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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

La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou autre, partiellement ou en totalité, sous quelque format que ce soit est interdite. Les schémas, les dessins, les vues, les commentaires les indications, l’organisation même du document qui sont rapportés dans la présente documentation, sont la propriété intellectuelle de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation exprès et formelle. Tous droits réservés.

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 strafoder 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.

ALLGEMEINE HINWEISE UND SICHERHEIT Group 00 (General characteristics and safety)

1-1

MOTOR Group 10 (Engine)

2-1

OPTIONEN - ANBAUGERÄTE Group 110 (Options - Attachments)

3-1

ANTRIEB Group 20 (Transmission)

4-1

ACHSBRÜCKE - ACHSE Group 30 (Axle)

5-1

BREMSE Group 40 (Brake)

6-1

TELESKOP Group 50 (Boom)

7-1

HYDRAULIK Group 70 (Hydraulic)

8-1

ELEKTRIZITAET Group 80 (Electricity)

9-1

- GENERAL INSTRUCTIONS AND SAFETY NOTICE

GENERAL

00 GENERAL INSTRUCTIONS AND SAFETY NOTICE

pages

- PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - MAINTENANCE POSITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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00-M186EN

General instructions and safety notice PREAMBLE

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. There is a manual in each truck - Follow the safety manual instructions. - Use the adequate tools for all work. - 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 efficient, dependable and profitable 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 specified.

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MAINTENANCE POSITION

Before any repair: 1 – Place the machine on a flat surface and block the wheels. 2 – Turn the engine off and take the key out of the ignition switch. 3 – Let the machine cool down. 4 – Take all the pressure out of the circuits concerned.

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General instructions and safety notice

00-M186EN

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-off. If the forklift truck is not equipped with battery cut-off, disconnect the battery connectors and gather them.

Before carrying out any welding operations, think of disconnecting computers. ECU

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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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-M186EN

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 flat, uniform surface, is sturdy enough to support the load, that its lifting capacity is sufficient 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.

max. min.

MAX

Never adjust a component to over the maximum capacity indicated by the manufacturer.

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ENGINE

- ENGINE CHARACTERISTICS AND SPECIFICATIONS - ENGINE CONTROL AND ADJUSTEMENT

647016EN (Engine 1104 D Euro 3 80 & 100 CV )

10 ENGINE CHARACTERISTICS AND SPECIFICATIONS

pages HIGH PRESSURE FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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10-01-M186EN

Engine characteristics and specifications

HIGH PRESSURE FUEL CIRCUIT

Key: (1) Electronic Unit Injector (2) High pressure fuel collector (3) Fuel level sensor (4) Fuel pressure relief valve (5) Fuel pump (6) Injection pump solenoid (7) Injection pump

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10 ENGINE CONTROL AND ADJUSTMENT

pages TIGHTENING TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – SILENTBLOC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ADJUSTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine control and adjustment

TIGHTENING TORQUE

SILENTBLOC MOTOR

110 N.m ±± 10% 10% 110 N.m

70 10% 70 N.m N.m±±10% 70 N.m ±± 10% 70 N.m 10%

70 70 N.m N.m ±±10% 10%

COOLING CIRCUIT

20 N.m ± 10% 20 N.m ± 10%

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Engine control and adjustment

ADJUSTING PROCEDURE

Fig. A

Fig. B

FUEL GAUGE

- Position the gauge (Item 1) (Fig. A) in the tank so that the spring (Item 2) (Fig. C) enters the housing (Item 3) (Fig. A) provided for this purpose at the bottom of the tank. NOTE: To guide you, you can empty the tank and insert a light through the drain hole 4 (Fig. A).

- A 12 to 14 mm gap A (Fig. B) between the top of the gauge and the tank indicates that the gauge is correctly positioned. If not, reposition the gauge.

Fig. C

- Position the top of the gauge to align the fixing holes with the tappings on the tank. (The gauge can only be fitted one way round as the holes are not equidistantly spaced) (Fig. D). - If necessary remove the remnants of gasket sealant from the fixing screws. - Place a copper washer (Ref. 48 499) under the head of each of the five screws (Item 1) (Fig. D), then fix the assembly to the tank. - Connect the harness. - If removed earlier, re-fit the drain plug, and then re-fill the tank.

Fig. D

1 1 1

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Engine control and adjustment

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CLEANFIX OPTION

pages INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SCHEMATIC DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REPAIR KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

110

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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110-M186C-EN

CleanFix Option

INTRODUCTION

K0 K1 5

K2 K3 K4 1

K9 10A

7.5A 7.5A 7.5A 5A 10A 15A 5A 15A

F30

7.5A 7.5A 7.5A 7.5A 15A 15A 15A

10A

F13 F14 F15 30A

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

110

KIT DE REPARATION REPARATURSATZ KIT KIT DI RIPARAZIONE KIT OF REPAIR KIT EQUIPO REPARACIÃN

110-M186C-EN

25A

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

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CleanFix Option

OPERATION “Clean Fix” is a reversible flow fan: - which draws air in and blows it out - on an automatic cycle Adjustable blades

It allows the direction of the fan blades to change, to create a powerful airflow which cleans the radiator honeycomb and grille (15 s/3 min).

Cooling

110

Cleaning

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110-M186C-EN

CleanFix Option

SCHEMATIC DIAGRAM + batt 12 V

C: Compressor Y1: By-pass Cleanfix unit Y1

batt. earth

110

Stage 1: Having rocked the switch, By-pass closes. Stage 2: Compressor is powered for 15 to 25 seconds (blade orientation and hold) Stage 3: Compressor and By-pass switched off (springs move blades back into position)

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CleanFix Option

REPAIR KIT

If one of the CleanFix fan blades breaks, blades must be changed in sets of three, to stop the fan going out of balance.

- Remove the fan from your machine.

- Remove the nine (M8-80) bolts (A) to the front. - Remove the cover B behind. - Replace the damaged blade as well as the two blades at 120° from it. - Refit the fan and check for smooth operation.

- Blade repair kit Ref. 787966. - It is obligatory to change blades in sets of three (120°).

110

- Repair kit for air intake pipework and 1 spring Ref. 786994

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110-M186C-EN

CleanFix Option

MAINTENANCE

Filter change every 500 hours. Ref.: 781443 1

110

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TRANSMISSION

- TRANSMISSION CONTROL AND ADJUSTMENT

- TRANSMISSION SECTIONS AND DIAGRAMS - SPECIFIC TRANSMISSION TOOLING

647020EN (Gearbox Compact Plus)

- TRANSMISSION CONTROL AND ADJUSTMENT

647058EN

(Angle gear box 15930-15932)

- TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS

- TRANSMISSION CONTROL AND ADJUSTMENT

pages Transmission tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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20-04-M186EN

TRANSMISSION CONTROL AND ADJUSTMENT

Transmission control and adjustment

TRANSMISSION TIGHTENING TORQUE 70 N.m ± 10%

170 N.m ± 10% 37 N.m ± 10%

30 N.m ± 10% 41 N.m ± 10%

60 N.m ± 10%

70 N.m ± 10%

170 N.m ± 10% 37 N.m ± 10% 37 N.m ± 10% 60 N.m ± 10% 60 N.m ± 10%

Standard torque settings to be used when no specific mention is made in dismantling and re-assembly. Torque expressed in N.m (*)

(*)

Thread diameter

Class 5.6

Class 5.8

Class 8.8

Class 10.9

Class 12.9

0,54

0,76

1,16

1,7

1,24

1,74

2,66

3,91

4,57

2,47

3,46

5,2

7,7

4,29

9,1

13,4

15,7

10,4

14,6

M10

M12

111

130

M14

121

178

209

M16

124

189

278

325

M18

122

171

261

384

449

M20

173

243

370

544

637

M22

238

334

509

748

875

M24

298

418

637

936

1095

M27

442

619

944

1386

1622

M30

600

840

1280

1880

2200

- Tightening torques are given for black or zinc-plated fasteners with light lubrication. - Tightening torques are given for automatic slip and reset torque wrenches and direct read dial torque wrenches. - For more information consult French Standard NF E25-030.

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AXLE

- AXLE CONTROL AND ADJUSTEMENT

- AXLE REMOVAL

- AXLE CONTROL AND ADJUSTEMENT M

- AXLE TROUBLESHOOTING - SPECIFIC AXLE TOOLING

547983 (Axle 212)

AXLE CONTROL AND ADJUSTMENT

pages Axle tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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30-04-M186EN

Axle control and adjustment

AXLE TIGHTENING TORQUES MLT 1035 LT LSU 340 N.m ± 10% 340 N.m ± 10% 340 N.m ± 10%

480 N.m ± 10%

63 N.m ± 15%

Standard torque settings to be used when no specific mention is made in dismantling and re-assembly. Torque expressed in N.m (*)

(*)

Thread diameter

Class 5.6

Class 5.8

Class 8.8

Class 10.9

Class 12.9

0,54

0,76

1,16

1,7

1,24

1,74

2,66

3,91

4,57

2,47

3,46

5,2

7,7

4,29

9,1

13,4

15,7

10,4

14,6

M10

M12

111

130

M14

121

178

209

M16

124

189

278

325

M18

122

171

261

384

449

M20

173

243

370

544

637

M22

238

334

509

748

875

M24

298

418

637

936

1095

M27

442

619

944

1386

1622

M30

600

840

1280

1880

2200

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AXLE REMOVAL

pages AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FRONT AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – RE-FITTING FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INTEGRAL ARTICULATION REAR AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – REAR AXLE RE-FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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30-06-M186EN

Axle removal

AXLE ASSEMBLY

340 N.m ± 10% 340 N.m ± 10% 340 N.m ± 10%

480 N.m ± 10%

63 N.m ± 15%

FRONT AXLE REMOVAL - Raise the boom and support it with a prop.

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Axle removal - Remove the two fixing clamps 1 at the axle end of the drive shaft.

- Disconnect the two hoses 1 from the steering ram.

1 1

- Remove the forward chassis cover plate 1. 1

- Disconnect the brake fluid supply pipe 1. - Plug the pipe and the union. - Disconnect the wheel direction sensor wiring 2. 2

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30-06-M186EN

Axle removal - Using a jack, raise the front of the chassis sufficiently to allow the axle to pass underneath. - Place the assembly on a support beam 1 (approx. 800 mm in length) supported by two stands.

Be careful with hoses and wiring underneath the chassis.

- Remove the axle plate fixing bolts 1.

- Wheel the axle forwards under the chassis.

Be careful not to let the axle rotate about the wheels.

RE-FITTING FRONT AXLE - Re-fitting is by reversing the operations described in “REMOVAL OF FRONT AXLE”. - Tighten all fasteners to the torques shown in “TIGHTENING TORQUE SETTINGS”.

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Axle removal

INTEGRAL ARTICULATION REAR AXLE REMOVAL

Remove the rear axle drive shaft - Remove the two clamps 1, one each side of the drive shaft. 1

- Disconnect the two hoses 1 from the steering ram (one on each side). - Plug hoses and unions.

2 2

- Disconnect the flexible brake hose 1. - Plug the hose and the union. - Put the hose to one side above the rear axle. - Disconnect the two greasing pipes 2.

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- Position the telehandler on horizontal ground, handbrake on and shuttle control and gear lever in neutral. - Chock the telehandler and lower the boom.

Axle removal - Remove the strain gauge cover 1.

- Remove the two mounting bolts 2. - Remove the strain gauge and secure in such a way that it will not be subject to load or shock.

- Disconnect the wiring 1 from the wheel direction switch. - Remove the fixing bolts 2 from the swivel point of the rear axle.

Remove only the hook fitted to the telehandler and leave the counter-weight in place. - Coupling ladder

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Axle removal - Raise the rear of the telehandler using a jack and place two stands and a support beam 1 under the chassis at the strong points.

- Remove the two rear wheels. - Remove the mudguard brackets 1. 1

- Arrange a lifting beam 1 above the telehandler. - Secure slings to each side of the axle. 1

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Axle removal - Remove the swivel axle 1 using a slide hammer.

- Lower the axle onto a pallet. - Remove the assembly using a fork lift truck or a pallet truck.

REAR AXLE RE-FITTING - Re-fitting is by reversing the operations described in “REAR AXLE REMOVAL”. - Tighten all fasteners to the torques shown in “TIGHTENING TORQUE SETTINGS”.

When the axle is re-fitted, fit the strain gauge using torque settings and adjust the safety system (see group 80 - ELECTRICITY).

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BRAKE

- BRAKE CHARACTERISTICS AND SPECIFICATIONS - BRAKE COMPONENTS LOCATION - BRAKE CONTROL AND ADJUSTEMENT

- SPECIFIC BRAKE TOOLS

BRAKE CHARACTERISTICS AND SPECIFICATIONS

pages MT-X BRAKE CIRCUIT CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – MT-X 732 – MT-X 1030 ST

(20/05/2011)

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Caractéristiques et spécifications frein

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BRAKE CIRCUIT CHARACTERISTICS MT-X

Brake characteristics and specifications

Disc brake: Brake fluid L.H.M S8 214 B SHELL V=0,75L

Number of discs per wheel

Braking surface per disc side

30,8 cm2

Total braking surface

61,6 cm2

Friction material

Master cylinder ø1’1/8 Cubic capacity: 20,2 cm3

Asbestos-free (CARLISLE CORP.)

Dynamic Friction Coefficient

0,2

Static friction coefficient

0,4

Static application: * Maximum permissible force at brake linkage (Fmax)

1890 N

* Average friction radius (Rmoy)

81 mm

* Max torque (Cmax= 0,014 x Fmax x Rmoy) Make

2143 N.m TURNER POWERTRAIN 203,8 mm

Disc thickness

9,5 mm

Wear adjustment

mechanical

Disc diameter

Braking ratio: 245/61 = 4,016

Towards rear drive axle (same as front drive axle)

Planetary reducer R = 1/6 Oil back brake disc: Number of discs per wheel

Braking surface per disc side

146,85 cm2

Total braking surface (front axle only)

2350 cm2

Total telehandler braking surface

4699 cm2

Pressure of use advised Friction material Dynamic Friction Coefficient

0,115

Static friction coefficient

0,095

Make

201,5 mm

Disc thickness

4,75 - 4,85 mm

Scope of action

88 mm

Slave cylinder surface Wear compensation

(20/06/2011)

DANA

Disc diameter

Number of receiver cylinders

SERVICE BRAKE

70 to 80 bar WELLMAN No.266

Track width

1 41,88 cm2 Auto 26,75 mm

PARKING BRAKE 40-01-M186EN

Brake characteristics and specifications

40-01-M186EN

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BRAKE COMPONENTS LOCATION

pages HYDRAULIC BRAKING CIRCUIT DIAGRAM KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 MT-X HYDRAULIC BRAKING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – MT-X 732 – MT-X 1030 ST

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40-03-M186EN

Brake components location

HYDRAULIC BRAKING CIRCUIT KEY Item

Designation

Feed block + accumulator

Master cylinder

Pump equipment

Steering pump

PFR(O)

Trailer brake plug integrated in the vafr (option)

RLF

Brake fluid tank

Circuit selector

SCFR(O)

Circuit selector (trailer brake option) Tank Movement cut-off valve

VAFR

Trailer brake valve

VAFR(O)

Trailer brake valve (option)

T/R VACM

40-03-M186EN

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MT-X BRAKE CIRCUIT LOCATIONS

Brake components location

V A

S P V1

SCFR

RLF

T LS

VAFR

TIO

MT-X 732 MT-X 1030 ST (20/06/2011)

T-X

PFR 40-03-M186EN

Brake components location

40-03-M186EN

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BRAKE CONTROL AND ADJUSTMENT

pages BRAKE CIRCUIT BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PARKING BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RE-FITTING PARKING BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CHECKING AND ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MT-X SERVICE BRAKE PEDAL HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 6

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Brake control and adjustment

BRAKE CIRCUIT BLEEDING REQUIRED EQUIPMENT: 1 pressurized brake bleeder (pressure 1 to 1,2 bar) Ref. 554 019.

- Raise the jib. - Remove the forward cover plat (Item 1).

- Remove the lower left dashboard cover (Item 2).

- Take the top off the brake fluid reservoir and fit the brake bleeder adapter (Item 3). 3

- Operate the bleed valve.

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Brake control and adjustment

- Place a transparent brake bleeding hose on the left hand bleed nipple (Item 5) on the rear axle (except MT 1033 H L). 4

- Loosen the vent screw, then when the brake fluid flows without air bubbles, retighten the vent screw. - Repeat the operation on the right hand bleed nipple (Item 6) on the rear axle (except MT 1033 H L). As a general rule, when bleeding the brake circuit start with the most distant bleed point and work towards the nearest.

