Manitou MHT 10225, Repair Manual

Page 1: ...0 Ancenis FRANCE Share capital 39 548 949 euros 857 802 508 RCS Nantes Tel 33 0 2 40 09 10 11 www manitou com REPAIR MANUAL MANUEL DE R PARATION REPARATURANLEITUNG MANUAL DE REPARACI N MANUALE RIPARAZ...

Page 2: ...ellungen Ansichten Kommentare Hinweise und der Aufbau der Druckschrift selbst die in der vorliegenden Dokumentation enthalten sind sind geistiges Eigentum von MANITOU BF Alle Verst e gegen das Vorsteh...

Page 3: ...INE Groupe 10 Engine 2 1 OPTIONS ACCESSORIES Groupe 110 Options Attachments 3 1 TRANSMISSION Groupe 20 Transmission 4 1 BRAKE Groupe 40 Brake 5 1 TELESCOPIC BOOM Groupe 50 Boom 6 1 HYDRAULIC Groupe 70...

Page 4: ...GENERAL INSTRUCTIONS AND SAFETY NOTICE GENERAL CONTROL AND ADJUSTMENT GENERAL 00...

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Page 6: ...00 00 M184EN GENERAL INSTRUCTIONS AND SAFETY NOTICE pages PREAMBLE 2 MAINTENANCE POSITION 3 RULES FOR MAINTENANCE 4 05 06 2012 00...

Page 7: ...causing grievous bodily harm and even death An efficient dependable and profitable combination will be formed if the operator follows the safety manual correctly and the machine is serviced properly W...

Page 8: ...any intervention 1 Place the machine on a flat surface and chock the wheels 2 Turn off the engine and remove the ignition key 3 Let the machine cool down 4 Take all the pressure out of the circuits co...

Page 9: ...liquids or parts when operations have to be done before the machine has had time to cool down Before carrying out any operation on an electrically powered component activate the battery cut off Ifthet...

Page 10: ...glasses gloves safety shoes as well as any other protection required for the work to be carried out When carrying out maintenance operations near a mobile object make sure it is securitized When chan...

Page 11: ...ng devices When using a jack make sure it is used on a flat uniform surface is sturdy enough to support the load that its lifting capacity is sufficient and that it is correctly placed and positioned...

Page 12: ...00 04 M184EN GENERAL CONTROL AND ADJUSTMENT pages STANDARD TIGHTENING TORQUES 2 05 06 2012 00...

Page 13: ...8 Grade 10 9 M3 x 0 5 1 1 5 M4 x 0 7 2 4 3 5 M5 x 0 8 4 8 7 1 M6 x 1 8 2 12 1 M8 x 1 25 20 30 M8 x 1 22 32 M10 x 1 5 40 59 M10 x 1 25 43 63 M10 x 1 46 68 M12 x 1 75 69 102 M12 x 1 5 74 108 M12 x 1 25...

Page 14: ...GINE COMPONENTS LOCATION ENGINE CONTROL AND ADJUSTMENT ENGINE REMOVAL ENGINE REFIT ENGINE CHARACTERISTICS AND SPECIFICATIONS ENGINE CONTROL AND ADJUSTMENT 10 647370EN ENGINE OM 904 LA 120 150 175 CV E...

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Page 16: ...05 06 2012 10 03 M184EN 10 ENGINE COMPONENTS LOCATION page MERCEDES ENGINE 2...

Page 17: ...05 06 2012 10 03 M184EN 10 2 ENGINE COMPONENTS LOCATION MERCEDES ENGINE Oil filter Alternator Belt Fuel pump and filter Engine cooling water pump...

Page 18: ...05 06 2012 10 03 M184EN 10 3 ENGINE COMPONENTS LOCATION Turbocompressor Oil filter Alternator Starter motor...

Page 19: ...05 06 2012 10 03 M184EN 10 4 ENGINE COMPONENTS LOCATION...

