mht-x 10120 l e3 groupe 20 (transmission)

TRANSMISSION

- TRANSMISSION SCHEMATIC DIAGRAMS

- TRANSMISSION COMPONENTS LOCATION

- TRANSMISSION CONTROL AND ADJUSTMENT

- TRANSMISSION REMOVAL

- TRANSMISSION REFIT

- SPECIFIC TRANSMISSION TOOLING

- TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS

- TRANSMISSION CONTROL AND ADJUSTMENT

20

647030DE/EN

(PUMP SERIES A4VG)

647031FR/EN

(ENGINE A6VM SERIE 63)

647375

(GEAR DANA SERIES 360/59)

647379

(GEAR DANA SERIES 357/216)

MR

MR

MR

MR

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TRANSMISSION SCHEMATIC DIAGRAMS

page

REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT . . . .3

REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT . . .4

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20

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3TRANSMISSION SCHEMATIC DIAGRAMS

70

70

CR

AB

T P

1 2

S.

MC

PF

VSLR

VCLR

FDARFDAVX2 BX1

T A

FeFa

ab

R T1 T2

G S MAX1

A

B

MB

X2

Ps

440bar35bar450bar

M.I.

R.

RAD.

3 bar

450bar

M.

P.I.

EV(S27)

EV(S28)

EV(S22)

EV(S21)

REXROTH HYDROSTATIC TRANSMISSION LAYOUT FORWARD MOVEMENT

Legend:

High pressure

Low pressure

Control air

Drainage pressure

Loading pressureSuction pressure

Return to discharge

Hydraulic manifoldCR

Forward movement solenoid valveEV(S21)

Reversing solenoid valveEV(S22)

Fast speed solenoid valve

Slow speed solenoid valve

Rear disk brakes

Front disk brakes

Brake pump

Engine with variable displacement

Brake pedal

Hydrostatic pump

EV(S27)

EV(S28)

FDAR

FDAV

MC

M.I.

PF

P.I.

See 70 - hydraulics Chapter

Oil tank

Radiator

Oil tank

Slow-fast control cylinder

Slow-fast selector valve

R.

RAD.

S.

VCLR

VSLR

FORWARD MOVEMENT

FRONT AXLE

REAR AXLE

I.C. engineM.

20

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4 TRANSMISSION SCHEMATIC DIAGRAMS

REXROTH HYDROSTATIC TRANSMISSION LAYOUT REVERSING MOVEMENT

70

70

CR

AB

T P

1 2

S.

MC

PF

VSLR

VCLR

FDARFDAVX2 BX1

T A

FeFaab

R T1 T2

G S MAX1

A

B

MB

X2

Ps

440bar35bar450bar

M.I.

R.

RAD.

3 bar

450bar

M.

P.I.

EV(S27)

EV(S28)

EV(S22)

EV(S21)

REVERSING MOVEMENT

FRONT AXLE

Legend:

High pressure

Low pressure

Control air

Drainage pressure

Loading pressureSuction pressure

Return to discharge

Hydraulic manifoldCR

Forward movement solenoid valveEV(S21)

Reversing solenoid valveEV(S22)

Fast speed solenoid valve

Slow speed solenoid valve

Rear disk brakes

Front disk brakes

Brake pump

Engine with variable displacement

Brake pedal

Hydrostatic pump

EV(S27)

EV(S28)

FDAR

FDAV

MC

M.I.

PF

P.I.

See 70 - hydraulics Chapter

Oil tank

Radiator

Oil tank

Slow-fast control cylinder

Slow-fast selector valve

R.

RAD.

S.

VCLR

VSLR

I.C. engineM.