- Carry out the same procedure on the right hand, then left hand bleed nipples (Item 7) on the front axle and then bleed the master cylinder if necessary. 6

- Top up the brake fluid tank level. Fluid to be used: See “CHARACTERISTICS” in chapter “O - GENERAL POINTS”.

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Brake control and adjustment

PARKING BRAKE PAD REMOVAL - Place the forklift truck on horizontal ground, with the handbrake off and in neutral. - Chock the forklift truck.

- Remove the parking brake cable (Item 1). - Remove the caliper upper mounting bolt (Item 2). - Swivel the caliper around the lower bolt (Item 3). 1

- Compress the spring (Item 4) using two screwdrivers. - Remove the pads (Item 5). 5

4 5

RE-FITTING PARKING BRAKE PADS - Re-fitting is the reverse of the operations described in the chapter “PARKING BRAKE PAD REMOVAL”. - Check and adjust the parking brake.

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Brake control and adjustment

CHECKING AND ADJUSTING THE PARKING BRAKE 1

A B

- Place the lift truck on level ground with the rated load in the transport position. - Check braking by locking the parking brake (Item 1) in position A. - Pull on the lift truck rear towing pin with a minimum force of 3500 daN. The wheels of the lift truck must not rotate. - Carry out adjustments if necessary: - Progressively tighten the end of the lever (Item 1) and recheck braking. - Repeat the operation until the correct braking adjustment is obtained. For non HRT approved lift truck - Place the lift truck on a slope less than 15% with the rated load in the transport position. - Check braking by locking the parking brake (Item 1) in position A. - The adjustment is correct when the lift truck is held stationary on a slope. - Carry out adjustments if necessary: - Press the service brake pedal, then release the parking brake moving the lever (Item 1) to position B. - Progressively tighten the end of the lever (Item 1) and recheck braking. - Repeat the operation until the correct braking adjustment is obtained.

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For public highway certified telehandlers

Brake control and adjustment

MT-X SERVICE BRAKE PEDAL HEIGHT ADJUSTMENT

1) - BRAKE PEDAL - Adjust the height of the pedal (Item A) from the cab floor without mats, to 140 mm for MLT and 155 mm for MT, using the stop (Item B). - Tighten the locknut (Item E). - Adjust the pedal free play (Item A) (3 to 4 mm) by turning the pushrod (Item C). - Tighten the locknut (Item D).

- Pedal in its rest position, against the stop (Item B). - Adjust the switch position (Item F) so that the transmission cut-off activates when the pedal is 125 mm high for MLT and 130 mm high for MT measured from the cab floor (see diagram).

B C D

Pedal free play 3 to 4 mm

A F 155 mm 130 mm

2) - TRANSMISSION CUT-OFF SWITCH

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SPECIFIC BRAKE TOOLING

pages HYDRAULIC BRAKE BLEED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

(22/06/2011)

40-09-M186EN

Specific brake tooling

HYDRAULIC BRAKE BLEED VALVE

Bleed valve supplied with all the components required for bleeding the hydraulic brake circuits of all Manitou products.

MANITOU Reference Hydraulic brake bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019 Spare parts: Top manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980 Bottom manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981 Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913 Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914

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BOOM

- BOOM CONTROL AND ADJUSTEMENT

- BOOM REMOVAL

BOOM CONTROL AND ADJUSTMENT

pages MLT 1035 LT LSU - Complete boom exploded diagram . . . . . . . . . . . . . . . . . . . . . . . 3 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

– Bleeding and filling boom extension cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 6 – Hose mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – Instructions for mounting slide pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – Instructions for slide pad greasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – Instructions for pivot greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – Instructions for greasing the boom interior . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal of crowd and accessory circuit hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – Checking the coiling of hoses inside the boom . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal of intermediate boom cylinder hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 – Checking the coiling of hoses inside the boom . . . . . . . . . . . . . . . . . . . . . . . . 18 Crowd cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inner boom extension cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 – Checking the coiling of hoses inside the boom . . . . . . . . . . . . . . . . . . . . . . . . 28 Removal of intermediate boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Clamp fork removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Inner boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Intermediate boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Complete boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 – Re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

MLT 634, MLT 731, MLT 735, MLT 741 Adjusting and shimming the boom slide pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal of twin hoses from the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 – Removal of twin hoses from the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 – Re-fitting twin hoses in the boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Crowd cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 – Crowd cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 – Crowd cylinder re-fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Clamp fork removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

– Clamp fork removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 – Fork clamp re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Boom extension cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 – Boom extension cylinder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 – Boom extension cylinder re-fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 – Boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 – Re-fitting the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Boom control and adjustment

MT-X 1030 ST - COMPLETE BOOM EXPLODED DIAGRAM

HYDRAULIQUE (Circuit flèche) HYDRAULIK (Auslegerkreis) HIDRAULICO (Circuito aguilón) HYDRAULIC (Jib circuit) IDRAULICO (Circuito bracci telescopici)

A B D

C B

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50-04-M186EN

Boom control and adjustment

HYDRAULIQUE (Circuit levage - Télescopage) HYDRAULIK (Aufwinden - Zusammenstroll kreis) HIDRAULICO (Circuito levantamiento -Teleccopaje) HYDRAULIC (Lifting - Teslescope circuit) IDRAULICO (Circuito sollevamento - braccio) ION AT AR EP ER ION ED AC AIR SATZ EPAR S S CE TUR E R NE ARA IO D P R RE ESA IT NE C K NE AIR RAZIO P PA E R RE IT K

ION AT AR EP ER ION E D Z RAC IR T A A SS SA EP CE TUR E R NE ARA IO D P R RE ESA IT NE C K NE AIR RAZIO P RE REPA KIT

HYDRAULIQUE (Circuit télescopage) HYDRAULIK (Zusammenstroll kreis) HIDRAULICO (Circuito teleccopaje) HYDRAULIC (Teslescope circuit) IDRAULICO (Circuito braccio)

N TIO RA PA RE N DE CIO E A AIR TZ AR SS SA EP CE TUR E R NE ARA IO D P R RE ESA IT NE C K NE AIR RAZIO P RE REPA KIT

36 35

34 36

ION AT AR EP N ER IO D E AC AIR TZ AR SS SA EP CE TUR E R NE ARA IO D P R RE ESA IT NE C K NE AIR RAZIO P RE REPA KIT

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Boom control and adjustment

HYDRAULIQUE (Circuit compensation - alimentation flèche) HYDRAULIK (Kompensation - Ausleger zuschiebung kreis) HIDRAULICO (Circuito compensación - alimentación aguilon) HYDRAULIC (Compensation - jib feed circuit) IDRAULICO (Circuito compensazione - Alimentazione bracci telescopici)

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Boom control and adjustment

RECOMMENDATIONS BLEEDING AND FILLING BOOM EXTENSION CYLINDERS - This operation is to be carried out when one of the boom extension cylinders has been removed or disconnected from its hydraulic oil supply. - Start the engine and completely retract the boom while maintaining pressure on the control block lever in order to fill the cylinders. Then slightly extend the boom, then retract it again. NOTE: To ensure correct simultaneous extension, you must regularly completely retract the boom.

HOSE MOUNTING INSTRUCTIONS - When you re-fit or replace a hose, you must always allow it to follow its natural coiling direction. Connections must be made without twisting or strain, so that the hose uncoils inside the boom without excessive twisting.

NOTE: The markings stamped on the hose ends must be positioned to the outside of the coiling direction

Marking

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Boom control and adjustment

INSTRUCTIONS FOR MOUNTING SLIDE PADS

Shim Slide pad 3 1

9 mm minimum

- When selecting bolts, ensure a minimum of 9 mm protrudes beyond the nut. - Apply normal Loctite to the stud/insert and nut/stud on all slide pad fittings that are inaccessible from the outside of the boom. - Screw the stud 1 by hand to the end of the thread on the insert 2. - Fit the nut 3. - Shim, then tighten the nut to a torque of 92,6 N.m ± 25%. - After shimming, play should be between 0 and 0,5 mm for all slide pads.

Clearance

NOTE: For fitting side slide pads special tool Ref. 552 829 should be used.

INSTRUCTIONS FOR SLIDE PAD GREASING This must be done when new slide pads are fitted to the boom. NOTE: To be done every 10 hours for the first 50 hours then one last time after 250 service hours. - Extend the jib completely. - Using a paintbrush, apply grease to all 4 sides of the boom sections. - Extend and retract the jib several times in order to spread the coat of grease evenly. - Remove the surplus of grease. Recommended grease: MANITOU multi-purpose NLGI Grease Ref. 161 590. If the telehandler is used in an abrasive atmosphere (dust, sand, coal) use an anti-friction coating (MANITOU Ref.: 483 536) available from your Manitou dealer.

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Boom control and adjustment

INSTRUCTIONS FOR PIVOT GREASING Greasing bushed pivots: - For new parts, fill all hollows or holes in the bushings with grease. - Apply a thin film of grease to the pin eyes. - Check for correct operation, then re-grease. Greasing pivots without bushings: - Apply a thin film of grease to the pin eye in unbushed bearings. Recommended grease: MANITOU Multi-purpose HD NLGI 2 Grease Ref. 554 973.

INSTRUCTIONS FOR GREASING THE BOOM INTERIOR

To be carried out after: - Fitting new hoses. - Fitting a new outer boom. - Outer boom cleaning.

- Completely extend the boom sections and grease the lower part of the outer boom over its entire length and width to ease the movement of hoses inside the boom. Recommended grease: MANITOU multi-purpose NLGI Grease Ref. 161 590.

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Boom control and adjustment

REMOVAL OF CROWD AND ACCESSORY CIRCUIT HOSES NOTE: The procedure below describes how to change the accessory circuit hoses; the procedure is identical for the crowd circuit. - Remove the two covers 1 at the back of the boom. 1

- Remove the two pads 1 only for 1st and 2nd generation machines. - Remove the hose guide 2.

- Remove the upper hose bracket 1.

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Boom control and adjustment - Extend the crowd cylinder 1 rod to half its length.

- Remove the inner boom cover plate 1.

- Depressurise the hydraulic circuit. - Disconnect and plug the accessory circuit hoses 1.

- Remove the hoses 1 through the back of the boom.

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Boom control and adjustment

3 4

- To make it easier to remove the hoses and brackets under the boom, disconnect and plug the intermediate boom extension cylinder feed hoses 1 and remove the clamps 2. - Have a recipient ready to catch the oil. - Remove the hose bracket 3 and recover the brackets from inside the boom. - Disconnect the two hoses 4.

- Take out the two hoses 1 passing them underneath the boom. 1

RE-FITTING - Re-fit the hoses 1 in the outer boom and connect them to the metal pipes. - Re-fit the hose bracket 2 with the clamps to the inside of the boom.

2 1

NOTE: - Bent or mis-shaped brackets should be changed. - Hoses 3 should be clamped in their original locations.

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Boom control and adjustment

2 1

NOTE: When re-fitting the bracket 1, ensure it does not overlap the clamp 2.

Good

- Re-connect the two boom extension cylinder hoses 1, then re-fit the the two clamps 2.

2 1

Bad

- Pull the hoses through the back of the boom and lay them totally flat and aligned with the telehandler. - Take the hoses one by one (ensuring they are not twisted) and put them in the boom head. When resistance is felt twist them to pass them above the crowd cylinder, then release.

- Connect the hoses at the inner boom.

- Re-fit but do not tighten the bracket 1.

NOTE: Bent or mis-shaped brackets must be changed. - Start the engine and move the accessory and crowd circuit lever. (Under pressure, the hoses go automatically to the right places). - Stop the engine, then depressurize the hydraulic circuits.

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Boom control and adjustment

1st fitting

Boom extension hoses

135

Crowd/accessory hoses

125

2nd fitting

148

Crowd/accessory hoses

138

Boom extension hoses

- Checking boom extension hose clearances. - Adjust the crowd and accessory cylinder hose clearance to that shown. NOTE: • Clearances are measured between the back of the cylinder and the back of the hose. This is the MAXIMUM clearance. • 1st GENERATION: The back of the cylinder is a machined part. • 2nd GENERATION: The back of the cylinder is a cast part. - Tighten the bracket 1 without bending it. - Re-fit the hose guide 2. - Re-fit the two blocks 1 if applicable. BLEED THE CIRCUIT: See “Bleeding and filling boom extension cylinders”. GREASING: See “Instructions for greasing the inside of the boom”. - Check the hydraulic oil level. - Put the fork clamp through its complete range of movement several times. - Check that all hoses are correctly located. - Check for leaks.

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Boom control and adjustment

CHECKING THE COILING OF HOSES INSIDE THE BOOM

- Extend the boom to its full extent. - Retract the boom sections, checking that hoses coil correctly. - The hoses must roll up while remaining vertical. - If you note that one or more hoses twists to the side as it rolls, re-check the orientation of the hose ends. - Repeat the operation until hoses roll up correctly. - Re-fit the two covers 1 at the back of the boom.

GOOD

BAD

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Boom control and adjustment

REMOVAL OF INTERMEDIATE BOOM CYLINDER HOSES - Remove the two covers 1 at the back of the boom.

- Depressurize the boom hydraulic circuit. - Remove the clamps 1on each side of the boom base section. - Disconnect and plug the hoses 2 from the boom extension cylinder. - Have a recipient ready to catch the oil.

- Remove the hose bracket 1 and recover the clamps inside the boom. - In case of difficulty removing the clamps from inside the boom, disconnect the U-bend 2.

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Boom control and adjustment - Disconnect and plug the hoses 1 from the boom extension cylinder. - Remove the hoses.

1 1

RE-FITTING - If you are fitting new hoses place a reference mark A (using adhesive tape) at the distance from the end of the hose shown below. - If you are re-fitting existing hoses, check and if necessary reposition a reference mark at the right distance from the end of the hose

NOTE: The hose reference number is marked on one of its end fittings.

3530 mm (2nd generation hose - Ref.: 243 821 lg 4500) 3470 mm (1st generation hose - Ref.: 232 004 lg 4420)

- Fit the hoses 1 in the boom and connect them to the back of the cylinder, following their roll direction, see “Instructions for fitting hoses”. - Re-fit the hose bracket 1 with the clamps inside the boom. - Place mark A on the hose (see above) in the intermediate of the interior clamp 1. - Tighten the hose clamps (do this before reconnecting the hoses 2 to avoid them twisting inside the boom). NOTE: Bent or deformed brackets must be replaced.

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Boom control and adjustment

2 1

NOTE: When re-fitting the bracket 1, ensure it does not overlap the clamp 2.

Good

2 1

Bad

ø 16 mm

- Re-connect the boom extension cylinder hoses 2. 1

NOTE: Befor reconnecting the hoses to the boom extension cylinder, check the sealing rings on the pipes 1 are in good condition and change them if necessary. Ref. Sealing rings: 169 438

- Re-fit the two clamps 1.

BLEED THE CIRCUIT: See “Bleeding and filling boom extension cylinders”. GREASING: See “Instructions for greasing the inside of the boom”.

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Boom control and adjustment

CHECKING THE COILING OF HOSES INSIDE THE BOOM

GOOD

BAD

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Boom control and adjustment

CROWD CYLINDER REMOVAL - Remove the inner boom cover plate 1.

- Depressurise the hydraulic circuit. - Disconnect and plug the crowd cylinder 1 hoses. 1

- Extend the boom sections by about one metre to improve accessibility. - Extend the crowd cylinder cylinder rod to half its length. - Remove the crowd cylinder head clevis pin 1. - Use a metal bar 2 to stop the clamp fork from rotating.

1 2

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Boom control and adjustment

- Put a metal bar 1 through the cylinder rod end. - Secure a chain on each side. - Remove the clevis pin 2 from the base of the cylinder. - Place a pallet under the cylinder. - Slowly lower the cylinder.

- Lay the cylinder 1 flat on the pallet.

The cylinder is heavy. Take care when laying it flat.

RE-FITTING - Re-fit the cylinder, takin care not to knock the rod or valve. NOTE: The crowd and accessory circuit hoses must pass above the base of the cylinder. - Re-fit the clevis pins and their locking devices. - Re-connect the hoses to the cylinder. - Re-fit the cover plate 1.

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Boom control and adjustment

INNER BOOM EXTENSION CYLINDER REMOVAL - Ensure there is clear space 3 m in front and 4 m behind the telehandler. - Remove the two covers 1 at the back of the boom.

- Raise the boom to its maximum elevation. - Remove the two circlips from the boom extension cylinder 1 clevis pin. - Put the boom in its horizontal position.

- Remove the inner boom cover plate 1.

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Boom control and adjustment

- Depressurize the boom hydraulic circuit. - Disconnect and plug the crowd circuit 1 hoses and, if fitted, the accessory circuit 2 hoses.

2 2

- Remove the hose bracket 1 from the back of the boom head. - Put to one side the crowd circuit hoses 2 and, if fitted, the accessory circuit hoses, 3 through the back of the boom.

