PILOT PRESSURE “PS”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROUBLE-SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

– PUMP/MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

– VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

MANITOU - HYDROSTATIC TRANSMISSION REGULATION CHART -

A4VG--DA / A6VM--DA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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20

3TRANSMISSION CONTROL AND

ADJUSTMENT

CHECKING THE PRESSURE

PRESSURE CONTROL POINTS ON A4VG 71 PUMP

Casing pressure connections

Necessary (the case must contain basic pressure gauge sockets Ref. 549671 + Hydromatik Kit Ref. 209572)

� 20-09 Special tools for the transmission

CONTROL AIR

• 2 Connectors 165711 (Ref. 55) (M 14 x 150)

• 2 Pressure gauge sockets 58181 (Ref. 49) (M 8 x 100)

• 2 Pressure gauges (0 - 40 bar)

• 2 Test fl exible tubes 549887

HIGH PRESSURE

• 2 Pressure gauge sockets 477484 (Ref. 51) (M 12 x 1.5)

• 2 Pressure gauges (0 - 600 bar)


BOOST PRESSURE

• 1 Connector + pressure gauge socket assembly 199175 (Ref. 53.1) (M 18 x 1.5)

• 1 Pressure gauge (0 - 40 bar)


CASING PRESSURE

• 1 Pressure gauge socket 477484 (Ref. 51) (M 12 x 1.5)



Control air socket

HP pressure socket

Boost pressure socket

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20


A6VM 107 MOTOR PRESSURE CONTROL POINTS

HP socket

NOTE: The actual assembly of the motor diff ers from that shown in the Figure since it is rotated

through 180°.

Necessary (the case must contain basic pressure gauge sockets Ref. 549671 + Hydromatik Kit Ref. 209572)

� 20-09 Special tools for the transmission

HIGH PRESSURE

• 1 Pressure gauge socket 58189 (Ref. 52) (M 14 x 150)



SWITCHING PRESSURE

• 1 Pressure gauge socket 477484 (Ref. 51) (M 12 x 150)



Switching pressure

socket

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20


ADJUSTMENT

CHECKING AND ADJUSTING THE TRANSMISSION

TRANSMISSION ADJUSTMENT POINTS

A4VG PUMP

A6VM MOTOR

DR valve

HP Valve

“DA” regulator valve

“DA” regulation start adjuster

Supercharger valve

HP Valve

Adjustment cam of plate

regulation end

Disk mechanical “0”

adjuster

Switching

regulation

adjuster screw

Minimum displacement

adjuster screw (do not

disrupt the adjustment)

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20


CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER A REPAIR

• Check the oil level in the tank.

• Check to ensure that all the connections of the hose pipes are tightened properly.

• Check the electrical connections of the solenoid valves.

• Ensure that the circuit is fi lled properly, and at the same time fi ll the oil fi lter before fi tting it.

• Check to ensure the control air tubes are fi tted correctly:

– X1 pump with X2 motor,

– X2 pump with X1 motor.

• In all the cases, the control air connection is opposite to the HP hose pipes. (For example: if the HP

hose pipe for forward movement is to the RH of the motor, the forward movement control air hose

pipe will be to the LH, and the other way around for the reversing).

• Connect the boost pressure socket pressure gauges - control air - HP - casing.

STARTING UP:

• For reasons of safety, place the vehicle on stands.

• Let the I.C. engine run without moving the vehicle to bleed the circuit properly. (disconnect the wire

of the stop solenoid valve on the injection pump).

• Make sure that the boost pressure increases at least to 15 bar on running the starter motor.

"DO NOT start up the transmission with insufficient boost pressure, as there is risk of wear of the

transmission".

• Reconnect the stop solenoid valve on the injection pump.

• Run the I.C. engine for a few minutes at minimum speed. Boost pressure 35 - 40 bar.

Unstability of the needle indicates air intake (emulsifi ed oil in the tank, and cavitation noise of the

transmission).

“Inverter in neutral” in the two HP circuit inlets. The pressure is equal to the boost pressure.

• Heat the oil in the circuit by accelerating progressively (keep the hand brake locked to allow

measurement of the HP with load blocked).

• When the oil is at a minimum temperature of 50°- 60° check the engine speed: at minimum, at

maximum without load. (See technical specifi cations).

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20


ADJUSTMENT

CHECKING AND ADJUSTING THE BOOST PRESSURE

The A4VG 71 series pump is equipped with an adjustable limiter.

To increase the boost pressure, tighten the screw.

At I.C. engine max speed, 40 bar.

The oil tempearture must not exceed 40 °C.

The pump is already equipped with a pressure socket as seen in the Figure.

The vehicle must be braked completely.

Check to make sure there are no leaks in the inching valve.

“FE” boost pressure socket

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ADJUSTING THE PUMP MECHANICAL “0”

– Connect two small scale (40 - 100 bar) pressure gauges on the HP pressure sockets.

– Make sure the hand brake is disengaged and that the vehicle is on stands (wheels suspended in the air):

– Engine running at minimum speed.

– Speed inverter in neutral.

– Slacken the lock nut of the mechanical "0" adjuster screw (hex wrench 19). Turn the screw gently

(using an Allen wrench 6) clockwise until the lowest HP variation is seen.

– Make a marking in the direction of the wrench.

Operate in the anticlockwise direction to change the HP in the other direction of movement.

Make a marking in the direction of the wrench.

– Then turn the adjuster screw until the wrench is in the centre of the two markings made earlier.

Tighten the lock nut.

CHECKING THE ADJUSTMENT:

– Connect the 2 pressure gauges on the HP sockets 600 bar scale:

1 - Check the beginning of the adjustment in forward movement and reversal with an rpm counter.

Accelerate the I.C. engine gently - selector in forward movement - until the wheels start moving.

Measure the I.C. engine rotation speed.

Repeat the operation with reversing movement.

Check the two I.C. engine rotation speeds which must be identical.