REAR AXLE

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TRANSMISSION COMPONENTS LOCATION

page

MHT 10120 HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION 4

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20

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3TRANSMISSION COMPONENTS LOCATIONMHT 10120 HYDROSTATIC TRANSMISSION

Radiator

Hydrostatic pump

Rear axle

Gearbox

Front axle

Shaft

Hydrostatic motor

20

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4 TRANSMISSION COMPONENTS LOCATION

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION

Radiator

Hydrostatic pump

Rear axle

Gearbox

Front axle

Shaft

Hydrostatic motor

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TRANSMISSION CONTROL AND ADJUSTMENT

page

CHECKING THE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PRESSURE CONTROL POINTS ON A4VG 71 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

CONTROL AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

CASING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

A6VM 107 MOTOR PRESSURE CONTROL POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SWITCHING PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHECKING AND ADJUSTING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

TRANSMISSION ADJUSTMENT POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

A4VG PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

A6VM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER

A REPAIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

STARTING UP: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CHECKING AND ADJUSTING THE BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ADJUSTING THE PUMP MECHANICAL 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

CHECKING THE ADJUSTMENT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

CHECKING AND ADJUSTING THE START OF REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . .9

BEGINNING OF THE REGULATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

CHECKING AND ADJUSTING THE END OF REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

CHECK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

END OF THE REGULATION:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CHECKING AND ADJUSTING THE HP LIMITERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

ADJUSTING THE HP LIMITERS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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ADJUSTING THE A6VM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

A. CHECK MINIMUM DISPLACEMENT (MAX SPEED): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

B. CHECKING THE BEGINNING OF THE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

C. MAX DISPLACEMENT: (MAX. TRACTION FORCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

REGULATING THE HYDROSTATIC TRANSMISSION PRESSURES . . . . . . . . . . . . . . . . . . . . . .13

GENERAL PRESSURE REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

ADJUSTING THE BOOST PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

REGULATING THE VEHICLE START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

CHECKING PILOT PRESSURE PS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

TROUBLE-SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

PUMP/MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

MANITOU - HYDROSTATIC TRANSMISSION REGULATION CHART -

A4VG--DA / A6VM--DA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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3TRANSMISSION CONTROL AND

ADJUSTMENT

CHECKING THE PRESSURE

PRESSURE CONTROL POINTS ON A4VG 71 PUMP

Casing pressure connections

Necessary (the case must contain basic pressure gauge sockets Ref. 549671 + Hydromatik Kit Ref. 209572) 20-09 Special tools for the transmission

CONTROL AIR

2 Connectors 165711 (Ref. 55) (M 14 x 150) 2 Pressure gauge sockets 58181 (Ref. 49) (M 8 x 100) 2 Pressure gauges (0 - 40 bar) 2 Test fl exible tubes 549887

HIGH PRESSURE

2 Pressure gauge sockets 477484 (Ref. 51) (M 12 x 1.5) 2 Pressure gauges (0 - 600 bar) 2 Test fl exible tubes 549887

BOOST PRESSURE

1 Connector + pressure gauge socket assembly 199175 (Ref. 53.1) (M 18 x 1.5) 1 Pressure gauge (0 - 40 bar) 1 Test fl exible tubes 549887

CASING PRESSURE

1 Pressure gauge socket 477484 (Ref. 51) (M 12 x 1.5) 1 Pressure gauge (0 - 40 bar) 1 Test fl exible tubes 549887

Control air socket

HP pressure socket

Boost pressure socket

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A6VM 107 MOTOR PRESSURE CONTROL POINTS

HP socket

NOTE: The actual assembly of the motor diff ers from that shown in the Figure since it is rotated through 180.

Necessary (the case must contain basic pressure gauge sockets Ref. 549671 + Hydromatik Kit Ref. 209572) 20-09 Special tools for the transmission

HIGH PRESSURE

1 Pressure gauge socket 58189 (Ref. 52) (M 14 x 150) 1 Pressure gauge (0 - 600 bar) 1 Test fl exible tubes 549887

SWITCHING PRESSURE

1 Pressure gauge socket 477484 (Ref. 51) (M 12 x 150) 1 Pressure gauge (0 - 600 bar) 1 Test fl exible tubes 549887

Switching pressure socket

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ADJUSTMENT

CHECKING AND ADJUSTING THE TRANSMISSION

TRANSMISSION ADJUSTMENT POINTS

A4VG PUMP

A6VM MOTOR

DR valve

HP Valve

DA regulator valve

DA regulation start adjuster

Supercharger valve

HP Valve

Adjustment cam of plate regulation end

Disk mechanical 0 adjuster

Switching regulation adjuster screw

Minimum displacement adjuster screw (do not disrupt the adjustment)