- Extend the boom sections by 60 cm approx. - Remove the inner boom extension cylinder clevis pin 1. - Retract the intermediate boom.

1 1

- Disconnect and plug the hoses 1 from the boom extension cylinder. - Have a recipient ready to catch the oil. NOTE: The aim of this procedure is to avoid hydraulic oil being sprayed inside the boom when you disconnect the hoses from the back of the boom head extension cylinder.

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Boom control and adjustment

- Remove the optional movement cut-off switch 1 if your telehandler is so equipped.

- Disconnect and plug the two boom extension cylinder supply hoses 1. - Plug the two unions on the cylinder valve. - Remove the two blocks 2 only for 1st and 2nd generation machines. - Remove the hose guide 3.

- Remove the left hand rear light bracket 1.

- From the left, drive the clevis pin 1 out from the base of the cylinder, so that it exits through the hole 2 in the chassis. - Remove the clevis pin 1. 1 2

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Boom control and adjustment

- Slightly raise the boom (max. 5°). - Lever the extension cylinder 1 towards the back. - Use a bar 2 to lock the cylinder in place at the back of the boom base section (to stop the cylinder moving into the boom when the intermediate boom section is extended).

1 2

- Remove the clevis pin 1 from the head of the intermediate boom section cylinder. - Extend the boom head 2 by 2 m. - Extend the intermediate boom 3 by 0,70 m.

- Continue by removing the boom extension cylinder 1 through the back of the machine. - If you notice resistance, place a bar 2 through the foot of the cylinder and use rotary movements to pass the guides of the cylinder head A over the inner boom slide pad fixings. 1

- Sling the cylinder and completely remove it. 1 1

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Boom control and adjustment

RE-FITTING 1st GENERATION

NOTE: Before re-fitting the boom extension cylinder, check the head orientation. - Re-fit the cylinder in the boom.

GOOD

BAD

2nd GENERATION

GOOD

BAD

- Stop any backwards motion by the cylinder using a bar 1. - Retract the intermediate boom 3. - Re-fit the intermediate boom cylinder head clevis pin 1. - Retract the inner boom 1. - Re-fit the clevis pin 1, carefully centring it in the intermediate boom section. - Re-fit the hose guide 3. - Re-fit the two slide pads 2, if applicable. - Re-connect the hoses 1 to the back of the cylinder.

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- When resistance is felt, place a bar 2 through the foot of the cylinder and use rotary movements to insert the cylinder head into the boom head and then to pass the guides of the cylinder head A (1st model cylinder) over the inner boom slide pad fixings.

Boom control and adjustment

1 2

- Position the crowd cylinder 1 and accessory circuit 2 hoses (if present) totally flat and aligned with with the telehandler. - Take the hoses one by one (ensuring they are not twisted) and put them in the inner boom. When resistance is felt twist them to pass them above the crowd cylinder, then release. - Re-fit but do not tighten the clamp 3. - Re-connect the hoses in the inner boom. - Re-connect the hoses 1 to the boom extension cylinder

BLEED THE CURCUIT

- Start the telehandler. - Extend the intermediate boom section 20 cm. - Retract the intermediate boom and maintain pressure for approximately ten seconds. - Extend the inner boom (using a hoist or other lifting equipment). - Re-fit the boom extension cylinder head clevis pin 1 and its circlips. - Raise the boom to its maximum elevation and re-fit the boom extension cylinder base clevis pin 1 circlips. - Lower the boom. - Move the accessory and crowd circuit lever (under pressure the hoses will automatically take up the correct position). - Stop the engine, then decompress the hydraulic circuits.

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Boom control and adjustment

1st fitting

Boom extension hoses

135

Crowd/accessory hoses

125

2nd fitting

148

Crowd/accessory hoses

138

Boom extension hoses

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Boom control and adjustment

CHECKING THE COILING OF HOSES INSIDE THE BOOM

GOOD

BAD

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Boom control and adjustment

REMOVAL OF INTERMEDIATE BOOM - Sling the cylinder 1.

- Depressurize the boom hydraulic circuit. - Disconnect the two hoses 2. - Remove the clevis pin 3 from the cylinder head. - Remove the U clamp 4.

4 2 2

- Disconnect the two cylinder supply hoses 5. - Remove the cylinder base clevis pin 6. - Remove the intermediate boom 1. 5

RE-FITTING - Carry out the operations described above in reverse order. BLEED THE CIRCUIT: See “Bleeding and filling boom extension cylinders”.

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Boom control and adjustment

CLAMP FORK REMOVAL - Remove the crowd cylinder head clevis pin 1. - Sling the clamp fork 2. - Remove the clamp fork pivot pin 3. - Remove the clamp fork 2.

The clamp fork is heavy. Take appropriate precautions when removing it.

RE-FITTING - Carry out the operations described above in reverse order.

GREASING: See “Instructions for pivot greasing”.

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Boom control and adjustment

INNER BOOM REMOVAL - Remove the fork clamp; see chapter “Fork clamp removal”. - Remove the crowd cylinder, see chapter “Crowd cylinder removal”. The operations described below are only to be undertaken when the inner boom is to be replaced. - Remove the boom extension cylinder from the inner boom, see chapter “Boom Head Extension Cylinder Removal”. - Remove the bracket mounting 1. - Remove the fixings from the side 2 and upper 3 slide pads. - Take note of and recover spacers and slide pads.

- Take note of and remove side and upper 1 slide pads and spacers from the intermediate boom section. - Sling the boom and slightly lift it, then take note of and remove the slide pads and spacers 2.

- Sling the boom head, then remove it.

- The centre of gravity of the bare boom is approximately 1000 mm from the attachment point of the base of the crowd cylinder.

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Boom control and adjustment

- The centre of gravity of the boom with fork clamp and crowd cylinder fitted is approximately 470 mm from the attachment point of the base of the crowd cylinder.

RE-FITTING

3 3

NOTE: The final shimming of the upper and side slide pads is carried out with the inner boom in place in the intermediate boom.

- Re-fit the lower slide pads 1 and spacers (if fitted). - Re-fit the side slide pads 2 and upper slide pads 3 without spacers.

1 1

- Fit the inner head in the intermediate boom. - Shim the slide pads at the back of the boom, see “Instructions for fitting slide pads”. - Re-fit the bracket mounting 1. - Re-fit the slide pads and spacers to the head of the intermediate boom, see “Instructions for fitting slide pads”. - Re-fit the boom head extension cylinder, see chapter “Boom head extension cylinder removal”. If applicable: - Re-fit the crowd cylinder, see chapter “Crowd cylinder removal”. - Re-fit the clamp fork, see chapter “Clamp fork removal”.

GREASING: see the chapter “Instructions for slide pad greasing”.

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Boom control and adjustment

INTERMEDIATE BOOM REMOVAL

- Remove the inner boom, see chapter “Inner boom removal”.

- Remove the side 1 and upper 2 slide pad fixings. - Take note of and recover spacers and slide pads.

- Remove and take note of the side and upper 1 slide pads and spacers at the outer boom. - Sling the intermediate boom 2, raise it slightly, then remove the slide pads and spacers 3.

1 4

NOTE: To facilitate the removal of the alignment collars 4 use a piece of 19 mm diameter rod between the guide and the intermediate boom.

3 3

1 3

- Remove the fixing clamps from the hoses 1 on both sides of the boom. - Disconnect the U-bend 2 under the base of the boom. - Remove the brackets 3 to avoid any possible interference with the intermediate boom lower slide pads.

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Boom control and adjustment

- Sling the intermediate boom and then remove it. NOTE: The centre of gravity of the intermediate boom is approximately 1620 mm from the lower tapping 1.

RE-FITTING 1st and 2nd generations

1st and 2nd generations: - Re-fit the lower slide pads 1 and spacers (if fitted). - Re-fit the side 2 and upper 3 slide pads, without spacers. - Re-fit the two slide pads 4.

3 2 2

4 1 1

3rd generation

- Re-fit the lower slide pads and spacers 1. - Re-fit the side 2 and upper 3 slide pads, without spacers.

3 3

2 2

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3rd generation:

NOTE: Final upper and side slide pad spacing is carried out when the intermediate boom section is in place in the outer boom. - Fit the intermediate boom in the base of the boom.

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Boom control and adjustment

- Position the clamps 1.

2 1 4

Good

NOTE: When re-fitting the upper bracket 1 ensure that it does not overlap the clamp 2.

1 2

- Re-connect the U-bend 3. - Tighten the clamps 1. - Re-fit the hose 4 clamps on both sides of the boom.

Bad

- Shim the slide pads at the back of the intermediate boom section. See chapter “Slide pad fitting instructions”. - Re-fit the slide pads and spacers at the head of the boom base. See chapter “Slide pad fitting Instructions”.

- Re-fit the inner boom. See chapter “Inner boom removal”.

GREASING: see chapter “Instructions for greasing slide pads”.

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Boom control and adjustment

COMPLETE BOOM REMOVAL

4 1 4

- Raise the boom sufficiently to gain access to the compensating cylinder 1. - Depressurize the boom hydraulic circuit. - Disconnect and plug the two hoses 2 from the extension cylinder. - Remove the clamps 3. - Disconnect and plug the two or four (as fitted) hoses 4 from the accessory and crowd circuit. - Remove the compensating cylinder pivot pin 1. - Retract the compensating cylinder rod then swivel the cylinder towards the back of the chassis.

- Position the boom 1 as shown. - Sling the boom using the forward eyes 2 provided for this purpose.

- Position a block 1 under the elevating cylinder 2. - Remove the elevating cylinder 3 pivot pin. - Retract the elevating cylinder rod.

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Boom control and adjustment

- Remove the boom pivot pin 1. - Lift the complete boom away, taking care not to knock it against the cab or chassis. 1

RE-FITTING Carry out the operations described above in reverse order. GREASING: see “Instructions for greasing pivots”.

GREASING: see “Instructions for greasing the inside of the boom”.

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Boom control and adjustment

MT-X 732 ADJUSTMENT AND SHIMMING OF BOOM SLIDE PADS - Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in neutral. - Put the boom in the horizontal position. FORWARD SLIDE PADS - Extend about 200 mm and measure the play on the lower, upper and side slide pads (Permissible play: 0 to 0,5 mm).

0 to 0,5 mm

- If necessary, fit spacers. - Completely unscrew the nuts 1. - Add spacers as necessary, balancing the thicknesses on both sides of the boom.

NOTE: Spacers are available in the following sizes: 0,5; 1; 2 and 4 mm. 1

NOTE: For side slide pads use MANITOU tool Ref. 552829.

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Boom control and adjustment

- Ensure that the studs 1 are well tightened to the bottom of the thread. - Re-fit the nuts 2 and tighten to 92,6 N.m ± 25%.

2 1 2

REAR SLIDE PADS - Remove the rear cover plate.

- Completely retract the boom and measure the play on the lower, upper and side slide pads. (Permissible play: 0 to 0,5 mm).

0 to 0,5 mm

- If necessary, fit spacers. - Completely unscrew the nuts 1. - Add spacers as necessary, balancing the thicknesses on both sides of the boom.

1 1

NOTE: Spacers are available in the following sizes: 0,5; 1; 2 and 4 mm.

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Boom control and adjustment NOTE: For side slide pads use MANITOU tool Ref. 552829.

1 2 1

- Ensure that the studs 1 are well tightened to the bottom of the thread. - Apply thread locking compound MANITOU Ref. 187526 to the nuts 2 and tighten to 92,6 N.m ± 25%.

2 2

- Re-fit rear cover.

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Boom control and adjustment

REMOVAL OF TWIN HOSES FROM THE BOOM REMOVAL OF TWIN HOSES FROM THE BOOM - Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in neutral. - Place the boom in its horizontal position and extend it 130 mm. - Switch on the telehandler ignition and remove the pressure in the crowd and accessory circuits by repeatedly activating the hydraulic controls.

- Overview of twin hose location.

- Remove the rear cover plate. - Put the lower back plate to one side.

- Place a recipient under the twin hoses. - Remove the fixing clamps 1, take note of the hose connections then disconnect them and plug the openings.

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Boom control and adjustment - Take note of the accessory 1 and crowd circuit 2 twin hose connections, disconnect them and plug the openings. 1

- Use adhesive tape to tightly tape the hoses together.

- Pull the hoses towards the front by the U-bends and completely remove them in a controlled manner.

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Boom control and adjustment

RE-FITTING TWIN HOSES IN THE BOOM - Re-fitting is by carrying out the operations described in the chapter “Removal of twin hoses from the boom” in reverse order, paying attention to the following points.

- Place the hoses in front of the boom with the U-bends pointing downwards: - the longer hoses are for the accessory circuit, - the shorter hoses are for the crowd circuit.

NOTE: When replacing old twin hoses with new ones, take note of the hydraulic connections of the old twin hoses and use this as a reference for fitting the new ones.

- Insert the twin hoses from underneath, as far as the back of the boom.

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- Working at the back of the boom, slide the hoses into the upper guide 1 and continue to insert them.

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- Tightly tape the twin hoses together at the end with the straight fitting 1, using adhesive tape.

Boom control and adjustment - At the inner boom, recover the hoses, remove the adhesive tape and re-connect them.

- Check the clearance between the hoses and the boom extension cylinder pin. - Test the boom for correct operation.

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Boom control and adjustment

CROWD CYLINDER REMOVAL CROWD CYLINDER REMOVAL - Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in neutral. - Put the boom in its horizontal position. - Switch on the telehandler ignition and depressurize the crowd circuit by repeatedly activating the hydraulic control.

- Take note of the crowd circuit twin hose connections, then disconnect them and plug the openings.

- Remove the electric cable reel bracket 1 if fitted. - Remove the crowd cylinder base pin 2. 1

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300 mm

Do not extend the crowd cylinder rod more than 300 mm so that it can be disengaged from the boom head.

Boom control and adjustment - Lash the crowd cylinder to the boom head.

- Using a hoist, for example, tilt the fork clamp in the crowd backward direction so that the crowd cylinder comes away from the boom head and place it on a block.

Take care with the weight of the crowd cylinder.

- Block the crowd cylinder under its rod. - Remove the cylinder head clevis pin and disengage the cylinder. Take care with linkages moving when the crowd cylinder head clevis pin is removed.

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Boom control and adjustment

CROWD CYLINDER RE-FITTING - Re-fitting is by carrying out the operations described in the chapter “Crowd cylinder removal” in reverse order, paying attention to the following points: - Test the crowd cylinder for correct operation. 2 1

- Before re-fitting pivot and clevis pins 1, clean them and apply a thin coat of grease. See chapter: “Telehandler characteristics” in section “0 - General Points”.

- Also clean and grease the pivots 2 with the same grease.

2 1

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Boom control and adjustment

CLAMP FORK REMOVAL CLAMP FORK REMOVAL - Remove the crowd cylinder before removing the fork clamp.

- Disconnect the hydraulic locking cylinder hoses at the solenoid valve and at the valve (optional).

- Sling the form clamp and remove the pivot pin.

- Remove the fork clamp.

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Boom control and adjustment

FORK CLAMP RE-FITTING - Re-fitting is by carrying out the operations described in the chapter “Fork clamp removal” in reverse order, paying attention to the following points.

1 2

2 - Before re-fitting the pivot pin 1, clean it and apply a thin coating of grease. See chapter: “Telehandler characteristics” in section “0 - General Points”.

(21/06/2011)

- Also clean and grease the pivots 2 with the same grease.

50-04-M186EN

Boom control and adjustment

BOOM EXTENSION CYLINDER REMOVAL BOOM EXTENSION CYLINDER REMOVAL - Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in neutral. - Put the boom in the horizontal position.

- Extend the boom sufficiently to gain access to the head of the boom extension cylinder. - Switch the telehandler ignition on and depressurize the boom extension circuit by repeatedly activating the hydraulic control. - Remove the circlip and remove the boom extension cylinder head pin.

- Remove the rear cover plate.

- Put the lower back plate to one side.

- Remove the hydraulic pipe clamps.

- Unscrew the hydraulic pipes from the extension cylinder.

- Line the cylinder base pin up with the opening in the plate.

- Remove the circlip and remove the extension cylinder base pin.

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Boom control and adjustment

- Pull the extension cylinder out about 1 m and sling it with a strap.

- Completely remove the extension cylinder ensuring it is appropriately slung at its centre of gravity and that it is carefully removed.

BOOM EXTENSION CYLINDER RE-FITTING - Re-fitting is by carrying out the operations described in the chapter “Boom extension cylinder removal” in reverse order, paying attention to the following points: - Test the extension boom for correct operation.

1 2 - Before re-fitting the pivot pins 1, clean them and apply a thin coating of grease (see chapter: “Telehandler characteristics” in section “0 - General Points”). - Also clean and grease the pivots 2 with the same grease. (21/06/2011)

50-04-M186EN

Boom control and adjustment

BOOM REMOVAL BOOM REMOVAL - Before removing the boom carry out the following operations: • Remove the boom twin hoses. • Remove the crowd cylinder. • Remove the fork clamp. • Remove the extension cylinder.