Page 20: ...02 08 2012 10 04 M184EN 10 ENGINE CONTROL AND ADJUSTMENT page ENGINE TIGHTENING TORQUE 2 ASSEMBLING THE ENGINE 2 FUEL CIRCUIT 2...

Page 21: ...012 10 04 M184EN 10 2 ENGINE CONTROL AND ADJUSTMENT ENGINE TIGHTENING TORQUE ASSEMBLING THE ENGINE FUEL CIRCUIT 25 Nm apply Loctite 243 45 Nm apply Loctite 243 45 Nm apply Loctite 243 210 Nm apply Loc...

Page 22: ...ATOR BELT 3 B REMOVING THE ALTERNATOR 4 C REMOVING THE STARTER MOTOR 6 D REMOVING THE OIL FILTER 7 E REMOVING THE FUEL OIL FILTER AND PUMP 8 F REMOVING THE ENGINE COOLING WATER PUMP 9 G REMOVING THE T...

Page 23: ...THE ENGINE COMPONENTS Legend 1 Alternator 2 Starter motor 3 Alternator belt 4 Fuel filter 5 Oil filter 6 Engine cooling water pump 7 Fuel pump 8 Turbocompressor PREPARATION AND SAFETY INSTRUCTIONS Dea...

Page 24: ...RNATOR BELT Open the hood Ref 1 of the engine compartment Remove the guard Ref 2 after unscrewing the screws Ref 3 and the nuts Ref 4 Insert an unlocking lever on the screw Ref 5 tilt the belt tension...

Page 25: ...ovethehose Ref 2 positioned on the air cooling radiator tube Slacken the screws Ref 3 and remove the bracket Ref 4 which supports the air cooling radiator tube Ref 5 move the tube downwards to make it...

Page 26: ...05 06 2012 10 06 M184EN 10 5 ENGINE REMOVAL Disconnect the electric wires Ref 8 and 9 for connection to the alternator Ref 7 The alternator can now be removed Ref 7 from the engine 8 9 7 7...

Page 27: ...acken the nut Ref 1 and remove the electric wires Ref 2 3 4 for the starter motor connection Ref 5 Slacken the screws Ref 6 and remove the starter motor Ref 5 from the engine base Remove the starter m...

Page 28: ...he bracket Ref 4 Disconnect the oil inlet pipe Ref 5 Fix the pipe using a clamp so that it does not slip in the bottom part of the engine housing and oil does not leak out Slacken the screw Ref 6 to f...

Page 29: ...g and outgoing tubes Ref 1 from the filter taking care to keep these facing upwards to avoid draining the tank Disconnect the connector Ref 2 from the fuel filter Ref 3 Slacken the screws REf 4 and re...

Page 30: ...r hose Ref 2 Place suitable sized containers to hold the quantity of liquid to be collected under the engine compartment Disconnect the lower hose Ref 2 from the pump slowly discharge overpressure fro...

Page 31: ...e the belt tensioner Ref 8 Slacken the screws Ref 9 and 10 and remove the bracket Ref 11 Slacken the clamp Ref 12 and disconnect the drainage tube Ref 13 from the thermostatic valve Disconnectthetempe...

Page 32: ...4EN 10 11 ENGINE REMOVAL Slacken the screws Ref 16 and 17 which block the thermostatic valve Ref 14 Slacken the 7 screws Ref 18 remove the pump Ref 19 and the thermostatic valve Ref 14 16 14 17 14 18...

Page 33: ...the 2 nuts Ref 1 and remove the 2 brackets Ref 2 which secure the air suction duct Ref 3 Slacken the screws Ref 4 and 5 and remove the bracket Ref 6 Slacken the clamp Ref 7 and remove the hose REf 8 b...

Page 34: ...the air radiator Slacken the clamp Ref 11 and remove the suction hose Ref 12 from the turbocompressor Ref 13 Unscrew the fitting Ref 14 and remove the lubrication delivery tube Ref 15 from the turboco...

