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Manitou MHT - 10225-Repair Manual
Manitou MHT - 10225-Repair Manual
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
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
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part
or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization
that are found in this document, are the intellectual property of 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. All rights are reserved.
Die vorliegende Broschüre dient allein zur Beratung. Nachdruck, Fotokopieren, Vervielfältigung, Darstellung, Erfassung,
Überlassung, Verbreitung oder Sonstiges (ganz oder teilweise) in jeglicher Form sind verboten. Die Entwürfe, Zeichnungen,
Bilder, Darstellungen, Ansichten, Kommentare, Hinweise und der Aufbau der Druckschrift selbst, die in der vorliegenden
Dokumentation enthalten sind, sind geistiges Eigentum von MANITOU BF. Alle Verstöße gegen das Vorstehende können zu straf-
oder zivilrechtlicher Verfolgung führen. Die Logos und Markenzeichen sowie Unternehmens- und Produktbezeichnungen sind
Eigentum von MANITOU BF und dürfen ohne ausdrückliche Genehmigung nicht verwendet werden. Alle Rechte vorbehalten.
Este folleto se ofrece a título meramente informativo y queda prohibida su reproducción, copia, representación, captación, cesión,
distribución y demás, parcial o total, en el formato que sea. Los esquemas, dibujos, vistas, comentarios, indicaciones, la organización
misma del documento aportado en esta documentación son propiedad intelectual de MANITOU BF. Cualquier infracción a lo
antedicho puede acarrear condenas civiles y penales. Los logotipos y la identidad visual de la empresa son propiedad de MANITOU
BF y no pueden utilizarse sin su autorización expresa y formaL. Reservados todos los derechos.
Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione,
acquisizione, cessione, distribuzione o altro, parziale o totale, e in qualsivoglia formato. Gli schemi, i disegni, le viste, i commenti,
le indicazioni e l’organizzazione stessa del documento, riportati nella presente documentazione, sono proprietà intellettuale
di MANITOU BF. Qualsiasi violazione a quanto riportato sopra è passibile di condanna civile e penale. I loghi e l’identità visiva
dell’azienda sono di proprietà di MANITOU BF e non possono essere utilizzati senza previa autorizzazione espressa e formale. Tutti i
diritti sono riservati.
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
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(05/06/2012) 00-00-M184EN
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.
Any non-compliance increases the risk of accidents occurring which may lead to 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.
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 specified.
00-00-M184EN (05/06/2012)
00
MAINTENANCE POSITION
2 4
1 3
(05/06/2012) 00-00-M184EN
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.
1
Before carrying out any operation on an electrically powered
2 component, activate the battery cut-off.
If the telehandler does not have a battery isolating switch, disconnect
the battery terminals then gather them.
00-00-M184EN (05/06/2012)
00
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.
(05/06/2012) 00-00-M184EN
max.
min.
MIN
00-00-M184EN (05/06/2012)
pages
(05/06/2012) 00-04-M184EN
b Where washers are used, the following coefficient 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%
00-04-M184EN (05/06/2012)
10
- ENGINE COMPONENTS LOCATION
- ENGINE REMOVAL
- ENGINE REFIT
M
R
SPECIFICATIONS
(ENGINE OM 904 LA
- ENGINE CONTROL AND ADJUSTMENT 120-150-175-CV EURO 3 )
page
MERCEDES ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(05/06/2012) 10-03-M184EN
MERCEDES ENGINE
Engine cooling
water pump
10
Oil filter
Alternator
Fuel pump
and filter
Belt
10-03-M184EN (05/06/2012)
10
Oil filter
Turbocompressor
Alternator
Starter
motor
(05/06/2012) 10-03-M184EN
10-03-M184EN (05/06/2012)
page
(02/08/2012) 10-04-M184EN
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
(05/06/2012) 10-06-M184EN
5
8
6 4
1
3
7
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
Deactivate the ignition key and disconnect the negative pole from the battery.
10-06-M184EN (05/06/2012)
10
A - REMOVING THE ALTERNATOR BELT
1
Open the hood (Ref. 1) of the engine compartment.
Insert an unlocking lever on the screw (Ref. 5), tilt the belt
tensioner roller upwards (Ref. 6) and remove the belt (Ref. 7).