- Disconnet the wiring from the reel at the solenoid valve in the boom head and put it to one side (option).

- Remove the wiring bracket (option).

- Hold the by-pass return hose, remove it and guide it round its reel (option).

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Boom control and adjustment

- Remove the electrical and hydraulic reel (option).

- Sling the boom, paying attention to distance “A”, depending on the options fitted to the telehandler.

6 m boom - Bare boom. A = mm - Boom with jib head solenoid valve. A = 780 mm 7 m boom - Bare boom. A = mm - Boom with jib head solenoid valve. A = mm

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- Put a bar through the opening in the head of the extension cylinder, for example, and extend the boom until the rear slide pads just butt up against the front ones.

Boom control and adjustment - Remove all slide pads and spacers on the inner boom, taking careful note of their positions for re-fitting.

- Take the section completely out and remove it.

- Remove all slide pads and spacers from the base of the section, taking careful note of their positions for re-fitting.

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Boom control and adjustment

RE-FITTING THE BOOM - Re-fitting is by carrying out the operations described in the chapter “Boom removal” in reverse order, paying attention to the following points:

STUD

- Cross-section of all boom slide pads fitting.

NUT SPACER INSERT

1 2 1 2

Rear boom slide pads: - Apply MANITOU thread locking compound Ref. 187526 to the end of the studs 1 and screw them to the bottom of the thread. - Apply MANITOU thread locking compound Ref. 187526 to the nuts 2 and tighten them to torque 92,6 N.m ± 25%.

1 1

Front slide pads on outer boom: - For the side slide pads us MANITOU tool Ref. 552829.

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SLIDE PAD

Boom control and adjustment - Screw the stud 1 in to the bottom of the thread. - Tighten the nuts 2 to 92,6 N.m ± 25%.

2 1 2

1 2

- Pre-load the reel with one and half turns before reconnecting the by-pass return hose.

- After re-fitting all boom components, adjust and shim the boom slide pads and verify the correct operation of the boom.

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BOOM REMOVAL

pages Complete boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– Complete boom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – Re-fitting the whole boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(21/06/2010)

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Boom removal

COMPLETE BOOM REMOVAL COMPLETE BOOM REMOVAL - Place the telehandler on horizontal ground, handbrake on, shuttle control and gear lever in neutral. - Completely retract the boom. - If an accessory is mounted on the clamp fork, remove it. NOTE: The removal shown is for a 6 m boom, but the procedure is identical for a 7 m boom.

- Switch on the telehandler ignition and depressurize the crowd, boom extension and accessory circuits by repeatedly activating the hydraulic controls.

- Raise the boom sufficiently to gain access to the compensation cylinder head pin 1 and the elevation cylinder head pin 2. 2

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- Sling the boom using the ring nearest the jib.

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Boom removal

- If fitted, disconnect the electric reel at the jib, cut the plastic clips along the boom and put the wiring to one side towards the rear.

- If fitted, remove the hydraulic reel hose from the jib, cut the clips along the boom and put it to one side towards the rear.

- Remove the rear cover plate.

- Unscrew the hydraulic pipes from the extension cylinder.

- Disconnect the four crowd and accessory circuit hoses and move them aside.

- Lash the elevating cylinder to the boom, remove the circlip and remove the cylinder head clevis pin using a slide hammer.

- Securely chock the cylinder in place and remove the lashing.

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Boom removal

- Remove the compensation cylinder head clevis pin using a slide hammer. - Support the boom under the fork clamp using a crane, to avoid it tipping when the boom pivot pin is removed. - Remove the boom pivot pin. Take note of the positioning of spacers (if fitted) on each side of the boom, then remove them.

- Carefully remove the whole boom.

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Boom removal

RE-FITTING THE WHOLE BOOM To re-fit the boom carry out the operations described in the chapter “WHOLE BOOM REMOVAL”, paying attention to the following points.

2 2 1

2 2

- Before re-fitting pivot pins 1, clean them and lightly grease them (See chapter: TELEHANDLER CHARACTERISTICS in group 0 - GENERAL POINTS).

- Also clean and grease the pivots 2 with the same grease.

- Re-fit the spacers 3 if fitted and re-fit the pivot pin.

3 3

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Boom removal

STANDARD TIGHTENING TORQUE TO BE USED WHEN NOT SPECIFICALLY MENTIONED IN REMOVAL AND RE-FITTING PROCEDURES.

Thread diameter M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 (*)

Class 5.6 0,54 1,24 2,47 4,29 10,4 20 35 57 88 122 173 238 298 442 600

TIGHTENING TORQUE (*) Class 5.8 Class 8.8 0,76 1,74 3,46 6 14,6 28 49 79 124 171 243 334 418 619 840

1,16 2,66 5,2 9,1 22 44 76 121 189 261 370 509 637 944 1280

Class 10.9 1,7 3,91 7,7 13,4 32 64 111 178 278 384 544 748 936 1386 1880

Class 12.9 2 4,57 9 15,7 38 75 130 209 325 449 637 875 1095 1622 2200

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HYDRAULIC

- HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS - HYDRAULIC SCHEMATIC DIAGRAMS - HYDRAULIC COMPONENTS LOCATION - HYDRAULIC CONTROL AND ADJUSTEMENT

- HYDRAULIC SPECIFIC TOOLING

HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS

HYDRAULIC COMPONENTS DATA SHEETS

– STEERING PUMP – COUNTER BALANCE VALVE – DOUBLE EXTENSION BALANCING VALVE

– DISCHARGE VALVE

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Hydraulic characteristics and specifications

STEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LS Values for information purposes only. T P

Role: - Direct and dose the flow in order to supply the steering circuit.

L R

- It is a rotating valve.

L 1. Secondary relief valve. 2. Pump valve.

3. Main pressure relief valve.

200 cm³/tr

-P -T -R -L - LS

: Pressure. : Return to tank. : Exit towards the right side. : Exit towards the left side. : Pilot line.

Notes: ____________________________________________________________________________________ ___________________________________________________________________________________________ (03/09/2008)

F70-3-0003EN

Hydraulic characteristics and specifications

Values for information purposes only.

When the driver turns the steering wheel towards the right, he passes the flowrate from P to R and sends pilot pressure towards the divisor to get priority. LS T

When there is an impact on a wheel, the pressure increases in the line. This pressure opens the valve which enables the resulting pressure to be evacuated and therefore protects the hydraulic and mechanical steering components.

LS T

When the wheels are locked to a maximum, the steering circuit increases in pressure, the LS line activates the relief valve and enables flow to the tank. LS T

What use do the two valves that are located opposite each other on the top part of the diagram have? What is the maximum pressure permitted in the steering circuit?

What is the LS line, without actions, connected to on the steering wheel?

F70-3-0003EN

(03/09/2008)

Hydraulic characteristics and specifications

COUNTER BALANCE VALVE

d1 Values for information purposes only.

Role: - Insulates the cylinder in case of hose breakage. - Cylinder movement requires the starting of the I.C. engine.

- Limits max. pressure due to impacts.

C1 1

1. Temporization screws.

2 4

2. By-pass valve. 3. Slide with max. adjustment screw.

4. Non-return valve.

Notes: ____________________________________________________________________________________ ___________________________________________________________________________________________ ___________________________________________________________________________________________ (03/09/2008)

F70-3-0008EN

Hydraulic characteristics and specifications Values for information purposes only.

Return control during cylinder descent.

When a position is secured, no component is able to exert sufficient pressure to open the valve. Only a pressure peak due to an impact can open it.

When the cylinder is pushed, the supply (no-return valve to pass) and return are free.

(03/09/2008)

Hydraulic characteristics and specifications

Values for information purposes only.

What is the valve opening pressure on the diagram?

What happens when the non-return valve starts to leak?

If the temporization screw is either screwed or unscrewed, what effect does it have on movement?

(03/09/2008)

F70-3-0008EN

Hydraulic characteristics and specifications

F70-3-0008EN

(03/09/2008)

Hydraulic characteristics and specifications

DOUBLE EXTENSION BALANCING VALVE

bf2,3 Values for information purposes only.

Role: - Insulates the cylinder in case of hose breakage.

C1 C2

- Cylinder movement requires the starting of the I.C. engine.

- Limits max. pressure due to impacts.

C1 300b

C2 1

1. Balancing valve.

300b

2. By-pass ring. 2

Maximum pressure (bar)

3. Temporization screws.

350

F70-3-0015EN

Hydraulic characteristics and specifications

F70-3-0015EN

(01/02/2011)

Hydraulic characteristics and specifications

DISCHARGE VALVE

Bf1 Values for information purposes only.

Role: - Discharge or accumulative flow from two different hydraulic lines.

T P

1. Non-return valve 2. Tank slide. 3. Pilot electrovalve.

1 Ø0,7

F70-3-0044EN

Hydraulic characteristics and specifications

F70-3-0044EN

(03/05/2011)

HYDRAULIC SCHEMATIC DIAGRAMS

Pages Série D - Série 4 :

– MT-X 732 Série D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – MT-X 1030 ST Série 4-E3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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70-02-M186EN

Hydraulic schematic diagrams MT-X 732 Série D-E3

HYDRAULIC DIAGRAM KEY Item

Designation

Position on diagram

Suction strainer

CSP

Counterbalance valve

CSD

Double counter balance valve

K37

4 component valve

O35

Inlet section

S24

EA(O)

Attachment component

S25

Lifting component

S28

Tilt component

S30

Telescoping component

S32

Closing component

S34

3 position steering valve

A12

Characteristics (Options)

S6 I24/I34/G37

Position 1: short steering Position 2: front wheel steering Position 3: crab position FDAV

Front disc brake

Return filter

O15

Turbo i.c. engine

Idle speed

930 rpm

Nominal loaded speed

1104d-44t/1104d-44ta

2200 rpm

Full speed unladen

2380 rpm (1104d-44t)

Full speed unladen

2400 rpm (1104d-44 ta)

Master cylinder

Level

Pump equipment

Front attachment plug (option)

E22

Steering pump

C11

Pressure port

O24

Hydraulic tank

RLF

Brake fluid tank

Compensation cylinder DE

I28

110x55 c310 (mt 7 and 9)

Tilt cylinder DE

E28

120x60 c416 (mt 7 and 9)

PAAV(O)

Discharge valve

O10

VDAV

Front steering cylinder DE

90x45 c80x2

VDAR

Rear steering cylinder DE

K11

90x45 c80x2

Lifting cylinder DE

G24

140x70 c720 (mt 7 and 9)

DE telescoping cylinder

I33

70x50 c2700 (mt 7)

VT1

DE telescoping cylinder

I38

100x60 c2600 (mt 9)

VT2

DE telescoping cylinder

G38

80x50 c2600 (mt 9)

Movement cut-off valve (option)

Q18

VACM(O)

NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine speed. 2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm. 3- The pressure relief valves should be adjusted at an oil temperature of 50°C.

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AV 3

B T

3 2

RLF

Hydraulic schematic diagrams

MT-X 732 Série D-E3

A 1

D3 P

R 200b

L 200b

200 cm3/tr

MC LS

140b

E T

VI PAAV(O)

CSP

G 110b V1

C2 315b +15 0

VC C1

CSP

C2 335b C1

FDAV

VDAV

VDAR

30b V1

CSP

V2 30b V1

ES. AR.

ES. AV.

C2 335b

K V2

PP C

O EF

CF OUT

21.99 cm3/tr 21.99 cm3/tr

B2 280b

FR 6b

B3 190b

280b

B4 190b

VACM(O)

first mount 10 μm absolute absolu 1ère monte absolute 15 μm absolu PR.spares parts

IN P

250b

125 μm absolu absolute

(21/0/2011)

Average : N Niveau level moyen: 104L

EA(O)

EF S

Capacity liter Capacité 128 128 litres

Réserve direction

70-02-M186EN

Hydraulic schematic diagrams

MT-X 1030 ST Série 4-E3

HYDRAULIC DIAGRAM KEY Item

Designation

Suction strainer

CSP

Counterbalance valve

CSD

Double counter balance valve

CPD D

HYDRAULIC DIAGRAM KEY Position on diagram

Characteristics (Options)

Item

Designation

Position on diagram

Characteristics (Options)

VDAV

Front steering cylinder DE

90x45 c80x2

I32/C34/I39

Tilt cylinder DE

A34

120x60 c416

K38

Lifting cylinder DE

G33

140x70 c720

Double counterbalance valve

I28

VSD

Right stabilizer cylinder DE

I26

125x60 c200

6 component valve

O38

VSG

Left stabilizer cylinder DE

I30

125x60 c200

Inlet section

S23

VT1

DE telescoping cylinder

I40

100x60 c2850

Optional equipment component

S25

VT2

DE telescoping cylinder

G40

80x50 c2850

ESD

Right stabilizer section

S27

VVT(O)

Ts locking cylinder DE (option)

A22

60x45 c183

ESG

Left stabilizer section

S29

Lifting component

S31

Tilt component

S34

Telescoping component

S36

Closing component

S38

3 position steering valve

A13

Position 1: short steering Position 2: front wheel steering Position 3: crab position EVTF(O)

Boom head electrovalve (option)

E23

Front disc brake

Rear disc brake

K14

Return filter

O15

Turbo i.c. engine

FDAV FDAR

930 rpm

Nominal loaded speed

2200 rpm

Full unladen speed (1104d-44t)

2380rpm

Full unladen speed (1104d-44ta)

2400 rpm

Master cylinder

Level

Pump equipment

PAAV

Front attachment plug

C21

PAAV(O)

Front attachment plug (option)

C20

Steering pump

C12

PFR(O)

Trailer brake plug integrated in the vafr (option)

PRF(O)

Leakage return plug (option)

E17

Pressure port

O22

Hydraulic tank

RLF

Brake fluid tank

SCFR(O)

Circuit selector (trailer brake option)

VACM(O)

Movement cut-off valve (option)

O17

VAFR(O)

Trailer brake valve (option)

VAI

Insulation valve

A26

VASS

Stabilizer safety valve

K28

Compensation cylinder DE

E34

Discharge valve

O12

VDAR

Rear steering cylinder DE

K12

70-02-M186EN

1104d-44t/1104d-44ta

Idle speed

110x55 c310

90x45 c80x2

(21/06/2011)

Hydraulic schematic diagrams

MT-X 1030 ST Série 4-E3 10

VVT(O) 3

A B T

VAI

3 2 AV

AR 3

D3 P

PAAV PD

L 200b 200b C4

PAAV(O)

RLF

CSP

200 cm3/tr

C2 +15

315b 0

C2 110b V1 V2

VC 140b

EVTF(O)

PRF(O)

SCFR(O) V2

S Ø1

Option OPTION Trailer brake FREINAGE REMORQUE

VT2

VL N

PFR

LS Ø 0.7 C2

280b

VSG C1

C2 100b

100b

C2 280b

CSP

C2 335b

CPD V1

VDAV

VDAR

FDAR

V2 B A

VASS

110b V2

VT1

V2 30b V1

CSD 300b ES. AR.

ES. AV.

315b +15 0

CSP

VSD

FDAV

VAFR(O)

C2 300b

PP C

O CF OUT

P 21.99 cm3/tr 21.99 cm3/tr

VACM(O)

P1 EF

B4 280b

B5 190b

280b

B6 190b

first mount 10 μm absolute absolu 1ère monte 15 μm absolute absolu PR.spares parts

IN P

250b

Average level : N Niveau moyen: 104L

(21/0/2011)

125 μm absolu absolute

ESD

ESG

EF S

Capacity Capacité128 128liter litres

Réserve direction

70-02-M186EN

Hydraulic schematic diagrams

70-02-M186EN

(21/06/2011)

HYDRAULIC COMPONENTS LOCATION

pages HYDRAULIC CIRCUITS KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 - MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 - BOOM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 - TELESCOPING LIFT HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 - BOOM COMPENSATION HYDRAULIC CIRCUIT - BOOM ALIMENTATION. . . . . . . . . . 7 5 - STABILISATOR HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 - STEERING HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic components location

HYDRAULIC CIRCUITS KEY Hydraulic circuits: 1 - Main 2 - Jib 3 - Telescoping lift

4 - Jib supply compensation 5 - Stabilisator 6 - Steering

Representation on circuit Item

Designation

SUCTION STRAINER

CSP

COUNTER BALANCE VALVE (Lift cylinder)

CSP

COUNTER BALANCE VALVE (Tilt cylinder)

CSP

COUNTER BALANCE VALVE (VT)

DISTRIBUTOR

3 POSITION STEERING VALVE

Ess.Ar.

REAR AXLE

Ess.Av.