Page 35: ...the cover plate Ref 19 from the exhaust manifold Slacken the screws Ref 20 which block the turbocompressor Slacken the 2 clamps Ref 21 and remove the suction hose Ref 22 from the engine Slacken the 8...

Page 36: ...05 06 2012 10 06 M184EN 10 15 ENGINE REMOVAL Slacken the nuts Ref 25 and remove the turbocompressor Ref 13 from the exhaust manifold Ref 24 13 25 25 24 25 25 24 13...

Page 37: ...05 06 2012 10 06 M184EN 10 16 ENGINE REMOVAL Step 1 DISASSEMBLING THE RADIATOR MOTOR Step 2 DISASSEMBLING THE RADIATOR Step 3 DISASSEMBLING THE I C ENGINE REMOVING THE ENGINE DISASSEMBLY ORDER...

Page 38: ...d Ref 3 Slacken the screws Ref 4 and remove the hood Ref 3 from the vehicle Slacken the screws Ref 5 and remove the silent blocks Ref 6 also in the lower part of the radiator Disconnect the feed pipe...

Page 39: ...as far as possible from the side opposite the engine Slacken the screws Ref 11 and remove the grille Ref 12 Slacken the nuts Ref 13 used for fitting the fan Ref 14 Remove the fan hub Ref 15 Slacken th...

Page 40: ...radiator motor operation Remove the guard Ref 1 after unscrewing the screws Ref 2 and the nuts Ref 3 Slacken the clamp Ref 4 and remove the hose Ref 5 Also disconnect pipes Ref 6 and 7 from the radiat...

Page 41: ...s Ref 11 to remove the clamp Ref 12 and remove the tube Ref 13 Position the eyebolt Ref 14 on the radiator Connect the overhead crane Ref 15 to the radiator to remove it Remove the radiator Ref 16 fro...

Page 42: ...Ref 1 from the engine control unit Ref 2 Disconnect all the electrical connections Ref 3 from the alternator Ref 4 Disconnect all the electrical connections Ref 5 from the starter motor Ref 6 Disconn...

Page 43: ...ect the tubes Ref 11 for the air conditioner Slacken the clamp Ref 12 and remove the hose Ref 13 from the suction duct Ref 14 Slacken the screws Ref 15 and remove the bracket Ref 16 which supports the...

Page 44: ...ef 20 and remove the hose Ref 21 entering the radiator Slacken the clamp Ref 22 and remove the hose Ref 23 from the turbocompressor Slacken the screws Ref 24 and remove the brackets Ref 25 Remove the...

Page 45: ...es Slacken the clamp Ref 33 and remove the hose Ref 34 from the water pump Secure the engine to the overhead crane and slacken the screws Ref 35 which fix the engine to the chassis Remove the four sil...

Page 46: ...05 06 2012 10 06 M184EN 10 25 ENGINE REMOVAL Remove the engine with the help of the overhead crane and place it on a pallet...

Page 47: ...05 06 2012 10 06 M184EN 10 26 ENGINE REMOVAL...

Page 48: ...RADIATOR MOTOR 9 REINSERTING THE ENGINE COMPONENTS 11 PREPARATION AND SAFETY INSTRUCTIONS 11 A REINSERTING THE TURBOCOMPRESSOR 12 B REINSERTING THE ENGINE COOLING WATER PUMP 16 C REINSERTING THE FUEL...

Page 49: ...25 11 2011 10 07 M184EN 10 2 ENGINE REFIT REINSERTING THE ENGINE REASSEMBLY ORDER Step 1 REINSERTING THE I C ENGINE Step 2 REINSERTING THE RADIATOR Step 3 REINSERTING THE RADIATOR MOTOR...

Page 50: ...crews Ref 2 to block the engine and remove the hydraulic jack positioned under the hydraulic pump Ref 3 during the disassembly Using an overhead crane insert the four silent blocks Ref 4 and fix the e...

Page 51: ...he support Ref 12 on the vehicle by means of the screws Ref 13 Insert the cooling system pipe Ref 14 and tighten the brackets Ref 15 by means of the screws Ref 16 Insert the hose Ref 17 on the turboco...

