PDF Handbook Manitou BP 249 Hydrostatic Transmission - 556 KB
This essential handbook provides critical information for the Manitou BP 249 hydrostatic transmission.
It thoroughly covers operational principles, vital maintenance checks, and effective troubleshooting tips for this key component.
Understanding the contents of this guide is vital for maintaining the performance and reliability of your Manitou equipment.
A must-have for technicians and operators alike.
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BP 249
44158 ANCENIS CEDEX - FRANCE
TEL : 33 (0)2 40 09 10 11
YOUR DEALER
REF : 47910 EN (30 / 07 / 2007)
HYDROSTATIC
TRANSMISSIONS
I.C. ENGINES
GENERALES
INFORMATIONS
HAND BOOK
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CHAPTER 1
" TECHNICAL SPECIFICATIONS
FOR HYDROSTATIC
TRANSMISSION EQUIPMENT "
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : 4 RE 30 HP - 4 RE 40 HP
I.C. ENGINE
- Type : PERKINS 4.236
• Rated rpm .......................................................................................... 2400 rpm
• Idle rpm ............................................................................................ 800 rpm
• Max. rpm (unladen) ............................................................................ 2500 rpm
• Power DIN .......................................................................................... 73 cv
• Starting rpm ...................................................................................... 1100 rpm
HYDROSTATIC PUMP reference : 86330
- Type A4V56DA
3
• Min./max. displacement .................................................................... 0 to 56 cm /tr
• Max. capacity .................................................................................... 137 l./mn
• Governing start rpm............................................................................ 1000 rpm
• Governing end rpm ............................................................................ 2000 rpm
BOOST PUMP
3
• Displacement .................................................................................... 11,4 cm /tr
• Max. capacity .................................................................................... 28,5 l./mn
HYDRAULIC MOTOR
- Type A6V80DA
3
• Min/max. displacement ...................................................................... 32,9 to 80 cm /tr
• Max. leak flow rate ............................................................................ 5 l/mn
AXLE : HURTH
- Type 724140
TRANSMISSION OPERATING PRESSURE
• H.P. relief valve set pressure .............................................................. 420 bar
• Boost pressure at neutral min. speed .................................................. 20 bar ±5
max. speed ................................................ 28 bar
• Boost pressure forward/reverse at rated rpm ...................................... 25 bar
• Pilot pressure at beginning of governed speed .................................... 7 bar
• Governing end pilot pressure .............................................................. 24 bar
• Gouverning end H.P............................................................................. 400 bar
• Governed pressure of hydraulic motor .................................................. 30 to 50 bar
• Max pression in housings.................................................................... 1 bar
• By-pass set pressure on oil cooler ...................................................... 2 bar
Maximum of travel speed .................................................................................... 25 Km/h
Drawbar pull in load condition .............................................................................. 6300 kg
Recommended oil type in the transmission............................................................ SHELL TELLUS T46
Capacity of transmission oil + Equipment .............................................................. 52 l.
Reference of transmission filter : 46028
Reference of the repair manual : 47312
21
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : MTI 235 - MTI 240
I.C. ENGINE
- Type : PERKINS 4.236
• Rated rpm .......................................................................................... 2300 rpm
• Idle rpm ............................................................................................ 800 rpm
• Max. rpm (unladen) ............................................................................ 2400 rpm
• Power DIN .......................................................................................... 80 cv
• Starting rpm ...................................................................................... 1150 rpm
• Engine rpm drop at transmission governing end.................................... 50 rpm
HYDROSTATIC PUMP reference : 2680781 MI
- Type BPV 100 AU.E.S.
3
• Min./max. displacement .................................................................... 0 to 100,3 cm /tr
• Max. outflow at rated rpm .................................................................. 240,7 l./mn
• Governing type .................................................................................. Automotive
BOOST PUMP
3
• Displacement .................................................................................... 52,2 cm /tr
HYDRAULIC MOTOR
- Type BMF 105
3
• Displacement .................................................................................... 104,9 cm /tr
• Max. leak flow rate ............................................................................ 8 l/mn
• Reducer reduction ratio ...................................................................... 17:1
TRANSMISSION OPERATING PRESSURE
• H.P. relief valve set pressure .............................................................. 420 bar
• Boost pressure at neutral min. speed .................................................. 16 bar
• Boost pressure forward/reverse at rated rpm ...................................... 16 bar
• Pilot pressure Governing end rpm ........................................................ 32 bar
• Gouverning end H.P............................................................................. 420 bar
• Max pression in housings.................................................................... 1,5 bar
• Max. pressure in the oil cooler ............................................................ 16 bar
• By-pass set pressure on oil cooler ...................................................... 32 bar
Transmission system oil max. temperature ............................................................ 60 °C
Recommended oil type in the transmission............................................................ SHELL TELLUS S46
Capacity of transmission oil + Equipment .............................................................. 14 l.