2 - Check the Hp and corresponding control air - wheels blocked - forward movement inverter selector

- accelerate the I.C. engine progressively up to max. speed.

Measure the forward movement and forward movement control air HP pressures.

Repeat the operation with reversing movement; the values must be identical.

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20


ADJUSTMENT

CHECKING AND ADJUSTING THE START OF REGULATION

“DA” regulator valve

“DA” regulation start adjuster

BEGINNING OF THE REGULATION:

• Measure the I.C. engine speed at the minimum which must be ~ 850 min-1.

The regulation must begin at 1050 min-1. To proceed with regulation, act on the adjuster screw

present on the end of the regulation start valve:

– Tighten the screw to delay the beginning of forward movement.

– Slacken it to advance the beginning of forward movement.

• Modifi cation of the beginning of the adjustment of the forward movement point shifts the fi eld of

regulation of the pump. The end of the adjustment must be systematically checked “400 bar for the

full speed of the motor in question”. (1600 - 1800 min-1).

• Checking the regulation is equal to checking the "mechanical 0" - Point 2.

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CHECKING AND ADJUSTING THE END OF REGULATION

End of regulation

CHECK:

– The vehicle must be on stands - brakes locked and inching (brake) in by pass.

– Inverter in forward movement.

– Motor at minimum, check the rotation speed of the I.C. engine.

– Accelerate progressively and check the speed of the I.C. engine (1600 - 1800 min-1) when the HP for

forward movement reaches 400 bar.

END OF THE REGULATION:

The adjustment of the end of regulation of the pump is obtained by acting on the eccentric screw which

changes the position of the plate (in the direction of rotation). This will increase or decrease the return

forces of the inclinable disk.

bThis adjustment must be made on the bench by the

manufacturer; it must not be changed, except with

permission from the Parent Company.

The milled surface of the cam must face the side of the

booster pump. The adjustment margin is

only by 90% to the RH and 90% to the LH. Do not exceed

this percentage (risk of mechanical breakage due to

interference between the plate and the casing). Like the

HP adjustment, this adjustment must be done with the

DR valve over-calibrated.

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ADJUSTMENT

CHECKING AND ADJUSTING THE HP LIMITERS

• Checking and adjustment of the HP limiters is done with the forklift truck on stands (wheels suspended

in mid-air) and the brakes locked.

The inching valve must be bypassed to eliminate the pump discharge function.

• Overcalibrate the DR valve -Ref. 1- to check the actual calibration value of the HP limiters.

• Turn the screw (Ref. 1) through one turn.

• The HP limiters (Ref. 2) must be calibrated

at 460 bar.

During this operation there will be a sharp

drop in the I.C. engine speed, about 500

- 600 min-1.

After checking the HP, adjust the DR valve

(Ref. 1) to a value less than 20 Bar below

HP (Ref. 2).

ADJUSTING THE HP LIMITERS:

A4VG 71 DA series Pump

• Remove the lead sealing A.

• Remove cap B.

• Unscrew lock nut D.

• Act on screw E to increase the pressure.

• Refi t the cap and lead-seal the adjuster screw again.

C D

A

B

E

1

2

2

MB

MA

2

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20


ADJUSTING THE A6VM MOTOR

A. CHECK MINIMUM DISPLACEMENT (MAX SPEED):

• The checking is done with: the truck on level ground, engine running at max. speed, moving forwards,

• Connect the two 600 bar scale pressure gauges as shown in the Figure. At max. vehicle speed, the

two pressures must be equal. Taking into account the ratio of the control cylinder surface, this means

that the engine is switched in minimum displacement.

• For actual checking of the speed (check the vehicle's technical specifi cations).

b This adjustment (Ref. 1) must be made on the bench by the manufacturer; it must not be changed,

except with permission from the Parent Company.

High pressure

B. CHECKING THE BEGINNING OF THE ADJUSTMENT

• When the vehicle is at max. speed, press progressively on the brakes to increase the HP (the inching

valve must be bypassed).

• Observe the two pressures. When the HP reaches a value of 260 - 280 bar, the switching pressure will

drop and the HP will continue to increase up to the DR valve calibration value.

• The beginning of the adjustment can be set by means of the adjuster screw on the engine.

C. MAX DISPLACEMENT: (MAX. TRACTION FORCE)

• To make this adjustment, the lift truck must be blocked (brakes locked).

The checking is done at max. engine speed with the vehicle moving forwards.

• The switching pressure (side of the greater cross-section of the control cylinder) must be close to

zero bar.

If necessary, adjust the adjuster screw (tighten to increase the switching pressure, slacken to decrease

the pressure).

• The traction force must be checked (at the hook) (for the values, see Use and Maintenance Manual).

1

Adjuster screw

for beginning of

the regulation of

switching

Switching pressure

( R e f . 1 ) M I N I M U M D I S P L A C E M E N T

ADJUSTER SCREW (tightening the screw will move the disk downwards. The displacement will thus increase while the speed will decrease).

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ADJUSTMENT

REGULATING THE HYDROSTATIC TRANSMISSION PRESSURES

“DA” regulator

valve

Beginning of adjustment

Mechanical zero

"G" boost pressure

adjustment

“ M a - M b ”

pressure test

HP valves

512 bar

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20


MaMb GENERAL PRESSURE REGULATION

Position the 600 bar scale pressure gauge connector on one of

the pressure test sockets positioned on the hydrostatic pump

marked as "Ma" (Ref. 1) or "Mb" (Ref.2).

Regulate the general pressure by acting on adjuster (Ref. 3)

provided on hydrostatic pump "DR".

With the diesel engine running at maximum speed, gear in fast

speed and oil temperature approx. 60 degrees C, the general

pressure must be 440 bar.

ADJUSTING THE BOOST PRESSURE

Position a T-union (Ref. 4) on the hydrostatic pump connector

marked with "G", remove the cover (Ref. 6) of the adjuster (Ref.

