PDF Repair Manual Manitou MHT Series Telehandler (OM 904 LA) - 1 MB
This is the official repair manual for the heavy-duty Manitou MHT series telehandlers, including models 7140, 10160, and 10210 equipped with the OM 904 LA engine.
The guide provides professional, step-by-step instructions for maintenance, troubleshooting, and major repairs.
It's an invaluable resource for keeping your powerful telehandler in peak operating condition.
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REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
This document has been printed from my e doc
MANITOU BF
Head office: 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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TRANSMISSION OPERATION (REGULATION)
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MHT 7140-10160-10210L MS
Series 3 EN
“DA” CONTROL CARTRIDGE
OPERATION
The pilot pressure is drawn via the control cartridge slide valve into the booster circuit. At
maximum IC engine speed, the pilot pressure is a few bars lower than the booster pressure.
On idling (850 rpm) the booster flow which passes through the calibrated opening in the
control cartridge slide valve is sufficient to create a drop in pressure capable of displacing
the slide valve 1 against the force of the spring 2. The pilot pressure is therefore nil.
When the operator accelerates in order to move forward (to approximately 1050 rpm), the
booster flow increases; the drop in pressure before the calibrated opening is now sufficient
to move the slide valve to the left, against the spring, thus revealing the pilot opening.
When the pilot pressure reaches approximately 6 to 7 bar, the servocontrol cylinder begins
to move, tilting the plate of the variable capacity pump. The pump begins to discharge (start
of control). The greater the engine speed, the more the booster flow increases thus increas-
es thus leading to a rise in the pilot pressure and therefore increased influence on the pump
and greater machine speed.
To halt this process, the operator stops accelerating, the booster flow drops, the pressure
drop is reduced and the spring 2 pushes back the slide valve 1 thus closing the booster
passage to the pilot conduit. The residual pilot pressure is discharged towrads the housing.
11
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MHT 7140-10160-10210L MS
Series 3 EN
3B CHECK AND ADJUST END OF REGULATION:
End of regulation
CHECK:
- The truck is supported on blocks, inching valve by passed, brakes applied (foot and park).
- Drive reverser in forward drive.
- Select forward drive.
- Engine at low idle-check rpm.
- Gradually increase the engine speed (1600÷1800rpm) until the forward HP reading is 465
bar. At this point check engine speed and compare with specifications.
END OF REGULATION:
The adjustment of the pump end of regulation is obtained using an eccentric screw which
restricts the pump flow creating back pressure against the swash plate.
This adjustment can only be set using a test bench.
It cannot be modified in any way without prior authorization from the manufacturer.
The slot in the eccentric screw should point towards the boost pump(opposite to
A4VG pump where slot pointed to drive shaft). The adjustment must not go beyond
90 to the left or right-Do not exceed or damage may occur.
As for the HP adjustment, this adjustment has to be done with the DR valve overcali-
brated.
21
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AS 372 KR
1
1.2 - Identification data
Exact reference to the "Model", the "Serial number"
and the "Year of Manufacture" of the axle is required
when requests for assistance under guarantee are
needed or when spare parts are ordered.
These data are written in the plate (fig.1.2), located
as shown in fig.1.3. Always refer to the axle data
whenever you contact the after-sales service.
This will enable immediate replies, while eliminating
the risk of misunderstanding and uncertainties in
Fig. 1.2
the solution of your problem.
As memorandum we suggest to write down all the
axle data.
1.3 - Packing and movement
1.3.1 - Packing
Before delivery the axle is accurately inspected.
Except for special request or particualr shipment as
naval transport, the axle is shipped without packing.
1.3.2 - Movement
Axle lifting and transport must be done using suitable
means. The axle type AS 372 KR weighs about
1450 kg.
Fig. 1.3
CAUTION !!!
Lift the axle with appropriate means and check
the stability. For safety move the axle and its
components keeping the load as low as possible.
If you use a lift truck the forks must be in the
widest position and positioned in the center of
axle. Nobody must be near the axle during
handling.
