Manitou MHT 10225 Repair Manual
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Manitou MHT 10225 Repair Manual

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REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
This document has been printed from
MANITOU BF
Head o ce: 430, Rue de l'Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com

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  • Page 1 MANUEL DE RÉPARATION REPARATURANLEITUNG MANUAL DE REPARACIÓN MANUALE RIPARAZIONE This document has been printed from MANITOU BF Head o ce: 430, Rue de l’Aubinière 44150 Ancenis - FRANCE Share capital: 39,548,949 euros 857 802 508 RCS Nantes Tel: +33 (0)2 40 09 10 11...
  • Page 2 MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization.
  • Page 3 GENERAL INSTRUCTIONS AND SAFETY NOTICE Group 00 (General characteristics and safety) ENGINE Groupe 10 (Engine) OPTIONS - ACCESSORIES Groupe 110 (Options - Attachments) TRANSMISSION Groupe 20 (Transmission) BRAKE Groupe 40 (Brake) TELESCOPIC BOOM Groupe 50 (Boom) HYDRAULIC Groupe 70 (Hydraulic) ELECTRICITY Groupe 80 (Electricity) DRIVER CAB...
  • Page 4 GENERAL - GENERAL INSTRUCTIONS AND SAFETY NOTICE - GENERAL CONTROL AND ADJUSTMENT...
  • Page 6 GENERAL INSTRUCTIONS AND SAFETY NOTICE pages PREAMBLE ............... .2 MAINTENANCE POSITION .
  • Page 7 At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or to the lift truck itself when you repair, service or drive it. Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other than those specifi ed.
  • Page 8 GENERAL INSTRUCTIONS AND SAFETY NOTICE MAINTENANCE POSITION Before any intervention: 1 - Place the machine on a fl at 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 concerned.
  • Page 9 GENERAL INSTRUCTIONS AND SAFETY NOTICE RULES FOR MAINTENANCE Do not carry out any work on the machine unless you have followed a suitable training course and have the knowledge required for it. Make sure you have taken into consideration all the indicator plates on the machine and in the instruction manual.
  • Page 10 GENERAL INSTRUCTIONS AND SAFETY NOTICE Never step on a part of the machine that has not been designed for it. Never wear clothes, jewelry or objects that could get caught during work and cause accidents. Always wear protection glasses, gloves, safety shoes as well as any other protection required for the work to be carried out.
  • Page 11 GENERAL INSTRUCTIONS AND SAFETY NOTICE When lifting or shoring a component of the machine, make sure the equipment used is suitable for at least the load for which it is subjected by the component and that it meets the national standards for lifting devices.
  • Page 12 GENERAL CONTROL AND ADJUSTMENT pages STANDARD TIGHTENING TORQUES ..........2 (05/06/2012) 00-04-M184EN...
  • Page 13 GENERAL CONTROL AND ADJUSTMENT STANDARD TIGHTENING TORQUES Standard tightening torque to be used when not otherwise indicated in the removal and refi tting operations: - The following tightening torques are given for hexagon head screws without flanges and cylinder head hexagon socket screws. - The torques are given for a friction coeffi cient μ...
  • Page 14 ENGINE - ENGINE COMPONENTS LOCATION - ENGINE CONTROL AND ADJUSTMENT - ENGINE REMOVAL - ENGINE REFIT - ENGINE CHARACTERISTICS AND 647370EN SPECIFICATIONS (ENGINE OM 904 LA - ENGINE CONTROL AND ADJUSTMENT 120-150-175-CV EURO 3 )
  • Page 16 ENGINE COMPONENTS LOCATION page MERCEDES ENGINE............2 (05/06/2012) 10-03-M184EN...
  • Page 17 ENGINE COMPONENTS LOCATION MERCEDES ENGINE Engine cooling water pump Oil fi lter Alternator Fuel pump and fi lter Belt 10-03-M184EN (05/06/2012)
  • Page 18 ENGINE COMPONENTS LOCATION Oil fi lter Turbocompressor Alternator Starter motor (05/06/2012) 10-03-M184EN...
  • Page 19 ENGINE COMPONENTS LOCATION 10-03-M184EN (05/06/2012)
  • Page 20 ENGINE CONTROL AND ADJUSTMENT page ENGINE TIGHTENING TORQUE ........... . .2 –...
  • Page 21 ENGINE CONTROL AND ADJUSTMENT ENGINE TIGHTENING TORQUE ASSEMBLING THE ENGINE 45 Nm + apply “Loctite 243” 45 Nm + apply “Loctite 243” 25 Nm + apply “Loctite 243” 210 Nm + apply “Loctite 243” FUEL CIRCUIT 10-04-M184EN (02/08/2012)

  • Page 22: Table Of Contents

    ENGINE REMOVAL page REMOVING THE ENGINE COMPONENTS ........2 PREPARATION AND SAFETY INSTRUCTIONS.