Page 52: ...amp Ref 22 Restore the radiator pipe Ref 23 to its position Fit the bracket Ref 24 by means of the screws Rif 25 to block the pipe Insert the hose Ref 26 on the suction duct Ref 27 and tighten the cla...

Page 53: ...30 and fit the screws Ref 31 Connect the temperature sensor Ref 33 to the thermostatic valve Ref 32 Connect all the electrical connections Ref 34 on the starter motor Ref 35 Connect all the electrica...

Page 54: ...n the engine control unit Ref 39 REINSERTING THE RADIATOR Insert the radiator Ref 1 on the vehicle with the help of an overhead crane Remove the eyebolt Ref 2 from the radiator Insert the pipe Ref 3 a...

Page 55: ...amp Ref 7 Connect pipe Ref 8 Reconnect the pipes Ref 9 and 10 on the radiator Insert the hose Ref 11 and screw the clamp Ref 12 Carry out the Reassembling the radiator motor operation Fit the guard Re...

Page 56: ...ef 1 on the grille Ref 2 and fix by means of screws Ref 3 Insert the fan hub Ref 4 Tighten the nuts Ref 5 used for fitting the fan Ref 6 Refit the grille Ref 2 by means of the screws Ref 8 on the radi...

Page 57: ...0 of the hydraulic motor Ref 1 Fit the silent blocks Ref 11 also in the lower part of the radiator using the screws Ref 12 Fit the hood Ref 13 on the vehicle by means of the screws Ref 14 Fit the scre...

Page 58: ...THE ENGINE COMPONENTS Legend 1 Turbocompressor 2 Fuel pump 3 Engine cooling water pump 4 Oil filter 5 Fuel filter 6 Alternator belt 7 Starter motor 8 Alternator PREPARATION AND SAFETY INSTRUCTIONS De...

Page 59: ...RBOCOMPRESSOR Refit the turbocompressor Ref 1 on the exhaust manifold Ref 2 by screwing the nuts Ref 3 use a 30 Nm tightening torque Refit the exhaust manifold Ref 2 on the engine base using the 8 scr...

Page 60: ...gine and tighten the 2 clamps Ref 6 Block the turbocompressor to the engine by tightening the screws Ref 7 Refit the cover plate Ref 8 on the exhaust mnifold by means of the 4 screws Ref 9 Refit the l...

Page 61: ...ompressor by screwing in the fitting Ref 13 Refit the suction hose Ref 14 on the turbocompressor Ref 1 and tighten the clamp Ref 15 Refit the suction hose Ref 16 on the air radiator and tighten the 2...

Page 62: ...N 10 15 ENGINE REFIT Refit the bracket Ref 20 on the air unit by means of the screws Ref 21 and 22 Refit the air suction pipe Ref 23 locking it by means of the 2 brackets Ref 24 and the two nuts Ref 2...

Page 63: ...2 on the engine by means of the 7 screws Ref 3 on which Loctite threadlock must be applied use a 25 Nm tightening torque Refit the thermostatic valve Ref 2 on the pump by means of the screws Ref 4 and...

Page 64: ...t the bracket Ref 9 on the air unit by means of the screws Ref 10 and 11 Refit the belt tightener Ref 12 by means of screws Ref 13 on which Loctite threadlock must be applied using a 50 Nm tightening...

Page 65: ...econnect the lower hose Ref 18 on the pump and screw the 2 clamps Ref 19 back on Fill the cooling system tank Ref 20 with the liquid concerned the liquid level must be between the two notches indicati...

Page 66: ...Reposition the fuel pump Ref 1 on the engine by means of the screws Ref 2 Reposition the fuel filter Ref 3 on the engine by means of the screws Ref 4 Reconnect the connector Ref 5 on the filter Ref 3...

Page 67: ...f 2 Restore the alternator Ref 3 to the correct position and tighten the screws Ref 4 Release the oil inlet pipe Ref 5 from the clamp by means of which it is fixed in the disassembly phase and refit i...