7
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3
3 - MAINTENANCE
3.1 - Foreword
3.2 - Tests conducted by the Manufacturer
3.3 - Routine inspections
3.4 - Checking and changing of the oil
3.5 - Recommended oils
3.6 - Recommended greases
3.7 - Greasing points
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5
5 - CLEANING AND INSPECTIONS
5.1 - Cleaning
5.2 - Bearings
5.3 - Brake disks
5.4 - Seals, oil retaining rings and thrust washer
5.5 - Gears
5.6 - Assemblies
5.7 - Use of thread-locking adhesive (Loctite®) and
paste seals (silicone)
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AS 372 KR
6
6.10 - Assembly of the wheel hub gear
- Check that the three planet gears pos.4 fig.6.20
are perfectly clean. Spread their central holes
with a film of hard grease. Use grease type FINA
MARSON EPL 3, NLGI:3 degree.
- Position the needles pos.3 inside the gears pos.4
so that it's fully filled, placing a spacer ring pos.6
between each row of needles.
- Position the two external thrust washers pos.5 and
insert the planet gear into the spider, carefully
centering the plug hole. For this purpose use tool
OMCI No.2 of chapter 7.
- Having perfectly centered the planet gear, remove
the centering tool and mount pin shaft pos.2, taking
care to position it so that the milling points towards
the circlip pos.1. Fig. 6.20
- Mount the remaining planetary gears in the same
way.
- Having correctly installed the three planet gears
and relative pins, position the circlip pos.1 and
check if it’s correctly installed.
- Apply a continuos thread of silicone to the coupling
surface between the wheel hub and the planet
spider.
- Mount the axle shaft, inserting it into the central
hole of the spindle. Keep it pushed downwards in
order to lift the other hand and slightly turn it to
center the teeth of the grooved profile. The axle
shaft has to enter the hole smoothly and without
resistance. If not the case, demount the axle shaft
and check for any dents on the grooved profile.
- Apply a drop of Loctite 262 onto the screws pos.1
fig.6.21 and tighten them to specified torque (see
Fig. 6.21
chapter 7).
- Fill with oil every part that needs it and lubricate
the greasing points. See chapter 3 for further
information.
For quality and quantity see paragraphs 3.5 and
3.6.
6.11 - Assembly of the brake cylinders
For assembly and installation of the brake cylinders
see the manual O.M.C.I. cod.031027 CCD.372110.
37
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RDE 92500-02-R/03.01
Schnittbild Reparaturanleitung A11VO
Sectional view Repair Instructions A11VO
A11VO...LRDS
LR
S
D
LR
Brueninghaus Hydromatik 3
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RDE 92500-02-R/03.01
Anschlußplatte, Regler demontieren Reparaturanleitung A11VO
Remove port plate, regulator Repair Instructions A11VO
Reglergehäuse abbauen.
Bei Regler mit Meßfeder z.B. DRL, EP, LRDH -
zuerst Steuerbuchse mit Meßfeder ausbauen,
dann Reglergehäuse abbauen.
Remove regulator housing.
For control with measuring spring for instance: DRL, EP,
LRDH - at first remove control bush with measuring spring,
than remove regulator housing.
O-Ringe, Meßkolben mit Büchse und
Feder ausbauen.
Remove O-ring, measuring piston
with bush and spring.
Ausführung mit Impeller!
Zuerst Impeller ausbauen.
Design with impeller!
At first remove impeller.
Lage der Anschlußplatte markieren.
Anschlußplattenbefestigung lösen.
Mark position of the connection plate.
Loosen connection plate fixation.
Brueninghaus Hydromatik 13
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RDE 92500-02-R/03.01
Überprüfungshinweise Reparaturanleitung A11VO
Inspection hints Repair Instructions A11VO
Kontrolle!
Kugelköpfe
Geschliffene Seite zur Wiege einbauen!
Inspection!
Fixing segments
Assemble the grinded side to the cradle!
Kontrolle!
Rückstellkolben (*)
Abstimmumg über Rückstellstange.
Rückstellkolben Inspection!
ohne Qmin-Stop Piston (*)
Adjustment ..
Rückstellkolben
mit Qmin-Stop
Kontrolle!
Stellkolben (1),
2 1 Bohrung - Stellbüchse (2).
Inspection!
1 Positioning piston (1),
Boring - control bush (2).
Kontrolle!
Bohrung (*),
Auflagefläche - Steuerplatte (1).
Inspection!