  • Page 23: Removing The Engine Components

    ENGINE REMOVAL REMOVING THE ENGINE COMPONENTS Legend: 1 - Alternator 2 - Starter motor 3 - Alternator belt 4 - Fuel fi lter 5 - Oil fi lter 6 - Engine cooling water pump 7 - Fuel pump 8 - Turbocompressor PREPARATION AND SAFETY INSTRUCTIONS Deactivate the ignition key and disconnect the negative pole from the battery.

  • Page 24: A - Removing The Alternator Belt

    ENGINE REMOVAL A - REMOVING THE ALTERNATOR 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 tensioner roller upwards (Ref.

  • Page 25: B - Removing The Alternator

    ENGINE REMOVAL B - REMOVING THE ALTERNATOR Carry out operation A. Slacken the clamps (Ref. 1) and remove the hose (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.
  • Page 26 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. (05/06/2012) 10-06-M184EN...

  • Page 27: C - Removing The Starter Motor

    ENGINE REMOVAL C - REMOVING THE STARTER MOTOR Slacken 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 motor (Ref.

  • Page 28: D - Removing The Oil Filter

    ENGINE REMOVAL D - REMOVING THE OIL FILTER Carry out operation B. Slacken the screw (Ref. 1) and remove the belt tensioner (Ref. 2). Slacken the screws (Ref. 3) and remove the 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.

  • Page 29: E - Removing The Fuel Oil Filter And Pump

    ENGINE REMOVAL E - REMOVING THE FUEL OIL FILTER AND PUMP Carry out operation A. Disconnect the fuel incoming and outgoing tubes (Ref. 1) from the fi lter, taking care to keep these facing upwards to avoid draining the tank. Disconnect the connector (Ref.

  • Page 30: F - Removing The Engine Cooling Water Pump

    ENGINE REMOVAL F - REMOVING THE ENGINE COOLING WATER PUMP Carry out operation A. Carry out the operations on the cooling system only if the coolant temperature is below 30 . Slacken the 2 clamps (Ref. 1) on the lower hose (Ref. 2). Place suitable sized containers to hold the quantity of liquid to be collected under the engine compartment.
  • Page 31 ENGINE REMOVAL Slacken the screw (Ref. 7) and remove 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. Disconnect the temperature sensor (Ref.
  • Page 32 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). (05/06/2012) 10-06-M184EN...

  • Page 33: G - Removing The Turbocompressor

    ENGINE REMOVAL G - REMOVING THE TURBOCOMPRESSOR Slacken 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.
  • Page 34 ENGINE REMOVAL Slacken the 2 clamps (Ref. 9) and remove the suction hose (REf. 10) on the air radiator. Slacken the clamp (Ref. 11) and remove the suction hose (Ref. 12) from the turbocompressor (Ref. 13). Unscrew the fi tting (Ref. 14) and remove the lubrication delivery tube (Ref.
  • Page 35 ENGINE REMOVAL Slacken the 4 screws (Ref. 18) and remove 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 screws (Ref.
  • Page 36 ENGINE REMOVAL Slacken the nuts (Ref. 25) and remove the turbocompressor (Ref. 13) from the exhaust manifold (Ref. 24). (05/06/2012) 10-06-M184EN...

  • Page 37: Removing The Engine

    ENGINE REMOVAL REMOVING THE ENGINE DISASSEMBLY ORDER DISASSEMBLING THE RADIATOR MOTOR Step 1 Step 2 DISASSEMBLING THE RADIATOR Step 3 DISASSEMBLING THE I.C. ENGINE 10-06-M184EN (05/06/2012)

  • Page 38: Removing The Radiator Motor

    ENGINE REMOVAL REMOVING THE RADIATOR MOTOR Slacken the screw (Ref. 1) to release the gas spring (Ref. 2) from the engine hood (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.
  • Page 39 ENGINE REMOVAL Secure the radiator (Ref. 10) to an overhead crane and incline it 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 fi tting the fan (Ref. 14). Remove the fan hub (Ref.

