Manitou MHT 10225 Operating instructions

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: [phone]
www.manitou.com
REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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GENERAL INSTRUCTIONS AND SAFETY NOTICE
Group 00 (General characteristics and safety) 1-1
ENGINE
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 (Hydraulic) 7-1
ELECTRICITY
Groupe 80 (Electricity) 8-1
DRIVER CAB
Groupe 85 (Driver s cab) 9-1

- GENERAL INSTRUCTIONS AND SAFETY
NOTICE
- GENERAL CONTROL AND ADJUSTMENT
GENERAL
00

00-00-M184EN
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
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GENERAL INSTRUCTIONS AND SAFETY NOTICE
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.
This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An ecient, dependable and protable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
When you see this symbol:
It means: Warning! Be careful! Your safety, somebody else’s or the safety of the lift truck itself
is at risk.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the safety manual are not exhaustive.
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 specied.
PREAMBLE
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00
2
00

00-00-M184EN
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Before any intervention:
1 - Place the machine on a at surface and chock the wheels.
2 - Turn o the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.
MAINTENANCE POSITION
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3
00
13
4
2

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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.
Be careful not to burn yourself when touching hot 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-o.
If the telehandler does not have a battery isolating switch, disconnect
the battery terminals then gather them.
bBefore carrying out any welding operations, think of
disconnecting computers.
A machine operating in a contaminated environment should be
specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.
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4
00
ECU
2
1

00-00-M184EN
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.
When carrying out maintenance operations near a mobile object,
make sure it is securitized.
When changing, or draining oils or fuel, or any other operation with
liquids, solids, gases that are harmful to the environment, make
sure the necessary precautions are taken to avoid contaminating
the environment.
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00

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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.
When using a jack, make sure it is used on a at, uniform surface, is
sturdy enough to support the load, that its lifting capacity is sucient
and that it is correctly placed and positioned under the machine.
Make sure no object or tool which could cause an accident is left
in the machine.
Never control any leaks using a hand.
Never adjust a component to over the maximum capacity indicated
by the manufacturer.
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6
00
max.
min.
MIN
MAX

00-04-M184EN
GENERAL CONTROL AND ADJUSTMENT
pages
STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
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GENERAL CONTROL AND ADJUSTMENT
STANDARD TIGHTENING TORQUES
Standard tightening torque to be used when not otherwise indicated in the removal and re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 coecient μ = 0,20 corresponding to dry-tted zinc-plated
fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent
to pneumatic screwdrivers).
NF E 25-030-1 Screw / Nut connection :
Tightening torque in N•m (±20%)
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “ne” pitch Grade 8.8 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 78 115
M14 x 2 111 163 M14 x 1,5 123 181
M16 x 2 175 256 M16 x 1,5 190 279
M18 x 2,5 240 352 M18 x 1,5 279 410
M20 x 2,5 341 501 M20 x 1,5 391 574
M22 x 2,5 470 691 M22 x 1,5 531 780
M24 x 3 588 864 M24 x 2 659 967
M27 x 3 874 1284 M27 x 2 965 1418
M30 x 3,5 1181 1735 M30 x 2 1351 1984
M33 x 3,5 1614 2371 M33 x 2 1821 2674
M36 x 4 2068 3037 - - -
bFor hexagon screws with anges:
Apply an increased torque of +10%.
(Standard NF E 25-030-1)
bWhere washers are used, the following coecient is to be applied (FD E 25-502) :
- Smooth tapered washer (CL): +5%
- Spring (or Grower) washer without jaws (W) : +10%
- Conical, internal teeth (CDJ-JZC) : +15%
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2
00

ENGINE
- ENGINE 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 EURO 3 )
MR

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10
ENGINE COMPONENTS LOCATION
page
MERCEDES ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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10
2ENGINE COMPONENTS LOCATION
MERCEDES ENGINE
Oil lter
Alternator
Belt
Fuel pump
and lter
Engine cooling
water pump

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10
3ENGINE COMPONENTS LOCATION
Turbocompressor
Oil lter
Alternator
Starter
motor

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10
4ENGINE COMPONENTS LOCATION

(02/08/2012) 10-04-M184EN
10
ENGINE CONTROL AND ADJUSTMENT
page
ENGINE TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– ASSEMBLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– FUEL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2