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CHECKS BEFORE STARTING UP THE TRANSMISSION OR AFTER A REPAIR

Check the oil level in the tank. Check to ensure that all the connections of the hose pipes are tightened properly. Check the electrical connections of the solenoid valves. Ensure that the circuit is fi lled properly, and at the same time fi ll the oil fi lter before fi tting it. Check to ensure the control air tubes are fi tted correctly:

X1 pump with X2 motor, X2 pump with X1 motor.

In all the cases, the control air connection is opposite to the HP hose pipes. (For example: if the HP hose pipe for forward movement is to the RH of the motor, the forward movement control air hose pipe will be to the LH, and the other way around for the reversing).

Connect the boost pressure socket pressure gauges - control air - HP - casing.

STARTING UP:

For reasons of safety, place the vehicle on stands. Let the I.C. engine run without moving the vehicle to bleed the circuit properly. (disconnect the wire

of the stop solenoid valve on the injection pump). Make sure that the boost pressure increases at least to 15 bar on running the starter motor.

"DO NOT start up the transmission with insufficient boost pressure, as there is risk of wear of the transmission".

Reconnect the stop solenoid valve on the injection pump. Run the I.C. engine for a few minutes at minimum speed. Boost pressure 35 - 40 bar.

Unstability of the needle indicates air intake (emulsifi ed oil in the tank, and cavitation noise of the transmission).

Inverter in neutral in the two HP circuit inlets. The pressure is equal to the boost pressure.

Heat the oil in the circuit by accelerating progressively (keep the hand brake locked to allow measurement of the HP with load blocked).

When the oil is at a minimum temperature of 50- 60 check the engine speed: at minimum, at maximum without load. (See technical specifi cations).

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ADJUSTMENT

CHECKING AND ADJUSTING THE BOOST PRESSURE

The A4VG 71 series pump is equipped with an adjustable limiter. To increase the boost pressure, tighten the screw.At I.C. engine max speed, 40 bar.The oil tempearture must not exceed 40 C.The pump is already equipped with a pressure socket as seen in the Figure.The vehicle must be braked completely.Check to make sure there are no leaks in the inching valve.

FE boost pressure socket

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ADJUSTING THE PUMP MECHANICAL 0

Connect two small scale (40 - 100 bar) pressure gauges on the HP pressure sockets. Make sure the hand brake is disengaged and that the vehicle is on stands (wheels suspended in the air): Engine running at minimum speed. Speed inverter in neutral. Slacken the lock nut of the mechanical "0" adjuster screw (hex wrench 19). Turn the screw gently

(using an Allen wrench 6) clockwise until the lowest HP variation is seen. Make a marking in the direction of the wrench.

Operate in the anticlockwise direction to change the HP in the other direction of movement.Make a marking in the direction of the wrench.

Then turn the adjuster screw until the wrench is in the centre of the two markings made earlier. Tighten the lock nut.

CHECKING THE ADJUSTMENT:

Connect the 2 pressure gauges on the HP sockets 600 bar scale:

1 - Check the beginning of the adjustment in forward movement and reversal with an rpm counter.Accelerate the I.C. engine gently - selector in forward movement - until the wheels start moving. Measure the I.C. engine rotation speed.Repeat the operation with reversing movement.Check the two I.C. engine rotation speeds which must be identical.

2 - Check the Hp and corresponding control air - wheels blocked - forward movement inverter selector - accelerate the I.C. engine progressively up to max. speed.Measure the forward movement and forward movement control air HP pressures.Repeat the operation with reversing movement; the values must be identical.