  • Page 40: Removing The Radiator

    ENGINE REMOVAL REMOVING THE RADIATOR Carry out the "Disassembling the 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.
  • Page 41 ENGINE REMOVAL Slacken the screws (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) from the vehicle, and place it on a pallet.

  • Page 42: Removing The Engine

    ENGINE REMOVAL REMOVING THE ENGINE Disconnect the plug (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). Disconnect the temperature sensor (Ref.
  • Page 43 ENGINE REMOVAL Slacken the screws (Ref. 9) and remove the hydraulic pump (Ref. 10). Disconnect 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.
  • Page 44 ENGINE REMOVAL Slacken the clamp (Ref. 18) and remove the hose (Ref. 19) for the exhaust gases. Slacken the clamp (Ref. 20) and remove the hose (Ref. 21) entering the radiator. Slacken the clamp (Ref. 22) and remove the hose (Ref. 23) from the turbocompressor.
  • Page 45 ENGINE REMOVAL Slacken the screws (Ref. 29) and slacken the clamps (Ref. 30). Disconnect the upper (Ref. 31) and lower (REf. 32) heating pipes. 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.
  • Page 46 ENGINE REMOVAL Remove the engine with the help of the overhead crane and place it on a pallet. (05/06/2012) 10-06-M184EN...
  • Page 47 ENGINE REMOVAL 10-06-M184EN (05/06/2012)
  • Page 48 ENGINE REFIT page REINSERTING THE ENGINE ............2 –...

  • Page 49: Reinserting The Engine

    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 10-07-M184EN (25/11/2011)

  • Page 50: Reinserting The Engine

    ENGINE REFIT REINSERTING THE ENGINE Secure the engine (Ref. 1) to an overhead crane and reposition it on the vehicle. Fit the screws (Ref. 2) to block the engine and remove the hydraulic jack, positioned under the hydraulic pump (Ref. 3) during the disassembly.
  • Page 51 ENGINE REFIT Connect the upper (Ref. 8) and lower (Ref. 9) heating pipes. Tighten the clamps (Ref. 10) by tightening the screws (Ref. 11). Fit the 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.
  • Page 52 ENGINE REFIT Insert the hose (Ref. 21) for the exhaust gases and tighten the clamp (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.
  • Page 53 ENGINE REFIT Insert the hydraulic pump (Ref. 30) and fi t 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 electrical connections (Ref.

  • Page 54: Reinserting The Radiator

    ENGINE REFIT Connect the plug (Ref. 38) on 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.
  • Page 55 ENGINE REFIT Insert the hose (Ref. 6) and screw the clamp (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 (Ref.

  • Page 56: Reinserting The Radiator Motor

    ENGINE REFIT REINSERTING THE RADIATOR MOTOR Inserting the hydraulic motor (Ref. 1) on the grille (Ref. 2) and fi x by means of screws Ref. 3). Insert the fan hub (Ref. 4). Tighten the nuts (Ref. 5) used for fi tting the fan (Ref. 6). Refi t the grille (Ref.
  • Page 57 ENGINE REFIT Reconnect the feed pipe (Ref. 9) and drainage pipe (Ref. 10) 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.

  • Page 58: Reinserting The Engine Components

    ENGINE REFIT REINSERTING THE ENGINE COMPONENTS Legend: 1 - Turbocompressor 2 - Fuel pump 3 - Engine cooling water pump 4 - Oil fi lter 5 - Fuel fi lter 6 - Alternator belt 7 - Starter motor 8 - Alternator PREPARATION AND SAFETY INSTRUCTIONS Deactivate the ignition key and disconnect the negative pole from the battery.