7) and fi t the connector of a 60 bar scale pressure gauge (ref.

5) on the union.

Adjust the boost pressure on the adjuster (Ref. 7).

With the engine running at maximum speed and the oil

temperature about 60 degrees, the boost pressure must be

about 35 bar and must vary by not more than 1 or 2 bar between

the minimum and maximum engine rpm.

3

4

5

6

7

1

2

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20


ADJUSTMENT

REGULATING THE VEHICLE START

Set the I.C. engine speed at about 100rpm more than the

minimum.

Regulate the adjuster (Ref. 8) at the end of the DA valve to

obtain vehicle start up.

Note: This adjustment must be made with the oil cold.

CHECKING PILOT PRESSURE "PS"

The oil temperature must be approx. 60°C.

Remove the pipe (Ref. 9) from the pump.

Position a T-union (Ref. 10) on the hydrostatic pump connector,

and fi t on the union the connection of a 60 bar scale pressure

gauge (Ref. 11).

The pilot pressure must be between 25 and 30 bar.

8

9

9

10

11

Pressure Value

Maximum 440 bar

Boost pressure 35 bar

Control air 25 / 30 bar

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20


TROUBLE-SHOOTING

PUMP/MOTOR

Suction

pressure

Supply pressure

Control air

High pressure

“S” A4VG pump

Measuring point

Cause

Direction of rotation

Suction pipe Oil tank fi lter

Type of oil

Oil temperature

Heat exchanger

“G” A4VG pump

Measuring point

Supply pressure

Cause

Auxiliary pump

Supercharger valve

Wear

Heat exchanger oil temperature

A6VM MOTOR

Wear

Washing valve

By-pass valve

Oil temperature

RPM

I.C. engine pump connection (coupling)

A6VM MOTOR

Measuring point

Supply pressure

Cause

Choke valvesDA regulator valve/inching valve/throttle valvePressure cut

Proportional solenoid valve/magnet

Control piping

“X1/X

2” A4VG pump

Suction pressure

A6VM MOTOR

Measuring point

Supply pressure

Cause

HP-DR valve

Pressure cut

Shifting distribution plate

“MA/M

B” A4VG pump

Suction pressure Wear

Heat exchanger oil temperature

Not blocked

Coupling

BrakeWear-leaked oil

Oil temperature

Heat exchangerI.C. engine

Min/Max rpm

Diesel fi lter

Air fi lter

Power

(24/02/2012) 20-04-M184EN

20


ADJUSTMENT

VEHICLE

The diesel engine runs

The vehicle does not stop

The vehicle movement is delayed

Insuffi cient

traction force

Max. transfer

speed is not

reached

A4VG PUMP

Mechanical zeroCause

Beginning of regulation

Proportional solenoid valve

A4VG PUMP

Cause

Choke valves

Suction pressure

Control air


Inching

Strong overload of

I.C. engine

DR valve

Wear

A6VM MOTOR

Cause

Pressure cut

Control air

Cause

Inching

Control air Beginning of regulation

Magnet

Inclination angleC C s c r e w adjustment

I.C. engine

RPM

Transmission

Wheels

Cause

A4VG PUMP

Shifting distribution plate


Inclination angle

I.C. engine

Injection pump

Fuel fi lter

A6VM MOTORA4VG PUMP VEHICLE

Shifting distribution plate W h e e l

diameter


Control air piping X1/X2

Magnet

Inclination angle

I.C. engine

RPM

A6VM MOTORA4VG PUMP VEHICLE

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20


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ED

(23/02/2012) 20-06-M184EN

20TRANSMISSION REMOVAL

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION . . . . . .4

– DISASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

– DISMANTLING THE HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MHT 10120 HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

– DISASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

– DISMANTLING THE HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(23/02/2012)20-06-M184EN

20

2 TRANSMISSION REMOVAL

PREPARATION AND SAFETY INSTRUCTIONS

– Position the truck on a level surface.

– Raise the boom and set it in safety to be able to access the upper part of the hydraulic pump.

– Discharge the pressure from the hydraulic system.

– Deactivate the ignition key and disconnect the negative pole from the battery.

Specifi c tools:

- Crane for lifting (5000 kg. minimum).

- Pallet jack

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.

DISASSEMBLING THE HYDROSTATIC TRANSMISSION

Take containers large enough to hold the hydraulic oil in the tank.

Place a container under the drainage cap (Ref. 1).

Remove the cap (Ref. 1) and let the oil fl ow out.

Slacken the screws and washers (Ref. 2 and 3) and remove the

guards (Ref. 4 and 5) in the area under the boom to access the

upper part of the pump.

1

3

2

3

23

2

4

5

(23/02/2012) 20-06-M184EN

20


Slacken the screws (Ref. 6) and remove the brackets (Ref. 7)

which block the universal shaft (Ref. 8) on the gearbox.

Slacken the screws (Ref. 9) and nuts (Ref. 10) which block the

universal shaft (Ref. 8) on the rear axle.

Remove the universal shaft from the vehicle.

Mark all the pipes and connections with a marker pen, before

disassembling, to ensure correct positioning in the reassembly

phase.

Free the cables and pipes from the clamps.

bPlug all the hydraulic openings of the pumps and motors

to prevent impurities from contaminating the hydraulic

circuit.

67

8

9

10

8

(23/02/2012)20-06-M184EN

20


MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225

HYDROSTATIC TRANSMISSION

DISASSEMBLING THE HYDROSTATIC PUMP

Slacken the screw (Ref. 1) and remove the coil from the solenoid

valve (Ref. 2) fi tted on the pump.

1

2

Disconnect the pipes of the hydraulic oil system, suction, from the hydrostatic pump (Ref. 3) and from

the movements pump (Ref. 4).

4

3

Secure the pumps by means of belts or ropes to an overhead

crane, passing these through the opening under the boom.

Slacken the screws (Ref. 5) which secure the pump (Ref. 3) to

the I.C. engine.