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ADJUSTMENT

CHECKING AND ADJUSTING THE START OF REGULATION

DA regulator valve

DA regulation start adjuster

BEGINNING OF THE REGULATION:

Measure the I.C. engine speed at the minimum which must be ~ 850 min-1. The regulation must begin at 1050 min-1. To proceed with regulation, act on the adjuster screw present on the end of the regulation start valve:

Tighten the screw to delay the beginning of forward movement. Slacken it to advance the beginning of forward movement.

Modifi cation of the beginning of the adjustment of the forward movement point shifts the fi eld of regulation of the pump. The end of the adjustment must be systematically checked 400 bar for the full speed of the motor in question. (1600 - 1800 min-1).

Checking the regulation is equal to checking the "mechanical 0" - Point 2.

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CHECKING AND ADJUSTING THE END OF REGULATION

End of regulation

CHECK:

The vehicle must be on stands - brakes locked and inching (brake) in by pass. Inverter in forward movement. Motor at minimum, check the rotation speed of the I.C. engine. Accelerate progressively and check the speed of the I.C. engine (1600 - 1800 min-1) when the HP for

forward movement reaches 400 bar.

END OF THE REGULATION:

The adjustment of the end of regulation of the pump is obtained by acting on the eccentric screw which changes the position of the plate (in the direction of rotation). This will increase or decrease the return forces of the inclinable disk.

bThis adjustment must be made on the bench by the manufacturer; it must not be changed, except with permission from the Parent Company. The milled surface of the cam must face the side of the booster pump. The adjustment margin is only by 90% to the RH and 90% to the LH. Do not exceed this percentage (risk of mechanical breakage due to interference between the plate and the casing). Like the HP adjustment, this adjustment must be done with the DR valve over-calibrated.

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ADJUSTMENT

CHECKING AND ADJUSTING THE HP LIMITERS

Checking and adjustment of the HP limiters is done with the forklift truck on stands (wheels suspended in mid-air) and the brakes locked.The inching valve must be bypassed to eliminate the pump discharge function.

Overcalibrate the DR valve -Ref. 1- to check the actual calibration value of the HP limiters.

Turn the screw (Ref. 1) through one turn. The HP limiters (Ref. 2) must be calibrated

at 460 bar.During this operation there will be a sharp drop in the I.C. engine speed, about 500 - 600 min-1.After checking the HP, adjust the DR valve (Ref. 1) to a value less than 20 Bar below HP (Ref. 2).

ADJUSTING THE HP LIMITERS:

A4VG 71 DA series Pump

Remove the lead sealing A. Remove cap B. Unscrew lock nut D. Act on screw E to increase the pressure. Refi t the cap and lead-seal the adjuster screw again.

C D

A

B

E

1

2

2

MB

MA

2

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2012


ADJUSTING THE A6VM MOTOR

A. CHECK MINIMUM DISPLACEMENT (MAX SPEED):

The checking is done with: the truck on level ground, engine running at max. speed, moving forwards, Connect the two 600 bar scale pressure gauges as shown in the Figure. At max. vehicle speed, the

two pressures must be equal. Taking into account the ratio of the control cylinder surface, this means that the engine is switched in minimum displacement.

For actual checking of the speed (check the vehicle's technical specifi cations).

b This adjustment (Ref. 1) must be made on the bench by the manufacturer; it must not be changed, except with permission from the Parent Company. High pressure

B. CHECKING THE BEGINNING OF THE ADJUSTMENT

When the vehicle is at max. speed, press progressively on the brakes to increase the HP (the inching valve must be bypassed).

Observe the two pressures. When the HP reaches a value of 260 - 280 bar, the switching pressure will drop and the HP will continue to increase up to the DR valve calibration value.

The beginning of the adjustment can be set by means of the adjuster screw on the engine.

C. MAX DISPLACEMENT: (MAX. TRACTION FORCE)

To make this adjustment, the lift truck must be blocked (brakes locked). The checking is done at max. engine speed with the vehicle moving forwards.

The switching pressure (side of the greater cross-section of the control cylinder) must be close to zero bar.If necessary, adjust the adjuster screw (tighten to increase the switching pressure, slacken to decrease the pressure).

The traction force must be checked (at the hook) (for the values, see Use and Maintenance Manual).