31
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : BT 420/425 - BTI 220/225 Serie I
I.C. ENGINE
- Type PERKINS 104.19
• Rated rpm .......................................................................................... 2800 rpm
• Idle rpm ............................................................................................ 800 rpm
• Max. rpm (unladen) ............................................................................ 2970 rpm
• Power DIN .......................................................................................... 41,3 CV
HYDROSTATIC PUMP reference : 162 844
• Type A4VG40DA
3
• Min./max. displacement .................................................................... 0 to 40 cm /tr
• Max. capacity .................................................................................... 110 l./mn
• Governing start rpm............................................................................ 1100 rpm
• Governing end rpm ............................................................................ 2500 rpm
BOOST PUMP 165 536
3
• Displacement .................................................................................... 8,4 cm /tr
• Max. capacity .................................................................................... 20 l./mn to
............................................................................................................ 2970 rpm
HYDRAULIC MOTOR A6VM80DA
• Reference MANITOU : 185 247 Classification A6VM80DA/60W0358PZB026B
3
• Min./max. displacement .................................................................... 37,2 to 80 cm /tr
• Commutation...................................................................................... 170 bar
• Max. leak flow ratei ............................................................................ appr 14 l./mn (including sca-
venger). At this level, the
motor is considered as worn.
• Axle : HURTH
• Type 304-140-85
TRANSMISSION OPERATING PRESSURE
• H.P. relief valve set pressure .............................................................. 440 bar
• Boost pressure at neutral min. speed .................................................. 23 to 25 bar
max. speed ................................................ 29 to 31 bar
• Boost pressure forward/reverse at rated rpm ...................................... 26 to 28 bar
• Pilot pressure at beginning of governed speed .................................... 6 to 7 bar
• Governing end pilot pressure ..............................................................
Rated rpm.................................................................... 21 to 23 bar
• Gouverning end H.P............................................................................. 400 bar
• Max pression in housings.................................................................... 3 bar (cold)
• By-pass set pressure on oil cooler ...................................................... 2 bar
Maximum of travel speed .................................................................................... 20,5 Km/h
Drawbar pull in load condition .............................................................................. 2400 Kg
Recommended oil type in the transmission............................................................ MANITOU HYDRAULIQUE ISO 46
Capacity of transmission oil tank .......................................................................... 45 l.
Reference of transmission filter : 487 890
41
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : MSI 20/25/30 G
I.C. ENGINE
- Type TOYOTA 4Y
• Rated rpm .......................................................................................... 2200 rpm
• Idle rpm ............................................................................................ 900 rpm + 50
–0
• Max. rpm (unladen) ............................................................................ 2400 rpm ± 50
• Max rpm at distributor lever ................................................................ 2000 rpm ± 100
• Power DIN (70-020) ............................................................................ 40 Kw
HYDROSTATIC PUMP reference :
- 206 517 Type A4VG90DA1D7/3.2 RPZF02F021S
3
• Min./max. displacement .................................................................... 0 to 90 cm /tr
• Max. capacity to 2400 T 27 bar HP .................................................... 215 l./mn
• Governing start rpm * HP 50 bar ...................................... 700 rpm ± 50
• Governing end rpm HP 400 bar .................................... 1600 rpm ± 100
BOOST PUMP
• Displacement .................................................................................... 18,7 cm3
• Max. capacity to 2400 rpm ................................................................ 44 l./mn
HYDRAULIC MOTOR A2FE
• MANITOU reference: 201 551 Classification A2FE 28/61W-NAL 306
• Fixed displacement ............................................................................ 28 cm3/tr
TRANSMISSION OPERATING PRESSURE
• D.R. valve set pressure ...................................................................... 470 bar
• H.P. relief valve set pressure .............................................................. 500 bar ± 10
• Boost pressure at neutral min. speed .................................................. 24 bar ±2
max. speed ................................................ 27 bar ±2
• Pilot pressure at beginning of governed speed .................................... 7 bar ±1
• Governing end pilot pressure to 1600 rpm .......................................... 13 bar ±1
at rated rpm in load condition ...................................... 19 bar
• Gouverning end H.P. 1600 rpm ± 100.................................................. 400 bar
• Max pression in housings.................................................................... 1,6 bar to 50° C
• By-pass set pressure on oil cooler ...................................................... 2 bar
Maximum of travel speed .................................................................................... 21 Km/h
Drawbar pull in load condition .............................................................................. 2500 daN
Recommended oil type in the transmission............................................................ MANITOU HYDRAULIQUE ISO 46
Capacity of transmission oil + Equipment .............................................................. 95 l.