7
6
(05/06/2012) 10-06-M184EN
Slacken the clamps (Ref. 1) and remove the hose (Ref. 2) positioned
1
on the air cooling radiator tube.
2
Slacken the screws (Ref. 3) and remove the bracket (Ref. 4) which
5 supports the air cooling radiator tube (Ref. 5), move the tube
downwards to make it easier to access the alternator.
4
3
10-06-M184EN (05/06/2012)
10
8
9
(05/06/2012) 10-06-M184EN
2
3
6
5
Remove the starter motor (Ref. 5) from the slot (Ref.f) under the
engine compartment.
10-06-M184EN (05/06/2012)
10
D - REMOVING THE OIL FILTER
3 Slacken the screw (Ref. 1) and remove the belt tensioner (Ref. 2).
Slacken the screws (Ref. 3) and remove the bracket (Ref. 4).
1
Slacken the screw (Ref. 6) to free the alternator (Ref. 7) and rotate
it downwards.
8 Slacken the screws (Ref. 8) which block the oil filter (Ref. 9) on
9
the engine supports and remove the filter from the engine.
(05/06/2012) 10-06-M184EN
3 Disconnect the connector (Ref. 2) from the fuel filter (Ref. 3).
3 Slacken the screws (REf. 4) and remove the fuel filter (Ref. 3)
from the engine.
5 6
10-06-M184EN (05/06/2012)
10
F - REMOVING THE ENGINE COOLING WATER PUMP
1
b Carry out the operations on the cooling system only if
the coolant temperature is below 30 .
4
3
Slacken the 4 screws (Ref. 5) and remove the pulley (Ref. 6).
(05/06/2012) 10-06-M184EN
Slacken the screw (Ref. 7) and remove the belt tensioner (Ref. 8).
10
Slacken the screws (Ref. 9 and 10) and remove the bracket (Ref.
11).
9
10
11
Slacken the clamp (Ref. 12) and disconnect the drainage tube
(Ref. 13) from the thermostatic valve.
13
12
15
10-06-M184EN (05/06/2012)
Slacken the screws (Ref. 16 and 17) which block the thermostatic
valve (Ref. 14).
10
16
17
14
14 Slacken the 7 screws (Ref. 18) remove the pump (Ref. 19) and
the thermostatic valve (Ref. 14).
19
18
18
18 18
18
18
18
(05/06/2012) 10-06-M184EN
Slacken the screws (Ref. 4 and 5) and remove the bracket (Ref. 6).
5 4
6
4
Slacken the clamp (Ref. 7) and remove the hose (REf. 8).
7
8 b Fit caps on all the ducts to prevent foreign bodies from
entering the circuits.
10-06-M184EN (05/06/2012)
Slacken the 2 clamps (Ref. 9) and remove the suction hose (REf.
10) on the air radiator.
10
9
10
9
Slacken the clamp (Ref. 11) and remove the suction hose (Ref.
12) from the turbocompressor (Ref. 13).
13
11
12
Unscrew the fitting (Ref. 14) and remove the lubrication delivery
tube (Ref. 15) from the turbocompressor.
15
14
Unscrew the fitting (Ref. 16) and remove the lubrication delivery
tube (Ref. 17).
17
16
(05/06/2012) 10-06-M184EN
Slacken the 4 screws (Ref. 18) and remove the cover plate (Ref.
19) from the exhaust manifold.
19
10
18
20
Slacken the 2 clamps (Ref. 21) and remove the suction hose
(Ref. 22) from the engine.
21
21
22
Slacken the 8 screws (Ref. 23) and remove the exhaust manifold
(Ref. 24).
23
23
23
24
10-06-M184EN (05/06/2012)
10
25
25
24
25
24
25
13
(05/06/2012) 10-06-M184EN
DISASSEMBLY ORDER
10
10-06-M184EN (05/06/2012)
Slacken the screw (Ref. 1) to release the gas spring (Ref. 2) from
1
the engine hood (Ref. 3).
10
2
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.
6 6
5
Disconnect the feed pipe (Ref. 7) and drainage pipe (Ref. 8) from
the hydraulic motor (Ref. 9).