5

3

(23/02/2012) 20-06-M184EN

20


Place the pumps (Ref. 3 and 4) on a pallet jack and take these

out of the vehicle.

Slacken the screws (Ref. 6) and remove the washers (Ref. 7) to

dismantle the hydrostatic pump (Ref. 3) from the movements

pump (Ref. 4).

DISMANTLING THE HYDROSTATIC MOTOR

Remove the drainage pipe (Ref. 2) on the back of the hydrostatic

motor (Ref. 1).

Remove the unions (Ref. 3) on the control air valve (Ref. 4).

Remove the connector (Ref. 5) of the vacuum gauge (Ref. 8)

from the oil fi lter.

3

4

3

4

6

7

2

3

3

5

1

4

(23/02/2012)20-06-M184EN

20


Remove the connector (Ref. 6) from the exhaust manifold (Ref. 7).

Remove the vacuum gauge (Ref. 8).

Slacken the screws (Ref. 9) from the fl anges (Ref. 10).

Unscrew the bottom drainage pipe (Ref. 11) from the lower

part of the vehicle.

6

8

7

9

10

10

11

(23/02/2012) 20-06-M184EN

20


Slacken the remaining screws (Ref. 9) remove the fl anges (Ref.

10) and remove the pipes (Ref. 12 and 13)..

Slacken the screws (Ref. 14) in the lower part of the motor

and in the upper part.

Secure the engine (Ref. 1) to an overhead crane by means of

ropes and remove it from the vehicle.

9

10

10

9

12

13

14

1414

1

(23/02/2012)20-06-M184EN

20


MHT 10120 HYDROSTATIC TRANSMISSION

DISASSEMBLING THE HYDROSTATIC PUMP

Disconnect the pipes of the hydraulic oil system, suction and the electrical connections of the hydrostatic

pump (Ref. 1).

1

2

Secure the pump by means of belts or ropes to an overhead crane, passing these through the opening

under the boom.

Remove the screws (Ref. 3) and the washers (Ref. 4 and 5) which block the hydrostatic pump (Ref. 1) to

the movements pump (Ref. 2).

Place the pump (Ref. 1) on a pallet jack and take it out of the vehicle.

5

4

3

(23/02/2012) 20-06-M184EN

20


DISMANTLING THE HYDROSTATIC MOTOR

Disconnect all the pipes of the hydraulic oil system from the motor (Ref. 1).

Secure the motor by means of belts or ropes to an overhead crane, passing these through the opening

under the boom.

Remove the nuts and washers (Ref. 2 and 3), the screws and washer (Ref. 4 and 5) and remove the

brackets (Ref. 6).

Remove the motor (Ref. 1) from the gearbox.

Place the motor (Ref. 1) on a pallet jack and take it out of the vehicle.

1

1

6

6

3

2

2

3

5

44

5

(23/02/2012)20-06-M184EN

20


(23/02/2012) 20-07-M184EN

20TRANSMISSION REFIT

page

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– REASSEMBLING THE HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– REASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MHT 10120 HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

– REASSEMBLING THE HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

– REASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(23/02/2012)20-07-M184EN

20

2 TRANSMISSION REFIT


– Position the truck on a level surface.

– Raise the boom and set it in safety to be able to access the upper part of the hydraulic pump.

– Deactivate the ignition key and disconnect the negative pole from the battery.

– Thoroughly wash and dry all the hydraulic oil system pipes before reassembly.

Specifi c tools:


- Pallet jack

REASSEMBLING THE HYDROSTATIC TRANSMISSION

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225

HYDROSTATIC TRANSMISSION

REASSEMBLING THE HYDROSTATIC MOTOR

Place the motor (Ref. 1) on the vehicle using ropes and an

overhead crane.

Fit the screws (Ref. 2) in the upper part of the motor

and in the lower part.

22

1

2

(23/02/2012) 20-07-M184EN

20

3TRANSMISSION REFIT

Fit the pipes (Ref. 3 and 4) on the hydrostatic motor locking these

by means of the fl anges (Ref. 5) and tighten the screws (Ref. 6).

Fit the drainage pipe (Ref. 7) on the lower part of the motor.

Fit the remaining screws (Ref. 6) on the fl anges (Ref. 5).

6

5

5

6

3

4

6

6

7

5

5

(23/02/2012)20-07-M184EN

20


Refi t the vacuum gauge (Ref. 8).

Fit the connector (Ref. 9) of the vacuum gauge on the oil fi lter.

Refi t the unions (Ref. 10) on the control air valve (Ref. 11).

Refi t the connector (Ref. 12) on the exhaust manifold (Ref. 13).

Fit the drainage pipe (Ref. 14) on the upper part of the motor

(Ref. 1).

14

10

10

9

12

1

11

13

8

(23/02/2012) 20-07-M184EN

20

5TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC PUMP

Fit the hydraulic system pump (Ref. 2) on the hydrostatic pump

(Ref. 1) by means of the screws and washers (Ref. 3 and 4).

Place the pumps (Ref. 1 and 2) on a pallet jack and position

these under the vehicle.

Lift the pumps by means of belts or ropes and an overhead

crane, passing these through the opening under the boom.

Block the pump (Ref. 1) on the I.C. engine by means of the screws

(Ref. 5) on which "Loctite Blue Threadlock" has been applied.

5

1

1

2

1

2

4

3

(23/02/2012)20-07-M184EN

20


Fit the coil (Ref. 6) on the solenoid valve (Ref. 7) fi tted on the

pump.

Clamp all the hydraulic pipes and electric cables.

Reposition the universal shaft (Ref. 8) under the vehicle and

screw it to the rear axle by means of the screws (Ref. 9) and nuts

(Ref. 19) using a 140 Nm tightening torque.

6

7

Fit all the pipes of the hydraulic oil system and suction on the hydrostatic pump (Ref. 1) and on the

hydraulic system pump (Ref. 2), taking care to position these correctly back in place according to the

markings made with the marker pen in the dismantling phase.