Page 68: ...on the starter motor by passing it through the slot Ref 1 under the engine compartment Refit the starter motor Ref 2 by means of the screws Ref 3 on the engine base Reconnect the electric wires Ref 4...

Page 69: ...GINE REFIT F REINSERTING THE ALTERNATOR Reposition the alternator Ref 1 Reconnect the electric wires Ref 2 and 3 for connection to the alternator Ref 1 Block the alternator Ref 1 to the engine by mean...

Page 70: ...M184EN 10 23 ENGINE REFIT Block the air cooling radiator pipe Ref 5 by means of the bracket Ref 6 using the screws o Ref 7 Refit the hose Ref 8 on the air cooling radiator pipe and tighten the clamps...

Page 71: ...Lift the belt tensioner roller Ref 2 by means of a lever positioned on the screw Ref 3 apply the belt then bring the belt tensioner roller backwards Remove the release lever and check to ensure the b...

Page 72: ...OPTIONS ATTACHMENTS OPTIONS ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS OPTIONS ATTACHMENTS COMPONENTS LOCATION OPTIONS ATTACHMENTS CONTROL AND ADJUSTMENT 110...

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Page 74: ...06 03 2012 110 01 M184EN 110 OPTIONS ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS page OPERATING PRINCIPLE 2 DESCRIPTION OF THE WORKING 3 FLUID CIRCUIT 4 DESCRIPTION OF THE COMPONENTS 5...

Page 75: ...R EVAPORATOR OUTSIDE THE VEHICLE high pressure circuit INSIDE THE VEHICLE CAB low pressure circuit Outside air Hot outside air Outside air or recirculation air Cooled and dehumidified air COMP High te...

Page 76: ...tion The fluid passes through the condenser Ref 2 to transmit its heat by means of a fan outside the vehicle When passing through the condenser the fluid is liquified maintaining a high temperature an...

Page 77: ...MENTS CHARACTERISTICS AND SPECIFICATIONS FLUID CIRCUIT 2 3 6 5 4 1 Fluid in gaseous state at high pressure and high temperature Fluid in liquid state at high pressure and high temperature Fluid in liq...

Page 78: ...ure switch Ref 6 Connected to the receiver filter it is the safety element of the plant and is sensitive to pressure variations It ensures safety of the system against very low pressure values or very...

Page 79: ...06 03 2012 110 01 M184EN 110 6 OPTIONS ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS...

Page 80: ...10180 UP TO VEHICLE 25061 760717 MHT 10210 UP TO VEHICLE 25668 761105 6 POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 7140 990 MHT 10180 UP TO VEHICLE 25061 760717 MHT 10210 UP TO VEHICLE 256...

Page 81: ...07 03 2012 110 03 M184EN 110 2 OPTIONS ATTACHMENTS COMPONENTS LOCATION...

Page 82: ...110 03 M184EN 3 OPTIONS ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING COMPONENTS Condenser kit Receiver filter Binary pressure switch Expansion valve Evaporator Compressor High pressur...

Page 83: ...valve 1 connector E11 E12 X104 2 Solenoid valve 2 connector E12 X104 3 Air conditioning pressure switch E8 X105 Recirculation connector K15 X106 Compressor connector Q30 X107 Unit power supply connect...

Page 84: ...AL CONNECTORS MHT 10120 10160 S Q O M K I G E C A 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 A C E G K M O Q S I 42 Au tos yst em...

Page 85: ...onnector E11 E12 X104 2 Solenoid valve 2 connector E12 X104 3 Air conditioning pressure switch E8 X105 Recirculation connector K15 X106 Compressor connector Q30 X107 Unit power supply connector M16 X1...

Page 86: ...UP TO VEHICLE 25061 760717 MHT 10210 UP TO VEHICLE 25668 761105 S Q O M K I G E C A 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 A...