Keep the pipes facing upwards to prevent the oil from flowing
out.
9
(05/06/2012) 10-06-M184EN
12
Slacken the nuts (Ref. 13) used for fitting the fan (Ref. 14).
14
13
15
Slacken the fixing screws (Ref. 16) and remove the hydraulic
motor
(Ref. 9) from the grille (Ref. 12).
12
16
10-06-M184EN (05/06/2012)
10
2
and the nuts (Ref. 3).
Slacken the clamp (Ref. 4) and remove the hose (Ref. 5).
5 4 Also disconnect pipes (Ref. 6 and 7) from the radiator.
6
7
Slacken the clamp (Ref. 9) and remove the hose (Ref. 10).
10
(05/06/2012) 10-06-M184EN
Slacken the screws (Ref. 11) to remove the clamp (Ref. 12) and
11 12 remove the tube (Ref. 13).
13
10
11 12
14
Connect the overhead crane (Ref. 15) to the radiator to remove it.
15
Remove the radiator (Ref. 16) from the vehicle, and place it on
16
a pallet.
10-06-M184EN (05/06/2012)
2
Disconnect the plug (Ref. 1) from the engine control unit (Ref. 2).
10
1
3 4
6
5
(05/06/2012) 10-06-M184EN
10
11 11
14
Slacken the clamp (Ref. 12) and remove the hose (Ref. 13) from
the suction duct (Ref. 14).
12
13
Slacken the screws (Ref. 15) and remove the bracket (Ref. 16)
which supports the radiator pipe (Ref. 17).
17 Shift the pipe downwards to make it easier to remove the engine.
16 15
10-06-M184EN (05/06/2012)
Slacken the clamp (Ref. 18) and remove the hose (Ref. 19) for
the exhaust gases.
10
18 19
Slacken the clamp (Ref. 20) and remove the hose (Ref. 21)
20 entering the radiator.
21
Slacken the clamp (Ref. 22) and remove the hose (Ref. 23) from
the turbocompressor.
23
22
Slacken the screws (Ref. 24) and remove the brackets (Ref. 25).
25 26 25
Remove the cooling system pipe (Ref. 26).
Slacken the screws (Ref. 27) and remove the support (Ref. 28)
24
from the vehicle.
24
28
27
(05/06/2012) 10-06-M184EN
31
Slacken the screws (Ref. 29) and slacken the clamps (Ref. 30).
Disconnect the upper (Ref. 31) and lower (REf. 32) heating pipes.
29
10
30 29
30
32
Slacken the clamp (Ref. 33) and remove the hose (Ref. 34) from
the water pump.
33
34
Secure the engine to the overhead crane and slacken the screws
(Ref. 35) which fix the engine to the chassis.
Remove the four silent blocks (Ref. 36).
35
36
37
38
10-06-M184EN (05/06/2012)
Remove the engine with the help of the overhead crane and
place it on a pallet.
10
(05/06/2012) 10-06-M184EN
10-06-M184EN (05/06/2012)
page
(25/11/2011) 10-07-M184EN
REASSEMBLY ORDER
10
10-07-M184EN (25/11/2011)
10
1
Fit the screws (Ref. 2) to block the engine and remove the
hydraulic jack, positioned under the hydraulic pump (Ref. 3)
during the disassembly.
Insert the hose (Ref. 6) on the water pump and tighten the
clamp (Ref. 7).
(25/11/2011) 10-07-M184EN
9
Connect the upper (Ref. 8) and lower (Ref. 9) heating pipes.
Tighten the clamps (Ref. 10) by tightening the screws (Ref. 11).
11
10
10 11
10
Fit the support (Ref. 12) on the vehicle by means of the screws
(Ref. 13).
15 14 15 Insert the cooling system pipe (Ref. 14) and tighten the brackets
(Ref. 15) by means of the screws (Ref. 16).
16
16
12
13
20
Insert the hose (Ref. 19) on the radiator pipe and tighten the
clamp (Ref. 20).
19
10-07-M184EN (25/11/2011)
Insert the hose (Ref. 21) for the exhaust gases and tighten the
clamp (Ref. 22).
10
22 21
24 25
28
26
Connect the tubes (Ref. 29) for the air conditioner on the
compressor.