2

1

9

10

8

(23/02/2012) 20-07-M184EN

20

7TRANSMISSION REFIT

Screw the universal shaft (Ref. 8) on the gearbox, blocking it

by means of the brackets (Ref. 11) and fi tting the screws (Ref.

2) on which "Loctite blue threadlock" is applied applying a 44

+ 8.5 tightening torque.

Refi t the guards (Ref. 13 and 14) in the area under the boom,

by means of the screws and washers (Ref. 15 and 16).

1211

8

16

15

16

1516

15

13

14

(23/02/2012)20-07-M184EN

20


MHT 10120 HYDROSTATIC TRANSMISSION

REASSEMBLING THE HYDROSTATIC MOTOR

Place the motor (Ref. 1) on the vehicle using ropes and an overhead crane.

Refi t the brackets (Ref. 6) fi xing them by means of the screws and washers (Ref. 4 and 5), and tighten

the nuts and washers (Ref. 2 and 3).

Reconnect all the hydraulic oil system pipes on the motor (Ref. 1).

1

1

6

6

3

2

2

3

5

44

5

(23/02/2012) 20-07-M184EN

20

9TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC PUMP

Place the motor (Ref. 1) on the vehicle using ropes and an overhead crane.

Refi t the hydrostatic pump (Ref. 1) on the movements pump (Ref. 2) by means of the screws (Ref. 3) and

washers (Ref. 4 and 5) on which "Loctite blue threadlock" has been applied.

1

2

Reconnect the pipes of the hydraulic oil system and reconnect the electrical connections on the

hydrostatic pump (Ref. 1).

5

4

3

(23/02/2012)20-07-M184EN

20


Set the forklift truck on a level surface with the I.C. engine

switched off , with the boom retracted and lowered as far as

possible.

Fill the tank with fresh hydraulic fl uid (�nd manual “LUBRICANTS”

according to the specifi ed type and quantity), through the hole

(Ref. 17), check the oil level by means of the rod (Ref. 18), and

close the tank by fi tting the screw cap (Ref. 19).

bUse an extremely clean funnel and wipe the upper part

of the oil drum before starting with the fi lling.

The oil level is correct when it reaches the red dot shown on

the rod (Ref. 17).

Visually inspect for leaks on the tank and pipes.

18

19

17

(20/02/2012) 20-09-M184EN

20SPECIFIC TRANSMISSION TOOLING

page

STANDARD BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

(20/02/2012)20-09-M184EN

20

2 SPECIFIC TRANSMISSION TOOLING

Standard

Maniscopic

1

9

2

3

4

4

5

6

6

77 7 7

8 8

Ref. Number Description QT.

1 549 671 Standard box 1

2 549 882 1/9 bar Pressure gauge 1





7 549 887 Hose 4

8 549 888 Hose for MANISCOPIC 2

9 549 889 Fitting for pressure gauge 7

STANDARD BOX

BRAKE

- BOOM COMPONENTS LOCATION

- BOOM CONTROL AND ADJUSTMENT

- SPECIFIC BOOM TOOLING

40

(16/03/2012) 40-03-M184EN

40

BRAKE COMPONENTS LOCATION

page

POSITION OF THE BRAKES COMPONENTS MHT 10120 . . . . . . . . . . . . . . . . . . . . . . . .2

POSITION OF THE BRAKES COMPONENTS MHT 7140 - 990 - 10160 - 10180 . . . . .3

POSITION OF THE BRAKES COMPONENTS MHT 10210 - 10225 . . . . . . . . . . . . . . . . .4

(16/03/2012)40-03-M184EN

40

2 BRAKE COMPONENTS LOCATION

POSITION OF THE BRAKES COMPONENTS MHT 10120

Positioning:

Legend:

1 - Brake pump

2 - Brake pedal

3 - Priority valve

4 - Accumulators

5 - Front axle

6 - Rear axle

2

1

5

3

4

4

6

(16/03/2012) 40-03-M184EN

40

3BRAKE COMPONENTS LOCATION

POSITION OF THE BRAKES COMPONENTS MHT 7140 - 990 - 10160 - 10180

Positioning:

Legend:

1 - Brake pump

2 - Brake pedal

3 - Brakes oil tank

4 - Accumulators

5 - Front axle

6 - Rear axle

2

1

3

5

64

4

(16/03/2012)40-03-M184EN

40

4 BRAKE COMPONENTS LOCATION

POSITION OF THE BRAKES COMPONENTS MHT 10210 - 10225

Positioning:

Legend:

1 - Brake pump

2 - Brake pedal

3 - Brakes oil tank

4 - Priority valve

5 - Accumulators

6 - Front axle

7 - Rear axle

2

1

3

6

7

4

5

5

(06/03/2012) 40-04-M184EN

40

BRAKE CONTROL AND ADJUSTMENT

page

BLEEDING AND ADJUSTING THE BRAKES MHT 10120 . . . . . . . . . . . . . . . . . . . . . . . . .2

– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– DEACTIVATE THE NEGATIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– CHECKING THE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BLEEDING AND ADJUSTING THE BRAKES MHT 7140 - 990 - 10160 - 10180 -

10210 - 10225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

– BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

– DEACTIVATE THE NEGATIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

– REACTIVATION OF NEGATIVE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(06/03/2012)40-04-M184EN

40

2 BRAKE CONTROL AND ADJUSTMENT

BLEEDING AND ADJUSTING THE BRAKES MHT 10120

BLEEDING PROCEDURE

With the engine switched on, press the brake pedal (Ref. 1)

repeatedly, slacken the bleed screw (Ref. 2) present on the

front axle, just enough to let a small amount of oil fl ow out;

continue until the oil fl owing out through the bleed connector

is completely devoid of air bubbles and then tighten the screw.

Repeat this operation on all the brakes, RH and LH, on the front

axle (Ref. 3) as well as on the rear axle (Ref. 4).