1Adjuster screw for beginning of the regulation of switching

Switching pressure

( R e f . 1 ) M I N I M U M D I S P L A C E M E N T ADJUSTER SCREW (tightening the screw will move the disk downwards. The displacement will thus increase while the speed will decrease).

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ADJUSTMENT

REGULATING THE HYDROSTATIC TRANSMISSION PRESSURES

DA regulator valve

Beginning of adjustment

Mechanical zero

"G" boost pressure adjustment

M a - M b pressure test

HP valves 512 bar

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2014


MaMb GENERAL PRESSURE REGULATION

Position the 600 bar scale pressure gauge connector on one of the pressure test sockets positioned on the hydrostatic pump marked as "Ma" (Ref. 1) or "Mb" (Ref.2).

Regulate the general pressure by acting on adjuster (Ref. 3) provided on hydrostatic pump "DR".

With the diesel engine running at maximum speed, gear in fast speed and oil temperature approx. 60 degrees C, the general pressure must be 440 bar.

ADJUSTING THE BOOST PRESSURE

Position a T-union (Ref. 4) on the hydrostatic pump connector marked with "G", remove the cover (Ref. 6) of the adjuster (Ref. 7) and fi t the connector of a 60 bar scale pressure gauge (ref. 5) on the union.

Adjust the boost pressure on the adjuster (Ref. 7).

With the engine running at maximum speed and the oil temperature about 60 degrees, the boost pressure must be about 35 bar and must vary by not more than 1 or 2 bar between the minimum and maximum engine rpm.

3

4

5

6

7

1

2

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ADJUSTMENT

REGULATING THE VEHICLE START

Set the I.C. engine speed at about 100rpm more than the minimum.Regulate the adjuster (Ref. 8) at the end of the DA valve to obtain vehicle start up.

Note: This adjustment must be made with the oil cold.

CHECKING PILOT PRESSURE "PS"

The oil temperature must be approx. 60C.Remove the pipe (Ref. 9) from the pump.

Position a T-union (Ref. 10) on the hydrostatic pump connector, and fi t on the union the connection of a 60 bar scale pressure gauge (Ref. 11).

The pilot pressure must be between 25 and 30 bar.

8

9

9

10

11

Pressure Value

Maximum 440 bar

Boost pressure 35 bar

Control air 25 / 30 bar

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TROUBLE-SHOOTING

PUMP/MOTOR

Suction pressure

Supply pressure

Control air

High pressure

S A4VG pump

Measuring point

Cause

Direction of rotation

Suction pipe Oil tank fi lterType of oilOil temperature

Heat exchanger

G A4VG pump

Measuring point

Supply pressure

Cause

Auxiliary pumpSupercharger valveWearHeat exchanger oil temperature

A6VM MOTOR

Wear

Washing valve

By-pass valveOil temperature

RPMI.C. engine pump connection (coupling)

A6VM MOTOR

Measuring point

Supply pressureCause

Choke valvesDA regulator valve/inching valve/throttle valvePressure cutProportional solenoid valve/magnet

Control piping

X1/X2 A4VG pump

Suction pressure

A6VM MOTOR

Measuring point

Supply pressureCause

HP-DR valvePressure cutShifting distribution plate

MA/MB A4VG pump

Suction pressure WearHeat exchanger oil temperature

Not blockedCouplingBrakeWear-leaked oil

Oil temperature

Heat exchangerI.C. engine

Min/Max rpm

Diesel fi lterAir fi lterPower

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ADJUSTMENT

VEHICLE

The diesel engine runsThe vehicle does not stop

The vehicle movement is delayed

Insuffi cient traction force

Max. transfer speed is not reached

A4VG PUMP

Mechanical zeroCause

Beginning of regulationProportional solenoid valve

A4VG PUMP

Cause

Choke valvesSuction pressure

Control airBeginning of regulation

Inching

Strong overload of I.C. engine

DR valveWear

A6VM MOTOR

Cause

Pressure cut

Control air

Cause

Inching

Control air Beginning of regulationMagnetInclination angleC C s c r e w adjustment