Boring (*),
Contact area control plate (1).
Brueninghaus Hydromatik 23
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RDE 92500-02-R/03.01
Prüfanweisung A11VO 40 - 130 LRDS Reparaturanleitung A11VO
Test instruction A11VO 40 - 130 LRDS Repair Instructions A11VO
1. Vorbereiten Funktionsprüfung 1. Preparation for functional testing
1.1 Leistungsdiagramm anfordern 1.1 Requisition of power curve diagram
1.2 Einbauen, befestigen und Gehäuse füllen 1.2 Install, fix and fill the housing
1.3 Drehrichtung festlegen 1.3 Check the direction of rotation
Anschlüsse / ports
A11VO 40 ... 130 LRDS
M: Meßstelle, Arbeitsanschluß /
Test ports, pressure port
M1: Meßstelle, Stellkammer /
Test port
LR: Leistungsregler /
HP-control
DR: Druckabschneidung /
Pressure cut-off
X: Anschluß für ∆P-Regler /
Port for ∆P-control
G: Anschluß für Stelldruck /
Port for positioning pressure
S: Load-Sensing-regler /
Load-sensing control
A11VO 40 ... 130 LRDH
M: Meßstelle, Arbeitsanschluß
Y Test point, pressure port
D M1: Meßstelle, Stellkammer
LR Test point, adjustment
H2/6 chamber
G: Anschluß für Stelldruck
Port for adjustment pressure
LR: Leistungdregler
HP-control
D: Druckabschneidung
Pressure cut-off
H2/6: Hydraulische Hubbe-
M G M1 grenzung Vg min - Vg max
Qmin - stop Qmax - stop Hydraulic stroke limiter
2. Einstellvorgang
2.1 Auf Prüftemperatur fahren 2. Setting process
2.2 Antriebsdrehzahl
2.3 Qmin- Anschlag ausschrauben 2.1 Drive to temperature
2.2 Input speed
2.3 Screw-out Qmin- stop
Brueninghaus Hydromatik 33
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RDE 92500-02-R/03.01
Prüfanweisung A11VO 40 - 130 LRDS / LRDH Reparaturanleitung A11VO
Test instruction A11VO 40 - 130 LRDS / LRDH Repair Instructions A11VO
D
2.13 Einstellen Druckregler 2.13 Setting of constant pressure
2.14 Mit Belastungsventil Druckregler nach 2.14 Setting with help of the charge valve
Leistungsdiagramm einstellen. the constant pressure control as to
HP diagram.
Beispiel 4
Druckreglereinstellung = 310 bar
p[bar]
400
Betriebsdruck mit Belastungsventil
auf ~ 350 bar erhöhen.
Blockierten Druckregler vorsichtig
310
herausdrehen bis 310 bar erreicht 300
wird.
Einstellschraube kontern.
200
Example 4
Setting of constant pressure
control = 310 bar
Increase operation pressure with 100
help of charge valve ~ to 350 bar.
Unscrew carefully blocked ppr
constant pressure control up Q = 343 l/min
bei ppr = 50 bar
to 310 bar.