DEACTIVATE THE NEGATIVE BRAKE

To deactivate the negative brake, act on the two screws

(Ref. 1) positioned on the two sides of the front axle box.

Slacken the lock nuts and tighten the screws until they come

to rest on the piston.

Now rotate through one or two turns until the brake is found

to be locked.

1

2

2

3

4

1

(06/03/2012) 40-04-M184EN

40

3BRAKE CONTROL AND ADJUSTMENT

CHECKING THE PRESSURES

Connect the T-unions as adapters for pressure gauges (Ref. 1,

2 and 3) on the pipes of the brakes pump.

The pressure values are measured with the engine running.

The pressure gauge (Ref. 1) is used for checking the operating

pressure: the value must be 120 bar.

The pressure gauges (Ref. 2 and 3) are used for checking the

pressure of the accumulators: the value must be 120 bar.

Connect the T-unions as adapters for the pressure gauges (Ref.

4 and 5) on the tubes of the front and rear axles.

The pressure values on the axles are measured with the engine

running and at maximum speed, pressing the pedal brake all

the way down.

The pressure gauge (Ref. 4) is used for checking the pressure

at the front axle inlet: the value must be 80 bar.

The pressure gauge (Ref. 5) is used for checking the pressure

at the rear axle inlet: the value must be 80 bar.

If the values are not correct, check the condition of the priority

valve (Ref. 6) and replace it if necessary.

1

2

3

4

5

6

(06/03/2012)40-04-M184EN

40


Brakes hydraulic system:

MHT 10120

0,7 Lt35 bar

35 bar0,7 Lt

V.F.

R2

R1

T2

T1

R N

FDAV

FDAV

FDAR

FDAR

MHT 7140 - 990 - 10160 - 10180

FDAV

FDAV

FDAR

FDAR

S.

MC

PF

(06/03/2012) 40-04-M184EN

40


MHT 10210 - 10225

FDAV

FDAV

FDAR

FDAR

S.

MC

PF

Pa 20 bar1.4 Lt A

Legend:

A: Pressure accumulator FDAR : Rear axle disk brake

FDAV : Front axle disk brake P.F. : Brake pedal

M.C. : Brakes pump R1 - R2 : Pressure accumulators

S. : Brakes oil tank V.F. : Brakes valve

Vehicle Pressure Boost pressure

MHT 10120 80 bar -

MHT 7140 - 990 - 10160 - 10180 80 bar 33 bar

MHT 10210 - 10225 120 bar 60 bar

(06/03/2012)40-04-M184EN

40


BLEEDING PROCEDURE

Unscrew the knob (Ref. 6) and remove the guard (Ref. 7) for

access to the tanks of the brakes oil and window-washer liquids.

Unscrew the cap (Ref. 8) from the tank (Ref. 3).

Use a bleeding kit (Ref. 9).

Fit the adapter (Ref. 10) of the bleeding kit (Ref. 9) on the tank

(Ref. 3).

Activate the bleeding device.

6

7

3

8

9

3

10

BLEEDING AND ADJUSTING THE BRAKES MHT 7140 - 990 - 10160 - 10180 - 10210 -

10225

(06/03/2012) 40-04-M184EN

40


Slacken the bleed screw (Ref. 11), situated on the brakes, just

enough to bleed a small amount of oil, then continue until the

oil fl owing out of the bleed connector is completely devoid of

air bubbles and then retighten the screw.

Repeat this operation on all the brakes, RH and LH, on the front

axle (Ref. 4) as well as on the rear axle (Ref. 5).

Fill the tank (Ref. 3) with oil (Ref. 12) to reach the MAX level

notch indicated on the tank (Ref. 3).

(Ref. 12): Manitou LHM type mineral oil, Manitou code: 490408

For more information regarding the type and quantity of oil:

“INSTRUCTION MANUAL” Chapter on “MAINTENANCE -

LUBRICANTS AND FUEL”.

11

3

12

(06/03/2012)40-04-M184EN

40


DEACTIVATE THE NEGATIVE BRAKE

– Unscrew the caps (Ref. 4 and 5).

– Remove the spring (Ref. 7).

– Use a 19mm wrench with outer diameter not more than 26mm to unscrew the lock nut (Ref. 9) and

unscrew nut (Ref. 1) to the required position (Ref. 8).

The brake is disengaged.

Note: In the absence of hydraulic servo-assistance of the direction and at the brakes, act slowly and

forcibly on these two commands.

Avoid sudden movements and jerks.

REACTIVATION OF NEGATIVE BRAKE

Adjusting the brake cylinder

– Unscrew the caps (Ref. 4 and 5).

– Remove the spring (Ref. 7).

– Use a 19mm wrench with outer diameter not more than 26mm to unscrew the lock nut (Ref. 9) and

unscrew nut (Ref. 1) to bring the piston to a maximum depth of 29-29.5 mm (quota "A").

The nut (Ref. 1) has a 1.75 mm pitch, it is therefore possible to calculate to what extent the nut is to be

tightened; if the quota "A" is 26 mm, it will have to be tightened through two turns (3.5 mm).

Check the measurement again as described and if it is found to be incorrect, repeat the operations

described so far.

– Tighten the lock nut (Ref. 9) up to the nut (Ref. 1).

– Refi t the spring (Ref. 7) and screw the caps (Ref. 4 and 5) back on again.

Note: Exceeding the measurement of 29.5 mm for quota "A" will not allow complete release of the brake,

therefore it gets overheated, leading to rapid deterioration.

b Incorrect adjustment can cause severe harm to the brakes and cause their rapid destruction. If

the nut (REf. 1) is slackened excessively the vehicle will not brake! Danger to life!

Pay attention to quota "B": if this is found to be less than 21.5 mm, the brake disks must be replaced.

9

8

A

7

4

5

1B

BRAKE CYLINDER

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40


CHECKING AND ADJUSTING INCHING COMMAND PRESSURE

Fit a T-union adapter for pressure gauge (Ref. 1) to the connection

point "PS" on the hydrostatic pump (Ref.2).