I.C. engine

RPM

Transmission

Wheels

Cause

A4VG PUMP

Shifting distribution plate

Beginning of regulationInclination angle

I.C. engine

Injection pump

Fuel fi lter

A6VM MOTORA4VG PUMP VEHICLEShifting distribution plate W h e e l diameter

Beginning of regulationControl air piping X1/X2MagnetInclination angle

I.C. engine

RPM

A6VM MOTORA4VG PUMP VEHICLE

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2018


MA

NIT

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(23/02/2012) 20-06-M184EN

20

TRANSMISSION REMOVAL

page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

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

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC TRANSMISSION . . . . . .4

DISASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DISMANTLING THE HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MHT 10120 HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

DISASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DISMANTLING THE HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(23/02/2012)20-06-M184EN

202 TRANSMISSION REMOVAL

PREPARATION AND SAFETY INSTRUCTIONS

Position the truck on a level surface. Raise the boom and set it in safety to be able to access the upper part of the hydraulic pump. Discharge the pressure from the hydraulic system. Deactivate the ignition key and disconnect the negative pole from the battery.

Specifi c tools:- Crane for lifting (5000 kg. minimum).- Pallet jack

GENERAL INFORMATION

The sequence for disassembly operations must be followed to access the various components.

DISASSEMBLING THE HYDROSTATIC TRANSMISSION

Take containers large enough to hold the hydraulic oil in the tank.Place a container under the drainage cap (Ref. 1).Remove the cap (Ref. 1) and let the oil fl ow out.

Slacken the screws and washers (Ref. 2 and 3) and remove the guards (Ref. 4 and 5) in the area under the boom to access the upper part of the pump.

1

3

2

3

23

2

4

5

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20

3TRANSMISSION REMOVAL

Slacken the screws (Ref. 6) and remove the brackets (Ref. 7) which block the universal shaft (Ref. 8) on the gearbox.

Slacken the screws (Ref. 9) and nuts (Ref. 10) which block the universal shaft (Ref. 8) on the rear axle.Remove the universal shaft from the vehicle.

Mark all the pipes and connections with a marker pen, before disassembling, to ensure correct positioning in the reassembly phase.Free the cables and pipes from the clamps.

bPlug all the hydraulic openings of the pumps and motors to prevent impurities from contaminating the hydraulic circuit.

67

8

9

10

8

(23/02/2012)20-06-M184EN



DISASSEMBLING THE HYDROSTATIC PUMP

Slacken the screw (Ref. 1) and remove the coil from the solenoid valve (Ref. 2) fi tted on the pump.

1

2

Disconnect the pipes of the hydraulic oil system, suction, from the hydrostatic pump (Ref. 3) and from the movements pump (Ref. 4).

4

3

Secure the pumps by means of belts or ropes to an overhead crane, passing these through the opening under the boom.Slacken the screws (Ref. 5) which secure the pump (Ref. 3) to the I.C. engine.

5

3

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20


Place the pumps (Ref. 3 and 4) on a pallet jack and take these out of the vehicle.

Slacken the screws (Ref. 6) and remove the washers (Ref. 7) to dismantle the hydrostatic pump (Ref. 3) from the movements pump (Ref. 4).

DISMANTLING THE HYDROSTATIC MOTOR

Remove the drainage pipe (Ref. 2) on the back of the hydrostatic motor (Ref. 1).

Remove the unions (Ref. 3) on the control air valve (Ref. 4).Remove the connector (Ref. 5) of the vacuum gauge (Ref. 8) from the oil fi lter.

3

4

3

4

67

2

3

3

5

1

4

(23/02/2012)20-06-M184EN


Remove the connector (Ref. 6) from the exhaust manifold (Ref. 7).

Remove the vacuum gauge (Ref. 8).

Slacken the screws (Ref. 9) from the fl anges (Ref. 10).

Unscrew the bottom drainage pipe (Ref. 11) from the lower part of the vehicle.

6

8

7

9

10

10

11

(23/02/2012) 20-06-M184EN

20


Slacken the remaining screws (Ref. 9) remove the fl anges (Ref. 10) and remove the pipes (Ref. 12 and 13)..