  • Page 59: A - Reinserting The Turbocompressor

    ENGINE REFIT A - REINSERTING THE TURBOCOMPRESSOR Refi t the turbocompressor (Ref. 1) on the exhaust manifold (Ref. 2) by screwing the nuts (Ref. 3); use a 30 Nm tightening torque. Refi t the exhaust manifold (Ref. 2) on the engine base using the 8 screws (Ref.
  • Page 60 ENGINE REFIT Reconnect the suction hose (Ref. 5) to the engine and tighten the 2 clamps (Ref. 6). Block the turbocompressor to the engine by tightening the screws (Ref. 7). Refi t the cover plate (Ref. 8) on the exhaust mnifold by means of the 4 screws (Ref.
  • Page 61 ENGINE REFIT Refi t the lubrication delivery pipe (Ref. 12) on the turbocompressor by screwing in the fi tting (Ref. 13). Refi t the suction hose (Ref. 14) on the turbocompressor (Ref. 1) and tighten the clamp (Ref. 15). Refi t the suction hose (Ref. 16) on the air radiator and tighten the 2 clamps (Ref.
  • Page 62 ENGINE REFIT Refi t the bracket (Ref. 20) on the air unit by means of the screws (Ref. 21 and 22). Refi t the air suction pipe (Ref. 23) locking it by means of the 2 brackets (Ref. 24) and the two nuts (Ref. 25). (25/11/2011) 10-07-M184EN...

  • Page 63: B - Reinserting The Engine Cooling Water Pump

    ENGINE REFIT B - REINSERTING THE ENGINE COOLING WATER PUMP Replace the gaskets with new ones, refi t the pump (Ref. 1) and the thermostatic valve (Rif. 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.
  • Page 64 ENGINE REFIT Refi t the exhaust pipe (Ref. 7) on the thermostatic valve and tighten the clamp (Ref. 8). Refi t the bracket (Ref. 9) on the air unit by means of the screws (Ref. 10 and 11). Refi t the belt tightener (Ref. 12) by means of screws (Ref. 13) on which Loctite threadlock must be applied, using a 50 Nm tightening torque.
  • Page 65 ENGINE REFIT Reconnect the upper hose (Ref. 16) on the pump and screw the 2 clamps (Ref. 17) back on. Reconnect 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 indicating the minimum and maximum levels (approx.

  • Page 66: C - Reinserting The Fuel Oil Filter And Pump

    ENGINE REFIT C - REINSERTING THE FUEL OIL FILTER AND PUMP Reposition the fuel pump (Ref. 1) on the engine by means of the screws (Ref. 2). Reposition the fuel fi lter (Ref. 3) on the engine by means of the screws (Ref.

  • Page 67: D - Reinserting The Oil Filter

    ENGINE REFIT D - REINSERTING THE OIL FILTER Reposition the fi lter (Ref. 1) on the engine supports by means of the screws (Ref. 2). Restore the alternator (Ref. 3) to the correct position and tighten the screws (Ref. 4). Release the oil inlet pipe (Ref.

  • Page 68: E - Reinserting The Starter Motor

    ENGINE REFIT E - REINSERTING THE STARTER MOTOR Reposition the starter motor by passing it through the slot (Ref. 1) under the engine compartment. Refi t the starter motor (Ref. 2) by means of the screws (Ref. 3) on the engine base. Reconnect the electric wires (Ref.

  • Page 69: F - Reinserting The Alternator

    ENGINE 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 means of the screws (Ref. 4). 10-07-M184EN (25/11/2011)
  • Page 70 ENGINE REFIT Block the air cooling radiator pipe (Ref. 5) by means of the bracket (Ref. 6), using the screws o(Ref. 7). Refi t the hose (Ref. 8) on the air cooling radiator pipe and tighten the clamps (Ref. 9). (25/11/2011) 10-07-M184EN...

  • Page 71: G - Reinserting The Alternator Belt

    ENGINE REFIT G - REINSERTING THE ALTERNATOR BELT Refi t the belt (Ref. 1) on all the pulleys with the exception of the belt tightener roller. 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.
  • Page 72 OPTIONS - ATTACHMENTS - OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS - OPTIONS - ATTACHMENTS COMPONENTS LOCATION - OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT...
  • Page 74 OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS page OPERATING PRINCIPLE ............2 DESCRIPTION OF THE WORKING .

  • Page 75: Operating Principle

    OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS AIR CONDITIONER OPERATING PRINCIPLE OUTSIDE THE VEHICLE (high pressure circuit) Outside air The fl uid is liquifi ed CONDENSER Hot outside air High temperature FILTER Purifi es and absorbs the liquid COMPRESSOR COMP REGULATOR Suction and compression Outside air or recirculation air...