Reference of transmission filter : 46 028
* On machine 950 rpm ± 50 - TH7 adjustment on accelerator
51
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : MT 1645 H SLT MONO ULTRA
I.C. ENGINE
- Type PERKINS 1004.40T AK 80920
• Rated rpm .......................................................................................... 2200 rpm
• Idle rpm ............................................................................................ 930 rpm + 20
– 0
• Max. rpm (unladen) ............................................................................ 2400 rpm
• Power ISO / TR 14396 ...................................................................... 76,5 Kw
HYDROSTATIC PUMP reference :
- 226 165 Type A4VG71 DA1 D7/3.2 RNZF02F041SH
3
• Min./max. displacement .................................................................... 0 to 71 cm /tr
• Max. capacity .................................................................................... 170 l./mn
• Governing start rpm (50 bar) .............................................................. 1200 rpm
• Governing end rpm (at 440 bar).......................................................... 1800 rpm
BOOST PUMP
• Displacement .................................................................................... 19,6 cm3
• Max. capacity .................................................................................... 47 l./mn
HYDRAULIC MOTOR Reference :
- 230 947 Type A6VM107DA2/63W-VZB 017B
• Min./max. displacement .................................................................... 32 to 107 cm3/tr
• Commutation (pilot pressure 20 bar) .................................................. 310 ± 10 bar
• Pilot ratio .......................................................................................... 5/100
• Scavenging ........................................................................................ 8 L/mn to 25 Bar
• Temporization .................................................................................... 0,55 mm
• Axle : HURTH
• Type 212/231 (AV)
212/232 (AR)
TRANSMISSION OPERATING PRESSURE
• D.R. valve set pressure ...................................................................... 470 bar
• H.P. relief valve set pressure .............................................................. 508 bar
• Boost pressure at neutral min. speed .................................................. 15 ± 2 bar
max. speed ................................................ 28 ± 2 bar
• Boost pressure forward/reverse at rated rpm ...................................... 28 ± 2 bar
• Pilot pressure at beginning of governed speed .................................... 7±1 bar
• Governing end pilot pressure .............................................................. 18 ± 2 bar
• Gouverning end H.P. 1800 rpm............................................................ 440 bar
• Max pression in housings.................................................................... 3 bar (cold)
• By-pass set pressure on oil cooler ...................................................... 2 bar
Maximum of travel speed .................................................................................... 25 Km/h
Drawbar pull in load condition .............................................................................. 7400 Kg
Recommended oil type in the transmission............................................................ MANITOU HYDRAULIQUE ISO 46
Capacity of transmission oil + Equipment .............................................................. l.
Reference of transmission filter : 600 675
61
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : MVT, AVT, 1135 L / 1230 SL / 1330 SL ATMO
I.C. ENGINE
- Type 1 : PERKINS 1004.4 AA80547
- Type 2 : PERKINS 1004.42 AR80980
• Rated rpm .......................................................................................... 2300 rpm
• Idle rpm ............................................................................................. 850 rpm
• Max. rpm (unladen)............................................................................. 2500 rpm
• Power DIN .......................................................................................... 67 Kw
HYDROSTATIC PUMP
- Type REXROTH A4VG56DA1D7/32R-PZCO2F025S-S
3
• Min./max. displacement ..................................................................... 0 to 56 cm /tr
• Max. capacity .................................................................................... 140 l./mn
• Governing start rpm............................................................................ 1050 rpm
• Governing end rpm ............................................................................. 1800 rpm
BOOST PUMP
3
• Displacement ..................................................................................... 11,1 cm /tr
• Max. capacity ..................................................................................... 25,5 l./mn
HYDRAULIC MOTOR
- Type REXROTH A6VM80DA/60W0370-PZB026B
3
• Min/max. displacement ...................................................................... 37 to 80 cm /tr
• Max. leak flow rate ............................................................................. 260 / 280 l/mn
AXLE : HURTH
- Type : 353/279/467 (AV)
279/145 (AR)
TRANSMISSION OPERATING PRESSURE
• D.R. valve set pressure ...................................................................... 440 bar
• H.P. relief valve set pressure ............................................................... 460 bar
• Boost pressure at neutral min. speed .................................................. 30 bar
max. speed ................................................. 32 bar
•Boost pressure forward/reverse at rated rpm........................................ 32 bar
• Pilot pressure at beginning of governed speed ..................................... 6 bar
• Governing end pilot pressure............................................................... 20 bar
• Gouverning end H.P............................................................................. 400 bar
• Max pression in housings.................................................................... 2 bar
• By-pass set pressure on oil cooler ....................................................... 2,5 bar
Maximum of travel speed ..................................................................................... 25 Km/h
Drawbar pull in load condition............................................................................... 9600 kg
Recommended oil type in the transmission............................................................ SHELL TELLUS T46
Capacity of transmission oil + Equipment .............................................................. 110 l.