Slacken the screws (Ref. 14) in the lower part of the motor

and in the upper part.

Secure the engine (Ref. 1) to an overhead crane by means of ropes and remove it from the vehicle.

9

10

10

9

12

13

14

1414

1

(23/02/2012)20-06-M184EN


MHT 10120 HYDROSTATIC TRANSMISSION

DISASSEMBLING THE HYDROSTATIC PUMP

Disconnect the pipes of the hydraulic oil system, suction and the electrical connections of the hydrostatic pump (Ref. 1).

1

2

Secure the pump by means of belts or ropes to an overhead crane, passing these through the opening under the boom.Remove the screws (Ref. 3) and the washers (Ref. 4 and 5) which block the hydrostatic pump (Ref. 1) to the movements pump (Ref. 2).Place the pump (Ref. 1) on a pallet jack and take it out of the vehicle.

54

3

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20


DISMANTLING THE HYDROSTATIC MOTOR

Disconnect all the pipes of the hydraulic oil system from the motor (Ref. 1).

Secure the motor by means of belts or ropes to an overhead crane, passing these through the opening under the boom.Remove the nuts and washers (Ref. 2 and 3), the screws and washer (Ref. 4 and 5) and remove the brackets (Ref. 6).Remove the motor (Ref. 1) from the gearbox.Place the motor (Ref. 1) on a pallet jack and take it out of the vehicle.

1

1

6

6

3

2

2

3

5

44

5

(23/02/2012)20-06-M184EN


(23/02/2012) 20-07-M184EN

20

TRANSMISSION REFIT

page

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

MHT 7140 - 990 - 10160 - 10180 - 10210 - 10225 HYDROSTATIC

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

REASSEMBLING THE HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

REASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

MHT 10120 HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

REASSEMBLING THE HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

REASSEMBLING THE HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(23/02/2012)20-07-M184EN

202 TRANSMISSION REFIT

PREPARATION AND SAFETY INSTRUCTIONS

Position the truck on a level surface. Raise the boom and set it in safety to be able to access the upper part of the hydraulic pump. Deactivate the ignition key and disconnect the negative pole from the battery. Thoroughly wash and dry all the hydraulic oil system pipes before reassembly.

Specifi c tools:- Crane for lifting (5000 kg. minimum).- Pallet jack

REASSEMBLING THE HYDROSTATIC TRANSMISSION


REASSEMBLING THE HYDROSTATIC MOTOR

Place the motor (Ref. 1) on the vehicle using ropes and an overhead crane.

Fit the screws (Ref. 2) in the upper part of the motor

and in the lower part.

22

1

2

(23/02/2012) 20-07-M184EN

20

3TRANSMISSION REFIT

Fit the pipes (Ref. 3 and 4) on the hydrostatic motor locking these by means of the fl anges (Ref. 5) and tighten the screws (Ref. 6).

Fit the drainage pipe (Ref. 7) on the lower part of the motor.

Fit the remaining screws (Ref. 6) on the fl anges (Ref. 5).

6

5

5

6

3

4

6

6

7

5

5

(23/02/2012)20-07-M184EN


Refi t the vacuum gauge (Ref. 8).

Fit the connector (Ref. 9) of the vacuum gauge on the oil fi lter.Refi t the unions (Ref. 10) on the control air valve (Ref. 11).

Refi t the connector (Ref. 12) on the exhaust manifold (Ref. 13).

Fit the drainage pipe (Ref. 14) on the upper part of the motor (Ref. 1).

14

10

10

9

12

1

11

13

8

(23/02/2012) 20-07-M184EN

20

5TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC PUMP

Fit the hydraulic system pump (Ref. 2) on the hydrostatic pump (Ref. 1) by means of the screws and washers (Ref. 3 and 4).

Place the pumps (Ref. 1 and 2) on a pallet jack and position these under the vehicle.

Lift the pumps by means of belts or ropes and an overhead crane, passing these through the opening under the boom.Block the pump (Ref. 1) on the I.C. engine by means of the screws (Ref. 5) on which "Loctite Blue Threadlock" has been applied.