  • Page 76: Description Of The Working

    OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS DESCRIPTION OF THE WORKING The air conditioning system reduces the ambient temperature inside the vehicle cab, removing and dispersing the heat from inside towards the outside. This heat exchange is made possible by using a coolant R134a, the properties of which make it possible to obtain very low temperatures at low pressure in expansion and the other way around, very high temperatures at medium pressure, by means of the compression process.

  • Page 77: Fluid Circuit

    OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS FLUID CIRCUIT – Fluid in gaseous state at high pressure and high temperature. – Fluid in liquid state at high pressure and high temperature. – Fluid in liquid state at low pressure and low temperature. 110-01-M184EN (06/03/2012)

  • Page 78: Description Of The Components

    OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS DESCRIPTION OF THE COMPONENTS The compressor The compressor (Ref. 1) is the organ which makes it possible to: • convey the fl uid through the suction circuit, in a gaseous state, from the evaporator at low pressure and low temperature.
  • Page 79 OPTIONS - ATTACHMENTS CHARACTERISTICS AND SPECIFICATIONS 110-01-M184EN (06/03/2012)
  • Page 80 OPTIONS - ATTACHMENTS COMPONENTS LOCATION page POSITION OF AIR CONDITIONING COMPONENTS ........3 POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 10120 - 10160 .
  • Page 81 OPTIONS - ATTACHMENTS COMPONENTS LOCATION 110-03-M184EN (07/03/2012)
  • Page 82 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING COMPONENTS Condenser kit Binary pressure switch Receiver fi lter Expansion valve Evaporator Compressor – High pressure – Low pressure (07/03/2012) 110-03-M184EN...
  • Page 83 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 10120 - 10160 Electrical connectors Position on the Ref. Description Observations diagram X100 Control unit connector X102 Fans activation control unit connector X103 Drier fi lter connector X104.1 Solenoid valve 1 connector E11 / E12 X104.2...
  • Page 84 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 10120 - 10160 X464 X104.1 X464 X104.2 X464 X104.3 X105 X176 X108 X102 X204.3 X107 X100 X109 X110 X111 X112 X103 X464 X106 (07/03/2012) 110-03-M184EN...
  • Page 85 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 7140-990, MHT 10180 UP TO VEHICLE 25061 - 760717, MHT 10210 UP TO VEHICLE 25668 - 761105 Electrical connectors Position on the Ref. Description Observations diagram X100 Control unit connector X102.p Fans activation control unit connector X102.s...
  • Page 86 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 7140-990, MHT 10180 UP TO VEHICLE 25061 - 760717, MHT 10210 UP TO VEHICLE 25668 - 761105 X464 X104.1 X464 X104.2 X464 X104.3 X105 X176 X108 X102 X204.3 X107 X100 X109...
  • Page 87 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 7140-990, MHT 10180 STARTING FROM VEHICLE 25989 - 760997, MHT 10210 STARTING FROM VEHICLE 25989 - 760997 Electrical connectors Position on the Ref. Description Observations diagram X100 Control unit connector X102 Fans activation control unit connector X103...
  • Page 88 OPTIONS - ATTACHMENTS COMPONENTS LOCATION POSITION OF AIR CONDITIONING ELECTRICAL CONNECTORS MHT 7140-990, MHT 10180 STARTING FROM VEHICLE 25989 - 760997, MHT 10210 STARTING FROM VEHICLE 25989 - 760997 X464 X104.1 X464 X104.2 X464 X104.3 X105 X176 X108 X102 X204.3 X107 X100 X109...
  • Page 89 OPTIONS - ATTACHMENTS COMPONENTS LOCATION 110-03-M184EN (07/03/2012)
  • Page 90 OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT page INSTRUCTIONS FOR ASSEMBLING THE AIR CONDITIONER ....2 FEATURES OF COOLANT R134A ..........4 PRECAUTIONS FOR HANDLING R134A .