FRONT AXLE

FILTRE RETOUR

HYDRAULIC CONTROL LEVER

HYDRAULIC PUMP

STEERING PUMP

HYDRAULIC TANK

COMPENSATING CYLINDER

DISCHARGE VALVE

TILT CYLINDER

LIFT CYLINDER

VSD

RIGHT HAND STABILIZER CYLINDER

VSG

LEFT HAND STABILIZER CYLINDER

TELESCOPING CYLINDER

VT1

1 TELESCOPING CYLINDER

VT2

2 TELESCOPING CYLINDER

70-03-M186EN

Electric code equivalence

x x x x x

x x

x x x

(21/06/2011)

Hydraulic components location

1 - MAIN HYDRAULIC CIRCUIT

MT-X732 S.D-E3

MA VD D

P R

MT-X1030 S Turbo S4-E3

VD D

P R

(21/06/2011)

70-03-M186EN

Hydraulic components location

2 - BOOM HYDRAULIC CIRCUIT MT-X732 S.D-E3

CSP

MT-X1030 S Turbo S4-E3

70-03-M186EN

CSP

(21/06/2011)

Hydraulic components location

3 - TELESCOPING LIFT HYDRAULIC CIRCUIT

MT-X732 S.D-E3

VT VL

CSP

MT-X1030 S Turbo S4-E3

VT VL CSP

CSP

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70-03-M186EN

Hydraulic components location

MT-X1030 S Turbo S4-E3

CSP VT1

CSP

VT2

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(21/06/2011)

Hydraulic components location

4 - BOOM COMPENSATION HYDRAULIC CIRCUIT - BOOM ALIMENTATION MT-X732 S.D-E3

MT-X 1030 S T S4-E3

(21/06/2011)

70-03-M186EN

Hydraulic components location

5 - STABILISATOR HYDRAULIC CIRCUIT MT-X 1030 S T S4-E3

CSP

VSG

CSP

VSD

CSP

6 - STEERING HYDRAULIC CIRCUIT

ESS.AV. PD

D3 R

ESS.AR. P

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HYDRAULIC CONTROL AND ADJUSTMENT

Pages HYDRAULIC PRESSURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1 - MAIN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 2 - STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TIGHTENING TORQUES MT-X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CYLINDER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

– 1 - HYDRAULIC LIFTING SYSTEMS STANDARDS . . . . . . . . . . . . . . . . . . . . . . . 5 – 2 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COMPLETE ROD . . . . . . . . . . . 5 – 3 - DISASSEMBLY AND RE-ASSEMBLY OF PISTON AND CYLINDER HEAD . . . . . 8 – 4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF PISTON SEALS . . . . . . . . . . . . . . . . 10 – 5 - DIS-ASSEMBLY AND RE-ASSEMBLY OF CYLINDER HEAD SEALS . . . . . . . . . 11 – 6 - APPLICATION OF THREAD LOCKING COMPOUND . . . . . . . . . . . . . . . . . . . . 12

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Hydraulic control and adjustment

HYDRAULIC PRESSURE CONTROL 1 - MAIN CIRCUIT Parts required : - 1 Manometer 0/400 bar 549 885 or 1 digital manometer (0-600 bar) 554 118 - 1 Connector 213 536 - 1 test hose 549 888 - 1 test plug 72 339 A Procedure - Check hydraulic oil level. - Remove the trim panel 1 (Fig. A) to the rear of the cab to gain access to the control block. - Bring the oil up to operating temperature (50°C) by carrying out hydraulic movements.

Checking and adjusting the pressure relief valve is carried out with full flow and the engine at maximum revolutions. Checking and adjusting the anti-shock valves is carried out with minimum flow and the engine operating at 1000 rpm.

Checking and adjusting the main pressure relief valve. - Connect the pressure gauge to the test port. - With the engine at maximum revolutions, activate the accessory circuit control and read the pressure shown on the gauge. - Main pressure relief valve: 240 bar (MT-X 732)

Checking and adjusting anti-shock valves.

- Prior to carrying out these procedures it is necessary to increase the setting on the main limiter 4 (Fig. B) by 50 bar. - Connect the pressure gauge to the pressure port. - Keep the relevant cylinder at the end of its travel and read the pressure shown on the gauge (See table of values). - When adjustment operations have been completed, return he main limiter to: 240 bar (MT-X 732)

1 4

Table of values MT-X 732 Key hydraulic circuit diagram

rod side

anti-shock valve tilt compensation

EI piston side EI rod side

280 b 190 b

anti-shock valve lifting

EL piston side

280 b

anti-shock valve telescoping

ET piston side

190 b

70-04-M186EN

piston side

(24/06/2011)

Hydraulic control and adjustment

2 - STEERING CIRCUIT Parts required : - 1 Manometer 0/400 bar 549 885 or 1 digital manometer (0-600 bar) 554 118 - 1 test hose 549 888 - 1 connector 173 567 - 1 test point 58 181

Procedure

A STEERING PUMP

- Using a T connector connect the pressure gauge to the pressure out pipe on the main pump (port P).

- With the engine operating at maximum revolutions, move the steering on to full lock and, holding that position, read the pressure on the pressure gauge. - Steering pressure: 140 bar

MAIN PUMP

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Hydraulic control and adjustment

TIGHTENING TORQUES MT-X J1

J2 N1

B A

B A K

H G H

D L

C I S

Ref

Designation

Number

Size (mm)

tightening torque (N.m)

Vis lever

Nut M10

Locknut

screw M12x20

screw M5x12

6,6

screw M5x14

6,6

screw M5x18

6,6

screw M5x25

6,6

screw M8x25

Complete pressure relief valve

Lever M12x200

Screw hood

6,6

Complete pressure relief valve

J1 Complete pressure relief valve (detail) J2 K

Complete pressure relief valve

K1 Complete pressure relief valve (detail) K2 L

N1 Complete pressure relief valve (detail) N2 O

Valve

Plug

Screw

Lever

70-04-M186EN

(24/06/2011)

Hydraulic control and adjustment

CYLINDER DISASSEMBLY 1 - HYDRAULIC LIFTING SYSTEMS STANDARDS Extracts from Standard Pr EN 1459 - 1997 5.5.2

Hydraulic lifting system

5.5.2.1

Load retention The lowering of a load due to a leak in the hydraulic system must not exceed 150mm in 10 minutes with the boom positioned in its least favorable position and the oil at its normal working temperature. The average speed of tilt forward caused by oil leaks must not exceed half a degree per minute.

6.3.3

Static load - leak test (elevation, tilt) Load lowering measurements due to hydraulic leaks (see 5.5.2.1) must be carried out with a test using the effective capacity, the telescoping boom completely extended and the maximum elevation angle. Load lowering and fork clamp tilt must be measured at the heel of the fork lift mast or close nearby.

Dis-assembly

Rod 1

Body 3

Cylinder head 2

2 - DIS-ASSEMBLY AND RE-ASSEMBLY OF THE COMPLETE ROD

Piston 4

- Place the cylinder in a vice fitted with soft jaws. - Tighten the vice moderately only to avoid deforming the cylinder body. - Loosen the cylinder head 2 (Fig. A1) with a hook wrench. - If you have difficulty loosening the cylinder head consult the paragraph “Dis-assembly” in chapter 6. - Completely unscrew the cylinder head 2 (Fig. A1). - Remove the entire rod from the cylinder body. NOTE: FOR LONG CYLINDERS

- Pull the rod out by 200 mm maximum. - Unscrew the cylinder head half of one turn (Carry out this operation very progressively, without any abrupt movements). - Pull the rod out by some 2500 mm. - Support the rod by its end to reduce stress on the cylinder head (Fig. A2). - Continue to unscrew the cylinder head. If resistance is felt raise and lower the rod to reduce friction. Never force the cylinder head to unscrew it as this might cause it to seize.

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Hydraulic control and adjustment

Inspection - De-grease and clean the cylinder interior. - Carry out a visual inspection of the cylinder body. It should be free of scrapes, burrs, rust etc. Re-fitting - Use a brush to apply hydraulic oil to the piston seals. - Replace the complete rod in the cylinder body 3 (Fig. A1). - Take care not to damage the piston seals when taking them past the thread on the piston body. NOTE: Tightening the cylinder head is different depending on if the cylinder body has a flange or not (Fig. A4). Follow the following instructions.CYLINDER WITHOUT FLANGE

Thread locking compound Rod

Cylinder head

- Apply hydraulic oil to the external sealing rings of the cylinder head. - Apply Loctite 222 thread locking compound (see chapter 6) to the cylinder head (Fig. A3). - Screw the cylinder head on. - Tighten using a hook wrench and torque wrench (see torque, Fig. A4) or use the procedure of tightening by angle (Fig. A4). - Turn the rod one rotation to ensure the seals are correctly in place. FLANGED CYLINDER

Seal

- Apply hydraulic oil to the seals and the thread of the cylinder head. - Screw the cylinder head on. - Tighten using a hook wrench and torque wrench (see torque, Fig. A4) or use the procedure of tightening by angle (Fig. A4). - Turn the rod one rotation to ensure the seals are correctly in place. Comments - We recommend testing the cylinder before re-fitting it to the telehandler. - Move the rod in and out several times.

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Hydraulic control and adjustment

A4 A4-1

Procedure for tightening the cylinder head using the angle method. - Tighten the cylinder head until it is in contact with the cylinder body. - Put a mark 1 (Fig. A4-1) on the cylinder body and on the cylinder head. - Further tighten the cylinder head over the distance X (Fig. A42). - Engage the flange with one of the nocks on the cylinder head.

1 1

Tightening torques for cylinder head

flange

A4-2 THREAD A

Ø BORE B

Ø FLANGE C

TIGHTENING TORQUE

M43 x 200

200 à 250 N.m

M48 x 200

200 à 250 N.m

M53 x 200

200 à 250 N.m

M58 x 200

250 à 300 N.m

M63 x 200

250 à 300 N.m

M66 x 200

250 à 300 N.m

M68 x 200

250 à 300 N.m

M73 x 200

300 à 350 N.m

M78 x 200

300 à 350 N.m

M83 x 200

350 à 400 N.m

M88 x 200

350 à 400 N.m

M93 x 200

107

350 à 400 N.m

M98 x 200

109

400 à 450 N.m

M104 x 200

100

119

400 à 450 N.m

M109 x 200

105

124

400 à 450 N.m

M114 x 200

110

129

450 à 500 N.m

M124 x 200

120

139

450 à 500 N.m

M129 x 200

125

139

450 à 500 N.m

M134 x 200

130

149

450 à 500 N.m

8 à 9 mm

140

450 à 500 N.m

8,5 à 9,7 mm

150

450 à 500 N.m

9,2 à 10,5 mm

(24/06/2011

DISTANCE X

70-04-M186EN

Hydraulic control and adjustment 3 - DISASSEMBLY AND RE-ASSEMBLY OF PISTON AND CYLINDER HEAD

Dis-assembly

Cylinder head 2

Piston 7 Piston 4 Nut 5

Rod 1

Screw 6

- Place the rod in a vice fitted with soft jaws. - Tighten sufficiently to stop the assembly rotating. - Loosen the nut 5 (Fig. B1) and completely unscrew it using a ring spanner. Or, depending on model, remove the set screw 6 (Fig. 1) with an Allen key. NOTE: The set screw 6 (Fig. B1) is fitted with Loctite and it is locked by striking it with a cold chisel.

B2 Cylinder head 2 Piston 4

Rod 1

- Dis-assemble the piston 4 (Fig. B2) by pulling it manually or, depending on model, by unscrewing the piston 7 (Fig. B1) with a hook wrench.

- Remove the cylinder head 2 (Fig. B3) by sliding it along the rod.

Cylinder head 2 Rod 1

Inspection

B4 Cylinder head 2 Rod 1

70-04-M186EN

- Check the rod for straightness using a dial gauge along its entire length (Fig. B4). - Check for flaking, corrosion or scraping on the rod.

(24/06/2011)

Hydraulic control and adjustment

Re-fitting B5

- Re-fit the cylinder head 2 (Fig. B5) over the rod 1 (Fig. B5). - Re-fit the piston 4 (Fig. B1) onto the rod. - Screw on and tighten the nut 5 (Fig. B1) using a ring spanner and a torque wrench (Fig. B6). Or, depending on model, re-screw the piston 7 (Fig. B1) using a hook wrench (see torque Fig. B6) and secure it with the set screw 6 (Fig. B1).

Cylinder head 2 Rod 1

NOTE:

PISTON TIGHTENING TORQUE 1400 1200

Torque (N.m)

1000

• The set screw must be secured with Loctite 243, see chapter 6. • Set screw torque = 20 N.m. • Use a cold chisel to knock the metal back over the set screw.

800 600 400

M20

M30

M40

M50

M60

200

M70

Thread

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Hydraulic control and adjustment

4 - DIS-ASSEMBLY AND RE-ASSEMBLY OF PISTON SEALS C1

NOTE: Never use sharp or cutting tools (screwdrivers, blades etc.) for fitting or removing seals. It is recommended to work on workbenches free of swarf.

Sealing rings

Dis-assembly - Remove the piston seals (Fig. C1 or C2). - Caution, ensure you do not damage the edges or bottom of the seal grooves. O-ring

Inspection - Degrease and clean the piston. - Inspect bottoms and sides of the seal grooves for smoothness and the absence of scrapes. - The grooves must be clear of foreign bodies.

C2 Sealing rings

Re-fitting

- Position the seals as per Fig. C1 or C2. - When fitting outside seals, expand them sufficiently to slide them into their grooves, taking care not to break them. - The inside seal must be fitted by hand. O-ring

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Hydraulic control and adjustment

5 - DIS-ASSEMBLY AND RE-ASSEMBLY OF CYLINDER HEAD SEALS D1 Anti-extrusion seal 2 O-ring 1

O-ring 3

NOTE: Never use sharp or cutting tools (screwdrivers, blades etc.) for fitting or removing seals. It is recommended to work on workbenches free of swarf. Dis-assembly - Remove the seals from the cylinder head. - Caution, ensure you do not damage the edges or bottom of the seal grooves.

Oil scraper 4 Rod seal 5

D2 Seal

Inspection - Degrease and clean the cylinder head. - Inspect bottoms and sides of the seal grooves for smoothness and the absence of scrapes. - The grooves must be clear of foreign bodies. - Slide the bare cylinder head over and along the piston rod. Slide it all the way along the rod. - The clearance should not be too great, but neither should it jam.

Plug 1

D3 Drift 2

Seal

- Place the seals as per Fig. D1. The lips on the rod seal should face the pressure side. - When fitting the rod seal, start by engaging it in the groove while holding it in place, possibly with your thumb or possibly with a plug 1 (Fig. D2) with no sharp edges. - Push it into its groove with the other hand or with a smooth drift 2 (Fig. D3). If it proves difficult to fit, soak it in hydraulic oil at 50°C before fitting. - Fit the oil scraper ring 4 (Fig. D1) using a mallet and a pad. The O-rings 1 and 3 (Fig. D1) and the anti-extrusion seal Ref. 2 (Fig. D1) are fitted by hand.

Plug 1

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70-04-M186EN

Re-fitting

Hydraulic control and adjustment

6 - APPLICATION OF THREAD LOCKING COMPOUND Characteristics Loctite 222 low strength threadlocker Application to cylinder head threads No activator Fixture time Cure time (Pressurizing the cylinder) With Loctite N Activator Fixture time Cure time (Pressurizing the cylinder) Shear strength

10 - 30 min. 3 - 6 hours

10 - 20 min. 2 - 4 hours 1,5 - 4 N/mm2

Loctite 243 medium strength threadlocker

Applied to M8 bolts for securing pistons. No activator Fixture time Cure time (Pressurizing the cylinder) With Loctite N Activator Fixture time Cure time (Pressurizing the cylinder) Shear strength

10 - 20 min. 3 - 6 hours

5 - 15 min. 2 - 4 hours 5 - 7,5 N/mm2

Dis-assembly If parts fitted with threadlocker cannot be undone with normal tools, it is recommended to heat the threadlocked zone to 250°C. For this a hot air gun is recommended, rather than a gas torch. Note If the temperature is close to 0°C when parts are fitted, it is recommended to use Loctite Activator. This brings with it the added benefit of a reduction in cure time.

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HYDRAULIC SPECIFIC TOOLING

pages BASIC MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(24/06/2011)

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Hydraulic specific tooling

BASIC MANOMETER BOX

This box contains all the components required for measuring pressure on all Manitou products.

Basic manometer box .................................................................................549671 Consisting of: 1. 2. 3. 4. 5. 6. 7. 8.