5

1

1

2

1

2

43

(23/02/2012)20-07-M184EN


Fit the coil (Ref. 6) on the solenoid valve (Ref. 7) fi tted on the pump. Clamp all the hydraulic pipes and electric cables.

Reposition the universal shaft (Ref. 8) under the vehicle and screw it to the rear axle by means of the screws (Ref. 9) and nuts (Ref. 19) using a 140 Nm tightening torque.

6

7

Fit all the pipes of the hydraulic oil system and suction on the hydrostatic pump (Ref. 1) and on the hydraulic system pump (Ref. 2), taking care to position these correctly back in place according to the markings made with the marker pen in the dismantling phase.

2

1

9

10

8

(23/02/2012) 20-07-M184EN

20

7TRANSMISSION REFIT

Screw the universal shaft (Ref. 8) on the gearbox, blocking it by means of the brackets (Ref. 11) and fi tting the screws (Ref. 2) on which "Loctite blue threadlock" is applied applying a 44 + 8.5 tightening torque.

Refi t the guards (Ref. 13 and 14) in the area under the boom, by means of the screws and washers (Ref. 15 and 16).

1211

8

16

15

16

1516

15

13

14

(23/02/2012)20-07-M184EN


MHT 10120 HYDROSTATIC TRANSMISSION

REASSEMBLING THE HYDROSTATIC MOTOR

Place the motor (Ref. 1) on the vehicle using ropes and an overhead crane.Refi t the brackets (Ref. 6) fi xing them by means of the screws and washers (Ref. 4 and 5), and tighten the nuts and washers (Ref. 2 and 3).

Reconnect all the hydraulic oil system pipes on the motor (Ref. 1).

1

1

6

6

3

2

2

3

5

44

5

(23/02/2012) 20-07-M184EN

20

9TRANSMISSION REFIT

REASSEMBLING THE HYDROSTATIC PUMP

Place the motor (Ref. 1) on the vehicle using ropes and an overhead crane.Refi t the hydrostatic pump (Ref. 1) on the movements pump (Ref. 2) by means of the screws (Ref. 3) and washers (Ref. 4 and 5) on which "Loctite blue threadlock" has been applied.

1

2

Reconnect the pipes of the hydraulic oil system and reconnect the electrical connections on the hydrostatic pump (Ref. 1).

54

3

(23/02/2012)20-07-M184EN


Set the forklift truck on a level surface with the I.C. engine switched off , with the boom retracted and lowered as far as possible.Fill the tank with fresh hydraulic fl uid (nd manual LUBRICANTS according to the specifi ed type and quantity), through the hole (Ref. 17), check the oil level by means of the rod (Ref. 18), and close the tank by fi tting the screw cap (Ref. 19).

bUse an extremely clean funnel and wipe the upper part of the oil drum before starting with the fi lling.The oil level is correct when it reaches the red dot shown on the rod (Ref. 17).Visually inspect for leaks on the tank and pipes.

18

19

17

(20/02/2012) 20-09-M184EN

20

SPECIFIC TRANSMISSION TOOLING

page

STANDARD BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

(20/02/2012)20-09-M184EN

202 SPECIFIC TRANSMISSION TOOLING

Standard

Maniscopic

1

9

2

3

4

4

5

6

6

77 7 7

8 8

Ref. Number Description QT.

1 549 671 Standard box 1

2 549 882 1/9 bar Pressure gauge 1





7 549 887 Hose 4

8 549 888 Hose for MANISCOPIC 2

9 549 889 Fitting for pressure gauge 7

STANDARD BOX

TABLE OF CONTENTS 20 TRANSMISSION SCHEMATIC DIAGRAMSTRANSMISSION COMPONENTS LOCATIONTRANSMISSION CONTROL AND ADJUSTMENTTRANSMISSION REMOVALTRANSMISSION REFITSPECIFIC TRANSMISSION TOOLING

mht-x 10120 l e3 groupe 20 (transmission)

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