29 29
(25/11/2011) 10-07-M184EN
Insert the hydraulic pump (Ref. 30) and fit the screws (Ref. 31).
31
10
30
32
33
35
34
36
36 37
10-07-M184EN (25/11/2011)
Connect the plug (Ref. 38) on the engine control unit (Ref. 39).
39
10
38
Insert the pipe (Ref. 3) and fit the brackets (Ref. 4) using the
4
screws (Ref. 5).
5
4
5
(25/11/2011) 10-07-M184EN
Insert the hose (Ref. 6) and screw the clamp (Ref. 7).
6
10
9
10
14
15
10-07-M184EN (25/11/2011)
10
2
Tighten the nuts (Ref. 5) used for fitting the fan (Ref. 6).
(25/11/2011) 10-07-M184EN
Reconnect the feed pipe (Ref. 9) and drainage pipe (Ref. 10) of
9
the hydraulic motor (Ref. 1).
10
10
Fit the silent blocks (Ref. 11), also in the lower part of the radiator,
using the screws (Ref. 12).
11 11
12
Fit the hood (Ref. 13) on the vehicle by means of the screws
(Ref. 14).
14
13
Fit the screw (Ref. 15) to block the gas spring (Ref. 16) on the
engine hood (Ref. 13).
15
16
13
10-07-M184EN (25/11/2011)
10
4
4
1
3 5
8
6
2
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
Deactivate the ignition key and disconnect the negative pole from the battery.
(25/11/2011) 10-07-M184EN
3
3
Refit the exhaust manifold (Ref. 2) on the engine base using the
8 screws (Ref. 4); use a 30 Nm tightening torque.
10-07-M184EN (25/11/2011)
10
6
11
(25/11/2011) 10-07-M184EN
12
10
13
15
14
Refit the suction hose (Ref. 16) on the air radiator and tighten
the 2 clamps (Ref. 17).
16
17
17
Refit the hose (Ref. 18) and tighten the clamp (Ref. 19).
18
19
10-07-M184EN (25/11/2011)
Refit the bracket (Ref. 20) on the air unit by means of the screws
(Ref. 21 and 22).
22 21
10
20
21
Refit the air suction pipe (Ref. 23) locking it by means of the 2
brackets (Ref. 24) and the two nuts (Ref. 25).
24
23
25
(25/11/2011) 10-07-M184EN
Replace the gaskets with new ones, refit the pump (Ref. 1) and
the thermostatic valve (Rif. 2) on the engine by means of the
1 7 screws (Ref. 3), on which Loctite threadlock must be applied;
3 use a 25 Nm tightening torque.
3
3
3
3
3 3
4
5
10-07-M184EN (25/11/2011)
10
7
8
Refit the bracket (Ref. 9) on the air unit by means of the screws
(Ref. 10 and 11).
10
11
10
Refit the belt tightener (Ref. 12) by means of screws (Ref. 13)
on which Loctite threadlock must be applied, using a 50 Nm
tightening torque.
13
12
Refit the pulley (Ref. 14) by means of the screws (Ref. 15) on
which Loctite threadlock must be applied.
14
15
(25/11/2011) 10-07-M184EN
Reconnect the upper hose (Ref. 16) on the pump and screw the
2 clamps (Ref. 17) back on.
17
10
16
17
Reconnect the lower hose (Ref. 18) on the pump and screw the
2 clamps (Ref. 19) back on.
18
19
19
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. 18 litres).
20 Remove the containers from under the engine compatment.
10-07-M184EN (25/11/2011)
10
3 C - REINSERTING THE FUEL OIL FILTER AND PUMP
2
1
Reconnect the fuel inlet and outlet pipes (Ref. 6) to the filter
(Ref. 3).
(25/11/2011) 10-07-M184EN
Release the oil inlet pipe (Ref. 5) from the clamp by means of
which it is fixed in the disassembly phase and refit it on the
filter (Ref. 1).
10-07-M184EN (25/11/2011)
10
E - REINSERTING THE STARTER MOTOR
3
2
6
7
4
5
(25/11/2011) 10-07-M184EN
10-07-M184EN (25/11/2011)
10
6
7
Refit the hose (Ref. 8) on the air cooling radiator pipe and tighten
the clamps (Ref. 9).