70-09-M186EN

1 Manometer 1/9 bar ..............................................................549882 1 Manometer 0/40 bar ............................................................549883 2 Manometers 0/60 bar ..........................................................549884 1 Manometer 0/400 bar ..........................................................549885 2 Manometers 0/600 bar ........................................................549886 4 Standard hoses ....................................................................549887 2 Hoses for Maniscopic ...........................................................549888 7 Manometer ports ..................................................................549889

(24/06/2011)

Hydraulic specific tooling

DIGITAL MANOMETER BOX FUNCTIONS: • Mano Function: the following combinations can be displayed: - Temperature upstream to +/- 2°C - Pressure upstream P1 with its min. and max. (700 bar in class 0.1) - Pressure downstream P2 with its min. and max. (700 bar in class 0.1) - Differential pressure dP=P1-P • Hold Function: the operator is able to freeze the display panel so that he can take notes whenever he wishes • Unit Function: the operator can change the measurement unit whenever he wishes (bar, psi, kPa, mCe). • Tare Function: enables offset to zero

• Recording Function: A max. of 16000 values may be recorded. The sampling period can be configured. • Zero Function: zero is carried out on 2 sensors

Digital Manometer box ...............................................................................662187 Consisting of: 1. 2. 3. 4.

(24/06/2011)

1 dP HP 700 bar Mano digital manometer 1 measurement hose DN2 1215/1620, L = 1,5m, 630 bar 2 measurement hoses DN2 1620/1620, L = 1,5m, 630 bar 2 1620 Manometer adaptors

70-09-M186EN

• Leakage test Function: enables the pressure variation to be measured over a programmed time period

Hydraulic specific tooling

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ELECTRIC

- ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS - ELECTRICAL SCHEMATIC DIAGRAMS - ELECTRICAL COMPONENTS LOCATION - ELECTRICAL CONTROL AND ADJUSTEMENT

- ELECTRICAL SPECIFIC TOOLING

ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS

Pages FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – Relay and fuse holder plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– Relay and fuse holder plate (details of FUSES) . . . . . . . . . . . . . . . . . . . . . . . . 3

(22/06/2011)

80-01-M186EN

Electrical characteristics and specifications

FUSES AND RELAYS Relay and fuse holder plate

F34

F42

F40

k16

K17 + K18 - F31 + F32 F43

F41

3 5

1 6

15A

25A

F30

25A

10A

F13 F14 F15

15A

7.5A

10A

7.5A

10A

15A

10A

7.5A 80-01-M186EN

F 1

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 F28 F29

10A

F9 F10 F11 F12

15A

30A

10A

15A

87a

85 2

7.5A

10A

7.5A

10A

I 5

87a

3 5

(22/06/2011)

Electrical characteristics and specifications

Section

Item

Current

Designation

FUSES

7,5 A

ELECTRONIC CONTROL UNIT SUPPLY OPTIONAL HYDRAULIC ACCESSORY LOCKING

10 A

WORKING TAIL LIGHT

7,5 A 10 A

REAR WINDSCREEN WIPER OPTIONAL SIDE AND ROOF SCREEN WIPERS

7,5 A

ENGINE STOP SOLENOID VALVE OPTIONAL HYDRAULIC ATTACHMENT EASY-CONNECT

7,5 A

ROTATING BEACON LIGHT

WHEEL DIRECTION

10 A

LONGITUDINAL STABILITY ALARM DEVICE TILTING CORRECTOR “SINGLE” HYDRAULIC MOVEMENT CUT-OFF “AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF

15 A

FORWARD/NEUTRAL/REVERSE GEAR SELECTION TRANSMISSION CUT-OFF REVERSING LIGHTS OPTIONAL AUDIBLE REVERSE WARNING

CONTROL PANEL

F10

15 A

HORN STOP SWITCH

F11

10 A

OPTION JIB HEAD LIGHT OPTIONAL FRONT AND REAR BLUE WORK LAMPS

F12

10 A

TURN INDICATOR SUPPLY

F13

30 A

HEATING

F14

10 A

CIGARETTE LIGHTER

F15

25 A

OPTIONAL OIL COOLER

F16

7,5 A

AIR CONDITIONING OPTION

10 A

F17

15 A

(22/06/2011)

OPTION JIB HEAD ELECTROVALVE OPTIONAL JIB SOLENOID VALVE AND ACCESSORY HYDRAULIC LOCKING OPTION ELECTRICAL JIB PROVISION OPTIONAL ANTI-THEFT PRE-WIRING OPTIONAL ANTI-THEFT SYSTEM OPTIONAL IMMOBILIZER SYSTEM OPTIONAL SELF-CLEANING FAN OPTION HYDRAULIC TOWING HOOK OPTIONAL SINGLE OR DOUBLE ACTING REAR HYDRAULIC PROVISION OPTIONAL PROVISION FOR TWO DOUBLE ACTING REAR HYDRAULIC OPTIONAL HYDRAULIC TOWING HOOK AND SINGLE OR DOUBLE ACTION HYDRAULICS PREWIRING OPTIONAL DOUBLE ACTING REAR HYDRAULIC PROVISION + SINGLE ACTING REAR HYDRAULIC PROVISION OPTIONAL JIB HEAD SOLENOID VALVE AND SELF-CLEANING FAN OPTIONAL PROVISION FOR TWO DOUBLE ACTING REAR HYDRAULIC OPTIONAL HYDRAULIC TOWING HOOK AND SINGLE OR DOUBLE ACTION HYDRAULICS PREWIRING OPTIONAL DOUBLE ACTION AND SINGLE ACTION REAR HYDRAULICS PRE-WIRING

F18

15 A

FRONT WORK LAMP

F19

15 A

OPTIONAL REAR WINDOW DEFROSTING

F20

10 A

OPTION PNEUMATIC SEAT

F21

10 A

FRONT WINDSCREEN WIPER AND WASHER

F22

10 A

OPTION JIB SUSPENSION 80-01-M186EN

Relay and fuse holder plate (details of FUSES)

Electrical characteristics and specifications

Section

Item

Current

Designation

F23

7,5 A

RIGHT-HAND SIDELIGHT SIDELIGHT ON WARNING LAMP CONTROL PANEL ILLUMINATION OPTIONAL NUMBER PLATE ILLUMINATION

F24

7,5 A

LEFT-HAND SIDELIGHT

F25

7,5 A

RIGHT-HAND INDICATOR LIGHT

F26

7,5 A

LEFT-HAND INDICATOR LIGHT

F27

15 A

DIPPED BEAM HEADLIGHTS DIPPED BEAM ON WARNING LAMP REAR FOG LIGHT

F28

15 A

MAIN BEAM HEADLIGHTS HEADLIGHTS WARNING LAMP

F29

15 A

HAZARD WARNING LIGHTS CEILING LIGHT OPTION (+) PERMANENT

F30

25 A

LIGHTING, HORN AND INDICATOR SWITCH

F31

25 A

STARTER

3A 5A

ELECTRO-PROPORTIONAL HYDRAULIC CONTROL MODULES OPTION JIB SUSPENSION “AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF OPTION ATTACHMENT HYDRAULIC CONTROL FORCED OPERATION

F33

ELECTRONIC CONTROL UNIT

F34

30 A

DIESEL ENGINE ELECTRONIC CONTROL MODULE

F35

DIAGNOSTIC CONNECTOR

F40

40 A

TELEHANDLER ELECTRICAL EQUIPMENT

F41

40 A

TELEHANDLER ELECTRICAL EQUIPMENT

F42

80 A

DIESEL ENGINE PRE-HEATING

F43

80 A

ALTERNATOR

F44

15 A

OPTION DIESEL FUEL HEATER

F32

RELAY

80-01-M186EN

AIR CONDITIONING OPTION

TRANSMISSION TO HYDRAULIC CONTROLS CUT-OFF RELAY

TRANSMISSION CUT-OFF RELAY FORWARD/REVERSE RELAY

REVERSE GEAR RELAY

FORWARD GEAR RELAY

BUZZER

OPTION JIB HEAD ELECTROVALVE OPTION ELECTRICAL JIB PROVISION OPTIONAL JIB HEAD SOLENOID VALVE AND HYDRAULIC ACCESSORY LOCKING

“SINGLE” HYDRAULIC MOVEMENT CUT-OFF “AGGRAVATING” HYDRAULIC MOVEMENT CUT-OFF

STARTER SAFETY RELAY

FLASHING UNIT

K10

OPTION JIB SUSPENSION

K11

OPTION JIB SUSPENSION

K12

OPTION

K15

PROPORTIONAL HYDRAULIC CONTROLS CUT-OFF RELAY

K16

ENGINE PRE-HEATING RELAY

K20

OPTIONAL DIESEL FUEL HEATER

(22/06/2011)

ELECTRICAL SCHEMATIC DIAGRAMS

Pages MT-X 732 Série D-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A 1

MT-X 1030 ST Série 4-E3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B 1

(22/06/2011)

80-02-M186EN

Electrical schematic diagrams

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 732 Série D-E3

Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7

(22/06/2011)

80-02-M186EN

Electrical schematic diagrams MT-X 732 Série D-E3

Components Item

Type

Rear right hand indicator light

Designation

Position on diagram B35

Front right-hand indicator light

B35

Rear left-hand indicator light

B36

Front left-hand indicator light

B36

Left hand brake light

B33

Right hand brake light

B33

Rear right hand side light

B44

Front right hand side light

B45

Rear left hand side light

B46

E10

Front left hand side light

B46

E11

Front left-hand dipped light

B46

E12

Front right-hand dipped light

B47

E13

Front left-hand headlight

B48

E14

Front right-hand headlight

B48

E15

Rear right-hand working light (option)

B42

E16

Rear left-hand working light (option)

B42

E17

Front left-hand working light (option)

B41

E18

Front right-hand working light (option)

B41

E19

Rotating beacon light

B17

E20

Left-hand reverse light (option)

B29

E21

Roof light

C37

E22

Right-hand reverse light (option)

B29

E23

Rear left-hand fog light (option)

B47

E24

Rear right-hand fog light (option)

B48

E25

Head jib left work light

B40

E26

Head jib right work light

B41

E27

License Plate light (option)

Fuse

Free (10A Max)

F11

Fuse

Rear working light (option) (15A)

F42

Fuse

Rear windscreen / roof wiper (7,5A)

F14

Fuse

Engine stop electrovalve (10A)

F18

Fuse

Rotating beacon light (7,5A)

F18

Fuse

Wheel alignment (5A)

F20

Fuse

Overload safety (10A)

F23

Fuse

Forward/reverse/neutral Transmission (15A)

F27

Fuse

Fault alarm/light (5A)

F10

Fuse

Alarm / brake (15A)

F33

F11

Fuse

Working light on boom (15A Max)

F40

F12

Fuse

Flashing lights (10A)

F38

F13

Fuse

Fan (30A)

F52

F14

Fuse

Free (10A)

F54

F15

Fuse

Free (25A Max)

F54

F16

Fuse

Air conditioning (option) (10A Max)

F52

F17

Fuse

Free (15A Max)

F55

F18

Fuse

Front working lights (option) (15A)

F41

F19

Fuse

Rear window defrosting (option) (15A Max)

F40

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 732 Série D-E3

Components Item

Type

F20

Fuse

Pneumatic seat (10A Max)

Designation

Position on diagram

F21

Fuse

Front windscreen wiper / windscreen-washer (10A)

F14

F22

Fuse

Free (15A Max)

F57

F23

Fuse

Right hand side lights / dashboard (7,5A)

C44

F24

Fuse

Left-hand side lights (7,5A)

C46

F25

Fuse

Right-hand indicator light (7,5A)

D35

F26

Fuse

Left-hand indicator light (7,5A)

C36

F27

Fuse

Dipped lights (15A)

C46

F28

Fuse

Headlights (15A)

C48

F29

Fuse

Warning / ceiling light (15A)

F37

F30

Fuse

Stalk switch (25A)

E46

F31

Fuse

Starter (20A)

F40

Fuse

Equipment (40A)

F41

Fuse

Equipment (40A)

F42

Fuse

Pre-heating (80A)

F43

Fuse

Alternator (80A)

Battery

F56

Alternator

H10

Indicator

Warning lamp

A37

H11

Indicator

Front wheel alignment light

B20

H14

Indicator

Rear wheel alignment light

B21

H15

Indicator

Counter/rotations light

B44

H16

Indicator

Cooland temperature light

B43

H17

Indicator

Diesel gauge light

B43

H19

Indicator

Fan light

B45

H20

Indicator

Relay

Air conditioning relay (option)

A54/D53

Relay

Free

A58/D58

Relay

Transmission cut-off relay

E28/B31

Relay

Reverse gear relay

B27/D28

Relay

Forward gear relay

C10/B26/D28

Relay

Machine fault alarm

Relay

Free

B43

A57/D57

Relay

Movement cut-off control relay

D24/A23

K7a

Relay

Forced movement switch relay

D24/C24

Relay

Starter safety relay

C2/B27

Relay

Flashing/Warning unit

B34

K10

Relay

Overload safety module

B22

K16

Relay

Preheater relay

B1/A2

K17

Relay

Module relay lights

B6/B7

K18

Relay

Transmission cut-off module

F29

Starter

Front screenwiper

B14

Windscreen washer

B13

Roof wiper (option)

B16

Alarm

B33

(22/06/2011)

Clock light

80-02-M186EN

Electrical schematic diagrams MT-X 732 Série D-E3

Components Item

Type

Fan

Designation

Position on diagram B52

Reverse gear alarm

B29

Rear cab screen wiper

B15

Diesel pump

B19

M10

Side windscreen wiper

B17

M11

Pneumatic compressor

A56

Hour meter

Fuel gauge

Engine coolant temperature

Preheating plugs

Fuel sensor

Sensor and thermo-switch for engine coolant temperature

Key switch

VL VI valve lever forward / reverse gear reverser

E27

Engine oil pressure switch

Brake fluid

Air filter clogging

Front wheel alignment detector

Brake switch

Front windscreen wiper and windscreen-washer switch

D15

B20 B11/D29

Alarm control

D33

S10

Wheel alignment switch

E20

S11

Warning light switch

E36

S12

Transmission oil pressure

B10

S13a

Side light stalk switch

E44

S13b

Dipped light/headlight stalk switch

E44

S13c

Indicator light stalk switch

E35

S14

Gear lever transmission cut-off switch

C31

S15

Front/rear working light switch (option)

D42

S16

Stop switch

D33

S17

Transmission oil temperature

B10

S18

Working lights on boom switch (option)

D41

S19

Rotating beacon switch

D18

S20

Rear windscreen wiper / roof switch

D17

S21

Fan switch

E52

S22

Overload stress gauge

E22

S23

Clogging hydraulic filter

S24

VL and VI valve lever transmission cut-off switch

E31

S25

Pedal transmission cut-off switch

D30

S26

Transmission cut-off switch

F31

S27

Rear wheel alignment detector

B21

S28

Rear window defrost switch (option)

D40

S29

Rear fog light switch (option)

D48

S30

Steering pressure

S31

Cold start switch

B18

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 732 Série D-E3

Components Type

S32

Seat switch

Designation

D29

S39

Pneumatic seat switch

C56

S42

Movement cut-off deletion switch

B23

S43

Retracted telescope switch

D22

S44

Telescope retraction switch

D23

S45

Deflation/dump switch

D23

S46

Boom lowering switch

C23

S47

Attachment switch

C23

Diode

Diode (only for TUV)

D44

Diode (LED) battery charge lamp

Diode (LED) engine oil pressure lamp

Diode (LED) engine coolant temperature lamp

Diode (LED) air/oil clogging lamp

Diode (LED) transmission oil pressure lamp

E10

Diode (LED) transmission oil temperature lamp

E10

Diode (LED) brake fluid lamp

V10

Diode (LED) brake lamp

E11

V11

Diode (LED) flashing/warning light lamp

B34

V12

Diode (LED) side lights lamp

B44

V13

Diode (LED) dipped lights light

B47

V14

Diode (LED) headlights light

B49

V15

Diode (LED) steering fault light

Electrovalve

Engine stop electrovalve

B19

Electrovalve

Forward gear electrovalve

B28

Electrovalve

Reverse gear electrovalve

B28

Electrovalve

Cold start electrovalve

B18

Electrovalve

Movement cut-off electrovalve

C24

Electrovalve

Discharge valve electrovalve

C12

Connector

Fuse / relay panel (13 contact plug)

Connector

Fuse / relay panel (13 contact plug)

Connector

Fuse / relay panel (13 contact plug)

Connector

Fuse / relay panel (6 contact plug)

Connector

Fuse / relay panel (8 contact plug)

Connector

Fuse / relay panel (8 contact plug)

Connector

Fuse / relay panel (21 contact plug)

Connector

Fuse / relay panel (5 contact plug)

Connector

Fuse / relay panel (7 contact plug)

Connector

Fuse / relay panel (8 contact plug + 2 contact plug)

Connector

K1 provision relay option

Connector

K0 provision relay option

Connector

provision option (8 contact plug + 1 contact plug)