Bring the oil to operating temperature (50° - 55°).

With the engine running at maximum speed and the brake pedal

in hold position, the pressure must be between 26 and 30 bar.

With the engine running at maximum speed, pressing the brake

pedal to reach the limit stop of the tie-rod

(Ref. 3) and engaging the gear, the vehicle must not move and

the pressure measured must be between 5 and 6 bar.

If this is not the case, adjust the nut (Ref. 4) of the tie-rod until

these values are reached.

1

4

3

PS

2

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40

SPECIFIC BRAKE TOOLING

page

HYDRAULIC BRAKE VENTING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

(20/02/2012)40-09-M184EN

40

2 SPECIFIC BRAKE TOOLING

HYDRAULIC BRAKE VENTING VALVE

MANITOU reference

Hydraulic brake venting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019

Spare parts:

Maximum pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980

Minimum pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981

Diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913

Brake tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914

Venting valve complete with components necessary

for venting the brakes hydraulic systems for all Manitou

products.

BOOM

- BOOM CHARACTERISTICS AND

SPECIFICATIONS

- BOOM COMPONENTS LOCATION

- BOOM CONTROL AND ADJUSTMENT

- BOOM REMOVAL

- BOOM REFIT

50

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50

BOOM CHARACTERISTICS AND SPECIFICATIONS

page

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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50

2BOOM CHARACTERISTICS AND SPECIFICATIONS

BOOM

Consists of two elements:

- 1 FIXED

- 1 MOVABLE (T1)

Boom weight:

Vehicle Boom weight:

MHT 990 3750 kg.

MHT 7140 3850 kg.

MHT 10120 3550 kg.

MHT 10160 4290 kg.

MHT 10180 4350 kg.

MHT 10210 4660 kg.

MHT 10225 4720 kg.

T1

Fixed elementFixing point

boom retracted

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50

BOOM COMPONENTS LOCATION

page

INDEX OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

POSITIONING OF THE MAIN COMPONENTS OF THE BOOM . . . . . . . . . . . . . . . . . . . .3

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50

2 BOOM COMPONENTS LOCATION

INDEX OF COMPONENTS

Ref. Description Observations

CSD BLOCK AND DOUBLE BALANCING VALVE � 70 - HYDRAULICSCSP CONTROLLED SAFETY VALVE

T1 TELESCOPIC 1

VI SLEWING CYLINDER � 70 - HYDRAULICSVT BOOM EXTENSION CYLINDER

X139 BOOM DOWN MICROSWITCH NC � 80 - ELECTRICITYX140 BOOM RETRACTED MICROSWITCH NC

50

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3BOOM COMPONENTS LOCATION

T1

Fixed element

ONLY FOR

MHT 10120

POSITIONING OF THE MAIN COMPONENTS OF THE BOOM

VI

CSP

VT

VI

CSP

VI

CSP

CSD

X139

X140

5

0

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4 BOOM COMPONENTS LOCATION

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BOOM CONTROL AND ADJUSTMENT

page

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

ADJUSTING THE SLIDING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

– REPLACING THE FRONT SLIDING BLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

– REPLACING THE REAR SLIDING BLOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

– ADJUSTING THE SLIDING BLOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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2 BOOM CONTROL AND ADJUSTMENT


Position the vehicle on a horizontal surface to ensure utmost stability and safety; do not switch off the

I.C. engine.

If the boom is dismantled, use a hydraulic control unit, connecting two pipes to the extension cylinder.

Specifi c tools:


ADJUSTING THE BOOM

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3BOOM CONTROL AND ADJUSTMENT

ADJUSTING THE SLIDING BLOCKS

REPLACING THE FRONT SLIDING BLOCKS

Extend the boom by about 80 - 100 cm.

Slacken the screws (Ref. 1) to free the upper sliding blocks (Ref. 2).

Loosen and remove the upper sliding blocks (Ref. 2) from the

boom.

Lift the boom using an overhead crane.

Slacken the screws (Ref. 4) to free the lower sliding blocks (Ref. 3).

111

1

2

2

2

3 3

4

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Loosen and remove the lower sliding blocks (Ref. 3) from the

boom.

Slacken the screws (Ref. 6) to free the sliding blocks (Ref. 5) on

both sides of the boom.

Check the condition of all the sliding blocks, and replace, if

necessary, with new ones.

REPLACING THE REAR SLIDING BLOCKS

Slacken the screws (Ref. 1) and remove the rear guard (Ref. 2),

taking care to disconnect the cable for the license plate lighting.

Slacken the screws (Ref. 4) to free the upper sliding blocks (Ref. 3).

3

5

6

4

44

4

33

12

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5BOOM CONTROL AND ADJUSTMENT

Loosen and remove the upper sliding blocks (Ref. 3) from the

boom.

Slacken the screws (Ref. 6) to free the lower sliding block (Ref. 5).

Fix a weight to the boom or lever on it to create the necessary

play to loosen and remove the lower sliding block (Ref. 5) easily

from the boom.

Slacken the screws (Ref. 8) to remove the sliding blocks (Ref. 7)

on both sides of the boom.

Check the condition of all the sliding blocks, and replace, if

necessary, with new ones.

6

5

8

8

7

5

3

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50

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7BOOM CONTROL AND ADJUSTMENTADJUSTING THE SLIDING BLOCKS

1 - Lubricate the surfaces of the boom on which the sliding blocks slide.

2 - Grease the sliding surfaces of each sliding block before inserting them.

3 - Insert the sliding blocks on the top, bottom and sides.

4 - Insert shims between the sliding blocks and boom to obtain a maximum play of 1 - 1.5 mm.

bApply threadlock Loctite on all the screws before tightening them.

Retract and extend the boom a number of times to spread the grease on the sliding surfaces.

