Manitou MHT 10225 Repair Manual

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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This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part
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Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione,
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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

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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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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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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.

b

Before 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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ECU

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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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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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max.

min.

MIN

MAX

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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 - - -

b

For 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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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 )

M

R

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ENGINE COMPONENTS LOCATION

page

MERCEDES ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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2 ENGINE COMPONENTS LOCATION

MERCEDES ENGINE

Oil  lter

Alternator

Belt

Fuel pump
and  lter

Engine cooling
water pump

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3ENGINE COMPONENTS LOCATION

Turbocompressor

Oil  lter

Alternator

Starter
motor

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4 ENGINE COMPONENTS LOCATION

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ENGINE CONTROL AND ADJUSTMENT

page

ENGINE TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– ASSEMBLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– FUEL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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2 ENGINE CONTROL AND ADJUSTMENT

ENGINE TIGHTENING TORQUE

ASSEMBLING THE ENGINE

FUEL CIRCUIT

25 Nm

+ apply “Loctite 243”

45 Nm

+ apply “Loctite 243”

45 Nm

+ apply “Loctite 243”

210 Nm

+ apply “Loctite 243”

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ENGINE REMOVAL

page

REMOVING THE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

 A  REMOVING THE ALTERNATOR BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

 B  REMOVING THE ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

 C  REMOVING THE STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

 D  REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

 E  REMOVING THE FUEL OIL FILTER AND PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

 F  REMOVING THE ENGINE COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

 G  REMOVING THE TURBOCOMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

 DISASSEMBLY ORDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

 REMOVING THE RADIATOR MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

 REMOVING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

 REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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2 ENGINE REMOVAL

1

5

6

3

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5

1

8

2

REMOVING THE ENGINE COMPONENTS

Legend:

1 - Alternator
2 - Starter motor
3 - Alternator belt
4 - Fuel  lter
5 - Oil  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.

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3ENGINE 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. 6) and remove the belt (Ref. 7).

1

3

5

7

6

2

4

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4 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. 5), move the tube
downwards to make it easier to access the alternator.

Slacken the screws (Ref. 6) which secure the alternator (Ref. 7)
to the engine.

6

3

5

4

2

1

1

7

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5ENGINE 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.

8

9

7

7

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6 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. 5) from the slot (Ref.f) under the
engine compartment.

5

5

4

1

2

3

6

7

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7ENGINE 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.

Slacken the screw (Ref. 6) to free the alternator (Ref. 7) and rotate
it downwards.
Slacken the screws (Ref. 8) which block the oil  lter (Ref. 9) on
the engine supports and remove the  lter from the engine.

2

1

5

8

8

6

7

9

34

3

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8 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  lter, taking care to keep these facing upwards to avoid
draining the tank.

Disconnect the connector (Ref. 2) from the fuel  lter (Ref. 3).

Slacken the screws (REf. 4) and remove the fuel  lter (Ref. 3)
from the engine.

Slacken the screws (Ref. 5) and remove the fuel pump
(Ref. 6) from the engine.

1

1

3

2

4

3

6

5

5

5

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9ENGINE REMOVAL

F - REMOVING THE ENGINE COOLING WATER PUMP

Carry out operation A.

b

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.
Disconnect the lower hose (Ref. 2) from the pump, slowly
discharge overpressure from the system, let the liquid drain out
of the cooling system, and empty it completely.

Slacken the 2 clamps (Ref. 3) on the upper hose (Ref. 4) and
disconnect it from the pump.

Slacken the 4 screws (Ref. 5) and remove the pulley (Ref. 6).

6

2

1

1

3

4

3

5