Connector

Engine box

Connector

Rear plug provision option (8 contact plug)

Connector

Stalk switch

Connector

Ventilation heating

(22/06/2011)

Position on diagram

Item

80-02-M186EN

Electrical schematic diagrams MT-X 732 Série D-E3

Components Item

Type

Connector

Option air conditioning

Designation

Connector

Cab

Connector

Front screenwiper

Connector

Strain gauge

Connector

Anti-theft connection

Connector

Aggravating movement cut-off connection

Connector

Aggravating movement cut-off diode connection

Connector

16 way plug (PCB Dashboard)

Connector

Car radio

Connector

Windscreen stalk switch connector (9 ways + 2 ways)

Connector

K6 relay option provision

Connector

Hour meter / rev counter

Z AA

Position on diagram

80-02-M186EN

(22/06/2011)

) + Perm

+ Apc

Fus.Therm. 2A

J J J J

321

I I I OP

30 30 17 17 50 19 19 54 15 58

118 118

119

129

141

K5 AD

204

F1 G E

V3 F

130 12 21

21 12

N N

N 23

B F40

F42

R1 K16

N 15

325

P S30

121 121

K17

P S4

14 13

K4 85

T S17

14 54 55

P S23

Y8 n

173

S12

jvt

3,5s

P S3

K17

121

322

324

140

323

116

139

V10 Z

263

202

V7 Z

121 203 121

K16

V8 Z

F43 29

V5 Z

V6 Z

V15 Z

F41

V9 Z

F31

V4 Z

156

227

)

+ Perm

+ Apc

F21

AB S8 0

157

EG Lateral

7 4

Ep3 cab

5 2

AB AB

151 150 149 148 147 152

+perm

2 1 vit 2 M 1

73 96

122

S19

S44

S43

105 121 167

m bc vt

315

S46 344

Ep2 cab

4 raz 3

1 M AR 1 Ep11 cab

Ep5 cab

146

289

4 raz 3

M4 2 vit

+perm

1 M 1

4 raz 3

TOIT

M10 2 +perm

1 vit 2 M 1

Ep14 cab

T S31

E19

Ep12 cab

336

K7a 334

332 331

Y1 18

S47

LAT

338

U U U U U U

M8 2 vit +perm

339

335

337

S45 WW

K7 K7a

127 342

Ep15 cab

153

341

SWF 521 005 + SWF 596 628

235

S10

229

S22

233

S AV

27 1

T T T T raz 3

S20 AB AB AB AB

F7 (10A)

S SWF 521 243 + SWF 596 307

5 F

A 135

EG Toitl

B 128

133

M9 19

S6 83

H11

121 167

S27

H14

121

S42

K10

315

340

333

13 (22/06/2011)

25 80-02-M186EN

Electrical schematic diagrams

MT-X 732 Série D-E3

Electrical schematic diagrams

MT-X 732 Série D-E3

J )

F 122

K18 B2

H 250

248

V V

123

184

E20

220

C O

177

E22 185

103

G M7

257

159

197

E5 184 O

C O

175

181

Z V11

185

254

155 158

E21

154

jvt

F26

378

F25

256

182

V g

I 194

330

V V 183

S14

315 56

176

193

PCB

315

S11

S25

265

S32

247

P S16

261

S24

249

266

191

264

PCB

185

163

180

166

184

H10

)

+ Perm + Apc

F19

F11

199

134

5 1

6 7

2 0 1

SWF 521 054 + SWF 596 151

313

E18

156

187

186

E15 E16 289

S 384

289

S 289

203

154 9

H20 121 N

202

H16 121

F23

140

F24 C

bl 174

320

121

H15b

162

F Z V12 Z

179

H19 166

E12 E11

E9 184

166 90

164

E10

178

E8 E7

F28

F27

jvt

122

200

H15a

H17 S

382

S29

C E17

205

E26

289

138

E25

381

Dégivrage vitre arrière

P bl

385

F30 J

S13b

136

S15

S18

S13a

SWF 521 110 + SWF 596 473

F2 A

SWF 521 008 + SWF 596 390

S28 D

F18

234

80-02-M186EN

F12

F29

S13c

F10

192

246

267

S26

262

+ Apc

+ Perm

196 105 121 167

AA C

F 380

206

207

165

383

Z V14

Z V13

+ R

E23 184

E24 185

E13 90

E14 166

Z A

(22/06/2011)

) + Perm

+ Apc

F16

F15

F17

F20

232

K0 Q G

G 239

226

231

329

Q D

238

230

286

G K6

228

G 283

S39

K1 G

284

G 281

282

AC K AC 217

218

131

R Q

M6 Q

287

S21

225

201

F22

132

F14

M M11

F13 E

(22/06/2011)

Electrical schematic diagrams

MT-X 732 Série D-E3

80-02-M186EN

A10

MT-X 732 Série D-E3

Electrical schematic diagrams

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 1030 ST Série 4-E3

Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7

(22/06/2011)

80-02-M186EN

Electrical schematic diagrams MT-X 1030 ST Série 4-E3

Components Item

Type

Rear right hand indicator light

Designation

Position on diagram B32

Front right-hand indicator light

B32

Rear left-hand indicator light

B33

Front left-hand indicator light

B33

Left hand brake light

B30

Right hand brake light

B30

Rear right hand side light

B52

Front right hand side light

B53

Rear left hand side light

B54

E10

Front left hand side light

B54

E11

Front left-hand dipped light

B54

E12

Front right-hand dipped light

B55

E13

Front left-hand headlight

B56

E14

Front right-hand headlight

B56

E15

Rear right-hand working light (option)

B50

E16

Rear left-hand working light (option)

B50

E17

Front left-hand working light (option)

B49

E18

Front right-hand working light (option)

B49

E19

Rotating beacon light

C45

E20

Left-hand reverse light (option)

B26

E21

Roof light

C34

E22

Right-hand reverse light (option)

B27

E23

Rear left-hand fog light (option)

B55

E24

Rear right-hand fog light (option)

B56

E25

Head jib left work light

B49

E26

Head jib right work light

B48

E27

License Plate light (option)

Fuse

Stabilizer safety (7,5A)

F19

Fuse

Rear working light (option) (15A)

F50

Fuse

Rear windscreen/roof wiper (7,5A)

F41

Fuse

Engine stop electrovalve (10A)

F12

Fuse

Rotating beacon light (7,5A)

F45

Fuse

Wheel alignment (5A)

F13

Fuse

Overload safety (10A)

F16

Fuse

Forward/rear/reverse transmission (15A)

F24

Fuse

Fault alarm/light (5A)

F10

Fuse

Alarm/brake (15A)

F29

F11

Fuse

Working lights on boom (15A)

F49

F12

Fuse

Flashing lights (10A)

F34

F13

Fuse

Fan (30A)

F36

F14

Fuse

Free (25A Max)

F38

F15

Fuse

Free (25A Max)

F39

F16

Fuse

Air conditioning (option) (10A Max)

F37

F17

Fuse

Free (15A Max)

F39

F18

Fuse

Front working lights (option) (15A)

F50

F19

Fuse

Rear window defrosting (option) (15A Max)

F48

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 1030 ST Série 4-E3

Components Item

Type

F20

Fuse

Pneumatic seat (10A)

Designation

Position on diagram

F21

Fuse

Front windscreen wiper/windscreen-washer (10A)

F42

F22

Fuse

Free (15A Max)

F41

F23

Fuse

Right-hand side lights/dashboard (7,5A)

C52

F24

Fuse

Left-hand side lights (7,5A)

C54

F25

Fuse

Right-hand indicator light (7,5A)

C32

F26

Fuse

Left-hand indicator light (7,5A)

C33

F27

Fuse

Dipped lights (15A)

C54

F28

Fuse

Headlights (15A)

C56

F29

Fuse

Warning/ceiling light (15A)

F54

F30

Fuse

Stalk switch (25A)

F34

F31

Fuse

Starter (20A)

F40

Fuse

Equipment (40A)

F41

Fuse

Equipment (40A)

F42

Fuse

Pre-heating (80A)

F43

Fuse

Alternator (80A)

Battery

F40

Alternator

H10

Indicator

Warning lamp

A34

H11

Indicator

Front wheel alignment light

B14

H14

Indicator

Rear wheel alignment light

C14

H15

Indicator

counter/rotations Light

H16

Indicator

Cooland temperature light

B51

H17

Indicator

Diesel gauge light

B51

H19

Indicator

Fan light

B53

H20

Indicator

Relay

Air conditioning relay (option)

D37/A37

Relay

Free

D21/A21

Relay

Transmission cut-off relay

D25/A28

Relay

Reverse gear relay

C25/B24

Relay

Forward gear relay

C11/C25/B23

Relay

Machine fault alarm

Relay

Free

D21/A21

Relay

Movement cut-off relay/(option)

A16/D16

Relay

Starter safety relay

C2/B24

B51

Relay

Flashing/Warning unit

C31

K10

Relay

Overload safety module

B15

K16

Relay

Preheater relay

B2/B1

K17

Relay

Module relay lights

B6/B7

K18

Relay

Transmission cut-off on seat module

D27

Starter

Front screenwiper

B42

Windscreen washer

B41

Roof wiper (option)

B44

Alarm

A29

Fan

C36

(22/06/2011)

Clock light

80-02-M186EN

Electrical schematic diagrams MT-X 1030 ST Série 4-E3

Components Item

Type

Reverse gear alarm

Designation

Position on diagram B26

Rear cab screen wiper

B43

Diesel pump

A12

M10

Side windscreen wiper

B45

M11

Pneumatic seat compressor

A40

Hour meter

Fuel gauge

Engine coolant temperature

Preheating plugs

Fuel sensor

Sensor and thermo-switch for engine coolant temperature

Key switch

VL and VI valve lever forward/reverse gear reverser

E24

Engine oil pressure switch

Brake fluid

Air filter clogging

Front wheel alignment detector

C13

Brake switch

Front windscreen wiper and windscreen-washer switch

D43

Alarm control

D30

S10

Wheel alignment switch

D14

S11

Warning light switch

E33

B11/D26

S12

Transmission oil pressure

B11

S13a

Side light stalk switch

E52

S13b

Headlight/dipped light stalk switch

E53

S13c

Indicator light stalk switch

E32

S14

Gear lever transmission cut-off switch

C28

S15

Front/rear working light switch (option)

D50

S16

Stop switch

E30

S17

Transmission oil temperature

B10

S18

Working lights on boom switch (option)

D49

S19

Rotating beacon switch

C46

S20

Rear windscreen wiper/roof switch

C44

S21

Fan switch

D37

S22

Overload stress gauge

E15

S23

Clogging hydraulic filter

S24

VL and VI valve lever transmission cut-off switch

D28

S25

Pedal transmission cut-off switch

D28

S26

Transmission cut-off switch

F28

S27

Rear wheel alignment detector

C14

S28

Rear window defrost switch (option)

D48

S29

Rear fog light switch (option)

D56

S30

Steering pressure

S31

Cold start switch

B12

S33

Telescope retraction switch

D19

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 1030 ST Série 4-E3

Components Item

Type

S36

Switch on seat

S39

Pneumatic seat switch

C40

S42

Movement cut-off deletion switch (option)

D17

S44

Telescope retraction switch (option)

D18

S45

Deflation/dump switch (option)

D18

S46

Boom lowering switch (option)

C18

S47

Attachment switch

C18

Diode

Diode (only for TUV)

D52

Diode (LED) battery charge lamp

Diode (LED) engine oil pressure lamp

Diode (LED) engine coolant temperature lamp

Diode (LED) air/oil clogging lamp

Diode (LED) transmission oil pressure lamp

E11

Diode (LED) transmission oil temperature lamp

E10

Diode (LED) brake fluid lamp

V10

Diode (LED) brake lamp

E11

V11

Diode (LED) flashing/warning light lamp

B31

V12

Diode (LED) side lights lamp

B52

V13

Diode (LED) dipped lights light

B55

V14

Diode (LED) headlights light

B57

V15

Diode (LED) steering fault light

Electrovalve

Engine stop electrovalve

A12

Electrovalve

Forward gear electrovalve

B25

Electrovalve

Reverse gear electrovalve

B25

Electrovalve

Cold start electrovalve

A12

Electrovalve

R.H. stabilizer electrovalve

B19

Electrovalve

L.H. stabilizer electrovalve

B20

Electrovalve

Movement cut-off electrovalve (option)

A17

Electrovalve

Discharge electrovalve

C20

Connector

Fuse/relay panel (13 contact plug)

Connector

Fuse/relay panel (13 contact plug)

Connector

Fuse/relay panel (13 contact plug)

Connector

Fuse/relay panel (6 contact plug)

Connector

Fuse/relay panel (8 contact plug)

Connector

Fuse/relay panel (8 contact plug)

Connector

Fuse/relay panel (21 contact plug)

Connector

Fuse/relay panel (5 contact plug)

Connector

Fuse/relay panel (7 contact plug)

Connector

Fuse/relay panel (8 contact plug + 2 contact plug)

Connector

K1 predisposition relay option

Connector

K0 predisposition relay option

Connector

Provision option (8 contact plug + 1 contact plug)

Connector

Engine box

Connector

Rear plug provision option (8 contact plug)

Connector

Stalk switch

(22/06/2011)

Position on diagram D27

Designation

80-02-M186EN

Electrical schematic diagrams MT-X 1030 ST Série 4-E3

Components Item

Type

Connector

Ventilation heating

Designation

Connector

Option air conditioning

Connector

Cab

Connector

Front screenwiper

Connector

Strain gauge

Connector

Movement cut-off provision

Connector

16 way plug (PCB Dashboard)

Connector

Car radio

Connector

Windscreen stalk switch connector (9 ways + 2 ways)

Connector

Digicode connector

AA AB

Position on diagram

80-02-M186EN

(22/06/2011)

Electrical schematic diagrams

MT-X 1030 ST Série 4-E3 J F

Fus.Therm. 2A

J J J J 118 118

321

I I I OP

30 30 17 17 50 19 19 54 15 58

K5 129

119 119 119 119

141

204

12 21

N N

8 3

11 6

F31

121 203 121

19 18 22

14 15

323

116

121 121

K17

V10 Z E n

I 85

K17

121

P S4

T S17

P S12

14 54 55

T S31 Y4

jvt

173

jvt

P S23

A 229

A 338

3,5s

M9 A

S22

235

239

D m bc vt

S42

S33 84

S47

U U U U U U

H11

105 196 195

283 284

281 282

258

14 13

258

S27 121

H14

S45 S46

340

286

156

AC AC

S44

287

227

S10

127

233

98 122

260

K10

217

218

261

41 197

13 (22/06/2011)

I 47

V7 Z E

J 4

v I

322

V8 Z F

324

325 15 15 20 120

V5 Z E

140

N N N

V1 B

30 10

S30

139

263

202

M 25

V6 Z E

K16

N 32

V9 Z F

K16

V4 Z E

V15 Z

V3 bl

F43

N 23

F41

F42

B F40

130 12 21

22 80-02-M186EN

Electrical schematic diagrams

MT-X 1030 ST Série 4-E3 J

122

246

A3 331

337

262

AC AC H

330

H ro

193

153

155

E20

197

264

367

220

184

185

177

jvt

S C

Z V11

E6 185

185

180

163

181

358

184

90 348

166

H10

F17

132

Q S21

F22

232

231

F21

A 133

201

F20

228

230

Q 225

M AC

SWF 521 243 + SWF 596 307 3

7 4

5 2

SWF 521 005 + SWF 596 628

S20

S19

350

S39

AB AB AB AB AB

343 99

351 349

238

73 96

342

M11

raz 3

AB 346

345

2 M 1

E19

T T M2 2 1 vit

+perm

353 352

131

0 2

341

226

239

135

128

EG Lateral

F15

F14

EG Toitl

F16

F13

4 raz 3

S M8 2 1 vit

+perm

M 1

T 146

344

4 raz 3

347

M4 2 1 vit

+perm

M 1

TOIT

raz 3

M10 2 1 vit +perm2

M 1

B LAT

S A

36 80-02-M186EN

jvt

E21

359 158

175

F26

C 366

E22

154

182

184

F25

176

194

D 16

S14

183

n n

++ R

315

S11

333

315

S36

364

S16 S24

97 365

245

249

S25

F12

F29

S13c

192

191

K18

265

329

PCB

267

F10 J

S26

339

46 (22/06/2011)

F19

F11

F18

199

234

S SWF+521 008

134 SWF 521 110 + SWF 596 473

SWF 596 390

S28

5 1

8 10

2 0 1

SWF 521 054 + SWF 596 151

P j

V2 313

187

186

320

138

122

F23

F24 C

C bl

179

174

E25

E17

E18

E16

H20

E15

H17 203

S 368

S 9

H16

121

121 202 140

H16B H15A F

121

Z V12

E7 185

Q H19 Q 131

E9 184

E10 90

O 2

C 195

164

206

207

165

178

E8 166

F28

C 88

S29

F27

C 162

200

Dégivrage vitre arrière

E26

205

357

369

S13b

F30

136

S13a

S15

S18

E11

E12 166

E23 Z V13

184

E13

E24 185

E14 166

Z V14 Z

(22/06/2011)