Reference of transmission filter : 485695
71
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TECHNICAL SPECIFICATIONS FOR
HYDROSTATIC TRANSMISSION EQUIPMENT
TYPE OF LIFT TRUCK : MANILOADER AL 70 e
I.C. ENGINE
- Type DEUTZ F4L1011F
• Rated rpm .......................................................................................... 2450 rpm
• Idle rpm ............................................................................................ 900 rpm ± 50
• Max. rpm (unladen) ............................................................................ 2475 rpm ± 25
• Power .............................................................................................. 36,5 Kw 50 cv
HYDROSTATIC PUMP :
- Type A4VG56DA
3
• Min./max. displacement .................................................................... 0 to 56 cm /tr
• Governing start rpm............................................................................ 1100 rpm ± 50
HYDRAULIC MOTOR :
- Type A6VM80HA
• Commutation...................................................................................... 170 ± 10 bar
• Axle :
• Type ZF APR 725 (AV)
ZF APR 725 (AR)
TRANSMISSION OPERATING PRESSURE
• D.R. valve set pressure ...................................................................... 390 bar ± 10
• H.P. relief valve set pressure .............................................................. 420 bar ± 10
• Boost pressure .................................................................................. 30 ± 1 bar
• Pilot pressure .................................................................................... 20 ± 1 bar
• Braking pressure at start of inching .................................................... 11 bar
Maximum of travel speed .................................................................................... 20 Km/h
Drawbar pull in load condition .............................................................................. 3600 Kg ± 200
Recommended oil type in the transmission............................................................ MANITOU HYDRAULIQUE ISO 46
81
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CHAPTER 2
"IC ENGINES TECHNICAL SPECIFICATIONS"
--- Page 12 ---
IC ENGINES TECHNICAL SPECIFICATIONS
ENGINE TYPE : 2714 E
Manufacturer : "FORD"
FITTED ON : MC 80 - MC 80 F - MC 90 F - MC 100 F - MP 800
TECHNICAL SPECIFICATIONS
• Power ............................................................................................................ 115 cv
• Number of cylinders .......................................................................................... 6
• Bore - Stroke .................................................................................................... 107 - 115 mm
• Displacement .................................................................................................. 6220 cm3
• Full load engine rpm.......................................................................................... 2500 rpm
• Unladen rating rpm .......................................................................................... 2750 rpm
• Idle rpm .......................................................................................................... 700 rpm
• Compression ratio ............................................................................................ 16,0 / 1
• Injection order .................................................................................................. 1-5-3-6
• Injection pump timing (en ligne SIMMS).............................................................. 20° before TDC
• Injection pressure ............................................................................................ 185 bar
• Engine oil pressure Min. ................................................................................ 1,5 bar
Max................................................................................. 3,5 bar
• Valve clearance (hot) Inlet. ............................................................................ 0,38 mm
Exh. .............................................................................. 0,38 mm
• Valve seat angle .............................................................................................. 30°
• Thermostat ...................................................................................................... 79 to 85 °C
TIGHTENING TORQUE (m/Kg)
• Cylinder head bolts .......................................................................................... 14,5 to 15,2
• Rocker arm assy bolts ...................................................................................... 2,3 to 3,0
• Fitting on nozzle holder...................................................................................... 8,3 to 10,4
• Nozzle holder.................................................................................................... 2,1
• Flywheel screw.................................................................................................. 11,1 to 12,4
• Crankshaft bearing caps.................................................................................... 15,9 to 16,6
• Connecting rod caps Nuts.......................................................................... 7,6 to 8,2
Bolts ........................................................................ 11,7 to 12,4
• Crankshaft pulley .............................................................................................. 32,2
CAPACITY
• Engine.............................................................................................................. 14,7 l
• Cooling system ................................................................................................ 17 l
• Injection pump governor .................................................................................... 0,25 l
VALVE CLEARANCE