(25/11/2011) 10-07-M184EN
Refit 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
1 roller backwards.
2 Remove the release lever and check to ensure the belt is housed
correctly on the pulleys.
3
10-07-M184EN (25/11/2011)
- OPTIONS - ATTACHMENTS
CHARACTERISTICS AND SPECIFICATIONS
110
page
OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
DESCRIPTION OF THE WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
FLUID CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
DESCRIPTION OF THE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
110
(06/03/2012) 110-01-M184EN
AIR CONDITIONER
OPERATING PRINCIPLE
Outside air
The fluid
is liquified
CONDENSER
REGULATOR Suction
and compression
EVAPORATOR
Expansion
of fluid and drop in
The
temperature
liquid evaporates
110-01-M184EN (06/03/2012)
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.
The properties of the fluid are used by following the cycle in a closed circuit the principle of which is:
Step 1: Compression
The fluid, in gaseous state at low pressure and low temperature, is sucked in and compressed by the
compressor (Ref. 1) which sends it, at high pressure and high temperature, to the condenser.
Step 2: Condensation
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 and high
pressure. It is then filtered in a dehydrator (or drier) (Ref. 3).
Step 3: Release
The fluid enters an expansion valve (Ref. 4) in which it is subjected to very great reduction of the pressure
and temperature, preserving the liquid state.
Step 4: Evaporation
The fluid flows through the evaporator (Ref. 5) to absorb heat from the air in the cab and vapourizes
while at the same time maintaining a low pressure and temperature.
The air from the cab, pushed by the engine fan, cools and loses humidity in contact with the evaporator.
The condensate from the air is then drained and discharged outside the vehicle.
The high and low pressure circuit is controlled by means of a pressure switch HP and LP (Ref. 6) fitted
directly on the drier filter.
Its safety functions are as follows:
Complete stop of the air conditioner if the pressure drops below 2 bar or exceeds 27 bar.
110
(06/03/2012) 110-01-M184EN
FLUID CIRCUIT
1
5
110-01-M184EN (06/03/2012)
The compressor
The compressor (Ref. 1) is the organ which makes it possible to:
• convey the fluid through the suction circuit, in a gaseous state, from the evaporator at low pressure
and low temperature.
• compress the fluid and transmit it at high pressure and temperature to the condenser.
The condenser
The condenser (Ref. 2) is a heat exchanger which transmits the heat recovered by the evaporator by
means of the fan to the outside and causes condensation of the fluid at high pressure.
The evaporator
The evaporator (Ref. 5) is a heat exchanger provided with a valve and a fan.
The fan sucks in air (cold) through the evporator, the moisture in the air condenses on the evaporator
fins, cools the air and pushes it out.
This heat exchange allows the coolant to evaporate at low pressure.
(06/03/2012) 110-01-M184EN
110-01-M184EN (06/03/2012)
page
110
(07/03/2012) 110-03-M184EN
110-03-M184EN (07/03/2012)
Condenser kit
Receiver filter
Expansion valve
Evaporator
Compressor
– High pressure
– Low pressure
110
(07/03/2012) 110-03-M184EN
Electrical connectors
Position on the
Ref. Description Observations
diagram
X100 Control unit connector M20
X102 Fans activation control unit connector K22
X103 Drier filter connector M18
X104.1 Solenoid 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 connector M16
X108 External temperature sensor connector K9
X109 Fan connector M16
X110 Fan connector M16
X111 Mixer valve connector M18
X112 Mixer valve connector M18
X176 Heating panel K19 / K20
X204.3 Gnd M19 / M20
110
110-03-M184EN (07/03/2012)
1 2 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 42
A A
C C
X104.1
X464
X104.2
X464
E E
X104.3
X464
G G
I I
X105
K K
X176
X108
X204.3 X102
X107
X100
X109
X110
Au
M M
tos