Electrical schematic diagrams

MT-X 1030 ST Série 4-E3

80-02-M186EN

B10

Electrical schematic diagrams

80-02-M186EN

(22/06/2011)

ELECTRICAL COMPONENTS LOCATION

pages MT-X 732 Série D – 2D locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3D locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MT-X 1030 ST Série 4 – 2D locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

– 3D locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(22/06/2011)

80-03-M186EN

Electrical components location

WIRING DIAGRAM KEY Item

Designation

Item

Designation

Relay and fuse holder plate

Strain gauge

Complete left front headlight

Complete right rear light

Complete left front headlight

Diode

Complete right front headlight

Harness

Complete right front headlight

Hand brake switch

Alarm

Complete left rear light

Hazard warning light switch

De-mister switch

Rotating beacon switch

Indicator lamp

Rear work lamp switch

Main harness

Rear work lamp switch

M8 C05 ZN.C nut

Fog light switch

M8 ZN nut

Wheel alignment switch

Clogged oil filter indicator

Transmission cut-off switch

Transmission oil pressure switch

Roof screenwiper switch

Oil temperature sensor

Clock

Electrical control valve

Key switch

Relay

Switch

Safety switch

Fuel gauge

Buzzer

Water temperature indicator

Safety valve block

Hour meter

Safety valve block

Brake fluid tank

Transmission cut-off module

Stop switch

Shunt

Transmission cut-off switch

Windscreen wiper motor

Windscreen washer reservoir

Sensor

Safety panel

Sensor

Boom pre-wiring switch

Windscreen wiper switch

Forced operation switch

80-03-M186EN

(22/06/2011)

Electrical components location

ELECTRIC CIRCUIT

MT-X 732 S.D-E3

57 v55

jvtM roG jvt50

r/nI

8 4

6 2

7 3

V 61

vtI

9 5

11 AA 1572

5 1

17 7

RPM x 100

m20 n/s43 jvtM

9 5

12 (U.K)13

9 4

jvt

OPTION OPCION OPZIONALE

33 3

00000000

16 8

A B

rG nG jvtM

gC bl/bcC jvtM bcC jC

1 4

mJ jvtM

TEST

bl/bc37

o31 rG

blC n41 gC bl/bcR o37 jvt41 o50 r37 jvt53 oEp1 nG r30 jvtM o bl41 nC g37 bl/bcC 1

jvtM jvtU

3 10

10 3

2 11

1 12

11 2

12 1

g56

63 6

vt59 blP roB ro59 vt/n59 n32 vtP r59 roA jP

vt/nX

vtX

viX

o55 r55 rV jvt55

r/nX bcG

P 36

jvt43 jvt19

mB nA roA vtB jG oA j52 gA g58 oG blB r63 r54 r/n28

viG jG nG oG blG rG bcG rG 1

6 3

m61 m60 rB

jvtM

11 AA 1572

vtQ vtP j62

mA vt62

bl10 mB

15 5

(22/06/2011)

jvt

jvt20

jvtM jvtM

bl62 jvtM vtA

1 1

mG jvtM rD bl/bcK

jvtM n60

r/nY

viY

r/n41 r/n37 rA

n/s61 jvt20

52 S

vtY

L vt/nY

j24

1 3

r24

ro62 r62

7 2

vt/n62

jL jL rS oL rS viS rS rS

jvt28 r24 jvtM r24

19 8 9 18 7 2 10 17 6 1 3 11 16 5 4 12 15 14 13

oK r/n19 gK bl/bcK jvtM rK

jvt28

j28

1 4

vt62

j24

jvtM jS jS jL jL

m31 r24

jvt27

6 BB 265 j58 vi24 viB

bl/s26

jvtS roL jvt26

roH jvtM jvtM g58 nH m21 m31

bl/s28

44 rN

bl28

vtI jvt23 gI j58 j24 viB j24 ro27 nI j24 blB jvtM jvtM m26 j24 r/n28 o24 jvtM jvtM

34 10 DA . . .

roO

g58

10 (U.K)11

jS bl/sC

vtL r/n49 gL g47 vt14 n/s40 m48 nL

1 j56

6 rR

g58

K0 K1

K2 K3 K4 8

bl54 nG r55

m20 n43 jvtM

gI jvt50

blK bl10 gK g12 j12 j10 n10 bc10 nK bc12 bl/bcK bl/bc12 bl/s28

rO r40 rH n56

E 1

jvtM m56 n/sI rN

30A

D 7

25A

10A

j64 m64

F13 F14 F15

C 13

F30

bl28 blL bl51

7.5A 7.5A 7.5A 7.5A 15A 15A 15A

oK1 rK1 bck1 nk1 vtk0 mk0 mR rR gG rok0 bc58 oV r21 viA jK6 ro50 n33 nK r33 jV blk6 vik6 rK6 vt57 vt50 nW

rV blW

10A

7.5A 7.5A 7.5A 5A 10A 15A 5A 15A

45 46

r26 vt30 r27 mP o29

54 1

j54 m54

13 14

7.5A

11 CA 125

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

vt57

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29

r/nL bl27 blB r/nV jvtM jvtS

jvt43 jvt56 jvt28 jvt37 jvt40 jvt29 jvt12 jvt33 jvtR jvtL jvt21 jvtQ jvtP jvtL jvt37 jvt61 jvtL jvt51 jvt50 jvt63 jvtK jvt10 jvt59 jvtO jvtS jvtS jvtP jvtP jvt60 jvtL g58

r20 ro62 blV vtV viS viL bl/n51

jvt63

blK oEp1

r30 jvtK r/n19

jvtK oEp1

vt23 jvt26

jvt27

bl/s27

jvt26

blP

vt26

jvt29 o21 mT n62 mJ

vtA

bl/s27

jvtM 3 nN

r41 rK vtB

23 jvtL

jvt50 jvt47 oK 4

g58

m40

o53

o41

jvt63 r63 rW

4 1

viG mP nV roV ro62 vtP rP oV gV oP g58 jP vt23 r19

bl/nB blB jvtM

Ep 1

jvt

vG vU v57 o63

BP 203

nC blC jvtM bcC jC

jvt32 jvtM oB

80-03-M186EN

Electrical components location

ELECTRICITY (ENGINE - TRANSMISSION)

MT-X 732 S.D-E3

8 6 7

KEY: WIRING DIAGRAM (ENGINE - TRANSMISSION) Item

80-03-M186EN

Designation

Glow plug

Engine oil pressure switch

Electrovalve

Water temperature sensor

Oil temperature sensor

O-ring

Transmission oil pressure switch

Solenoid valve (Delphi) (22/06/2011)

Electrical components location

ELECTRIC CIRCUIT

MT-X 1030 ST S.4-E3

nC blC jvtM bcC jC

jvt32 jvtM oB jvt

jvtM roG jvt50

r/nI

8 4 8

6 2

7 3

5 1

oA r/n28

V 61

9 5

2 1

(U.K)13

22 9 1

OPTION OPCION OPZIONALE

54 3

2 1

gC bl/bcC jvtM bcC jC

10 AG 222

jvt54 bl54 bl39

2 3 1

rG nG jvt21

m20 n/s43 jvtM

r 7

vtI

1 4

jvtM jvt55 bl55

33 3

RPM x 100

18 7

TEST

mJ jvtM jvt33

bl/bc37

3 10

g56

10 3

blC n41 gC bl/bcR o37 jvt41 o50 r37 oEp1 nG r30 jvtM bl41 nC g37 bl/bcC

vt/nX

(22/06/2011)

2 11

g39

gO 1

1 12

11 2

nA roA vtB gA g58 oG blB

o31 rG

vtX 7

bl59 mP roB bl59 n59 jP bc59 roA vtP n32

12 1

6 3

viX r/nX

jvt43 jvt19

11 AA 1279

jvt

m61 m60 rB

n60

11 AA 1279

o 2

jvtM

vt62 1

bl10 mB

vtQ vtP

j62

m62 jvtM vtA

jvtM jvtM

viY

vtY

r/nY

n/s61 jvt20

vt/nY

S F

1 3

mG jvtM rG rD bl/bcK

jvtM jvt20

24 r/n41 r/n37 rA

1 1

oK r/n19 gK bl/bcK jvtM rK

8 18 7 2 10 17 6 1 3 11 16 5 4 12 15 14 13

viG jG nG oG blG rG bcG rG

r24 jvtM r24

bl62 bc62

j28 j24

n62

6 BB 184

1 4

bl62

jL jL rS oL rS viS rS rS

j24

00000000

jvtM jS jS jL jL

vt50

r24 vi24 r24 viB

jvt27

bl/s26

g58 m31

jvt26 bl/s28

roH jvtM jvtM g58 nH m21 m31

jvt28 roL

10 DA 330

bl28

44 gI vtI jvt23 g58 j24 viB j24 ro27 nI j24 blB jvtM jvtM m26 j24 r/n28 o24 jvtM jvtM

roO

g58

bl/sC

n j56

vtL r/n49 gL g47 vt14 n/s40 m48 nL

10 (U.K)11

g58

oK1 rK1 bck1 nk1 vtk0 mk0 mR rR gG rok0 g58 oV r21 viA jK6 ro50 n33 nK r33 jV blk6 vik6 rK6

K0 K1

K2 K3 K4 1

m20 n43 jvtM

bl55 g58

blK bl10 gK g12 j12 j10 n10 bc10 nK bc12 bl/bcK bl/bc12 bl/s28

rO r40 rH n56

30A

D 7

gI jvt50

25A

jvtM m56 n/sI rN

F13 F14 F15

C 13

bl28 blL bl51

10A

7.5A 7.5A 7.5A 7.5A 15A 15A 15A

vt30 r27 mP o29

45 46

10A

7.5A 7.5A 7.5A 5A 10A 15A 5A 15A

F30

39 j52 m52

r26

7.5A

j39 m39

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12

11 CA 93

F16 F17 F18 F19 F20 F21 F22 F23 F24 F25 F26 F27 28 F29

53 13 14

r20 ro62 blV vtV viS viL bl/n51

blK oEp1

r/nL bl27 blB r/nV jvtM jvt27

jvt54 jvt56 jvt28 jvt37 jvt40 jvt29 jvt12 jvt19 jvtR jvtL jvt21 jvtQ jvtP jvtL jvtP jvt61 jvtL jvt51 jvt50 jvt53 jvtK jvt10 jvt59 jvtO jvtS jvtJ jvtP jvtP jvt60 jvtL g58

jvtM oEp1

r30 jvtK r/n19

bl/s27

r23 jvt26

jvt27

1 6

bl/s27

jvt26

blP

r26

jvt29 o21 mT n62 mJ

2 1

jvtM 3 nN

r41 rK vtB

jvt50 jvt47 oK

23 jvtL

o53

g58

m40

o41

viG mP nV roV ro62 vtP rP oV gV oP g58 jP vt23 r19

6 1

80-03-M186EN

Ep 1

bl/nB blB jvtM

BP 203

Electrical components location

ELECTRICITY (ENGINE - TRANSMISSION)

MT-X 1030 ST S.4-E3

6 7 2

3 9

KEY: WIRING DIAGRAM (ENGINE - TRANSMISSION) MT 1030 ST S.4-E.3 Item

80-03-M186EN

Designation

Glow plug

Engine oil pressure switch

Electrovalve

Water temperature sensor

Oil temperature sensor

O-ring

Transmission oil pressure switch

Solenoid valve (Delphi) (22/06/2011)

ELECTRICAL CONTROL AND ADJUSTMENT

Pages Operation and adjustment of the longitudinal stability warning device . . . . . . . . . . . . E2 Safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3 Procedure for checking the strain gauge on the longitudinal stability warning device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4 – Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4

– Electric checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4

(23/06/2011)

80-04-M186EN

Electrical control and adjustment

Operation and adjustment of the longitudinal stability warning device

This adjustment must be made with a stable rear axle temperature. Do not carry out this adjustment after carrying out brake tests as the difference in temperature between the axle and the gauge will adversely affect the adjustment. Before adjusting the unit move the machine in order to ensure the strain gauge is positioned. A last check of this setting must be made before the machine is delivered.

Diagram 2

Diagram 1

Affix the adhesive label after carrying out adjustments and checking compliance. (A new label to be affixed whenever adjustment is carried out)

1 Red LED

SE SA LY

2 Red LEDs 2 Yellow LEDs 4 Green LEDs

224 777

Adjustment control access hole. (Tool diameter 2 mm; length 40 mm minimum)

80-04-M186EN

(23/06/2011)

Electrical control and adjustment

Safety system

2 Red LEDs Test button

Audible warning disabled indicator light 2 Yellow LEDs

Disable audible warning button

DEUTSCH IPD - USA DT04-3P

4 Green LEDs

Power connector and signal out from aggravating movement cut-off

Connection to strain gauge Adjustment micro-contact (accessible with 6 mm Allen key)

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80-04-M186EN

Electrical control and adjustment

Procedure for checking the longitudinal stability warning device strain gauge Connections Supply + Supply - and PT 100 Measurement + Measurement PT 100 Shielding

red wire/contact brown wire/contact yellow wire/contact green wire/contact blue wire/contact white wire/contact

No1 No2 No3 No4 No5 No6

Description of strain gauge connectors

Shielding 6

1 Supply A+

PT 100 5

2 Supply A-

3 Measurement M+

Measurement - M 4

Before carrying out any electrical test, visually inspect the gauge and its connections.

Electrical check

Disconnect the gauge from the electrical circuit.

350 Ω off

500Ω 5 KΩ

Using a multi-meter, take the following measurements. Fig. A Measure the resistance between A+ and A- = Z supply (supply resistance) Values: 300Ω ≤ Z supply ≤ 400Ω

Fig. A

80-04-M186EN

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Electrical control and adjustment

350 Ω off

500Ω

Fig. B Measure the resistance M+ and M- = Z supply (measurement system resistance) Values: 300Ω ≤ Z supply ≤ 400Ω

5 KΩ

Fig. B

109 Ω off

500Ω 5 KΩ

Fig. C Measure the resistance between A- and PT100 = Z PT100 Values: 101Ω + 0,39xT (gauge temperature) Example: T = 20°C so Z PT100 = 101Ω + 7,8Ω = 109Ω

Fig. C

l off

500Ω

5 KΩ

Fig. D Measure the resistance between A+ and the shielding: Zbl Zbl > 30MΩ (infinite resistance or open circuit)

Fig. D

l off

500Ω 5 KΩ

Fig. E Measure the resistance between A+ and the telehandler earth: Z earth Z earth > 30MΩ (infinite resistance or open circuit)

Fig. E

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80-04-M186EN

Electrical control and adjustment

80-04-M186EN

(23/06/2011)

ELECTRICAL SPECIFIC TOOLING

pages DIAGNOSTIC CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DOCKING STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 WORKSHOP AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 BREAK OUT BOX KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SOLENOID ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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80-09-M186EN

Electrical specific tooling

DIAGNOSTIC CASE

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Electrical specific tooling

12 11

10 5 9 13

1 3

Diagnostic toolkit .......................................................................................746120 Consisting of: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. (23/06/2011)

1 Cigar lighter socket supply cable ............................................745240 1 Red battery crocodile clip and cable .......................................745241 1 Black battery crocodile clip and cable .....................................745242 1 Supply cable ........................................................................745243 1 Portable VCI cable ................................................................745244 1 Manitou OBD Diag cable .......................................................745245 1 Manitou RC2/RC4 Diag cable ................................................745246 1 CE L standard Mains cable: 3m .............................................745247 1 Diag power supply unit 3G 60W .............................................745251 1 Battery LI-ION 7.4V/9.6AH ....................................................745367 1 PAD (rugged PC and case kit) ................................................745438 1 VCI (Vehicle Communication Interface/PAD)............................745439 Styli (batch of 3) ......................................................................745368 80-09-M186EN

Electrical specific tooling

DOCKING STATION

Docking station (battery charging)..............................................................745236

WORKSHOP AREA

Workshop area (area + station)...................................................................745235

80-09-M186EN

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Electrical specific tooling

BREAK OUT BOX KIT

Break out box (DT type connectors)

Break out box (DTM type connectors)

Break out box kit .......................................................................................785503 Consisting of: 1 break out box (DT type connectors) ........................................785504 1 Break out box (DTM type connectors) .....................................785505

1. 2.

SOLENOID ADAPTER

Solenoid adapter ........................................................................................662196

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80-09-M186EN

Electrical specific tooling

80-09-M186EN

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