Page 87: ...4 3 Air conditioning pressure switch E8 X105 Recirculation connector K15 X106 Compressor connector Q30 X107 Unit power supply connector M16 X108 External temperature sensor connector K9 X109 Fan conne...

Page 88: ...29 30 31 32 33 34 35 36 37 38 39 40 41 A C E G K M O Q S I 42 Au tos yst em X464 X104 3 X464 X104 1 X464 X104 2 X464 X106 X105 X102 X176 X204 3 X108 X110 X109 X107 X112 X111 X100 X103 RL1 FUS 1 FUS 2...

Page 89: ...110 07 03 2012 110 03 M184EN 10 OPTIONS ATTACHMENTS COMPONENTS LOCATION...

Page 90: ...age INSTRUCTIONS FOR ASSEMBLING THE AIR CONDITIONER 2 FEATURES OF COOLANT R134A 4 PRECAUTIONS FOR HANDLING R134A 4 FILLING COOLANT IN THE AIR CONDITIONING SYSTEM 5 FILLING METHOD 5 CHECKING THE WORKIN...

Page 91: ...bly Description Type Tightening torque Condenser outlet filter inlet pipe M6 16 N m Filter outlet expansion valve inlet pipe M6 16 N m Compressor outlet cab inlet pipe M8 25 N m Cab outlet condenser i...

Page 92: ...07 03 2012 110 04 M184EN 110 3 OPTIONS ATTACHMENTS CONTROL AND ADJUSTMENT Connection to mixer valve Legend 4 Feed pipe 5 Mixer valve 6 Return pipe 6 5 5 4...

Page 93: ...kaline metals and alkaline earth metal salts in powder form Al Zn Be Flash point Non flammable very stable Ignition temperature Above 75 C Explosiveness limit less than or more than none Ozone depleti...

Page 94: ...utes 3 Filling operation maximum 10 minutes Filling liquid after an operation duration 90 minutes 1 Preparation approx 15 minutes Connect the station to the circuit Run the engine at 800 to 1200rpm At...

Page 95: ...NER CONTROLS bThe air conditioner works only when the telescopic lift is started up With the air conditioner running always work with the doors and windows closed In winter To ensure the correct worki...

Page 96: ...4 Automatic function reset ERROR CODES In case of a fault that affects the automatic regulation the control unit displays an error code consisting of the letter E followed by a number which identifies...

Page 97: ...he following error codes appear on the display E3 Internal air temperature sensor IT open E4 Internal air temperature sensor IT short circuit 4 Operating the compressor On pressing the ECON button the...

Page 98: ...icle engine Switch on the air conditioner as follows Select air diffusion speed I by means of the fan knob Press the air conditioning switch so that the LED lights up Adjust the temperature regulation...

Page 99: ...EN 110 10 OPTIONS ATTACHMENTS CONTROL AND ADJUSTMENT Examples LP 0 8 bar and HP 12 5 bar LP 1 4 bar and HP 15 bar Note These values are indicative and can change according to the ambient temperature a...

Page 100: ...USTMENT TRANSMISSION REMOVAL TRANSMISSION REFIT SPECIFIC TRANSMISSION TOOLING TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS TRANSMISSION CONTROL AND ADJUSTMENT 20 647030DE EN PUMP SERIES A4VG 647031...

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Page 102: ...06 06 2012 20 02 M184EN 20 TRANSMISSION SCHEMATIC DIAGRAMS page REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT 3 REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT 4...

Page 103: ...06 06 2012 20 02 M184EN 20 2 TRANSMISSION SCHEMATIC DIAGRAMS...

Page 104: ...ir Drainage pressure Loading pressure Suction pressure Return to discharge Hydraulic manifold CR Forward movement solenoid valve EV S21 Reversing solenoid valve EV S22 Fast speed solenoid valve Slow s...

Page 105: ...ressure Low pressure Control air Drainage pressure Loading pressure Suction pressure Return to discharge Hydraulic manifold CR Forward movement solenoid valve EV S21 Reversing solenoid valve EV S22 Fa...