yst
em
X111
X112
X103
O O
X106
X464
Q Q
110
S S
(07/03/2012) 110-03-M184EN
Electrical connectors
Position on the
Ref. Description Observations
diagram
X100 Control unit connector M20
X102.p Fans activation control unit connector K22
X102.s Fans activation control unit connector K22
X103 Drier filter connector M18
X104.1 Solenoid 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 connector M16
X108 External temperature sensor connector K9
X109 Fan connector M16
X110 Fan connector M16
X111 Mixer valve connector M18
X112 Mixer valve connector M18
X176 Heating panel K19 / K20
X204.3 Gnd M19 / M20
110
110-03-M184EN (07/03/2012)
A A
C C
X104.1
X464
X104.2
X464
E E
X104.3
X464
G G
I I
X105
K K
X176
X108
X204.3 X102
X107
X100
X109
X110
Au
M M
tos
yst
em
X111
X112
X103
O O
X106
X464
Q Q
110
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(07/03/2012) 110-03-M184EN
Electrical connectors
Position on the
Ref. Description Observations
diagram
X100 Control unit connector M20
X102 Fans activation control unit connector K22
X103 Drier filter connector M18
X104.1 Solenoid 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 connector M16
X108 External temperature sensor connector K9
X109 Fan connector M16
X110 Fan connector M16
X111 Mixer valve connector M18
X112 Mixer valve connector M18
X176 Heating panel K19 / K20
X204.3 Gnd M19 / M20
RL1 M19
FUS.1 O18
FUS.2 O19
FUS.3 O18
FUS.4 O19
110
110-03-M184EN (07/03/2012)
A A
C C
X104.1
X464
X104.2
X464
E E
X104.3
X464
G G
I I
X105
K K
X176
X108
X204.3 X102
X107
X100
X109
X110
Au
M M
tos
yst
em
X111
X112
X103 RL1
FUS.1 FUS.2
FUS.3 FUS.4
O O
X106
X464
Q Q
110
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(07/03/2012) 110-03-M184EN
110-03-M184EN (07/03/2012)
page
110
(07/03/2012) 110-04-M184EN
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.
Compressor connection:
Legend:
1 - Compressor
2 - Cab outlet/compressor inlet pipe
3 - Compressor outlet/cab inlet pipe
2
3
110-04-M184EN (07/03/2012)
Legend:
4 - Feed pipe
5 - Mixer valve
6 - Return pipe
110
(07/03/2012) 110-04-M184EN
Description Hydrofluorocarbon
Use Coolant
Chemical features Tetrafluoroethane 134a
Chemical formula CH2F-CF3
Physical state Liquified gas
Colour Colourless
Odour Slightly ethereal
Boiling point (at atmospheric pressure) - 26.5 °C
Melting point - 101 °C
Density at 25°C 1.21 kg/l
Critical pressure 40.7 bar
Critical temperature + 101 °C
Weight in vapour state 5 times heavier than air
1 kg in liquid state less than 1 bar 200 l in gaseous state
Solubility of water in product 0.097% in weight
Thermal decomposition Starting from 110 °C
Hazardous decomposition products Halides of hydrogen and traces of carbonyl halides
Hazardous reactions With alkaline 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 depletion potential None, ODP=0
2 - First aid: In case of inhalation remove immediately to fresh air, administer oxygen and give artificial
respiration depending on the degree of the emergency (do not administer drugs). Get medical
attention. In case of contact with eyes, flush eyes with plenty of water for 15 minutes and get
medical attention. In case of contact with the skin, flush with plenty of clean water and remove
contaminated clothing.
3 - Storage conditions: Store the R134a liquid in a cool, dry well-ventilated place.
5 - Accidental release measures: In case of exposure of liquid R134a to fire, wear breathing apparatus.
110
110-04-M184EN (07/03/2012)
Coolant: R134a
Refilling equipment: Refilling station
Quantity of fluid: 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.
FILLING METHOD
Before using a filling station, consult the relevant user handbook for the device.
Filling liquid in the circuit for the first time (duration 56 minutes)
(07/03/2012) 110-04-M184EN
b In the open air, liquid R134a is a colourless odourless gas heavier than air and in certain conditions
it can be hazardous for humans. Always recover the coolant from the refilling station.