0 100 200 300
Jam setting screw. Q[l/min]
Brueninghaus Hydromatik 43
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I30 9 Stop pressure switch M7 15 Front windscreen washer pump R36 14 4 inputs and 4 outputs circuit
I31 11 Back-up lights switch M8 15 Rear wiper motor S1 20 1200 rpm solenoid valve
I32 21 Emergency pump switch M9 13 Rear aeration solenoid valve S2 8 Forward movement solenoid valve
I33 17 Manoeuvres manipulator M10 13 Air conditioner compressor S3 8 Reverse solenoid valve
I34 10 Levelling switch M11 13 Cab aeration fan motor S4 10 LH levelling solenoid valve
I38 11 Air filter pressure switch M13 21 Pneumatic seat S5 9 Anti-tilting solenoid valve
IP 6 Ceiling light switch M14 15 Top wiper motor S6 10 RH levelling solenoid valve
L1 11 Battery optical indicator P3 7 Identification plate light S7 9 Fast movement solenoid valve
L2 11 Turn indicators optical indicator P17 6 Cab light S8 9 Slow movement solenoid valve
L3 11 Position lights optical indicator PPA 10 Provision for front axle alignment S9 5 Differential block solenoid valve
L4 11 High beam lights optical indicator proximity switch S10 17 Boom extension solenoid valve
L5 11 Low beam lights optical indicator PPP 10 Provision for rear axle alignment S11 17 Boom retract solenoid valve
L6 11 Air filter clogged optical indicator proximity switch S12 18 Optional 1 solenoid valve
L7 11 Oil pressure optical indicator R1a 4 Start-up enable relay S13 18 Optional 2 solenoid valve
L8 11 Oil level optical indicator R1b 19 Work lights power supply relay S14 15 Crab steering solenoid valve
L9 11 Water temperature optical indica- R2b 19 Forward movement relay S15 15 Concentric steering solenoid
MHT 7140-10160-10210 L MSeries
tor R3a 8 Reverse relay S16 17 Optional double solenoid valve
L10 11 Control unit fault optical indicator R4a 4 Machine locked with key power S19 21 Mixer bucket solenoid valve
L11 11 Parking brake optical indicator supply relay S20 17 Optional triple solenoid valve
L12 11 Brakes oil level optical indicator R4b 4 Machine locked with key power ST1 12 Hour meter and rev counter
L13 9 Slow speed optical indicator supply relay ST2 12 Water temperature instrument
L14 9 Fast speed optical indicator R5a 7 Low beam lights relay ST3 12 Fuel level instrument
L15 15 Crab steering optical indicator R5b 14 Oil cooling fan relay ST4 9 Anti-tilting control unit
L16 15 Concentric steering optical indica- R6a 7 High beam lights relay ST5 9 Load cell
tor R6b 14 Oil cooling fan relay ST6 9 Load cell
L17 17 Boom top second outlet optical R7a 11 Parking optical indicator relay ST7 9 Anti-tilting control unit
indicator R7b 14 Oil cooling fan relay T1 19 Float
L18 17 Control unit fault indicator R8a 20 1200 rpm solenoid valve relay TR 21 Thermo-starter
L19 18 Control unit fault indicator R8b 10 Levelling relay X2 16 Mercedes adm control unit
L20 9 Anti-tilting exclusion optical indi- R9a 9 Anti-tilting relay X17 16 Diagnostics connector
cator R9b 5 Differential block relay X21/A 17 RC2-2/20 Rexroth 1st control unit
L20b 9 Anti-tilting exclusion optical indi- R10a 6 Relay intermittence relay X21/B 18 RC2-2/20 Rexroth 2nd control unit
cator R10b 5 Horn relay X30 16 Mercedes motor control unit
L21 17 Boom top 3rd outlet optical indica- R11b 5 Buzzer and reversal lights relay X31 16 Accelerator pedal connector
tor R12a 5 Brake lights relay X35 20 Antitheft connector
L22 15 Normal steering optical indicator R12b 14 Oil cooling relay X36 20 Car radio connector
M1 4 Starter motor R13 6 Intermittence X61 21 Basket connector
M2 14 Hydraulic oil cooling fan R14a 21 Air heater relay
M3 14 Hydraulic oil cooling fan R16b 8 Starter motor relay
M4 14 Hydraulic oil cooling fan R33 9 Slow-fast bistatic relay
5
M5 14 Hydraulic oil cooling fan R34 17 Optional double relay
4
M6 15 Front wiper motor R35 17 Boom top outputs set-reset relay
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MHT 7140-10160-10210 L MSeries
MHT 990-7140-10160 M SERIES DISTRIBUTORE REXROTH (09-2003) / MHT 990-7140-10160 M SERIES DISTRIBUTOR REXROTH (09-2003) TAVOLA
Denominazione
TABLE
MANIP. LIVELLAMENTO E LAMPADA ROTANTE
15
Name: LEVELLING AND WORKING LAMP 10
4
--- Page 20 ---
MHT 7140-10160-10210 L MSeries
MHT 990-7140-10160 M SERIES DISTRIBUTORE REXROTH (09-2003) / MHT 990-7140-10160 M SERIES DISTRIBUTOR REXROTH (09-2003) TAVOLA
Denominazione
TABLE
ANTIFURTO, AUTORADIO
25
Name: ANTI-THIEFT, RADIO 20
4