5

0

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50

BOOM REMOVAL

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DISASSEMBLING THE BOOM FROM THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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2 BOOM REMOVAL

GENERAL INFORMATION



Position the vehicle on a horizontal surface (do not switch off the I.C. engine).

Specifi c tools:

– Crane for lifting (5000 kg. minimum).

– Pallet jack.

DISASSEMBLING THE BOOM

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3BOOM REMOVAL

DISASSEMBLING THE BOOM FROM THE VEHICLE

Mark the hydraulic pipes for correct reassembly.

bSwitch the vehicle off and discharge the pressure from

the hydraulic circuit before disconnecting the hydraulic

pipes.

Plug all the pipes and connectors to prevent impurities from

contaminating the hydraulic circuit.

Secure the compensation cylinder (Ref. 1) with a rope (Ref. 2)

to the overhead crane.

Slacken the screw (Ref. 3) and the nut (Ref. 4) which block the

upper pin (Ref. 5) of the compensation cylinder (Ref. 1).

Remove the pin (Ref. 5).

Using an overhead crane, lower the compensation cylinder (Ref.

1) until it comes to rest upon the vehicle chassis.

1

2

4

3

5

1

1

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4 BOOM REMOVAL

Set the boom in safety by placing it under a column (Ref. 6) that

can stand the weight.

Slacken the screw (Ref. 7) and the nut (Ref. 8) which block the

upper pin (Ref. 9) of the lift cylinder (Ref. 10).


Using an overhead crane, lower the lift cylinder (Ref. 10) until

it comes to rest upon the vehicle chassis.

Place the boom (Ref. 1) on a supporting column

(Ref. 12) that can hold the weight.

6

87

9

10

10

11

12

9

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5BOOM REMOVAL

Remove all the clamps that secure the electric cables on the

boom.

Slacken the screws (Ref. 13) and remove the cable reel (Ref. 14)

from the vehicle.

Slacken the screws (Ref. 15) and remove the guard (Ref. 16)

from the cable reel.

Remove the cables retainer collar (Ref. 17).

14

13

15

16

17

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6 BOOM REMOVAL

Unscrew the clamp (Ref. 18).

Remove the cables (Ref. 19) from the cable reel, and reposition

them on the vehicle.


from the vehicle.

Remove the connector (Ref. 22) and reposition the cable reel

on the vehicle.

18

19

20

21

22

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7BOOM REMOVAL

Disassemble all the connectors positioned above the boom.

Slacken the screw (Ref. 23) and the nut (Ref. 24) which block

the upper pin (Ref. 25) that blocks the boom on the chassis.


Remove the boom (Ref. 11) from the vehicle with the help of

the overhead crane and place it on the stands provided for the

purpose.

bTake care while lifting. The boom must be guided by an

operator to prevent it from losing balance and rolling

on itself.

23

24

25

11

25

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8 BOOM REMOVAL

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BOOM REFIT

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

REASSEMBLING THE BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

(28/02/2012)50-07-M184EN

50

2 BOOM REFIT

GENERAL INFORMATION



Position the vehicle on a horizontal surface (do not switch off the I.C. engine).

Specifi c tools:

– Crane for lifting (5000 kg. minimum).

– Pallet jack.

REASSEMBLING THE BOOM

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50

3BOOM REFIT

REASSEMBLING THE BOOM

Reposition the boom (Ref. 1) on the vehicle with the help of an

overhead crane.

bTake care while lifting. The boom must be guided by an

operator to prevent it from losing balance and rolling

on itself.

Insert the pin (Ref. 2) blocking the boom to the chassis.

Fit the screw (Ref. 3) and the nut (Ref. 4) to block the upper pin

(Ref. 2).

Lift the boom (Ref. 5) with the help of an overhead crane and

place it on a supporting column (Ref. 6) that can hold its weight.

3

4

2

1

6

5

2

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4 BOOM REFIT

Reconnect the hydraulic pipes above the boom, taking care to

position them correctly, by following the markings made in the

disassembly phase.


from the vehicle.

Refi t the connector (Ref. 9) and reposition the cable reel (Ref.

8) on the vehicle by tightening the screws (Ref. 7)..


from the vehicle.

7

8

9

10

11

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5BOOM REFIT

Insert the cable (Ref. 12) in the clamp (Ref. 13).

Refi t the cables retainer collar (Ref. 14).

Refi t the guard (Ref. 15) on the cable reel fi xing it by means of

the screws (Ref. 16).

Refit the cable reel (Ref. 11) on the vehicle by means of the

screws (Ref. 10).

Secure the cable by means of the clamp on the boom.

11

10

16

15

14

13

12

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6 BOOM REFIT

Remove the supporting column and place the boom on a

column (Ref. 17) that can hold its weight.

Lift the lift cylinder (Ref. 19) using the overhead crane until the

hole on the cylinder rod is aligned with its seat on the boom.

Insert the upper pin (Ref. 18).

Fit the screw (Ref. 20) and the nut (Ref. 21) to block the upper

pin (Ref. 18) of the lift cylinder (Ref. 19).

Lift the compensation cylinder (Ref. 22) using the overhead

crane until the hole on the cylinder rod is aligned with the seat

on the boom.

1819

2120

19

22

17

18

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7BOOM REFIT

Insert the upper pin (Ref. 23).

Fit the screw (Ref. 24) and the nut (Ref. 25) which block the upper

pin (Ref. 23) of the compensation cylinder (Ref. 22).

25

24

23

23

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8 BOOM REFIT

HYDRAULIC

- HYDRAULIC SCHEMATIC DIAGRAMS

- HYDRAULIC COMPONENTS LOCATION

- HYDRAULIC CONTROL AND ADJUSTMENT

- HYDRAULIC COMPONENTS REMOVAL

- HYDRAULIC COMPONENTS REFIT

- HYDRAULIC SPECIFIC TOOLING

70

mht 10120 hydrostatic transmission ......a6vm 107 motor pressure control points hp socket note: the...

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