The following checks must be performed with the vehicle engine switched on.
b The 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 working and complete efficacy of the air conditioning system,
start up the compressor once a week, even if it is only for short periods, to allow lubrication of
the internal gaskets. At low temperatures: Heat the engine before starting up the
compressor to allow the coolant in the liquid state, collected at the bottom of the compressor
circuit, to get transformed into gas under the action of the heat given out by the engine; in the
liquid state the coolant can damage the compressor.
b If the air conditioner is not working properly, have it checked by your dealer (see: 3 - MAINTENANCE:
F - EVERY 2000 HOURS OF OPERATION). Never attempt to repair faults yourself.
110
110-04-M184EN (07/03/2012)
A - Control unit
A Legend of functions:
14 13 12 11 10
To switch off the unit, press the «Fan speed reduction command» button (Ref. 8) to deactivate the fan
completely; to switch it back on again, press the «Fan speed increase command» button (Ref. 7).
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 the type of fault according to the following Table::
Since automatic regulation is not possible, the keys for increasing and decreasing the internal temperature
are used to change the position of the mixer, while the fan speed is fixed at the 2a speed.
If the error is solved, the control unit resumes normal operation only after resetting the + key.
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(07/03/2012) 110-04-M184EN
7 - °C and °F selection
When the relative LED is Off, the temperature is indicated in °C , when the LED is On the temperature
is read in °F (Fahrenheit).
The maximum cab temperature value setting is 37°C or 99°F.
110-04-M184EN (07/03/2012)
2
3
(07/03/2012) 110-04-M184EN
Examples:
Note:
These values are indicative and can change according to the ambient temperature and the type of vehicle.
110
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20
- TRANSMISSION COMPONENTS LOCATION
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
647030DE/EN
R
SPECIFICATIONS
(ENGINE A6VM SERIE 63)
- TRANSMISSION CONTROL AND
ADJUSTMENT
M
647375
R
647379
R
20
page
(06/06/2012) 20-02-M184EN
20-02-M184EN (06/06/2012)
Legend:
High pressure
Low pressure
Control air
VSLR MC Drainage pressure
EV(S28)
EV(S27)
20
B A Loading pressure
1 2 PF
Suction pressure
S.
T P
Return to discharge
§ 70 See «70 - hydraulics» Chapter
CR Hydraulic manifold
EV(S21) Forward movement solenoid valve
EV(S22) Reversing solenoid valve
EV(S27) Fast speed solenoid valve
EV(S28) Slow speed solenoid valve
CR
FORWARD MOVEMENT FDAR Rear disk brakes
FDAV Front disk brakes
M. I.C. engine
MC Brake pump
M.I. Engine with variable displacement
PF Brake pedal
P.I. Hydrostatic pump
VCLR R. Oil tank
RAD. Radiator
3 bar S. Oil tank
EV EV VCLR
(S22) (S21)
Slow-fast control cylinder
T A
VSLR Slow-fast selector valve
b a
R T1 T2 Ps Fa Fe MB
450bar B
M.
450bar 35bar 440bar
P.I. A
FDAV X1 X2 G S MA
M.I. FDAR
X1 X2 B
§ 70
FRONT REAR
AXLE RAD. AXLE
R.
(06/06/2012) 20-02-M184EN
Legend:
High pressure
Low pressure
Control air
20
B A Loading pressure
1 2 PF
Suction pressure
T P
S.
Return to discharge
§ 70 See «70 - hydraulics» Chapter
CR Hydraulic manifold
EV(S21) Forward movement solenoid valve
EV(S22) Reversing solenoid valve
EV(S27) Fast speed solenoid valve
EV(S28) Slow speed solenoid valve
REVERSING MOVEMENT CR
FDAR Rear disk brakes
FDAV Front disk brakes
M. I.C. engine
MC Brake pump
M.I. Engine with variable displacement
PF Brake pedal
P.I. Hydrostatic pump
R. Oil tank
VCLR RAD. Radiator
S. Oil tank
3 bar
VCLR Slow-fast control cylinder
EV EV
(S22) (S21) T A VSLR Slow-fast selector valve
b a
R T1 T2 Ps Fa Fe MB
450bar B
M.
450bar 35bar 440bar
P.I. A
FDAV M.I. FDAR
X1 X2 G S MA
X1 X2 B
§ 70
FRONT REAR
AXLE AXLE
RAD.
R.
20-02-M184EN (06/06/2012)