  • Page 91: Instructions For Assembling The Air Conditioner

    OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT AIR CONDITIONER INSTRUCTIONS FOR ASSEMBLING THE AIR CONDITIONER Carry out the assembling operations in a dry, dust-free area. Use PAG ISO 100 SP 20 COMPRESSOR oil for lubricating all the gaskets and sealing surfaces before assembly. Description Type Tightening torque...
  • Page 92 OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT Connection to mixer valve: Legend: 4 - Feed pipe 5 - Mixer valve 6 - Return pipe (07/03/2012) 110-04-M184EN...

  • Page 93: Features Of Coolant R134A

    OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT FEATURES OF COOLANT R134a Description Hydrofl uorocarbon Coolant Chemical features Tetrafl uoroethane 134a Chemical formula CH2F-CF3 Physical state Liquifi ed gas Colour Colourless Odour Slightly ethereal Boiling point (at atmospheric pressure) - 26.5 °C Melting point - 101 °C Density at 25°C...

  • Page 94: Filling Coolant In The Air Conditioning System

    OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT FILLING COOLANT IN THE AIR CONDITIONING SYSTEM Coolant: R134a Refi lling equipment: Refi lling station Quantity of fl uid: 1200 gr ± 50 gr PAG ISO 100 SP20 Oil: No oil must be added. Just check to make sure there are 135ml of oil in the compressor.

  • Page 95: Checking The Working

    OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT Excess liquids (duration 15 minutes) with the vehicle engine running 1 - Preparation (approx. 10 minutes). – Connect the station to the circuit. – Run the engine at 800 to 1200rpm. – At the same time start up the air conditioner at maximum speed. 2 - Additional fi lling (approx.
  • Page 96 OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT A - Control unit Legend of functions: 1 - Decrease internal temperature 2 - Increase internal temperature 3 - Temperature indicator setting 4 - Indicator 1 fan speed 5 - Indicator 2 fan speed 6 - Indicator 3 fan speed 7 - Fan speed increase command...
  • Page 97 OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT AIRCONDITIONING PLANT – CHECKING THE WORKING Electronic control of the temperature (E.AC.C.) To check to ensure the correct working of the heating and cooling system, make sure the engine is started up with the hoods closed, at ambient temperature between +15°C and 30°C and the engine cooling fl uid suffi ciently hot.

  • Page 98: Adjusting The Air Conditioning Pressures

    OPTIONS - ATTACHMENTS CONTROL AND ADJUSTMENT ADJUSTING THE AIR CONDITIONING PRESSURES Remove the caps (Ref. 1 and 2) on the compressor connections (Ref. 3). Connect the high pressure (Ref. 4) and low pressure (Ref. 5) pipes of the refi lling station on the compressor (Ref. 3). •...
  • Page 99 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 and the type of vehicle. 110-04-M184EN (07/03/2012)
  • Page 100 TRANSMISSION - TRANSMISSION SCHEMATIC DIAGRAMS - TRANSMISSION COMPONENTS LOCATION - TRANSMISSION CONTROL AND ADJUSTMENT - TRANSMISSION REMOVAL - TRANSMISSION REFIT - SPECIFIC TRANSMISSION TOOLING 647030DE/EN (PUMP SERIES A4VG) - TRANSMISSION CHARACTERISTICS AND 647031FR/EN SPECIFICATIONS (ENGINE A6VM SERIE 63) - TRANSMISSION CONTROL AND ADJUSTMENT 647375 (GEAR DANA SERIES 360/59)
  • Page 102 TRANSMISSION SCHEMATIC DIAGRAMS page REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT ..3 REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT . . .4 (06/06/2012) 20-02-M184EN...
  • Page 103 TRANSMISSION SCHEMATIC DIAGRAMS 20-02-M184EN (06/06/2012)
  • Page 104 TRANSMISSION SCHEMATIC DIAGRAMS REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT Legend: High pressure Low pressure Control air Drainage pressure VSLR Loading pressure Suction pressure Return to discharge See «70 - hydraulics» Chapter § 70 Hydraulic manifold EV(S21) Forward movement solenoid valve EV(S22) Reversing solenoid valve EV(S27)
  • Page 105 TRANSMISSION SCHEMATIC DIAGRAMS REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT Legend: High pressure Low pressure Control air Drainage pressure VSLR Loading pressure Suction pressure Return to discharge See «70 - hydraulics» Chapter § 70 Hydraulic manifold EV(S21) Forward movement solenoid valve EV(S22) Reversing solenoid valve EV(S27)

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